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[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/509,618, filed Oct. 8, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to construction brackets for framing. Particularly, the present invention relates to construction brackets for a roof. More particularly, the present invention relates to construction brackets for roof rafters for more efficient construction and for venting of roofs.
[0004] 2. Description of the Prior Art
[0005] In wood frame building construction, a plurality of paired roof rafters are connected together forming a roof structure. Typically during construction, a ridge board is used to facilitate the roof rafter framing process. Roofs are typically vented to prevent excess heat and associated problems such as increased cooling costs in hot climates and ice formation on the roof in cold climates. The formation of ice results from a lack of free flowing air from the eaves to the ridge of the roof. The ice forms dams (known as ice dams) that cause the water from melting snow to become trapped behind the ice dam. Water then backs up under the shingles causing water damage to the roof, roof structure and internal walls and ceilings.
[0006] In roof structures that do not incorporate an attic, a ridge vent is typically installed along the ridge of the roof so that ambient air is allowed to freely flow from the eaves to the ridge vent along paths between the rafters. There are several disadvantages of using ridge vents. In cold climates, snow may accumulate on the roof and the ridge vent, thus blocking the ridge vent. Blocking of the ridge vent prevents proper venting of the roof that leads to the formation of ice dams. In addition, proper venting of roof hips or valleys or around gables tends to be ignored. This creates venting problems for construction designs that incorporate large numbers of gables and no attic space between the rafters and ceiling joists. Further, ridge vents create a ridge line that is not aesthetically pleasing. It creates the look of a misaligned ridge like a ridge cap that doesn't quite belong. This is unlike the use of roof cupolas that add an aesthetically pleasing feature to a roof or the use of gable vents.
[0007] U.S. Pat. No. 4,942,699 (1990, Spinelli) discloses a ridge vent comprising a matting or matrix of randomly convoluted polymeric filaments heat bonded to a porous sheet material layer. The sheet material layer overlies the ridge peak opening and is wrapped around the edges of the filament matrix to prevent entry of foreign material into the matrix as well as into the attic. The sheet material layer permits the flow of ventilating air through the peak opening and outwardly beneath the ridge cap shingles.
[0008] U.S. Pat. No. 6,418,678 (2002, Rotter) discloses a contoured roof ventilation system. The ventilation system has a strip with an air-permeable portion located adjacent a ridge slot. Standoff clips are provided which can be placed over the air-permeable strip at fastener locations which are located on flat portions of the roof panels. A sealing material may be place beneath the air-permeable strip at such fastener locations to prevent the ingress of moisture beneath the panels.
[0009] Both of these device suffer from the same disadvantages described earlier, i.e., the problem of snow accumulation blocking ventilation along the ridge and the unaesthetic look of a ridge vent. Consequently, the proper venting of a roof continues to be a problem.
[0010] Not only is roof venting a problem, but also connecting one rafter to another requires that the rafters be attached securely. Various hangers have been devised to facilitate the attachment of rafters and joists. The following are examples of such devices.
[0011] U.S. Pat. No. 5,797,694 (1998, Breivik) discloses an adjustable ridge connector. The adjustable ridge connector has an elongated spine with a longitudinal axis. The spine has a first portion and a second portion. First and second opposed ears extend from the first portion of the spine in a direction transverse to the axis. Each of the ears has distal ends. First and second opposed flanges extend from the spine in a direction transverse to the longitudinal axis and are adjacent to the first and second ears. The first and second flanges form an arcuate taper towards the second portion of the spine. A first and a second seat tab extend longitudinally from the second portion of the spine in a direction transverse to the longitudinal axis and form an acute angle with respect to the longitudinal axis of the spine. Each of the seat tabs have distal ends. The flanges define a plurality of fastener openings. The openings are aligned about a plurality of vertically spaced axes. At least two sets of openings are formed by the plurality of openings; each set is distinguishable from the other for designating either skewed or non-skewed configurations.
[0012] U.S. Pat. No. 5,240,342 (1993, Kresa, Jr.) discloses a variable angle joist support. The variable angle joist support includes a base plate mounted to a first surface of a supporting beam and a pair of spaced apart support sides flexibly attached to the base plate. The support sides sandwich a joist to be supported at a variable interface angle relative to the beam. Each support side includes a support section which is positionable to fit flush against a respective side surface of the joist. The flexible attachment of the support sides to the base plate allows the support sides to pivot about a beam mounted base plate in order to receive a joist at any desired interface angle. The support sides can be flexibly attached to the base plate using hinges or malleable accordion shaped sections. The support sides can be provided with coplanar bottom flanges for support of and interconnection to a bottom surface of the joist. The support sides may be made of a malleable material or include multiple hinged support sections.
[0013] A disadvantage of these connector devices is the need to cut the butting end of the joist or rafter at the proper angle for attachment to a ridge board or other joist. This requires skill to determine the proper angle to form along with the proper length of the board. Another disadvantage is the time required to perform the cut of the joist or rafter at the proper angle for attachment to these connector devices.
[0014] Therefore, what is needed is a construction bracket that provides a more efficient way of connecting rafters during the framing/construction process. What is further needed is a construction bracket that does not require a user to perform an acute angle cut of the end of the joist or rafter before attaching to the construction bracket. What is also needed is a construction bracket that, when used to connect roof rafters at roof ridges, hips or valleys, creates a passageway to improve roof ventilation. What is yet further needed is construction bracket that forms a roof ventilation system unaffected by snow accumulation.
SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to provide a construction bracket that provides a more efficient way of connecting roof rafters by decreasing framing time and reducing the number of angle cuts required to fabricate sloped roofs. It is another object of the present invention is to provide a construction bracket that eliminates the need for compound angle cuts on rafter ends for roof hips and valleys. It is still another object of the present invention to provide a construction bracket that allows for easier attachment of light framing to large structural members at angled building configurations. It is a further object of the present invention to provide an internal ducting system for venting a roof that is more aesthetic than external systems and does not increase the height of the ridge. It is yet a further object of the present invention to provide improved airflow in a ventilated roof, even roofs with multiple gables, hips and/or valleys. It is another object of the present invention to provide proper roof ventilation even when the roof is covered with snow.
[0016] The present invention achieves these and other objectives by providing a construction bracket that has at least a first flange and a second flange connected to each other along one edge of each flange forming a “V” shaped bracket, which is either at a fixed or an adjustable angle. In its simplest configuration, the first flange is configured to connect to the end of a roof rafter that is square cut. An end having a square cut is one whose end is substantially perpendicular to the length of the board. The second flange is configured to connect to the end of a second roof rafter that is the opposing rafter to the one attached to the first flange, or in the case of a shed roof, to a header board. Because the need to make angled or compound angle cuts to the ends of the rafters forming the roof structure is eliminated, the time required to frame a roof is decreased thus providing a savings on labor cost.
[0017] Using a construction bracket of the present invention to join each paired rafter, or a shed roof rafter to a header board, creates a continuous internal space at the ridge, hip, or valley of a roof bounded by a covering such as the roof sheathing, which is typically plywood, or at the junction of the rafters of a shed roof with the header wall bounded by the shed roof sheathing. Unlike the typical construction structure where a ridge board, hip board or valley board is used to facilitate connecting the paired rafters together and creating a solid junction with the sheathing along these structures, this feature of the present invention, i.e. creating a continuous internal space along the rafter/rafter junctions, allows for improved airflow and roof ventilation even when the roof is covered by snow or when a large number of gables, ridges, hips, and valleys are present. This is so because no ridge vent is required. Gable end vents provide the vent outlet for the internal space. It also allows for improved airflow of shed roofs. An added feature is the improved aesthetic look of the roof line. Even in long, extended roof ridges, cupolas may be used to vent the roof at predetermined locations. The use of cupolas is an aesthetically pleasing and acceptable roof design feature.
[0018] The construction bracket of the present invention may be provided in a variety of configurations. In one embodiment, the construction bracket may include a pivotable junction between the first and second flange. The pivotable junction allows for adaptability and adjustability to practically any roof angle design. “A rafter joining board” may be used to connect a plurality of construction brackets together along each of the first and second flanges to facilitate the joining of all of the roof rafters together. These rafter joining boards are used to connect the rafters together in much the same way a ridge board is used to facilitate joining of roof rafters as currently practiced in the art.
[0019] In addition to the use of rafter joining boards, standard joist brackets may also be used to attach to the rafter joining boards to further facilitate the rafter construction/assembly process. In another embodiment, the construction bracket may have joist hangers attached directly to each of the first and second flanges or may be integrally formed with the construction bracket. In yet another embodiment of the present invention, the construction bracket may have a predetermined, continuous length capable of receiving a predetermined number of rafters. An advantage of this embodiment having a pivotable junction allows the framers to attach a predetermined number of rafters to the construction bracket and then raise this “pre-built” section of roof framing to the desired location. Markings may also be incorporated onto the surface of each flange at locations that match the proper construction code-defined spacing between each rafter to eliminate the need to measure, mark, and attach each rafter according to the required construction code spacing. This has the advantage of also saving time during the framing process.
[0020] For roofs of relatively low pitch, another embodiment of the present invention provides a way to insure that a sufficient internal space is formed between the rafters. In this embodiment, the construction bracket includes a base between the first and second flanges. In use, this embodiment has the shape of square-shaped “U” where the extending legs flare away from the inside of the “U”. The base, which corresponds to the bottom of the square-shaped “U”, provides the necessary spacing between the first and second flanges to create a sufficient internal volume between the rafters. Like the V-shaped construction bracket of the present invention, the first and second flanges may be fixedly attached to each side of the base or they may be pivotably attached allowing for a range of roof pitches.
[0021] The U-shaped bracket of the present invention may also have the additional features that the V-shaped bracket may have as described above. Both the U-shaped and V-shaped brackets may incorporate a predetermined amount of insulation at the bottoms of the brackets to further reduce possible heat loss through the bracket. The U-shaped bracket may be further configured to accommodate a ridge beam against the outside surface of the base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1A and 1B are perspective views of a simplified embodiment of the present invention.
[0023] FIG. 2 is a side plan view of one embodiment of the present invention showing rafter ends connected directly to the first and second flanges.
[0024] FIG. 3 is a side plan view of the present invention in FIG. 2 showing the use of a rafter connecting board between each of the first and second flanges.
[0025] FIG. 4 is a side plan view of the present invention in FIG. 3 showing the use of the construction bracket for connecting the rafter ends of a shed roof to a wall.
[0026] FIGS. 5A and 5B are side plan views of another embodiment of the present invention showing the first and second flanges connected to each other through a base portion.
[0027] FIG. 6 is a side plan view of the embodiment of the present invention in FIG. 5A showing the rafter ends connected directly to the first and second flanges.
[0028] FIG. 7 is a side plan view of the embodiment of the present invention in FIG. 5B showing the use of a rafter connecting board between each of the first and second flanges.
[0029] FIG. 8 is a perspective view of another embodiment of the present invention showing an elongated construction bracket with first and second flanges for receiving a plurality of rafters.
[0030] FIG. 9 is a perspective view of another embodiment of the present invention showing an elongated construction bracket with a base and first and second flanges for receiving a plurality of rafters.
[0031] FIG. 10 is a perspective view of another embodiment of the present invention showing a plate-type construction bracket with a pivotable joint.
[0032] FIG. 11 is a side view of the embodiment in FIG. 10 showing the embodiment mounted to a pair of rafters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] The preferred embodiment(s) of the present invention are illustrated in FIGS. 1-9 . FIG. 1A shows a perspective view of a simplified construction bracket 10 of the present invention. Construction bracket 10 includes a first flange 20 having first flange edge 21 , a first flange inside surface 22 and a first flange outside surface 24 (not shown), and a second flange 40 having a second flange edge 41 , a second flange inside surface 42 (not shown) and a second flange outside surface 44 . First flange 20 and second flange 40 are joined along first flange edge 21 and second flange edge 41 . Construction bracket 10 may be constructed by connecting first flange 20 to second flange 40 by any means known to those skilled in the art for attaching one flange to another flange. If construction bracket 10 is made of metal, first flange 20 may be welded to second flange 40 at a predetermined angle of separation θ. Construction bracket 10 may also be formed as a single piece such as by casting or stamping. If construction bracket 10 is made of nonmetal, first flange 20 may be attached to second flange 40 using fasteners, adhesives, joining components, etc. Turning now to FIG. 1B , there is illustrated a construction bracket 10 having an adjustable angle of separation θ. Construction bracket 10 includes a hinge 30 joining first flange 20 to second flange 40 . Flanges 20 and 40 may optionally include a plurality of holes/openings 12 for receiving construction fasteners such as nails, screws and the like.
[0034] FIG. 2 shows the construction bracket 10 in cross-section in a typical roof frame application. A first rafter 110 is connected to first flange outside surface 24 and a second rafter 110 ′ is connected to second flange outside surface 44 . When a covering such as roof sheathing 120 is applied to the rafters to enclose the roof, the plurality of construction brackets 10 form an internal ducting space 130 . Optionally, insulation 140 may be provided on the inside of construction bracket 10 .
[0035] Turning now to FIG. 3 , there is illustrated construction bracket 10 where a rafter joining board 150 is incorporated to facilitate the assembly of the roof frame. Rafter joining board 150 joins a plurality of construction brackets 10 much like construction methods currently used where a ridge board is used to join the roof rafters together. Additionally, optional joist hangers 152 may be used to attach rafters 110 and 110 ′ to rafter joining board 150 . It should be noted that construction brackets 10 may also be provided with joist hangers already attached to first flange surface 24 and second flange surface 44 forming an integral unit.
[0036] Construction bracket 10 may also be used in shed roof construction. FIG. 4 illustrates a partial cross-sectional view of construction bracket 10 connecting shed roof rafter 110 to first flange 20 and second flange 40 attached or connected to wall 122 . This illustration shows the use of a rafter joining board 150 and joist hanger 152 . It is noted that an internal ducting space 130 is also formed between wall 122 and construction bracket 10 and enclosed by roof sheathing 120 . Internal ducting space 130 may be vented with outside wall vents in an unobtrusive and aesthetically pleasing way while providing proper venting to the shed roof.
[0037] A second embodiment of construction bracket 10 is illustrated in FIGS. 5A and 5B . Turning to FIG. 5A , construction bracket 10 ′ includes a first flange 20 having first flange edge 21 , an first flange inside surface 22 and a first flange outside surface 24 (not shown), a base 60 having first base side 61 , a second base edge 61 ′ , a base inside surface 62 , and a base outside surface 64 (not shown) and a second flange 40 having a second flange edge 41 , a second flange inside surface 42 (not shown) and a second flange outside surface 44 . First flange 20 and second flange 40 are joined to base 60 along first flange edge 21 and first base edge 61 and along second flange side 41 and second base edge 61 ′.
[0038] Construction bracket 10 ′ may be constructed by connecting first flange 20 and second flange 40 to base 60 by any means known to those skilled in the art. If construction bracket 10 ′ is made of metal, first flange 20 and second flange 40 may be welded to first base edge 61 and second base edge 61 ′ , respectively, at a predetermined angle of separation θ. Construction bracket 10 ′ may also be formed as a single piece such as by casting or stamping. If construction bracket 10 ′ is made of nonmetal, first flange 20 and second flange 40 may be attached to base 60 using fasteners, adhesives, joining components, etc. Turning now to FIG. 5B , there is illustrated a construction bracket 10 ′ having an adjustable angle of separation θ. Construction bracket 10 ′ includes a first hinge 30 and a second hinge 30 ′ joining first flange 20 and second flange 40 to base 60 . Flanges 20 and 40 and base 60 may optionally include a plurality of holes/openings 12 for receiving construction fasteners such as nails, screws and the like.
[0039] FIG. 6 shows the construction bracket 10 ′ in cross-section in a typical roof frame application. A first rafter 110 is connected to first flange outside surface 24 and a second rafter 110 ′ is connected to second flange outside surface 44 . When roof sheathing 120 is applied to the rafters to enclose the roof, the plurality of construction brackets 10 ′ form an internal ducting space 130 . Construction bracket 10 ′ is preferably used in roof construction having a relatively low pitch. Base 60 of construction bracket 10 ′ provides a predefined separation between first flange 20 and second flange 40 to allow the formation of internal ducting space 130 having sufficient volume for venting the roof. Optionally, insulation 140 may be provided on the inside of construction bracket 10 ′.
[0040] Turning now to FIG. 7 , there is illustrated construction bracket 10 ′ where a rafter joining board 150 is incorporated to facilitate the assembly of the roof frame. Rafter joining board 150 joins a plurality of construction brackets 10 ′ much like construction methods currently used where a ridge board is used to join the roof rafters together. Additionally, optional joist hangers 152 may be used to attach rafters 110 and 110 ′ to rafter joining board 150 . It should be noted that construction brackets 10 ′ may also be provided with joist hangers already attached to first flange surface 24 and second flange surface 44 as integral components. Base 60 may optionally be attached to a ridge beam 126 in construction where ridge beam 126 is incorporated in the roof design.
[0041] It is noted that construction brackets 10 and 10 ′ may be used not only on roof ridges, but may also be incorporated into roof hips, valleys and gables. Even where roof ventilation is not a major concern, construction brackets 10 and 10 ′ will reduce the cost of constructing the roof frame by eliminating the need to make angle cuts at the rafter ends used for framing roof ridges, hips, valley, gables, and shed roofs. Whether I-beams or other dimensioned lumber is used, construction brackets 10 and 10 ′ may be adapted for attachment to the necessary joining structure.
[0042] Turning now to FIGS. 8 and 9 , there is illustrated yet other embodiments of construction brackets 10 and 10 ′. FIG. 8 shows a construction bracket 11 that is similar to construction bracket 10 but may optionally be of any length to accommodate attachment of a plurality of rafters. This would facilitate pre-assembling of roof sections that could be joined together to form the roof frame. Construction bracket 11 may also include indicia 170 on any of the surfaces 22 , 24 , 42 , and 44 that would indicate proper placement of the roof rafter without requiring the user to measure the required distance between each adjacent rafter.
[0043] FIG. 9 shows construction bracket 11 ′ that is similar to construction bracket 10 ′ but may optionally be of any length to accommodate attachment of a plurality of rafters. This would also facilitate pre-assembling of roof sections that could be joined together to form the roof frame. Construction bracket 11 ′ may also include indicia 170 on any of the surfaces 22 , 24 , 42 , and 44 that would indicate proper placement of the roof rafter without requiring the user to measure the required distance between each adjacent rafter.
[0044] Turning now to FIG. 10 , there is illustrated yet another embodiment of the present invention. Construction bracket 200 includes a first rafter bracket 210 , a second rafter bracket 220 , and a bracket connecting plate 230 . Each of the brackets 210 and 220 and the connecting plate 230 have a pivotable hinge point 212 , 222 and 232 , respectively. First rafter bracket 210 includes a first bracket plate 214 with a an edge portion 215 having a first bracket pivot extension 216 that is coplanar with plate 214 and a first bracket tab portion 217 extending substantially perpendicular to plate 214 . First bracket pivot extension 216 incorporates pivotable hinge point 212 . First bracket tab portion 217 is used to abut the end of the rafter to which it is attached.
[0045] Second rafter bracket 220 is a mirror-image of first rafter bracket 210 and includes a second bracket plate 224 with a an edge portion 225 having a second bracket pivot extension 226 that is coplanar with plate 224 and a second bracket tab portion 227 extending substantially perpendicular to plate 224 . Second bracket pivot extension 226 incorporates pivotable hinge point 222 . Second bracket tab portion 227 is used to abut the end of the rafter to which it is attached.
[0046] Bracket connecting plate 230 is a substantially flat plate used for securing the construction rafters at a predefined angle of the roof to create the internal duct space 250 (not shown). Bracket connecting plate 230 , first rafter bracket 210 and second rafter bracket 220 may be connected to each other at pivotable hinge points 232 , 212 and 222 using any known fastening mechanism that permits pivotal movement of the first and second rafter brackets 210 and 220 , respectively. One example of an inexpensive fastener is a rivet sized to allow the components of construction bracket 200 to pivot relative to each other. The first and second rafter brackets 210 and 220 and the bracket connection plate 230 each have a plurality of openings 202 for receiving fasteners such as nails or screws or lag bolts or the like for securing the construction bracket 200 to the roof rafters and fixing the angle of the roof rafters.
[0047] FIG. 11 shows the construction bracket 200 in cross-section in a typical roof frame application. A first rafter 110 is connected to first bracket plate 214 and first bracket tab portion 217 and a second rafter 110 ′ is connected to second bracket plate 224 and second bracket tab portion 227 . Once the proper roof angle is set by the user, then bracket connecting plate 230 is secured to first rafter 110 and second rafter 110 ′ through first rafter bracket 210 and through second rafter bracket 220 . When roof sheathing 120 is applied to the rafters to enclose the roof, the plurality of construction brackets 200 form an internal ducting space 250 .
[0048] Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims.
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A method of creating a roof venting space includes assembling a plurality of roof rafters where at least one end of the plurality of roof rafters are assembled to a surface to define a space between the one end of the plurality of roof rafters and the surface, attaching roof sheathing to the outside of the plurality of roof rafters where the roof sheathing covers the space creating a continuous internal ducting space, and connecting a vent to the continuous internal ducting space.
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BACKGROUND
[0001] Tools in the downhole drilling and completions industry are often located in a borehole by the use of no-go profiles (or landing nipples, radially inner restrictions, etc.). While these no-go profiles are relied upon for providing positive indication that a tool is properly set, too much load on the tool can deform or swage the tool and/or the no-go profile. If a tool becomes swaged into a no-go profile, retrieval of the tool can become difficult and the tool and profile can become damaged. As a result, advances to the setting and subsequent retrieval of tools, particularly those overcoming the above problems, are well received by the industry.
BRIEF DESCRIPTION
[0002] A system for setting and retrieving a tool including a tubular having a first profile and a tool having a second profile, the first and second profiles complementarily formed and engagable together for enabling the tool to be located in a borehole with respect to the tubular, the first profile or the second profile at least partially formed from a degradable material, the degradable material degradable upon exposure to a downhole fluid.
[0003] A system for setting and retrieving a tool including an engagement including a first profile of a first component and a second profile of a second component, the engagement operatively arranged for locating the first component in a borehole with respect to the second component, the first profile at least partially degradable by exposure to a downhole fluid.
[0004] A component of a no-go engagement including a first profile operatively arranged to engage with a second profile of the no-go engagement for locating a tool downhole, the first profile at least partially degradable upon exposure to a downhole fluid.
[0005] A method of setting and retrieving a tool downhole including landing a first profile of a tool at a second profile of a tubular, exposing the first profile or the second profile to a downhole fluid for degrading the first profile or the second profile at least partially.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0007] FIG. 1 is a quarter-sectional view of a system having a no-go engagement between a tubular and a tool;
[0008] FIG. 2 is an enlarged view of the area generally encircled in FIG. 1 ;
[0009] FIG. 3 is a quarter-sectional view of the system of FIG. 1 having dogs of the tool set into recesses of the tubular;
[0010] FIG. 4A is a cross-sectional view of the system taken generally along line 4 A- 4 A in FIG. 1 ;
[0011] FIG. 4B is a cross-sectional view of the system taken generally along line 4 B- 4 B in FIG. 1 ;
[0012] FIG. 5 is a quarter-sectional view of the system of FIG. 1 after application of an additional load on the tool;
[0013] FIG. 6 is an enlarged view of area generally encircled in FIG. 5 ; and
[0014] FIG. 7 is a quarter-sectional view of the system of FIG. 1 after a ring of the no-go engagement has been removed by degradation.
DETAILED DESCRIPTION
[0015] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0016] Referring now to FIG. 1 , a system 10 is shown having a tool 12 being run in a tubular 14 . As shown in more detail in FIG. 2 , the system 10 includes a no-go engagement 16 comprising a landing profile 18 on the tubular 14 and a no-go ring 20 on the tool 12 having a corresponding profile 22 . Once received at the landing profile 18 , positive interference or radial overlap with the profile 22 of the ring 20 prevents the tool 12 from traveling further downhole. The tool 12 is illustrated throughout the Figures in the form of a lock mandrel, but it will be appreciated that other tools or downhole components (the term “tool” used collectively herein) could utilize the no-go engagement of the current invention. That is, for example, tools benefiting from the current invention include those that carry a load in excess of the setting load such as plugs, tubing hangers, check valves, etc.
[0017] Accordingly, after landing at the profile 18 , a setting load is applied to the tool 12 , specifically on a sub 24 for the tool 12 . The sub 24 includes a mandrel 26 for engaging with one or more dogs 28 and expanding the dogs 28 radially outwardly into complementarily formed recesses 30 in the tubular 14 , as shown in FIG. 3 . This creates positive interference or a radial overlap between the dogs 28 and the tubular 14 , which can be appreciated by comparing FIGS. 4A and 4B .
[0018] Under high pressure or an additional force or load after being set (e.g., the tool including or being formed as a plug housing, check valve retainer, tubing hanger, etc., as noted above), the tool 12 is shifted downhole such that the dogs 28 result in an engagement at a surface 32 of the recesses 30 , as shown in FIG. 4 . Once the dogs 28 are fully engaged against the walls of the recesses 30 , the tubular 14 , via the dogs 28 , picks up the weight of the tool 12 and any components hanging therefrom or pressures applied thereto.
[0019] Shifting the dogs 28 downhole to engage at the surface 32 , however, causes the ring 20 of the tool 12 to also shift downhole, becoming swaged into the landing profile 18 of the tubular 14 . As shown in more detail in FIG. 5 , the ring 20 is deformed a distance D into the landing profile 18 of the tubular 12 . This swaging makes retrieval of the tool 12 difficult as it significantly increases the force required to pull the ring 20 , and therefore the tool 12 , free of the tubular 14 .
[0020] In order to facilitate the retrieval of the tool 12 in the system 10 , the no-go engagement 16 is at least partially degradable. “Degradable” is intended to mean that the ring is disintegratable, dissolvable, corrodible, consumable, or otherwise removable. It is to be understood that use herein of the term “degrade”, or any of its forms, incorporates the stated meaning. The ring 20 is formed as any known degradable material, such as a metal, polymer, composite, etc. that is removed or weakened by exposure to a downhole fluid, for example, water, oil, acid, brine, etc. In FIG. 6 the ring 20 has been removed by exposure to one of the downhole fluids, for example, by spotting acid to the ring 20 . In another example, the material of the ring 20 could be selected such that is degrades more slowly over time, and is sufficiently weakened or removed by the time any additional load is applied to the tool 12 . Once the ring 20 is removed, there is no longer a swaged engagement of the tool 12 with the tubular 14 , thereby facilitating removal of the tool 12 . It is also to be appreciated that degrading of the ring 20 could occur before application of the additional pressure or force on the tool 12 , such that swaging never occurs, in which case the dogs 28 would engage with the surface 32 before the application of any additional pressures, loads, or forces (e.g., for or with operation of a plug, check valve, tubing hanger, etc.).
[0021] Although the system 10 is shown with the tool 12 disposed radially inwardly of the tubular 14 , in another embodiment a tool could be located radially outwardly of a tubular, with a degradable ring disposed radially inwardly of the tool. In another embodiment, the degradable ring could be formed as part of the tubular with the tool including a non-degradable landing profile. The ring 20 could be a c-ring, a full ring held by a retainer, a full ring that is press fit onto or into the tool or tubular, etc. Furthermore, although the term “ring” is used consistently herein, it is to be appreciated that other members or portions of a non-go engagement could be used for decreasing the amount of undesirable swaging between two components in order to facilitate retrieval of one or both of the components.
[0022] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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A system for setting and retrieving a tool including a tubular having a first profile and a tool haing a second profile, the first and second profiles complementarily formed and engagable together for enabling the tool to be located in a borehole with respect to the tubular, the first profile or the second profile at least partially formed from a degradable material, the degradable material degradable upon exposure to a downhole fluid.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a Continuation-In-Part patent application which claims priority to U.S. Utility patent application Ser. No. 14/833,138, filed on Aug. 23, 2015, entitled “Thermal break system and method for door and windows”, now U.S. Pat. No. 9,470,037 to issue Oct. 18, 2016, which claims priority to U.S. Provisional Patent Application Ser. No. 61/926,412, filed on Jan. 13, 2014, further this application claim priority to Chinese Patent Application serial number 201620628542.8, filed Jun. 23, 2016 the disclosures of which is hereby incorporated in its entirety at least by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the technical field of building materials, more particularly a thermal break system and method for doors and windows.
BACKGROUND OF THE INVENTION
[0003] Aluminum and other metals are often used for the structure of many doors and windows due to their strength and ductability, which facilitates the fabrication of strong windows and doors in a variety of shapes. However, the high conductivity of metal results in low thermal efficiency. Heat is conducted through the door or window structure, into the building on hot days and out of the building on cold days. Extra energy is required to offset this heat transfer and maintain a comfortable environment within the building. Also, on cold days, condensation or even frost can build up on the door or window structure, inside the building, potentially damaging floors and surrounding areas. Consequently, there is a need for a thermal break system that can limit heat transfer and provide energy-saving benefits.
BRIEF SUMMARY
[0004] A door assembly is provided, comprising a door frame including an inside steel panel having an inner surface and an outer surface, and a C-shaped section extending about a periphery thereof with a portion of the C-shaped section extending in part parallel to the inner surface of the inside steel panel; an outside steel panel having an inner surface and an outer surface, and a C-shaped section extending about a periphery thereof with a portion of the C-shaped section extending in part parallel to the inner surface of the outside steel panel; an insulating material interposed between respective C-shaped sections of the inside steel panel and the outside steel panel to thermally isolate the inside steel panel and the outside steel panel from each other, and said inside steel panel and outside steel panel being secured together at respective C-shaped sections to form the thermal break system; and a doorjamb including a threshold comprising a second insulating material positioned between a first threshold portion and second threshold portion, wherein the first threshold portion is sloped and includes one or more internal weep tubes passing through the second insulating material and first threshold portion allowing residual rainwater to discharge from the assembly.
[0005] In one embodiment, a lockset including lock plates and latch plates, wherein the lockset is offset and positioned entirely in either one of the respective C-shaped section preventing heat transfer though the lock plates and the latch plates.
[0006] In another aspect of the invention, a door assembly is provided, comprising a door frame including a first side having a first inner surface, a first outer surface, a first edge, and a second edge, the distance between the first edge and second edge defining a first width; a first panel located at the first edge extending perpendicularly from the first inner surface at a first depth; a second panel located at the second edge extending perpendicularly from the first inner surface at a second depth; a first land perpendicularly connected to the first panel extending parallel to the first inner surface, the first land having a first length; a second land perpendicularly connected to the second panel extending parallel to the first inner surface, the second land having a second length; a second side having a second inner surface, a second outer surface, a third edge, and a fourth edge, the distance between the third edge and fourth edge defining a second width; a third panel located at the third edge extending perpendicularly from the second inner surface at a third depth; a fourth panel located at the fourth edge extending perpendicularly from the second inner surface at a fourth depth; a third land perpendicularly connected to the third panel extending parallel to the second inner surface, the third land having a third length; a fourth land perpendicularly connected to the fourth panel extending parallel to the second inner surface, the fourth land having a fourth length; a first thermal break having a third width positioned between the first and third land; a second thermal break having a fourth width positioned between the second and fourth land; the first width and the second width being identical; the first length, third length, and third width being identical; the second length, the fourth length, and the fourth width being identical; the first depth and the second depth being identical; the third depth and the fourth depth being identical; wherein the outer surface of the first side is exposed to an external environment and the second outer surface of the second side is exposed to an internal environment; and the third and fourth depths are greater than the first and second depths corresponding to the first and second thermal breaks positioned closer to the external environment improving efficiency.
[0007] In one embodiment, a plurality of metal screws provided, wherein the plurality of metal screws are designed to clamp the first land, the third land, and the first thermal break together and the second land, the fourth land, and the second thermal break together, the plurality of metal screws providing mechanical strength. In another embodiment, a doorjamb is provided, including a threshold having a third thermal break positioned between a first threshold portion, a second threshold portion, and the doorjamb, wherein the first threshold portion is sloped and includes one or more internal weep tubes passing through the third thermal break and first threshold portion, wherein the one or more internal weep tubes have openings and exits allowing residual rainwater to discharge from the assembly. In one embodiment, the second threshold portion is sloped to allow infiltrated water to flow toward the one or more internal weep tube openings.
[0008] In one embodiment, a pair of bottom sweeps are provided, wherein the pair of bottom sweeps are mounted below a door to prevent air in the external environmental from entering the internal environment while providing a heat insulation effect. In another embodiment, a seal is provided, wherein the seal is positioned toward a front end of the first threshold portion providing insulation while blocking air and water infiltration. In one embodiment, a vertical lip is welded to a bottom portion of the door that connects with the seal creating a positive seal against air and water infiltration. In yet another embodiment, a lockset including lock plates and latch plates is provided, wherein the lockset is offset and positioned entirely in either the first side or second side preventing heat transfer though the lock plates and the latch plates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a perspective view of a pair of doors constructed according to the present invention.
[0011] FIG. 2 is an exploded cross section view of a thermal break created in a straight tube assembly.
[0012] FIG. 3 is a cross-section view of a tube after construction shown with two sides connected through an insulating strip.
[0013] FIG. 4 is a partial top section view of an arched door constructed according to the invention.
[0014] FIG. 5 is an exploded view of the door of FIG. 4 showing the components thereof.
[0015] FIG. 6 is a cross-section view of a threshold according to the present invention.
[0016] FIG. 7 is partial perspective view of a lockset according to the present invention.
[0017] FIG. 8 is a perspective view of a doorjamb according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0018] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out their invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the general principles of the present invention have been defined herein to specifically provide a thermal break system and method for doors and windows.
[0019] Referring now to FIGS. 1-8 , a thermal break system and method for doors and windows is provided. FIG. 1 illustrates a double-insulated door 100 , wherein a threshold ( FIG. 6 ) is located below the double-insulated open doors. The double-insulated doors includes Door 1 and Door 2 each comprising a first vertical rail 101 , a second vertical rail 102 , a horizontal door panel 105 , a curved rail 103 , and a curved reinforcing plate 104 . The horizontal door panel connects the first and second vertical rails at the bottom of each of the double-insulated open doors, while the curved reinforcing plate is mounted a low portion on the first and second vertical rails as illustrated. Likewise, the curved rail connects the first and second vertical rails at the top of each of the double-insulated open door. Thermal break 8 is affixed between door profiles sides 1 and 2 , creating a metal tube. The connection and assembly of these profiles will be described in detail below.
[0020] Referring now to FIGS. 2 and 3 , a tube is constructed using two sides, 1 and 2 , made in a “C” profile having identical widths 3 with varying depths 4 and 5 . One tube 1 is made up of an outer surface and an inner surface of an outside steel panel, for example, making up the surface of a door facing the exterior. The outer surface thereof faces the exterior of a building. The inner surface faces the tube 2 making up the panel facing the interior of a building. With respect to tube 2 , its inner surface faces the inner surface of tube 1 , and its outer surface faces the interior of a building when assembled. The sides terminate with lands 6 and 7 having a width which is less than 50% of the width of profiles 1 and 2 , determined by the strength requirement of the particular application. Insulating strips 8 , with a width approximately the same as lands 6 and a depth sufficient to provide the degree of insulation required, are sandwiched between profiles 1 and 2 , coincident with lands 6 and 7 . The assembly is joined using a plurality of self-drilling, self-tapping screws 9 in combination with an adhesive means applied to adjacent faces of lands 6 and 7 , and insulating strips 8 . Screws 9 , having an insulating washer means 11 under the screw head, pass through temporary access holes 10 , whose diameter is sufficient to allow washer means 11 to easily pass. Typical adhesives useful for the invention include Liquid Nails, Bostick, Dap or Tightbond. Alternative screw arrangements may be self-tapping but not self-drilling, in which case suitable pilot holes may be pre-drilled in lands 6 and 7 , as well as insulating strips 8 along an axis coincident with access holes 10 .
[0021] It is a particular advantage of the present invention that the insulating strips 8 are positioned toward the outside, that is the thermal break is positioned closer to the exterior, wherein depth 4 is larger than depth 5 . This configuration reduces the mass on the outside panel or side 2 . Further since the weight of the door is carried by the side 1 , it lowers stress on door joints and reduces exposure of the outside panel to elements which improves efficiency.
[0022] FIG. 3 is a cross-section view of a tube after construction shown with two sides connected through an insulating strip. FIG. 3 shows a cross section of the tube after construction where the sides 1 and 2 are connected with insulating strips 8 , typically made of ABS, sandwiched between them. The adjoining faces of lands are connected using a suitable adhesive medium and/or a mechanical connection using a plurality of screws 9 with insulated washer means 11 to connect lands 6 and 7 , passing through insulating strips 8 . Access holes 10 are not shown since they have been closed with electric arc welding.
[0023] FIG. 4 is a partial top section view of an arched door constructed according to the invention. Referring now to FIG. 4 a top section of an arched door frame is shown, which has been constructed using the same method as shown for the embodiment in FIG. 2 and FIG. 3 . However, in this case the assembly comprises two upright stiles 31 and 32 and a curved rail 33 . The method of construction is essentially similar to that shown in FIG. 2 and FIG. 3 .
[0024] FIG. 5 shows the components of the same section of door shown in FIG. 4 but prior to assembly. Side 1 and side 2 are each comprised of three “C” sections of steel. Side 1 comprises upright stiles 41 and 42 , plus a curved rail 43 . Side 2 comprises upright stiles 44 and 45 , plus a curved rail 46 . Upright stiles 42 , 42 , 44 and 45 have been made by bending sheet steel in a press break. Curved rails 43 and 46 have been fabricated out of sheet steel by cutting the curved shapes that are required in the vertical plane and cutting and bending the shapes needed in the horizontal plain. These components are then welded together to form the curved “C” sections. Specifically, upright stiles 41 and 42 are welded to curved rail 43 to form side 1 of the assembly. Similarly, curved rail 46 and upright stiles 44 and 45 are welded together to form side 2 . Side 1 and 2 include lands (a), (b), (c), and (d). Insulating strips 48 and 49 comprising sections (e), (f), (g), (h), (i), and (j) are cut from sheet material to a size and shape coincident with lands (a), (b), (c), and (d) of sides 1 and 2 . A plurality of temporary access holes 47 are drilled into side 2 so as to facilitate assembly with adhesive and screws the same as shown in FIGS. 2 and 3 . These access holes will be welded closed after assembly.
[0025] FIG. 6 is a cross-section view of a threshold according to the present invention. Referring now to FIG. 6 , insulation 50 (thermal break) is positioned toward the inner end of an outer threshold portion 51 , and toward the inside of an inner threshold portion 52 constituting the intermediate heat shield. Preferably, threshold portions 51 and 52 are foam filled. The outside of the front end of the threshold comprises a slope 53 , which helps discharge rainwater. Welded to door is a downward slope element 56 or drip guard to direct rainwater to slope 53 . Threshold outer portion 51 comprises a weep tube 54 with opening 55 , allowing the residual rainwater through the weep to exit beyond the threshold to the outside preventing water and rainfall buildup above the thermal break which would spill into the building. Portion includes sloped surface 59 so that any water infiltrated flows towards weep tube opening 55 . Bottom sweeps 57 are mounted below the door, wherein the door sweeps prevents air outside from entering into the building from the outside and provides the heat insulation effect. An embedded kerf seal 58 is included toward the front end of the outer threshold portion 51 , wherein the embedded seal provides insulation while blocking air and water infiltration. Although one weep tube is illustrated it is understood that more than one weep tube may be included. Vertical lip 60 welded to door bottom connects with seal 58 , creating a positive seal against air and water infiltration. It is a particular advantage of the present invention, that the weep tube passes through thermal break 50 while allowing any accumulated water from space 61 to enter opening 55 of weep tube 54 and exit the threshold.
[0026] In one embodiment, the double-insulation door may be comprised of glass. Further, the C-shaped metal tube may be constructed of steel, aluminum, copper or aluminum alloy, or any other conductive material that would require a thermal break in order to control heat transfer. This design approach can be very effective in reducing the energy exchange, energy conservation in cold areas play a positive role. It is a particular advantage of the present invention to protect the doors and windows in cold areas to prevent damage to the doors and windows via frost.
[0027] Referring now to FIG. 7 , a lockset is illustrated. In another preferred embodiment, C sections 1 and 2 have unequal depths 4 and 5 , so that the constructed tube of FIG. 3 is comprised of a larger side and smaller side. The installation of the lockset and/or deadbolt is also offset from center slightly so as to allow the mechanism and edge borings to be contained exclusively within the larger side. This prevents the lock plates 72 and striker plates 71 from creating a thermal bridge by crossing the thermal break, greatly increasing the thermal insulation effect at the position of the lockset, while facilitating the retention of a standard door thickness, between 1¾″ and 2¼″ thick. It should be understood that although FIG. 7 illustrates side 1 as the larger side, it is understood that side 2 may be the larger side, wherein the wherein the lockset is offset and positioned entirely in the larger side preventing heat transfer though the lock plates and the latch plates.
[0028] Referring now to FIG. 8 , a doorjamb is illustrated. Similarly to the door frame assembly described above, the doorjamb is comprised of two sides 81 and 82 with an insulation strip or thermal break 83 positioned between the two sides. The doorjamb supports the door frame and threshold as well known in the art.
[0029] It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.
[0030] In addition, reference to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) are not used to show a serial or numerical limitation but instead are used to distinguish or identify the various members of the group.
[0031] In addition, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of,” “act of,” “operation of,” or “operational act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.
[0032] While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.
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A door assembly providing a door frame including an inside steel panel having an inner surface and an outer surface, and a C-shaped section extending about a periphery thereof with a portion of the C-shaped section extending in part parallel to the inner surface of the inside steel panel; an outside steel panel having an inner surface and an outer surface, and a C-shaped section extending about a periphery thereof with a portion of the C-shaped section extending in part parallel to the inner surface of the outside steel panel; an insulating material interposed between respective C-shaped sections of the inside steel panel and the outside steel panel to thermally isolate the inside steel panel and the outside steel panel from each other, and said inside steel panel and outside steel panel being secured together at respective C-shaped sections to form the thermal break system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from U.S. Provisional Application No. 62/047,198, filed Sep. 8, 2014, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] This invention generally relates to lath, and more particularly to a stapling system for affixing a drainage material to lath.
BACKGROUND OF THE INVENTION
[0003] The use of hard coat stucco has been employed as a building material since literally ancient days. For stucco and plaster applications, a lath or mesh substrate is typically applied to the surface of the wall or ceiling structure. This provides a base for mechanical holding or keying for the unhardened stucco or plaster. Metal lath is often used as the reinforcement when stucco or plaster is applied over open frame construction, sheathed frame construction, or a solid base having a surface that might otherwise provide an unsatisfactory bond for the stucco or plaster. Plastic and other kinds of lath have also been used. When applied over frame construction, one may often employ base coats of plaster with a total thickness of approximately ⅜ inch to approximately ¾ inch to produce a solid base for a decorative finish coat.
[0004] According to the International Conference of Building Officials Acceptance Criteria for Cementitious Exterior Wall Coatings, AC 11, effective Oct. 1, 2002, and evaluation report NER-676, issued Jul. 1, 2003, wire fabric lath should be a minimum of No. 20 gauge, inch (25.4 mm) (spacing) galvanized steel woven-wire fabric. The lath should be self-furred, or furred when applied over all substrates except unbacked polystyrene board. Metal lath has structural integrity, but if made of steel can corrode over time. The metal can also unfavorably react with the chemistry of the plaster or stucco. Hence, plastic or non-metal lath has gained popularity.
[0005] Stone veneer has also gained in popularity. Mounting of stone veneer using lath can present similar issues to that of plaster and stucco. A concern with the stone veneer, and even stucco, is that moisture can find its way behind the outer stone or stucco surface. This can present itself by way of hole penetrations in putting up the lath, and water condensing or otherwise migrating behind the lath.
[0006] Also, a matrix of randomly oriented plastic or other durable fibers which are relatively rigid, or which can be treated to be relatively rigid or organized into a matrix that is relatively rigid, has been employed as the lath. An example of the foregoing kind of material is sold under the name MORTAR NET, sold by Mortar Net, Inc. of Burns Harbor, Ind., and such as disclosed in U.S. Pat. No. Re. 36,676. Such a matrix lath has typically been on the order of around except ¼″ thick (in front-to-back width).
[0007] Mortar Net, Inc. has created a system to allow water which may have penetrated cracks in the stucco or between the mortar and veneer to drain out, and to prevent water from entering the structure. To that end, a layer that forms a water channel layer has been applied in combination with the lath. The water channel layer has typically been of material similar to that of the foregoing matrix lath, but of a smaller fibrous diameter entangled randomly-oriented plastic or other durable fiber, formed in a thinner width, such as 3/16″ or ¼″ WALLNET product, made or sold under that name by Mortar Net, Inc. from stock material made by the Fiber Bond Corporation. More details of the foregoing system and product can be gleaned from U.S. application Ser. No. 13/838,993, filed Mar. 22, 2013.
SUMMARY OF THE INVENTION
[0008] An improvement on the foregoing water channel and lath combination is to combine the water channel layer with the lath prior to its installation, as on an inner wall structure, The combination results in a stock material that enables easier, faster installation compared to individual lath and drainage components being assembled in situ. Further, the combination of the two layers can reduce penetrations to other layers or elements of the wall structure which are not desired to necessarily be punctured (leading to water entry points, for instance).
[0009] The implementations discussed herein are a cost-effective and expeditious way of attaching a water channel layer to lath pre-installation, for subsequent application to an inner wall structure, increasing the efficiency and decreasing the cost of building construction.
[0010] In one example, a water channel layer is placed in contact (as in vertically atop) a layer of lath. The surface area of the water channel layer may preferably be less than that of the lath, such that a region of lath remains exposed along at least one long edge and one short edge of the water channel layer. This enables ready overlap of completed combined lath-and-water channel layer constructs in wall construction.
[0011] A stapling mechanism then lowers, such as vertically from an original vertical resting position above the water channel layer applied to the lath surface, to the top surface of the water channel layer at one or more predetermined positions on the surface of the water channel layer, and inserts one staple at the predetermined position or each of the predetermined positions, such that the head of the applied staple or staples is on the surface of the water channel layer and the ends are clinched to engage the backside of the lath (i.e., the side not in contact with the water channel material). The staple or staples may engage in an outward clinch (that is, the staple legs are bent outwardly), such that the bend returns the tip of the staple approximately to the top surface of the water channel layer while engaging the wire of the lath. The lath and water channel layer need not be horizontally oriented for fixation together, but this is currently deemed most desirable.
[0012] In one embodiment, the stapling frame uses multiple pneumatically operated staplers on a frame. The staplers are located to be inboard from the edge of the water channel layer and spaced about the combined water channel layer/lath. The staplers may be simultaneously engaged to perform the stapling operation. The stapling mechanism then rises vertically to its vertical resting position while the water channel layer and lath combination is removed and new, separate rectangular portions of water channel layer and lath of equivalent dimensions to the previous portions are placed in position. The frame could also be hinged along one side to open and receive the combined water channel layer/lath in a clamshell arrangement. Further, the frame could move, in a plane above (or below) the water channel layer/lath, into position for stapling.
[0013] The water channel layer may optionally be 0.25″ or 0.40″ thick, among other possible sizes. The staplers may optionally be positioned to apply one or more staples at the predetermined position(s) evenly spaced along the length of rectangular sections (“sheets”) of water channel layer and lath at a predetermined distance inward from the edge of the surface of the water channel layer. The staplers are preferably positioned to apply one or more staples at predetermined position(s) generally evenly spaced along the width of the rectangular portions of water channel layer and lath at a predetermined distance inward from the edge of the surface of the water channel layer. Although systems using pneumatically operated staplers are discussed herein, many kinds of staplers are available.
[0014] In an alternative embodiment, a rectangular portion of water channel layer, approximately 25.5 inches width by 95.5 inches length, is placed vertically atop of a rectangular portion of lath of approximately 27 inches width by 97 inches length such that the water channel layer and lath are flush along one length and one adjacent width, and along the other length and adjacent width of lath, approximately 1.5 inches of surface area of lath is exposed beyond the edge of the water channel layer.
[0015] In an alternative embodiment, the stapling frame may be a generally solid surface equipped with one or more staplers engaged to deliver staples through apertures in the surface of the frame. The stapling frame is equipped to slide horizontally over an adjacent surface carrying the combined water channel layer atop a layer of lath on such adjacent surface. The frame may be positioned such that it slides over the combined water channel layer/lath just above the same, or it could be slightly lowered once in position, to thereby compress the combined materials. The staplers may then be simultaneously engaged to deliver staples through the apertures in the surface of the frame such that the heads of the applied staples are on the top surface of the water channel layer and the ends of the applied staple are clinched such as to engage the lath. The stapling frame may then slide horizontally to its original starting position so that the attached rectangular portions of water channel layer and lath may be removed and new, separate rectangular portions of water channel and lath may be inserted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a wall structure with lath and water channel layers made by an example stapling system, as applied to a frame construction.
[0017] FIG. 2A is a partial corner view of a lath and water channel layer as attached by an example stapling system.
[0018] FIG. 2B shows a lath and water channel layer attached with a staple according to an example embodiment.
[0019] FIG. 3 is a perspective view of a stapling system according to an example embodiment, deployed to operate on lath and water channel layers atop a flat surface.
[0020] FIG. 4 is a perspective view of a stapling system according to another example embodiment, deployed to slide into position to operate on a lath and water channel layer atop a flat surface.
[0021] FIG. 5 is a lath and water channel layer combined into an integrated unit via staples, according to an example embodiment.
DETAILED DESCRIPTION
[0022] Referring now to FIG. 1 in particular, a wall structure with lath and water channel layers previously stapled together by the method discussed herein is depicted. The inner wall is typical, but not limited, to that shown here as using a CMU wall structure. Additionally, the elements shown need not be employed in the exact order shown in FIG. 1 . The systems and methods discussed herein are directed to combining the water channel layer and lath to yield a stock material for later installation with whatever wall structure is desired, regardless of whether water channel layer 120 surface or lath 115 surface is selected as the outboard surface. A wood (stud) wall structure and others may be used, of course.
[0023] Outboard of an exterior-grade sheathing 100 is a weather resistive barrier 105 , which may be a heavy-duty plastic sheeting, operating as a moisture barrier. Outboard of the weather resistive barrier 105 is the lath-and-water channel layer combination 110 . The lath-and-water channel layer combination 110 is in this illustrative embodiment applied to the sheathing in a conventional manner such that the lath 115 is outboard to the water channel layer 120 and affixed to the sheathing.
[0024] The water channel layer 120 material may be, as noted previously, a fibrous diameter entangled randomly oriented plastic or other durable fiber, formed in a thinner width, such as 3/16″ or ¼″ WALLNET product, made or sold under that name by Mortar Net, Inc. The lath 115 may be any commonly used which is readily combinable with the water channel material by stapling, as hereinafter discussed. There are many known types of lath, including metal and plastic being most commonly used. Fiberglass lath, typically supplied in continuous rolls, may be used. The lath serves as the main supporting structure for receiving and holding plaster or stucco, or some cementitious or other adhesive compound for holding thin stone veneer or stucco finish coat 140 , and may be outboard to the water channel layer 120 as shown here, or inboard to the water channel layer 120 .
[0025] FIG. 1 shows the lath 115 peeled back to illustrate the water channel layer 120 . The surface area of the water channel layer 120 may preferably be less than that of the lath 115 such that a region of lath 115 is exposed along at least one long edge and one short edge of the water channel layer 120 . Consequently, one segment of the lath-and-water channel layer combination 110 may be enabled for ready overlap 125 of an adjacent segment of lath-and-water channel layer constructs, creating code-compliant lath and continuous water channel layer in one. This can also be seen in FIG. 5 .
[0026] Outboard to the lath-and-water channel layer combination 110 is base coat 130 . Outboard to the base coat 130 is a scratch coat 135 . Finally, outboard to the scratch coat 135 is thin stone veneer or stucco finish coat 140 . It will be understood that some of the foregoing elements need not be employed in the exact order shown in FIG. 1 .
[0027] FIG. 2A shows a partial corner vie of an example lath-and-water channel layer combination 200 . The corner view shows that the surface area of the water channel layer 205 may preferably be less than that of the lath 210 , such that a region of lath exposed along at least one long edge and one short edge of the water channel layer 205 . A staple 215 has been applied to the water channel layer 205 , which is also shown in FIG. 2B . The head 215 a of the staple 215 is on the top surface 205 a of the water channel layer 205 and the two ends 215 b, 215 c of the applied staple 215 are clinched such as to engage the opposite side of the lath 210 (i.e., the side not in facial contact with the layer 205 ). Further, in the example shown in FIG. 2B , the ends 215 b, 215 c of the staple 215 are clinched outwardly such that each end returns approximately to the top surface 205 a of the water channel later 205 while engaging the lath 210 . As noted above the lath-and-water channel layer combination 200 may be installed such that the water channel layer 205 or the lath 210 is the outboard surface.
[0028] FIG. 3 shows a perspective view of the stapling system deployed to operate on lath 305 and water channel layer 310 atop a flat surface 315 . The frame 300 , which is equipped with one or more staplers 320 positioned at predetermined positions, is cooperatively affixed to a vertical deployment mechanism 325 providing for movement of the frame 300 towards and away from the flat surface 315 . The staplers 320 may be simultaneously engaged to perform the stapling operation, although they need not be. The staplers here are pneumatically operated by cooperatively engaging the staplers 320 with pneumatic mechanism 330 . The stapling system may optionally be engaged for use with fiberglass lath, which is typically supplied in continuous rolls, such that the water channel layer would be delivered to the flat surface 315 in a roll to roll process rather than sheets. The staplers and the pneumatic system along with a suitable controller are well known in the art. The arrangement of the components in this system is new.
[0029] FIG. 4 shows a perspective view of an alternative embodiment of a stapling system deployed to operate on lath 405 and water channel layer 410 atop a flat surface 415 . The stapling frame 420 is a surface equipped with one or more staplers 425 engaged to deliver staples through apertures 445 in the surface of the stapling frame 420 . The stapling frame 420 is equipped on its ends 440 to slide horizontally via a sliding mechanism 430 over the adjacent flat surface 415 , and over a rectangular portion of water channel layer 410 atop a rectangular portion of lath 405 on such adjacent flat surface 415 . The staplers 425 may then be simultaneously engaged to deliver staples through the apertures 445 in the surface of the stapling frame 420 such that the heads of the applied staples are on the top surface of the water channel layer 410 and the ends of the applied staples are clinched such as to engage the lath 405 . The stapling frame 420 may then slide horizontally to its original starting position so that the attached rectangular portions of water channel layer 410 and lath 405 may be removed and new, separate rectangular portions of water channel layer 410 and lath 405 may be inserted atop the flat surface 415 . The staplers may optionally be pneumatically operated by cooperatively engaging the staplers 425 with pneumatic mechanism 435 .
[0030] In one alternative to the foregoing, a more open frame could be used for mounting the staplers, as described with the first embodiment. In another alternative to the foregoing, the stapling system may be engaged for use with fiberglass lath, which is typically supplied in continuous rolls, such that the water channel layer would be delivered to the flat surface 415 in a roll to roll process rather than sheets.
[0031] FIG. 5 shows a lath 505 and water channel layer 510 combined into an integrated unit via staples 515 . The staples 515 are generally evenly spaced along the width of the integrated unit, as shown by the spacing 525 between each staple 515 . Further, the staples 515 begin at predetermined distance 520 from inward from the long edge of the water channel layer 510 . Similarly, the staples 515 are generally evenly spaced along the length of the integrated unit, as shown by the spacing 535 between each staple 515 . Further, the staples 515 begin at predetermined distance 530 from inward from the short edge of the water channel layer 510 .
[0032] While the present invention has been described with respect to certain embodiments, numerous changes and modifications will be apparent to those of skill in the art, and such changes and modifications are intended to be encompassed within the spirit of the invention, as defined by the claims.
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A cost-effective and expeditious method for attaching a water channel layer to lath pre-installation, for subsequent application to an inner wall structure, increasing the efficiency and decreasing the cost of building construction, and also encompasses the stock material made thereby. In one form, there is a stapling frame equipped to be placed in juxtaposition to a water channel layer atop a layer of lath on and adjacent surface. A plurality of staplers mounted to the frame then combine the water channel layer and lath to form an integrated stock material that can then be used in a wall structure.
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BACKGROUND OF THE INVENTION
This invention relates to a fluid for conditioning plastics materials. Throughout this specification the term `conditioning` should be taken to include one or more of the following functions, namely cleaning, polishing, restoring dull faded colours, covering light scratches, waterproofing and protecting.
There is a considerable market for cleaning and polishing fluids for enhancing the appearance of motor cars. In particular, there are many formulations for restoring and polishing the paintwork of motor cars. Nowadays, however, many car bodywork panels (such as bumpers, roof panels and side bars) are made of plastics materials, and known paintwork formulations are unsuitable for conditioning such panels.
SUMMARY OF THE INVENTION
The present invention provides a conditioning fluid comprising between one and three parts by volume of silicone fluid and between two and six parts by volume of vegetable oil.
Preferably, the conditioning fluid further comprises a solvent for the silicone fluid and the vegetable oil. Advantageously, the solvent has a volume that is at least twice that of the combined volume of the silicone fluid and the vegetable oil.
The solvent may be constituted by D-limonene and white spirit. Conveniently, there are four parts by volume of D-limonene and ten parts by volume of white spirit.
In a preferred embodiment, the conditioning fluid is 20% by volume of vegetable oil, 10% by volume of silicone oil, 20% by volume of D-limonene and 50% by volume of white spirit.
The vegetable oil may be rapeseed oil, corn oil, sunflower oil or nut oil, and the silicone fluid is of 1000 viscosity.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will now be described in greater detail, by way of example, with reference to the following example.
EXAMPLE
A conditioning fluid is made by mixing together:
200 mil vegetable oil;
100 mil silicone fluid;
200 mil D-limonene; and
500 mil white spirit.
The vegetable oil can be, for example, rapeseed oil, corn oil, sunflower oil or nut oil, and the silicone fluid is of 1000 viscosity.
The functions of the four ingredients are as follows:
(i) Vegetable Oil
Vegetable oil reduces surface wear and gives a depth of natural colour to plastics materials such as vinyls. It also provides a waterproofing function, and enhances the appearance of plastics materials to make them look new. Vegetable oil is particularly effective on plastics materials that are black.
(ii) Silicone Fluid
Silicone fluid is a transparent oil with polishing properties. It also has a waterproofing function, is durable, and it negates the natural stickiness of the vegetable oil. It promotes smooth `touch` finish to the surfaces of plastics materials to which it is applied.
(iii) D-limonene
D-limonene is a mild solvent with cleaning properties. It has a powerful odour of citrus fruits (oranges and lemons), which negates the bland odour of the other ingredients.
(iv) White Spirit
White spirit is a mild solvent with cleaning properties. Its main function is to dilute the vegetable oil and silicone fluid to form a creamy mixture that can easily be applied to, and spread over, the surfaces of plastics materials.
As mentioned above, the proportions of the ingredients can be varied, the effects of which are as follows:
(a) Varying the proportion of vegetable oil results in variations in the depth of colour produced by the conditioning fluid. Thus, increasing the proportion of vegetable oil in the conditioning fluid will result in an increase in the resultant depth of colour, albeit with an undesirable increase in the stickiness of the finish. Any reduction in the concentration of vegetable oil should, however, be balanced by a corresponding increase in the concentration of silicone fluid, thereby to maintain the `gloss` appearance of the surface to which the conditioning fluid is applied. However, even small increases in the proportion of vegetable oil will increase the viscosity of the conditioning fluid, and this is not desirable.
(b) Increasing the proportion of silicone fluid has the advantages of increasing the durability of the finish, but will increase the cost of the conditioning fluid (as silicone fluid is the most expensive of the ingredients). Such a increase does, however, have the disadvantage of increasing the viscosity of the conditioning fluid. It will also result in an increase in the high gloss finish which results from the application of the conditioning fluid. The durability and waterproofing properties of the conditioning fluid will also be increased.
(c) Varying the proportion of D-limonene merely affects the odour of the finished product. Any reduction in the concentration of D-limonene should be compensated for by an increase in the proportion of white spirit. White spirit is not, as indicated above, an essential ingredient. It is used principally because it is a cheap solvent. Again, D-limonene is not an essential ingredient--it is included in the optimum formulation to negate the unpleasant odour of the white spirit.
It will be apparent, therefore, that the only two essential ingredients are the vegetable oil and the silicone fluid. In order to provide a conditioning fluid that is easy to apply, however, at least one solvent should be included. The two essential ingredients can each vary by up to 50% from its optimum concentration, with the proviso that an increase in the proportion of vegetable oil should be balanced by a decrease in the proportion of silicone oil, and vice versa.
In use, the conditioning fluid is applied to the plastics material surface to be conditioned using a soft cloth, preferably one such as a cotton cloth or a J-cloth, which does not have loose fibres. This surface should preferably be dry (though this is not essential) with any surface dirt (such as mud) removed. If a gloss finish is required, the conditioning fluid is left to dry. For satin or matt finishes, the surface is buffed before the conditioning fluid dries, thereby reducing the gloss finish to a satin or matt finish depending upon the length of time the fluid is left to dry before buffing commences.
The conditioning fluid described above can be used on all plastics materials such as ABS, acrylics, polypropylene, polystyrene, HDPE, vinyl materials such as polyvinylchloride, thermosetting plastics materials and melamine formaldehyde.
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A conditioning fluid comprises between one and three parts by volume of silicone fluid and between two and six parts by volume of vegetable oil in a solvent comprising D-limonene and white spirit.
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BACKGROUND OF THE INVENTION
This invention pertains, generally, to centrifugal pumps used in the pulp industry to pump pulp slurries, and in particular to a centrifugal pump of such configuration as renders it capable of handling pulp slurry having up to approximately a fifteen percent consistency for long fibered pulp.
Traditionally, centrifugal pumps have been limited to handling pulp slurries of approximately four percent consistency. For higher consistencies, up to about eighteen percent, positive displacement pumps have been used. In the industry, recent developments by some manufacturers have pushed the limit for centrifugal pumps up to about a twelve percent consistency. Claims of the manufacturers notwithstanding, these pumps actually run in the ten to twelve percent consistency range, depending upon fiber length, and not the up to fifteen percent consistency alleged therefor.
It is very desirable to have a centrifugal pump which can run reliably at the fifteen percent consistency for long fibered pulp for the following reasons:
1. Bleach towers tend to channel at consistencies below fourteen percent, and thus shorten the retention time of the product. This becomes more important as the capacities increase and the bleach towers get larger in diameter.
2. More steam is required to heat a more dilute slurry.
3. Storage tanks are built, at some considerable expense, to store pulp, not water.
4. Typically available infeeding filters discharge at fourteen to fifteen percent consistency. Dilution, then, to render the product acceptable to a receiving centrifugal pump is undesirable involving as it does another, expensive processing procedure.
Centrifugal pumps designed to handle higher consistency (albeit not fifteen percent) pulps incorporate the following design features:
1. A larger diameter infeed section.
2. A pulp inducer with an overfeeding capacity.
3. Non-converging flow passages in the inducer and impeller.
4. Large size flow channels in the inducer and impeller to minimize friction and to allow passage of tramp metal.
These centrifugal pumps, however, have serious defects. The overfeeding inducer recirculates some pulp into the feed area (i.e., regurgitation). The recirculated pulp has a large rotational velocity and causes a strong vortex ahead of the inducer. The vortex increases in intensity as it is drawn towards the eye of the impeller (i.e., as a contracting vortex). This vortex has several disadvantages:
1. Pulp at medium consistency (from ten to fifteen percent) contains a significant amount of air. This air is not harmful if it is evenly dispersed. But, the vortex will centrifuge air out of the suspension. Air will accumulate at the eye of the impeller and air-bind the pump.
2. A feed screw pushes the pulp towards the inducer. In that the feed screw rotates in the same direction as the impeller, the rotating vortex tends to stop or impede the pulp flow in the feed screw. This is depicted in FIG. 1, herein.
3. The vortex creates a low pressure zone at the eye of the impeller; i.e., the suction head of the pump is negative.
4. The vortex consumes unnecessary power.
The foregoing details the limitations and disadvantages known to exist in the prior art. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the aforesaid limitations and disadvantages. Accordingly, a suitable alternative, embodied in a novel pulp slurry-handling, centrifugal pump, is set forth herein, the same having features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the instant invention, the desired alternative is found in a pulp slurry-handling, centrifugal pump, comprising a volute housing; and an impeller-inducer journalled in said housing; wherein said housing has (a) an inlet, and (b) an outlet; and means fixed to said housing, intermediate said inlet and said impeller-inducer, for inhibiting formation of a vortex upstream of said impeller-inducer.
Further aspects of the invention, as well as the novel features thereof, will become apparent by reference to the following description, taken in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side, elevational view, partly cross-sectioned, of a prior art, pulp slurry-handling, centrifugal pump;
FIG. 2 is a view, like that of FIG. 1, depicting the novel centrifugal pump of the instant invention, according to an embodiment thereof;
FIG. 3 is a view of the directing vanes, the same taken along section 3--3 of FIG. 2;
FIG. 4 is a detailed view taken along arcuate section 4--4 of FIG. 3;
FIG. 5 is a detailed view taken along arcuate section 5--5 of FIG. 3; and
FIG. 6 is a perspective view of the flow deflector of FIGS. 2 and 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a prior art, pulp slurry-handling, centrifugal pump 10, the same having a volute housing 12, an impeller 14 journalled in the housing, and the housing having a slurry inlet 16 and an outlet 18. The arrows 20 represent the recirculation flow which occurs in the inlet 16, and arrows 22 represent the vortex flow. Finally, arrow 24 represents the relative pulp flow. As can be seen, the pulp flow, arrow 24, must overcome the opposing vortex flow, arrows 22, velocity head.
The novel centrifugal pump 10a shown in FIG. 2, the same being an embodiment of the invention, overcomes the vortex problem. Pump 10a has a volute housing 12a, with an impeller-inducer 14a journalled therein. The housing 12a has a slurry inlet 16a and an outlet 18a. In addition, now, the pump 10a has fixed, i.e., stationary, vanes 26, 28 and 30 in the housing 12a. Vane 26 is visible in FIG. 2, whereas all three of the vanes are shown in FIG. 3. Arrows 20a represent the recirculation flow, in FIGS. 2 through 6. It can be seen that the diversion vanes 26, 28, and 30 deflect the recirculation flow back into the central zone 32 of the housing 12a. The impeller-inducer is force-fed by its own recirculation. Too, the recirculation flow, arrows 20a, complements the feed pulp flow, shown by arrows 24a, as depicted in FIGS. 4 through 6. The circulation conforms with the directional flow of the feed pulp, as supplied by the feed screw 34.
The vanes 26, 28, and 30 are equally spaced apart, and confront the blades 36 of the impeller-inducer 14a. They are radially disposed about the center of the housing 12a. The spacing of the vanes 26, 28, and 30 defines openings 38 therebetween for admitting slurry. FIG. 6 shows the pump flow deflector and the paths of feed pulp 24a and regurgitated pulp 20a.
As shown in FIG. 6, the vanes 26, 28, 30 have a curved three dimensional scoop shape. In addition, the vanes depicted in the FIGURES have three edges 50, 51, 52. The first edge 50 extends circumferentially along a portion of an outer ring 54; the second edge 51 extends from the outer ring 54 to an inner cylinder 55; and the third edge 52 extends from the inner cylinder to the outer ring 54.
As noted, the impeller-inducer 14a is force fed by its own recirculation. This creates a highly agitated zone 40 ahead of the impeller-inducer 14a in which to fluidize the pulp-air-water mixture. Consequently, a higher consistency of pulp slurry, i.e., up to fifteen percent or so, can enter the pump 10a without causing plugging thereof. The pump 10a requires no suction head for priming thereof. Too, it starts more easily and can readily handle more air. The power requirements therefor are minimized because the agitated zone 40 is small, and the velocity head is utilized for feeding.
New pulp slurry is pulled into the agitated zone 40 by the recirculation flow (arrows 20a). In fact, a feed screw, such as feed screw 34, is not required for consistencies up to approximately twelve percent. For consistencies over twelve percent, the feed screw 34 is beneficial to avoid pulp bridging in the feed chute.
In the prior art there is a centrifugal pump which uses fluidizer vanes on the impeller to induce a vortex ahead of the rotor, and it removes the air with a separate air removal system. However, in this it is most difficult to prevent the air removal system from plugging with pulp fibers. Also, it requires a high feed chute for a high, positive suction head. This is not desirable, because the preceding pulp washer needs to be elevated accordingly. Another prior art centrifugal pump uses a feed screw with an opposite rotation to that of the pump impeller. This kills the vortex, but without utilizing its energy to advantage. Too, feeding of this pump is erratic and uses more power. Finally, another prior art centrifugal pump uses a separately driven fluidizer roll ahead of the pump inlet, with a rotating axis ninety degrees of arc to the impeller axis. This creates a large fluidized zone which absorbs considerably more power. Too, the velocity head of the fluidizing flow is not utilized.
While I have described my invention in connection with a specific embodiment thereof, it is to be understood that this is done only by way of example and not as a limitation to the scope of the invention as set forth in the aspects thereof and in the appended claims.
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Deflecting vanes, confronting the blades of the impeller-inducer, and fixed in the housing, inhibit the formation of a vortex upstream of the impeller-inducer. Too, the vanes direct the recirculation flow back into the central zone of the pump. The impeller-inducer is force-fed by its own recirculation.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. 119 based upon Japanese Patent Application Serial No. 2006-273382, filed on Oct. 4, 2006. The entire disclosures of the aforesaid applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to poultry feed and a method for producing a hen egg. Particularly, the present invention relates to a method for obtaining a high quality hen egg having improved productivity.
BACKGROUND OF THE INVENTION
[0003] Feed has conventionally been improved in various ways in order to enhance the quality of eggs of poultry including chickens. For example, attempts have been made to improve quality and productivity of eggs including a survival rate of chickens, an egg-laying rate, the Haugh unit of eggs and eggshell strength by adding to feed e.g., vitamin B6 and substances having antioxidative effects such as tea extracts, polyphenol, isoflavon agricons and plum vinegars (See Patent Literatures 1-5).
PRIOR ART LITERATURE
Patent Literature
[0004] Patent Literature 1: Japanese Patent Application Kokai Publication No. H08-56585
[0005] Patent Literature 2: Japanese Patent Application Kokai Publication No. H08-266230
[0006] Patent Literature 3: Japanese Patent No. 4302895
[0007] Patent Literature 4: Japanese Patent Application Kokai Publication No. 2002-330707
[0008] Patent Literature 5: Japanese Patent Application Kokai Publication No. 2005-73651
SUMMARY OF THE INVENTION
[0009] All of the abovementioned conventional methods are based on the principle that feed is eutrophicated by adding nourishing substances containing antioxidative nutriments to thereby increase nutritive values of eggs produced by chickens that ate the eutrophicated feed. In other words, those methods simply increase nutritive values of eggs by feeding hens on feed having highly nutritive values but not enhance the hens' natural ability of laying eggs (e.g., increased ability of laying eggs having highly nutritive values and increased ability of producing high quality eggs).
[0010] The present invention has been designed in view of the abovementioned circumstance, and the object of the present invention is to provide a method for producing high quality eggs and enhancing productivity thereof without significantly changing conventional feed, breeding methods, etc. in raising poultry for egg production. Moreover, the object of the present invention is to provide a method for producing high quality eggs and enhancing productivity thereof by adding the immunostimulating substance according to the present invention to not only poultry feed but drinking water as well.
[0011] The present invention is based on the finding that an immunostimulating substance produced by cytolysis that accompanies sporulation of MRE symbiotic bacteria enhances the life force of poultry to thereby effectively solve the abovementioned problems. The present inventors found that when they diluted an immunostimulating substance produced by MRE symbiotic bacteria about 1000-fold and had chickens drink it, chickens that had stopped laying eggs started laying eggs again and the Haugh unit and eggshell strength of those eggs were markedly improved and that chickens became less susceptible to infectious diseases during breeding and the rate of dead chickens dramatically declined.
[0012] Accordingly, a first major aspect of the present invention provides a method characterized in producing a hen egg having improved quality and productivity, the method comprising feeding a hen on supplemented feed obtained by adding to poultry feed an immunostimulating substance produced by cytolysis associated with spore formation of MRE symbiotic bacteria group and/or on supplemented drinking water obtained by adding the immunostimulating substance to drinking water, wherein the immunostimulating substance is obtained by incubating the MRE symbiotic bacteria group, placing a resultant culture medium under a starvation condition, thereby causing the symbiotic bacteria group to internally sporulate, and removing from the culture medium impurities containing the internally sporulated bacteria group.
[0013] The abovementioned constitution enables to markedly improve quality of eggs produced by chickens as well as productivity thereof Moreover, the present invention can reinforce chickens' natural immunity, resulting in increased antibacterial, antiviral and antifungal effects. As a result, the chickens' natural ability of laying eggs can be enhanced.
[0014] Moreover, according to one embodiment of the present invention, in such a method, the abovementioned improved quality is improved Haugh unit, yolk height and eggshell strength.
[0015] Moreover, according to another embodiment of the present invention, in such a method, the abovementioned improved productivity is an improved dead chicken rate, an enhanced egg-laying rate and a reduced egg breakage rate.
[0016] Moreover, according to another embodiment of the present invention, in such a method, the abovementioned hen is selected from the group consisting of White Leghorn, Sakura, Momiji, ISA Brown, Dekalb Warren Sexalink, Harvard Comet, Shaver Starcross, Hisex Brown, Hyline Brown, Yellow Plymouth Rock, Rhode Island Red, Hoshino Cross, Norin Cross, Nagoya Cochin, Rock Horn, White Plymouth Rock, Minorca, Araucana and Silky Fowl.
[0017] Moreover, according to another embodiment of the present invention, in such a method, the abovementioned immostimulating substance is added to the drinking water by a fluid delivery device.
[0018] A second major aspect of the present invention provides poultry feed obtained by adding an immunostimulating substance produced by cytolysis associated with spore formation of MRE symbiotic bacteria group, wherein the immunostimulating substance is obtained by incubating the MRE symbiotic bacteria group, placing a resultant culture medium under a starvation condition, thereby causing the symbiotic bacteria group to internally sporulate, and removing from the culture medium impurities containing the internally sporulated bacteria group.
[0019] Furthermore, a third major aspect of the present invention provides an egg produced by the abovementioned method.
[0020] Other features and marked effects of the present invention other than those described above will become apparent to those skilled in the art by referring to the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] A description of one embodiment and several examples according to the present invention is given below.
[0022] As described above, the present invention enables to produce hen eggs having improved quality and productivity by adding to poultry feed and drinking water an immunostimulating substance produced by cytolysis that accompanies sporulation of MRE symbiotic bacteria and then feeding chickens on the supplemented feed and drinking water. In other words, the present invention is different from a conventional method in which nutrition is supplemented by mixing nutritional supplements with feed in that the invention enables to reinforce the chickens' natural ability of laying eggs and thereby produce high quality eggs simply by diluting an immunostimulating substance originated from MRE in a proper manner and then adding it to feed, drinking water, etc.
[0023] Unlike a conventional method in which nourishing substances containing antioxidative nutriments are mixed with feed, the present method establishes poultry technology that improves egg quality including the reduced number of chickens that die of diseases, an improved egg-laying rate, a marked increase of Haugh unit, and increased eggshell strength and yolk height by a method of activating chickens' natural immunity. The method according to the present invention simply requires providing a small amount of an MRE-derived immunostimulating substance, which is a natural immunity activating substance, and therefore high quality hen eggs can be produced simply by diluting and mixing the substance with chickens' drinking water.
[0024] When an MRE-derived immunostimulating substance, which is a natural immunity activating substance, is provided, production of so-called SOS materials, i.e., interferon-alpha and interferon-beta, which are type I interferons, is activated. Then, secretion of various antimicrobial substances including alpha-defensin and beta-defensin from phagocytes such as epithelial cells and neutrophils is activated to thereby reinforce antimicrobial force against pathogenic germs such as viruses, bacteria and fungi. Accordingly, a reduced dead chicken rate can be achieved.
[0025] Table 1 shows the result of measuring production of type I interferons by an MRE-derived immunostimulating substance by using human blood. Since the body temperature of chickens is significantly higher than human, it is believed that the amount of type I interferons and antimicrobial substances released as a result of stimulation by type I interferons is by far more in chickens than in human.
[0000]
TABLE 1
Secretion of type I interferon by MRE immunostimulating substance
Production of type I IFN-alpha (pg/mL)
6.00%
Test subject
Control
dilution of MRE
Ratio
A female 51
1.0
4.2
4.2
B female 54
4.1
21.1
5.1
C male 72
7.8
14.3
1.8
D male 25
4.7
11.2
2.4
Average
4.4
12.7
2.89
[0026] There seems to be two reasons why the activation of chickens' natural immunity results in increased egg-laying rate, Haugh unit, eggshell strength and yolk height.
[0027] The first reason is that the body temperature of birds including chickens is extremely higher than that of mammals. By way of example, the normal body temperature of human is about 36.5° C. while that of chickens is as high as about 42° C. The normal body temperatures of other mammals are equal to or lower than 39° C. As to the body temperature, 42° C. is on the risk level for human.
[0028] It has been known that a mechanism referred to as autophagy works as part of natural immunity, wherein deteriorated cell organelles are decomposed by a lysosomal enzyme as a result of molecular-level switching. For example, a mechanism of decomposing a deteriorated ill-efficient mitochondrion by a lysosomal enzyme and then replacing it with a new mitochondrion has been proven. It has been known that the lysosomal enzyme becomes active in high-temperature regions. Its decomposing ability becomes maximum at 40° C. to 65° C. at which the decomposing ability of normal digestive enzymes dramatically declines. Accordingly, a lysosomal enzyme actively works in birds more than in mammals because of the action of an MRE-derived immunostimulating substance to thereby increase the decomposing ability. In other words, the high body temperature of chickens is the reason why the effect of an MRE-derived immunostimulating substance is enhanced.
[0029] The other reason is related to the fact that a large number of mitochondria are contained in one egg cell. It is believed that the number of mitochondria contained in one muscular cell is 500-2000. On the other hand, the number of mitochondria contained in one egg cell is believed to be several tens of thousands to two hundred thousand. The fact that one egg cell contains an extremely large number of mitochondria, which are energy factories for producing ATP, suggests that a tremendous amount of energy is required for giving birth to life.
[0030] The MRE-derived immunostimulating substance according to the present application not only activates a natural immune system but also decomposes and removes deteriorated and poorly-operating mitochondria within an egg cell and promotes the reproduction of young mitochondria. A chicken's ovary normally has about 30,000 egg cells, and a matured egg cell is laid as an egg, wherein one hen usually lays 300-320 eggs and is culled when the egg-laying rate drops. When a MRE-derived immunostimulating substance is given to mitochondria within an egg cell, ATP synthesis is activated by young mitochondria and the life force of the egg cell increased so that the egg-laying rate is improved and a high quality egg produced.
[0031] A hen egg produced by the method of the present invention has increased Haugh unit, eggshell strength and yolk height and can keep more freshness than normal hen eggs.
[0032] The “immunostimulating substance” according to the present invention can be obtained by decomposing cells of MRE symbiotic bacteria, which are aerophilic bacteria, to a low molecular range of 3000 Da or below (preferably 1000 Da to 300 Da) with mother cell lytic enzymes, lysosomal enzymes or the like.
[0033] The MRE symbiotic bacteria comprises Bacillus sp. (FERM BP-11209, ID No. MK-005), Lysinibacillus fusiformis (FERM BP-11206, ID No. MK-001), Bacillus sonorensis (ID No. MK-004), Lysinibacillus sp. (FERM BP-11207, ID No. MK-002), and Comamonas sp. (FERM BP-11208, ID No. MK-003), wherein all of them are aerophilic bacteria.
[0034] In the present invention, MRE symbiotic bacteria are cultured and then converted to endospores (sporulation) to thereby induce mother cell lytic enzymes, resulting in decomposition of cells into low molecules. More specifically, liquid culture is first performed for culture liquid of MRE symbiotic bacteria under the culture conditions of pH 6.0-6.8, a temperature of 25-30° C. and 0.1-1.0 mg/L in concentration of dissolved oxygen by aeration. Nourishing substances given to bacterial cells include fish powder, rice bran, oil cake, bouillon, and minerals including magnesium sulfate and silica. In the case of mixed bacteria, it should be waited until a stable symbiotic relationship is established in the mixed bacteria.
[0035] After the bacterial culture is stabilized, the bacterial in a vegetative cell state are transferred to another aeration culture tank, and then culture is continued. Next, while aeration is continued in the transferred aeration culture tank, all nourishing substances except silica are discontinued to place the bacteria in a depleted state. Around the time when the remaining nourishing substances are consumed, depletion of nitrogen components triggers sporulation (conversion to endospores), and liquid gradually becomes transparent. After confirming the completion of sporulation, aeration (supply of oxygen) is stopped and the culture liquid allowed to stand for a while, and then spores (endospores) starts precipitating all at once to give a supernatant liquid. By filtrating the supernatant liquid thus obtained with a membrane of 0.2 μm, an extremely small amount of remaining culture cells as well as remaining floating endospores (spores) are removed to give an undiluted liquid of an immunostimulating substance, which becomes a ligand for natural immunity of poultry. If need be, the liquid may be filtrated with a filter of 0.02 μm. In the method according to the present invention, all of the supernatant liquid, the liquid obtained by membrane filtration, and filtration with a filter of 0.02 μm can be used.
[0036] By way of example, a 1m 3 culture liquid of MRE symbiotic bacteria (MK-001, MK-002, MK-003, MK-004 and MK-005) is placed in each of two 1.2 m 3 culture aeration vessels of the same shape and then aeration is performed such that the concentration of dissolved oxygen becomes 0.5-1.2 mg/L. One of those vessels is referred to as a culture cell tank and the other as a sporulation tank. To the culture cell tank, we added 500 g of fish powder, 500 g of rice bran, 250 g of oil cake and 50 g of bouillon as minimum nourishing substances and continued culture by performing aeration under the conditions of pH 6.0-6.8 and a culture temperature of 25-35° C. On the other hand, in the sporulation tank, all of nourishing substances were discontinued to place the liquid in a depleted state and aeration continued at 25-35° C., and then depletion of nitrogen components triggered sporulation. After waiting until the culture liquid became more and more transparent, aeration (supply of oxygen) was stopped and then endospores started precipitating all at once to give a transparent solution. This solution was filtrated with a membrane of 0.2 μm, further filtrated with a filter of 0.02 μm and then put back to the sporulation tank that had been well washed. Here, the liquid obtained by removing remaining mother cells and spores with a filter from a liquid in which MRE bacteria was converted to endospores is referred to as an MRE filtrate. Accordingly, the MRE filtrate contains no bacteria or spores, yet the MRE filtrate contains an immunostimulating substance. The present invention utilizes this immunostimulating substance.
[0037] In the present invention, the sizes of membranes and filters used in the abovementioned solution are not particularly limited. By way of example, the size of membranes may be 1 μm, 0.7 μm, 0.5 μm, 0.3 μm or the like and is preferably 0.2 μm. The size of filters may be 0.15 μm, 0.1 μm, 0.07 μm, 0.05 μm, 0.03 μm or the like and is preferably 0.02 μm.
[0038] In the present invention, we used the abovementioned culture cell tank and sporulation tank, performed aeration such that the concentration of dissolved oxygen became 0.5-1.2 mg/L in both tanks, and then conducted the following experiment.
[0039] A solution whose raw material is MRE containing the immunostimulating substance thus obtained, which activates natural immunity, is mixed with drinking water for poultry 1-fold to 1000-fold, preferably 100-fold to 500-fold, and more preferably 1000-fold to 3000-fold, yet its concentration is not particularly limited as far as preferable effects can be achieved. More specifically, since the amount of water drunk by one chicken a day is about 300 mL, a solution containing 0.03-0.6 mL and preferably 0.1-0.15 mL per chicken of the abovementioned MRE as a raw material is mixed with or infused in 300 mL of drinking water. For example, given that the number of hens is 10,000, 1-1.5 L of the abovementioned solution may be mixed with or infused in 3000 L of drinking water. Moreover, a solution containing the immunostimulating substance according to the present invention can be added to drinking water by using a fluid delivery device, wherein the adjustment of concentration by infusion only requires replacing an infusion bag, and therefore the present method is very efficient.
[0040] In a conventional method (e.g., a method of using plum vinegar), 2.5 g of plum vinegar per chicken needs to be mixed with feed daily, and therefore as much as 250 kg of plum vinegar must be mixed daily for 10,000 chickens, and additionally vinegar has a peculiar odor. In this respect, an MRE-derived solution according to the present invention is a liquid having no taste or odor, and therefore chickens are not picking or choosing. Furthermore, only 1 L of the liquid is required for 10,000 chickens, and natural immunity is activated; therefore an excellent secondary effect can be expected.
[0041] This secondary effect enables to nearly eliminate chickens that die of diseases, and it is also possible to make the dead chicken rate close to zero simply by improving the size of a cage. In fact, when we fed about 8120 chickens on drinking water added with the immunostimulating substance according to the present invention in a chicken farm having a large cage on the suburbs of Peking, the number of chicken that died of diseases or accidents was zero.
[0042] Moreover, in the method according to the present invention, the similar result can also be achieved by adding a solution containing the immunostimulating substance obtained above to poultry feed. In this case, the concentration of the immunostimulating substance relative to the entire poultry feed can be adjusted in a manner similar to that of drinking water described above.
[0043] Furthermore, the quality and productivity of eggs can be improved by using the immunostimulating substance according to the present invention for any birds that produce edible eggs in addition to chickens including quails, ducks, pigeons and ostriches.
[0044] Moreover, in the present invention, chickens capable of improving the quality and productivity of eggs include, but are not limited to, White Leghorn, Sakura, Momiji, ISA Brown, Dekalb Warren Sexalink, Harvard Comet, Shaver Starcross, Hisex Brown, Hyline Brown, Yellow Plymouth Rock, Rhode Island Red, Hoshino Cross, Norin Cross, Nagoya Cochin, Rock Horn, White Plymouth Rock, Minorca, Araucana and Silky Fowl
EXAMPLES
[0045] As described above, the method according to the present invention enables to not only dramatically enhance the quality and productivity of eggs but improve the taste of eggs as well. More specifically, what can be achieved includes reduced dead chicken rate, increased egg-laying rate and egg-laying days, improved Haugh unit, increased eggshell strength, increased yolk height, and increased number of days during which the yolk can be picked by chopsticks. Specific examples will be described below.
Example 1
Reduced Dead Chicken Rate
[0046] We raised 100,290 chickens each by using a normal breeding method (hereinafter referred to as the “normal breeding”) and a breeding method according to the present invention (hereinafter referred to as the “MRE breeding”). On the 300 th days of breeding, 5,721 chickens died (dead chicken rate: 5.7%) in the normal breeding while only 1,685 chickens died (dead chicken rate: 1.7%) in the MRE breeding. This result shows that the MRE-derived immunostimulating substance according to the present application significantly lowers the dead chicken rate. Furthermore, the number of chickens that died of diseases was zero in the MRE breeding. Accordingly, it is possible to make the dead chicken rate close to zero by enlarging the size of a cage.
Example 2
Increased Egg-Laying Rate and Egg-Laying Days
[0047] When we fed chickens that no longer laid eggs on the MRE-derived immunostimulating substance according to the present application, those chickens started laying eggs. The egg-laying rate increased by about 5%.
Example 3
Improved Quality of Eggs
[0048] We divided 20 white leghorns into two groups, i.e., a group A (10 chickens) and a group B (10 chickens) and then mixed drinking water in the group B with a solution containing an MRE-derived immunostimulating substance by using a fluid delivery device, wherein the solution was diluted 1000-fold during the first month and 3000-fold on the second month and thereafter.
[0049] We picked up eggs laid by chickens in the group A and the group B nine times for two months, measured and recorded the Haugh unit, eggshell strength, yolk height yolk color and egg weight and then found the total each.
[0050] Table 2 shows the result, and a description of the result is given below.
[0051] 1. Improved Haugh unit (HU): as table 2 shows, the average HU value of eggs in an comparative example (normal breeding) is 79.1 while the average HU value of eggs laid in the MRE breeding is 87.9 and the maximum average 93.4, showing a significant increase.
[0052] 2. Increased yolk height: as table 2 shows, yolk height is 6.4 mm in a comparative example (normal breeding) while that of eggs laid in the MRE breeding is 7.9 mm and the maximum average 9.0 mm, showing a significant increase.
[0053] 3. Increased eggshell strength: as table 2 shows, eggshell strength is 4.0 kg/cm 2 in a comparative example (normal breeding) while that of eggs laid in the MRE breeding is 4.4 kg/cm 2 and the maximum average 5.1 kg/cm 2 , showing significantly enhanced strength.
[0054] 4. Number of days during which the yolk can be picked with chopsticks: the yolk can no longer be picked on the 2 nd day or the 3 rd day in a comparative example (normal breeding) while the yolk of eggs laid in the MRE breeding can be picked even on the 6 th day.
[0000]
TABLE 2
1 st
2 nd
3 rd
4 th
5 th
6 th
7 th
8 th
9 th
Average
Number of eggs measured
10
10
10
10
10
10
10
10
10
90
Haugh unit
Normal
78.5
76.4
80.5
80.4
88.5
76.1
80.3
79.4
76.7
79.1
MRE
91.2
95.4
88.4
82.5
88.6
87.1
80.2
89.5
88.6
87.9
(MAX)
96.9
99.8
92.5
68.7
92.2
95.9
86.2
97.5
93.6
93.4
Yolk height
Normal
6.4
5.3
6.8
6.7
7.2
6.1
6.5
6.5
6.3
6.4
MRE
8.2
9.1
7.7
6.9
8.0
7.8
6.6
8.4
8.0
7.9
(MAX)
9.9
9.9
8.1
7.7
10.0
9.3
7.5
10.1
9.1
9.0
Eggshell strength
Normal
4.0
4.3
4.0
3.9
4.1
4.0
3.6
3.8
4.0
4.0
MRE
5.1
4.0
4.6
4.7
4.1
4.3
4.7
4.6
3.9
4.4
(MAX)
5.6
5.3
5.4
5.6
5.0
4.7
5.3
4.9
5.0
5.1
Yolk
Normal
12.1
12.6
12.6
12.8
12.1
12.1
12.1
12.6
11.9
12.3
MRE
11.5
12.0
11.7
11.7
11.7
11.8
12.4
12.5
12.7
12.0
(MAX)
12.5
18.0
12.6
12.5
12.5
12.7
13.0
18.4
18.4
12.8
Egg weight
Normal
63.3
67.5
64.2
64.6
62.8
63.8
60.3
63.1
63.9
63.7
MRE
57.6
58.3
58.1
60.7
63.4
63.8
62.7
68.7
63.3
61.8
(MAX)
62.6
65.0
61.8
68.2
66.6
73.4
68.6
78.9
67.3
67.8
indicates data missing or illegible when filed
Example 4
Reduced Dead Chicken Rate, Increased Egg-Laying Rate and Reduced Egg Breakage Rate
[0055] We conducted a comparative test by using two chicken houses in a chicken farm that was raising 155,000 chickens and producing eggs. We raised 6400 hens each in the chicken houses under the same conditions and provided ordinary water to hens in one chicken house (group A) as drinking water while drinking water in the other chicken house (group B) was mixed with a solution containing an MRE-derived immunostimulating substance by using a fluid delivery device, wherein the solution was diluted 1000-fold during the first month and 3000-fold on the second month and thereafter. Since 6400 hens drank about 1860 L of water daily on average, we mixed drinking water in the chicken house of the group B with 1.9 L of the solution containing an MRE-derived immunostimulating substance daily on the first month and 620 mL daily on the second month and thereafter.
[0056] As a result, the annual dead chicken rate was 6.94% in the normal breeding group A while the annual dead chicken rate in the group B provided with MRE drinking water was 2.19%, showing a significant decline. Additionally, hens in the group B rarely died of diseases: the main cause was accidental deaths arising out of a narrow cage.
[0057] The egg-laying rate also increased by 5.2% on average. When 380 days have passed after the start of breeding, the egg-laying rate was less than 71.3% in the group A while the group B maintained 82.6%. The annual egg breakage rate was 2.2% in the group A while it was 1.0% in the group B.
Example 5
Production of Immunostimulating Substance
[0058] MRE symbiotic bacteria are cultured by an ordinary culture method for aerophilic Gram-positive bacteria. A 1.2 m 3 culture aeration tank is charged with 1000 L of water, and then aeration is performed. To the culture aeration tank were added 3 kg of fish powder, 3 kg of rice bran, 1.6 kg of oil cake and 350 g of bouillon, and furthermore a proper amount of minerals such as magnesium sulfate and silica is added. Then, MRE symbiotic bacteria are added and then cultured while performing aeration such that the concentration of dissolved oxygen becomes 0.5-1.2 mg/under the culture conditions of pH 6.0-6.8 and a culture temperature of 25-35° C.
[0059] After waiting until bacteria grow enough and are stabilized, all of nourishing substances for MRE symbiotic bacteria are discontinued to place the culture liquid in a depleted state and aeration continued at 15-35° C., and then depletion of nitrogen components triggers sporulation of MRE symbiotic bacteria. After waiting until the culture liquid becomes more and more transparent, aeration (supply of oxygen) is stopped and then endospores starts precipitating all at once to give a transparent supernatant.
[0060] The supernatant thus obtained is filtrated with a membrane of 0.2 μm under reduced pressure to give an MRE decomposed solution containing an immunostimulating substance. Aeration may also be stopped after confirming the completion of sporulation under a phase difference microscope.
[0061] It goes without saying that the present invention is not limited to the abovementioned embodiment and can be modified in various manners without departing from the spirit of the invention.
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The object of the invention is to enable production of high quality eggs in poultry and to provide a method for improving productivity thereof. The invention provides a method for producing a hen egg having improved quality and productivity, the method characterized in comprising a step for feeding a hen on supplemented feed obtained by adding to poultry feed an immunostimulating substance produced by cytolysis that accompanies sporulation of MRE symbiotic bacteria and/or on supplemented drinking water obtained by adding the immunostimulating substance to drinking water, wherein the immunostimulating substance is obtained by culturing the MRE symbiotic bacteria, leaving the resulting culture fluid in a depleted state to thereby cause the symbiotic bacteria to convert to endospores, and removing impurities including the endosporic symbiotic bacteria from the culture fluid.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional application Ser. No. 61/619,186 filed Apr. 2, 2012, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] High efficiency fireplaces or heaters can produce significant condensate. Various embodiments employ a tray located above the firebox to evaporate the condensed products of combustion and humidify in the area around the appliance. However, if a heater does not include a large, hot firebox, there is not enough heat generated within the heater itself to evaporate all the condensate.
[0003] Also, such heaters are generally used in cold weather to heat a space within a building. Often there is low humidity in the enclosed space as a result of the operation of heaters and furnaces. Low humidity can aggravate inhabitants by drying the skin and mucous membranes of inhabitants of the heated space.
[0004] It would be advantageous, therefore, to have an efficient apparatus within the heater to evaporate condensation and moisture. Moreover, it would be beneficial to use the evaporated condensate to humidify the area around the heater.
SUMMARY OF THE INVENTION
[0005] A heater having a condensate trap and an evaporating and humidifying apparatus, the apparatus comprising an evaporation pan with a heating element wherein heat from the heating element evaporates moisture from the evaporating pan to eliminate the moisture and generate humidity.
[0006] In another aspect, the pan comprises an ultrasonic vaporizing element to vaporize moisture collected in the pan.
[0007] The apparatus can include a sensor with a feedback to heater controls. Also the heater can include a water trap that normally feeds condensate to the apparatus. The trap can include a sensor with feedback to the heater controls.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a front elevational view of a heater employing the apparatus of the present invention, sans cover, to show the internal components of the heater;
[0009] FIG. 2 is an end plan view of the heater;
[0010] FIG. 3 is an enlarged perspective view of one embodiment of a condensate trap;
[0011] FIG. 4 is a perspective view of an assembled evaporation apparatus; and
[0012] FIG. 5 is an exploded view of an evaporation apparatus.
DETAILED DESCRIPTION
[0013] In general, the present invention employs an electric element to heat condensate from the products of combustion for the purpose of humidification.
[0014] FIGS. 1 and 2 illustrates a heater, indicated generally by number 10 , which employs a representative embodiment of an evaporating apparatus indicating generally by reference number 12 . Apparatus 12 also can be referred to as a humidifying apparatus, as will be understood from the detailed description, below.
[0015] The salient components of heater 10 include an outer housing 14 which enclose the inner working parts inside chamber 16 . The working parts include an induced draft blower 18 that draws combustion products from a heat exchanger 24 . An exhaust pipe 26 is in fluid communication with the heat exchanger and blower 18 to discharge exhaust gas. A burner housing 27 houses gas burners (not seen). Flames from the gas burner enter heat exchanger 24 tubes adjacent burner housing 27 . A circulating air blower 28 draws in room air from the upper rear area of heater 10 across heat exchanger 24 and discharges heated air out of the lower front of the unit. Chamber 16 generally comprises sheet metal walls that define the inner chamber and shields, such as shield 29 over heat exchanger 24 .
[0016] Heater 10 is operated or controlled in any acceptable way. One preferred aspect of a heater control system is disclosed in the assignee's patent application Ser. No. 13/770,446, filed Feb. 19, 2013, which is incorporated herein by reference
[0017] During operation, condensation occurs inside the heat exchanger tubes when the products of combustion are cooled below the dew point. This is a consequence of highly efficient gas heating equipment. There is a condensate collection point, indicated generally by number 30 adjacent induced draft blower 18 to collect condensation from combustion chamber 16 . There is a second condensation collection point, indicated generally by number 32 , on exhaust pipe 26 . It will be appreciated that the two condensation collection points described herein are merely illustrative of the broad aspects of the invention. One skilled in the art will appreciate that there can be one or there can be a plurality of collection points, optimally positioned within housing 14 to collect moisture and condensation. The number or location of the collection points is incidental.
[0018] In any event, heater 10 can include an apparatus to trap or collect the condensate from the collection points. One aspect of such an apparatus is trap assembly 34 shown in FIG. 3 . Trap assembly 34 is a container or canister which can have a top 36 , a closed bottom 38 and circumferential wall 40 that define and inner chamber 41 that has sufficient volume to accommodate a continuous flow of condensate from the condensate collection points without filling up. Conduits or tubes 42 and 44 extend through top 36 and terminate near the bottom of the inner chamber at their first ends and each one is in fluid communication with a condensate collection point at a second end of the tube.
[0019] There is an overflow drain 46 that extends through circumferential wall 40 and is in fluid communication with the inner cavity. Drain 46 is position on wall 40 adjacent top 36 . This allows some level of fluid accumulation within the trap before it flows out of the overflow drain to the evaporating apparatus 12 , as will be explained below. Hence, the position of the overflow drain may vary depending upon the fluid level desired.
[0020] Trap assembly 34 is positioned below blower 28 such that condensate will flow under force of gravity from the collection points into the chamber. The purpose of the condensate trap is to allow condensate to flow from the collection points even though the collection points are each at different pressures. These pressures are different from the pressure at evaporation apparatus 12 . Trap 34 allows condensate to flow without allowing flue gas to escape. Overflow drain 46 is in fluid communication with the upper end 48 of a condensate drain tube 50 . Tube 50 extends downwardly and terminates in with an open end adjacent evaporating apparatus 12 . Although in a preferred aspect of the invention, drain tube 50 terminates adjacent evaporating apparatus 12 , it also may terminate in a discharge to or drain outside housing 14 to dispose of condensate.
[0021] Nevertheless, it will be understood that condensation is collected from the condensation points 30 and 32 and flows into trap assembly 34 . When the fluid level reaches a predetermined level, i.e. at the level of overflow drain 46 , it will flow out, through the upper end 48 of drain tube 50 . In a preferred aspect it drains into evaporating apparatus 12 . The location and configuration of the trap, the tubing and the condensation collection points can vary between heaters. The salient principle is that the heater may include apparatus to collect condensation and transport the condensate to the novel evaporating apparatus 12 .
[0022] Trap assembly 34 can include a sensor, indicated generally by reference number 51 . Sensor 51 can be any type of acceptable sensor, such as a float, electric eye, electrical connection switch. It will be noted that sensor 51 can be located within the canister or outside, depending upon the type. Regardless of the type of sensor employed, sensor 51 is configured to detect an excess accumulation of water in the trap, which could indicate a blocked drain or other impediment to fluid flow. Sensor 51 can be operatively connected to the heater controls so that detection of a critical fluid accumulation would shut down the heater to prevent overflow of condensate. Also, it can be operatively connected to the evaporating apparatus to shut down the evaporating heating element, as will be explained.
[0023] Evaporating apparatus 12 is shown in detail in FIGS. 4 and 5 . In the exemplary embodiment, apparatus 12 includes a bottom pan 52 which, in the illustrated embodiment, has a generally rectangular shape. It will be understood that apparatus 12 can have any useful configuration that works well in the intended environment. Pan 52 includes a bottom wall 54 , a first end wall 56 with holes 58 and 60 , a second end wall 62 and first side wall 64 and a second side wall 66 . The recited walls define an inner cavity 68 . In one aspect, an insulative sheet 70 may be positioned in the cavity on bottom wall 54 . Insulative sheet 70 can be constructed from any acceptable insulative material. Furthermore, top surface 72 of the insulative sheet can be heat reflective.
[0024] Apparatus 12 includes a vaporization element. In one aspect, the vaporization element is an electric heating element 74 is positioned in cavity 64 . If the apparatus includes an insulative sheet, heating element 74 is positioned above the insulative sheet. Heating element 74 can be any conventional heating element with electrical connections 76 and 78 that protrude through holes 58 and 60 and are connected to electricity. In one aspect, an evaporating pan 80 is positioned on top of heating element 74 and under the open end of tube 50 . Pan 80 has a bottom wall 82 , a first end wall 84 , a second end wall 85 , a first side wall 86 and an opposed second side wall 88 . The recited walls and bottom define an inner cavity 90 . It will be noted that the configuration of pan 80 is complementary to that of bottom pan 52 and sized so as to nest in the bottom pan. In other aspects or embodiments of the invention, there can be a layer of metal (not shown) between insulative sheet 70 and heating element 74 . The size and configuration of the various components of the evaporating apparatus may vary without departing from the scope of the invention.
[0025] Also, it will be recognized by one skilled in the art that the evaporation apparatus can comprise only one pan, with a heating element operatively associated with the pan. By way of example, heating element 74 can be positioned inside an evaporation pan or outside, for example, under the pan. Moreover, the heating element can be integrated into the pan itself, for example, with heating wires within the pan material. In the appropriate circumstances, the heating element could be a gas flame, rather than an electric heating element. Hence, the term heating element can encompass any apparatus that heats moisture to evaporate or vaporize the moisture.
[0026] Furthermore, although the exemplary embodiments refer to pans for simplicity and convenience, it will be understood that any type of fluid reservoir that can collect and hold fluid such as condensate is within the scope of the invention.
[0027] In operation, there can be a sensor 92 associated with evaporating pan 80 to sense an accumulation of liquid in the pan. A feedback loop can actuate a switch to turn on heating element 74 . In other aspects, a temperature sensor may be employed to sense when the condensate has boiled and can include a feedback loop to de-energize or shut off the heating element.
[0028] The heat from the heating element causes evaporation of the liquid in pan 80 . Consequently, condensate from the operation of heater 10 is dissipated through evaporation. Sensor 92 (or another sensor) can be used to determine if the fluid level in the patent exceeds a predetermined level and shut down the heater to prevent further fluid accumulation. Sensor 92 can be any appropriate sensor that serves its intended purposes, such as the sensors described above relative to trap assembly 3 and can be located in or on, or associated with any of the evaporation apparatus components.
[0029] As set out above, heating element 74 can be operatively associated with sensor 51 of the trap assembly. If there is an increase in fluid in the trap, it could indicate that fluid is not flowing to the evaporation apparatus and the sensor could shut down the heating element or the entire heater.
[0030] In another aspect or evaporation apparatus 12 , the vaporization element may be an ultrasonic vaporization device 94 in the pan, as shown in FIG. 5 . An ultrasonic vaporization device uses a metal diaphragm vibrating at an ultrasonic frequency, much like the element in a high-frequency speaker, to create water droplets. An ultrasonic vaporization device is usually silent, and also produces a cool fog.
[0031] It will be appreciated that evaporated or vaporized liquid serves as a source of humidity for the space where the heater is located. As shown, evaporating apparatus 12 is located adjacent the bottom of heater 10 , below heat exchanger 24 and blower 28 . This arrangement permits air forced downward by the blower across the heat exchanger to pick up moisture from apparatus 12 and expel it into a room from the bottom front of the heater. However, other locations of apparatus 12 that accomplish the desired purposes are intended to be included in the broad disclosure.
[0032] Heater 10 can include sensors and switches that allow the heating element or ultrasonic vaporizer to be actuated only when blower 28 is operating so vapor from the condensate is introduced into room air rather than building up in the heater. The heater with the evaporating apparatus 12 serves the dual function of providing heat and humidity.
[0033] The evaporation or vaporization feature of the heater may be employed in any heater that produces moisture in operation and has means for collecting the moisture and diverting it to the evaporation and vaporization elements.
[0034] The foregoing description and accompanying drawings are intended to be illustrative of exemplary embodiments of the heater only and should not be construed in any manner that limits the scope of the appended claims.
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A heater having an evaporating and humidifying apparatus therein, the evaporating and humidifying apparatus comprising a fluid pan with a heating element. In one aspect, the pan is in fluid communication with a condensate trap assembly. In one aspect the apparatus can include a base pan, the heating element, an insulator and an evaporation pan above the heating element. The evaporating and humidifying apparatus can include a fluid level sensor operatively associated with the heater controls. The condensate trap assembly may include a fluid level sensor operatively associated with the heater controls to determine fluid levels in the trap assembly. In one aspect the pan comprises an ultrasonic vaporization element in lieu of a heating element.
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BACKGROUND OF THE INVENTION
The subject application disclosed yarn control and feeding apparatus in which concepts from tufting procedures which have become known as the "Spanel tufting system" are utilized. Generally, the Spanel system utilizes pneumatic means to transport yarn to a tufting station, either in metered lengths of unsevered yarn or in discrete bits, after which time the yarn is tufted, by needles or other bit-applying elements to a backing layer to form a tufted product such as a rug.
The present invention discloses yarn control and feeding apparatus which, in some respects, operationally improves embodiments of early Spanel patents, including U.S. Pat. No. 3,554,147, which issued to Abram N. Spanel and George J. Brennan on Jan. 12, 1971, and U.S. Pat. No. Re. 27,165, which issued Aug. 10, 1971 to Abram N. Spanel and Lloyd E. Barton.
The aforementioned U.S. Pat. No. Re. 27,165 discloses a pneumatic yarn transport system having multicolor selection capability in which yarn strands and/or discrete bits of yarn are transported pneumatically to a tufting station where they are applied by tufting elements to a backing layer. The aforementioned U.S. Pat. No. 3,554,147 describes an alternative system to U.S. Pat. No. Re. 27,165, and provides for the simultaneous selection of bit-lengths of yarn of various colors for each tufting cycle at each individual tufting station. A collator structure in which individual channels transport yarn into a common passageway adjacent the tufting station is utilized. The capability of severing a bit-length of yarn before, during or after threading of the tufting element and before or during actual tufting is disclosed.
In addition to the above Spanel patents, co-pending Spanel Application Ser. No. 419,417 discloses a tufting device which utilizes a cutting arrangement employing an axially reciprocable passageway section to provide access for yarn severing means to sever the yarn into selectively sized yarn bits. In addition, co-pending Spanel Application Ser. No. 474,264 discloses a tufting machine which includes a rotatable yarn feed having modified driving and brake means engageable with said rotatable yarn feed means. A pneumatic yarn transport means is provided which includes selective control of gas flow for transporting metered lengths of yarn to a tufting station for severance into yarn bits and subsequent implantation into a backing. As in U.S. Pat. No. 3,554,147, a collator structure is utilized which leads into a common passageway adjacent the tufting station. A yarn pullback or retraction means for retracting yarn from the common passageway is disclosed which will cause only minimal yarn deformation during operation. The pullback function is necessary to remove a particular yarn strand from the common passageway after a yarn bit has been severed therefrom for tufting. This is to enable the advancing of another yarn strand of a different color to the tufting station to supply a yarn bit for the next cycle.
In addition to the above Spanel patents, U.S. Pat. No. 3,824,939 and co-pending Spanel Application Ser. Nos. 419,417, 474,465 and 474,266 all disclose various aspects of Spanel tufting techniques.
BRIEF SUMMARY OF THE INVENTION
In accordance with the subject invention, the apparatus disclosed herein utilizes a yarn control metering and feeding system which utilizes a unique type of actuator and selection means which is actuated by pulsed solenoid means. Basically, the invention sets forth a means by which yarn strands of different colors are selected for and transported to stations with a multiplicity of strands being selectable for each tufting station. The subject invention is directed to yarn control and feeding apparatus and, accordingly, other aspects of Spanel tufting techniques as disclosed in other Spanel patents and applications will not be shown and discussed in detail. It is to be understood that a collator structure such as disclosed in Spanel U.S. Pat. No. 3,554,147 may be utilized which includes a common throat into which a series of yarn tubes merge to provide yarn to tufting needles such as shown in Spanel U.S. Pat. No. 3,554,147.
The subject disclosure utilizes a selector means which engages a key element of a selector plunger for each unit, the key element being actuated by an actuator element responsive to pulsed solenoid means. The selector means provides the drive for each individual selector plunger and upon the actuation of a desired unit, a rotatable yarn feed wheel is released to provide a metered length of yarn. This is accomplished by securing engagement between feed wheel elements and a drive shaft which is separate from the selector means. Simultaneously, as the yarn feeding takes place, the pneumatic system comprising pneumatic yarn advancing and pullback means is actuated by the selector plunger to first feed a selective length of yarn into the common throat area and to the tufting station, and secondly, after severance of a bit-length of yarn from the selected yarn strand to withdraw the yarn clear of the common throat to permit passage of the next selected yarn strand.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 discloses a perspective view of the yarn control and feeding apparatus;
FIG. 2 discloses a modified yarn pullback device which may be utilized in the apparatus of FIG. 1;
FIGS. 3 through 11 show sequential cross-section views depicting the operation of the yarn control and feeding apparatus of FIG. 1;
FIG. 12 discloses a representative timing diagram of the elements of the yarn control and feeding apparatus.
DETAILED DESCRIPTION
With reference to FIG. 1, the illustrated yarn selection and feeding unit 10 has two primary shafts which are utilized to drive various major elements of the system. A selector shaft 12 is utilized in the yarn selection process and a drive shaft 14 is utilized to drive yarn feed wheel 15. Both of the shaft units 12 and 14 are in constant oscillating rocking motion, and when viewed with relation to each individual unit 10, these and air valve plate 62 are the only elements moving when a particular yarn has not been selected. For each tufting needle (See FIG. 11), there may be a multiplicity of tufting selection and feeding units 10 which may be conveniently positioned in tiers. The selector and drive shafts 12 and 14 may extend across the width of the tufting machine and, accordingly, provide drive for all units of a particular tier.
When a particular yarn strand is called for as, for example, the yarn strands shown in subject unit 10 of FIG. 1, selector plunger 16 is actuated as follows. A solenoid 18 is shown mounted on the left leg of magnetic core member 20 while the right leg is near but not toughing actuator 22 which is pivotally mounted on shaft 21. As shown, the left end of actuator 22 is closely positioned above solenoid 18 so that only a slight air gap 23 is found between the top of the magnetic core member 20 and the actuator 22. The end of actuator 22, remote from the solenoid 18, terminates in an upturned tab 24. Above the upturned tab 24 is a selector key 26 pivotally secured to selector plunger 16 by means of connecting pin 28. The selector plunger 16 extends to the right into selector body 30, in which the pneumatic apparatus of the system is contained, and, through intermediate elements, controls the operation of yarn feed wheel 15 to the right of selector body 30. Spring 34 engages the lefthand end of selector plunger 16 and biases the plunger to the right.
When solenoid 18 is energized, the actuator tab 24 impacts against selector key 26 causing its free end to pivot upwardly where it can be engaged by cam lobe 32 that extends along the length of selector shaft 12. As the shaft 12 rocks in a clockwise direction, the selector key 26 and selector plunger 16 are driven to the left causing actuation of the pneumatic system and feed system as will be described.
Yarn strand S can be seen extending downwardly from a yarn creel (not shown) over a prefeed bar 36 which oscillates in timed relation with the drive shaft 14 and the selector shaft 12 to the feed wheel 15 elements of which are positioned around drive shaft 14. Drive disc 38 has the drive shaft 14 extending through its center and has mounted on its outer surface an engaging substance 40, such as Fibertran produced by the 3M Company. Around the outside perimeter of the drive disc 38 is a feed rim 42 that has clutch teeth 44 around its inside surface. The combination clutch teeth 44 and Fibertran fibers provide a one-way clutch to prevent slippage between drive disc 38 and feed rim 42. It is to be understood that any type of one-way clutch may be used in place of the type shown. Mounted to the drive disc 38 is a rigidly secured cam and lock arm 46 under which is an engaging member 48 pivotally secured to drive disc 38 by means of pin 50. The right hand end of engaging member 48, which terminates in key 49, is biased by key spring 52 to an upward position where the key 49 will engage key slot 54 of drive shaft 14 until the spring bias is overcome. Yarn strand S from the creel (not shown) travels over prefeed bar 36 into yarn guide groove 56 formed within bifurcated feed rim 42 and extends around yarn feed wheel 15 and upwardly into the aligned yarn guide channel 58 positioned on the top and left side of selector body 30.
The selector body 30 contains an air manifold 60 below which air valve structure comprises upper air valve plate 62 which is slideably placed upon lower valve plate 64 which is stationary. Air chambers 66, 68 and 70 are found below air valve plates 62 and 64, and it will be noted that air valve plate 62 has air ports 72, 74 and 76 which permit air to be supplied from manifold 60 to the lower chambers 66, 68 and 70 through air ports 71, 73, 75, respectively, as permitted by the cycling of air valve plate 62. It will be noted that air can always flow into the middle chamber 68 through ports 73 and 74 because of the configuration of port 74 which, unlike ports 72 and 76, extends a sufficient distance widthwise to always permit air flow through port 73. Below chambers 66, 68 and 70, a prefeed air channel 78, a pullback air channel 80 and a primary feed air channel 82 extend downwardly from chambers 66, 68 and 70, respectively.
It can be seen that selector plunger 16 extends to the selector body 30 where it is rigidly secured by pin 83 to a cylindrical valve stem 84 that bisects the prefeed, pullback and primary feed air channels 78, 80 and 82, respectively. The valve stem 84 includes vertical ports 86 and 88 which extend through valve stem 84 so that when the port 86 is aligned with either prefeed air channel 78 or pullback air channel 80, or when port 88 is aligned with primary feed air channel 82, air may pass downwardly from the respective chambers 66, 68 and 70.
The prefeed channel 78 and the pullback channel 80 are shown extending by means of angular extension channels 90 and 92 to points of intersection with yarn guide channel 58 along the lower lefthand side of selector body 30. In the proximity of the angular extensions 90 and 92, a prefeed and pullback storage pocket 94 is located to the outside of the yarn guide channel 58. Side air vents 96 and base air vents 98 are disclosed to permit the passage of air from the system. It will be seen that the yarn guide channel 58 leads into enclosed passageway 100 at the base of the selector body 30 and that to the right of this enclosed yarn passageways 100 is a yarn tube 102. The yarn tube 102 from each unit extends into a common throat (See FIG. 11) adjacent tufting needles (See FIG. 11) as disclosed in Spanel U.S. Pat. No. 3,554,147 and co-pending Spanel Application Ser. No. 474,264. A Venturi-like nozzle 104 is disclosed in the cutaway area adjacent to which is an air chamber 106 into which air flow from the primary feed air channel 82 is received. Outer air passageways 108 within the yarn tube 102 permit air to pass from chamber 106 over nozzle 104 and into unobstructed yarn tube 102 to propel the yarn to the right through the yarn tube 102 to the tufting station (See FIG. 11).
The far right end of valve stem 84 is secured to cam plate 110 which is laterally shiftable along with selector plunger 16 and valve stem 84 and is engageable with cam and lock arm 46. A camming surface 112 is provided, below which is a recessed area 114 which extends downwardly and terminates in a release tab 116.
As can be seen in FIG. 1, when cam plate 110 shifts to the left, engaging member 48 will drop as it effectively is released by release tab 116, thus causing the engaging member 48 to be biased by key spring 52 into engagement with drive shaft 14. It will also be appreciated that cam and lock arm 46 can urge cam plate 110 to the left as the cam and lock arm 46 swings through a downward arc with its left extremity engaging camming surface 112.
The operation of each of the above described yarn selection units 10 is as follows. As soon as a pulse is given for the selection of a particular yarn strand S, the selection elements are energized by means of solenoid 18. The magnetic attraction from the solenoid magnetic core member 20 attracts the actuator 22 and closes the air gap between the lefthand end of the actuator 22 and the top of the lefthand side of the member 20. As this happens, the righthand tab 24 of the actuator 22 impacts against the bottom of selector key 26 and urges it upwardly toward the selector shaft 12. As seen in FIG. 1, movement of the selector key 26 is limited by the cam lobe 32. As the selector shaft 12 rocks in a counterclockwise direction to a load position, the cam lobe 32 will clear the end of the selector key 26 allowing the selector key to reach its upward position. Effectively, the selector shaft 12 now has the selector key 26 engaged by the cam lobe 32 and when the selector shaft 12 rotates in a clockwise direction, the selector key 26 together with the selector plunger 16 are moved leftwardly. As the selector key 26 reaches its furthest possible position to the left, the tab 24 of actuator 22, which is still being urged upwardly, will pop up to its uppermost position when the base of the selector key 26 slides sufficiently far to the left. As this happens, a mechanical clip is formed between the base of the selector key 26 and the actuator tab 24. This enables actuation to consist of pulsing the solenoid 18 with, for example, a high voltage pulse which need be only for an extremely short interval of time, such as ten milliseconds. A much smaller voltage may be used for part of the cycle and the voltage turned off for the rest of the cycle since the mechanical engagement between selector key 26 and actuator tab 24 secures the selector key 26 to the left in its desired position.
Using a high voltage pulse is further desirable since the pull of a solenoid varies nonlinearly with the gap distance, and the greatest pull is required when the gap is largest. Accordingly, the gap is closed instantly, and this condition can then be maintained by a very small voltage.
As the selector key 26 is driven to the left, the selector plunger 16 and the valve stem 84 are also driven to the left overcoming the bias of spring 34. This serves to bring valve ports 86 and 88 in line with prefeed air channel 78 and primary feed channel 82, respectively, so that as air is admitted to chambers 66 and 70, the air pressure will continue down through channels 78 and 82, respectively. Thus, as upper air valve plate 62 oscillates, its air ports 72 and 76 will be in and out of alignment with air ports 71 and 75 in the lower valve plate 64 to provide quick bursts of air through to the prefeed air channel 78 and the primary feed air channel 82, respectively. As can be seen from the positioning of the ports 72 and 76 of the upper air valve plate 62, the air bursts to the two respective chambers below will be at slightly different times. Accordingly, when the selector mechanism 16 and valve stem 84 move to the left, the ports 86 and 88 permit the quick bursts of air which are necessary to the prefeed and primary feed yarn cycles as will be discussed. As will be described in more detail when the sequential views in FIGS. 3 through 11 are discussed, air is introduced into yarn guide channel 58 from prefeed air channel 78 to propel the yarn strand S into the prefeed and pullback storage pocket 94 as the yarn is released from the rotatable yarn feed system. Once the yarn strand S has been fed into the prefeed and pullback storage pocket 94, it may then be advanced to the needles (not shown) by air from the primary feed air channel 82 which feeds into the yarn tube 102 through Venturi-like nozzle structure 104.
As the selector plunger 16 and the valve stem 84 are moved to the left, as above discussed, cam plate 110, which is rigidly secured to the end of the valve stem 84, also moves leftwardly and as it does, the lefthand end of engaging member 48 drops and it is released from its position on top of the release tap 116. As this release occurs, the engaging member 48 pivots around pin 50, as the righthand end key 49 of the engaging member 48 is urged upwardly by means of key spring 52. It has been previously noted that drive shaft 14 constantly oscillates in a rocking motion. The distance of the motion may be adjustable to determine the length of yarn that will be fed. This adjustment may be made by an adjusting wheel on the machine (not shown) which controls the number of degrees that the drive shaft will move in its clockwise rotation. The drive shaft 14 counterclockwise rotation always stops at the same position. As the righthand key 49 of engaging member 48 rises, it will pop into key way 54 in the drive shaft 14. Since the engaging member 48 is pivotally pinned to the drive disc 38, the drive disc 38 will be driven by the drive shaft 14 as the latter rotates in a clockwise rotation.
As previously described on the periphery of the drive disc 38, an engaging surface 40 of Fibertran fibers serves as a one-way clutch since the fibers are attached at an angle to the disc and will engage the slanted clutch teeth 44 of the feed rim 42. The teeth of the feed rim are slanted in such a direction as to effectively work against the Fibertran fibers. As the counterclockwise rotation of the drive disc 38, that is imparted by the drive shaft 14, is also imparted through the one-way clutch to the clutch teeth 44 of the feed rim 42, the outer feed rim 42, which is in engagement with the yarn, will be driven. Thus, during clockwise rotation, the drive disc 38 rotates and, as an example, for approximately 180° of machine time, delivers yarn off of the feed rim 42 into the yarn channel 58. For the first 120° of this approximate 180° rotation, the yarn comes off the feed rim 42 and into the yarn channel 58 until it reaches the prefeed and pullback storage pocket 94. The prefeed air channel 78 through this 120° of the cycle may be on to admit air through port 72 and through vertical port 86 of valve stem 84 which, at this time, will be aligned with prefeed air channel 78. Thus, the air from the prefeed air channel 78 drives the yarn into the prefeed and pullback storage pocket 94 to await the time when needles (See FIG. 11) are in position to accept the yarn. After 120° machine time rotation in the clockwise rotation of drive shaft 14, the air port 62 will be synchronized to close the prefeed system and at this time, the primary feed system will open as port 76 aligns itself with port 75 so that air will flow down through primary feed air channel 82 unimpeded by valve stem 84 since port 88 is aligned with the primary feed air channel 82. Air will thus pass over the Venturi-like nozzle 104 and through the yarn tube 102 to carry the yarn strand S which has been delivered into the prefeed and pullback storage pocket 94 causing the yarn strand S to feed through the yarn tube 102 to the tufting station (See FIG. 11). For the next 60° of the machine time, the yarn feed wheel continues its feeding and the yarn continues through the yarn channel 58 as pulled by the air through primary feed air channel 82 and into yarn feed tube 102.
Assume that this particular color yarn strand S is no longer required and it is necessary or desirable to change to another color from another unit. It is necessary to draw the yarn back from the common passageway (See FIG. 11) to permit the next strand to reach the tufting station. At this point in time, the solenoid is de-energized and the tab 24 of the actuator 22 becomes ready to drop to its normal rest position, however, since it is still mechanically latched to the selector key 26 and since spring 34 is pushing the selector key 26 to the right, the latch condition is maintained. However, as selector shaft 12 rotates in a clockwise direction during its next cycle, it will push the selector key 26 to the left approximately a few thousandths of an inch to release the mechanical interference and allow the actuator tab 24 to drop. The spring 34 is now free to bias selector plunger 16, valve stem 84 and the cam plate 110 to the right, and as this occurs, the valve stem 84 reaches its furthest position to the right. The port 86, which was originally aligned with the prefeed air channel 78, now moves to the right and aligns itself with the pullback air channel 80. Also, the port 88 moves out of alignment with the primary feed air channel 82. As notes previously, the pullback chamber 68 is designed to receive air at all times and the oscillation of upper air valve plate 62 does not affect the flow of air because of the large size of air port 74. Thus, the pullback air flow is controlled totally by the movement of the valve stem 84 and when valve port 86 aligns with the pullback air channel 80, air flows there through causing the yarn strand S to be retracted through yarn tube 102 and withdrawn from the common throat area (See FIG. 11) as it is stored in the prefeed and pullback storage pocket 94.
Also, the movement to the right of cam plate 110 occurs after the solenoid 18 has been de-energized, and as this happens, when feed rim 42 and drive disc 38 move in a counterclockwise direction, the cam and lock arm 46 swings downwardly against the cam plate 110 along with the engaging member 48, the key of which 49 is still engaged in keyway 54. As the cam and lock arm 46 impacts against camming surface 112 of the cam plate 110, the cam plate 110 is forced to the left as the cam and lock arm 46 rides over the camming surface 112 and into the recessed area 114 to secure the cam plate 110 slightly to the left of this most rightward position. This effectively causes the port 86 of valve stem 84 to be slightly to the left of the pullback air channel 80, and the pullback air is accordingly turned off. As the lefthand end of the cam and lock arm 46 drops within the recessed area 114, the continued counterclockwise rotation of drive shaft 14 forces the engaging member 48 against release tab 116, thus, overcoming the bias of the key spring 52 and forcing the removal of the key 49 from the drive shaft keyway 54. Thus, the drive shaft 14 will continue to rotate, but without feeding yarn until the solenoid is once again energized.
With reference to FIG. 2, a modified pullback system is disclosed. In place of the pneumatic flow which impacts directly against the yarn strand S, a pneumatic piston-like plunger 118 is disclosed which physically drives the yarn into the prefeed and pullback storage pocket 94.
For a more detailed understanding of the subject invention, reference should be made to the sequential views shown in FIGS. 3 through 11. With reference to FIG. 3, the unit is in its standby or non-operating condition. The solenoid 18 is not being energized and the selector key 26 is in its standby position with everything being static except for the continual rocking motion of the selector shaft 12 and the drive shaft 14 and the airvalve plate 62. The yarn feed system is static. As can be seen at this time, yarn from the preceding cycle is stored in the prefeed and pullback storage pocket 94. A dog brake 120 not shown in previous Figs. is shown which is spring loaded and which will keep the feed rim 42 from rotating where there is counterclockwise motion of the drive disc 38.
With reference to FIG. 4, the particular yarn of this unit is selected and the solenoid 18 is energized with a high voltage pulse. At this point, the drive shaft 14 and the selector shaft 12 are shown going in counterclockwise directions as the solenoid 18 is energized with the tab 24 of actuator 22 moving upwardly to urge selector key 26 to its upward position. The air gap 23 has closed as this is achieved and the selection key 26 is now in its operating position.
With reference to FIG. 5, the selector key 26 is shown in the up position and the selector shaft 12 is rotating clockwise and engages selector key 26 to drive the selector plunger 16 to the left, which permits the selector key 26 to drop beside the actuator tab 24 causing mechanical hooking therebetween. The leftward movement of cam plate 110 has permitted the cam and lock arm 46 to be released from recessed area 114 and permits the engaging member 48 to be clear of release tab 116, thus dropping at its lefthand end as the key spring 52 biases the key 49 into engagement with keyway 54. The drive shaft 14 has started in the clockwise direction and is, at this time, ready to feed yarn. The air from the pressure chamber is shown going down through the port 76 of upper air valve plate 62 through the chamber 70 and down through primary feed channel 82 as permitted by the alignment of port 88 with the primary feed channel 82. As this occurs, the yarn strand S is shown being advanced from its pullback position as temporarily stored in the prefeed and pullback storage pocket 94 through yarn tube 102.
With reference to FIG. 6, the drive shaft 14 is shown continuing in its clockwise rotation as drive disc 38, engaging member 48, cam and lock arm 46 and feed rim 42 all rotate. The upper air valve plate 62 shifts and air flows through port 72 into chamber 66 and through aperture 86 into the prefeed channel 78. Yarn being delivered by the yarn feed wheel 15 is progressing down through the yarn guide channel 58 and is starting to be delivered into the prefeed and pullback storage pocket 94 as propelled by the air from the prefeed channel 78. At this point, the portion of the yarn strand S in the yarn tube 102 has no motion. The prefeed bar 36 starts shifting to the right. The selector shaft 12 has started rocking in the counterclockwise direction, again leaving the selector key 26 hooked on the actuator tab 24 in its leftward position.
With reference to FIG. 7, the rotation of the yarn feed wheel 15 in its clockwise direction is shown as yarn delivery continues. The prefeed air from channel 78 is continuing to deliver the yarn to the prefeed and pullback storage pocket 94 and the selector shaft 12 has again contacted the selector key 26, at which time the solenoid 18 goes off if that particular strand of yarn is no longer desired. If the solenoid 18 is programmed off, another solenoid in another unit for the same needle station will be programmed on before the yarn has been delivered to the needles on the previous selection. As shown in FIG. 7, as the selector shaft 12 returns in the clockwise direction, it taps the selector key 26 relieving the pressure on it, thus allowing the actuator tab 24 to drop since the solenoid 18 is de-energized.
In FIG. 8, the selector key 26 is still engaged by the selector shaft 12 and at this point, the upper air valve plate 62 shifts again turning the primary feed air flow back on as previously. Since the clockwise rotation of the drive shaft 14 and the feed wheel 15 is continuing, the primary feed air flow is delivering prefed yarn which had been stored in the prefeed and pullback storage pocket 94 while continuing to feed yarn that is still being delivered by the feed wheel 15. During the last 60° of machine time, the yarn is delivered directly into the yarn tube 102 without going into the prefeed and pullback storage pocket 94.
With reference to FIG. 9, the rotation of the selector shaft 12 in its counterclockwise direction begins and after the completed clockwise motion of the yarn feed wheel 15 is finished, the counterclockwise motion of the drive shaft 14 begins. As can be seen, the counterclockwise rotation of the selector shaft 12 allows the selector key 26 and the selector plunger 16 to be biased to the right by spring 34. As this occurs, the valve stem 84 moves to the right and port 86 moves from the prefeed channel 78 to the pullback channel 80. Insofar as the tufting cycle is concerned at this time, severance of the yarn has been completed and once the pullback air is on, the yarn is pulled back through yarn tube 102 to clear the common throat area (See FIG. 11) adjacent the tufting station. The cam and lock arm 46 and the engaging member 48 are headed to their rest positions as the drive shaft 14 moves in a counterclockwise direction. The yarn prefeed bar 36 moves to the left and the spring biased dog brake 120, which is in engagement with the feed rim 42, prevents the counterclockwise rotation of the feed rim 42 as drive disc 38 rotates in a counterclockwise direction free of the influence of clutch teeth 44.
With reference to FIG. 10, the cam plate 110 is shown right before being engaged by the cam and lock arm 46 which will subsequently force the cam plate 110 back to its neutral or standby position. As shown in FIG. 10, at this moment, pullback air continues.
With reference to FIG. 11, the cam and lock arm 46 has pushed the cam plate 110 slightly to the left to its neutral position, thus sliding port 86 of valve stem 84 out of alignment with the pullback channel 80 to shut off the pullback air. The cam and lock arm 46 has caused the engaging member 48 to be pushed against selector release tab 116, as key 49 disengages with the keyway 54 of drive shaft 14, thus completing cycle.
Also shown in FIG. 11 are other elements which are common to some other embodiments of Spanel techniques as disclosed in Spanel patents and other co-pending applications. Yarn tube 102 is shown leading into common throat 122 along with a representative yarn tube 123, functionally the same as yarn tube 102, only extending from another selection unit. Severing means 124 and bit-applying elements, such as tufting needles 126, are schematically shown at tufting station 127 and it is to be understood that yarn strands once transported into common throat 122 are severed by severing means 124 and tufted into a backing layer by tufting needles 126.
The timing diagram of FIG. 12 is essentially self-explanatory and shows representative periods of machine time cycles for the various elements that have been emphasized through the preceding discussion of the sequential views in FIG. 3-11.
It is to be noted that the rotational distance of the drive shaft 14 can be adjusted to readily provide bit-lengths of yarn of different sizes. Also, it will be appreciated that the dimensions of the feed wheel 15 could be changed to adjust the bit-length sizes although such a change could not be made as readily as changing the rotational distance of drive shaft 14.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification as indicating the scope of the invention.
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A yarn control and feeding apparatus for use with tufting machines and similar apparatus wherein yarn, normally precut, is tufted into a backing layer. A pulsing-type solenoid actuator is utilized to selectively control yarn metering and feeding functions carried out by a rotatable yarn feed wheel and to further control pneumatic yarn transport means including advancing and retracting yarn during various stages of the tufting cycle.
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REFERENCE TO RELATED APPLICATION
The present application claims the benefit of U.S. Provisional Patent Application No. 60/665,860, filed Mar. 29, 2005, whose disclosure is hereby incorporated in its entirety into the present application.
FIELD OF THE INVENTION
The present invention is directed to a method of measuring physical characteristics, particularly but not exclusively strain, displacement and temperature, and in particular a method based on the measurement and analysis of the Brillouin scattering spectrum in optical fiber. The present invention is further directed to a distributed fiber optic sensing system for use in rapidly measuring such physical characteristics at a fast measurement rate.
DESCRIPTION OF RELATED ART
The use of fiber optic technology for sensing environmental and structural properties is well known in many industries where it provides meaningful information to help ensure safety and efficiency of operation. Fiber optic sensors can be deployed in many ways such as being applied to the surface of structures, embedded in materials, buried underground, etc. In situations where relatively large areas require monitoring, distributed sensing techniques are often used to gather information.
Many different techniques exist for using fiber optic technology for sensing applications. The application of Brillouin scattering to distributed fiber optic sensing has been successfully researched and developed by several academic and industry organizations. Brillouin scattering is known in the art to have well-defined thermal and mechanical dependencies. Measuring the spectrum of the Brillouin process in a distributed fashion allows for physical characteristics to be determined.
Brillouin scattering is a non-linear process that occurs through the generation of a backward propagating Stokes wave, which is downshifted in frequency from the original wave by an amount determined by the non-linear medium. The Brillouin spectrum has a Lorentzian profile centered about the Brillouin frequency of the fiber. However, this frequency is sensitive to strain and temperature, and changes in a linear fashion in response to both. Strain and temperature distribution along the fiber can be obtained by measuring the frequency shift as a function of location.
This principle was first applied to sensing in 1989. A pump pulse was launched into one end of a fiber and a cw probe was launched into the other side. When the frequency difference between the two waves equaled the Brillouin frequency for a particular location on the fiber, the cw experienced gain at that location. In this way the frequency difference was stepped over a range of values to get the overall Brillouin spectrum. The temperature accuracy was 3° C., with spatial resolution of 100 m on a 1200 m fiber.
To increase the overall sensing length of BOTDA, Bao et al. proposed a method based on Brillouin loss signal rather than the gain. Unlike the previous case, now the frequency of the probe was greater than the frequency of the pulse. As a result, the pump experienced amplification and the probe experienced loss. This resulted in longer sensing lengths because the pump did not experience depletion. Bao et al. demonstrated a temperature resolution of one degree Celsius and a spatial resolution of 10 meters on a 50 km fiber.
The next major development was the single-ended BOTDA system developed by the research group at Swiss Federal Institute of Technology (EPFL). In this, an Electro Optic Modulator connected to a microwave source generates upper and lower sidebands along with pulses. This frequency shifted pulse interacts with the reflected cw wave from the far end of the fiber to produce Brillouin scattering. A temperature resolution of 1° C. and a strain up to 20 με with a 1 m spatial resolution on fibers 10 km in length has been demonstrated.
Dynamic strain is an emerging area of research for applications in civil and aerospace structures like structural fatigue evaluation due to material aging (reference), and also wind induced vibrations of optical fiber composite overhead ground wire.
One of the major applications of this would be in intrusion detection of pipelines caused by third party damage. Gas pipelines are several hundred km long and sometimes they are damaged by construction equipment like boring and drilling machines. Current methods which include periodic aerial surveillance, using satellite images, acoustic methods etc. require too much human intervention and their reliability is dependant on climatic conditions. When the construction equipment is near, an optical fiber sensor buried with the pipeline would undergo stress due to the vibrations and compressions of the surrounding soil. This change could be detected using the principle of BOTDA. This would allow continuous, real time monitoring of pipelines and alert the authorities even before the damage is caused, thereby saving millions of dollars. However, this system should be able to distinguish between vibrations caused by normal conditions like an overhead passing train, lawn mowing etc. and potentially hazardous equipment.
The Brillouin signal has low SNR and hence averaging is usually required to obtain the fiber information. Also, to cover the entire spectrum, the frequency difference between the two lasers has to be stepped through various values and a measurement has to be taken each time. These result in measurement times in the range of minutes for BOTDA based systems, whereas, systems based on other properties like Polarization Optical Time Domain Reflectometry, Optical Coherence Domain Reflectometry, and Frequency Modulated Continuous Wave Techniques require measurement times in the millisecond range. However, the ratio of the spatial resolution to the measurement range is as low as 0.01% for BOTDA (relative spatial resolution range) which is very good compared to other schemes.
Brillouin ring amplification was first proposed for dynamic strain measurement. This measured dynamic strain having a period of 2 s, but the spatial resolution was ≈100 m. Dynamic strain measurement at 1 Hz was also made using a correlation based technique. However, the vibrating section was only 5 cm long. Measurements for pipeline intrusion detection were made using a modified OTDR method leading load variations detection upto 5 Hz.
When light travels through a fiber, it interacts with matter and undergoes scattering. This results in conversion of light from one frequency to another through the emission (Stokes process) or absorption (Anti-Stokes process) of acoustic phonons. The number of photons scattered per mode length is given by:
ⅆ
N
S
ⅆ
z
=
AN
I
(
N
S
+
1
)
(
2.1
)
where N S , and N I are the number of scattered and incident photons, A is the gain factor.
If the incident light intensity is weak, then the number of scattered photons per mode is small (N S <<1), then the above equation is approximated by a linear equation:
N S =AN I l (2.2)
This is known as spontaneous scattering.
However, as the intensity of the incident light increases, a large number of scattered photons are generated (N S >>1) and equation (2.1) becomes:
N S =N S (0)exp( AN I l ) (2.3)
This will lead to an exponential or stimulated amplification of scattered light.
Brillouin scattering is caused by the vibrations of the molecular structure of glass which in turn leads to refractive index variations. These vibrations are termed as acoustic phonons and travel at the speed of sound (V A ) and cause a frequency shift in the pump light due to Doppler effect:
v
B
=
2
nV
A
λ
(
2.4
)
This is termed as the Brillouin frequency shift. This shift is dependent on the refractive index (n) and acoustic velocity (V A ) of the fiber, both of which are in turn related to the strain and temperature of the fiber and this phenomenon is exploited in strain and temperature sensing.
However, this scattering does not occur at one particular frequency only. Instead it is spread over a range due to the finite lifetime of acoustic phonons (typically 10 ns). The decay process is assumed to be exponential resulting in a Lorentzian Brillouin profile:
g
(
v
)
=
g
B
1
+
4
[
v
-
v
B
Δ
v
B
]
(
2.5
)
where g B is the peak value of the Brillouin gain occurring at v=v B . Δv B is the Brillouin line width (of the order of 30 MHz).
The Stokes process is observed more commonly as compared to the anti-Stokes process. It results in the creation of acoustic phonons which further stimulate scattering. However, the incident light intensity has to be greater than a threshold value to allow for stimulated scattering to occur. This threshold is the value of the pump intensity at which the gain of the Stokes wave overcomes the fiber loss. This value can be reached at lasers powers as low as a few mill watts because of the high power densities in the small core fiber as well as the low loss of modern fibers.
BOTDA based systems work on the principle of Brillouin amplification. They consist of two lasers injecting light from opposite ends of the fiber at frequencies v 1 (probe laser) and v 2 (pump laser). The frequencies of the lasers are adjusted such that v 2 =v 1 +v B . This results in the probe light having the same frequency as that of the Brillouin scattered light generated by the pump laser. The probe intensity is thus added to the pump scattering intensity resulting in stimulated scattering of the pump. The net result is that the pump undergoes loss and the probe beam undergoes gain.
In real systems, the value of the Brillouin frequency is not known beforehand. Hence, the frequency difference of the two lasers is scanned through a range of values and at each value the gain/loss of the probe/pump is measured. This can in turn be used to construct the Brillouin spectrum g(v) and from this the Brillouin frequency can be determined.
In U.S. Pat. Nos. 6,813,403, 6,380,534, and 5,880,463, the authors teach various methods of fiber optic sensing using the Brillouin scattering process. These techniques differ in the means by which they interrogate the optical fiber to determine its thermal and mechanical properties in a distributed manner. However they are all similar with respect to how each relies on the interaction between two counter propagating light beams of different frequency in the fiber. To provide spatial information, it is common to pulse one of the laser beams in order define a characteristic sensing length and to enable the extraction of spatially-resolved Brillouin spectrum information through optical time domain analysis. Furthermore, the techniques taught in the art are similar in how they rely on a sequential, iterative process of varying the relative frequency difference between the counter propagating light beams in order to determine the spectrum of the Brillouin scattering process throughout the fiber. With knowledge of the spectrum, the fiber's strain and temperature properties can be determined. The use of a sequential, iterative procedure for varying the frequency difference results in a time-consuming measurement process. As the length of sensing fiber increases and the range of possible strain and temperature conditions increase, the time required to collect a complete measurement grows rapidly and ability to measure dynamic physical processes decreases. In situations where dynamic measurements are required, such as for monitoring vibrations, the previously described methods that exist in the prior art are not able to provide sufficiently rapid measurement rates.
In U.S. Pat. Nos. 5,818,585, 6,674,928, the authors teach methods of using a collection of discrete optical sensing points, referred to in the art as fiber Bragg gratings (FBGs), in an optical fiber to collect strain and/or temperature measurements along said optical fiber. Although this technique offers dynamic measurement capabilities, it suffers from several limitations. First, sensing elements must be introduced at discrete points in the fiber. This process often degrades said fiber's mechanical strength and increases the overall cost of the length of sensing fiber. Second, there are practical limits to the total number of FBG sensors that can be applied to the sensing fiber. This limitation can reduce the maximum length of sensing fiber and can result in large distances between discrete FBG sensing points.
SUMMARY OF THE INVENTION
The present invention teaches an improved method of distributed sensing with Brillouin scattering that allows for significantly shorter measurement times, thereby providing the capability to monitor dynamic processes.
The present invention provides a distributed fiber optic based sensor system using Brillouin scattering that overcomes the previously described limitations of all known systems that use the Brillouin scattering process by allowing for rapid measurements of the Brillouin spectrum using a single pass of light through the fiber.
This invention employs a novel technique for simultaneously interrogating the sensing fiber with two counter propagating light beams. One beam is set to a constant frequency, consistent with prior art. The second beam is modified to contain a “comb” of frequencies, with each frequency component in the comb offset by a predetermined amount. Each of the frequency components in the comb, herein referred to as teeth, is able to interact with the counter-propagating beam through the Brillouin scattering process. With proper selection of the comb characteristics such as the number of teeth, the frequency spacing of teeth, the spectral width of teeth, and the relative amplitude of the teeth, a representation of the Brillouin spectrum at each point in the fiber can be obtained simultaneously with a single pass through the fiber. The use of a comb of frequencies eliminates the need for the slow process of sequentially stepping through a range of frequencies using a distinct pass of light through the fiber at each frequency. The use of a comb of frequencies allows the interrogation process to occur at many different frequencies simultaneously. This innovation significantly reduces the time required to measure the Brillouin spectrum for any length of sensing fiber. In this way, a system for rapidly collecting distributed measurements from fiber optic cable results.
The technique disclosed herein will be able to update the strain information with each two way travel time of the fiber. Thus, a 2 km sensor fiber could be updated at the rate of 50 kHz.
Accordingly, one object of the invention is to provide an improved sensing system for measuring physical characteristics.
A further object of the invention is to provide a fiber optic sensing system that uses the Brillouin scattering process to measure physical characteristics
A further object of the invention is to provide a sensor system that can be used to monitor variations in physical characteristic.
A further object of the invention is to provide a sensor system that can be used to monitor vibrations in large structures in a distributed fashion.
A further object of the invention is use the Brillouin scattering process to collect distributed measurements of physical characteristics over a prescribed length of optical fiber.
A further object is to provide a means of rapidly measuring the Brillouin scattering spectrum with a single pass of light through the optical fiber.
A further object is to provide a means of rapidly measuring the Brillouin scattering spectrum through the use of a light beam modified to contain to a comb of frequency components.
A further object is to provide a means to vary the characteristics of the comb to allow each of its frequency components to interact independently through the Brillouin process.
A further object is to use a suitable detection system to monitor the interaction of each frequency component in the comb in order to extract piece-wise measurements of the Brillouin spectrum with a single pass of the comb through the fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention will be set forth in detail with reference to the drawings, which show the following:
FIG. 1 BOTDA Based system used by the FROST group at UNB (the University of New Brunswick);
FIG. 2( a ) Time domain plot for a frequency difference of 12.92 GHz;
FIG. 2( b ) Frequency Spectrum for the point undergoing loss shown in FIG. 2( a );
FIG. 3( a ) Single frequency pump without Brillouin interaction;
FIG. 3( b ) Pump signal after Brillouin interaction;
FIG. 4 Frequency domain signal broadening after Brillouin interaction;
FIG. 5 Time Domain Comb Signal;
FIG. 6 Frequency Domain Comb Signal;
FIG. 7 Time domain trace of sum of sinusoids with random phase;
FIG. 8 Frequency Domain trace of sum of sinusoids with random phase;
FIG. 9 Broadening of Comb teeth after Brillouin interaction;
FIG. 10 Wide comb teeth spacing resulting in insufficient information on the comb teeth to get entire Brillouin spectrum;
FIG. 11( a ) Fiber with two continuous uniformly strained 10 m section;
(b) 10 ns pulse; (c) Probe signal after interaction; (d) FFT of signal in (c) showing broadening of the frequency comb due to the interaction;
FIG. 12( a ) Fiber with two continuous uniformly strained 20 m section;
(b) 100 ns pulse; (c) Probe signal after interaction; (d) FFT of signal in (c) showing broadening of the frequency comb due to the interaction;
FIG. 13 Pulse Laser not synchronized with the probe laser resulting in different interaction in each measurement;
FIG. 14 Frequency spectrum for the case of two lasers having a frequency difference corresponding to the Brillouin frequency;
FIG. 15 Frequency spectrum of narrowband PM waveform;
FIG. 16 Transfer Function of EOM;
FIG. 17 Frequency Spectrum of the EOM output for various values of the bias voltage;
FIG. 18 Lorentzian Brillouin profile;
FIG. 19 A.M. wave;
FIG. 20 Illustration of the fiber simulated in Matlab;
FIG. 21 Brillouin interacted wave;
FIG. 22 Down converted after mixing at photodetector;
FIG. 23 Proposed Signal Configuration;
FIG. 24 Algorithm used for post processing;
FIG. 25 3-D view of Brillouin Spectrum for the entire fiber;
FIG. 26 Lorentzian profile with little variation between maximum and minimum;
FIG. 27 Time domain waveforms for each frequency tooth obtained after simulation;
FIG. 28 Coherent Parallel Receiver Brillouin Sensing system;
FIG. 29 Frequency Spectrum of the Brillouin interacted signal;
FIG. 30 Zoomed in spectrum for the comb tooth at the exact Brillouin frequency difference for a range of pulse width excitations;
FIG. 31( a ) Output waveform at the Brillouin frequency of the cooled section at 12.72 GHz;
FIG. 31( b ) Output waveform at the Brillouin frequency of the normal fiber at 12.78 GHz;
FIG. 32( a ) Waveform obtained using ESA as receiver in zero span mode at 12.72 GHz;
FIG. 32( b ) Waveform obtained using ESA as receiver in zero span at 12.78 GHz;
FIG. 33 Flowchart for the algorithm used for post processing;
FIGS. 34( a )-( g ) Waveforms obtained after each step of the algorithm;
FIGS. 35( a ) and ( b ) 64 waveforms of a sequence superimposed on each other;
FIG. 36 Plots of the Brillouin frequency at every point on the fiber using coherent Parallel receiver for temperature measurements and averaging on the scope;
FIG. 37 Positions taken in static case for reference measurement;
FIG. 38 Time Domain waveform obtained after Brillouin interaction;
FIG. 39( a ) Brillouin frequency of all the points for the case of nearest position using original system;
FIGS. 39( b ), ( c ),( d ) Zoomed plots for region around the strained section;
FIG. 40 Approximated positions for dynamic strain measurements; and
FIG. 41 Strain profile of a point located around 900 ns on the fiber as the fiber is subjected to dynamic strain.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention and modifications thereof will be set forth in detail with reference to the drawings, in which like reference numerals refer to like elements or steps throughout.
The sensor system according to the preferred embodiment is based on the principle of Brillouin loss mechanism. The overall system diagram is shown in FIG. 1 as 100 . The Nd:YAG lasers 102 , 104 operate at 1319 nm. The pulsed light from the pump laser 102 enters one end of the fiber 106 , and the cw light from the probe laser 104 enters the other end of the fiber. The frequency difference is varied over a range of values to cover the entire Brillouin spectrum on each point on the fiber. The entire system is automated using software called NTControl which automatically changes the frequency and acquires the data. NTControl is user friendly software having a window in which 35 settings can be adjusted, the most important ones being the fiber start, fiber end, time base, minimum frequency, maximum frequency, frequency step size, and baseline regions.
A part of the output of the two lasers is tapped and mixed using a 50:50 coupler 108 and detector 110 and input to an XL microwave frequency lockbox 112 . The lockbox compares the difference signal to an internal reference and generates an error signal that locks the lasers to the internal reference.
The EOM 114 modulates the light to produce pulses. A part of the output of the modulator is tapped out using a 99:1 coupler 116 and input into a DC-1 GHz photodetector 118 to monitor the pulse power, duration and also get a trigger signal for data acquisition. The remaining light enters the sensing fiber 106 under test after passing through a circulator 120 . The light from the pump laser enters into the fiber after passing through a polarization controller 122 , attenuator 124 and isolator 126 . The polarization controller is used to rotate the polarization state to two orthogonal polarizations and the results are averaged to get the signal from all of the fiber. The attenuator helps in controlling the pump power so as to avoid stimulated scattering. The isolator prevents the pulsed light from traveling through the fiber and into the probe laser and thereby causing its destabilization. The Brillouin interacted pump laser goes into the circulator port B and impinges on the detector from circulator port C.
The signal out of the circulator port C is incident on a 1 GHz photodetector 128 . The output current is then amplified in an amplifier 130 and displayed as a time domain trace on the oscilloscope screen of a data acquisition system 132 . Since the system operates on the principle of Optical Time Domain Analysis and a pulsed laser is being used for the system, interaction at any instant can only occur at a particular location corresponding to the position of the pulse. Since the pulse travels along the fiber, each point on the output signal will correspond to a unique location on the fiber. The width of the pulse governs the spatial resolution of the instrument since all the fiber within the pulse is illuminated simultaneously.
Different points on the fiber will have different Brillouin frequencies due to varying strain and/or temperature. Therefore, as the frequency difference is stepped through various values, different points will undergo varying amounts of gain. For example, if ƒ 1 is the frequency difference of the two lasers and this corresponds to the Brillouin frequency of the middle of the fiber, the time domain trace will have a dip in the middle and will be relatively flat for the rest of the time.
The data obtained for each section of the fiber is a series of points corresponding to the frequency step-size. This data is then fitted to the expected Brilloiun profile shape. This is performed using the software SigmaPlot. The algorithm used for the non-linear least squares fitting is based upon the Marquardt-Levenburg algorithm. An initial estimate is specified for the parameters and an iterative approach is applied until the error function has been minimized.
The basic algorithm on which the above system functions is as follows:
1) Initially, the frequency difference between the two lasers is set to a minimum value. The pump and the cw waves are launched from both ends of the fiber and the time domain trace is recorded. The recorded waveforms are the Brillouin power as a function of time.
2) In this way, a number of time domain waveforms are recorded by stepping the frequency difference from a minimum value to a maximum value to cover the entire Brillouin spectrum of the fiber.
3) From this, a three dimensional plot with time-frequency-power on the x-y-z axes is obtained. From this plot, we obtain the Brillouin frequency of each point by plotting the power as a function of frequency (taking slices in the x-z plane).
4) Finally, the strain (or temperature) is calculated from the Brillouin frequency for each point and the strain (or temperature) is plotted as a function of time thereby giving the distribution for each point on the fiber.
A typical measurement using the system described above takes 5-8 minutes to get the entire Brillouin spectrum and is shown in FIGS. 2 a and 2 b . This disclosure presents the various steps in testing the above system using a novel idea which will help in obtaining the entire Brillouin spectrum for each point on the fiber in one measurement as opposed to using one measurement for each frequency. This in turn decreases the measurement time, thereby allowing making dynamic strain measurements possible and thus observing how the Brillouin spectrum changes in short time duration.
The configuration of BOTDA being used at UNB consists of a cw Stokes signal and a pulsed probe signal at a single frequency each. The power of the cw signal before and after the Brillouin interaction is shown in FIGS. 3( a ) and 3 ( b ).
The signal in FIG. 3( b ) will vary depending on the interaction in the fiber. In the frequency domain this corresponds to broadening of the delta function, as shown in FIG. 4 .
The amount of broadening will depend on the width of the pulsed laser and the length of the strained and/or temperature section. The greater the width of the laser signal, the smaller will be the broadening of the line.
For applications like civil structural monitoring and aerospace vehicle sensing, although BOTDA systems provide centimeter resolutions and kilometers ranges, they lack the capability to measure dynamic strain. Fundamentally, the information is there in the signal, we just need to devise a methodology to extract it fast enough. Consider modulating the pump signal in order to extract this information.
The new signal should be such that it contains multiple frequencies at the same time at one point on the fiber so that the entire Brillouin spectrum can be obtained in two to three measurements.
The power of the new pump signal is controlled using an attenuator to prevent saturation of the detector and stimulated scattering.
Two signal configurations were found to be suitable for this approach: the comb signal and the signal obtained by summation of sinusoids with random phase.
The comb signal (S 1 ) is a special kind of signal which consists of discrete delta functions both in the time as well as frequency domain (comb teeth). Since ideal delta functions cannot be generated using arbitrary waveform generator, we used the following approximate expression of a pulse train to generate the comb signal:
x
(
t
)
=
V
[
k
+
2
π
sin
(
k
π
)
cos
(
ω
o
t
)
+
1
2
sin
(
2
k
π
)
cos
(
2
ω
o
t
)
+
…
+
1
n
sin
(
nk
π
)
cos
(
n
ω
o
t
)
+
…
]
(
2.1
)
where t is the width of the individual pulses,
k = t T o ,
T 0 is the spacing between adjacent pulses
The above expression represents a train of rectangular pulses in time domain. By setting the width of the pulses to be very small, we can approximate a train of delta functions. The signal is shown in the time domain in FIG. 5 and in the frequency domain in FIG. 6 .
The second signal (S 2 ) is obtained by direct addition of sinusoids with random phase:
x
(
t
)
=
[
sin
(
ω
m
t
+
R
(
1
)
)
+
sin
(
2
ω
m
t
+
2
R
(
2
)
)
+
sin
(
3
ω
m
t
+
3
R
(
3
)
)
+
…
+
sin
(
n
ω
m
t
+
nR
(
n
)
)
]
(
2.2
)
where ω m is the lowest frequency at which the comb signal appears
R ( 1 ), R ( 2 ), R ( 3 ) . . . are the elements of an array representing random phase
This signal consists of delta functions (comb teeth) in the frequency domain, but in the time domain it does not go to zero at points between the periods of the pulse. This signal is shown in the time domain in FIG. 7 and in the frequency domain in FIG. 8 .
For the purpose of this disclosure, the second signal was found to be suitable for the following reasons.
First, the energy of the components at higher frequencies tends to fall-off for the comb signal, whereas the second signal has equal energy in all its frequency content. From the point of view of Brillouin interaction, the pump signal should have as much power as possible for maximum interaction but it should be below the Brillouin threshold to prevent stimulated scattering. Thus it would be preferable to have all teeth at maximum power below threshold to have good SNR.
Second if there is variation in the various frequency components due to some interaction other than the Brillouin interaction, then it will be much easier to scale the various frequency components by pre-multiplying in the arbitrary waveform generator in the case of the second signal. This is because the energy in the various components was equal to start with in this case.
Third, in the time domain, the ideal comb signal goes to zero between pulses. In effect, this would make both the pump and probe to be pulses. Hence, there will be regions where there is no pump light and hence, no interaction. For the random phase sinusoid, there will be an optimum combination of phases for which the amplitude is maximized and this can be used for the interaction.
The analysis to follow assumes that the signal obtained by summation of sinusoids with random phase has been selected.
To obtain the Brillouin spectrum accurately, the comb teeth spacing in the frequency domain should be as small as possible. But each of the teeth will undergo broadening after the interaction on the fiber, as shown in FIG. 9 . This places a lower limit on the spacing between the teeth.
Spatial resolution is determined by the pulse width. Greater spatial resolution implies a smaller period pump signal and consequently, more bandwidth and greater distance between the comb teeth in frequency. More spacing between the comb teeth implies that the Brillouin spectra cannot be obtained completely in one measurement because the spectrum itself is about 30 MHz wide and hence information is lost. Thus, there are two contradictory situations.
In FIG. 10 , f 1 is frequency of the pump laser ≈192 THz in our case.
f 2 =f 1 +25 MHz; f 3 =f 1 +50 MHz; f 4 =f 1 +75 MHz
The Brillouin frequency might fall at f 1 +37 MHz and hence the measurement might not yield accurate results.
As mentioned earlier, each of the comb teeth will undergo broadening due to the Brillouin interaction and the amount of broadening will depend on the laser pulse signal width. This will be explained with reference to FIGS. 11( a )-( d ). FIG. 11( a ) shows a length of fiber 1100 including a strained portion 1102 between points 1101 and 1103 and another portion 1104 between points 1103 and 1105 .
Assuming that the Brillouin coefficient remains constant over the length of fiber of uniform strain, the Brillouin signal can be thought of as a convolution of the shape of the uniformly strained section (approximately rectangular) and the pulse shape (rectangular), the latter of which is shown in FIG. 11( b ). The convolution will thus result in a triangular shape. As the pulse enters the fiber 1100 at point 1101 , the probe signal starts decreasing and reaches a minimum at point 1103 when the pulse signal is fully within the strained section 1102 . When the leading edge of the pulse leaves the strained section at point 1103 , the signal starts to increase again and increases till the lagging edge leaves point B. The resulting pulse is shown in FIG. 11( c ). The broadening of the comb in the frequency domain is shown in FIG. 11( d ).
A similar situation, except with different numerical values, will be explained with reference to FIGS. 12( a )-( d ). In FIG. 12( a ), a fiber 1200 includes a 20 m uniformly strained section 1202 between points 1201 and 1203 and another section 1204 between points 1203 and 1205 . FIGS. 12( b )-( d ) correspond to FIGS. 11( b )-( d ), except that they relate to the fiber 1200 of FIG. 12 .
Now when there is a 20 m uniformly strained section and a pulse width of 100 ns is used, the signal once again decreases as the leading edge of the pulse enters the fiber but the slope at which it decreases is smaller than the previous case. The minimum and a maximum are reached in the same way as the previous case. Hence, in the frequency domain this signal will contain a smaller spread around each tooth because of the smaller rate of change (slope) of the cw signal due to the interaction. Also the intensity of the spread due to the interaction will be stronger due to the fact that the 100 ns pulse has more power than the 10 ns pulse. But now the spatial resolution is lesser than before.
Hence the pulse width governs the bandwidth. Moreover, as seen from the above Figures, to obtain more than one point on the strained section in the measurement, the pulsewidth should be less than the length of the strained section.
Since both the pump and the Stokes signal in the new configuration are periodic, the timing at which the pulse is sent down the fiber becomes very important. The pump signal is continuously running on the fiber and a single pulsed probe signal is sent down the fiber at a certain repetition rate. If the pulses are being generated at their own frequency without synchronization with the pump signal, then for each new measurement, the interaction starts at a different location on the comb signal, as shown in FIG. 13 .
In FIGS. 11( c ) and 12 ( c ), pulse A corresponds to the first measurement. Pulse B corresponds to the second measurement and C to the third one. In order to get interaction at the same relative positions of both signals each time, the pulse has to be triggered by the comb signal.
After deciding the new modulating signal format, the mathematical expressions for the signals after Brillouin interaction on the line are obtained. This approach is useful because it gives an intuitive idea of the Brillouin interaction with the new signal configuration before performing the actual experiments. Two modulation schemes were found to be suitable for generating the new pump signal: Amplitude Modulation (AM) and Phase Modulation (PM).
For the initial analysis, with reference to FIG. 14 , we are considering the case of only two sidebands on the carrier signal and later it will be generalized for the case of multiple frequencies.
The AM wave is given by:
e
s
(
t
)
=
E
s
[
1
+
m
cos
ω
m
t
]
cos
ω
c
t
=
E
s
[
cos
ω
c
t
+
m
2
cos
(
ω
m
+
ω
c
)
t
+
m
2
cos
(
ω
m
-
ω
c
)
t
]
(
2.3
)
where ω m is the modulating signal frequency, ω c is the carrier signal (pump laser) frequency, ω s is the Stokes laser frequency, ω c −ω s =the Brillouin frequency of the fiber.
To do a mathematical analysis of the Brillouin interaction, the Brillouin signal acting on the pump is denoted by b(t). This is a time varying signal whose form changes depending on where we are on the 30 MHz wide Brillouin spectrum. However, this signal acts only on the carrier signal because that signal is located at the Brillouin frequency of the fiber. For this analysis, we assume that the sidebands are outside the spectrum and hence undergo no interaction. Basically, the AM carrier signal above undergoes a secondary AM on interaction with the Brillouin signal b(t):
e
s
(
t
)
=
E
s
[
b
(
t
)
cos
ω
c
t
+
m
2
cos
(
ω
m
+
ω
c
)
t
+
m
2
cos
(
ω
m
-
ω
c
)
t
]
=
E
s
[
b
(
t
)
+
m
cos
(
ω
m
t
)
]
cos
(
ω
c
t
)
=
Re
{
E
s
[
b
(
t
)
+
m
cos
(
ω
m
t
)
]
ⅇ
jω
c
t
}
(
2.4
)
At the detector, heterodyne detection is performed by coupling the signal with a local oscillator (probe laser signal) and then impinging on a detector. The signal at the output of coupler is:
e
s
(
t
)
=
Re
[
E
s
{
b
(
t
)
+
m
cos
(
ω
m
t
)
}
ⅇ
jω
c
t
+
E
L
ⅇ
j
(
ω
c
-
ω
d
)
t
]
=
Re
[
V
(
t
)
]
(
2.5
)
where ω d is the frequency difference between the pump and the local oscillator (probe), which in this case is the Brillouin frequency.
The current detected at the photodetector is:
i
c
(
t
)
α
V
(
t
)
V
*
(
t
)
=
[
E
s
{
b
(
t
)
+
m
cos
(
ω
m
t
)
}
ⅇ
jω
c
t
+
E
L
ⅇ
j
(
ω
c
-
ω
d
)
t
]
×
[
E
s
{
b
(
t
)
+
m
cos
(
ω
m
t
)
}
ⅇ
-
jω
c
t
+
E
L
ⅇ
-
j
(
ω
c
-
ω
d
)
t
]
=
E
L
2
+
m
2
E
S
2
2
+
E
S
2
b
2
(
t
)
+
2
mE
S
2
b
(
t
)
cos
(
ω
m
t
)
+
2
E
S
E
L
b
(
t
)
cos
(
ω
d
t
)
+
mE
S
E
L
cos
(
ω
c
+
ω
m
)
t
+
mE
S
E
L
cos
(
ω
c
-
ω
m
)
t
Taking the Fourier Transform of the above expression gives the following:
i
c
(
ω
)
=
(
2.6
)
E
L
2
+
m
2
E
S
2
2
+
E
S
2
(
B
(
ω
)
*
B
(
ω
)
)
+
2
mE
S
2
{
B
(
ω
-
ω
m
)
+
B
(
ω
+
ω
m
)
}
+
2
E
S
E
L
{
B
(
w
-
w
d
)
+
B
(
w
+
w
d
)
}
+
2
E
S
E
L
{
B
(
w
-
w
d
)
+
B
(
w
+
w
d
)
}
mE
S
E
L
{
δ
(
ω
-
(
ω
m
+
ω
c
)
)
+
δ
(
ω
+
(
ω
m
+
ω
c
)
)
}
+
mE
S
E
L
{
δ
(
ω
-
(
ω
c
-
ω
m
)
)
+
δ
(
ω
+
(
ω
c
-
ω
m
)
)
}
From equation 2.6, it is clear that the term in bold is the Brillouin signal at the difference frequency of the two lasers. This signal will be spread in a small band around ω d . The spread will be governed by various factors like the pulsewidth, and the width of the strained section. This analysis confirms the intuitive understanding that each of the teeth will undergo broadening governed by their location with respect to the Brillouin spectrum.
A similar analysis can be carried out for the case of the carrier and one of the sidebands falling within the Brillouin gain spectrum. In this case, the carrier and the sideband will interact with two different Brillouin signals instead of one as in the above case.
The above two analyses can also be generalized for the case of more than one modulating signal for an AM wave of the form below but will not be presented here. In this case each of the sideband within the Brillouin spectrum will be multiplied by a different Brillouin signal.
s
(
t
)
=
A
c
[
cos
ω
c
t
+
m
2
cos
(
ω
m
1
+
ω
c
)
t
+
m
2
cos
(
ω
m
1
-
ω
c
)
t
+
m
2
cos
(
ω
m
2
+
ω
c
)
t
+
m
2
cos
(
ω
m
2
-
ω
c
)
t
+
m
2
cos
(
ω
m
3
+
ω
c
)
t
+
m
2
cos
(
ω
m
3
-
ω
c
)
t
+
…
]
Next the case of phase modulation of the pump signal is considered. The mathematical formula for only two teeth in the comb is derived and the validity of the approach is confirmed. PM is a good choice for modulation scheme because in this case, the lasers will always be in the on state.
The general expression for a PM signal is:
s ( t )= A c cos[ω c t +βcosω m t ] (2.7)
where ω c is the carrier frequency (pump laser)≈192 THz; ω m is the modulating signal frequency; β is the modulation index
s
(
t
)
=
Re
[
A
c
exp
(
jω
c
t
+
jβsinω
m
t
)
]
=
Re
[
A
c
∑
-
∞
∞
J
n
(
β
)
ⅇ
j
(
ω
c
+
n
ω
m
)
t
]
Now only the signal at frequency ω c undergoes Brillouin interaction. So as in the previous case, the Brillouin signal is represented by b(t) and it multiplies with the carrier signal only.
s
(
t
)
=
Re
[
A
c
J
o
(
β
)
b
(
t
)
ⅇ
jω
c
t
+
A
c
∑
n
=
-
∞
,
n
≠
0
∞
J
n
(
β
)
ⅇ
j
(
ω
c
+
n
ω
m
)
t
]
At the detector, after coupling with the local oscillator, the signal becomes
s
(
t
)
=
Re
[
A
c
J
o
(
β
)
b
(
t
)
ⅇ
jω
c
t
+
A
c
∑
n
=
-
∞
,
n
≠
0
∞
J
n
(
β
)
ⅇ
j
(
ω
c
+
n
ω
m
)
t
+
E
L
ⅇ
j
(
ω
c
-
ω
d
)
t
]
=
Re
[
V
(
t
)
]
(
2.8
)
The current at the output of the photodetector after simplification is:
s
(
t
)
=
V
(
t
)
×
V
*
(
t
)
=
A
c
J
o
2
(
β
)
b
2
(
t
)
+
2
A
c
J
o
(
β
)
E
L
b
(
t
)
cos
ω
d
t
+
2
A
c
2
J
o
(
β
)
b
(
t
)
∑
∀
n
,
n
≠
0
J
n
(
β
)
cos
(
n
ω
m
t
)
+
2
E
L
A
c
∑
∀
n
,
n
≠
0
J
n
(
β
)
cos
(
ω
d
+
n
ω
m
)
t
+
A
c
2
∑
n
=
m
,
n
≠
0
J
n
(
β
)
J
m
*
(
β
)
+
A
c
2
∑
n
=
m
,
n
≠
0
J
n
(
β
)
J
m
*
(
β
)
cos
(
n
-
m
)
ω
m
t
+
jA
c
2
∑
n
=
m
,
n
≠
0
J
n
(
β
)
J
m
*
(
β
)
sin
(
n
-
m
)
ω
m
t
+
E
L
2
Taking the Fourier Transform of the above expression yields
i
c
(
ω
)
=
A
c
2
J
o
2
(
β
)
{
B
(
ω
)
⊗
B
(
ω
)
}
+
A
c
J
o
(
β
)
E
L
{
B
(
ω
-
ω
d
)
+
B
(
ω
+
ω
d
)
}
+
A
c
2
J
o
(
β
)
×
∑
∀
n
,
n
≠
0
J
n
(
β
)
{
B
(
ω
-
n
ω
m
)
+
B
(
ω
+
n
ω
m
)
}
+
A
c
E
L
∑
∀
n
,
n
≠
0
J
n
(
β
)
{
B
(
ω
-
(
ω
d
+
n
ω
m
)
)
+
B
(
ω
+
(
ω
d
+
n
ω
m
)
)
}
+
A
c
2
∑
n
=
m
,
n
≠
0
J
n
(
β
)
J
m
*
(
β
)
+
∑
n
≠
m
,
n
≠
0
J
n
(
β
)
J
m
*
(
β
)
2
×
[
δ
(
ω
-
(
n
-
m
)
ω
m
+
δ
(
ω
-
(
n
-
m
)
ω
m
]
+
∑
n
≠
m
,
n
≠
0
J
n
(
β
)
J
m
*
(
β
)
2
[
δ
(
ω
-
(
n
-
m
)
ω
m
)
-
δ
(
ω
+
(
n
-
m
)
ω
m
)
]
+
E
L
2
On simplification of the above expression,
i
c
(
ω
)
=
A
c
2
∑
n
=
m
,
n
≠
0
J
n
(
β
)
J
m
*
(
β
)
+
A
c
2
J
o
2
(
β
)
{
B
(
ω
)
⊗
B
(
ω
)
}
+
A
c
J
o
(
β
)
E
L
{
B
(
ω
-
ω
d
)
+
B
(
ω
+
ω
d
)
}
+
A
c
2
J
o
(
β
)
∑
∀
n
≠
0
J
n
(
β
)
{
B
(
ω
-
n
ω
m
)
+
B
(
ω
+
n
ω
m
)
}
+
A
c
E
L
∑
∀
n
≠
0
J
n
(
β
)
×
{
B
(
ω
-
(
ω
d
+
n
ω
m
)
+
B
(
ω
+
(
ω
d
+
n
ω
m
)
}
+
∑
n
≠
m
≠
0
J
n
(
β
)
J
m
*
(
β
)
{
δω
-
(
n
-
m
)
ω
m
}
+
E
L
2
If
β
<<
1
,
then
J
o
(
β
)
≈
1
,
J
1
(
β
)
=
β
2
,
J
n
(
β
)
=
0
∀
n
≠
0
,
1
(
2.9
)
Equation 2.9 simplifies to
i
c
(
ω
)
=
A
c
2
β
2
4
+
A
c
2
{
B
(
ω
)
*
B
(
ω
)
}
+
A
c
E
L
{
B
(
ω
-
ω
d
)
+
B
(
ω
+
ω
d
)
}
+
A
c
2
β
2
{
B
(
ω
-
ω
m
)
+
B
(
ω
-
ω
m
)
}
+
A
c
E
L
β
2
{
B
(
ω
-
(
ω
d
+
ω
m
)
+
B
(
ω
+
(
ω
d
+
ω
m
)
}
+
E
L
2
(
2.10
)
The content of the above expression is analyzed term by term. It consists of the following terms:
D.C. Component and Brillouin Signal at baseband A large component at the difference frequency ω d of the L.O. and the pump (desired signal) Component at frequency ω m (∀ n ≠0). This component has very small amplitude scaled by β.
Other terms are small in amplitude and negligible
If the phase modulation index β is kept small, then the PM approximates AM with only one upper and lower sideband. This is known as narrow band phase modulation. We can extend the narrow-band PM case to have multiple comb frequencies with almost equal amplitude if β is kept very small. The mathematical expression for this case is:
s ( t )= A c cos{ω c t +βcosω m1 t +βcosω m2 t +βcosω m3 t + . . . +βcosω mn t} (2.11)
This signal can be analyzed in the same way as the PM case above, to obtain expressions for Brillouin interacted signal. When simulated, the narrowband PM case was found to have a relatively flat spectrum. The signal obtained is shown below.
As seen from FIG. 15 , the comb teeth obtained were relatively flat. However, one problem with the PM signal is that the carrier signal is very large as compared to the sidebands. In the simulations, the carrier was almost 20 times larger. This is not seen in the Figure because it is a zoomed in view. This means that the high power of the carrier will result in causing stimulated Brillouin scattering in the fiber which is undesirable. But in the case of AM, the carrier signal is not very large as compared to the sidebands and its amplitude can also be controlled by changing the dc bias of the modulator. So, the AM case was chosen for the new system.
The theoretical basis for the new system was developed. Two different signals were found to be suitable for this: the ideal comb and the signal obtained by random phase summation of sinusoids. The second signal was selected and analyzed with respect to the Brillouin sensing requirements. Finally, expressions were obtained for both AM and PM modulated, Brillouin interacted signals and the Amplitude Modulation scheme was found to be suitable.
Before proceeding with the actual experiments, a detailed model for the Brillouin interaction was developed in MATLAB. The signals formulated above are used to simulate this model. The results obtained here would give an idea of what to expect in the experimental results.
Two modulators will be used in the new system configuration: one on the pump laser end and the other on the probe laser end. In order to understand the functioning of the system, simulations were performed to determine the functioning of the electro-optical modulator. The output signal of the modulator is given by:
s
o
(
t
)
=
cos
(
ΔΦ
2
)
E
i
ⅇ
-
jΦ
o
ⅇ
-
jω
c
t
where
Φ o = Φ 1 + Φ 2 2
is the average phase delay, and ΔΦ is the phase delay between the two arms of the modulator.
The transfer function is given by
I
o
I
i
=
cos
2
(
ΔΦ
2
)
(
4.1
)
In the above figure, the value of the half wave voltage V π =20 V. The transfer function is shown in FIG. 16 .
The applied signal was a summation of 12 sinusoids having random phase with frequency spacing of 10 MHz. The carrier frequency for amplitude modulation was 1.1 GHz. The value of the bias point was changed so that the carrier amplitude is as close to the comb teeth amplitude as possible. The frequency spectrum of the output waveform was plotted. The plots are shown in FIG. 17 .
From the plots of FIG. 17 , it is observed that the optimum value of the bias point for which the carrier amplitude comes close to the side bands lies somewhere between
θ
=
γπ
=
3
π
4
and
θ
=
π
(
extinction
)
i.e. the value of the dc bias voltage for low carrier amplitude lies between 15 V and 20 V. For the simulations, a value of 17.5159 (θ=2.75) was chosen.
As seen in FIG. 17 , the values of the individual comb teeth are not equal. This is because when the signal goes through the modulator, there are a number of other frequency components which contribute to the signal.
The Brillouin power as a function of frequency was plotted using the formula:
P
(
v
)
=
P
c
ⅇ
-
α
L
[
1
-
exp
(
-
g
B
(
v
)
)
P
p
L
eff
A
eff
]
(
4.2
)
where P P and P c are the powers of the probe and the pump lasers, A eff is the effective core area,
L eff = 1 α ( 1 - ⅇ - α L )
is the effective fiber length, L=actual fiber length, α=attenuation in Np/m, g B (v) is the Brillouin gain spectrum given by the Lorentzian profile shown in FIG. 18 . Illustrative examples of the parameters are given in Table I below:
TABLE I
Parameter
Value
P P
30.9
mW
P c
1.8
mW
A eff
80 × 10 −12 m 2
L eff
30
α
0.040295
Np/m
Δv B
30
MHz
The above function is a gain function. In our case, the pump laser is undergoing loss on the fiber, so the above profile was inverted and normalized to 1. Two profiles were created at different frequencies: one corresponding to the Brillouin frequency of the unstrained fiber ω B1 and the other corresponding to that of the strained section ω B2 .
The amplitude modulated waveform has a carrier frequency of 192 THz and there are 12 sidebands located at a frequency spacing of 20 MHz. This AM waveform is 8000 points long. This wave was created by passing it through the EOM with a transfer function given in equation 4.1 and is shown in FIG. 19 .
A simulation of a fiber to be used in the calculations to be described immediately below will be described with reference to FIG. 20 . A fiber 2000 has a unstrained section 2002 which is 4000 points long, a strained section 2004 which is 2000 points long, and an unstrained section 2006 which is 2000 points long.
In order to simulate a fiber with multiple strained sections, the fft of the first 4000 points was multiplied with the first Brillouin profile (dotted line in FIG. 18 ) created above having a Brillouin frequency of ω B1 (12.78 GHz). The fft of the next 2000 points was multiplied by the second Brillouin profile (solid line) having a Brillouin frequency of ω B2 (12.90 GHz) corresponding to a strained section. Finally, the frequency spectrum of the remaining 2000 points was again multiplied by the first profile. The waveforms are shown in FIGS. 21 and 22 .
In the above figure, the frequency domain plot shows a big dip at 12.78 GHz and a smaller dip at 12.90 GHz as shown by the arrows at those frequencies. For the detection process, heterodyne detection was simulated because when the new system was simulated using direct detection, the lower and upper sidebands overlap and the information is lost. In this, the Brillouin signal is combined with a local oscillator laser using a coupler and then detected at the photodetector. This produces a current at the difference frequency of the two input signals. A local oscillator with a frequency of 192 THz+13.66 GHz, so at the output we got a signal centered at 700 MHz.
As discussed earlier, the frequency spacing between the individual comb teeth should be small, but this spacing cannot be made very small because the teeth will undergo broadening on Brillouin interaction. But more spatial resolution requires more spacing between the teeth. To satisfy these two contradictory requirements, as well as obtain the entire spectrum fast without loss of spatial resolution, the frequency spacing can be kept large (hence more spatial resolution), say 20 MHz and one measurement taken. Then, all the comb teeth can be shifted by a small amount, say 10 MHz, while maintaining the same relative frequency difference and another measurement taken and the information from the two combined. An example is shown in FIG. 23 .
The solid lines correspond to one measurement. The dotted lines correspond to the next set of measurement after shifting all the comb teeth by a small frequency. In this way there will be many comb frequencies over the 30 MHz spectrum of the Brillouin profile.
The algorithm used in the detection process is shown in FIG. 24 . In step 2402 , the data are taken from the first set of measurement. In step 2404 , values are set for the frequency of the lowest comb tooth, the spacing between comb teeth and a counter value n. In step 2406 , the teeth are band pass filtered at a frequency i and are inverse Fourier transformed. In step 2408 , the envelope detection is performed by squaring the signal and then low pass filtering. If it is determined in step 2410 that there are more teeth in the signal, then the value of i is incremented by f in step 2412 , and the process loops to step 2406 with the incremented value of i. If there are no more teeth in the signal, then in step 2414 , n is incremented by one. If it is determined in step 2416 that n has not yet reached a value equal to the number of measurements, then in step 2418 , the data from the second set of measurement are taken, and the process loops back to step 2404 . Otherwise, the process ends in step 2420 .
For the case of large signal variations, there is a 100% variation caused due to the Brillouin interaction. However, for this case the system was simulated for one measurement only, corresponding to the solid line spectrum in FIG. 23 . The time domain waveform for all the teeth is obtained using the above algorithm. These are then plotted in a 3-D plot with time (x-axis), frequency (y-axis) and Brillouin amplitude (z-axis). As we move along the x-axis, we see how the power of each frequency changes down the fiber. As we move along the y-axis, we observe the Brillouin spectrum for each point on the line. The resulting 3-D plot is shown in FIG. 25 .
The Brillouin frequency of the above fiber is 12.78 GHz hence at this frequency, the signal on the entire fiber experiences loss, except for the strained section at around 1.5 μs. This section has a Brillouin shifted frequency of 12.90 GHz and hence there is a loss at this frequency as seen on the third plot along the frequency axis. The new sensing system should be able to obtain all the above information in one measurement and this entire 3-D plot will be updated in short intervals of time to yield dynamic strain changes.
The analysis shown above is visually informative because the artificial Brillouin profile was normalized to have a minimum of 0 and thereby have a 100% change between the minimum and maximum in FIG. 18 . But in actual experiments, the Brillouin information is 40-50 dB below the carrier. This corresponds to 0.01%-0.001% variation due to Brillouin interaction, as shown in FIG. 26 . Hence a separate analysis needs to be done to prove that this detection scheme will be able to detect very small changes also.
Both these cases are combined into one and an analysis similar to the previous case is followed for the Brillouin interaction and the signal detection. To observe very small changes, the time domain signal for each comb tooth after Brillouin interaction was subtracted from the original AM time domain signal for the same frequency in addition to the processing steps in FIG. 24 . The figures were then plotted alternately.
In FIG. 27 , a ), c ), e ), g ), i ), k ), m ), o ), q ), s ), u ), w ), correspond to solid line spectrum in FIG. 23 (relative comb frequencies of 20 MHz, 40 MHz, 60 MHz . . . etc.). Figure b),d),f),h),j),l),n),p),r),t),v),x), correspond to the dotted line spectrum in FIG. 23 (relative comb spacing of 10 MHz, 30 MHz, 50 MHz, etc.) corresponding to the next measurement.
From FIG. 27 ( a )-( l ), we notice that the signal around 1.7 μs decreases progressively and then comes back to zero. This is because at 12.90 GHz, the signal at around 1.7 μs experiences loss and decreases; hence the difference is negative. From FIG. 27 ( m )-( x ), we notice that all other points on the fiber except the signal around 1.7 μs experience loss because 12.78 GHz corresponds to their Brillouin frequency. Moreover, the small change in the signal profile is seen more clearly by combining the graphs obtained by using the two profiles of FIG. 26 . Also, in the simulations for both the large and small signal variations, only the lower sideband was undergoing the Brillouin interaction. Hence, there are only 12 waveforms in FIGS. 25 and 12 waveforms for each of the 2 measurements in FIG. 27 .
The sensing system was modeled by characterizing the modulator, followed by the explaining the steps used in the simulation for the generation of the Brillouin interacted signal. Heterodyne detection mechanism was simulated. Post-detection processing was performed using a novel algorithm and it was found to be effective in extracting the information from the signal even when the changes were very small. The simulations also showed the potential of the system for dynamic measurements because a 3-D graph was obtained with time, frequency (or strain) and Brillouin amplitude for the entire fiber in a single measurement.
The theoretical and practical investigations of the previous chapters are implemented and measurements on the BOTDA system at the Optical Fiber Systems Lab (OFSL) at UNB are performed, both with and without these improvements.
In the new system, shown in FIG. 28 as 2800 , the pump laser 2802 is amplitude modulated by a random phase summation of sinusoids. The receiver is a coherent heterodyne detection system in which the Stokes laser 2804 acts as the L.O. All measurements using the new system are done by manually changing the frequency of the lock box because NTControl was not configured to automate the system at this stage.
The AWG 2806 (Tetronix model no. AWG 520) is used to produce a summation of random phase sinusoids by writing a program in it. This signal is in turn fed to the RF port of the EOM 2808 . Initially, the amplitudes of all the frequency terms were equal. The second channel of the AWG outputs trigger signals to the pulse generator 2810 so that both the pump and Stokes laser are synchronized and interact at the same relative position with each pulse sequence.
The 5% output of the 95:5 coupler 2812 at the Stokes laser end is split using a 90:10 coupler 2814 . The 10% output is fed into a set of paddles 2816 which can be adjusted to change the polarization of the Stokes signal to match that of the Brillouin interacted pump. The output of the paddles is coupled with the Brillouin interacted pump signal using the 70% arm of a 70:30 coupler 2818 for heterodyne detection.
In the original system, a polarization controller 2820 was used to change the state of polarization of the pump laser to take measurements in two orthogonal polarizations. By averaging the two measurements, interaction between co-polarized pump and Stokes signals could be assured even though the polarization changes with bending and twisting of the fiber.
Now, a General Photonics PSW-001 fiber optic polaswitch 2822 is placed at the output of the EOM at the Stokes laser end. When +5 V DC is applied to the switch, it has one polarization state and when −5 V is applied, it produces an orthogonal polarization. This has two distinct advantages over changing the polarization of the pump laser.
First, the time of measurement between the two orthogonal polarization states is reduced because only the power supplies to the switch have to be interchanged. The switching time of the polaswitch is 100 μs. Hence the system can be automated by applying a periodic square wave to change the polarization, which is limited only by the switching speed of the polaswitch. If the polaswitch were not there, then the polarizations would have to be changed using the 4 settings of the polarization controller using the computer for the two orthogonal measurements. Thus, there are less chances of the polarization to change between the two measurements.
Second, the original method was suitable for direct detection and was also automated to flip the polarizations fast. But in heterodyne detection, the polarization states of the L.O. and the signal should also be aligned completely. If we continued to use the original method, a separate polarization controller would be required to be placed at the output between the circulator output and the 30% arm of the 70:30 coupler. Each time the polarization of the pump laser was flipped at the input, this polarization controller would have to do a corresponding change in polarization to match the state of the Brillouin interacted signal to that of the L.O. But now by keeping the state of the pump signal constant, we are required to set the paddles only once to match the polarization of the Stokes wave to that of the pump because now the two lasers will always be aligned for both the orthogonal measurements.
The first step in the experiments would be to find the pulse width of the Stokes laser to be used because this will in turn govern the comb teeth spacing.
The Electrical bandwidth of the system is given by:
B
.
W
.
=
0.35
t
r
5.1
where t r is the time it takes to reach from 10% to 90% of the final value.
When the Electrical Spectrum Analyzer is used as a heterodyne receiver in zero span mode, it has a resolution bandwidth ≦3 MHz. Therefore,
t r ≧116.67 ns
Hence, the pulse width should be greater than 116.67 ns.
The above result was also confirmed experimentally. For this, AM was carried out with only 2 sidebands 20 MHz apart from the carrier on an SMF-28 fiber which was 120 m long. The frequency difference was adjusted such that the lower sideband was at the Brillouin frequency of 12.78 GHz. The F.F.T. of the waveform was taken on the scope and the resulting waveform captured. These measurements were taken for different pulse widths of 20 ns, 40 ns, 60 ns, 90 ns, 120 ns. The Electrical L.O. was adjusted such that the final signal was centered at 320 MHz. In order to get a smoother profile, 7 measurements were taken for each pulse width and the average of the Fourier transform was taken before plotting in MATLAB. The plots are shown in FIGS. 29 through 31( b )
From FIG. 29 , it is clear that the Brillouin information is 40-50 dB below the peak value of the comb and the noise floor of the display appears as 60 dB below the peak. This corresponds to a change of 0.01%-0.001% due to the Brillouin interaction. Hence, the receiver should have enough dynamic range to be able to detect these changes.
As seen in FIG. 30 , for pulse widths of 20, 40 and 60 ns, the spreading in linewidth due to the Brillouin interaction is more than 20 MHz, thereby extending the response into the next tooth. Hence, even if we place the comb teeth 30 MHz apart, there will be overlapping of information from adjacent teeth. For FIGS. 30( d ) and ( e ), the signal bandwidth appears to be 20 MHz or less. So the 120 ns pulse was chosen so as to avoid interaction with adjacent teeth.
The first step was to establish a reference set of data using the automated stepped frequency BOTDA system shown in FIG. 1 .
Temperature sensing was used in the initial steps because it is much easier to get uniform temperature sections which are very long. The system was tuned from 12.70 GHz to 13.05 GHz in steps of 5 MHz.
A 24 m section of the fiber near the Stokes laser end and a 24 m section of the fiber near the pump laser end were placed inside a temperature controlled box with a 48 m section between the cooled ends remaining at room temperature. This 48 m section also had a 4 m strained section at its center. The temperature control box was set to cooling to a temperature of −15° C. A length of 24 m was chosen because a 120 ns pulse corresponds to a spatial resolution of 12 m, so we chose double the length to get more than one point in the cooled section in the final results. Pulsewidths of 10 ns and 120 ns were used to confirm that the 120 ns pulse did indeed provide results.
Since the two 24 m fiber sections were cooled, the Brillouin frequency shifted down to 12.72 GHz. This is clearly seen by the 2 dips at around 200 ns and 1000 ns in FIG. 31 ( a ). In FIG. 31( b ), at 12.78 GHz, the rest of the fiber experiences loss whereas the signal in the two cooled section remains the same. The 10 ns signal has much more detailed information due to the larger bandwidth. Moreover, the 120 ns case in FIG. 31( b ) shows a small peak at the center of the 48 m room temperature section. This peak corresponds to the 4 m strained section and hence the 120 ns does not completely lose the information about sections shorter than its pulsewidth.
Having established the reference set of data, the system is connected as shown in FIG. 28 , except that the output of the photodetector is connected directly to the ESA. For these measurements, we used AM with only two sidebands 40 MHz offset from the carrier. The video output of the ESA was connected to the oscilloscope. The video output is the signal obtained after envelope detection of the waveform. When the ESA was used in the zero-span mode, it acted as a fixed-tuned heterodyne receiver. The Resolution Bandwidth (RBW) of the ESA determined the bandwidth of the bandpass filter through which the tooth was passed. This was set to the maximum value of 5 MHz. As seen from FIG. 30( e ), the spread in information extends beyond 5 MHz and hence, there may be loss of some information, but it does give a band limited view of the information. The Video Bandwidth (VBW) of the ESA determines the bandwidth of the lowpass filter after the detector. This was also set to the maximum value of 3 MHz.
The pulse width used was 120 ns. The frequency difference was set to be 12.76 GHz and 12.82 GHz in two separate measurements, so that the lower sideband was at a frequency of 12.72 GHz and 12.78 GHz, respectively.
FIG. 32( a ) is similar to FIG. 31( a ). As seen in the above figure, at 12.78 GHz, the signal along the entire fiber undergoes loss except for the two cold sections. Another important thing noticed was that even when the figures were plotted for one polarization, they did not differ significantly from those obtained by polarization averaging. The limited bandwidth of the ESA produces the triangular shapes seen in FIGS. 32( a ) and ( b ) as opposed to the faster rise times seen in FIGS. 31( a ) and ( b ).
The above experiment confirms that a coherent heterodyne receiver with a large dynamic range can extract the Brillouin information from the system.
Having demonstrated that data from a single tooth can be captured and processed and the Brillouin information extracted, we extend this to the entire comb. In this parallel receiver configuration, the optical comb on the pump laser signal is coherently detected and electrically mixed down to 300 MHz as shown in FIG. 34( a ). The entire comb is captured on the oscilloscope and through DSP the data on each tooth is extracted.
The data obtained from the new system configuration is in the form of a summation of sinusoids with random phase and additional post-processing is required to extract the information. The Brillouin information is approximately 40 dB below the sinusoid amplitude and is thus challenging to recover.
The basic algorithm used for simulation is shown FIG. 24 . In addition, more processing was done on the experimental data, as shown in FIG. 33 . The overview of the steps is:
Step 3302 , capture waveform on oscilloscope (corresponds to FIG. 34( a )).
Step 3304 , take the average of the 64 waveforms in MATLAB.
Step 3306 , take the FFT of the entire waveform and find the maximum value of each tooth (corresponds to FIG. 34( b )).
Step 3308 , bandpass filter each comb tooth (corresponds to FIG. 34( c )).
Step 3310 , divide each tooth by the value found in step 3306 .
Step 3312 , square and lowpass filter each tooth (corresponds to FIGS. 34( d ) and ( e )).
Step 3314 , make all of the waveforms zero mean (corresponds to FIG. 34( f )).
Step 3316 , plot the minimum value of each point for all frequencies and curve-fit to a Lorentzian (corresponds to FIG. 34( g )).
The waveforms obtained in each step are shown in FIGS. 34( a )-( g ). The scope was run in sequence mode with 64 sequences, and the post-processing outside the scope similar to the ESA.
The XL microwave lockbox was replaced with an EIP model 575 source locking microwave counter for the new system because it allowed a larger number of sequences to be taken without losing phase lock. This was confirmed by plotting each of the 64 waveforms of one of the sequences on top of each other and observing the shift. Each of the 64 waveforms had a period of 2 μs. The XL microwave unit showed a lot of phase variation as compared to the EIP unit as shown in FIGS. 35( a ) and 35 ( b ).
It is very important that the whole system is phase-locked for these measurements; otherwise, averaging of the detected signal to improve SNR will yield zero due to random phase. For this, a 10 MHz reference signal from electrical L.O. was fed into the lockbox and the AWG. The AWG delivered a trigger signal every 40 μs on Channel 2, while the comb was running continuously on Channel 1.
The most important thing for testing the new system is to have uniform strain or temperature along the entire length of the strained/temperature section. The temperature control box was heated to 50° C. The system was first run using the direct detection receiver and data acquired using the original system using NTControl to establish a reference set. Next the heterodyne receiver was connected.
The pump signal consisted of 21 teeth including the carrier, spaced 10 MHz apart as shown in FIG. 34( b ). The lasers were tuned to a frequency difference in the region outside the Brillouin interaction (13.60 GHz) and the different frequencies were premultiplied in the AWG by different scaling factors to get a relatively flat spectrum. Leveling the comb teeth allows each tooth to operate at the maximum power, just below the stimulated scattering point. The carrier amplitude was adjusted by changing the D.C. bias of the modulator.
The output was then connected to the oscilloscope and the laser frequency difference was tuned back to the Brillouin interaction region of 12.82 GHz. The oscilloscope was operated in single acquisition mode and acquisitions were taken repeatedly until a good amplitude signal was obtained, implying phase lock. The averaged waveform was captured. After this, the polaswitch supply leads were interchanged and an acquisition taken for the orthogonal polarization. The laser frequency difference was changed to 12.825 GHz and the above measurement repeated. This corresponded to taking data at frequencies in between the frequencies for the previous case to get 5 MHz steps. Measurements were also taken at differences of 13.03 GHz, and 13.035 GHz for both orthogonal polarizations in each case. This gave a continuous spectrum from 12.82 GHz to 13.135 GHz in steps of 5 MHz. Post processing was performed using the algorithm of FIG. 24 .
The sections from approximately 200 to 400 ns and 900-1100 ns correspond to the heated part of the fiber and hence they have a higher frequency Brillouin frequency of around 12.81 GHz. The section from 600-700 ns was a strained section but it was less than the pulse width and hence it does not show clearly. The other sections have the normal Brillouin frequency of around 12.78 GHz. The pulse width used was 120 ns.
From FIG. 36 it is clear that the results from the new system closely match those from the original BOTDA system for the initial part of the fiber but for the latter part they tend to drift a little. It is observed the dotted line has sharper edges than the solid line. This does not necessarily imply that the new system is more accurate.
The next steps involved making the system work for the static strain case and observing the Brillouin spectrum. A setup shown in FIG. 37 as 3700 was used. For this case, a 120 m SMF-28 fiber length having a Brillouin frequency at around 12.78 GHz was used. A 20 m length of OFS Depressed Clad fiber having a Brillouin frequency at 12.804 GHz was spliced near the pump laser end. The Depressed Clad fiber did not have any jacket on it so it would be easier to apply uniform strain on it. A 17 m OFS fiber section 3702 was placed in a straight line and fixed at one end. The other end was connected to a rotating wheel 3704 to provide periodic strain. The wheel was placed in one of the following four positions A, B, C, or D and a measurement taken at each using the original system configuration 3706 and with CPR. This establishes a reference set of data.
The acquisition sequence for this measurement is as follows:
a) The AWG delivers a trigger signal to the pulse generator every 2 μs
b) The comb signal is output on channel 1 first and 4 μs later, the first trigger signal to the pulse generator starts;
c) Subsequently, the AWG outputs 64 trigger signals over the next 128 μs and then stops.
d) This constitutes an acquisition sequence that is repeated following a 2 s delay.
The advantage of this is that when the wheel is rotating, 64 waveforms can be acquired after every 2 s movement and each set of 64 waveforms will have data for one position which can be averaged separately. The value of 2 μs was chosen because of the following reasons.
First, the two ways travel time of the pulse on the fiber is around 1.4 μs. Hence, anytime after this, the next pulse can be sent for the next Brillouin interaction. Initially, the system was being pulsed every 40 μs, which resulted in much dead time.
Second, the line width of the lasers is Δν<5 kHz/ms. Hence the coherence time is
τ
c
=
1
πΔυ
τ
c
>
63.69
μ
s
Thus, with triggers every 40 μs, the total time for 64 pulses would be 2560 μs. This is enough time for the lasers to fall out of phase lock.
Third, this also makes the overall system fast because now theoretically, strains can be measured after every 128 μs corresponding to a vibration frequency of 3.9 kHz for Nyquist sampling.
The reference data was first obtained for the static strain case using the NT Control system. Then the CPR was connected and measurements were taken at a frequency difference of 12.87 GHz between the two lasers and a single polarization. The pulse width was 120 ns. A typical capture of the time domain waveform on the oscilloscope screen is shown in FIG. 38 .
Since the oscilloscope is run in sequence mode, there are 10 sequences of 128 μs each having 64 waveforms. The bottom trace is the pulse sequences from the Stokes laser which are synchronized with the top trace.
After processing using the steps in FIG. 33 , the waveforms were obtained. In FIG. 39( a ), the Brillouin frequencies for the entire fiber for position A were plotted showing the strained section clearly. As we move from FIG. 39( b ) to ( c ) to ( d ), it is observed that the Brillouin frequency for the strained section shifts from 12.89 GHz to 12.935 GHz corresponding to minimum to maximum strain shift. The plots also closely match those obtained using the direct detection system. Since these measurements are for the static case, all the 10 sequences in FIG. 37 should contain the information about the same position. This was confirmed by plotting the waveforms from all the sequences.
The final step involved taking dynamic strain measurements. For this, the wheel in FIG. 37 was rotated at a speed of 12 s per cycle. This is because rotating it faster would result in polarizations changes and since the measurements were taken for only single polarization, faster rotations would result in loss of data. The wheel was set to the nearest position and rotated and a measurement was taken for 10 sequences on the scope with 1.2 μs between each sequence. Point 10 in FIG. 40 corresponds to the position of lowest strain.
Five sets of measurements were taken using the above setup. For each measurement, the wheel was brought to the nearest position and then started and the data captured for one cycle. Then the above process was repeated again.
The values obtained from the measurements were in the units of frequency (GHz). These had to be converted to strain values before plotting. The Brillouin frequency of the Depressed Clad fiber is 12804 MHz. The temperature and strain coefficient of the fiber are 1.66 MHz/° C. and 0.9566 MHz/με. The temperature of the room where the fiber was kept was 7° C. Assuming the normal room temperature to be 27° C., this means that the Brillouin frequency is shifted to:
12804−{(27−7)×1.66}=12770.8 MHz.
The average Brillouin frequency for the position of maximum and minimum strain from all the measurements was found to be 12936 MHz and 12889 MHz. Hence the strain values are:
Maximum
Strain
position
:
(
12936
-
12770.8
)
0.0566
=
2918.7
μɛ
Minimum
Strain
position
:
(
12936
-
12770.8
)
0.0566
=
2088.3
μɛ
The strain change is thus =2918.7−2088.3=830.4 με
The data obtained from experiment was processed using the algorithm in FIG. 33 . Next a single point in the region near the center of the strained section of the fiber was picked and its Brillouin frequency was plotted for all the 10 strained positions shown in FIG. 40 for each of the 12 measurements. Since the motion of the wheel was circular, the strain profile was expected to be sinusoidal.
The points in different gray scales in FIG. 41 correspond to different sets of measurements. Each of the points shown above was obtained in 128 μs, hence the new Brillouin sensing system has the potential to update the information at a rate of
1 256 × 10 - 6 = 3.9 kHz .
As seen, the data follows the sinusoid closely.
As the wheel rotated, this caused straining of the fiber over a distance of ΔL=1.55 cm. The total length of the strained section was L=17 m. Hence, the strain change was
Δ
L
L
=
1.55
×
10
-
2
17
=
911.76
μɛ
Hence, the values obtained from the calculation and experiments are close to each other.
In the dynamic sensing system, the time duration between measurements is very small and there is not enough time to interchange the polarswitch settings between the measurements to get the orthogonal polarizations. Hence, all measurements were taken for a single polarization case only. The changes due to polarization caused errors during the curve fitting because the Lorentzian profile sometimes tried to fit to a frequency outside the actual region.
If the wheel was rotated very fast (at 1.2 Hz), the polarization was found to change drastically and thereby, the shift in Brillouin frequency with position could not be observed. A solution to this problem is to have the whole system to be made of polarization maintaining (PM) fiber. This would have the advantages of always perfectly aligned fields and no need for the second orthogonal polarization measurement. The disadvantages are the high cost of the PM fiber and it will have more loss.
Frequency interpolation was done for the temperature measurement, wherein the second measurement consisted of shifting all the frequencies by 5 MHz from the previous measurement and combining the results of the two. However, in the dynamic sensing system, due to the short time between successive measurements, it was not possible to change the lock box settings fast enough to capture these changes. Another option which was not implemented in the present measurement would be to change the AWG to a sequence mode, wherein it outputs two completely different waveforms alternately at a user specified rate. So for the first 128 μs, it would output a comb at frequencies at say 10 MHz, 20 MHz, 30 MHz etc. and then after a short time (say 10 μs) it outputs a comb at frequencies 15 MHz, 25 MHz, 35 MHz etc for the next 128 μs. Then for the next measurement, this whole sequence would be repeated.
As discussed previously, the Brillouin information has its maximum values 40-50 dB below the comb teeth level. The SNR of an N bit digital sample is given by:
SNR (dB)=(6.02 ×N )+1.76 (5.1)
The oscilloscope has only N=8 bits which corresponds to an SNR of 49.9 dB. Now averaging and oversampling on the scope increases the number of bits. The relation is given by:
ƒ os =4 w ·ƒ S (5.2)
where ƒ OS is the oversampling frequency, ƒ S is the original sampling frequency requirement and w is the additional number of bits of resolution obtained.
In the present case, the highest signal frequency coming into the scope was at 400 MHz. Hence the required sampling frequency was 800 MHz; but the sampling was being done at 4 GHz in the scope. Substituting these values in equation 5.2 gives a value of 1.16 for w. Now, the total number of bits available is 9 which increase the SNR to 55.9 dB.
Moreover, an average of 64 waveforms was taken during post-detection processing. Since the SNR varies as the square root of the number of averages, averaging further increased the SNR by a factor of √{square root over (64)}=8, which gives an SNR of 64 dB.
Thus, there is a severe limitation in the receiver sensitivity even after oversampling and averaging. This was one of the reasons why the spectrum analyzer gave a much better signal at the output without any averaging as compared to the new receiver.
Digital filtering was applied in MATLAB for the post processing of the data. This included both the bandpass filters for extracting each of the comb teeth and the lowpass filter applied following envelope detection. Since the teeth were only 10 MHz apart and there was a frequency spread due to the Brillouin interaction, the bandpass filter must be selected carefully. A 3 dB bandwidth of 8 MHz was chosen for all these filters and the stopband was chosen to be 60 dB below at frequency spacing of 10 MHz from the center. The lowpass filer had a bandwidth of 5 MHz and the stopband at 12 MHz was 60 dB below.
The sharpness of the roll-off from passband to stopband can be improved by increasing the number of filter coefficients. The output of the filter is given by:
y
[
n
]
=
h
[
n
]
*
x
[
n
]
=
∑
k
=
0
N
-
1
h
[
k
]
x
[
n
-
k
]
(
5.3
)
where h[k] is filter impulse response, x[n] is the input, N is the number of coefficients.
All the registers need to be full before a valid output is obtained at the filter, and this requires N multiply-accumulate cycles per output. So there will be an initial delay in the time domain signal until the registers are full. This will prevent us from obtaining the Brillouin interaction information from the whole line. The problem is further compounded by the fact that after loss of data from the bandpass filter, the signal goes into the lowpass filter and this filter will result in further loss of information because the data coming into it has a shifted starting point. In MATLAB, the size of the band pass filters was 1558 coefficients and the size of the low pass filters was 1448 coefficients. So the total delay in the time domain corresponded to 3006 multiply-accumulate cycles. Hence, a compromise was reached by keeping the comb teeth spacing equal to 10 MHz and having filters with relatively gradual pass band to stop band transition.
Although the EIP lock-box performance in terms of locking was much better than the previous one, it was still not able to perfectly lock the lasers, and hence this might be a source of error when taking the averages.
The post-processing of data forms one of the most important steps in obtaining accurate information about the fiber. The files captured from the oscilloscope are more than 100 MB in size each. These are then taken and processed following the steps shown in FIGS. 24 and 29 . The files contain almost 8 million data points. These numbers are obtained as follows:
There were 10 sequences with 64 samples each of 2 μs duration each and sampling was done at 4 Gs/s. This gives 10×64×2×10 −6 ×4×10 9 =5,120,000 Points There is an initial delay of 44 μs before each sequence starts and there is an extra 28 μs after the end of each sequence. Hence the points due to these are: 10×(44+28)×2×10 −6 ×4×10 9 =2880004 The total number of points=5,120,000+2,880,004=8,000,004 points
The delay on the scope was set to be 40 μs implying that the fiber starts after this time. Each 2 μs chunk of data after that corresponds to one measurement and has 8000 points. Thus, if the start point is chosen wrongly, in the worst case, it might include information from 2 separate measurements and lead to errors.
The strained section should not have any splices in it otherwise, prolonged testing might lead to breaking of the connection and hence large reflections. As far as possible, the strain should be uniform all over the section of fiber otherwise there will be multiple peaks in the Brillouin profile thereby, making it difficult to observe the shifts due to dynamic strain. About 28 m of fiber was first wound in 4 turns around two pulleys placed 7 m apart in the lab. But the results were not good because of polarization changes and non-uniform strain. Hence, we moved to a larger room where a single 17 m straight run was strained uniformly but now the length was reduced. When taking multiple measurements, it was necessary to periodically check the spectrum and adjust the modulator bias to compensate for the modulator drift. The amplitude of the comb signal coming out of the AWG should also be carefully controlled.
The Brillouin information was found to be 40-50 dB below the comb teeth and required a highly sensitive receiver for extracting the information. Tests were conducted using ESA as a coherent heterodyne receiver in zero span mode and the fiber temperature was varied and found to give accurate results similar to the automated stepped-sweep direct detection system. Finally, the lock box was changed, the whole system phase locked and dynamic strain measurements taken with a 12 s periodic strain cycle. The Brillouin frequency of the strained section was found to shift over a range of 50 MHz from the minimum to maximum strain position and then come back following a sinusoidal curve over one rotation. The strain change between the two extreme strain positions was found to be 830.4 με from the Brillouin frequency shift while the direct calculation using the mathematical formula gave a value of 911.76 με. Thus, modulating the pump signal using a comb of frequencies and then employing a Coherent Parallel Receiver was able to measure dynamic strain changes.
The first detailed investigation of dynamic strain sensing at UNB has been presented in this document. Modulation of the pump laser was introduced to produce multiple frequencies in the same signal. A Coherent heterodyne receiver was employed to extract the Brillouin information and this led to the development of an innovative sensing system which has the capability to measure strains over short intervals of time.
A novel dynamic Brillouin sensing scheme was simulated and tested using BOTDA system at UNB. The pump laser was modulated, a coherent receiver was used and dynamic strain measurements were made when the strain was varied periodically over a 13 s cycle. Each data point was captured in 128 μs. In the future, reduction in the measurement time and increased accuracy can be achieved by using PM fiber, building better sensitivity receiver, and better signal processing.
While the above invention has been shown and described in relation to particular arrangements of optical fibers, and in relation to particular geometries, materials and electronic circuitry, it will be understood by those skilled in the art that various changes or modifications could be made without varying from the scope of the present invention. For example, disclosures of specific numerical values are illustrative rather than limiting. Therefore, the present invention should be construed as limited only by the appended claims.
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A distributed fiber optic sensor simultaneously interrogates the sensing fiber with two counter propagating light beams. One beam is set to a constant frequency. The second beam is modified to contain a “comb” of frequencies, with each frequency component in the comb offset by a predetermined amount. Each of the frequency components in the comb, herein referred to as teeth, is able to interact with the counter-propagating beam through the Brillouin scattering process. With proper selection of the comb characteristics such as the number of teeth, the frequency spacing of teeth, the spectral width of teeth, and the relative amplitude of the teeth, a representation of the Brillouin spectrum at each point in the fiber can be obtained simultaneously with a single pass through the fiber.
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|
FIELD OF THE INVENTION
The invention relates generally to the field of laser marking systems. More particularly, the invention concerns an apparatus that uses laser energy for marking indicia on photosensitive web with a dramatic reduction in the occurrence of fog on the photosensitive web.
BACKGROUND OF THE INVENTION
Conventional edge marking in photographic film manufacturing involves printing some sort of identification indicia along the edge of film rolls during the finishing operation. Edge marked film has direct verification of roll identity, sheet identity and waste identity during all stages of the manufacturing process. Importantly, edge marked film provides accurate footage identification that enables operators to quickly identify, trace and remove film imperfections, thereby minimizing the amount of product waste. More generally, edge marked film increases process understanding by allowing process interactions to be more closely identified with their corresponding effect on the product. Traditional embossing marking techniques are being replaced by laser edge marking. Current mechanical embossing techniques (embossing wheels) are not programmable, generate poor quality marks and require excessive maintenance. Laser edge marking, on the other hand, is particularly advantageous in the industry because it provides a permanent record and can be read before and after film processing.
Advances in laser technology enabled the use of a dot matrix CO 2 laser marking system to be used to replace existing embossing technology. Off the shelf laser marking equipment will mark the film at required throughput rate, however, an unacceptable level of fog spots occurred.
Thus, a particular shortcoming of these advanced high powered laser systems used for edge marking photosensitive film is that they produce a by-product that impinges on the film surface. Laser energy by-products in the form of a plume of energized smoke and irradiated debris on the film surface is known to cause the localized fogging on the film. Experience has shown that localized fogging is not easily eliminated even when the film is immersed in a 99.8% nitrogen atmosphere.
More recent developments in laser technology enabled the development of high speed marking systems using short pulse lasers. Short pulse laser exposure on photosensitive film shows some promise in reducing the occurrences of fog spots. Our experience also indicates that an air jet directed at the laser impingement point on the film surface further reduce the occurrence of fog. Statistical methods have been employed to gain information on fog incidence reduction when laser marking photosensitive film. It has been experimentally proven that laser pulse width does not have a significant effect on fog. Importantly, however, our experience does suggest that laser peak power has a dramatic effect on the reduction of occurrences of fog spots by a factor of about 30. In addition, significant statistical benefits can be derived from an air jet that we believe can further reduce the incidences of fog spots by a factor of about 10.
Hence, laser marking without controlling peak power will result in 14% to 50% of the laser-generated dots of dot matrix characters to have fog spots around the dots. There are no present attempts known to the inventors to control peak power in laser edge marking devices because embossing techniques still remain prevalent in the industry and, more importantly, the fog spots remain a significant quality issue during the finishing process.
Therefore, a need persists for variable information to be permanently marked on die edge of each sheet of photosensitive web, such as photographic film, without significant incidences of fog spots on the surface of the film.
SUMMARY OF THE INVENTION
It is, therefore, an object of die invention to provide an apparatus for laser marking indicia on a moving photosensitive web while substantially reducing the occurrence of deleterious fog spots on the photosensitive web.
It is another object of the invention to provide an apparatus for exposing a moving photosensitive web to laser energy while controlling the peak power of the laser energy.
Yet another object of the invention is to provide an apparatus for laser printing indicia on a photosensitive web by further directing a jet of air onto the laser energy impinged surface of the photosensitive web.
It is a feature of the invention that the apparatus for laser marking indicia on a moving photosensitive web has a nozzle element for reducing the incident of fog spots on the laser impinged photosensitive web.
To accomplish these and other objects and features and advantages of the invention, there is provided, in one aspect of the invention, an apparatus for marking indicia on a moving photosensitive web, comprising:
a source of laser energy;
laser printer means operably connected to said source of laser energy, said laser printer means being provided with:
a laser head;
a laser beam tube connected to said laser head, said laser beam tube having an active end; and,
a nozzle element structurally associated with said active end of said laser beam tube, said nozzle element comprising a chamber having a laser energy inlet end and a laser energy outlet end; an air jet member arranged in said chamber for directing a burst of air onto a laser beam impingeable surface; at least one lens arranged in said chamber for focusing each one of a plurality of laser beams passing through said chamber; a lens cleaning member arranged in said chamber proximate to said at least one lens; and, a vacuum port extending from said chamber, said vacuum port providing means for evacuating said chamber of smoke and debris generated during laser marking; and wherein said laser head has a plurality of lasers disposed therein for generating a plurality of laser beams, a lens arranged in said laser beam tube for focusing said each one of a plurality of laser beams along a predetermined optical path through said laser beam tube and into impinging contact with said moving photosensitive web thereby producing said indicia thereon.
It is, therefore, an advantageous effect of the present invention that laser edge markings on photosensitive web can be accomplished with an apparatus that is easy to operate, simple and cost effective to produce and that substantially reduces the occurrence of fog spots on the photosensitive web.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features, and advantages of the present invention will become more apparent when taken in conjunction with the following description and drawings wherein identical reference numerals have been used, where possible, to designate identical features that are common to the figures, and wherein:
FIG. 1 is a schematic diagram of a laser edge marking system of the invention;
FIG. 2 a is a front elevational view of the laser head showing an attenuating member therein;
FIG. 2 b 1 is an enlarged view of the mesh screen depicted in FIG. 2 b;
FIG. 2 b is a top elevational view of the mesh screen;
FIG. 2 c is an isometric view of the beam splitter;
FIG. 3 is a graph of tie relationship between focus position effect (inversely proportional to peak power) on fog spots formed on the photosensitive film;
FIGS. 4 and 5 show the effects of an attenuating screen of the invention on incidents of fog spots; and,
FIG. 6 is an isometric view of the nozzle element used in the apparatus of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, and in particular to FIG. 1, the apparatus 10 according to the principles of the invention for printing indicia on a moving laser impingeable surface, such as a moving photosensitive web 1 , is illustrated. According to FIG. 1, apparatus 10 has a source 12 of laser energy for producing a range of laser power. A laser printer means 14 is operably connected to the source 12 of laser energy.
Referring to FIG. 1, laser printer means 14 , preferably a Domino DDC2 Digital Laser Coder, manufactured by Domino Lasers, Inc. of Gurnee, Ill., is provided with laser head 16 and a laser beam tube 18 structurally associated with the laser head 16 . Laser beam tube 18 has an active end 20 positioned proximate to the moving photosensitive web 1 and a plurality of lasers 22 disposed in die laser beam tube 18 for generating a plurality of laser beams. Importantly, a nozzle clement 40 , described more fully below, is structurally associated with the active end of the beam tube 18 , as shown in FIGS. 1 and 2 a.
According to FIG. 2 a , in the preferred apparatus 10 , seven lasers 22 are employed, each being a medium power CO 2 laser that operates at about 30 watts maximum power. Each laser 22 corresponds to a row of dots in a dot matrix character. This type of laser 22 has enough power to mark small characters or indicia into photosensitive materials, for example emulsion coated film. At least one lens 49 is arranged in the laser beam tube 18 for focusing each one of the plurality of laser beams along a predetermined optical path 23 and into impinging contact with the laser impingeable material, such as photosensitive web 1 thereby producing indicia thereon.
Referring to FIGS. 2 a - 2 c , means for controlling peak power, preferably a laser beam attenuating member 26 (FIG. 2 a ), is disposed in the optical path 23 for attenuating the laser beams passing through the laser beam tube 18 . In the preferred embodiment, attenuating member 26 is a metallic mesh screen 30 (FIG. 2 b ) arranged in the laser beam tube 18 . Preferably, metallic mesh screen 30 is made of materials selected from the group consisting of brass, steel, copper and metal alloys. We consider copper to be most preferred because it has more suitable thermal conductivity and reflective characteristics of the wavelengths contemplated by the invention. Moreover, the mesh screen 30 has a plurality of openings 32 . Openings 32 each have a wire diameter in the range of from about 0.00025 inches (0.000635 cm) to about 0.025 inches (0.0635 cm) and a clear opening having a dimension in the range from about 0.001 inches (0.00254 cm) to about 0.100 inches (0.254 cm). In the preferred embodiment, mesh screen 30 has clear opening dimension of 0.055 inches (0.140 cm), and a wire diameter of 0.016 inches (0.041 cm).
As shown in FIG. 2 c , alternatively, attenuating member 26 may include at least one beam splitter 27 arranged along the optical path in the beam tube 18 . Moreover, attenuating member 26 may include a neutral density filter (not shown).
Referring to FIGS. 2 a and 6 , nozzle element 40 has a preferably generally cylindrical shaped chamber 42 with a laser energy inlet end 44 and a laser energy outlet end 46 . Inlet end 44 is adaptable to any laser energy output device, such as a laser marking system for marking indicia on photosensitive web. Laser energy outlet end 46 is configured to focus beams of radiation onto a moving photosensitive web material 1 and to be spaced proximate to the moving photosensitive web material 1 . Preferably, laser energy outlet end 46 has a generally conical shape for concentrating the vacuum nearest the photosensitive web material 1 and, a generally conical lip 47 for concentrating the air surrounding lens 49 .
Referring to FIGS. 2 a and 6 , an air jet member 48 is arranged in the chamber 42 near the outlet end 46 . Air to air jet member 48 may be supplied by any general source (not shown). Air jet member 48 is configured for directing a burst of air onto a laser beam impingeable surface, such as a photosensitive web material 1 positioned proximate to the air jet member 48 .
Referring to FIG. 2 a , chamber 42 may have at least one lens 49 arranged therein for focusing each one of a plurality of laser beams passing through the chamber 42 . Lens 49 is preferably a short focal length zinc selenide lens. Lens 49 may be mounted in any one of a variety of ways in chamber 42 , for instance using a typical lens mount (not shown).
Referring to FIGS. 2 a and 6 , a lens cleaning member 50 is arranged in the chamber 42 proximate the lens 49 . Nozzle element 40 was developed to keep the lens 49 clean, prevent plume and draw away vapors associated with impinging laser energy. In the preferred embodiment, lens cleaning member 50 is a positive air flow pattern surrounding the lens 49 that shields the lens 49 from particulate matter. Alternatively, lens cleaning member 50 may be a burst of air directed at the lens 49 (not shown).
Turning again to FIGS. 2 a and 6 , chamber 42 further has a vacuum inlet port 52 and a vacuum outlet port 54 in fluid communication with the chamber 42 . Vacuum outlet port 54 provides means for evacuating the chamber 42 of smoke and debris generated during laser marking. To concentrate vacuum at a predetermined location, vacuum inlet port 52 preferably has a generally conical shape. Affluence generated by the marking process without vacuum resulted in no detection of cyanide, sulfur dioxide, hydrochloric acid, or carbon monoxide. Carbon dioxide could be detected but the level was below exposure limits. Mercury, silver and aldehydes vapors were adequately removed by the Fumex FA2 fume extraction machine.
Vacuum outlet port 54 , is connected to a source of vacuum (not shown), and provides a means for receiving such particulates that are collected through vacuum inlet port 52 .
FIG. 2 a illustrates nozzle element 40 adapted to a laser beam tube 18 having a plurality of lasers 22 therein. Laser beam tube 18 is preferably the output end of a laser marking system 10 (only partially shown).
Preferably, nozzle clement 40 is made from any structurally rigid material such as any metallic material. We prefer using aluminum because it is light-weight and can be easily formed.
Referring to FIG. 3, peak power of each of the plurality of lasers 22 was determined to be a primary factor controlling the incidences of fog spots occurring on the photosensitive web material 1 after impingement by laser energy. According to FIG. 3, we observed that the incidences of fog spots decreased as the focus position of the lens 49 moved further out of focus. This corresponded to an effective reduction in peak power that enabled the inventors to select controlling peak power for minimizing the incidences of fog spots.
Referring to FIGS. 4 and 5, performance of mesh screens 30 used as laser beam attenuating member 26 in the apparatus 10 of the invention are illustrated. According to both FIGS. 4 and 5, the incidences of fog spots are well below expected levels generally experienced in the industry.
In another embodiment of the invention, a method of controlling peak power of a laser marking apparatus 10 (FIG. 1) adapted for marking predetermined indicia 2 on a moving photosensitive web material 1 comprises the steps of providing a source 12 of laser energy. A laser printing means 14 (described above) is structurally connected to the source 12 of laser energy which has a laser head 16 , a laser beam tube 18 connected to the laser head 16 . As indicated above, the laser beam tube 18 has an active end 20 and a nozzle element 40 arranged on the active end 20 positioned proximate to the moving photosensitive web material 1 . A plurality of lasers 22 is disposed in the laser head 16 for generating a plurality of laser beams. A lens 49 is arranged in the laser beam tube 18 , preferably near the active end 20 , for focusing each one of the plurality of laser beams along a predetermined optical path 23 (FIG. 2 a ) and into impinging contact with the moving photosensitive web material 1 thereby producing indicia 2 thereon.
Further, the source 12 of laser energy is activated so as to energize each one of the plurality of lasers 22 for impinging laser beams forming predetermined indicia 2 on the moving photosensitive web material 1 . Importantly, the peak power to each one of the plurality of lasers 22 is controlled, as described above, for minimizing fog spots on the photosensitive web material 1 .
The invention has been described with reference to a preferred embodiment. However, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention.
PARTS LIST
1 photosensitive web material
2 indicia
10 apparatus of the invention
12 source of laser energy
14 printer means
16 laser head
18 laser beam tube
20 active end of laser beam tube 18
22 lasers
23 optical path
26 means for controlling peak power or laser beam attenuating member
27 beam splitter
30 metallic mesh screen
32 openings in metallic mesh screen 30
40 nozzle element
42 chamber
44 laser energy inlet end
46 laser energy outlet end
47 lip
48 air jet member
49 lens
50 lens cleaning member
52 vacuum inlet port
54 vacuum outlet port
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An apparatus for laser marking indicia on a moving photosensitive web by impinging laser energy upon the moving web with a laser printer device. The laser printer device is provided with a nozzle element that concentrates beams of radiation onto the web with substantially reduced incidences of fog spots on the web. The nozzle element extends circumferentially, substantially around a laser beam tube and the predetermined optical path defined by laser beams emanating from the laser beam tube.
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BACKGROUND OF THE INVENTION
[0001] Refrigerant systems are known to utilize refrigerant circulating throughout a closed-loop circuit to condition a secondary fluid. Typically, a refrigerant system includes a compressor for compressing the refrigerant, and delivering the refrigerant to a downstream heat exchanger. Refrigerant from that downstream heat exchanger passes through an expansion device, and then to an evaporator. In traditional refrigerant systems, the expansion device is a fixed area restriction or a valve that may be controlled such that the amount of expansion is tailored to achieve desired characteristics in operation of the refrigerant system.
[0002] In some advanced refrigerant systems, the work which is available from the expansion process of the refrigerant is utilized to drive or assist in driving at least one component within the refrigerant system.
[0003] In one known refrigerant system configuration, a secondary compressor operates in parallel with a main compressor. This secondary compressor compresses a portion of the refrigerant circulated throughout the refrigerant system. The secondary compressor is driven by the expander, with the expander operating much like a turbine, to receive the compressed refrigerant, and expand that refrigerant to a lower pressure and temperature. The work from this expansion process is utilized to drive the secondary compressor. This known combination of a compressor and an expander, located on the same shaft, is called an expresser. The use of the expresser is known in the industry, where the expander drives or assists in driving the corresponding compressor. The refrigerant exiting a heat rejection heat exchanger enters the expander, and then is expanded to a lower pressure and temperature. A two-phase flow exiting the expander enters the evaporator. The work extracted from the expansion process in the expander is used to drive the secondary compressor that is quite often located on the same shaft as the expander. In addition to extracting useful work from the expansion process, the refrigerant passing through the expander acquires a higher cooling thermodynamic potential, as it expands through the expander, since it follows a more efficient isentropic process. The use of the expresser technology is especially expected to grow in CO 2 applications, where the potential for the expansion energy recovery is higher than for the conventional refrigerants.
[0004] One of the disadvantages of positioning the expander and the associated compressor into a closely coupled mechanical engagement, such as locating them on the same shaft, is that the expander speed is not actively controlled. In other words, the expander will settle at a speed at which the power extracted by the expander from the refrigerant expansion process is roughly equal to and is balanced by the power delivered to the compressor. Since the expander speed cannot be actively controlled, the expansion process through the expander is typically not optimal. If the expansion process is not optimal, then the amount of refrigerant delivered to the evaporator, and its thermodynamic state, cannot be precisely controlled. If a delivered amount of refrigerant cannot be adjusted, it may result, for instance, in less than optimal gas cooler pressure, in transcritical applications, and/or undesirable conditions at the compressor entrance.
[0005] In other words, to optimize the expansion process for given operating and environmental conditions, such as gas cooler pressure, suction superheat, etc., flexibility in varying the expander speed must be provided. One way to enhance the control of the expander is to install an expansion valve that is located in series with the expander. However, the expansion valve would reduce/limit the amount of the work extracted from the expansion process by the expander. This reduction would occur, as part of the expansion process would take place in the expansion valve, and not in the expander. Therefore, a need exists to optimize the expresser operation.
SUMMARY OF THE INVENTION
[0006] In this invention, the expansion process in the expander is controlled by adjusting the speed of the expander. The higher the expander speed, the more refrigerant can be passed through the expander. Similarly, the lower the expander speed, the less refrigerant passes through the expander. The expander speed of the expresser (a mechanically coupled compressor-expender configuration) is adjusted by changing the load on the compressor component of the expresser. Compressor unloading can be accomplished by using various unloading techniques such as, for example, moving a slide valve of a screw compressor, opening a bypass port of the scroll compressor, using suction cutoff of a reciprocating compressor, installing a suction modulation valve, or utilizing any other known techniques to reduce the compressor load. This compressor load reduction causes the expander speed to increase.
[0007] Similarly, loading the associated compressor component of the expresser results in a speed decrease of the expander component of the expresser. Therefore, by utilizing the proper amount of compressor unloading we can very the expresser speed and thus optimize the expansion process. This is true since the expander speed varies along with the expresser speed, as both the compressor and expander are closely mechanically coupled, such as located on the same shaft. An ability to change the expander speed is similar to adjusting the amount of flow by using a variable restriction expansion device, such as an electronic expansion valve, in comparison to inefficient fixed cross-sectional area expansion device, such as a capillary tube or orifice.
[0008] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic view of a refrigerant system incorporating the present invention.
[0010] FIG. 2 is a view of another schematic.
[0011] FIG. 3 is a view of another schematic.
[0012] FIG. 4 is a view of another schematic.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] A refrigerant system 20 is illustrated in FIG. 1 . A main compressor 22 compresses a refrigerant received from a main suction line 24 . As shown, a secondary suction line 26 delivers a portion of the refrigerant flow through a secondary compressor 28 . Refrigerant compressed by the secondary compressor 28 is delivered through a secondary discharge line 30 to a main discharge line 46 , positioned on a high side of the refrigerant system 20 , to be combined with the refrigerant delivered from the main compressor 22 . The combined refrigerant flow passes through a heat rejection heat exchanger 32 , where the heat is removed from the refrigerant by a secondary fluid typically delivered to an ambient environment. The heat rejection heat exchanger 32 is called a condenser, if the refrigerant passes through the thermodynamic states within the heat exchanger 32 that are below the critical point, or a gas cooler, if the refrigerant passes through the thermodynamic states within the heat exchanger 32 that are above the critical point.
[0014] Downstream of the condenser 32 , an expansion process, to a lower pressure and temperature, occurs in an expander 34 . As known, the expander 34 takes the compressed refrigerant from the heat rejection heat exchanger (a subcritical condenser or a supercritical gas cooler) 32 , and utilizes energy from that compressed refrigerant to drive the expander, while the compressed refrigerant is “isentropically” expanded to a lower pressure and temperature. A shaft 36 (alternatively a generator) is driven by the expander 34 , and this shaft (or power from the generator) in turn drives the secondary compressor 28 . Such systems are known as “expressers.”
[0015] A heat exchanger, or an evaporator, 38 is positioned downstream of the expander 34 . The evaporator 38 is located on a lower pressure side of the refrigerant system 20 , and heat is transferred to the refrigerant in the evaporator 38 from a secondary fluid to be delivered to a climate-controlled space. Refrigerant passes from the expander 34 , through the evaporator 38 , and back into the suction line 24 to return to the compressors 22 and 28 . The refrigerant system 20 , as described to this point, is as known in the art. Obviously, the basic refrigerant system 20 may have additional features or enhancement options. All these variations in refrigerant system configurations are within the scope and can equally benefit from the invention.
[0016] A control 50 for the refrigerant system 20 operates components such as a bypass valve 40 , and/or a suction modulation valve 44 , both associated with the secondary compressor 28 , to limit the amount of refrigerant compressed by the secondary compressor 28 , and thus to unload the compressor 28 . By reducing the amount of refrigerant compressed by the secondary compressor 28 , the speed of the expander 34 mechanically coupled with the compressor 28 can be increased. The expander speed adjustment achieves desired thermodynamic characteristics of the expanding refrigerant that can be optimized for specific operating conditions. The desired thermodynamic characteristics of the expanding refrigerant tailored to a specific set of operating conditions are as known in the art, and have been utilized for operation and control of electronic expansion valves. However, achieving desired thermodynamic characteristics of the expanding refrigerant have been limited with systems utilizing expanders, since the expander speed is not usually actively controlled.
[0017] However, by utilizing the control 50 , and selectively operating, for example, either the bypass valve 40 to control the amount of refrigerant bypassed through a bypass line 42 , or by limiting the amount of refrigerant passing through a suction modulation valve 44 and reaching the secondary compressor 28 , the amount of refrigerant compressed by the secondary compressor 28 , and thus the speed of the expander 34 , can be controlled. The control 50 may also be operated in a pulse width modulation mode to rapidly cycle either valve 40 or 44 between open and closed positions to achieve precise control over the amount of refrigerant compressed by the secondary compressor 28 . Obviously, the valves 40 and 44 may operate in conjunction with each other to achieve the desired level of unloading of the secondary compressor 28 .
[0018] Compressor unloading can be accomplished by using various unloading techniques such as, for example, moving a slide valve of a screw compressor, opening a bypass port of the scroll compressor, using suction cutoff of a reciprocating compressor, installing a suction modulation valve, or utilizing any other known techniques to reduce the compressor load.
[0019] To be operational and to take advantage of the invention, the expander 34 does not have to be connected to the high source of pressure associated with the heat rejection heat exchanger 32 and to the source of low pressure associated with the evaporator 38 . To perform the expansion function, the expander can be connected to an intermediate pressure point in the refrigerant system 120 as shown in FIG. 2 . In refrigerant system 120 , the main compressor may consist of two compressor stages 22 and 222 connected in series. In the embodiment shown in FIG. 2 , the expander 34 is incorporated into a loop associated with a vapor injection or economizer cycle, where the expander 34 is expanding the refrigerant from the pressure associated with the heat rejection heat exchanger 32 to the intermediate cycle pressure approximated by the pressure between the first compression stage 22 and the second compression stage 222 . Economizer cycles are known in the art, and the benefits provided by economizer cycles are associated with additional subcooling obtained in the economizer heat exchanger 224 and a more efficient compression process, due to refrigerant vapor injection between sequential compression stages 22 and 222 . The refrigerant undergoing expansion in the expander 34 , from a high-side to intermediate pressure, provides even greater subcooling to the main flow in the economizer heat exchanger 224 , where the main flow undergoes expansion in a main expansion device 226 . This greater subcooling, and higher cooling thermodynamic potential for refrigerant entering the evaporator 38 , is achieved due to more efficient isentropic expansion process, in comparison to isenthalpic expansion process provided by traditional expansion devices. The expansion device 226 can be, for example, a fixed area orifice, a capillary tube, a thermostatic expansion valve, an electronic expansion valve, another expander or a combination of different expansion devices. As in the embodiment shown in FIG. 1 , the expander 34 of the FIG. 2 embodiment is associated with secondary compressor 28 and takes advantages of the selective unloading of this compressor, as discussed above. In this case, the secondary compressor 28 operates in a parallel arrangement (or in tandem) with the primary compressor 22 , which in combination with the compressor 28 , provide the first stage of compression, from a suction pressure to an intermediate pressure. Of course, as known in the art, the two compression stages 22 and 222 may be provided within a single compressor housing.
[0020] Similarly, in the embodiment 220 shown in FIG. 3 , the secondary compressor 28 may be positioned to operate in parallel (or in tandem) with the second compression stage 222 and to compress refrigerant from an intermediate pressure to a discharge pressure. Other arrangements are also possible, where for instance, the main and secondary compressor operating in tandem may compress refrigerant to a pressure lower then the pressure associated with the heat rejection heat exchanger 32 . Further, if multiple intermediate pressure levels are available within the refrigerant cycle, the secondary compressor 28 may operate between its own pressure levels, and not exactly in tandem with any of the primary compressors. These arrangements would also be typical of compressors installed in series.
[0021] Even further arrangements are possible, where, for example, the secondary compressor 28 is not compressing the refrigerant, but instead is compressing some other process fluid. In this case, in the embodiment 320 shown in FIG. 4 , the secondary compressor may be used, for example, to compress air and deliver it from an inlet line 321 to an outlet line 322 . As described above, a similar bypass arrangement may be used to control the amount of the bypassed air to shed off the compressor load to control the speed of the expander. Of course, in this case, since both the compressor 28 and the expander 34 are located on the same shaft, a special seal needs to be added onto the rotating shaft, as known, that would prevent the leakage of the refrigerant to the ambient environment.
[0022] Further, in all the embodiments above, a clutch can be installed on the rotating shaft 36 connecting the secondary compressor 28 and the expander 34 to selectively engage and disengage a mechanical coupling of these two expresser components.
[0023] It should be pointed out that many different compressor and expander types could be used in this invention. For example, scroll, screw, rotary, centrifugal or reciprocating compressors and expanders can be employed.
[0024] The refrigerant systems that utilize this invention can be used in many different applications, including, but not limited to, air conditioning systems, heat pump systems, marine container units, refrigeration truck-trailer units, and supermarket refrigeration systems.
[0025] Furthermore, it has to be understood that although this invention can be applied to any economized refrigerant systems, the refrigerant systems employing CO 2 as a refrigerant would particularly benefit from this invention, since these systems have inherit deficiencies and require additional means for the performance enhancement.
[0026] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in the art would recommend that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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A refrigerant system utilizes an expander to expand refrigerant and to drive or assist in driving an associated compressor. By varying the compressor load, the speed of the expander can be adjusted to achieve the desired thermodynamic characteristics of the expanding refrigerant and enhance expander operation.
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More than one reissue application has been filed for the reissue of U.S. Pat. No. 7,784,704, which is hereby incorporated by reference in its entirety. The reissue applications are application Ser. Nos. 13/551,543 (the parent reissue application, which is incorporated herein by reference in its entirety) and 14/714,535 (the present reissue application).
This application is a reissue continuation of application Ser. No. 13/551,543, now U.S. Pat. No. Re. 45,574, which is an application for reissue of U.S. Pat. No. 7,784,704.
FIELD OF THE INVENTION
The subject invention generally pertains to a room or building thermostat and more specifically to a method of programming such a thermostat, wherein the thermostat can in effect program itself for various daily and/or weekly temperature setpoints upon learning temperature setting habits of a user and can do such self-programming without ever knowing the actual time of day or day of the week.
BACKGROUND OF RELATED ART
Furnaces, air conditioners and other types of temperature conditioning units typically respond to a thermostat in controlling the air temperature of a room or other area of a building. Currently, thermostats can be classified as manual or programmable.
With manual thermostats, a user manually enters into the thermostat a desired temperature setpoint, and then thermostat controls the temperature conditioning unit to bring the actual room temperature to that setpoint. At various times throughout the day, the user might adjust the setpoint for comfort or to save energy. When operating in a heating mode, for instance, a user might lower the setpoint temperature at night and raise it again in the morning. Although manual thermostats are easy to understand and use, having to repeatedly adjust the setpoint manually can be a nuisance.
Programmable thermostats, on the other hand, can be programmed to automatically adjust the setpoint to predetermined temperatures at specified times. The specified times can initiate automatic setpoint adjustments that occur daily such as on Monday-Friday, or the adjustments might occur weekly on days such as every Saturday or Sunday. For a given day, programmable thermostats can also be programmed to make multiple setpoint adjustments throughout the day, such as at 8:00 AM and 11:00 PM on Saturday or at 6:00 AM and 10 PM on Monday through Friday. Such programming, however, can be confusing as it can involve several steps including: 1) synchronizing the thermostat's clock with the current time of day; 2) entering into the thermostat the current date or day of the week; and 3) entering various chosen days, times and setpoint temperatures. One or more of these steps may need to be repeated in the event of daylight savings time, electrical power interruption, change in user preferences, and various other reasons.
Consequently, there is a need for a thermostat that offers the simplicity of a manual thermostat while providing the convenience and versatility of a programmed thermostat.
SUMMARY OF THE INVENTION
An object of the invention is to provide an essentially self-programmable thermostat for people that do not enjoy programming conventional programmable thermostats.
An object of some embodiments of the invention is to provide a programmable thermostat that does not rely on having to know the time of day, thus a user does not have to enter that.
Another object of some embodiments is to provide a programmable thermostat with both daily and weekly occurring settings, yet the thermostat does not rely on having to know the day of the week, thus a user does not have to enter that.
Another object of some embodiments is to provide a programmable thermostat that does not rely on onscreen menus for programming.
Another object of some embodiments is to provide a thermostat that effectively programs itself as it is being used as a manual thermostat.
Another object of some embodiments is to provide a thermostat that automatically switches from a manual mode to a programmed mode when it recognizes an opportunity to do so.
Another object of some embodiments is to provide a thermostat that automatically switches from a programmed mode to a manual mode simply by manually entering a new desired setpoint temperature.
Another object of some embodiments is to observe and learn the temperature setting habits of a user and automatically program a thermostat accordingly.
Another object of some embodiments is to provide a self-programming thermostat that not only learns a user's temperature setting habits, but if those habits or temperature-setting preferences change over time, the thermostat continues learning and will adapt to the new habits and setpoints as well.
Another object of some embodiments is to minimize the number of inputs and actions from which a user can choose, thereby simplifying the use of a thermostat.
Another object of some embodiments is to provide a thermostat that can effectively self-program virtually an infinite number of setpoint temperatures and times, rather than be limited to a select few number of preprogrammed settings.
Another object of some embodiments is to provide a simple way of clearing programmed settings of a thermostat.
One or more of these and/or other objects of the invention are provided by a thermostat and method that learns the manual temperature setting habits of a user and programs itself accordingly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a thermostat controlling a temperature conditioning unit.
FIG. 2 shows an example of algorithm for a thermostat method.
FIG. 3 shows another example of algorithm for a thermostat method.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-3 show a thermostat 10 and a method for automatically programming it. Initially, thermostat 10 might first appear and function as an ordinary manual thermostat. Thermostat 10 , for instance, includes a manual input 12 (e.g., dial, keyboard, pointer, slider, potentiometer, pushbutton, etc.) that enables a user to manually enter a manual setpoint 14 that defines a manually entered setpoint temperature 16 . The manually entered setpoint temperature 16 is the user's desired target temperature for a comfort zone 18 . Upon comparing the manually entered setpoint temperature 16 to the comfort zone's actual temperature 20 (provided by a temperature sensor 22 ), thermostat 10 provides an output signal 24 that controls a temperature conditioning unit 26 (e.g., furnace, heater, air conditioner, heat pump, etc.) to heat or cool air 28 in comfort zone 18 , thereby urging the comfort zone's actual temperature 20 toward the manually entered setpoint temperature 16 .
A digital display 30 can be used for displaying the current setpoint temperature, and another display 32 can show the comfort zone's actual temperature. Displays 30 and 32 could be combined into a single display unit, wherein the combined display unit could show the current setpoint temperature and the zone's actual temperature simultaneously or in an alternating manner. Thermostat 10 might also include a selector switch 34 for manually switching between a cooling mode for cooling zone 18 and a heating mode for heating zone 18 . Items such as display 30 , selector switch 34 , manual input 12 , and output 24 are well known to those of ordinary skill in the art. One or more of such items, for example, can be found in a model CT8775C manual thermostat provided by Honeywell Inc. of Golden Valley, Minn.
Although thermostat 10 can operate as a regular manual thermostat by controlling unit 26 as a function of a differential between the actual zone temperature and the most recently entered manual setpoint temperature, thermostat 10 includes a microprocessor 36 (e.g., computer, CPU, firmware programmed chip, etc.) that enables thermostat 10 to observe the temperature setting habits of the user (e.g., person that manually enters setpoint temperatures into the thermostat). After several manual settings, microprocessor 36 may learn the user's preferred setpoint temperatures and timestamps them with the aide of a timer 38 . With one or more learned setpoint temperatures and timestamps 48 , microprocessor 36 can begin anticipating the user's desires and automatically adjust the thermostat's setpoint temperatures accordingly. Thus, thermostat 10 can begin operating as a programmed thermostat, rather than just a manual one.
Since a user's desired temperature setpoints and time preferences might change for various reasons, any manually entered setpoint temperature 16 overrides the currently active setpoint temperature regardless of whether the current setpoint temperature was manually entered or was automatically activated as a learned setpoint temperature. Once overridden, another learned setpoint temperature might later be activated at a learned time to return thermostat 10 back to its programmed mode. Thus, thermostat 10 is somewhat of a hybrid manual/programmable thermostat in that it can shift automatically between manual and programmed operation.
To assign timestamps 48 to manually entered setpoint temperatures, timer 38 can actually comprise one or more timers and/or counters. In some embodiments, for example, timer 38 includes a continuously running daily or 24 -hour timer that resets itself every 24 hours. The time increments can be in minutes, seconds, or any preferred unit. In some cases, timer 38 is a continuously operating weekly or 168-hour timer that resets itself every seven days. The increments can be in days, hours, minutes, seconds, or any preferred unit. The weekly timer could also be a seven-increment counter that indexes one increment every 24 hours in response to a daily or 24-hour timer. Timer 38 , however, is not necessarily synchronized with the actual time of day or day of the week. Such synchronization preferably is not required; otherwise the user might have to manually enter or set the correct time and day of the week.
In the case where timer 36 comprises a weekly timer in the form of a 7-increment counter triggered by each 24-hour cycle of a daily timer, timestamp 48 might a be a two-part number such as (X and Y) wherein X cycles from 1 to 7 as a weekly timer, and Y cycles from 0 to 1,439 (1,440 minutes per day) as a daily timer. In this case, a timestamp 48 might be (3 and 700) to indicate 700 minutes elapsed during day-3. Whether day-3 represents Monday, Tuesday or some other day is immaterial, and whether the 700-minute represents 2:00 AM, 7:30 PM or some other time of day is also immaterial. As one way to provide a programmable thermostat that can operate independently of an actual time of day clock and to provide thermostat 10 with other functionality, microprocessor 36 can be firmware programmed to execute one or more of the following rules:
Rule-1 —Upon receiving a manually entered setpoint temperature, microprocessor assigns an (X and Y) timestamp 48 to the manually entered setpoint temperature, wherein the timestamp indicates when the setpoint temperature was entered relative to other timestamps. The manually entered setpoint temperature and its timestamp 48 are stored in memory for later reference.
Rule-2 —Microprocessor 36 looks for patterns of manual setpoints, wherein each manual setpoint has a manually entered setpoint temperature and a timestamp 48 .
A daily pattern, for example, can be defined as three consecutive days in which a series of three similar manually entered setpoint temperatures (e.g., within a predetermined deviation of perhaps 2° F. or 5° F. of each other) have similar daily timestamps 48 (e.g., each Y-value being within a predetermined deviation of perhaps 90 minutes of each other). Such a daily pattern can then be assigned a learned daily setpoint temperature and a learned daily time. The learned daily setpoint temperature could be, for example, an average of the three similar manually entered setpoints temperatures or the most recent of the three. The learned daily time could be, for example, 20 minutes before the three similar timestamps. For future automatic settings, the 20 minutes might allow microprocessor 36 to activate the learned daily setpoint temperature before the user would normally want to adjust the setpoint.
A weekly pattern, for example, can be defined as three manual setpoints spaced 7 days apart (e.g., same X-value after one complete 7-day cycle) in which three similar manually entered setpoint temperatures (e.g., within 2° F. or 5° F. of each other) have similar timestamps 48 (e.g., each Y-value being within 90 minutes of each other). Such a weekly pattern can then be assigned a learned weekly setpoint temperature and a learned weekly time. The learned weekly setpoint temperature could be, for example, an average of the three similar manually entered setpoints temperatures spaced 7 days apart or the most recent of the three. The learned time could be, for example, 20 minutes before the three similar timestamps.
Rule-3 —Automatically activate a learned daily setpoint temperature at its learned daily time (at its assigned Y-value), whereby thermostat 10 controls unit 26 based on the learned daily setpoint temperature and continues to do so until interrupted by one of the following: a) the user enters a manually entered setpoint temperature (adjusts the temp), b) another learned daily setpoint temperature becomes activated at its learned daily time, or c) a learned weekly setpoint temperature becomes activated at its learned weekly time.
Rule-4 —Automatically activate a learned weekly setpoint temperature at its learned weekly time (at its assigned X and Y values), whereby thermostat 10 controls unit 26 based on the learned weekly setpoint temperature and continues to do so until interrupted by one of the following: a) the user enters a manually entered setpoint temperature (adjusts the temp), b) a learned daily setpoint temperature becomes activated at its learned daily time (but see Rule-5), or c) another learned weekly setpoint temperature becomes activated at its learned weekly time.
Rule-5 —A weekly pattern overrides or supersedes a daily pattern if their assigned timestamps 48 are within a predetermined period of each other such as, for example, within three hours of each other based on the Y-values of their timestamps.
Rule-6 —If a user enters a manually entered setpoint temperature, thermostat 10 controls unit 26 in response to the manually entered setpoint temperature and continues to do so until interrupted by one of the following: a) the user enters another manually entered setpoint temperature (adjusts the temp), b) a learned daily setpoint temperature becomes activated at its learned daily time, or c) a learned weekly setpoint temperature becomes activated at its learned weekly time.
Rule-7 —If a user enters two manually entered setpoint temperatures within a predetermined short period of each other, e.g., within 90 minutes of each other, the first of the two manual entries is disregarded as being erroneous and is not to be considered as part of any learned pattern.
Rule-8 —If a learned daily setpoint temperature is activated at a learned time and is soon interrupted by the user entering a manually entered setpoint temperature within a predetermined short period (e.g., within 3 hours), and this occurs a predetermined number of days in a row (e.g., 3 days in a row as indicated by the X-value of timer 38 ), then the daily pattern associated with the learned daily setpoint temperature is erased from the memory.
Rule-9 —If a learned weekly setpoint temperature is activated at a learned time and is soon interrupted by the user entering a manually entered setpoint temperature within a predetermined short period (e.g., within 3 hours), and this occurs a predetermined number of weeks in a row (e.g., 2 weeks in a row as indicated by an additional counter that counts the cycles of the X-value of timer 38 ), then the weekly pattern associated with the learned weekly setpoint temperature is erased from the memory.
Rule-10 —Actuating switch 34 between cool and heat or actuating some other manual input can be used for erasing the entire collection of learned data.
Rules 1-10 might be summarized more concisely but perhaps less accurately as follows:
1) Assign timestamps 48 to every manually entered setpoint temperature.
2) Identify daily patterns (similar manually entered temperatures and times 3 days in a row), and identify weekly patterns (3 similar manually entered temperatures and times each spaced a week apart). Based on those patterns, establish learned setpoint temperatures and learned times.
3) Activate learned daily setpoints at learned times, and keep them active until the activated setpoint is overridden by the next learned setpoint or interrupted by a manually entered setpoint.
4) Activate learned weekly setpoints at learned times, and keep them active until the activated setpoint is overridden by the next learned setpoint or interrupted by a manually entered setpoint.
5) If a learned weekly setpoint and a learned daily setpoint are set to occur near the same time on given day, the learned daily setpoint is ignored on that day because the day is probably a Saturday or Sunday.
6) Whenever the user manually adjusts the temperature, the manually entered setpoint temperature always overrides the currently active setting. The manually entered setpoint remains active until it is interrupted by a subsequent manual or learned setting.
7) If a user repeatedly tweaks or adjusts the temperature within a short period, only the last manually entered setpoint temperature is used for learning purposes, as the other settings are assumed to be trial-and-error mistakes by the user.
8) If a user has to repeatedly correct a learned daily setpoint (e.g., correct it 3 days in a row), that learned setpoint is deleted and no longer used. Using 3 days as the cutoff avoids deleting a good daily pattern due to 2 days of corrections over a weekend.
9) If a user has to repeatedly correct a learned weekly setpoint (e.g., correct it 2 weeks in a row), that learned setpoint is deleted and no longer used.
10) Switching between heating and cooling, for at least 5 seconds or so, deletes the entire collection of learned data.
To execute one or more of the aforementioned rules, microprocessor 36 could operate under the control of various algorithms, such as, for example, an algorithm 40 of FIG. 2 , an algorithm 42 of FIG. 3 , a combination of algorithms 40 and 42 , or another algorithm altogether.
Referring to the example of FIG. 2 , a block 44 represents receiving a plurality of manual setpoints 14 that are manually entered at various points in time over a period, each of the manual setpoints 14 provides a manually entered setpoint temperature 16 that in block 46 becomes associated with a timestamp 48 via timer 38 . Timer 38 can run independently or irrespective of the actual time of day and irrespective of the actual day of the week. In blocks 50 and 52 , thermostat 10 controls unit 26 as a function of a differential between the actual zone temperature 20 and a currently active manually entered setpoint. In block 54 , microprocessor 36 recognizes patterns with the manually entered setpoints. Based on the patterns, in block 56 microprocessor 10 establishes learned setpoint temperatures and corresponding learned times. In block 58 , some time after controlling unit 26 in response to the manually entered setpoint temperatures (block 50 ), automatically switching at the learned time to controlling the temperature conditioning unit in response to the learned setpoint temperature. This might continue until interrupted by block 60 , wherein microprocessor 36 encounters another recognized pattern or upon receiving another manual setpoint, at which point unit 26 is controlled in response thereto.
Referring to the example of FIG. 3 , a block 62 represents microprocessor 36 receiving temperature feedback signal 20 from temperature sensor 22 . Sensor 22 could be incorporated within thermostat 10 , as shown in FIG. 1 , or sensor 22 could be installed at some other location to sense the room temperature such as the temperature of air 28 entering unit 26 . Blocks 64 , 66 and 68 represent microprocessor 36 sequentially receiving first, second and third manually entered setpoint temperatures. Blocks 70 , 72 and 74 represent thermostat 10 controlling unit 26 at sequential periods in response to a differential between the comfort zone temperature and the various manually entered setpoint temperatures. Block 76 represents assigning timestamps 48 to the various manually entered setpoint temperatures. A block 78 represents microprocessor 36 identifying a learned setpoint temperature based on the first, second and third manually entered setpoint temperatures. In block 80 , thermostat 10 controls unit 26 in response to a differential between the learned setpoint temperature and the actual zone temperature. Block 82 represents subsequently receiving a fourth manually entered setpoint temperature. Block 84 represents controlling unit 26 in response to the fourth manually entered setpoint temperature. Some time after that, thermostat 10 returns to controlling unit 26 in response to the learned setpoint temperature, as indicated by block 86 .
Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those of ordinary skill in the art. The scope of the invention, therefore, is to be determined by reference to the following claims:
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A hybrid manual/programmable thermostat for a furnace or air conditioner offers the simplicity of a manual thermostat while providing the convenience and versatility of a programmable one. Initially, the hybrid thermostat appears to function as an ordinary manual thermostat; however, it privately observes and learns a user's manual temperature setting habits and eventually programs itself accordingly. If users begin changing their preferred temperature settings due to seasonal changes or other reasons, the thermostat continues learning and will adapt to those changes as well. For ease of use, the thermostat does not require an onscreen menu as a user interface. In some embodiments, the thermostat can effectively program itself for temperature settings that are set to occur at particular times daily or just on weekends, yet the user is not required to enter the time of day or the day of the week.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to automated manufacturing systems and, more particularly, to an apparatus for automatically seaming a sleeve or pant leg for a sweat suit or the like.
(2) Description of the Prior Art
The manufacture of textile clothing articles such as sweat suits and outer garments has resisted automation. This is due largely because of the difficulty in accurately handling so called "soft" materials. For example, the fleece material commonly used in sweat suits may wrinkle, stick to one another and stretch significantly when handled.
Even where automation has begun to make in-roads, other difficulties remain. For example, sleeves and pant legs must be sewn "inside out" in order to make a garment having clean seams. This has always been a manual operation because of the dexterity required to locate the cut fabric piece, inspect it for defects and feed it into the sewing machine. Unfortunately, repetitive actions such as sewing a garment may cause health problems. However, it has been extremely difficult to design a device which can reliably locate, inspect and sew a fabric piece to form a garment piece such as a sleeve or pant leg time after time.
Thus, there remains a need for an apparatus for automatically seaming a sleeve or pant leg for a sweat suit or the like which will operate reliably time after time while, at the same time, it can be carried out completely automatically without the need for a skilled operator.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for receiving a garment piece at a first workstation and moving the garment piece to a second workstation where the garment piece is seamed together. The apparatus includes a garment piece transfer system located adjacent to the first workstation for engaging the garment piece at the first workstation and for moving the garment piece to the second workstation.
In the preferred embodiment, the transfer system includes a support table located between the first workstation and the second workstation. The support table has a smooth, generally horizontal planar top surface for supporting the garment piece thereon. A robot is positioned adjacent to the table and has an arm and presser foot attached thereto. The robot arm includes means for selectively moving the presser foot between a non-engagement position and an engagement position with the planar surface whereby the presser foot engages the garment piece on the surface of the support table. The robot also includes means for rotating the presser foot to orient it with respect to the garment piece. Finally, the robot arm includes means for moving the presser foot between the first workstation and the second workstation when in the engagement position to slidably move the garment piece along the surface of the table from the first workstation to the second workstation.
A vision and control system is located adjacent to the first workstation for determining the position of the garment piece at the first workstation and sending a control signal to the garment piece transfer system to engage the garment piece at the first workstation and move the garment piece to the second workstation.
A sewing machine is located at the second workstation for seaming the garment piece together.
Accordingly, one aspect of the present invention is to provide an apparatus for receiving a garment piece at a first workstation and moving the garment piece to a second workstation. The apparatus includes: (a) a garment piece transfer system located adjacent to the first workstation for engaging the garment piece at the first workstation and for moving the garment piece to the second workstation; and (b) a vision and control system located adjacent to the first workstation for determining the position of the garment piece at the first workstation and sending a control signal to the garment piece transfer system to engage the garment piece at the first workstation and move the garment piece to the second workstation.
Another aspect of the present invention is to provide a garment piece transfer system for moving a garment piece from a first workstation to a second workstation. The apparatus includes: (a) a support table located between the first workstation and the second workstation having a smooth, generally horizontal planar top surface for supporting the garment piece thereon; and (b) a robot positioned adjacent the table and having an arm and presser foot attached thereto, the robot arm including means for selectively moving the presser foot between a non-engagement position and an engagement position with the planar surface whereby the presser foot engages the garment piece on the surface of the support table, the robot arm including means for moving the presser foot between the first workstation and the second workstation when in the engagement position to slidably move the garment piece along the surface of the table from the first workstation to the second workstation.
Still another aspect of the present invention is to provide an apparatus for receiving a garment piece at a first workstation and moving the garment piece to a second workstation. The apparatus includes: (a) a garment piece transfer system located adjacent to the first workstation for engaging the garment piece at the first workstation and for moving the garment piece to the second workstation, the transfer system includes: (i) a support table located between the first workstation and the second workstation having a smooth, generally horizontal planar top surface for supporting the garment piece thereon; and (ii) a robot positioned adjacent the table and having an arm and presser foot attached thereto, the robot arm including means for selectively moving the presser foot between a non-engagement position and an engagement position with the planar surface whereby the presser foot engages the garment piece on the surface of the support table, the robot arm including means for moving the presser foot between the first workstation and the second workstation when in the engagement position to slidably move the garment piece along the surface of the table from the first workstation to the second workstation; (b) a vision and control system located adjacent to the first workstation for determining the position of the garment piece at the first workstation and sending a control signal to the garment piece transfer system to engage the garment piece at the first workstation and move the garment piece to the second workstation; and (c) a sewing machine located at the second workstation for performing a sewing operation on the garment piece.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a garment piece positioner and seamer constructed according to the present invention;
FIG. 2 is a side elevation view of the garment piece positioner and seamer shown in FIG. 1;
FIG. 3 is a partial, enlarged plan view of FIG. 1 illustrating a garment piece loaded on the table at the loading station;
FIG. 4 is a schematic of the operations program used to control the positioner and seamer;
FIG. 5 is a flow chart of the inspection program;
FIG. 6 is a top view showing a garment piece loaded at the loading station and a schematic depiction of the garment piece being located by the vision system;
FIG. 7 is a flow chart of the reject program;
FIG. 8 is a flow chart of the guidance program;
FIG. 9 is a flow chart of the learning program;
FIG. 10 is a flow chart of the transfer-station positioning program; and
FIGS. 11A-11E are a sequence of schematic views showing a garment assembling cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms.
Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1, a garment piece positioner and seamer, generally designated 10, is shown constructed according to the present invention.
Garment piece positioner and seamer 10 is used in the apparel industry to assemble clothing articles. In the assembling process of a clothing article, a garment piece must be moved to one or more assembling stations. The garment piece is sewn, attached to other garment pieces, and/or transferred to other apparatuses at the various assembling stations to create a clothing article.
Garment piece positioner and seamer 10 can be used to assemble a wide variety of clothing articles. The preferred embodiment of garment piece positioner and seamer 10 is used to assemble a garment piece into a sleeve for attachment to a shirt. In the preferred embodiment, garment pieces are successively loaded at a loading station 30 where they are moved first to a sewing station 32 for seaming and then to a transfer station 34 for subsequently assembling the garment piece into a finished sleeve.
Garment piece positioner and seamer 10 includes a positioner 12 for moving garment pieces to assembling stations 32,34 and a vision system 20 for controlling positioner 12. Positioner 12 includes a table 14 and robot 16. Robot 16 slidably moves a garment piece over table 14 to position the garment piece from loading station 30 to stations 32, 34. Robot 16 moves a garment piece between stations 30-34 by slidably moving the garment piece over table 14. The movement of robot 16 is controlled by vision system 20 which includes a camera 52 and a controller (not shown). Vision system 20 locates a garment piece that has been randomly loaded onto table 14 at the loading station 30 and produces garment piece location data which corresponds to the garment piece's location. The garment piece location data is communicated to robot 16 which uses the data to selectively engage the garment piece and to control the movement of robot 16 in order to precisely position the garment piece at stations 32, 34.
As shown in FIGS. 1 and 2, robot 16 is adjacently positioned to table 14. Table 14 includes a support frame 24 and a generally horizontal planar surface 26. The planar surface 26 of table 14 is designed to have a smooth surface so that a garment piece can be slidably moved over the planar surface 26 with minimum frictional resistance. In the preferred embodiment, the generally horizontal planar surface 26 is made from glass or transparent plastic.
Located around table 14 are loading station 30, sewing station 32, and transfer station 34. Loading station 30 provides an area where a garment piece can be initially positioned on the table 14. Sewing station 32 includes a sewing machine 44 that functions to sew along a selected line of a garment piece moved through the stationary sewing station 32. Sewing machine 44 is supported by a sewing machine table 46 that can be automatically retracted from table 14 for necessary repairs. Transfer station 34 is the last work station for the garment piece positioner and seamer 10 and the garment piece is transferred from station 34 for further assembling.
Robot 16 includes a robot arm 36 and an attached robot presser foot 40 positioned above table 14 for precisely positioning a garment piece from loading station 30 to stations 32 and 34. Presser foot 40 is attached to a tool changer 41 located at one end of robot arm 36. Tool changer 41 and attached robot presser foot 40 can be positioned in both vertical and horizontal directions with respect to table 14. In addition, robot presser foot 40 can be rotated in a plane parallel to the planar surface 26 of table 14. Rotating presser foot 40 varies the orientation at which the robot presser foot 40 is attached to robot arm 36. The ability to move robot presser foot 40 in this manner allows presser foot 40 to selectively engage a garment piece loaded at loading station 30 and to then slidably move the engaged garment piece to stations 32 and 34. Presser foot 40 has a planar bottom surface 40A for engaging a garment piece that has been laid flat on table 14 at loading station 30.
Presser foot 40 is placed in an engagement position with a garment piece on table 14 by positioning bottom surface 40A against the garment piece such that the garment piece is sandwiched between presser foot 40 and table 14. Placing the presser foot 40 in the engagement position results in the garment piece being frictionally engaged by presser foot 40. Presser foot 40 is positioned on a selected portion of the garment piece when in the engagement position. With the presser foot 40 in the engagement position, the garment piece can be slidably moved along table 14 by moving presser foot 40 in a planar path. Presser foot 40 is sized so that bottom surface 40A has a surface area capable of engaging a sufficient amount of the garment piece's surface area so that the garment piece is maintained in a flat position as the garment piece is moved.
In the preferred embodiment, a felt-type material is attached to the bottom planar surface of presser foot 40. The felt-type material has a higher coefficient of friction than that of the planar surface 26 of table 14. This allows the presser foot 40 to maintain contact with the garment piece as it is moved across the surface of the table to the next workstation.
Robot 16 includes a robot processor (not shown) for directing the movement of robot arm 36 and attached robot presser foot 40. The robot processor uses location data to position presser foot 40 in the engagement position and to selectively position the garment piece at stations 32 and 34. The location data used to position presser foot 40 includes data which represents the fixed locations of sewing machine 44, transfer station 34, and the position of robot presser foot 40 when it is in an operator-defined home position. In addition, the location data includes data generated by the vision and control system 20 that represents the location in the loading station 30 of a randomly loaded garment piece. By processing the fixed location data, the robot processor can selectively engage a loaded garment piece and control the path of travel of robot arm 36 and the orientation of robot presser foot 40.
In order for robot 16 to engage a garment piece which has been randomly loaded onto table 14 at loading station 30, the position of the garment piece on table 14 must be inputed to the robot processor. Vision system 20 is provided to locate a garment piece loaded at the loading station 30 and to produce garment piece location data which represents the position of the garment piece on table 14. The garment piece location data is communicated from vision system 20 to robot 16 for use in controlling the positioning of a garment piece by robot 16.
Vision system 20 includes camera 52 which is supported above the loading station 30 by camera support 50. Camera 52 is used to take pictures of the loading station 30 to locate the position of a garment piece located in the loading station 30. To enable vision system 20 to locate a garment piece, a vision back-lighting apparatus 54 is positioned beneath table 14 at loading station 30. Vision back-lighting apparatus 54 shines light upwardly through the transparent, planar surface 26 of table 14. A garment piece placed at the loading station 30 blocks light produced by vision back-lighting 54. Vision system 20 locates the garment piece by detecting where light is being blocked on the table 14.
As shown in FIG. 3, vision system 20 divides loading station 30 into an inspection area 56 and a protection area 60. Protection area 60 is located at a forward section of loading station 30 and inspection area 56 is located in an adjacent, rear section of loading station 30. As will be described in more detail below, the protection area 60 is a safety feature designed to prevent the operation of robot 16 when an operator's hands have not been moved free of the table 14, and inspection area 56 is the area where the loaded garment piece is inspected and first engaged by robot 16.
In the preferred embodiment, garment piece positioner and seamer 10 is used to assemble a garment piece into a sleeve. The garment piece loaded onto table 14 at loading station 30 is a single sheet of fabric that has been folded over. As shown in FIG. 3, a garment piece G has been loaded into the inspection area 56 and includes a fold edge A, a sewing edge B, a cuff edge C, and a shoulder opening D. Garment piece G is folded over at fold edge A so that the garment piece has a bottom fabric layer and an overlapping, top fabric layer. The bottom and top layers of the garment piece are not connected to one another at sewing edge B, cuff edge C, and shoulder opening D. Garment piece positioner and seamer 10 functions to sew closed the bottom and top layers of a garment piece along and adjacent sewing edge B and to selectively position cuff edge C at transfer station 34.
An operations program controls the operation of garment piece positioner and seamer 10 such that successively loaded garment pieces are assembled into sleeves. As shown by FIG. 4, the operations program includes an inspection program, a guidance program, a learning program, a transfer station positioning program, and a reject program. As depicted in FIG. 4, the operations program includes a control program for controlling the overall operation of garment piece positioner and seamer 10.
Each of these programs performs a different function in controlling the garment piece positioner and seamer 10. The inspection program tests a garment piece loaded on the loading station 30 and determines whether the loaded garment piece should be rejected as unsuitable. The guidance program and pattern learning program provide for two different methods to selectively position a loaded garment piece at the sewing station 32 to sew the sewing edge B of the garment piece. The transfer station positioning program detects the location of the cuff edge C of a garment piece and selectively positions the cuff edge C at the transfer station 34. The reject program disposes of a loaded garment piece that has been determined by the vision system 20 to be defective.
With reference to the flow chart shown in FIG. 5, the inspection program operates as follows. Camera 52 is turned on to repeatedly take pictures of loading station 30. Vision system 20 first analyzes the pictures to determine if the designated protection area 60 is free of obstructions. A person's arm or a portion of the garment piece in the protection area 60 will result in vision system 10 detecting an obstruction. If an obstruction is detected, vision system 20 will not signal robot 16 to move from its home position to the loading station 30. Accordingly, robot 16 is prevented from moving to the loading station at any time during operation of the garment piece positioner and seamer 10 unless the loading station is free of obstructions. Continuously checking for an obstruction in protection area 60 is a safety feature that helps prevent a person loading garment pieces from being struck and injured by robot 16. In addition, the inspection program will not proceed until the garment piece being loaded is fully inserted into the inspection area 56 and no section of the garment piece is overlying protection area 60. The person loading the garment pieces is notified that the garment piece has not been properly loaded in the inspection area 56.
If the protection area 60 is free of obstructions, the inspection program proceeds and vision system 20 analyzes the pictures of the inspection area 56 to test if a garment piece of sufficient area has been loaded. The area of the loaded garment piece is calculated by determining what portion of the inspection area 56 is blocked by the loaded garment piece. The measure area of the garment piece is then compared to stored reference data to determine if a garment of sufficient area has been loaded.
The inspection program also analyzes the pictures and locates in inspection area 56 a reference axis 61 having an x-axis and a y-axis, as shown in FIG. 6. The reference axis 61 is formed on the loaded garment piece with the origin of the reference axis 61 located at the corner of the fold edge A and cuff edge C of the garment piece. The x-axis of the reference axis 61 fits approximately along fold edge A and the y-axis extends from the origin in perpendicular relation with the x-axis.
It is necessary to form a reference axis 61 on the loaded garment piece so that measurements can be made of the garment piece and the position of the garment piece can by determined. The garment piece loaded into inspection area 56 is loaded randomly and has no fixed or exact position in inspection area 56. The position of the garment piece is determined by locating the reference axis 61 on the garment piece.
Several steps are performed by vision system 20 to form the reference axis on the garment piece. As shown in FIG. 6, the inspection area 56 is segmented to include a first search region 62 and a second search region 64. The first search region 62 is located along a rearward section of the inspection area 56 and the second search region 64 is located along one side of the inspection area 56, as shown in FIG. 6.
The vision system 20 analyzes the first search region 62 to locate fold edge A of the garment piece and forms the x-axis of the reference axis along fold edge A. The vision system 20 also analyzes the second search region 64 to locate cuff edge C. Accordingly, at least a section of the fold edge A of the garment piece must be located in the first search region 62 for the reference axis to be formed on the garment piece. The locations of cuff edge C and fold edge A are processed by the vision system 20 to determine the location of the intersection of fold edge A and cuff edge C. The origin of the reference axis is located at this intersection. The x-axis is extended from the origin to approximately along fold edge A and the y-axis is extended perpendicular from the x-axis.
Once the reference axis has been formed on the garment piece in this manner, the inspection program makes measurements of the garment piece. In particular, the distance between the fold edge A and sewing edge B at various points along the x-axis is calculated. These distance measurements are then compared with reference distances that correspond to an ideal or suitable garment piece to determine if the loaded garment piece is defective. Other tests such as whether there are holes in the garment piece are also made. If the garment piece is determined to be defective then the reject program can be run to discard the garment piece.
Referring to FIG. 7, the reject program operates to discard a garment piece determined to be a reject. The reject program operates by first locating the position of the garment piece to be rejected. Robot 16 is then moved to loading station 30 and into engagement with the garment piece. Robot 16 is then moved in a planar path to a reject location 35 where the garment piece is moved off of the surface of the table into a reject bin (not shown).
If the garment piece is determined not to be a reject, the guidance program and/or the transfer station positioning program are run. Referring to FIG. 8, the guidance program is run when garment pieces having a sewing edge B with a known pattern are being loaded and reference coordinates corresponding to sewing edge B have been previously inputed. The guidance program determines where the sewing line 65, shown in FIG. 6, will be located on the garment piece and operates as follows. First, the coordinates of the sewing edge B on the reference axis are located and stored. The sewing edge coordinates are then compared with ideal sewing edge coordinates to determine if the garment piece falls within an ideal garment piece class.
If the garment piece falls within an ideal garment piece class, then an ideal sewing line is located on the garment piece. The ideal sewing line is spaced a selected distance from fold line A and extends generally adjacent to sewing edge B. Vision system 20 then directs robot presser foot 40 to move to loading station 30 and engage the garment piece at a selected distance from the ideal sewing line.
In order to engage the garment piece at a select distance from the ideal sewing line, robot arm 36 is rotated from its home position to the loading station 30 and the presser foot 40 is positioned over the garment piece. Once presser foot 40 is positioned over the garment piece, the presser foot 40 is rotated to align itself with the garment piece. The presser foot 40 is then lowered to engage the garment piece on the surface of the support table.
Robot presser foot 40 is then moved to the sewing station 32 such that the garment piece is slidably moved through sewing machine 44. The sewing machine is activated and the garment piece is selectively moved through sewing machine 44 such that the garment piece is sewn along the ideal sewing line. Any excess material extending outwardly from the ideal sewing line is cut and discarded by sewing machine 44 during the sewing process. The sewing machine 44 is deactivated after the garment piece passes therethrough and the guidance program is ended.
If the guidance program determines that a loaded garment piece is not ideal, then the garment piece is placed in an acceptable garment piece class and an acceptable sewing line is formed on the garment piece. The acceptable sewing line is formed a selected distance from the sewing edge B. Vision system 20 then directs robot presser foot 40 to move to loading station 30 and engage the garment piece a selected distance from the acceptable sewing line. The sewing machine 44 is then activated.
Robot presser foot 40 is moved to the sewing station 32 such that the garment piece is slidably moved through sewing machine 44. The garment piece is selectively moved through sewing machine 44 such that the garment piece is sewn along the acceptable sewing line. The sewing machine 44 is deactivated after the garment piece passes therethrough and the guidance program is ended.
Referring to FIG. 9, the learning program is used where garment pieces having a sewing edge B with an unknown pattern are being loaded. To determine the pattern of sewing edge B, the learning program first locates and stores a sewing edge coordinate spaced vertically from the x-axis. The incremental slope tangent to the sewing edge coordinate is also calculated and stored. A selected number of sewing edge coordinates and their tangential slopes are determined and stored. The sewing edge coordinates and their tangential slopes are processed to form a sewing line adjacent to sewing edge B.
The learning program then moves the robot presser foot to the loading station 30 and engages the garment piece a selected distance from the sewing line. The sewing machine 44 is activated and the robot presser foot 40 moved in a planar path to the sewing station 32. The robot is controlled to move the garment piece through the sewing machine 44 such that the garment piece is sewn along the ideal sewing line. Sewing the garment piece along the ideal sewing line connects the bottom and upper layers of the garment piece together generally along the sewing edge B and the learning program is completed.
Referring to FIG. 10, the transfer station positioning program operates in conjunction with either the guidance program or the learning program. The transfer station positioning program operates to determine the position of the cuff edge C in the inspection station 30 so that the cuff edge C can be selectively positioned at transfer station 34.
While the garment piece is at the loading station 30, the transfer station positioning program calculates and stores cuff-edge coordinates on the reference axis. The cuff-edge coordinates are processed to determine how the robot presser foot 40 will be positioned at transfer station 34. The transfer station positioning program controls the movement of the robot presser foot 40 from the sewing station 32 to the transfer station 34 and how the garment piece is positioned at the transfer station.
The control program for the garment piece positioner and seamer 10 controls the sequence of operations required for the garment pieces to be sewn and transferred. The control program is designed such that operations on two different garment pieces are performed simultaneously. For example, a first garment piece can be transferred from sewing station 32 to transfer station 34 while, at the same time, a second garment piece is being inspected at loading station 30.
In order to provide such control of the operations performed the garment piece positioner and seamer 10, various status signals are generated and used. The generated status signals include a loaded signal generated when a garment piece is loaded at inspection station 30; a sewn signal generated when a garment piece is sewn at sewing station 32; and a transferred signal generated when a garment piece has been transferred from transfer station 34.
In operation, garment piece positioner and seamer 10 operates to automatically position and assemble garment pieces into a sleeve or pant leg. The sequence of positioning and assembling a garment piece into an assembled sleeve is shown in FIGS. 11A-11E. As shown in FIGS. 1-3 and FIG. 11A, a garment piece is initially loaded in the inspection area 56 of loading station 30 and camera 52 is activated. The garment piece G1 is inspected by vision system 20 and a loaded status signal is generated. If the garment piece G1 fails inspection, the robot presser foot 40 engages the garment piece and slidably moves the garment piece to a rejection area 35, shown in FIG. 11E, where the garment piece is discarded into a reject bin (not shown).
If the garment piece passes inspection, vision system 20 makes further calculations of the garment piece as previously discussed. Upon completion the inspection, camera 52 is turned off. The robot 16 then moves from a home position to the loading station 30 and engages the garment piece G1, as shown in FIG. 11B. The garment piece is then slidably moved from the loading station 30 to the sewing station 32, as shown in FIG. 11C, where the garment piece is sewn generally along the sewing edge of the garment piece. After the garment piece is sewn, a sewn signal is generated and camera 52 is turned on again.
As shown in FIG. 11C, another garment piece G2 is loaded at the loading station 30 as soon as robot 16 has moved garment piece G1 to the sewing station 32. Vision system 20 inspects the second loaded garment piece and generates a loaded signal for garment piece G2. As will be discussed below, the loaded signal for garment piece G2 controls the positioning of the robot 16 after garment piece G1 has been transferred from the transfer station 34.
After sewing garment piece G1 at the sewing station 32, the robot presser foot 40 and garment piece G1 remain at the sewing station until a garment piece transfer signal is received. The garment piece transfer signal indicates that there is not another garment piece at transfer station 34. Once the garment piece transfer signal is received, the robot presser foot 40 moves garment piece G1 to the transfer station 34, as shown in FIG. 11D, where the cuff edge is properly positioned for a cuff to be attached to garment piece G1.
After the garment piece G1 has been transferred from transfer station 34, robot 16 determines if a loaded signal has been generated for garment G2. If a loaded signal has been generated, the robot 16 moves directly from the transfer station 34 to the loading station 30 and engages the loaded garment piece. The positioning and assembling of the engaged garment piece is then performed as previously discussed. If the a garment piece loaded signal is not detected, the robot 16 moves to the home position and awaits for the loading of another garment piece. Directly positioning the robot from the transfer station 34 to the loading station 30 when a garment piece loaded signal is generated improves the efficiency of the positioning and assembling process.
Garment piece positioner and seamer 10 provides an efficient device and method for positioning and assembling garment pieces. Garment piece positioner and seamer provides for precise positioning at various work stations of randomly loaded garment pieces.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, the present invention can be adapted to assemble other "flat" sewn garments such as shirt shoulder seams and side and crotch seams for briefs. Also, binding or edge trim could be applied. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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An apparatus for receiving a garment piece at a first workstation and moving the garment piece to a second workstation where the garment piece is seamed together. The apparatus includes a garment piece transfer system located adjacent to the first workstation for engaging the garment piece at the first workstation and for moving the garment piece to the second workstation. A vision and control system is located adjacent to the first workstation for determining the position of the garment piece at the first workstation and sending a control signal to the garment piece transfer system to engage the garment piece at the first workstation and move the garment piece to the second workstation. A sewing machine is located at the second workstation for seaming the garment piece together. The vision and control system also determines a parameter value for a selected parameter of the garment and places the garment into a reject or a non-reject class based on a comparison of the parameter value and a reference value. The garment piece is moved to the second workstation for sewing in response to the garment being placed in the non-reject class.
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BACKGROUND OF THE INVENTION
The use of double metal cyanide catalysts in the preparation of high molecular weight polyols is well-established in the art. For example, U.S. Pat. No. 3,829,505, assigned to General Tire & Rubber Company, discloses the preparation of high molecular weight diols, triols etc., using these catalysts. The polyols prepared using these catalysts can be fabricated to have a higher molecular weight and a lower amount of end group unsaturation than can be prepared using commonly-used KOH catalysts. The '505 patent discloses that these high molecular weight polyol products are useful in the preparation of nonionic surface active agents, lubricants and coolants, textile sizes, packaging films, as well as in the preparation of solid or flexible polyurethanes by reaction with polyisocyanates.
Polyols prepared using double metal cyanide catalysts contain catalyst residues that interfere with the subsequent use of the polyol in a subsequent polyurethane-forming reaction. More specifically, the catalyst residues will cause undesirable side reactions to form unwanted by-products such as allophanates. Attempts have been made in the past to remove the catalyst residues from the polyol after production of the polyol. For example, U.S. Pat. No. 4,355,188 teaches that removal of the double metal cyanide catalyst residues can be effected by adding to the polyol-residue mixture a strong base selected from potassium hydroxide, potassium metal, and sodium metal in order to convert the residues to ionic species, and adding ethylene oxide while the base is in contact with the polyol. The ionic species are then separated by filtration, for example by contact with an ion exchange resin, in order to provide a purified polyol essentially free of the residues. Unfortunately, the use and handling of sodium or potassium metal poses an unwanted fire and explosion hazard.
As another illustration, U.S. Pat. No. 4,721,818 discloses a process which comprises (a) incorporating into the catalyst residue-containing polyol an effective amount of an alkali metal hydride in order to convert the double metal cyanide complex catalyst into an insoluble ionic metal species separable from the polyol, and wherein the polyol hydroxyl groups are also converted to alkoxide groups, and (b) separating the insoluble ionic metal species from the polyol. Practical application of this process requires an intermediate step between steps (a) and (b) involving the incorporation of an effective amount of ethylene oxide ("EO") into the catalyst residue-containing polyol/alkali metal hydroxide mixture in order to "EO cap" the polyol, and hence convert the secondary hydroxyl groups of the polyol to primary hydroxyl groups. Unfortunately, when following this procedure, a relatively low percentage of primary hydroxyl groups is obtained using a conventional amount of base, as described more fully in Part C of the working example provided hereinbelow. If the amount of base is increased, the primary hydroxyl groups can also be increased; however, the base separation problem becomes more difficult.
As yet another illustration, U.S. Pat. No. 4,877,906 discloses a complicated method involving (a) treating a DMC catalyst residue-containing polyol with alkali metal compound(s), (b) filtering and (c) treating the filtered polyol with a phosphorus compound to convert the soluble portion of the DMC catalyst residue into an insoluble portion, (d) filtering again, and then (e) recovering the polyol. This process is not as simple and straightforward as might be desired, and the phosphorus compound itself can cause a residue problem in the polyol.
The processes disclosed in the above discussed patents have the disadvantage of being applicable only to specific polyols and utilizing treatment chemicals which themselves cause the formation of residues in the polyol. New approaches, for providing catalyst residue removal and efficient EO capping with a high percentage of primary hydroxyl groups in the polyol, that are inexpensive, generally applicable to all polyols, and do not themselves cause a residue problem would be highly desired by the polyol manufacturing community.
SUMMARY OF THE INVENTION
In one aspect, the present invention relates to a process for producing an ethylene oxide-capped polyol which is essentially free of catalyst residues, wherein the polyol is produced using a double metal cyanide catalyst, which comprises after polyol formation the steps of:
(a) contacting a catalyst residue(s)-containing polyol with an effective amount of an oxidant (preferably selected from the group consisting of: oxygen-containing gas(es), peroxide(s), acids, and combinations thereof) to cause said catalyst residue(s) to form insoluble residues that are insoluble in the polyol,
(b) separating the insoluble residues from the polyol to provide an essentially double metal cyanide catalyst residue-free polyol,
(c) treating said double metal cyanide catalyst residue-free polyol with a base to provided a base-treated polyol,
(d) contacting said base-treated polyol with ethylene oxide to produce an ethylene oxide-capped Polyol containing base, wherein at least a portion of the secondary hydroxyl groups on said polyol are converted into Primary hydroxyl groups, and
(e) separating said base from said ethylene oxide capped polyol to provide a purified ethylene oxide capped polyol.
In another aspect, the present invention relates to a process for producing an ethylene oxide-capped polyol which is essentially free of catalyst residues, wherein the polyol is produced using a double metal cyanide catalyst, which comprises after polyol formation the steps of:
(a) contacting a catalyst residue(s)-containing polyol with an effective amount of an oxidant (preferably selected from the group consisting of: oxygen-containing gas(es), peroxide(s), acids, and combinations thereof) to cause said catalyst residue(s) to form insoluble residues that are insoluble in the polyol,
(b) treating said insoluble residue-containing polyol with a base to provided a base-treated polyol,
(c) contacting said base-treated polyol with ethylene oxide to produce an ethylene oxide-capped polyol wherein at least a portion of the secondary hydroxyl groups on said polyol are converted into primary hydroxyl groups, and
(d) separating said insoluble residues from said ethylene oxide-capped polyol to provide a Purified polyol which is essentially free of catalyst-residues.
These and other aspects will become apparent from a reading of 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 multi-step Processes employing the use of an oxidant to insolubilize DMC catalyst residues in a polyol, followed by ethylene oxide (EO) capping of the polyol, provide a high purity EO-capped polyol. Using the processes of the present invention, the polyols are efficiently EO capped.
The oxygen-containing gas useful as an oxidant in the present invention is suitably any such gas, preferably oxygen, air, ozone, or a combination thereof, and the like.
The acid useful as an oxidant in the present invention is suitably any acid, such as a mineral acid or a Lewis acid such as sulfuric acid, phosphoric acid, hydrochloric acid, nitric acid, antimony pentachloride, boron trifluoroetherate, toluene sulfonic acid, combinations thereof, and the like. The preferred acid is sulfuric acid.
The peroxide useful as an oxidant in the process of the present invention is suitably any peroxide, or hydroperoxide such as hydrogen peroxide, t-butyl peroxide, t-butyl peroxypivalate, decanoyl peroxide, lauroyl peroxide, propionyl peroxide, acetyl peroxide, combinations thereof, and the like.
The treatment time for contacting the DMC catalyst-containing polyol with the oxidant is generally between a few minutes or less and ten hours or more, preferably between about one and about four hours. The treatment temperature is suitably between 70° C. and about 140° C., preferably between about 90° C. and about 120° C.
The oxidant(s) is generally employed, if in liquid form, in a total amount of between about 5% and about 0.02%, preferably between about 0.40% and about 0.15% based upon the total weight of the polyol and may be adjusted based upon the total amount of DMC catalyst employed, it is used in an amount sufficient to cause formation of the insoluble catalyst residues.
In a particularly advantageous aspect of the present invention, an oxygen-containing gas or hydrogen Peroxide is utilized in combination with sulfuric acid to produce enhanced efficacy of separation of the treated DMC catalyst residue from the polyol. Alternatively, sulfuric acid or hydrogen peroxide are utilized singly to provide good separation of the catalyst residue from the polyol.
The base useful in the processes of the present invention is suitably selected from the group consisting of alkalii metal hydroxides, alakaline earth metal hydroxides, alkali metal hydrides, alkaline earth metal hydrides, alkali metal alkoxides containing between one and eight carbon atoms per molecule, alkaline earth metal alkoxides, and combinations thereof. The alkali metal alkoxides and alkaline earth metal alkoxides useful in the process of the present invention generally have between one and 23, preferably between one and eight, more preferably between one and six, carbon atoms per molecule. Suitable alkali metal alkoxides include, for example, sodium methoxide, potassium methoxide, lithium methoxide, as well as the ethoxides, propoxides, butoxides, pentoxides, dodecyloxides,and the like. Suitable alkaline earth metal alkoxides include, for example, the calcium and magnesium salts of the above-mentioned alkoxides. Other useful bases include sodium hydroxide, potassium hydroxide, sodium hydride, potassium hydride, and combinations thereof, with the preferred base being sodium hydroxide. Molar ratios of hydroxyl groups on the polyol to alkali metal alkoxide or alkaline earth metal alkoxide of from 1:1 to 500:1 are contemplated. In order to enhance the rate of the ethylene oxide capping catalyzed by the base it is desirable to heat the mixture. Heating at a temperature within the range of from about 40° C. to about 150° C. until a substantial portion of the ethylene oxide has reacted as evidenced by a drop in pressure, typically between about one to about eight hours has been found advantageous. Removal of base from the polyol is preferably effected by treatment with a silicate compound, as described more fully hereinbelow.
The polyols utilized in the present invention are typically prepared by condensing an alkylene oxide, or a mixture of alkylene oxides using random or step-wise addition, with a polyhydric initiator or mixture of initiators, in the presence of a double metal cyanide catalyst. Illustrative alkylene oxides include ethylene oxide, propylene oxide, butylene oxide, amylene oxide, aralkylene oxides such as styrene oxide, and combinations thereof, and the like. The most preferred alkylene oxide is propylene oxide or a mixture thereof with ethylene oxide using random or step-wise oxyalkylation.
The polyhydric initiator used in preparing the polyol reactant includes the following and mixtures thereof: the aliphatic triols such as glycerol, propoxylated glycerol adducts, trimethylolpropane, triethylolpropane, trimethylolhexane, and diols such as ethylene glycol, 1,3-propylene glycol, dipropylene glycol, butylene glycols, propoxylated glycol adducts, butane diols, pentane diols, and the like.
The alkylene oxide-polyhydric initiator condensation reaction is carried out in the presence of a double metal cyanide catalyst. Without wishing to be bound by any particular theory, it is speculated by the present inventor that unsaturated end groups result in monofunctional species that act as chain stoppers in elastomer formation. In polyol synthesis with KOH catalysis the unsaturation formed increases as a direct function of equivalent weight. Eventually conditions are established wherein further propylene oxide addition fails to increase the molecular weight. In other words the use of alkali catalysts to produce high molecular weight, hydroxy terminated polyoxypropylene ethers results in a substantial loss in hydroxy functionality. With double metal cyanide catalysis much less unsaturation is formed allowing higher equivalent weight polyols to be prepared.
The double metal cyanide complex class catalysts suitable for use and their preparation are described in U.S. Pat. Nos. 4,472,560 and 4,477,589 to Shell Chemical Company and U.S. Pat. Nos. 3,941,849 and 4,335,188 to General Tire & Rubber Company. The teachings of the foregoing patents are incorporated herein by reference.
Double metal cyanide complex catalysts found Particularly suitable for use are zinc hexacyanometallates of formula:
Zn.sub.3 [M(CN)6].sub.2.xZnCl.sub.2.ySOLVENT.zH.sub.2 O
wherein M may be Co(III), or Cr(III) or Fe(II) or Fe(III); x, y, and z may be fractional numbers, integers, or zero and vary depending on the exact method of preparation of the complex, preferably each independantly being between 0 and 15, and the solvent is Preferably an ether, such as glyme or diglyme, or an alcohol, such as ethanol, isopropanol, n-propanol, t-butanol, isobutanol, or n-butanol.
After the double metal cyanide complex catalyst residue has been converted to the insoluble ionic metal species, it can be separated from the polyol by conventional methods such as filtration using, for example, diatomaceous earth, or passing through an acidic ion exchange resin as taught in U.S. Pat, No. 4,355,188.
Separation of the treated residue from the polyol is suitably effected utilizing well-known techniques such as filtration, extraction, centrafugation, or a combination thereof alone or in combination with conventional filter aids such as diatomaceous earth, alumina, magnesium silicate (MAGNESOL), CELITE, silica gel, or the like. Extraction, if used, is suitably conducted with water in the presence or absence of a nonpolar solvent, such as petroleum ether, ligroin, toluene, and the like. In addition to facilitating separation, it has been discovered that treatment with a silicate compound also converts polyol alkoxide groups to hydroxyl groups and absorbs the resulting alkali metal hydroxide. Treatment with a silicate compound is preferred for base catalyst removal.
Typically, the amount of silicate added will be from about 0.1 to about 5 parts by weight per each 100 parts by weight of the polyol containing catalyst residue mixture and the mixture will be heated for 1 to 12 hours at a temperature of from about 80° C. to about 150° C. before filtration. It is preferred that the silicate can be finely divided and have a high surface area.
As used herein, the term "molecular weight" is intended to designate number average molecular weight.
While the invention has been described above with reference to specific embodiments thereof, it is apparent that many changes, modifications and variations can be made without departing from the inventive concept disclosed herein. Accordingly, it is intended to embrace all such changes, modifications and variations that fall within the spirit and broad scope of the appended claims. All patent applications, patents and other publications cited are incorporated herein by reference in their entirety.
EXAMPLE 1
Part A--Preparation of a High Molecular Weight Polyol Using a Double Metal Cyanice Catalyst
A propoxylated glycerine precursor 100 g (133.6 eq. wt., 0.748 eq) was added to a 1 liter autoclave. Zinc hexacyanocobaltate (0.3 g) was added and the autoclave was flushed with nitrogen three times. The mixture was heated to 100° C. Propylene oxide (30 g) was added and it reacted as evidenced by a drop in pressure. Propylene oxide was fed into the reactor at a rate to maintain the pressure below 20 psi. 609.0 g of PO was added within two hours. At this point 548 g of the mixture was removed to allow space for more epoxide leaving 162.1 grams in the reactor. An additional 340 g of propylene oxide was added over a period of 1.5 hours to produce a polyol containing predominantly secondary hydroxyls with a molecular weight of 10,000, hydroxyl number 16.8.
Part B (Comparative Example)--EO Capping in Presence of Double Metal Cyanide Catalyst--Low Percentage of Primary Hydroxyl Groups Obtained
A polyol containing active double metal cyanide catalyst which was prepared as described in Part A above was heated to 110° C. and ethylene oxide (50 g, 10 wt. %) was added. The mixture was allowed to react for 3 hours at which time the pressure was no longer decreasing. MAGNESOL (5.5 g) and CELITE (2.8 G) were added and the mixture was heated at ambient pressure for one hour then vacuum stripped for one hour and filtered. The polyol was analyzed and found to contain 28% primary hydroxyl groups.
Part C (Comparative Example)--EO Capping by Adding KOH to a Polyol Containing Double Metal Cyanide Catalyst; Low Percentage of Primary Hydroxyl Obtained
A polyol containing active DMC catalyst, which was prepared as described in Part A above, was combined with KOH (0.75 g, 0.15 wt. %). Ethylene oxide (50 g, 10 wt. %) was added and the mixture was allowed to react for 3 hours at which time the pressure was no longer decreasing. The polyol was treated with MAGNESOL 5.5 g and CELITE 2.8 g and allowed to stir at ambient pressure for one hour, then vacuum stripped for 2 hours and filtered. The polyol was analyzed and found to contain 37% primary hydroxyl groups.
Part D--Removal of Double Metal Cyanide Catalyst by Peroxide Treatment Followed by EO Capping using KOH--High Percentage of Primary Hydroxyl Groups Obtained
A polyol containing active double metal cyanide catalyst, which was prepared as described in Example 1, was heated to 110° C. and 30% hydrogen peroxide (3.0 g, 0.2 wt. % H 2 O 2 ) was added. The mixture was heated at 110° C. for one hour and then CELITE (10 g, 2 wt. %) was added and the mixture was vacuum stripped for one hour and then filtered. The polyol was analyzed by X-ray fluorescence and found to contain 0 ppm cobalt and 0 ppm zinc.
KOH (0.75 g, 0.15 wt. %) was added and the mixture was vacuum stripped in an autoclave at 100° C. for one hour. Ethylene oxide (50 g, 10 wt. %) was added and the mixture was allowed to react for 3 hours. The mixture was treated with MAGNESOL (5.5 g) and CELITE (2.8 g) and heated at 110° C. for one hour then vacuum stripped for one hour and filtered. The polyol was analyzed and found to contain 75% primary hydroxyl groups.
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A process for producing an ethylene oxide-capped polyol which is essentially free of catalyst residues, wherein the polyol is produced using a double metal cyanide catalyst, which comprises after polyol formation the steps of: (a) contacting a catalyst residue(s)- containing polyol with an effective amount of an oxidant (preferably selected from the group consisting of: oxygen-containing gas(es), peroxide(s), acids, and combinations thereof) to cause said catalyst residue(s) to form insoluble residues that are insoluble in the polyol; (b) separating the insoluble residues from the polyol to provide an essentially double metal cyanide catalyst residue-free polyol; (c) treating said double metal cyanide catalyst residue-free polyol with a base to provided a base-treated polyol; (d) contacting said base-treated polyol with ethylene oxide to produce an ethylene oxide-capped polyol containing base, wherein at least a portion of the secondary hydroxyl groups on said polyol are converted into primary hydroxyl groups, and (e) separating said base from said ethylene oxide capped polyol to provide a purified ethylene oxide capped polyol. In another aspect of the invention, the catalyst residue separation step is effected after EO-capping of the polyol.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/044,610, filed Apr. 14, 2008 and incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to an apparatus for and method of installing a window or panel within a poured concrete wall.
DESCRIPTION OF RELATED ART
Concrete walls offer resistance to rot, rodents, termites and fungus, and are not toxic. Solid concrete walls possess greater flexural and compressive strength than concrete blocks and can better resist lateral pressure. They are also more fire resistant and more impervious to water. These advantages make a poured concrete wall an excellent choice as a foundational wall.
Glass block windows or panels provide functional as well as aesthetic purpose. They offer medium privacy, allow light transmission, form a sound barrier, and enhance the beauty of the decor. Furthermore, glass blocks are durable and easy to clean.
Glass block is typically installed in a poured concrete wall after the wall is poured. It would be desirable to pour the wall with the glass block window in place, rather than installing the block after the wall is poured.
BRIEF SUMMARY OF INVENTION
A method for installing a window in or within a poured concrete wall is disclosed. The method comprises a kit with at least one window block. It also includes a first spacer adapted to abut a first side of the glass block and a second spacer adapted to abut a second side of the window block. The method implementing the kit includes the steps of erecting a wall form comprising of a first and a second form, locating the kit in between the first and second form, placing concrete into the wall form around the window kit, removing the first and second wall forms, and removing the first and second spacers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a perspective view of an assembled window kit.
FIG. 2 is an angled side view of the assembled kit.
FIG. 3 is an exploded view of the kit showing all the components.
FIG. 4 is a perspective view of the metal hanger.
FIG. 5A is a cross-sectional side view of the assembled kit installed in a wall form.
FIG. 5B is a top view of the assembled kit installed in a wall form.
FIG. 6 is a perspective view of the cured wall with the window in place.
FIG. 7 is a table listing the dimensions of the inside and outside spacers according to the thickness of the desired window.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described with reference to the figures, wherein like reference numerals are used to refer to like elements throughout. It is to be appreciated that the various illustrations are not necessarily absolute, and in particular that the size of the components are suitable for the example and for facilitating the understanding of the method. 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 can be practiced without these specific details. Additionally, other embodiments of the invention are possible and the invention is capable of being practiced and carried out in ways other than as described. The terminology and phraseology used in describing the invention is employed for the purpose of promoting an understanding of the invention and should not be taken as limiting.
Disclosed is a system and method for installing a device in a poured concrete wall. Example devices which can be installed in a poured wall using the disclosed system and method include windows, (e.g., glass block, hopper, etc.), doors, vents and pipe sleeves. Conventional method of installing such devices in a poured concrete wall include making a form, placing the concrete into the form and around the device preform, then installing the desired device into the opening left from the device preform. In the current disclosure, the method hangs the device between the forms for the poured wall prior to pouring concrete. The device is held in place by the cured concrete wall and does not have to be separately installed after the wall is formed. This eliminates any need for custom preparation in the making of a form and also eliminates any need for custom fitting of the device during installation and after the concrete wall has been constructed.
The system and method will be described below with respect to the installation of a glass block window in a poured concrete wall. It is to be appreciated that the system and method are applicable to the installation of other devices in poured concrete walls, such as doors, vents and pipe sleeves. As used herein, the term “poured” refers to any method well known to one of ordinary skill in the art including pouring the concrete, pumping the concrete into the desired position and placing the concrete via a gravity fed method.
With reference to FIG. 3 , the components of an assembly or kit 10 are shown in an exploded view. A pre-assembled panel 16 , such as a glass block panel, can include several individual glass blocks 14 that are held together via an adhesive, such as a silicone adhesive. The panel 16 can vary in size, shape, number of blocks, or it can be a composite of two or more window types. For example, as shown in FIG. 6 , the window can include more than one row of glass blocks 14 , and also can contain a fully transparent window that can be adapted to open to allow for air circulation. Additionally, the kit can only contain a window panel 16 and can not include glass blocks 14 .
With further reference to FIGS. 1-3 , and in one embodiment, the panel 16 can be dispersed between a first and second spacer 12 , 18 respectively. In another embodiment, the first or second spacer 12 , 18 can be, for example, a 2½ inch thick rectangular prism whose length and width substantially correspond to the length and width of the pre-assembled panel 16 . The second spacer 18 can be installed on the opposing side of the panel 16 with generally the same dimensions as first spacer 12 . Additionally, in one embodiment, the second spacer 18 can have an angled edge 20 , to be discussed later.
Furthermore, the spacers 12 , 18 can have dimensions that are substantially equivalent to the width w and height h dimensions of the panel 16 . Moreover, the thickness of the spacers 12 , 18 and overall thickness of the kit 10 can tend to be equivalent to the desired thickness of the wall to be constructed. The spacers 12 , 18 in one embodiment can be formed out of extruded 2 lb. polystyrene foam, but should not be solely limited to these examples.
As an additional example, a 7⅝ inch thick wall can require that the overall thickness of the kit 10 be equivalent to 7⅝ inches. In one embodiment, the first spacer 12 can have a thickness of 2½ inches and second spacer 18 can have a thickness of 2 inches and panel 16 can have a thickness of about 3⅛ inches. Thus, removal of the spacers 12 , 18 can result in a recess on both sides of the panel 16 . Accordingly, in a 7⅝ inch thick wall the inner recess can be 2½ inches and the outer recess can be 2 inches. However, the spacers 12 , 18 can be customized to fit any desired width w, height h, and thickness to meet the specifications and requirements of an application.
With reference to FIG. 7 , the example dimensions are listed showing various sizes of spacers 12 , 18 and panels 16 . It should be noted that actual dimensions can vary slightly, as the nominal and actual dimensions are listed. The nominal dimensions are noted to simplify calculations for brick masons and other tradesmen. For example, if a wall to be constructed has an overall nominal thickness of 7¼ inches (7⅛ inches actual) and a nominal dimensioned 32×16 inch panel 16 (31×15½ inches actual dimension) is to be a installed within the wall, the first spacer 12 (inside piece) can have dimensions of 31¼″×15⅝″×2″ and the second spacer 18 (outside piece) can have dimensions of 31¼″×16¼×2″. It should also be noted that the difference in height between the first and second spacer is due to the angled edge 20 . Therefore, as the actual height of the panel 16 is 15½ inches and actual width is 31 inches, and as the spacers 12 , 18 both have a relative height of 15⅝ inches and width of 31¼ inches, a space of about ⅛ inch remains around the sides and bottom while the top of the panel 16 is flush with the opening. As a result of the ⅛ inch, if a glass block 14 were to become damaged and require a replacement, the dimension differences between the spacers 12 , 18 and panel 16 can aid in removal of one or more glass blocks 14 from a finished wall.
As discussed above and shown in FIGS. 1 and 2 , the second spacer 18 can have an angled edge 20 . The panel 16 and related angled edge 20 are meant to be the exterior portion of the finished window 54 . After the wall has cured, the angled edge 20 , forms a wash 50 , shown in FIG. 6 , in the finished wall 52 below the panel 16 so moisture flows away from the exterior recess. Accordingly, the side of the second spacer 18 facing away from the panel 16 can have a larger surface area than the side of the second spacer 18 abutting the panel 16 .
As shown in FIGS. 1-3 , a flex band 24 can be installed around the panel 16 and the first and second spacers 12 , 18 along the width, w, of the first and second spacers. The flex band 24 can provide enough force to hold the first and second spacers 12 , 18 in place around the panel 16 . More than one flex band 24 can be used to hold the kit together, depending on the strength of the flex band and the weight of the kit 10 . In another embodiment, if the flex band 24 is a single length having two opposing ends, a fastener 22 can be used to connect the two ends of the flex band 24 together around the kit 10 . In yet another embodiment, the flex band 24 can be a continuous loop, thus a fastener 22 would not be required. Therefore, if a plurality of kits were being constructed having a standard number of glass blocks, a continuous loop flex band can be used to eliminate the fastener 22 . However, if constructed kits were variable as to width, w, height, h and thickness, one flex band 24 would not appropriately hold the kit together, fasteners 22 can be used.
In yet another embodiment, the spacers 12 , 18 can be secured directly to the panel 16 . This can be done by placing a small amount of glue or epoxy onto each glass block 14 , contacting the spacers 12 , 18 to the panel 16 and applying pressure to the spacers 12 , 18 to form a secure connection. It should be noted that flex bands 24 are optional in this embodiment. After both spacers 12 , 18 have been secured to the panel 16 , a bead of epoxy can be laid around the edge between the panel and each spacer. The dried glue acts as barrier and prevents the viscous concrete from flowing between the panel 16 and each spacer 12 , 18 at the time of construction. In a related embodiment, the spacers 12 , 18 can be substantially wrapped in packing tape. The packing tape is designed to protect the foam spacers 12 , 18 and also aids in separating the spacers 12 , 18 from the panel 16 after construction of the wall is complete.
Additionally, a handle feature can be added to assist in transporting the kit 10 . By using two fasteners 22 at opposing ends of the shorter flex band and secured to the flex band 24 , the shorter flex band creates a handle to provide a single-handed carrying method for the kit 10 . In another embodiment, more than one short flex band can be attached to more than one flex band 24 , for increased load capability. For example, a first short flex band can be attached to a first flex band 24 , and a second short flex band can be attached to a second flex band 32 . The first and second short flex bands can then be fastened together to create one handle, thus adding additional stability and increased durability.
In yet another embodiment, a large number of glass blocks in a single panel 16 can require that the fasteners 22 can be made of a metal or metal alloy. The fastener 22 can be required to hold the two ends of the flex band 24 together while being subjected to the large amount of force produced by the weight of the panel 16 . However, less demanding applications can permit the use of a plastic fastener 22 . In yet another embodiment, fasteners 22 can be integrated into the two ends of the length of flex band 24 . The fasteners can posses other means of fastening the two ends of the flex band 24 together, such as hook and loop fasteners or an interlocking means.
With further reference to FIGS. 1-3 , 90° side protectors 26 can be positioned at the four edges of the kit 10 with respect to the width w where the flex band 24 would contact the spacers 12 , 18 . Depending on the strength of the flex bands 24 , a large amount of force can be subjected onto the corner of each spacer 12 , 18 and can create a groove in the corners of the spacers 12 , 18 which would possibly result in unwanted movement between the glass block panel and spacers 12 , 18 . Thus, the side protectors 26 would protect the corners of the spacers 12 , 18 from the concentration of force that the flex bands 24 can apply and prevent any component shifting. Additionally, side protectors 26 can protect the spacers 12 , 18 during shipment to the construction site and during the placement and pouring process. In another embodiment, a 30° protector 28 is positioned on the lip 30 of second spacer 18 which protects the lip 30 of the second spacer during shipment to the site and during the placement and pouring process. The edge of the 30° protector 28 that contacts the second spacer 18 can be coated with an adhesive, so that the 30° protector 28 stays in contact and protects the second spacer until the second spacer is separated from the panel 16 . In an alternative embodiment where the spacers 12 , 18 are glued to the panel 16 , side protectors 26 can not be required.
As shown in FIG. 1 , an internally threaded metal hanger 34 can be located at each of the upper corners of the panel 16 . As shown in FIG. 4 , the metal hanger 34 can have flanges 40 that can permit a second flex band 32 to pass over the flange 40 and secure the metal hanger 34 to the panel 16 in a direction that can be parallel to the height, h. The flanges 40 can be welded to the hanger 34 . The metal hanger 34 can be, for example, a hex-coupling nut or rod coupler, with internal female threading 38 that is adapted to accept a male threaded connection. For this application, an acceptable hex-coupling nut size can be about a ¼ inch. Also, since the metal hanger 34 has a pair of flanges 40 , an additional second flex band 32 can be used to provide additional strength with which to hold the metal hanger 34 to the panel 16 . In an alternative embodiment, the hex coupling nuts are secured directly to the panel 16 using an adhesive, such as an epoxy or a waterproof two-sided tape. In this embodiment, the flange 40 can be eliminated. Accordingly, the metal hanger 34 sans flanges 40 can be glued directly to each side of the panel 16 .
In yet another embodiment, and as shown in FIGS. 1 and 5A , wall anchors 48 are secured, for example glued, in between the individual glass blocks 14 of panel 16 during assembly of the panel. The wall anchors 48 extend perpendicularly from the panel 16 into the concrete wall, providing additional window reinforcement and stability. Additionally, the number of wall anchors 48 can be tailored to the specifications of the builder, so that the panel 16 is adequately secured to the poured wall.
A method of using the window kit is hereby described.
After a panel 16 is constructed from one or more glass blocks 14 and wall anchors 48 secured into place, metal hangers 34 are secured to the upper corners of the panel 16 . If the second flex band 32 has a length and is not a continuous band, the flex band is fastened together via a fastener 22 . After the metal hanger 34 has been fastened to the panel 16 , the spacers 12 , 18 are attached to each side of the panel 16 . Side protectors 26 are placed on the edges of each spacer 12 , 18 , and the flex band 24 is then wrapped around the two spacers and contacting the protectors 28 , which secures the two spacers to the panel 16 . At this point or any point prior, the 30° protector 28 can be connected to the angled edge 20 on the second spacer 18 . After assembly of the kit 10 is completed, the entire window assembly is shipped to a construction site in its assembled form.
With reference to FIGS. 5A and 5B , in preparation for pouring concrete to form a freestanding wall, opposing wall forms 42 can be erected. The opposing wall form 42 is made up of two freestanding elements that act as the barrier for the poured concrete. Thus, when the concrete is poured into the wall form 42 , the free standing elements will hold the concrete in place, allowing it to cure. Once the concrete has cured, the wall form 42 is removed, revealing the concrete wall. This process is well known to a person of skill in the art and therefore will not be discussed further.
Once the wall forms 42 are erected, a male threaded bolt 46 is inserted through a hole in a mount 44 or cross-bar and secured together. This process is repeated for a second male threaded bolt 46 and a second mount 44 . Then the male threaded bolt 46 is secured into the metal hanger 34 at each corner of the kit 10 . Once the bolt and mount assembly is securely fastened to the kit 10 via the metal hanger 34 , the window kit 10 is then lowered in between the wall forms 42 until the mount 44 rests on the top edges of the wall forms 42 , thus hanging the window kit 10 at the desired height and position, as shown in FIG. 5A . In another embodiment, the metal hanger 34 can be adapted to be secured to internal concrete wall reinforcements, such as reinforcing bars, or “rebar”.
Additionally, as shown in FIG. 5B , the spacers 12 , 18 can be in flush contact with the wall form 42 . The window kit 10 should fit tightly into the wall form so that it prevents any concrete from flowing between each spacer 12 , 18 and corresponding wall form.
After the window kit 10 is securely in place, concrete can be poured into the wall form 42 and around the window kit 10 . If the desired location of the window makes the window kit 10 accessible after the pouring of and drying of the concrete, any remains of the kit, such as flex bands, can be removed. Once the concrete has cured and wall forms removed, the spacers 12 , 18 can be removed. What is left is panel 16 window securely fastened to the concrete wall, with a wash 50 on the exterior portion of the wall 52 of the finished window 54 , as shown in FIG. 6 .
The invention has been described with reference to the example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Examples embodiments incorporating one or more aspects of the invention are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.
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A method for installing a window in or within a poured concrete wall is disclosed. The method comprises a kit with at least one window block. It also includes a first spacer adapted to abut a first side of the glass block and a second spacer adapted to abut a second side of the window block. The method implementing the kit includes the steps of erecting a wall form comprising of a first and a second form, locating the kit in between the first and second form, placing concrete into the wall form around the window kit, removing the first and second wall forms, and removing the first and second spacers.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Substitute for application Ser. No. 12/804,315
[0002] Filing Date: Jul. 19, 2010
[0003] Previous filing: WO/1998/031406 Holistic Breast Patch,
[0004] International Application Number: PCT/US1997/002461
[0005] Filing Date: 14 Feb. 1997
[0006] Publication Date: 23 Jul. 1998
[0007] U.S. patent application Ser. No. 09/552,159, abandoned 19 Mar. 2002
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0008] Not applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0009] Not applicable
BACKGROUND OF THE INVENTION
[0010] This invention endeavors to provide a safe, comfortable, easy to use device to relieve the pain and discomfort associated with postpartum breast milk engorgement, to expedite the suppression of lactation for women who choose not to breast-feed, and to aid in the treatment of prolactin dependent and related diseases and disorders. This is accomplished by inhibiting the production of prolactin which suppresses lactation.
[0011] After pregnancy, a woman naturally produces breast milk for a period of time. The length of time for postpartum milk production varies depending upon whether or not the mother breast-feeds and how long she breast-feeds. For breast-feeding mothers, milk production can continue up to twenty four months or longer. For non-breast-feeding women, the duration is impacted by whether or not and for how long her breasts were pumped or stimulated to produce milk. Women who choose not to breast-feed experience discomfort and pain due to breast engorgement. Relief is sought through breast pumping and stimulation which prolongs production and delays suppression of milk production, ice packs, breast binding which can cause mastitis and various other means that have proven to be dangerous or otherwise unsuccessful.
[0012] According to Treatment for Lactation Suppression, Little Progress in One Hundred Years (Am J Obstet Gynecol 1998; 179:1485-90) “Engorgement and breast pain may encompass most of the first postpartum week. Up to one third of women who do not breast-feed and who use a brassiere or binder, ice packs, or analgesics may experience severe breast pain. Specific studies of nonpharmacologic methods of lactation suppression were limited and inconclusive. Available data suggest that many women using currently recommended strategies for treatment of symptoms may nevertheless experience engorgement or pain for most of the first postpartum week.
[0013] There is no Federal Drug Administration (FDA) approved treatment for the relief of breast milk engorgement pain. Prescription drugs such as, parlodel (bromocriptine mesylate), a previously FDA approved lactation suppressant and estrogens and androgens (gonadotrophic hormones) have been prescribed and are possibly still being used as a prolactin inhibitor to suppress milk production for breast engorgement relief and to treat prolactin related disease and conditions.
[0014] Parlodel inhibits the secretion of the hormone prolactin from the pituitary gland. It also mimics the action of dopamine, a chemical lacking in the brain of a person with Parkinson's disease. Palodel and estrogens and androgens have been used to treat a variety of medical conditions, including lactation suppression, Infertility, menstrual problems such as galactorrhoea and prolactin dependent amenorrhea, with or without excessive production of milk. However, it has been well documented in the literature that these drugs and hormones have produced adverse effects including death. Some of the documentation is in the literature that follows.
[0015] To address problems involved in the prior art, reference is made to the Dec. 1, 1989 FDA Consumer which states “FDA has asked that the manufacturer of the drug Parlodel (bromocriptine) stop labeling the drug for use in drying up milk production and preventing breast engorgement in mothers who don't breast-feed. (Parlodel is approved for treatment of Parkinson's disease.)
[0016] In a related move, FDA requested that the manufacturers of products containing estrogen and androgens stop labeling these gonadotrophic hormones as lactation suppressants. FDA's Fertility and Maternal Health Drugs Advisory Committee suggested the changes, in part, because these drugs, which can have serious side effects, benefit only 10 percent of the women who use them to suppress lactation. Also, the drugs' effectiveness is also diminished because of the high occurrence of rebound. Breasts become engorged again after the woman stops taking the drugs.”
[0017] The Health facts newspaper Sep. 1, 1994, edition states “Parlodel, a drug widely used to suppress breast milk following childbirth has finally been withdrawn by its manufacturer Sandoz, five years after it was found to be dangerous and ineffective. The action came on the heels of a national TV investigative report and a lawsuit against the FDA by the Public Citizen's Health Research Group and the National Women's Health Network.
[0018] The two consumer groups took legal action against the FDA because the agency failed to ban the drug as a lactation suppressant after receiving reports of its dangers. Since 1980, according to Public Citizen, the FDA had received 531 adverse reactions reports, including 32 deaths, 14 from stroke and five heart attacks. Among the nonfatal reactions, there were 36 strokes, 14 heart attacks, and 98 seizures; many of these cases involve permanent disability. Underreporting is a very real possibility as the FDA's post market surveillance system is notoriously weak (Rx News August 1994).”
[0019] In the Oct. 1, 1994, issue of Trial Magazine, it is stated “Under a barrage of consumer criticism and a lawsuit, the manufacturer of Parlodel said it will no longer market the drug as a lactation suppressant. The drug has been blamed for the deaths of at least 32 new mothers and for medical problems in hundreds of women since it received U.S. Food and Drug Administration (FDA) approval in 1980.”
[0020] In the United States, the sharp restriction in the use of pharmaceuticals to aid the suppression of breast milk and the discomfort and pain from engorgement, has resulted in essentially no recognized mechanism for lactation suppression and relieving the discomfort of breast milk engorgement. The formerly used pharmaceutical items are no longer available as a prescription for lactation suppression. They are however, offered online through Canadian and United Kingdom Pharmacies without a prescription. This availability again exposes mothers to the serious documented risks. Accordingly, there is an urgent need for an alternative method which will relieve the discomfort of breast engorgement pain and expedite the suppression of breast milk production in a safe, convenient, efficient, and legal manner.
[0021] “There is increasing evidence that prolactin (PRL), a hormone/cytokine, plays a role in breast, prostate, and colorectal cancers via local production or accumulation.” (Cancer Res 2009; 69(12):5226-33) Breast cancer is the most common cancer among American women, except for skin cancers. The chance of developing invasive breast cancer at some time in a woman's life is a little less than 1 in 8 (12%). Breast cancer is the second leading cause of cancer death in women, exceeded only by king cancer.” (American Cancer Society, Dec. 9, 2011) Other than skin cancer prostate cancer is the most common cancer in American men. About 1 man in 6 will be diagnosed with prostate cancer during his lifetime. Prostate cancer is the second leading cause of cancer death in American men, behind only lung cancer.” (American Cancer Society Oct. 12, 2011)
[0022] Current treatment of prolactin dependent and related diseases and conditions involves the use of neutralizing prolactin receptor antibodies and antigen binding fragments, through pharmaceutical agents including dopamine antagonists and monoclonal drugs. These pharmaceutical drugs effect the amino acid sequence of the extracellular domain of the prolactin receptor and the nucleic acid sequence whereby the pharmaceutical composition antagonizes the prolactin receptor mediated signaling. (US Fed News Service, Including US State News, Jun. 16, 2011, WIPO Assigns Patent To Bayer Schering Pharma for “Neutralizing Prolactin Receptor Antibodies and their therapeutic use.” abstract) Recent studies indicate “Several PRL receptor (PRLR) antagonists have been identified in the past decades, but their in vivo growth inhibitory potency was restricted by low receptor affinity, rendering them pharmacologically unattractive for clinical treatment.” PEDS Oxford Journals; Life Sciences & Medicine; Volume 24, Issue 11)
BRIEF SUMMARY OF THE INVENTION
[0023] Postpartum milk suppression will readily occur without intervention. This process, however can be lengthy, tedious, and is usually painful without the aid of breast pumps and medication to relieve breast engorgement pain.
[0024] This very surprising discovery, a “Holistic (Carbonyl Group) Breast Patch”, referred to as the “Patch”, when worn by postpartum women in a prescribed regimen will significantly reduce the time for lactation suppression to occur. When lactation is suppressed, the discomfort of pain associated with breast milk engorgement is relieved and the support of prolactin dependent and related diseases and disorders is interrupted by inhibiting prolactin production.
[0025] The approximately 1½ inch by ¾ inch breast patch is worn by postpartum women, generally in the form of a Telfa pad which the mother applies to her chest. The FDA approved Telfa pad consisting of inactive ingredients is the exterior housing for the “Carbonyl Group” disc containing the active ingredients.
[0026] It is easily applied by the mother between her breasts. This unique patch can be put on and removed easily without pain due to Telfa's nonstick adhesive properties. In the rare event of adhesive sensitivity, the Patch can be applied with latex free microspore cotton tape.
[0027] The scientific method of the “Holistic Breast Patch” is called “transdermal” because the patch is applied to the skin for the “Carbonyl Group” elements of the Patch to cause lactation suppression a much shorter length of time than without the aid of the Patch.
[0028] The Patch is highly effective in that it successfully suppresses postpartum milk production in three to eight days by comparison to six to eight weeks or longer without its use.
[0029] The Patch conveniently allows postpartum mothers who choose not to breast-feed the opportunity to recover from childbirth, return to employment more quickly, protect the newborn from HIV transmission from an HIV positive mother or ease the grief for the mother who suffers the loss of her newborn.
[0030] Furthermore, the Holistic Breast Patch is safe in that it has no known side effects. Therefore, no warnings or precautions are required. When marketed, it will eliminate all of the dangerous, reported fatal adverse effects of previously used methods to quickly produce lactation suppression for relief of pain associated with breast milk engorgement. It will also provide a safe and effective method for treatment of diseases and conditions that require the inhibition of prolactin production. The interior disc of this product consists of all natural fibers and it is labeled by the Food & Drug Administration (FDA) as a device and not a drug. The FDA has determined that the Patch meets its definition of a nonsignificant risk device (21 CFR 812).
[0031] Many other advantages and other purposes will be made more fully apparent from a consideration of the forms in which this invention may be embodied. These forms are illustrated in the following detailed description of the invention and in the accompanying drawings. However, this detailed description and the drawings are set forth only for the purpose of illustrating the general principles of this invention and are not limited to this illustration only.
OBJECTS OF THE INVENTION
[0032] The primary objective of this invention is to provide a safe device to significantly reduce the time to achieve lactation suppression, thus expediting the relief of discomfort of breast engorgement pain in the form of a breast patch which is applied between a woman's breasts.
[0033] It is a further object of the present invention to provide a method of relieving the discomfort of breast engorgement pain and the drying of breast milk without the administration drugs.
[0034] It is an additional object of the present invention to provide a device of the type stated which is highly efficient, and easy to use.
[0035] It is another object of the present invention to provide other benefits to be determined through consumer testing and/or clinical trial, including but not limited to. treatment of prolactin dependent and related diseases.
[0036] Consequently, this invention resides in the novel features form, construction, arrangement and combination of part presently described and pointed out in the claims.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
[0037] Having thus described the invention in general terms, reference will now be made to the accompanying drawings in which:
[0038] FIG. 1 is an exploded, perspective view of the Holistic Breast Patch 28 : the Telfa pad 30 which is gauze lined on the interior side and non-adherent perforated film bonded 24 on the exterior side; gauze 22 ; the “Carbonyl Group” disc 10 and the Telfa pad 30 embodying the present invention.
[0039] FIG. 2 is a bottom plan view of the disc 10 illustrating the grooves 16 .
[0040] FIG. 3 is a vertical sectional view of the grooves 16 also designating the inner and outer core 18 and 20 through the interior of the “Carbonyl Group” disc 10 taken along line 3 - 3 of FIG. 2 .
[0041] FIG. 4 is an elevational view of the disc 10 facing side 12 or 14 with the top facing up.
[0042] FIG. 5 is a perspective view of the disc 10 with the bottom facing up.
[0043] FIG. 6 is a bottom plan view of the Holistic Breast Patch 28 with the left half of the Telfa pad and gauze removed.
[0044] FIG. 7 is a top plan view of the Holistic Breast Patch 28 with the right half of the Telfa pad and gauze removed.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Explaining now the process of making and using this unique invention, reference characters to the drawings which illustrate a preferred embodiment of the invention will also be made in order to give a description in more detail.
[0046] The designated lactation suppression and engorgement pain relief device, the Holistic Breast Patch is worn by postpartum women, generally in the form of a sterile Telfa pad consisting of inactive ingredients: poly(ethylene terephthalate), a thin plastic film lined with a thin layer of cotton gauze 22 . As shown in FIG. 1 , this Telfa pad 30 is the exterior housing for the disc 10 which houses the active ingredients: (“Formula” R—Co—R) nickel, manganese, phosphorus, silicon, sulfur, and carbon) in the form of an interior disc. This formula is called “Carbonyl Group”.
[0047] The preferred embodiment is constructed initially as a thin flexible, flat disc 10 . This Carbonyl Group” disc 10 is about . 75 inch square, has a top flat surface 17 , a bottom grooved surface FIG. 2 , and is provided with 4 very thin sides 12 , 13 , 14 and 15 , FIG. 1 , FIG. 2 , FIG. 3 . The thickness of the sides is described in paragraphs 43 and 44 .
[0048] The inner core of the disc 10 is preferably constructed by forming a piece of high carbon content metal into the shape of a flat disc and this forming may be by stamping the same from a sheet of such metal.
[0049] The inner core 18 should preferably have a thickness of about 49.7 mils, although this can range from about 49.7 mils to about 49.9 mils. The essentially pure nickel outer layer should have a thickness of about 0.3 mils, although the thickness of the outer layer may range from about 0.1 mils to about 1.0 mils.
[0050] The entire disc is preferred to have an overall thickness of about 50 mils, that is, from the top 17 to the bottom 19 FIG. 5 . This thickness is preferred since the disc will then have the necessary structural integrity, although it will not be unduly heavy. However, it should be understood that the thickness of the disc could vary, depending upon the desired thickness of the inner core and of the outer layer, as hereinafter described.
[0051] The metal which is employed as the inner core 18 contains a substantially high carbon content, as aforesaid, This carbon content could be 0.7% by weight to about 1.5% by weight. In a more preferable range, the amount of carbon would range from about 0.6% to about 0.9% referred to as high carbon steel. The remaining content of the inner core would be formed of basic metal elements which would include some minor amounts of manganese, chromium, and possibly a minor amount of nickel. The minor amounts of these other components, such as manganese, chromium, and possibly even nickel, would be less than about 1.0%.
[0052] Extending between the sides 12 and 14 , and parallel to the sides 13 and 15 of the disc 10 FIG. 2 are a plurality of elongated grooves or openings. These grooves 16 constitute openings on the rear face of the disc 10 per 19 , FIG. 2 . They serve as air holes and also as relief for the disc to bend to conform to the different chest curvatures of the user, but do not extend in depth through the front surface of the disc 10 per 17 , FIG. 4 . The grooves are depressed to a depth of about 25 mils, although they could be depressed into the disc for a depth of about 40 mils.
[0053] The distance between each of the grooves 16 , FIG. 2 is preferably about 0.075 inches (75 mils) and the width of each groove 16 is about 0.075 inches (75 mils). In connection with the invention, it is preferred that the width of the grooves 16 is equal to the width of the space between each of the grooves 16 , FIG. 2 .
[0054] By reference to the drawings FIG. 3 , it can be seen that the interior disc 10 is comprised of an inner core 18 of a metal containing a high carbon content and which is enclosed within an outer nickel layer 20 . The outer nickel layer is substantially pure nickel.
[0055] In a slightly different embodiment of the invention, the metal elements used in the formation of the disc would include the carbon and the nickel in the percentages as aforesaid. However, minor amounts of other elements would also be in the composition and these include, for example, phosphorus in an amount of 0.6% by weight, and silicon in an amount of 0.30% by weight. Manganese may be present in an amount of about 0.60% by weight. Vanadium, molybdenum and chromium may also be present in minor trace amounts. The phosphorus could actually range from about 0.4% to about 1.0%. The manganese could also range from about 0.1% to about 0.8%, and the silicon could also range from about 0.1% to about 0.8%.
[0056] The aforesaid composition provides a disc of substantial hardness. However, it is not unduly brittle, and moreover, it is still flexible providing curvature and has a moderately light weight so that it can be worn comfortably and easily by a user
[0057] The invention can further be embodied such that the grooves 16 constitute openings which extend between sides 12 and 14 , 25 to 40 mils in length. FIG. 1 , FIG. 4 , FIG. 5 and FIG. 7 illustrate an embodiment in which the grooves are located on one flat surface of the disc, but do not extend all the way through from flat surface 17 to flat surface 19 .
[0058] The interior disc of the Patch which is all natural and organic is adapted to be seated between cotton gauze on both sides and then 2 Telfa pads as shown in FIG. 1 .
[0059] The exterior housing of the disc consists of Telfa inner lined with cotton gauze, FIG. 1 . Telfa is FDA approved under the classification of various bandages and consists of a thin layer of absorbent cotton fibers, enclosed in a sleeve of polyethylene terephthalate, and bonded with a thin layer of a perforated non-adherent film. This film does not adhere to the skin therefore, eliminating discomfort when removed. The Telfa and cotton are inactive ingredients.
[0060] This milk suppression aid device was constructed by forming a piece of high-carbon content metal into the shape illustrated in 10 , FIG. 1 and FIG. 2 . The disc has the overall dimension of 0.75 inch square, FIG. 2 . The width of the spaces between each of the grooves 16 is 0.075 inches and the width (horizontal dimension) of each of the individual grooves itself is 0.075 inches.
[0061] The overall device has a thickness of 343 mils or approximately ⅓ inch. The grooves 16 have a depth into the device of about 20 mils on each of the flat faces. The thickness of the inner core of high-carbon metal is about 49.7 mils and the thickness of the outer layer of nickel is about 0.3 mils.
[0062] Notably, the success of this invention resides in the wearing of the Patch between the woman's breasts. For optimal results women who will not be breast-feeding should start wearing the breast patch within twenty-four hours after child delivery. It should be worn continuously until engorgement pain and milk production cease. However, positive results are still achieved when started more than twenty-four hours after delivery.
[0063] One of the important aspects of this disc is that it does cause any adverse effects. The use of the disc for the purpose of aiding the drying of breast milk and relieving breast engorgement pain has been explored in conjunction with interaction with commonly used drugs. The interaction, if any, is set forth below:
[0000]
DRUG
INTERACTION
1. Ampicillin
None known
2. Anticoagulants
None known
3. Anticonvulsant hydantoin
None known
4. Antidepressants tricyclic (TEA)
None known
5. Anti-diabetic agents
None known
6. Antihistamines
None known
7. Barbiturates
None known
8. Chloramphenicol
None known
9. Clofibrate
None known
10. .Dextrothyroxine
None known
11. Guanethidine
None known
12. Hypoglycemic (oral)
None known
13. Insulin
None known
14. Meperidine
None known
15. Meprobamate
None known
16. Mineral oil
None known
17. Non-steroidal anti-inflammatory drugs (NSAID's)
None known
18. Rifampin
None known
19. Sulfadiazine and Pyrimethamine
None known
20. Terazosin
None known
21. Tetracyclic
None known
22. Urosodiol
None known
23. Vitamin A
None known
24. Vitamin E
None known
25. Anticoagulants (oral)
None known
26. Anti-diabetic (oral)
None known
27. Carbamazepine
None known
28. Phenobarbital
None known
29. Primidone
None known
30. Tamoxifen
None known
31. Thyriodhormones
None known
32. Bromocriptine
None known
33. Hypoglycemic (oral)
None known
34. Oxyphenbutazone
None known
35. Phenothiazines
None known
36. Phenylbutazone
None known
[0064] The use of the Holistic Breast Patch has also been explored for possible interaction with other substances. The interaction with several substances, or lack thereof, is set forth below.
[0000]
SUBSTANCE
COMBINED EFFECT
1. Alcoholic beverages
None Known
2. Nonalcoholic beverages
None Known
3. Cocaine
None Known
4. Foods/salt
None Known
5. Marijuana
None Known
6. Tobacco/all forms
None Known
EXAMPLES
[0065] The invention is further illustrated, but not limited to, the following examples:
Example 1
[0066] The Holistic Breast Patch aid device was used by a group of ten women. Each of the women was provided the device within twenty-four hours after giving birth. After wearing the device between the breasts for three to five days each of the women reported that lactation was suppressed.
Example 2
[0067] The aid device was again used by a group of ten women. Each of the women was provided the device almost immediately after delivery. In each case, the birth was a normal delivery. After wearing the device between the breasts for three to five days, engorgement of the breasts was reduced.
[0068] Thus, there has been illustrated and described a unique and novel device and method for aiding suppression of milk after pregnancy and relieving breast engorgement pain which, therefore, fulfills all of the objects and advantages which have been sought. It should be understood that many changes, modifications, variations and other uses and applications will become apparent to those skilled in the art after considering this specification and the accompanying drawings.
[0069] Therefore, any and all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention.
[0070] The claims of said device are inclusive of but not limited to the descriptions and claims in the Specification.
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The Holistic Breast Patch is the first known, non pharmaceutical, effective device available which inhibits prolactin production safely and aids the relief of discomfort from breast engorgement pain by drying breast milk after pregnancy. It will also aid in the treatment of prolactin dependent diseases and conditions that respond to prolactin inhibition. The availability of this device greatly eliminates the serious risks of health complications and fatalities that have been documented by the use of prescription drugs, hormones and pharmaceuticals lacking FDA approval for this use. The Holistic Breast Patch works transdermally and is comprised of a unique, natural and organic carbonyl disc housed within cotton gauze and nonstick adhesive Telfa forming an approximately 1½ inch by ¾ inch adhesive] patch. The Federal Drug Administration has determined it to be a non-significant risk device (21 CFR 812).
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FIELD OF THE INVENTION
[0001] The invention relates to innovative polysiloxanes having quaternary ammonium groups and also to a process for preparing them. It further relates to the use of these polymers as an active care ingredient in formulations for the care and cleaning of skin and epidermal derivatives, such as, for example, as conditioning agents for hair, and also in cleaning and maintenance products in household and industry.
PRIOR ART
[0002] Polysiloxanes having quaternary ammonium groups and the application thereof as additives for haircare or textile softeners are known from the patent literature.
[0003] Thus, for example, DE 14 93 384, EP 0017122, and U.S. Pat. No. 4,895,964 describe structures in which siloxanes have been modified in middle positions with quaternary ammonium groups distributed statistically over the polymer. These compounds have the disadvantage that they do not possess a pronounced silicone character, and effective activity as conditioning agents for hair or textiles, for example, is not observed. A pronounced silicone character is possessed by cationic polysiloxanes of the kind described in DE 37 19 086 and EP 0 294 642. With the structures described in DE 37 19 086 and the structures described in EP 0 294 642, the quaternary functions are attached in terminal positions on the polysiloxane. Compounds of these kinds offer advantages in terms of their effect as conditioning agents not only for hair and textiles but also for hard surfaces. The use of such compounds in cosmetic formulations has been described in, for example, EP0530974, EP617607, EP1080714, WO2001082879, and U.S. Pat. No. 6,207,141.
[0004] Nevertheless, the structures described therein possess only two cationic groups. On account of the relatively low substantivity, the affinity of the polysiloxanes for particular surfaces is relatively small.
[0005] Known from DE-A 33 40 708 are polyquaternary polysiloxane polymers. Polyquaternary polysiloxane polymers of this type do not have the disadvantages described above. The practical use of these compounds is opposed, however, by the complex and expensive processes by which they are prepared. The compounds are preparable in economically unacceptable yields of <60% of theory.
[0006] Human hair is daily exposed to a very wide variety of influences. As well as mechanical stresses from brushing, combing, putting up or tying back, the hair is also attacked by environmental influences such as, for example, strong UV radiation, cold, wind, and water. The physiological status (e.g., age, health) of the person in question also affects the state of the keratinic fibers.
[0007] Treatment with chemical agents, in particular, alters structure and surface properties of the hair. Methods such as, for example, permanent-waving, bleaching, coloring, tinting, straightening, etc., and also frequent washing with aggressive surfactants, are among the causes of more or less severe damage to the hair structure. In the case of a permanent-wave treatment, for example, both the cortex and the cuticle of the hair are attacked. The disulfide bridges of the cystine are broken by the reducing step and partly oxidized to acid cysteine in the subsequent oxidation step.
[0008] In the case of bleaching, not only is the melanine destroyed, but also about 15% to 25% of the disulfide bonds in the cystine are oxidized in the case of a mild bleaching treatment, In the case of excessive bleaching, the figure may be even up to 45% (K. F. de Polo, A Short Textbook of Cosmetology, 2000, Verlag für chemische Industrie, H. Ziolkowsky GmbH).
[0009] Accordingly, the chemical treatments, the frequent washing or the CV irradiation produce adverse mechanical properties for the hair, induced by removal of naturally secreted hair fats or humectants (sebum), The hair, as a result, becomes brittle, dry, dull, porous, and difficult to comb.
[0010] Moreover, thoroughly cleaned hair is commonly very difficult to comb, in both the wet and dry states, since the individual hairs tend to become frizzy and to knot. The hair therefore loses its resistance initially during washing and subsequently during combing. This loss of resistance is manifested in a significant decrease in the tensile strength in wet hair. Moreover, it is less resistant than healthy hair to further damage from chemicals, surfactants, and environmental effects.
[0011] For the care of hair damaged in this way there are specific preparations, such as, for example, hair rinses, hair repair treatments, shampoos, leave-in conditioners, and so on, which are able, however, to improve in particular the combability, the feel and the sheen of damaged hair. Commercial haircare compositions of these kinds comprise primarily cationic, alkylammonium-based surfactants, polymers, waxes or oils or silicone fluids. The activity of these compounds can be attributed to effects including the hydrophobizing of the hair surface.
[0012] With all of these compositions, the care effect (conditioning) of the hair that is achieved is good, and yet the appearance, particularly the sheen of the hair, is not improved by the care products, and in some cases is even impaired.
[0013] Consequently, then, there continues to be a demand for versatile active ingredients forpersonal hygiene and care compositions such as shampoos, hair treatment compositions, and hair aftertreatment compositions, which as well as the cleaning effect enhance the care of the hair and at the same time impart good sheen, which protect the hair from damage to the hair structure, and which minimize the structural damage already caused to the hair through environmental effects and also shaping and coloring treatments.
[0014] It is an object of the invention to provide an active ingredient of this kind which is capable not only of enhancing properties such as combability, softness, volume, shapability, handlability, and detanglability of damaged and undamaged hair, but also of giving the hair an attractive sheen. The compounds, therefore, are to exhibit an improved or at least equally good individual effect, but overall an improved combined effect of mechanical and other properties.
DESCRIPTION OF THE INVENTION
[0015] Surprisingly it has been found that siloxanes of the general formula (I), comprising quaternary ammonium groups and being branched in the siloxane moiety, achieve the stated objects.
[0016] One advantage of the siloxanes of the invention is that they unite the advantages of sidechain-modified siloxanes and of α,ω-modified siloxanes and exhibit a higher degree of modification in the sense of a greater number of substitution possibilities in comparison to purely linear structures. As a result it is possible to access structures with a long, undisrupted siloxane backbone that are able to introduce an especially good conditioning effect into cosmetic, dermatological, and pharmaceutical formulations. Another advantage of the siloxanes of the invention is that they and the downstream products manufactured from them possess no tendency, or virtually no tendency, to gel, and can therefore be stored for a relatively long period of time without critical change in the viscosity of the products. This advantage can be emphasized specifically for products of high molecular mass. The products of the invention are therefore based in particular on organically modified siloxanes which comprise quaternary ammonium groups and are branched in the silicone moiety and which are therefore highly branched and also of relatively high molecular mass (average molar mass >3000 g/mol), these structures nevertheless being free from gelling and hence of comparatively low viscosity.
[0017] A further advantage of the invention is that the polysiloxanes with quaternary ammonium groups as per formula (I) are able to exert outstanding conditioning effects on skin and hair. As a result of this conditioning effect on the skin, a dry, brittle or rough skin state following applications of an aqueous, surfactant-containing formulation can be prevented, and a pleasant, velvety-silky skin feel obtained.
[0018] Another advantage is that the inventive use as active care ingredient contributes to enhanced initial foaming, an increased foam volume, and a better foam creaminess in the formulations.
[0019] Furthermore, the inventive use of the structures as an active care ingredient leads to improved hair sheen.
[0020] Where the present invention describes compounds, such as polysiloxanes, for example, which can have various units multiply, these units may occur in statistical distribution (random oligomer) or in ordered form (block oligomer) in these compounds. Data for the number of units in such compounds should be understood as an average value, averaged over all such compounds.
[0021] All percentages (%) indicated are percent by mass unless indicated otherwise.
[0022] All conditions such as pressure and temperature, for example, are standard conditions unless otherwise specified.
[0023] The present invention accordingly provides polysiloxanes which comprise at least one quaternary ammonium groups and are of the general formula (I)
[0000] M a M′ a1 M″ a2 M′″ a3 D b D′ b1 D″ b2 D′″ b3 T c T′ c1 Q d formula (I)
[0000] where
[0024] M=(R 1 3 SiO 1/2 )
[0025] M′=(R 2 R 1 2 SiO 1/2 )
[0026] M″=(R 3 R 1 2 SiO 1/2 )
[0027] M′″=(R 4 R 1 2 SiO 1/2 )
[0028] D=(R 1 2 SiO 2/2 )
[0029] D′=(R 2 R 1 SiO 2/2 )
[0030] D″=(R 3 R 1 SiO 2/2 )
[0031] D′″=(R 4 R 1 SiO 2/2 )
[0032] T=(R 5 SiO 3/2 )
[0033] T′=(R 2 SiO 3/2 )
[0034] Q=(SiO 4/2 )
[0035] a=0 to 32; preferably 0 to 22, more particularly 0 to 12;
[0036] a1=0 to 10, preferably 0 to 5, more particularly 0;
[0037] a2=0 to 32; preferably 0 to 22, more particularly 1 to 12;
[0038] a3=0 to 10; preferably 0 to 5, more particularly 0; with the proviso that
[0039] a+a1+a2+a3>3, preferably >4;
[0040] b=1 to 600, preferably 10 to 500, more particularly 20 to 400;
[0041] b1=0 to 10, preferably 0 to 5, more particularly 0;
[0042] b2=0 to 80, preferably 0 to 50, more particularly 0 to 10;
[0043] b3=0 to 20, preferably 0 to 10, more particularly 0;
[0044] c=0 to 30, preferably 1 to 20, more particularly 2 to 15;
[0045] c1=0 to 10, preferably 0 to 5, more particularly 0;
[0046] d=0 to 15, preferably 1 to 12, more particularly 2 to 10;
[0047] with the proviso that
[0048] a2+b2≧1, preferably >3 and
[0049] c+c1+d>1, preferably >2, more particularly ≧3;
[0050] R 1 =independently of one another identical or different linear or branched, optionally aromatic hydrocarbon radicals having 1 to 30 carbon atoms, preferably methyl or phenyl, more particularly methyl;
[0051] R 2 =independently of one another identical or different alkoxy or acyloxy radicals, such as, for example, methoxy, ethoxy, n-propoxy or isopropoxy radicals, acetoxy, more particularly ethoxy or isopropoxy radicals;
[0052] R 3 =independently of one another identical or different organic radicals which carry quaternary ammonium functions;
[0053] R 4 =independently of one another identical or different organic epoxy radicals;
[0054] R 5 =independently of one another identical or different radicals R 1 , R 3 or R 4 , preferably R 1 , more particularly methyl, phenyl, dodecyl or hexadecyl.
[0055] Suitable epoxy radicals R 4 are, for example, preferably identical or different radicals selected from the group
[0000]
[0056] Suitable radicals R 3 are, for example, groups with the structure —R 6 —R 7 ,
[0057] in which
[0058] R 6 radicals are preferably identical or different divalent radicals selected from the group
[0000]
[0059] R 6 is preferably:
[0000]
[0060] R 7 is selected from the group consisting of
[0000]
[0061] R 8 are identical or different radicals from the group of hydrogen or alkyl having 1 to 6 C atoms, preferably methyl;
[0062] R 9 are identical or different divalent hydrocarbon radicals which optionally contain ether functions, preferably methylene;
[0063] R 10 , R 11 , and R 12 are in each case independently of one another hydrogen or alkyl radicals having 1 to 30 C atoms, or radicals of the formula
[0000]
[0064] R 13 are identical or different radicals from the group —O—; —NR 16 —;
[0065] R 14 are identical or different optionally branched divalent hydrocarbon radicals, preferably ethylene or propylene;
[0066] R 15 are identical or different alkyl, aryl or alkaryl radicals having 1 to 30 C atoms, which optionally contain ether functions, preferably methyl, ethyl or phenyl, more particularly methyl;
[0067] R 16 are identical or different radicals from the group of hydrogen or alkyl having 1 to 6 C atoms;
[0068] m=2 to 18;
[0069] n=2 to 18, preferably 3;
[0070] o=0 to 30, preferably 0 to 10, more particularly 1 to 3;
[0071] p=0 to 30, preferably 0 to 10;
[0072] A − are identical or different counterions to the positive charges on the quaternized nitrogen groups, selected from inorganic or organic anions of the acids HA, and also derivatives thereof.
[0073] In a further preferred embodiment of the present invention, the counterion A − to the positive charges on the quaternized nitrogen groups consists of the anion of a physiologically tolerated acid HA, which with particular preference is selected from acetic acid, L-hydroxy-carboxylic acids, more particularly lactic acid, or aromatic carboxylic acids.
[0074] Other preferred counterions come from common quaternizing agents. These are more particularly ethylsulfate, methylsulfate, toluenesulfonate, chloride, and bromide.
[0075] To the skilled person it is a familiar concept that the compounds in the form of a mixture are present with a distribution governed essentially by laws of statistics.
Preparation of the Siloxanes of the Invention
[0076] The present invention further provides a process for preparing the polysiloxanes of the general formula (I) according to the invention, comprising the steps of
[0077] A) preparing an SiH-group-containing siloxane framework, branched via at least two units selected from T and Q units, by equilibration and condensation of a mixture comprising the components
[0078] a) at least one SiH-functional siloxane,
[0079] b) at least one SiH-function-free siloxane, and either component c) or component d), or both components c) and d), where
[0080] c) is at least one tetraalkoxysilane,
[0081] d) is at least one trialkoxysilane with addition of water and at least one suitable catalyst,
[0082] B) hydrosilylating the Sili-functional siloxanes from process step A) with at least one unsaturated epoxide,
[0083] C) quaternizing the epoxysiloxanes from process step B) with at least one tertiary amine.
[0084] It is preferred in accordance with the invention for the catalyst used in step A) of the process to be a solid catalyst, preferably a solid, Brønsted-acidic catalyst. As acid ion exchangers it is possible to use the ion exchangers known from the prior art. In step A) of the process of the invention it is possible to use not only natural ion exchangers, such as, for example, zeolites, montmorillonites, attapulgites, bentonites, and other aluminum silicates, but also synthetic ion exchangers. The latter are preferably solids (usually in grain form) having a three-dimensional, water-insoluble, high. molecular mass matrix based on phenol-formaldehyde resins, or are copolymers of styrene-divinylbenzene into which numerous “anchor groups” of various acidities are incorporated. In process step A) it is possible more particualrly to use acidic aluminas or acidic ion exchange resins, such as, for example, the products known under the brand names Amberlite®, Amberlyst® or Dowex®, and Lewatit®. As acidic ion exchanger it is particularly preferred to use a sulfonic-acid ion exchange resin.
[0085] Acidic ion exchangers used in step A) of the process of the invention are preferably those of the kind described in EP 1 439 200.
[0086] It may be advantageous if in step A) of the process of the invention the catalyst used comprises at least one solid acidic ion exchanger (catalyst 1) and at least one other, nonsolid Brønsted-acidic catalyst (catalyst 2), more particularly a liquid acid. As catalyst 2 it is possible here to use a mineral acid, preferably sulfuric acid, and/or, preferably, an organic sulfonic acid, preferably trifluoromethanesulfonic acid. This catalyst mixture is preferably added directly to the reaction mixture. As catalyst it is preferred to use a mixture of trifluoromethanesulfonic acid and a sulfonic-acid ion exchange resin, preferably Lewatit® K 2621 (Bayer Material Science). The catalyst mixture preferably has a mass ratio of catalyst 1 to catalyst 2 of 10:1 to 100:1. This mass ratio is preferred more particularly for the use of a Lewatit® catalyst as catalyst 1 and of trifluoro-methanesulfonic acid as catalyst 2.
[0087] Where the two catalysts 1 and 2 are used as catalyst in step A) of the process, it may be advantageous if the catalyst 2 is added first of all, preferably completely, to the mixture of starting materials, then the water is added, and the catalyst 1 is added only after the preferably complete addition of water. Alternatively, the catalysts 1 and 2 may both be added to the starting materials before the water is added.
[0088] Suitable and preferred conditions for process step A) are described in particular in patent applications DE 102008041601.0 and DE 102007055485.2, which therefore are considered in their entirety to form part of the disclosure content of this application.
[0089] In process step A) it is possible, depending on the nature of the process, for residual alkoxy groups (after partially incomplete condensation) to be present in the SiH functional siloxane. This may be achieved, for example, by discontinuing the reaction before the complete conversion is achieved in the hydrolysis and condensation reaction, or by using the water that is needed for hydrolysis in substoichiometric portions, so that not all of the alkoxy groups of the alkoxysilanes can be reacted.
[0090] Process step B) is carried out preferably in the presence of a noble metal catalyst, more particularly Pt, Rh or Ru catalysts.
[0091] Unsaturated epoxides used preferably in step of the process are, for example, allyl glycidyl ether, vinylcyclohexene oxide, norbornadiene monoepoxide. Suitable and preferred conditions for the hydrosilylation reaction in process step B) are described in particular in EP 1520870, for example; that patent is hereby introduced by reference and considered to be part of the disclosure content of the present invention.
[0092] In process step B) it is possible for some of the SiH groups not to be consumed by reaction in an SiC linking reaction, but instead to be linked to the siloxane by reaction of SiOC-attached alkoxy or acyloxy groups on the hydroxyl function. Through a suitable choice of the reaction conditions (including of the catalyst/cocatalyst, reaction temperature, sequence of addition of reactants, use of solvents), this secondary reaction can usually be sufficiently suppressed.
[0093] The epoxysiloxanes obtained in process step B) can lastly, in process step C), be reacted with tertiary amines to form the desired siloxanes which carry quaternary ammonium groups. Suitable and preferred conditions for process step C) are described in DE 37 19 086 and EP 0 294 642, for example.
[0094] The skilled person is aware that as part of a reaction sequence of this kind it is likely that secondary reactions will occur, both with regard to the equilibration of the SiH-functional siloxanes (process step A) and with regard to the hydrolysilylation (process step B) and the quaternization (process step C). The extent of the secondary reactions is dependent on factors including the nature of the reactants and the reaction conditions. Thus, for example, for the reaction of epoxysiloxanes with tertiary amines in the presence of carboxylic acids by commonplace methods, the degree of quaternization is approximately 80% to 95%.
[0095] To the skilled person it is obvious that the process of the invention will lead to mixtures of polysiloxanes, more particularly to technical mixtures. Such mixtures should be understood to be included in the term “compound of the general formula (I) prepared in accordance with the process of the invention” or “siloxane prepared in accordance with the process of the invention” as used in connection with the invention.
Use of the Products of the Invention
[0096] Additionally provided by this invention is the use of the polysiloxane of the invention or of a polysiloxane obtainable, preferably obtained, by the process of the invention for producing cosmetic, pharmaceutical or dermatological compositions.
[0097] In accordance with the invention it is possible to use water-soluble or water-insoluble polysiloxanes—this also applies in respect of the inventive uses specified below. Depending on the formulation to be produced (turbid or clear formulations), the skilled person is familiar with whether he or she should use water-soluble or insoluble polysiloxanes for producing the formulation. The term “water-insoluble” in the sense of the present invention is defined as a solubility of less than 0.01 percent by weight in aqueous solution at 20° C. and 1 bar pressure. The term “water-soluble” in the sense of the present invention is defined as a solubility of greater than or equal to 0.01 percent by weight in aqueous solution at 20° C. and 1 bar pressure.
[0098] Additionally provided by this invention is the use of the polysiloxane of the invention, or of a polysiloxane obtainable, preferably obtained, by the process of the invention as an active care ingredient in care and cleaning formulations, preferably surfactant-containing aqueous care and cleaning formulations.
[0099] The term “active care ingredient” here means a substance which fulfills the purpose of maintaining an article in its original form, of lessening or preventing the effects of external influences (e.g., time, light, temperature, pressure, soiling, chemical reaction with other reactive compounds that come into contact with the article) such as, for example, aging, soiling, fatigue, fading, or even, indeed, of improving desired positive qualities of the article. Instances of the latter include improved hair sheen or a greater elasticity in the article in question. A preferred care formulation in this context is a sheen improving care formulation.
[0100] In this context, the care and cleaning formulations are not confined to cosmetic, pharmaceutical or dermatological compositions, but instead may be any such formulations that are used in household and industry, as for instance for the care and cleaning of surfaces of inanimate articles such as, for example, tiles, wood, glass, ceramic, linoleum, plastic, painted surfaces, leather, fabrics, fibers. Examples of such articles are window panes and window sills, shower partitions, flooring such as carpets, tiles, laminates, woodblock, cork floors, marble, stone and fine stoneware floors, household ceramics such as WCs, basins, bidets, shower trays, bath tubs, door handles, fittings, household appliances such as washing machines, dryers, dishwashers, ceramic or stainless steel sinks, furniture such as tables, chairs, shelving, storage surfaces, windows, kitchenware, tableware, and cutlery, laundry, especially that more close to the body (underwear), watercraft, vehicles, and aircraft such as cars, buses, motorboats, and sailboats, tools such as surgical instruments, vacuum cleaners, machines, pipelines, tanks, and apparatus for transport, processing, and storage in food processing. In this context, therefore, the formulations are used in cleaning and care compositions for household, industry, and institutions.
[0101] In this context, the surface to be cared for and cleaned is preferably the surface of a fiber or a textile, more particularly the surface of woven textiles, laundry, upholstery or carpets.
[0102] This invention further provides for the use of the polysiloxane of the invention or of a polysiloxane obtainable, preferably obtained, by the process of the invention as a conditioning agent for hair treatment compositions and hair aftertreatment compositions, and also as an agent for improving the hair structure.
Formulations/Compositions
[0103] Further provided by this invention are cosmetic, pharmaceutical or dermatological compositions, with more particular preference surfactant-containing aqueous care and cleaning formulations, especially hair treatment compositions and hair aftertreatment compositions to be rinsed out of or left in the hair, examples being shampoos with or without a pronounced conditioning effect, 2in1 shampoos, rinses, hair treatments, hair masks, styling aids, styling compositions, blow-waving lotions, hair-setting compositions, permanent-waving compositions, hair-smoothing compositions, and compositions for coloring the hair, comprising at least one of the polysiloxanes of the invention or one of the polysiloxanes obtainable, preferably obtained, by the process of the invention.
[0104] In the compositions of the invention the polysiloxanes of the invention are used advantageously at a concentration of 0.01 to 20 percent by mass, preferably 0.1 to 8 percent by mass, more preferably of 0.2 to 4 percent by mass.
[0105] The composition of the invention may comprise, for example, at least one additional component selected from the group of
[0106] emollients,
[0107] emulsifiers,
[0108] thickeners/viscosity regulators/stabilizers,
[0109] antioxidants,
[0110] hydrotropes (or polyols),
[0111] solids and fillers,
[0112] pearlescent additives,
[0113] active deodorant and antiperspirant ingredients,
[0114] insect repellents,
[0115] self-tanning agents,
[0116] preservatives,
[0117] conditioners,
[0118] perfümes,
[0119] dyes,
[0120] active cosmetic ingredients,
[0121] care additives,
[0122] superfatting agents,
[0123] solvents.
[0124] Substances which may be used as exemplary representatives of the individual groups are known to the skilled person and can be found in German application DE 102008001788.4, for example. This patent application is hereby introduced by reference and hence considered to be part of the disclosure content.
[0125] With regard to other optional components and also to the amounts of these components that are used, reference is made expressly to the relevant handbooks that are known to the skilled person, an example being K. Schrader, “Grundlagen and Rezepturen der Kosmetika”, 2nd edition, pages 329 to 341, Hüthig Buch Verlag Heidelberg.
[0126] The amounts of each of the additions are dependent on the intended use.
[0127] Typical guideline formulas for the particular applications are known prior art and are contained for example in the brochures from the manufacturers of the respective base materials and active ingredients. These existing formulations can usually be adopted without change. As and when necessary, however, the desired modifications can be undertaken without complication by means of simple tests, for adaptation and optimization.
[0128] This invention additionally provides cleaning and care formulations for household, industrial, and institutional applications, such as, for example, disinfectants, disinfectant cleaners, foam cleaners, floor cleaners, carpet cleaners, upholstery cleaners, floorcare products, marble cleaners, woodblock floor cleaners, stone and ceramic floor cleaners, wipe care compositions, stainless steel cleaners, glass cleaners, dishwashing detergents, cleaners for plastics, sanitary cleaners, wood cleaners, leather cleaners, laundry detergents, laundry care compositions, disinfectant detergents, heavy-duty detergents, mild detergents, wool detergents, fabric softeners, and impregnating compositions, comprising at least one of the polysiloxanes of the invention or one of the polysiloxanes obtainable, preferably obtained, by the process of the invention. Cleaning and care formulations for household, industrial, and institutional applications that are preferred in this context are laundry detergents, laundry care compositions, heavy-duty detergents, mild detergents, wool detergents, fabric softeners, and impregnating compositions, more particularly fabric softeners.
Working Examples
[0129] In the examples set out below, the present invention is described by way of example for the purpose of illustrating the invention, without any intention that the invention, whose breadth of application is indicated by the overall description and the claims, should be confined to the embodiments stated in the examples. Where, in the text below, ranges, general formulae or classes of compound are specified, they are intended to encompass not only the corresponding ranges or groups of compounds that are explicitly mentioned, but also all subranges and subgroups of compounds which may be obtained by extracting individual values (ranges) or compounds. Where the present description cites documents, the intention is that their content should belong in full to the disclosure content of the present invention. Where the present invention describes compounds, such as organically modified polysiloxanes, for example, which can have different monomer units multiply, these units can occur in random distribution (random oligomer) or in ordered form (block oligomer) in these compounds. Figures for numbers of units in such compounds should be understood to refer to the statistical average value, averaged over all corresponding compounds.
Preparation of the Inventive Example Product 1
A) Equilibration of a Branched SiH-Functional Polysiloxane
[0130] In accordance with the instructions in patent applications DE 102008041601.0 and DE 102007055485.2, 22.9 g (0.11 mol) of tetraethoxysilane (>98%, available from Fluka), 366.4 g (0.99 mol) of decamethylcyclopentasiloxane (available from Gelest Inc.), and 112.6 g of an α,ω-dihydrogenopolydimethyl-siloxane having a hydrogen content (SiH) of 2.93 mol SiH/kg were charged to a four-neck flask equipped with KPG stirrer, internal thermometer, dropping funnel, and distillation bridge, at 40° C. with stirring. 0.5 g of trifluoromethanesulfonic acid (available from Sigma Aldrich) was added and the mixture was stirred for 2 hours. Subsequently a mixture of 7.9 g of deionized water and 2.0 g of ethanol was added dropwise over the course of 5 minutes with stirring, and the mixture was stirred at 40° C. for 1 hour. Following addition of 30.1 g of the predried sulfonic-acid cation exchange resin Lewatit® K 2621 (10% by weight water content determined by a method based on the Karl-Fischer method), excess water and alcohol were removed by distillation under a reduced pressure of approximately 15 mbar at 40° C. for 1 hour, After the resin had been isolated by filtration, it was neutralized with 10.0 g of sodium hydrogencarbonate and filtered again. This gave a clear, colorless liquid having a hydrogen (Sib) content of 0.0655%.
B) Preparation of an Epoxysiloxane
[0131] In a 500 ml three-neck flask equipped with KPG stirrer, dropping funnel, internal thermometer, and reflux condenser, 230.8 g (0.15 mol Sib) of the SiH-siloxane prepared as per example la) were reacted with 22.3 g (0.20 mol) of allyl glycidyl ether, with addition of 15 ppm of cisplatin catalyst, at 120° C. under a nitrogen atmosphere. After 2 hours, complete Sib conversion was achieved. Subsequent distillation at 120° C. and 1 mbar gave a clear, colorless liquid having an epoxy content of 0.98%.
C) Reaction to Form the Quaternary Polysiloxane
[0132] A 500 ml three-neck flask equipped with KPG stirrer, dropping funnel, internal thermometer, and reflux condenser was charged at room temperature with 27.0 g (0.095 mol) of 3-N,N-dimethylaminopropyllauramide, 5.9 g (0.098 mol) of acetic acid, and 80 ml of isopropanol, and this initial charge was stirred for 1 hour. Subsequently 155.1 g (0.095 mol epoxy) of the compound prepared as per example lb) were added dropwise. The mixture was then stirred at 65° C. under a nitrogen atmosphere for 8 hours. The isopropanol, finally, was removed by distillation at 65° C. and 1 mbar. This gave a clear, yellowish, highly viscous liquid which is described by the following statistical formula:
[0000] (R 2 Me 2 SiO 1/2 ) 6 (Me 2 SiO 1/2 ) 112 (SiO 4/2 ) 2
[0000] where R 2 =
[0000]
Preparation of the Inventive Example Product 2
A) Equilibration of a Branched SiH-Functional Polysiloxane
[0133] In accordance with the instructions in patent applications DE 102008041601.0 and DE 102007055485.2, 89.2 g (0.50 mol) of methyltriethoxysilane (Dynasylan® MTES from Evonik Degussa GmbH), 1023.4 g (2.76 mol) of decamethylcyclopentasiloxane (available from Gelest Inc.), and 47.0 g (0.35 mol) of 1,1,3,3-tetra-methyldisiloxane (available from Gelest Inc.) were charged to a four-neck flask equipped with KPG stirrer, internal thermometer, dropping funnel, and distillation bridge, at 40° C. with stirring. 1.2 g of trifluoromethanesulfonic acid (available from Sigma Aldrich) were added and the mixture was stirred for 2 hours. Subsequently a mixture of 27.0 g of deionized water and 6.8 g of ethanol was added dropwise over the course of 5 minutes with stirring, and the mixture was stirred at 40° C. for 1 hour. Following addition of 70.0 g of the predried sulfonic-acid cation exchange resin Lewatit® K 2621 (10% by weight water content—determined by a method based on the Karl-Fischer method), excess water and alcohol were removed by distillation under a reduced pressure of approximately 15 mbar at 40° C. for 1 hour. After the resin had been isolated by filtration, it was neutralized with 23.2 g of sodium hydrogencarbonate and filtered again. This gave a clear, colorless liquid having a hydrogen (SiH) content of 0.0634%.
B) Preparation of an Epoxysiloxane
[0134] In a 500 ml three-neck flask equipped with KPG stirrer, dropping funnel, internal thermometer, and reflux condenser, 200.0 g (0.126 mol SiH) of the SiH-siloxane prepared as per example 2a) were reacted with 18.7 g (0.164 mol) of allyl glycidyl ether, with addition of 15 ppm of cisplatin catalyst, at 120° C. under a nitrogen atmosphere. After 2 hours, complete SiH conversion was achieved. Subsequent distillation at 120° C. and 1 mbar gave a clear, colorless liquid having an epoxy content of 0.95%.
C) Reaction to Form the Quaternary Polysiloxane
[0135] A 500 ml three-neck flask equipped with KPG stirrer, dropping funnel, internal thermometer, and reflux condenser was charged at room temperature with 25.3 g (0.089 mol) of 3-N,N-dimethylaminopropyllauramide, 5.5 g (0.092 mol) of acetic acid, and 80 ml of isopropanol, and this initial charge was stirred for 1 hour. Subsequently 150.0 g (0.089 mol epoxy) of the compound prepared as per example 2b) were added dropwise. The mixture was then stirred at 65° C. under a nitrogen atmosphere for 8 hours. The isopropanol, finally, was removed by distillation at 65° C. and 1 mbar. This gave a clear, yellowish, highly viscous liquid which is described by the following statistical formula:
[0000] (R 2 Me 2 SiO 1/2 ) 7 (Me 2 SiO 1/2 ) 138 (MeSiO 3/2 ) 5
[0000] where R 2 =
[0000]
Preparation of the Comparative Example Product 3 (Not Inventive)
a) Preparation of an Epoxysiloxane
[0136] In a 1 l three-neck flask equipped with KPG stirrer, dropping funnel, internal thermometer and reflux condenser, 367 g (0.4 mol SiH) of a siloxane with conventional comblike SiH modification, of the formula
[0000] (Me 3 SiO 1/2 ) 2 (Me 2 SiO 1/2 ) 44 (MeHSiO 1/2 ) 4 ,
[0000] were reacted with 59 g (0.52 mol) of allyl glycidyl ether, with addition of 15 ppm of cisplatin catalyst, at 120° C. under a nitrogen atmosphere. After 2 hours, complete SiH conversion was achieved. Subsequent distillation at 120° C. and 1 mbar gave a clear, colorless liquid having an epoxy content of 1.55%.
b) Reaction to Form the Quaternary Polysiloxane
[0137] A 500 ml three-neck flask equipped with KPG stirrer, dropping funnel, internal thermometer, and reflux condenser was charged at room temperature with 28.4 g (0.10 mol) of 3-N,N-dimethylaminopropyllauramide, 6.3 g (0.105 mol) of acetic acid, and 120 ml of isopropanol, and this initial charge was stirred for 1 hour. Subsequently 206 g (0.1 mol epoxy) of the compound prepared as per example 3a) were added dropwise. The mixture was then stirred at 65° C. under a nitrogen atmosphere for 8 hours. The isopropanol, finally, was removed by distillation at 65° C. and 1 mbar. This gave a clear, yellowish, highly viscous liquid which is described by the following statistical formula:
[0000] (Me 3 SiO 1/2 ) 2 (Me 2 SiO 1/2 ) 44 (RMeSiO 1/2 ) 4
[0000] where R=
[0000]
Performance Properties
[0138] The formulating ingredients are designated in the compositions in the form of the generally recognized INCI nomenclature, using the English terms. All concentrations in the application examples are given in percent by weight.
1.) Testing the Conditioning of Skin (Skincare Performance) and Foam Properties by Means of a Handwashing Test:
[0139] To evaluate the conditioning of skin (skincare performance) and the foam properties of the organically modified siloxane product 1 of the invention, with branching in the silicone moiety, in aqueous surfactant formulations, sensory handwashing tests were carried out in comparison to comparative example 3 according to the prior art.
[0140] Comparative example 3 is a widespread active care ingredient in the industry and is considered to be a highly effective active care ingredient in aqueous surfactant formulations.
[0141] A group consisting of 10 trained subjects washed their hands in a defined way and evaluated foam properties and skin feel using a grading scale from 1 (poor) to 5 (very good).
[0142] The products used were each tested in a standardized surfactant formulation (table 1).
[0143] As a control formulation Ob, a formulation without addition of an organically modified siloxane is used.
[0000]
TABLE 1
Test formulations for handwashing test.
Formulating examples
0b
1b
C2b
Texapon NSO ®, 28% form, Cognis
32%
32%
32%
(INCI: Sodium Laureth Sulfate)
TEGO Betain F 50 ®, 38% form,
8%
8%
8%
Evonik Goldschmidt GmbH
(INCI: Cocamidopropyl Betaine)
NaCl
2%
2%
2%
Water, demineralized
ad 100.0%
Product 1 (inventive)
0.5%
Produkt 3
0.5%
(not inventive)
[0144] The sensory test results are summarized in table 2.
[0000]
TABLE 2
Results of handwashing test
Test formulation
0b
1b
C2b
Initial foaming
3.0
3.5
3.3
Foam volume
2.8
3.2
2.9
Foam creaminess
2.3
3.3
3.0
Skin feel during washing
2.8
3.8
3.7
Skin smoothness
1.4
3.3
2.9
Skin softness
2.0
3.1
2.9
Skin smoothness after 3 minutes
2.6
3.9
3.6
Skin softness after 3 minutes
2.5
3.8
3.5
[0145] Table 2 sets out the results of the handwashing test. From the results of measurement it is clear that the inventive formulation lb using the inventive product 1 is superior in all applications properties by comparison with the prior-art comparative formulation C2b.
[0146] In this light, the results for inventive formulation lb can be said to be very good.
[0147] From the measurement values it is apparent that inventive product 1 in formulation lb leads to an improvement in skin properties and foam properties as compared with product 3 in formulation C2b.
[0148] Furthermore, the measurement values indicate that the control formulation Ob without a silicone compound exhibits poorer measurement values that the formulations 1b and C2b.
2.) Testing of Hair Conditioning by Sensory Tests:
[0149] For the performance assessment of the conditioning of hair, the inventive product 2 and the comparative product 3 were used in simple cosmetic formulations (shampoo and hair rinse).
[0150] The use properties in a shampoo were verified in the following formulas:
[0000]
TABLE 3
Shampoo formulations for testing the hair-conditioning properties.
Formulating examples
0c
1c
C2c
Texapon NSO ®, 28% form, Cognis
32%
32%
32%
(INCI: Sodium Laureth Sulfate)
TEGO ® Betain F 50, 38% form,
8%
8%
8%
Evonik Goldschmidt GmbH
(INCI: Cocamidopropyl Betaine)
Jaguar 162, Rhodia
0.3%
0.3%
0.3%
(INCI: Guar Hydroxypropyl
trimonium Chloride)
(cationic polymer for improving the
activity of conditioners)
Water, demineralized
ad 100.0%
Citric acid
ad. pH 6.0 ± 0.3
Product 2 (inventive)
0.5%
Product 3 (not inventive)
0.5%
[0151] For the evaluation of the properties of the shampoo formulation, there was no aftertreatment with a rinse included in the test procedure.
[0152] The use properties in hair rinses were verified in the following formulas:
[0000]
TABLE 4
Hair rinse formulations for testing the hair-conditioning properties.
Formulating
examples
0d
1d
C2d
TEGINACID ® C, Evonik Goldschmidt GmbH
0.5%
0.5%
0.5%
(INCI: Ceteareth-25)
TEGO ® Alkanol 16, Evonik Goldschmidt GmbH
4%
4%
4%
(INCI: Cetyl Alcohol)
VARISOFT ® 300, 30% form, Evonik Goldschmidt
3.3%
3.3%
3.3%
GmbH
(INCI: Cetrimonium Chloride)
Water, demineralized
Ad 100.0%
Citric acid
ad. pH 4.0 ± 0.3
Product 2 (inventive)
0.5%
Product 3 (not inventive)
0.5%
[0153] When testing for the properties of hair rinses, the hair is pretreated by a shampoo containing no conditioning agents.
[0154] For the performance evaluation, hair tresses used for sensory tests are subjected to standardized preliminary damage by a permanent-waving treatment and a bleaching treatment. These treatments are carried out using standard hairdresser products. The test procedure, the base materials used and the details of the assessment criteria are described in DE 103 27 871.
[0155] Standardized treatment of ready-damaged hair strands with conditioning samples:
[0156] The hair strands subjected to preliminary damage as described above are treated as follows with the above-described shampoo or with the above-described conditioning rinse:
[0157] The hair strands are wetted under hot running water. The excess water is squeezed. out easily by hand, and then the shampoo is applied and incorporated gently into the hair (1 ml/hair strand (2 g)). After a residence time of 1 minute, the hair is rinsed for 1 minute.
[0158] Directly thereafter, if desired, the rinse is applied and incorporated gently into the hair (1 ml/hair strand (2 g)). After a residence time of 1 minute, the hair is rinsed for 1 minute.
[0159] Prior to sensory assessment, the hair is dried in the air at 50% humidity and 25° C. for at least 12 hours.
Assessment Criteria:
[0160] The sensory evaluations take place according to gradings which are awarded on a scale from 1 to 5, with 1 being the poorest and 5 the best evaluation. The individual test criteria each receive a separate evaluation.
[0161] The test criteria are as follows: wet combability, wet feel, dry combability, dry feel, appearance/sheen.
[0162] In the table below, the results of sensory assessment for the treatment, carried out as described above, of the hair strands with the inventive formulation 1c, the comparative formulation C2c, and the control formulation 0c (placebo without test substance) are compared.
[0000]
TABLE 5
Results of conditioning of hair from shampoo formulation
Wet
Wet
Dry
Dry
combability
feel
combability
feel
Sheen
Inventive
3.7
3.5
3.3
4.3
4.1
formulation 1c
Comparative
3.2
3.1
3.1
3.8
3.3
formulation C2c
(not inventive)
Control formulation
2.3
2.5
2.5
3.3
2.3
0c (Placebo)
[0163] The results show surprisingly that the inventive formulation 1c with inventive product 2 obtains significantly better evaluations than the comparative formulation C2c with the prior-art product 3. Particularly noteworthy is the good evaluation of the sheen properties of all of the inventive formulations.
[0000]
TABLE 6
Results of conditioning of hair from hair rinse formulations
Wet
Wet
Dry
Dry
combability
feel
combability
feel
Sheen
Inventive
4.9
4.9
4.7
4.8
4.5
formulation 1d
Comparative
4.4
4.3
4.4
4.5
3.9
formulation C2d
(not inventive)
Control formulation
3.8
3.9
4.0
3.8
2.9
0d
[0164] In the hair rinse application as well, the inventive formulation ld with inventive product 2 exhibits very good cosmetic evaluations in the sensory assessment. Here, the already very good properties of the comparative formulation C2d, with comparative product 3, were increased still further by the inventive formulation 1d, with the inventive compound 2.
[0165] A significantly better evaluation is also achieved for sheen through the use of the inventive formulation 1d.
Formulating Examples
[0166] The formulating examples below show that inventive polysiloxanes with quaternary ammonium groups can be employed in a multiplicity of cosmetic formulations.
Formulating Example 1) Clear Shampoo
[0167]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
Compound of example 1
0.50%
Perfume
0.50%
Water
57.50%
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
ANTIL ® 171 Evonik Goldschmidt GmbH
1.00%
(INCI: PEG-18 Glyceryl Oleate/Cocoate)
NaCl
0.50%
Preservative
q.s.
Formulating Example 2) Clear Conditioning Shampoo
[0168]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
Compound of example 1
1.00%
Perfume
0.50%
Water
55.70%
TEGO ® Cosmo C 100, Evonik Goldschmidt
1.00%
GmbH, (INCI: Creatine)
Jaguar C-162, Rhodia
0.30%
(INCI: Hydroxypropyl Guar
Hydroxypropyltrimonium Chloride)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
1.50%
Preservative
q.s.
Formulating Example 3) Clear Conditioning Shampoo
[0169]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
ANTIL ® 200, Evonik Goldschmidt GmbH
2.00%
(INCI: PEG-200 Hydrogenated Glyceryl
Palmate; PEG-7 Glyceryl Cocoate)
Compound of example 2
1.00%
Perfume
0.25%
Water
56.25%
Polymer JR 400, Amerchol
0.20%
(INCI: Polyquaternium-10)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
INCI: Cocamidopropyl Betaine)
NaCl
0.30%
Preservative
q.s.
Formulating Example 4) Clear Conditioning Shampoo
[0170]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
ANTIL ® 200, Evonik Goldschmidt GmbH
2.00%
(INCI: PEG-200 Hydrogenated Glyceryl
Palmate; PEG-7 Glyceryl Cocoate)
ABIL ® Quat 3272, Evonik Goldschmidt GmbH
0.75%
(INCI: Quaternium-80)
Compound of example 1
0.50%
Perfume
0.25%
Water
56.00%
Polymer JR 400, Amerchol
0.20%
(INCI: Polyquaternium-10)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
0.30%
Preservative
q.s.
Formulating Example 5) Clear Conditioning Shampoo
[0171]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
ANTIL ® 200, Evonik Goldschmidt GmbH
2.00%
(INCI: PEG-200 Hydrogenated Glyceryl
Palmate; PEG-7 Glyceryl Cocoate)
ABIL ® B 8832, Evonik Goldschmidt GmbH
1.00%
(INCI: Bis-PEG/PPG-20/20 Dimethicone)
Compound of example 1
0.50%
Perfume
0.25%
Water
55.75%
Polymer JR 400, Amerchol
0.20%
(INCI: Polyquaternium-10)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
0.30%
Preservative
q.s.
Formulating Example 6) Clear Conditioning Shampoo
[0172]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
VARISOFT ® PATC, Evonik Goldschmidt GmbH
1.50%
(INCI: Palmitamidopropyltrimonium
Chloride)
REWODERM ® LI S 80, Evonik Goldschmidt
2.00%
GmbH
(INCI: PEG-200 Hydrogenated Glyceryl
Palmate; PEG-7 Glyceryl Cocoate)
Compound of example 2
0.50%
Perfume
0.25%
Water
54.05%
TEGO ® Cosmo C 100, Evonik Goldschmidt
1.00%
GmbH, (INCI: Creatine)
Jaguar C-162, Rhodia
0.20%
(INCI: Hydroxypropyl Guar
Hydroxypropyltrimonium Chloride)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
0.50%
Preservative
q.s.
Formulating example 7) Clear Conditioning Shampoo
[0173]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
REWODERM ® LI S 80, Evonik Goldschmidt
2.00%
GmbH
(INCI: PEG-200 Hydrogenated Glyceryl
Palmate; PEG-7 Glyceryl Cocoate)
Compound of example 2
0.50%
Perfume
0.25%
Water
55.55%
TEGO ® Cosmo C 100, Evonik Goldschmidt
1.00%
GmbH, (INCI: Creatine)
Jaguar C-162, Rhodia
0.20%
(INCI: Hydroxypropyl Guar
Hydroxypropyltrimonium Chloride)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
0.50%
Preservative
q.s.
Formulating Example 8) Pearlized Shampoo
[0174]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
Compound of example 1
0.50%
Perfume
0.25%
Water
55.25%
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
TEGO ® Pearl N 300 Evonik Goldschmidt GmbH
2.00%
(INCI: Glycol Distearate; Laureth-4;
Cocamidopropyl Betaine)
ANTIL ® 171 Evonik Goldschmidt GmbH
1.50%
(INCI: PEG-18 Glyceryl Oleate/Cocoate)
NaCl
0.50%
Preservative
q.s.
Formulating Example 9) 2 in 1 Shampoo
[0175]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
VARISOFT ® PATC, Evonik Goldschmidt GmbH
1.50%
(INCI: Palmitamidopropyltrimonium
Chloride)
REWODERM ® LI S 80, Evonik Goldschmidt
2.00%
GmbH
(INCI: PEG-200 Hydrogenated Glyceryl
Palmate; PEG-7 Glyceryl Cocoate)
Compound of example 1
0.50%
Perfume
0.25%
Water
54.05%
TEGO ® Cosmo C 100, Evonik Goldschmidt
1.00%
GmbH, (INCI: Creatine)
Jaguar C-162, Rhodia
0.20%
(INCI: Hydroxypropyl Guar
Hydroxypropyltrimonium Chloride)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
0.50%
Preservative
q.s.
Formulating Example 10) Rinse-Off Conditioner
[0176]
[0000]
Water
90.50%
VARISOFT ® BT 85, Evonik Goldschmidt GmbH
3.00%
(INCI: Behentrimonium Chloride)
Compound of example 1
1.50%
TEGO ® Alkanol 1618, Evonik Goldschmidt
5.00%
GmbH (INCI: Cetearyl Alcohol)
Preservative, Perfume
q.s.
Formulating Example 11) Rinse-Off Conditioner
[0177]
[0000]
Water
90.20%
VARISOFT ® EQ 65, Evonik Goldschmidt GmbH
2.00%
(INCI: Distearyl Dimonium Chloride,
Cetearyl Alcohol)
VARISOFT ® BT 85, Evonik Goldschmidt GmbH
2.00%
(INCI: Behentrimonium Chloride)
Compound of example 1
0.80%
TEGO ® Alkanol 1618, Evonik Goldschmidt
5.00%
GmbH (INCI: Cetearyl Alcohol)
Preservative, Perfume
q.s.
Formulating Example 12) Rinse-Off Conditioner
[0178]
[0000]
Water
89.20%
VARISOFT ® EQ 65, Evonik Goldschmidt GmbH
2.00%
(INCI: Distearyl Dimonium Chloride,
Cetearyl Alcohol)
VARISOFT ® BT 85, Evonik Goldschmidt GmbH
2.00%
(INCI: Behentrimonium Chloride)
ABIL ® Quat 3272, Evonik Goldschmidt GmbH
1.00%
(INCI: Quaternium-80)
Compound of example 1
0.80%
TEGO ® Alkanol 1618, Evonik Goldschmidt
5.00%
GmbH (INCI: Cetearyl Alcohol)
Preservative, Perfume
q.s.
Formulating Example 13) Rinse-Off Conditioner
[0179]
[0000]
TEGINACID ® C, Evonik Goldschmidt GmbH
0.50%
(INCI: Ceteareth-25)
TEGO ® Alkanol 16, Evonik Goldschmidt
2.00%
GmbH (INCI: Cetyl Alcohol)
TEGO ® Amid S 18, Evonik Goldschmidt GmbH
1.00%
INCI: Stearamidopropyl Dimethylamine)
Compound of example 1
1.50%
Propylene Glycol
2.00%
Citric Acid Monohydrate
0.30%
Water
92.70%
Preservative, Perfume
q.s.
Formulating Example 14) Rinse-Off Conditioner
[0180]
[0000]
TEGINACID ® C, Evonik Goldschmidt GmbH
0.50%
(INCI: Ceteareth-25)
TEGO ® Alkanol 16, Evonik Goldschmidt
5.00%
GmbH (INCI: Cetyl Alcohol)
TEGOSOFT ® DEC, Evonik Goldschmidt GmbH
1.00%
INCI: Diethylhexyl Carbonate)
Compound of example 2
1.50%
Water
89.20%
TEGO ® Cosmo C 100 Evonik Goldschmidt
0.50%
GmbH (INCI: Creatine)
Propylene Glycol
2.00%
Citric Acid Monohydrate
0.30%
Preservative, Perfume
q.s.
Formulating Example 15) Leave-In Conditioner Spray
[0181]
[0000]
Lactic Acid, 80%
0.40%
Water
95.30%
TEGO ® Amid S 18, Evonik Goldschmidt GmbH
1.20%
(INCI: Stearamidopropyl Dimethylamine)
TEGIN ® G 1100 Pellets, Evonik
0.60%
Goldschmidt GmbH
(INCI: Glycol Distearate)
TEGO ® Care PS, Evonik Goldschmidt GmbH
1.20%
(INCI: Methyl Glucose Sesquistearate)
TEGOSOFT ® DEC, Evonik Goldschmidt GmbH
0.30%
(INCI: Diethylhexyl Carbonate)
Compound of example 1
1.00%
Preservative, Perfume
q.s.
Formulating Example 16) Leave-In Conditioner Spray
[0182]
[0000]
TAGAT ® CH-40, Evonik Goldschmidt GmbH
2.00%
(INCI: PEG-40 Hydrogenated Castor Oil)
Ceramide VI, Evonik Goldschmidt GmbH
0.05%
(INCI: Ceramide 6 II)
Perfume
0.20%
Water
90.95%
Compound of example 1
0.50%
LACTIL ® Evonik Goldschmidt GmbH
2.00%
(INCI: Sodium Lactate; Sodium PCA;
Glycine; Fructose; Urea; Niacinamide;
Inositol; Sodium benzoate; Lactic Acid)
TEGO ® Betain F 50 Evonik Goldschmidt
2.30%
GmbH 38%
(INCI: Cocamidopropyl Betaine)
Citric Acid (10% in water)
2.00%
Formulating Example 17) Leave-In Conditioner Foam
[0183]
[0000]
Compound of example 1
0.50%
TAGAT ® CH-40, Evonik Goldschmidt GmbH
0.50%
(INCI: PEG-40 Hydrogenated Castor Oil)
Perfume
0.30%
TEGO ® Betain 810, Evonik Goldschmidt
2.00%
GmbH
(INCI: Capryl/Capramidopropyl Betaine)
Water
94.00%
TEGO ® Cosmo C 100, Evonik Goldschmidt
0.50%
GmbH (INCI: Creatine)
TEGOCEL ® HPM 50, Evonik Goldschmidt GmbH
0.30%
(INCI: Hydroxypropyl Methylcellulose)
VARISOFT ® 300, Evonik Goldschmidt GmbH
1.30%
(INCI: Cetrimonium Chloride)
LACTIL ® Evonik Goldschmidt GmbH
0.50%
(INCI: Sodium Lactate; Sodium PCA;
Glycine; Fructose; Urea; Niacinamide;
Inositol; Sodium benzoate; Lactic Acid)
Citric Acid (30% in water)
0.10%
Preservative
q.s.
Formulating Example 18) Strong Hold Styling Gel
[0184]
[0000]
TEGO ® Carbomer 141, Evonik Goldschmidt
1.20%
GmbH (INCI: Carbomer)
Water
67.00%
NaOH, 25%
2.70%
PVP/VA W-735, ISP
16.00%
(INCI: PVP/VA Copolymer)
Compound of example 1
0.50%
Alcohol Denat.
10.00%
TAGAT ® O 2 V, Evonik Goldschmidt GmbH
2.00%
(INCI: PEG-20 Glyceryl Oleate)
Perfume
0.30%
ABIL ® B 88183, Evonik Goldschmidt GmbH
0.30%
(INCI: PEG/PPG-20/6 Dimethicone)
Preservative
q.s.
Formulating Example 19) Body Care Foam
[0185]
[0000]
TEXAPON ® NSO, Cognis, 28% form
14.30%
(INCI: Sodium Laureth Sulfate)
Perfume
0.30%
Compound of example 1
0.50%
REWOTERIC ® AM C, Evonik Goldschmidt
8.00%
GmbH, 32% form
(INCI: Sodium Cocoamphoacetate)
Water
74.90%
TEGOCEL ® HPM 50, Evonik Goldschmidt GmbH
0.50%
(INCI: Hydroxypropyl Methylcellulose)
LACTIL ®, Evonik Goldschmidt GmbH
1.00%
(INCI: Sodium Lactate; Sodium PCA;
Glycine; Fructose; Urea; Niacinamide;
Inositol; Sodium benzoate; Lactic Acid)
Citric Acid Monohydrate
0.50%
Formulating Example 20) Body Care Composition
[0186]
[0000]
TEXAPON ® NSO, Cognis, 28% form
30.00%
(INCI: Sodium Laureth Sulfate)
TEGOSOFT ® PC 31, Evonik Goldschmidt GmbH
0.50%
(INCI: Polyglyceryl-3 Caprate)
Compound of example 2
0.50%
Perfume
0.30%
Water
53.90%
TEGOCEL ® HPM 4000, Evonik Goldschmidt
0.30%
GmbH
(INCI: Hydroxypropyl Methylcellulose)
REWOTERIC ® AM C, Evonik Goldschmidt
10.00%
GmbH, 32% form
(INCI: Sodium Cocoamphoacetate)
Citric Acid Monohydrate
0.50%
REWODERM ® LI S 80, Evonik Goldschmidt
2.00%
GmbH
(INCI: PEG-200 Hydrogenated Glyceryl
Palmate; PEG-7 Glyceryl Cocoate)
TEGO ® Pearl N 300, Evonik Goldschmidt
2.00%
GmbH
(INCI: Glycol Distearate; Laureth-4;
Cocamidopropyl Betaine)
Formulating Example 21) Body Care Foam
[0187]
[0000]
TEXAPON ® NSO, Cognis, 28% form
14.30%
(INCI: Sodium Laureth Sulfate)
Perfume
0.30%
Compound of example 1
0.50%
REWOTERIC ® AM C, Evonik Goldschmidt
8.00%
GmbH, 32% form
(INCI: Sodium Cocoamphoacetate)
Water
75.10%
Polyquaternium-7
0.30%
LACTIL ®, Evonik Goldschmidt GmbH
1.00%
(INCI: Sodium Lactate; Sodium PCA;
Glycine; Fructose; Urea; Niacinamide;
Inositol; Sodium benzoate; Lactic Acid)
Citric Acid Monohydrate
0.50%
Formulating Example 22) Mild Foam Bath
[0188]
[0000]
TEXAPON ® NSO, Cognis, 28% form
27.00%
(INCI: Sodium Laureth Sulfate)
REWOPOL ® SB FA 30, Evonik Goldschmidt
12.00%
GmbH, 40% form
(INCI: Disodium Laureth Sulfosuccinate)
TEGOSOFT ® LSE 65 K SOFT, Evonik
2.00%
Goldschmidt GmbH
(INCI: Sucrose Cocoate)
Water
39.00%
REWOTERIC ® AM C, Evonik Goldschmidt
13.00%
GmbH, 32% form
(INCI: Sodium Cocoamphoacetate)
Compound of example 1
0.50%
Citric Acid (30% in water)
3.00%
ANTIL ® 171 Evonik Goldschmidt GmbH
1.50%
(INCI: PEG-18 Glyceryl Oleate/Cocoate)
TEGO ® Pearl N 300 Evonik Goldschmidt GmbH
2.00%
(INCI: Glycol Distearate; Laureth-4;
Cocamidopropyl Betaine)
Formulating Example 23) Body Care Foam
[0189]
[0000]
TEGOCEL ® HPM 50, Evonik Goldschmidt GmbH
0.50%
(INCI: Hydroxypropyl Methylcellulose)
Water
80.10%
Perfume
0.20%
Compound of example 1
0.50%
TEGOSOFT ® GC, Evonik Goldschmidt GmbH,
1.30%
(INCI: PEG-7 Glyceryl Cocoate)
TEGO ® Betain 810, Evonik Goldschmidt
16.90%
GmbH
(INCI: Capryl/Capramidopropyl Betaine)
LACTIL ®, Evonik Goldschmidt GmbH
0.50%
(INCI: Sodium Lactate; Sodium PCA;
Glycine; Fructose; Urea; Niacinamide;
Inositol; Sodium benzoate; Lactic Acid)
Preservative
q.s.
Formulating Example 24) Clear Shampoo
[0190]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
Compound of example 2
0.50%
Perfume
0.25%
Water
56.05%
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
ANTIL ® 171 Evonik Goldschmidt GmbH
2.50%
(INCI: PEG-18 Glyceryl Oleate/Cocoate)
NaCl
0.70%
Preservative
q.s.
Formulating Example 25) Clear Shampoo
[0191]
[0000]
TEXAPON ® NSO, Cognis, 28% form
32.00%
(INCI: Sodium Laureth Sulfate)
Compound of example 1
0.50%
Perfume
0.25%
Water
55.35%
REWOTERIC ® AMC, Evonik Goldschmidt GmbH,
9.40%
(INCI: Sodium Cocoamphoacetate)
ANTIL ® 171 Evonik Goldschmidt GmbH
2.50%
(INCI: PEG-18 Glyceryl Oleate/Cocoate)
Preservative
q.s.
Formulating Example 25) Clear Shampoo
[0192]
[0000]
TEXAPON ® NSO, Cognis, 28% form
17.90%
(INCI: Sodium Laureth Sulfate)
Compound of example 1
0.50%
Perfume
0.25%
Water
62.50%
TEGO ® Betain F 50, Evonik Goldschmidt
6.60%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
REWOPOL ® SB FA 30, Evonik Goldschmidt
6.25%
GmbH,
(INCI: Disodium Laureth Sulfosuccinate)
ANTIL ® 171 Evonik Goldschmidt GmbH
5.00%
(INCI: PEG-18 Glyceryl Oleate/Cocoate)
NaCl
1.00%
Preservative
q.s.
Formulating Example 26) Rinse-Off Conditioner
[0193]
[0000]
Water
89.20%
VARISOFT ® EQ 65, Evonik Goldschmidt GmbH
2.00%
(INCI: Distearyl Dimonium Chloride,
Cetearyl Alcohol)
VARISOFT ® BT 85, Evonik Goldschmidt GmbH
2.00%
(INCI: Behentrimonium Chloride)
ABIL ® OSW 5, Evonik Goldschmidt GmbH
1.00%
(INCI: Cyclopentasiloxane; Dimethiconol)
Compound of example 1
0.80%
TEGO ® Alkanol 1618, Evonik Goldschmidt
5.00%
GmbH (INCI: Cetearyl Alcohol)
Preservative, Perfume
q.s.
Formulating Example 27) Rinse-Off Conditioner
[0194]
[0000]
Water
89.20%
VARISOFT ® EQ 65, Evonik Goldschmidt GmbH
2.00%
(INCI: Distearyl Dimonium Chloride,
Cetearyl Alcohol)
VARISOFT ® BT 85, Evonik Goldschmidt GmbH
2.00%
(INCI: Behentrimonium Chloride)
ABIL ® Soft AF 100, Evonik Goldschmidt
1.00%
GmbH
(INCI: Methoxy PEG/PPG-7/3 Aminopropyl
Dimethicone)
Compound of example 1
0.80%
TEGO ® Alkanol 1618, Evonik Goldschmidt
5.00%
GmbH (INCI: Cetearyl Alcohol)
Preservative, Perfume
q.s.
Formulating Example 28) Rinse-Off Conditioner
[0195]
[0000]
Water
89.20%
VARISOFT ® EQ 65, Evonik Goldschmidt GmbH
2.00%
(INCI: Distearyl Dimonium Chloride,
Cetearyl Alcohol)
VARISOFT ® BT 85, Evonik Goldschmidt GmbH
2.00%
(INCI: Behentrimonium Chloride)
SF 1708, Momentive
1.00%
(INCI: Amodimethicone)
Compound of example 1
0.80%
TEGO ® Alkanol 1618, Evonik Goldschmidt
5.00%
GmbH (INCI: Cetearyl Alcohol)
Preservative, Perfume
q.s.
Formulating Example 29) Conditioning Shampoo
[0196]
[0000]
TEXAPON ® NSO, Cognis, 28% form
27.00%
(INCI: Sodium Laureth Sulfate)
Plantacare 818 UP, Cognis 51.4% form
5.00%
(INCI: Coco Glucoside)
Compound of example 2
1.50%
Perfume
0.25%
Water
56.55%
TEGO ® Cosmo C 100, Evonik Goldschmidt
1.00%
GmbH, (INCI: Creatine)
Jaguar C-162, Rhodia
0.20%
(INCI: Hydroxypropyl Guar
Hydroxypropyltrimonium Chloride)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
0.50%
Preservative
q.s.
Formulating Example 30) Conditioning Shampoo
[0197]
[0000]
Plantacare 818 UP, Cognis 51.4% form
18.00%
(INCI: Coco Glucoside)
Compound of example 2
1.50%
Perfume
0.25%
Water
70.55%
TEGO ® Cosmo C 100, Evonik Goldschmidt
1.00%
GmbH, (INCI: Creatine)
Jaguar C-162, Rhodia
0.20%
(INCI: Hydroxypropyl Guar
Hydroxypropyltrimonium Chloride)
TEGO ® Betain F 50, Evonik Goldschmidt
8.00%
GmbH, 38% form
(INCI: Cocamidopropyl Betaine)
NaCl
0.50%
Preservative
q.s.
|
The invention relates to novel polysiloxanes having quaternary ammonium groups, and to a method for producing same. The invention further relates to the use of said polymers as an active care ingredient in formulations for the care and cleansing of skin and skin appendages, for example, as conditioning agents for hair.
| 0
|
BACKGROUND TO THE INVENTION
This application is a continuation-in-part of application Ser. No. 939,783 filed on Dec. 9, 1986 now abandoned.
FIELD OF THE INVENTION
This invention concerns means for colouring bait especially live bait, such as minnows, worms, crawfish, frogs, leeches or insects to attract fish to strike at a lure and enable an angler to catch fish.
In addition to using live bait, colored artificial lures are often used to catch fish. Live bait may be used along with a coloured artificial lure. Brightly coloured fish, such as goldfish and other exotic fish, when used as lures can produce dramatic results but cause an undesirable negative environmental side effect in that alien species can be released. The practice is often illegal and certainly should be discouraged.
Sets of artificial lures of different colours have been used in conjunction with a colour-selection meter such as Color-C-Lector*. Such a meter guides the user as to which lure colour to use at what depth in clear, stained or muddy water. The user may have to make allowances for preferences of the fish. Combining colours has also been suggested as well as purchasing all-white artificial lures and using marking pens or paints that match the colour recommended by the reading of the colour selection meter. Artificial lures attempt to simulate the natural attributing attractors of live bait which assist in inducing a fish to strike such as movement and shape, with the addition of attractive colors, and also every sound and scent.
DESCRIPTION OF PRIOR ART
Canadian Pat. No. 664,579 discloses a process for dyeing bait fish eggs while compressed, in the presence of a preservative and bait eggs produced thereby.
There is therefore a need for an improved means for live bait fishing which is biologically and environmentally acceptable and can be used in as many water conditions as possible with a wide range of target fish species. There is also a need for an improved bait for sport and commercial fishing use.
SUMMARY OF THE INVENTION
According to the present invention there is provided a composition for colouring bait which comprises (a) a least one biologically acceptable and palatable colourant; (b) a mordant for binding said colourant to bait; (c) a surfactant or an acidulant; and (d) an aqueous carrier, preferably distilled water.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In such a composition of the invention, summarized above, the colourant is preferably selected from FD&C Yellow No. 5 FD&C Yellow No. 6, FD&C Red No. 2, FD&C Red No. 3, FD&C Red No. 4, FD&C Red No. 40, FD&C Green No. 3, FD&C Blue No. 1 and FD&C Blue No. 2.
The mordant is preferably a suitable water-soluble aluminum, calcium or barium salt such as aluminum sulphate, aluminum chloride, aluminum nitrate, calcium chloride, calcium sulphate, calcium nitrate, barium chloride and barium nitrate.
The surfactant, which should of course be biologically acceptable, preferably comprises up to about 3% by weight of the composition, particularly preferably about 1% by weight of the composition. We have found an alkoxylate surfactant, especially a nonylphenyl alkoxylate, such as that sold under the trade name NP-9 by Alkaril of Mississauga, Ontario to be particularly useful.
The acidulant is preferably selected from sulphuric acid, hydrochloric acid, citric acid, acetic acid, fumaric acid, malic acid or oxalic acid and preferably should be present in an amount sufficient to give a pH of less than 5.0, even more preferably a pH of less than 3.5. but should not be so strong as to be dangerous to the user or to repel fish when used in the bait.
The above-mentioned compositions are preferably used in combination with (e) a biologically acceptable suspending agent for improving stability and homogeneity of a solution of said composition. Preferably the suspending agent is selected from a vegetable gum, a derivatized starch polymer, a derivatized cellulose, a dextran, a fumed silica and a polyvinyl pyrrolidone. Aragum 2000* and xanthan gum are especially useful.
Preferably the colourant, mordant, such as aluminum sulphate, and the acidulant such as citric acid each separately comprise about 10% by weight of the composition, the surfactant comprises about 1% by weight of the composition and, when present, the suspending agent, such as Aragum 2000 or xanthan gum, comprises about 4% by weight of the composition.
According to another aspect of the invention there is provided a multi-component kit for colouring bait which kit comprises in separate containers components (a) at least one biologically acceptable and palatable colourant; (b) a mordant for binding said colourant to bait; and (c) a surfactant or an acidulant to make acidic an aqueous composition of the components of said kit.
A preferred kit comprises
(a) at least one biologically acceptable and palatable colourant selected from FD&C Yellow No. 5, FD&C Yellow No. 6, FD&C Red No. 2, FD&C Red No. 3, FD&C Red No. 4, FD&C Red No. 40, FD&C Green No. 3, FD&C Blue No. 1 and FD&C Blue No. 2;
(b) a mordant for binding said colourant to bait selected from aluminum sulphate, aluminum chloride, aluminum nitrate, calcium chloride, calcium sulphate, calcium nitrate, barium chloride and barium nitrate; and
(c) a surfactant or an acidulant to make the pH of the composition less than 5.0 selected from sulphuric acid, hydrochloric acid, citric acid, acetic acid, fumaric acid and malic acid.
Preferably the kit of the invention should also contain a biologically acceptable suspending agent for improving stability and homogeneity of an aqueous composition of the components of the kit. Such a suspending agent may be selected from a vegetable gum, a derivatized starch polymer, a derivatized cellulose, a dextran, a fumed silica and a polyvinyl pyrrolidone. Especially preferred suspending agents include Aragum 2000 and xanthan gum.
The preferred food dyes which are used as colourants have an affinity for proteins, particularly for collagen, the main component of fish scales. When applied to live minnows, however the food dyes were not effective in staining the minnows. We found that if the dyes are dissolved in a moderately acidic solution that they were then able to effectively stain the minnows' scales. It appears that the food dyes alone were ineffective because of a mucopolysaccharide slime layer that encoats the live minnow. Inorganic mineral acids (e.g. hydrochloric or sulphuric acid) or organic acids (e.g. citric or acetic acid) are suitable acidulants.
The staining ability of the colourants is enhanced by using a mordant. A mordant, in the context of this invention, is a substance which facilitates binding of the colourant to the bait. The preferred food dyes are soluble because of the presence of sulphonic acid groups in their molecular structure. They are also sodium salts. Conversion of the sodium salt to the salt of another selected metal reduces dye solubility and enhances deposition onto an insoluble substrate (in this case, the bait). Mordants of soluble aluminum, calcium or barium are particularly suitable. It should be noted that salts of aluminum have a dual functionality in the context of this invention, especially with respect to colouring minnows in that their solutions are acidic (e.g. a pH of 3.0 for a 10% solution of aluminum sulphate). This means that as well as supplying aluminum ions for insoluble salt formation they also provide the acidity required to penetrate the mucopolysaccharide slime layer.
The surfactant is especially useful when intending to use these coloured baits in cold waters. It enhances adherence of the colourants to the bait.
Colouring bait can be enhanced with the optional use of a suitable suspending agent. The agent should be biologically acceptable. The suspending agents improve the stability and homogeneity of the compositions. In addition they also modify the viscosity and surface tension of the compositions, thus improving the clinging of the composition to the bait.
Table 1 is a comparison chart using the colour composition on minnows and comparing the catches with those made with plain minnows. In general, two people fished from different sides of the same boat exchanging positions and bait type at intervals in an effort to remove any effect of the individual fisher or of the position with respect to the boat.
The colour composition can be applied to the bait in a variety of ways, e.g. by dipping the bait in a bath of the composition, by brushing the composition onto the bait, by applying drops by means of a pipette or by squirting the composition from a squeeze bottle. It is possible to apply the colour composition from an aerosol container, but this is expensive and therefore not preferred. The bait can be coloured by wiping it with or squeezing it in a sponge or absorbent pad saturated with the colour composition.
TABLE 1______________________________________Comparison ChartNumber of bites, including catchesUsing Color Composition Using Plain Minnows______________________________________ Day 15 23 Perch 11 Perch 2 Small Mouth Bass 0 4 Rock Bass 0 Day 14 5 Lake Trout 1 Lake Trout Day 13 3 Lake Trout 0 Day 12 2 Small Mouth Bass 0 Day 11 2 Small Mouth Bass 1 Small Mouth Bass 1 Large Mouth Bass Day 10 4 Lake Trout 2 Lake TroutDay 9 7 Perch 2 Perch 2 Small Mouth Bass 0 2 Catfish 0Day 8 6 Lake Trout 1 Lake TroutDay 7 2 Lake Trout 1 Lake Trout 1 Small Mouth Bass 0Day 6 4 Lake Trout 2 Lake TroutDay 5 6 Small Mouth Bass 1 Small Mouth BassDay 4 14 Perch 6 PerchDay 3 2 Lake Trout 1 Lake TroutDay 2 6 Lake Trout 2 Lake TroutDay 1 6 Lake Trout 2 Lake Trout______________________________________
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A composition for coloring bait which comprises (a) at least one biologically acceptable and palatable colorant; (b) a mordant for binding said colorant to live bait; (c) a surfactant or an acidulant; and (d) an aqueous carrier. A kit for coloring live bait to catch fish comprising (a), (b) and (c) of the composition also forms part of the invention.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns the use of a high molecular weight polyalkylmethacrylate to reduce the pour point of a wax isomerate.
2. Description of Related Art
The addition of polyalkylmethacrylates to lubricating oils is known. For example, U.S. Pat. No. 2,628,225 discloses that polyalkylmethacrylates can be used as VI improvers and pour point depressants in lubricating oils. In addition, U.S. Pat. No. 4,968,444 discloses that the pour point of a lubricating oil can be reduced by adding a mixture of acrylate or methacrylate polymers. Each polymer contains several acrylate or methacrylate esters. The molecular weight of both polymers ranges from 50,000 to 500,000. More recently, U.S. Ser. No. 630,466 discloses that the pour point of a wax isomerate can be reduced by using a combination of low and high molecular weight polyalkylmethacrylates.
However, these disclosures do not suggest reducing the pour point of a wax isomerate using the particular high molecular weight polyalkylmethacrylate described below.
SUMMARY OF THE INVENTION
This invention relates to a wax isomerate having a reduced pour point which comprises
(a) a major amount of a wax isomerate, and
(b) a minor amount of a polyalkylmethacrylate having a weight average molecular weight of at least 600,000,
wherein the isomerate thus formed has a lower pour point than would have been obtained using a polyalkylmethacrylate having a weight average molecular weight below 600,000.
DETAILED DESCRIPTION OF THE INVENTION
This invention requires a wax isomerate and a high molecular weight polyalkylmethacrylate.
The wax isomerates used in this invention are the lubes fraction remaining following dewaxing the isomerate formed from isomerizing wax in the presence of a suitable catalyst under isomerization conditions.
The wax which is isomerized may originate from any number of sources. Synthetic waxes from Fischer-Tropsch processes may be used, as may be waxes recovered from the solvent or autorefrigerative dewaxing of conventional hydrocarbon oils, or mixtures of these waxes. Waxes from dewaxing conventional hydrocarbon oils are commonly called slack waxes and usually contain an appreciable amount of oil. The oil content of these slack waxes can range anywhere from 0 to 45% or more, but usually from 5 to 30% oil.
Isomerization is conducted over a catalyst containing a hydrogenating metal component--typically one from Group VI, or Group VIII, or mixtures thereof, preferably Group VIII, more preferably noble Group VIII, and most preferably platinum on a halogenated refractory metal oxide support. The catalyst typically contains from 0.1 to 5.0 wt. %, preferably 0.1 to 1.0 wt. %, and most preferably from 0.2 to 0.8 wt. % metal. The halogenated metal oxide support is typically an alumina (e.g. gamma or eta) containing chlorides (typically from 0.1 to 2 wt. %, preferably 0.5 to 1.5 wt. %) and fluorides (typically 0.1 to 10 wt. %, preferably 0.3 to 0.8 wt. %).
Isomerization is conducted under conditions of temperatures between about 270° to 400° C. (preferably between 300° to 360° C.), at pressures of from 500 to 3000 psi H 2 (preferably 1000-1500 psi H 2 ), at hydrogen gas rates of from 1000 to 10,000 SCF/bbl, and at a space velocity in the range of from 0.1 to 10 v/v/hr, preferably from 1 to 2 v/v/hr.
Following isomerization, the isomerate may undergo hydrogenation to stabilize the oil and remove residual aromatics. The resulting product may then be fractionated into a lubes cut and fuels cut, the lubes cut being identified as that fraction boiling in the 330° C. + range, preferably the 370° C. + range, or even higher. This lubes fraction is then dewaxed to reduce the pour point, typically to between about -15° to about -24° C. This fraction is the "wax isomerate" to which the high polyalkylmethacrylate of this invention is added. The polyalkylmethacrylate may also be added to a lubricating oil comprising a major amount of wax isomerate, a minor amount of the polyalkylmethacrylate, and a minor amount of a lubricating oil base stock (such as is described in U.S. Pat. No. 4,906,389, the disclosure of which is incorporated herein by reference).
The high molecular weight polyalkylmethacrylate should have a weight average molecular weight of at least about 600,000, preferably from 600,000 to about 1,000,000, as measured by gel permeation chromatography (GPC). The amount of high molecular weight polyalkylmethacrylate used can range from about 1 up to 20 wt. % or more. Practically, however, the amount of high molecular weight polyalkylmethacrylate will range from about 2 to about 10 wt. %, most preferably from about 3 to about 8 wt. %, based on weight of the final product.
The alkyl group comprising the high molecular weight polyalkylmethacrylate used in this invention may be straight chained or branched and should contain from 4 to 22 carbon atoms. Preferably, the polyalkylmethacrylate will contain C 4 , C 6 , C 8 , C 10 , C 12 , C 14 , C 18 , and C 20 carbons. These polyalkylmethacrylates are known articles of commerce and, as such, are readily available in the marketplace. Frequently, the polyalkylmethacrylates are available from vendors in mixture with a solvent.
This invention will be better understood by reference to the following example, which includes a preferred embodiment of this invention.
EXAMPLE
Use of Low and High MW Polyalkylmethacrylates in Slack Wax Isomerate Basestock
The pour point of several samples of a 10W40 formulation containing various polyalkylmethacrylates (PMA) was determined using ASTM D-97. The results of these tests are shown in Table 1 below:
TABLE 1______________________________________Sample A B C______________________________________Composition, wt. %SWI (1) 61.2600 Neutral 20.4Other additives (2) 12.6PMA, wt. %500,000 (3) 5.8 -- --511,000 (4) -- 5.8 --600,000+ (5) -- -- 5.8Pour Point, °C. -30 -33 -42______________________________________ (1) A slack wax isomerate having a viscosity of 29.4 cSt at 40° C. a viscosity index of 143, greater than 99.5% saturates, an initial boilin point of 341° C., a mid boiling point of 465° C., and a final boiling point of 570° C. (2) Includes antifoaming agents, antioxidants, antiwear agents, detergents, dispersants, and friction modifiers. (3) A commercially available VI improver available from Rohm and Haas as Ac 954. (4) A commercially available VI improver available from Rohm and Haas as Ac 702. (5) A commercially available VI improver available from Rohm and Haas as Ac 953.
The data in Table 1 show that the pour point of a slack wax isomerate can be reduced to -40° C. or lower (preferably -42° C. or lower) by using a single polyalkylmethacrylate provided it has a weight average molecular weight of at least 600,000.
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The addition of a polyalkylmethacrylate having a weight average molecular weight of at least 600,000 has been found to be effective in reducing the pour point of a wax isomerate to a level that cannot be obtained with conventional pour point depressants. In a preferred embodiment, the wax isomerate is a slack wax isomerate.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National Phase application of PCT International Application No. PCT/FR2012/051998, filed Sep. 6, 2012, and claims priority to French Patent Application No. 1158871, filed Sep. 30, 2011, the disclosures of which are incorporated by reference in their entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to a process for producing mechanical paper pulp. It also relates to a composition employed in this method, and to the use of this composition in a method for producing mechanical paper pulp. It relates, lastly, to a papermaking process.
BACKGROUND OF THE INVENTION
[0003] Paper pulps called “mechanical pulps” or “high-yield pulps” or “wood pulps” are obtained directly from wood by a sequence of mechanical treatments, generally referred to collectively as mechanical “refining”, and carried out by means of grindstones and/or refiners. The mechanical paper pulp is subsequently subjected to a bleaching phase, which may comprise one or more stages, depending on the degree of whiteness required.
[0004] The advantage of a mechanical pulp production process is its high material yield as compared with a “chemical” pulp production method. The reason is that, unlike the chemical pulp production methods, in which the lignin present in the untreated wood is removed almost entirely by cooking in the presence of chemical products, around 90% of the untreated wood is conserved in the pulps obtained at the outcome of a mechanical pulp production method.
[0005] The mechanical refining in a mechanical pulp production method typically comprises a number of refining steps, such as a primary refining operation, generally called “defibering”, a secondary refining operation, a tertiary refining operation, an operation of refining screening wastes, etc. These refining steps provide pulps which have different degrees of refining, in order to progressively transform the wood into individualized fibers and so to allow the production of paper pulp.
[0006] Mechanical refining has the drawback of being highly energy-consuming, consuming typically from 1500 to 3000 kWh per metric ton of mechanical pulp produced. This energy on the one hand represents a substantial cost and on the other hand may cause damage to the wood fibers. Various pathways have therefore been conceived in order to reduce the required energy.
[0007] Accordingly, document EP 1728917 proposes carrying out a refining operation at low consistency, in other words at low pulp dry matter content. A treatment of this kind, however, requires a host of apparatus, and is of limited efficacy.
[0008] Document WO 08081078, in turn, proposes a mechanical pulp production method comprising a step of ozone treatment during refining. This treatment, however, has the drawback of giving rise to chromophoric groups on the polysaccharide molecules contained in the wood, these groups proving difficult to oxidize when the pulp is subsequently bleached conventionally.
[0009] Moreover, a particular interest has developed in enzymatic wood treatments within mechanical pulp production methods, owing to their gentle environmental impact.
[0010] Known accordingly is document U.S. Pat. No. 6,267,841, which describes a mechanical pulp production method comprising an enzymatic treatment step performed between two refining steps or prior to one refining step. The enzyme is selected from pectinases, xylanases, laccases, cellulases, manganese peroxidases, and mixtures thereof. These treatments, however, have the drawback of degrading the wood fibers, and/or require refining to be carried out at a high temperature, thereby limiting the energy saving that is realizable.
[0011] Documents EP 429422 and WO 91/11552 also describe mechanical pulp production methods which comprise a step of enzymatic pretreatment of a fibrous material for the purpose of facilitating its subsequent refining. In document EP 429422, the redox potential of the enzymes described is adjusted using regulators such as gaseous oxygen or nitrogen, antioxidants, sugars, organic acids, or inorganic salts. In document WO 91/11552, a recommendation is made to carry out the enzymatic pretreatment beyond a certain redox potential. Adjusting the redox potential of the enzymes, however, is a delicate operation, and proves to be costly.
[0012] Document EP 0745 154 describes a chemical pulp production method employing a multiple-component system for the modification, decomposition, or decoloring of the lignin, comprising in particular an oxidoreductase enzyme, a mediator, a free amine and an oxidizing agent. This system is employed for bleaching a chemical pulp which has been delignified with oxygen beforehand. This system has the drawbacks of generating effluents that are harmful to the environment, and of giving rise to high production costs.
[0013] Optimizing the enzymatic activity of laccases, moreover, has been studied in document U.S. 2008/0189871. This document proposes an LMS system (Laccase Mediator System) comprising a mediator derived from 2,6-dimethoxyphenol. This system is employed for bleaching a cloth. It is stated on the one hand that it may be used during the manufacture of pulp and on the other hand that it may be used during the bleaching of a pulp.
[0014] The methods and the products used in the prior art, therefore, do not provide complete satisfaction.
[0015] In particular there is still a need existing to reduce the energy demand of mechanical pulp production methods and to ensure, furthermore, a mechanical pulp having papermaking qualities that are equivalent to or an improvement on those obtained by the known techniques. There is also a need existing for a mechanical pulp having a degree of whiteness greater at the outcome of refining, and/or developing an improved capacity for bleaching, relative to those obtained by the known techniques. A need exists, lastly, to reduce the amount of chemical products required to bleach a mechanical pulp while ensuring an equivalent or improved degree of whiteness in relation to the mechanical pulps obtained with the techniques of the prior art.
SUMMARY OF THE INVENTION
[0016] The present invention accordingly provides a method for producing a mechanical paper pulp.
[0017] More specifically the invention relates in the first instance to a process for producing a mechanical paper pulp, comprising at least:
a step of impregnating an untreated wood, comprising contacting the untreated wood with an impregnating composition comprising at least one laccase enzyme and a mediator of formula (I):
[0000]
in which R1 and R2 are identical or different groups selected from a hydrogen atom and a saturated or unsaturated, linear or branched hydrocarbon chain comprising from 1 to 14 carbon atoms, it being possible for each hydrocarbon chain to be substituted by one or more functional groups selected from —OH, —SO3, benzyl, amino, mercapto, keto, and carboxyl, where R1 and R2 may together form a cyclic structure (as in piperidinyloxy compounds), to give an impregnated wood; and
a step of mechanically refining the impregnated wood, so as to obtain a mechanical paper pulp.
[0021] More preferably, the process for producing a mechanical paper pulp of the invention comprises at least:
a step of impregnating an untreated wood, comprising contacting the untreated wood with an impregnating composition comprising at least one laccase enzyme and a mediator of formula (I):
[0000]
in which R1 and R2 are identical or different groups selected from a hydrogen atom or a C1 to C8 alkyl chain, to give an impregnated wood; and
a step of mechanically refining the impregnated wood, so as to obtain a mechanical paper pulp.
[0025] Further preference among the mediators of formula (I) is given to those for which at least one of R1 and R2 is different from H. Even further preference is given to those for which R1=R2 and they each represent a C1-C8, more particularly C1-C6, and more preferably C1-C4 alkyl radical. One particularly preferred example would be N,N-diethylhydroxylamine.
[0026] The invention likewise relates to the impregnating composition employed in this method.
[0027] The invention also provides for the use of said impregnating composition in a method for producing mechanical paper pulp, for lowering the energy consumption of said method.
[0028] The invention further provides for the use of said impregnating composition in a method for producing mechanical paper pulp, for enhancing the whiteness of said pulp.
[0029] The invention also provides for the use of said impregnating composition in a method for producing mechanical paper pulp comprising a step of mechanical refining, said impregnating composition being used before the step of mechanical refining.
[0030] The invention provides, lastly, a papermaking process comprising the production of a mechanical paper pulp by the above method, and also to the use of this mechanical paper pulp for manufacturing paper.
[0031] The present invention may allow for the drawbacks of the prior art to be overcome. More particularly, it provides a method for producing mechanical paper pulp that is more energy-saving and which ensures a pulp and paper whose papermaking qualities are equivalent to or an improvement over those of the known methods. It likewise provides a mechanical paper pulp having a degree of whiteness that is greater at the end of refining and/or that develops a better capacity for bleaching, relative to the mechanical paper pulps obtained with the known methods. The invention also permits a reduction in the amount of chemical products to be employed for bleaching the mechanical paper pulp while ensuring a degree of whiteness at the outcome of bleaching that is at least equivalent to, or even greater than that of the mechanical paper pulps produced with the known methods. This is accomplished by virtue of a step of impregnating wood with a specific impregnating composition, prior to its refining.
[0032] More particularly, the composition according to the invention oxidizes the phenolic and nonphenolic units in the lignin, thereby weakening the bonds between the fibers. The Applicant has, in particular, developed an impregnating composition which acts specifically on the cell wall of the fibers, allowing the cohesion between the fibers to be reduced while at the same time preserving the fibers. Therefore, when the composition of the invention is used on wood prior to its refining, it allows a reduction in the energy it would be necessary to supply during refining in order to separate the fibers of the wood if no pretreatment was carried out, or if a prior-art technique was employed instead. Moreover, the length of the fibers obtained from the initial wood, and their strength, are preserved in the mechanical paper pulp produced and in the paper obtained from it.
[0033] Lastly, in contrast to the compositions proposed by the prior art, the impregnating composition according to the invention is inexpensive, available in large quantity and less toxic for the environment.
DEFINITIONS
[0034] A “mediator”, according to the invention, is a compound which enhances the capacity of an enzyme to oxidize wood.
[0035] “Wood” means the entirety of the strong secondary (support, transfer, and reserve) tissues which form the trunks, branches, and roots of woody plants, in the sense of standard NF B 50-003.
[0036] By “untreated” wood is meant the condition of wood prior to its treatment with an impregnating composition according to the invention, and by “impregnated” wood is meant the condition of wood after its treatment with an impregnating composition according to the invention.
[0037] Unless otherwise specified, the percentages of material stated are percentages by weight.
[0038] Unless otherwise indicated, the percentages by weight of wood are given by weight of dry wood. “Dry wood” means that the wood has been dried in an oven in accordance with standard ISO 638:2008, namely at a temperature of from 103° C. to 107° C., for a time which is at least 30 minutes and does not exceed 16 hours, at atmospheric pressure.
[0039] The “consistency” of the mechanical paper pulp denotes the pulp concentration as defined in the ISO 4119 Standard of June 1996. This is the ratio of the dry mass of material which may be filtered from a sample of pulp in suspension, to the mass of the unfiltered sample, the test being carried out in accordance with said International Standard. The concentration of pulp is expressed herein as a percentage by mass.
[0040] Unless otherwise specified, the percentages by weight of mechanical paper pulp are given by weight of dry mechanical paper pulp. “Dry mechanical paper pulp” means the dry mass of material in a sample of pulp in suspension, as defined in the above ISO 4119 Standard, as measured after filtration and drying in accordance with said Standard.
[0041] Unless instructed otherwise, the measurements are performed at atmospheric pressure.
[0042] When reference is made to ranges, the expressions of the type “of from . . . to” include the endpoints of the range. Conversely, the expressions of the type “of between . . . and . . . ” exclude the endpoints of the range.
DETAILED DESCRIPTION
[0043] The invention is now described in more detail and nonlimitatively in the description which follows.
[0044] In schematic terms, the method for producing mechanical paper pulp according to the invention comprises at least:
a step of impregnating untreated wood, comprising contacting the untreated wood with an impregnating composition according to the invention, to give an impregnated wood, a step of mechanical refining of the impregnated wood, to give a mechanical paper pulp.
[0047] In more detail, the method for producing mechanical paper pulp of the invention comprises, preferably in this order, the following steps:
optionally an operation of steaming an untreated wood, optionally an operation of pressing an untreated wood, at least one step of impregnating an untreated wood with an impregnating composition according to the invention, to give an impregnated wood, optionally an operation of steaming the impregnated wood, at least one step of mechanically refining the impregnated wood, to give a mechanical pulp, optionally a step of chelating the mechanical pulp, optionally an operation of bleaching the mechanical pulp.
[0055] The starting material used is untreated wood.
[0056] According to one embodiment, the untreated wood is selected from coniferous woods, deciduous woods, or mixtures thereof. Suitable coniferous woods include Douglas fir, spruce, Aleppo pine, maritime pine, black pine, Scots pine, loblolly pine, red cedar ( Thulya plicata ), or mixtures thereof. Suitable deciduous woods include poplar, aspen, birch, maple, oak, eucalyptus, acacia, beech, chestnut, hornbeam, elm, or mixtures thereof. Preference is given to using spruce, poplar, eucalyptus, or a mixture thereof.
[0057] According to one embodiment, for producing a chemithermomechanical pulp (CTMP), the untreated wood may be selected from coniferous woods such as those stated above, deciduous woods such as those stated above, or else bamboo, hemp, cereal straw, as for example wheat straw or rice straw, cotton, or mixtures thereof.
[0058] According to one preferred embodiment, the untreated wood is in the form of chips. The term “chips” is employed in the sense conventional to the skilled person. It designates wood particles obtainable by any industrial process conventionally used in the mechanical pulp field. The size of the chips is typically subject to distribution in accordance with the standard SCAN-CM 40:01. This form facilitates in particular the subsequent impregnation treatment of the wood, and enhances its effectiveness. The chips may typically be obtained from debarked and cut logs of untreated wood, or from residual byproducts of the wood industry.
[0059] According to one embodiment, the wood, before or after the impregnating step, preferably before the impregnating step, undergoes at least one pretreatment selected from a thermal pretreatment, a chemical pretreatment, a mechanical pretreatment, or a combination of these. Suitable thermal pretreatment includes steaming, hot-water treatment, or a combination of these. Suitable chemical pretreatment includes an impregnating treatment on the wood with at least one chemical agent selected from an acid, a base, an oxidizing agent, a reducing agent, a chelating agent, a stabilizer, a surfactant, an enzyme, or mixtures thereof. Suitable mechanical pretreatment includes pressing.
[0060] According to one embodiment, the wood, before or after the impregnating step, preferably before the impregnating step, undergoes steaming, which gives the wood a uniform moisture content. Steaming comprises contacting the wood with steam. Steaming is preferably performed at atmospheric pressure. Steaming lasts preferably for from 5 to 30 minutes, more preferably from 10 to 20 minutes.
[0061] According to one embodiment, the untreated wood, before or after the impregnating step, preferably before the impregnating step, undergoes pressing. Pressing may be carried out using any means known to the skilled person, preferably using a compression device such as a screw press or a cylinder press.
[0062] The aforementioned embodiments may advantageously be combined with one another: according to one preferred embodiment, the untreated wood is initially in the form of chips, and the chips undergo steaming as defined above; according to another preferred embodiment, the untreated wood, before the impregnating step, undergoes steaming followed by pressing as defined above.
[0063] According to one particular embodiment, the wood does not undergo chemical pretreatment before the impregnating step, in particular no acid washing or chelation treatment.
[0064] The various pretreatments identified above may be performed before or after the impregnating step. They may also be repeated if necessary. For example, it is possible to perform one of these pretreatments before the impregnating step, to carry out the impregnating step, and then to repeat said pretreatment after the impregnating step.
[0065] The production method according to the invention comprises a step of impregnating untreated wood, comprising contacting the untreated wood with an impregnating composition according to the invention, to give an impregnated wood. Said impregnating composition comprises at least one laccase enzyme and a mediator with a specific formula. The impregnating composition according to the invention accordingly comprises a mediator of formula (I):
[0000]
[0066] in which R1 and R2 are identical or different groups selected from a hydrogen atom or a C1 to C8 alkyl chain.
[0067] R1 and R2 are preferably identical or different groups selected from a hydrogen atom or a C1 to C4 alkyl chain. More preferably, R1 and R2 are identical or different C1 to C4 alkyl chains. Even more preferably, R1 and R2 are identical alkyl chains of formula C2H5: the preferred mediator is therefore diethyl hydroxylamine (DEHA).
[0068] The mediator may be present in the impregnating composition in pure form, in solution in water, or in the form of one of its salts.
[0069] The mediator content of the impregnating composition is preferably from 0.1% to 10% by weight, preferably from 0.15% to 4.5% by weight, preferably from 0.19% to 4% by weight, preferably from 0.19% to 3% by weight, or even from 0.23% to 2% by weight, relative to the total weight of the impregnating composition.
[0070] The mediator content, relative to the mass of dry untreated wood for treatment, is preferably from 0.1% to 10%, from 0.2% to 10%, from 0.2% to 5%, more preferably from 0.2% to 0.5%, or even from 0.25% to 0.5%, by weight of dry wood.
[0071] The laccase enzyme may be selected from class EC 1.10.3.2 of the enzymes nomenclature. Mycellophthora laccase is particularly preferred. The laccase enzyme may be in crude extract form or in purified or semipurified form.
[0072] The amount of 1000 LAMU/mL laccase solution, relative to the mass of dry untreated wood for treatment, is preferably from 0.1 to 10 L/t, from 1 to 5 L/t, more preferably from 1 to 2 L/t of the dry untreated wood.
[0073] The amount of 1000 LAMU/mL laccase solution in the impregnating composition is preferably from 0.01% to 10° ,6 by weight, from 0.05% to 5% by weight, from 0.05% to 1% by weight, more particularly from 0.09% to 0.2% by weight, relative to the total weight of the impregnating composition.
[0074] The impregnating composition according to the invention may further comprise one or more additives usual for the skilled person, provided that their presence does not diminish the efficacy of the composition. Such additives may in particular be selected from the following: an enzyme other than laccase, an oxidizing agent, a reducing agent, an acid, a base, a chelating agent, a stabilizer, a surfactant, and combinations thereof. When present, the amount of total additive in the impregnating composition is preferably less than 3% by weight, more particularly less than 2% by weight, relative to the total weight of the composition. According to one embodiment, the impregnating composition does not comprise additive.
[0075] According to one embodiment, the impregnating composition is an aqueous solution. The water content of the composition then corresponds to the balance to 100% by weight of the sum of the amounts of mediator, of enzyme, and of optional additives.
[0076] According to one embodiment, the impregnating composition is used at a rate of 0.1 to 12 L/kg of the dry untreated wood for impregnation, preferably at a rate of from 1 to 10 L/kg of the untreated wood for impregnation. The excess impregnating composition may advantageously be recycled for carrying out a new impregnating step on another untreated wood or on the impregnated wood.
[0077] According to one embodiment, the contacting of the untreated wood with the impregnating composition comprises (or even consists of) spraying the impregnating composition onto the untreated wood, or immersing the untreated wood in a bath of impregnating composition.
[0078] According to one particular embodiment, the untreated wood is immersed in the impregnating composition for a time sufficient to allow impregnation of the wood with impregnating composition, after which the wood is withdrawn from the composition and left to incubate for a time sufficient to allow the enzyme to act on the wood. As a variant, the untreated wood is immersed in the impregnating composition and is left therein to incubate for a time sufficient to allow the enzyme to act on the wood. Incubation may be performed in any suitable device known to the skilled person, as for example in a storage vat.
[0079] According to one preferred embodiment, the contacting of the untreated wood with the impregnating composition is performed by spraying chips of untreated wood, which have been compressed, straight from a compression screw into a bath of impregnating composition. This allows optimum absorption by the chips (the chips draw up the composition in the manner of a sponge) and promotes the action of the composition at the core of the wood fibers.
[0080] Contacting of the untreated wood with the impregnating composition is preferably performed for a time of from 5 minutes to 240 minutes, from 25 minutes to 180 minutes, from 45 minutes to 120 minutes, more preferably from 55 min to 65 min. The impregnating composition is preferably employed at a temperature of from 35 to 80° C., from 40 to 70° C., more particularly from 45 to 55° C. It is preferably employed at a pH of from 3 to 11, from 4 to 7, more preferably from 4.5 to 5.5. Such conditions are advantageous for optimizing the efficacy of the composition according to the invention.
[0081] The impregnating step may be discontinued by steaming (contacting the impregnated wood with steam) or by washing with water, in order to halt the activity of the enzyme. The duration of the steaming or the washing with water is preferably from 1 to 10 minutes, more preferably from 3 to 7 minutes. Preference is given to steaming at atmospheric pressure.
[0082] The impregnating step is advantageously repeated a number of times, more particularly two to four times. The various aforementioned embodiments may also be combined with one another. Lastly, it should be noted that the impregnating composition may be prepared separately and then contacted with the untreated wood, as explained above, but may also be prepared directly in contact with the untreated wood. In this case, the various compounds of the impregnating composition are added successively and directly to the untreated wood.
[0083] Further to impregnation, the wood may be subjected to an additional treatment, referred to as aftertreatment. This aftertreatment involves contact with a chemical composition comprising an alkaline agent and a reducing agent. This aftertreatment is advantageous for softening the lignin and developing the mechanical characteristics of the fibers. It is advantageous more particularly when the aim is to produce a chemithermomechanical pulp (CTMP).
[0084] This step is preferably performed after the impregnating step, in order to prevent potential inhibition of the enzymes in the impregnating composition. It may be performed before or after the refining step. It is preferably performed between the impregnating step and the refining step, thereby allowing a greater energy saving to be made in the refining.
[0085] According to one embodiment, the contacting of the wood with the chemical composition comprises spraying of said composition onto the wood, or immersion of the wood into a bath of said composition.
[0086] According to one embodiment, the alkaline agent is selected from sodium hydroxide, magnesium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, sodium silicate, or mixtures thereof. The alkaline agent is preferably selected from sodium silicate, sodium hydroxide, or a mixture thereof.
[0087] According to one embodiment, the reducing agent is selected from sodium sulfite Na 2 S 2 O 3 , sodium bisulfite NaHSO 3 , or a mixture thereof.
[0088] According to one embodiment, the alkaline agent is present in an amount of from 0.1% to 20% by weight, preferably from 1% to 10% by weight, relative to the weight of wood.
[0089] According to one embodiment, the reducing agent is present in an amount of from 0.1% to 30% by weight, preferably from 1% to 20% by weight, relative to the weight of wood.
[0090] The chemical aftertreatment step is preferably performed at a temperature of from 10° C. to 150° C., more particularly from 60° C. to 120° C. It is preferably performed for a time of from 1 minute to 120 minutes, preferably from 1 to 60 minutes.
[0091] The chemical aftertreatment step may be brought to an end by any means that stops the reaction of the chemical agents on the wood, as for example by washing with water.
[0092] The chemical aftertreatment step may advantageously be repeated a number of times, more particularly two times to four times, therefore allowing the papermaking capacities of the fibers to be reinforced further.
[0093] After the impregnating step (and the optional chemical aftertreatment step), the impregnated wood is mechanically refined, to give a mechanical paper pulp. The mechanical refining comprises primary mechanical refining (also called defibration), which is intended to pulp the wood optionally, followed by at least one secondary mechanical refining, which is intended to develop the papermaking capacities of the fibers. The secondary refining is optionally followed by one or more subsequent mechanical refining operations (tertiary refining, refining of wastes, etc.).
[0094] Mechanical refining is preferably carried out under pressure in order to allow more selective separation of the fibers.
[0095] Primary refining may be performed by milling or grinding the wood on a grindstone (in a stream of water) or in a disk refiner.
[0096] According to one embodiment, the primary refining of the wood is performed in a disk refiner. The pressure is preferably set so as to achieve a refining temperature of between 105° C. and 115° C. The pressure is advantageously from 0.5 to 5 bar, preferably from 1 to 3 bar. The rotary speed of the disks is preferably from 1000 to 5000 revolutions/minute, preferably from 1000 to 3000 revolutions/minute.
[0097] According to one embodiment, the secondary refining of the wood is performed in a disk refiner. Secondary refining is preferably performed under a pressure of from 0.1 to 5 bar, preferably from 0.5 to 3 bar. The rotary speed of the disks is preferably from 1000 to 5000 revolutions/minute, preferably from 1000 to 3000 revolutions/minute.
[0098] According to one embodiment, secondary refining is performed such that the resultant pulps have a degree of dewatering of from 250 to 50 mL CSF (Canadian Standard Freeness).
[0099] The refining step or steps subsequent to defibration may comprise a plurality of stages. For example, after defibration, the product may be separated into an accepted fraction and a rejected fraction, and the rejected fraction may be refined before being blended with the accepted fraction. Such intermediate separations may be provided a plurality of times.
[0100] At the outcome of refining, a mechanical paper pulp is obtained which may in particular be:
a defibrator mechanical pulp (SGW) obtained from logs or blocks refined at atmospheric pressure using grinding disks; a pressure defibrator mechanical pulp (PGW) obtained from logs or blocks refined under pressure using grinding disks; a refiner mechanical pulp (RMP) obtained from chips or shives in refiners operating at atmospheric pressure; a thermomechanical pulp (TMP) or high-temperature thermomechanical pulp (HTMP) obtained from chips or shives in refiners after heat treatment of the wood by steaming at elevated pressure; a chemithermomechanical pulp (CTMP) obtained by chemical treatment in the presence of a chemical composition comprising an alkaline agent and a reducing agent at a temperature greater than or equal to 100° C. and by refining under pressure.
[0106] At the end of refining, a mechanical pulp is obtained which preferably has a brightness, measured in accordance with standard ISO 2470, of greater than or equal to 50%, preferably greater than or equal to 55%, ideally greater than or equal to 57%.
[0107] The specific energy saving achieved by virtue of the invention is advantageously greater than or equal to 10%, or even greater than or equal to 12%, or even greater than or equal to 14%, or even greater than or equal to 18% or even greater than or equal to 32%, by comparison with a method for producing a mechanical pulp obtained by refining preimpregnated wood under the same conditions, but with water.
[0108] Chelation, when practiced, comes preferably after the impregnating step (that is, when the impregnating step has been accomplished), advantageously after refining, in order to prevent any possible inhibitory interaction with the enzyme. Chelation comprises contacting the mechanical paper pulp obtained from refining with a chelating composition comprising a chelating agent, said chelating composition being preferably an aqueous solution.
[0109] The chelating agent may be any chemical compound conventionally used for this purpose in the art. Preferably it involves ethylene diamine tetraacetic acid or one of its sodium salts, or diethylene triamine pentaacetic acid or one of its sodium salts.
[0110] The chelating agent possesses a particular affinity for the metal cations present as traces in the mechanical pulp. The objective of the chelation treatment is to neutralize these cations by sequestering them and withdrawing them from the mechanical pulp by washing of said pulp. Carrying out the chelating step makes a contribution to enhancing the performance level of a subsequent bleaching treatment (in particular with hydrogen peroxide).
[0111] The amount of chelating agent used in the chelating step is preferably from 0.05% to 3% by weight, preferably from 0.1% to 2% by weight, preferably from 0.2% to 1% by weight, more particularly from 0.3% to 0.5% by weight, relative to the weight of dry mechanical pulp.
[0112] The duration of the chelating step is preferably greater than or equal to about 30 minutes.
[0113] The chelating step is performed at a temperature of preferably from 4° C. to 95° C., preferably from 25° C. to 85° C., more preferably from 35° C. to 80° C. A temperature of about 60° C. is particularly appropriate.
[0114] The consistency of the mechanical pulp during the chelating step is preferably from 0.5% to 20% by weight of dry mechanical pulp, preferably from 2 to 15% by weight of dry mechanical pulp, more preferably from 3 to 12% by weight of dry mechanical pulp, relative to the weight of nondry mechanical pulp.
[0115] Bleaching comes preferably after chelation (or after refining, if no chelation is carried out), in other words when the chelating step (or the refining step if chelation is not carried out) has been accomplished.
[0116] Bleaching comprises contacting the mechanical paper pulp from the chelating step (or refining step if chelation is not carried out) with a bleaching composition.
[0117] The consistency during the bleaching step is preferably from 1% to 50% by weight of dry mechanical pulp, preferably from 10 to 40% by weight of dry mechanical pulp, more preferably from 20 to 30% by weight of dry mechanical pulp, relative to the weight of nondry mechanical pulp.
[0118] Bleaching has reaction kinetics that are more rapid at high consistency (whereas, for chelation, the reaction kinetics are rapid even at low consistency). It is possible to increase the consistency of the mechanical pulp, by pressing it, for example, and by removing filtrates comprising, in particular, the chelated metals.
[0119] Contacting takes place preferably by simple mixing of the bleaching composition with the pulp. The type of apparatus used for mixing is adapted to the consistency of the pulp: direct mixing by means of an injection pump if the consistency is low or medium (less than 10%); blender or mixer for a higher consistency (up to about 40%).
[0120] The bleaching composition is preferably an aqueous solution. The bleaching composition preferably comprises a bleaching agent and an alkaline agent. The bleaching agent may be any chemical compound conventionally used for this purpose in the art. Preference is given to hydrogen peroxide or sodium hydrosulfite.
[0121] The amount of bleaching agent used is preferably from 0.5% to 10% by weight, preferably from 1% to 8% by weight, preferably from 1.5% to 6% by weight, more particularly from 2% to 4% by weight, relative to the weight of dry mechanical pulp.
[0122] The alkaline agent may be selected from alkaline metal and alkaline earth metal oxides, hydroxides, silicates, and carbonates, ammonia, aqueous ammonia, and mixtures thereof. The preferred basic species for selection of the alkaline agent including potassium hydroxide, sodium hydroxide, magnesium hydroxide, calcium hydroxide, sodium carbonate, sodium silicate, magnesium carbonate, and mixtures thereof. Sodium hydroxide, potassium hydroxide, or a mixture thereof is particularly preferred. The alkaline agent of the bleaching composition preferably comprises sodium silicate. Sodium silicate has an auxiliary function of stabilizing the bleaching agent (especially the hydrogen peroxide). In the bleaching composition it is also possible to provide another stabilizing agent, in addition to or instead of the sodium silicate. Polyhydroxyacrylate compounds constitute possible stabilizing agents.
[0123] The amount of alkaline agent used is preferably from 0.5% to 10% by weight, preferably from 1% to 6% by weight, preferably from 1.4% to 4% by weight, more particularly from 1.6% to 2.5% by weight, relative to the weight of dry mechanical pulp.
[0124] The bleaching composition may further comprise a chelating agent as defined above, especially if the chelating step is not carried out or ended at incomplete chelation.
[0125] It should be noted that the bleaching composition may be prepared separately and then contacted with the mechanical pulp, but it may also be prepared directly in contact with the mechanical pulp. In this second case, the various compounds of the bleaching composition are added successively and directly to the mechanical pulp.
[0126] The duration of the bleaching step varies with the type of agent used.
[0127] In the case of hydrogen peroxide, this duration is preferably from 10 minutes to 8 hours, preferably from 30 minutes to 6 hours, more preferably from 2 hours to 4 hours.
[0128] The bleaching step is carried out at a temperature of preferably from 4° C. to 95° C., preferably from 25° C. to 85° C., more preferably from 35° C. to 80° C. A temperature of about 70° C. is particularly suitable.
[0129] The bleaching step may be repeated a number of times, as for example twice.
[0130] At the end of the first bleaching, a mechanical pulp is obtained which preferably has a brightness, measured in accordance with standard ISO 2470-2:2008, of greater than or equal to 57%, more preferably of greater than or equal to 60%, ideally greater than or equal to 62% or even greater than or equal to 65%.
[0131] The invention relates, lastly, to a papermaking process that comprises producing mechanical paper pulp by the method above, then using this mechanical pulp to manufacture paper.
[0132] The mechanical pulp may in particular be dried and converted to sheets in a paper machine conventional in the art.
[0133] The mechanical pulp may also be introduced into a wet machine, in order to be dried and preformed into sheets. The sheets may be baled, before being transferred to a papermaking plant, where they may undergo subsequent treatments.
[0134] The tearing resistance of the paper obtained by implementation of the present invention (as measured in accordance with standard NF EN 21974 after the mechanical pulp has been formed into sheets in accordance with standard NF EN 5269-1) is advantageously increased by 3%, or even 9%, or even 11%, relative to a mechanical pulp obtained by refining wood preimpregnated with water.
[0135] Measurement Parameters
[0136] The activity of the laccase enzyme is expressed in LAMU/mL. One LAMU unit corresponds to the amount of laccase enzyme which, under given conditions (pH 7.5 and 30° C. temperature), breaks down 1 μmol of syringaldazine per minute. This activity can be determined on the basis of spectrophotometric absorbance measurements. The reason is that, in the course of the reaction in which a laccase (E.C. 1.10.3.2), p-diphenol:dioxygene oxidoreductase, catalyzes the oxidation of syringaldazine (4,4′-[azinobis(methanylylidine)]bis(2,6-dimethoxyphenol)) to the corresponding quinone (4,4′-[azobis(methanylylidine)]bis(2,6-dimethoxycyclohexa-2,5-dien-1-one), there is a change in absorption by the syringaldazine at a wavelength of 530 nm.
[0000] The measurement uses:
a 25 mM tris/malate buffer solution (pH 7.5) (prepared from 25 mL of a 1.0 M aqueous solution of tris(hydroxymethyl)aminomethane, 5 mL of a 1.0 M aqueous solution of maleic acid, and the amount of water sufficient to give 1 L of buffer solution), a 0.28 mM syringaldazine solution (prepared by diluting 25 mL of a 0.56 mM alcoholic solution of syringaldazine in the amount of water sufficient to give 50 mL of syringaldazine solution, the 0.56 mM alcoholic syringaldazine solution being itself obtained by dissolution of 10.0 mg of syringaldazine (Sigma S-7896) in the amount of 96% ethanol sufficient to give 50 mL of alcoholic syringaldazine solution), a 6% by weight aqueous solution of ethanol, an enzyme dilution solution (containing 25.0 g of PEG 6000, 5.0 g of Triton X-100, and an amount of water sufficient to give 0.5 L of solution). The test laccase samples are diluted by a factor F using this solution, to approach an activity of 0.18 LAMU/mL.
The absorbance measurements are carried out with the spectrophotometer at an operating temperature of 30° C.: a tank is prepared with 1 mL of buffer solution, 25 μL of diluted laccase, and finally 75 μL of a 0.28 mM syringaldazine solution are added. After brief mixing, acquisition of the absorbance measurement is initiated straight away, for radiation with a wavelength of 530 nm.
[0141] The activity is calculated according to the following formula:
[0000] Activity ( LAMU /mL)=Δ A 530nm ×0.677' F
[0000] where ΔA 530nm is the difference in absorbance at 530 nm measured over the 60-90 seconds period, and F is the enzyme dilution factor.
[0142] The dewatering index, referred to as “Canadian Standard Freeness” (CSF), is measured in accordance with international standard ISO 5267-2. It conveys the ease with which water can be extracted from a mechanical paper pulp. The smaller the index, the poorer the dewatering of the mechanical pulp. This parameter is an indicator of the degree of refining achieved during mechanical refining of the pulp.
[0143] The brightness of the mechanical pulp is determined by measuring its diffuse blue reflectance factor as defined in standard ISO 2470-2: 2008.
[0144] For a test X, the gain in brightness corresponds to the difference between brightness measured at the end of bleaching QP, and the brightness measured at the end of refining.
[0145] The total specific refining energy is obtained by adding the values of electrical consumption measured for each of the steps prior to refining and up to its end (for example, compression of wood chips, defibration, and secondary refining).
[0146] For a test X, the energy saving achieved corresponds to the difference between the specific refining energy of a reference test, carried out under the same conditions as test X but with use of an abiotic impregnating composition, and the specific refining energy of the test X.
[0147] In order to evaluate the resistance of the fibers in the mechanical pulp produced, this pulp is formed into sheets in accordance with standard NF EN 52694, and the tearing resistance of the sheets is measured in accordance with standard NF EN 21974.
EXAMPLES
[0148] The examples which follow illustrate the invention without limiting it.
The starting materials used are as follows:
fresh Norwegian spruce chips, supplied by the Holmen company, chips from fresh poplar logs, supplied by a forestry enterprise in the Lyons region, fresh Spanish eucalyptus chips, supplied by the Ence company, Myceliophthora laccases sold by the Novozymes company under reference NS51003, having an activity of 1000 LAMU/mL as measured in accordance with the protocol indicated above, diethylhydroxylamine (DEHA) sold by the Arkema company, 4-hydroxy-3,5-dimethoxybenzaldehyde (syringaldehyde), diethylene triamine pentaacetic acid (DTPA), hydrogen peroxide, sodium silicate, sodium hydroxide, magnesium sulfate.
Table 1: Impregnating Composition
[0160] For each test, an impregnating composition in accordance with table 1 is prepared (the percentages are given by weight relative to the total weight of the composition). For this purpose, the water is heated to 50° C., the pH is adjusted to 5 by addition of sulfuric acid, and the commercial laccase solution and, lastly, the DEHA (or the syringaldehyde, where appropriate) are added. The impregnating compositions of tests 1, 6, and 9 are abiotic reference compositions. The compositions of tests 2, 4, and 5 are comparatives. The compositions in accordance with the invention are those of tests 3, 7, 8, 10, and 11.
[0161] The effective absorption capacity of the dry chips is 1.04 L of impregnating composition per kilogram of dry wood chips. For each test, the composition is used in excess, at a rate of 70 L per 10 kg of dry wood chips.
[0000]
Laccase
solution
Syring-
at 1000
alde-
Water
LAMU/mL
DEHA
hyde
at pH 5
TMP
Test 1
100%
(ref)
Test 2
0.192%
1.92%
balance to 100%
(comp)
Test 3
0.192%
1.92%
balance to 100%
(inv)
Test 4
0.192%
balance to 100%
(comp)
Test 5
1.92%
balance to 100%
(comp)
TMP
Test 6
100%
(ref)
Test 7
0.096%
0.48%
balance to 100%
(inv)
Test 8
0.096%
0.24%
balance to 100%
(inv)
CTMP
Test 9
100%
(ref)
Test 10
0.096%
1.92%
balance to 100%
(inv)
Test 11
0.096%
0.192%
balance to 100%
(inv)
Tests 1 to 5: Thermomechanical Pulping (TMP) and Bleaching
[0162] Spruce wood chips are subjected to steaming at atmospheric pressure for 15 minutes, then introduced into a compression screw (6-inch model Modular Screw Device Impressafiner™ from Andritz AG), connected to a vat containing the impregnating composition. At the screw exit, the compressed chips are expelled directly into the impregnating composition, where they are left to incubate for 1 hour. The impregnating composition is extracted, and the chips are then subjected to steaming for 5 minutes to halt the enzymatic activity.
[0163] The chips pretreated in this way are transferred to a pilot-scale mechanical paper pulper (disk refiner), in which they are mechanically defibrated and then refined. Defibrating (primary refining) is performed at a pressure of 2 bar with disks rotating at 3000 revolutions/min. Secondary refining is performed at a pressure of 1 bar. The spacing between the disks is adjusted gradually so as to give five mechanical pulps with dewatering indices of 250 mL to 50 mL CSF. The brightness of the five mechanical pulps is measured according to standard ISO 2470-2:2008.
[0164] After refining, each resulting TMP mechanical pulp is bleached by a two-step method comprising a chelating step (Q) followed by hydrogen peroxide bleaching (P). In step Q, the consistency of the mechanical pulp is adjusted to 10% by weight. Step Q comprises contacting this mechanical pulp, at a temperature of 60° C. for 30 minutes, with 0.4% by weight of diethylene triamine pentaacetic acid (DTPA), relative to the total weight of dry mechanical pulp. During step P, the consistency of the mechanical pulp obtained at the outcome of step Q is adjusted to 25% by weight. Step P comprises contacting this mechanical pulp, at a temperature of 70° C. for 120 minutes, with a bleaching composition comprising 3% of hydrogen peroxide, 1.9% of sodium hydroxide, and 2% of sodium silicate, in percentages by weight relative to the total weight of dry mechanical pulp. The brightness of the five mechanical pulps is measured according to standard ISO 2470-2:2008.
[0165] The mechanical pulps are subsequently formed into sheets in accordance with standard NF EN 5269-1. The tearing resistance of the sheets is measured according to standard NF EN 21974.
[0166] The specific energy consumption is calculated as described earlier on above—that is, by adding up the energy consumption at each step in the mechanical pulp production method up to the end of refining: 1st steaming, compression/expulsion, 2nd steaming, defibration and subsequent refining operations.
[0167] The results are reported in table 2 below, following interpolation of the values to 100 mL CSF.
[0000] TABLE 2 TMP Test 1 Test 2 Test 3 Test 4 Test 5 (ref) (comp) (inv) (comp) (comp) After refining Specific energy 2480 2350 2170 2380 2360 consumed (kWh/t) Energy saving/ref ref 52% 12.5% 4.0% 4.8% Brightness (%) 54.2 52.1 54 53.9 54.3 (B R ) After bleaching Brightness after QP (%) 68.5 65.7 70.8 67.6 68 (B QP ) Brightness gain 26.4% 26.1% 31.1% 25.4% 25.2% (B QP − B R )/B R After sheet formation Tearing resistance 6.2 6 6.4 5.8 4.8 (mNm 2 /g)
Concerning the specific energy consumption of refining, test 3 according to the invention shows that:
the invention allows a significant reduction in the specific energy consumption of refining; the combination of laccase and DEHA allows a greater reduction in the specific energy consumption of refining than the compounds taken separately (tests 4 and 5); in combination with laccase, DEHA allows a greater reduction in the specific energy consumption of refining than syringaldehyde (test 2).
Concerning the brightness of the mechanical pulp, test 3 according to the invention shows that:
the invention allows a significant increase in the brightness of the mechanical pulp produced (test 1); the combination of laccase and DEHA allows an increase in the brightness of the pulp, in contrast to the compounds taken separately (tests 4 and 5 versus test 1); in combination with laccase, DEHA increases the brightness of the pulp more than syringaldehyde (test 2).
Concerning the tearing resistance of the paper, test 3 shows that the invention preserves the papermaking qualities of the fibers.
Tests 6 to 8: Effect of the Amount of Compounds in the Impregnating Composition
[0174] These complementary tests are carried out to determine the effect of the amount of reagents used in the impregnating composition according to the invention. The impregnating composition used for each test is given in table 1. The impregnating composition of test 6 corresponds to an abiotic reference composition. The compositions of tests 7 and 8 are in accordance with the invention. The procedure is exactly the same as for tests 1 to 4. The results are reported in table 3 below.
[0000]
TABLE 3
TMP
Test 6
Test 7
Test 8
(ref)
(inv)
(inv)
After
Specific energy
2451
2006
2595
Refining
consumed (kWh/t)
Energy saving/ref
ref
18.2%
−5.9%
Brightness (%) (B R )
54.2
55
57.2
After
Brightness after QP (%)
70
73
73.5
Bleaching
(B QP )
Brightness gain
29.2%
32.7%
28.5%
(B QP − B R )/B R
After
Tearing resistance
6.44
7.05
7.20
sheet
(mNm 2 /g)
formation
[0175] Test 7 (by comparison with test 6) shows that, even when the amounts of laccase and DEHA are reduced, the impregnating composition according to the invention reduces the specific energy consumption of refining, increases the brightness of the mechanical pulp produced, and preserves the strength of the paper obtained from said pulp.
[0176] Test 8 (by comparison with tests 6 and 7) shows that below a certain mediator content, the impregnating composition no longer reduces the specific energy consumption of refining, but still increases the brightness of the mechanical pulp produced and preserves the strength of the paper obtained from said pulp.
Tests 9 to 11: Chemithermomechanical Pulping (CTMP) and Bleaching
[0177] Poplar wood chips are pulped according to steps of steaming, compression, and impregnation that are identical to those of tests 1 to 4. The impregnating composition used for each of the tests is indicated in table 1. In particular, the impregnating composition of test 9 corresponds to an abiotic composition which serves as reference. The compositions of tests 10 and 11 are in accordance with the invention.
[0178] A second treatment of the chips is performed by addition to the vat of 2% by weight of sodium sulfite and 1% by weight of sodium hydroxide, relative to the total weight of dry chips. The temperature of the medium is raised to 125° C., and the chips are left to impregnate for 15 minutes.
[0179] The impregnated chips are subjected to defibration at a pressure of 2 bar with disks rotating at 3000 revolutions per minute, and then to a second mechanical refining at atmospheric pressure. The spacing between the disks is adjusted progressively so as to give five mechanical pulps with dewatering indices of from 400 to 100 mL CSF. The brightness of the five mechanical pulps is determined according to standard ISO 2470-2:2008.
[0180] After refining, each mechanical pulp CTMP obtained is subjected to bleaching comprising three steps: one chelating step (Q), followed by two successive treatments with hydrogen peroxide (PP).
[0181] During step Q, the consistency of the mechanical pulp is adjusted to 10% by weight. Step Q comprises the contacting, at a temperature of 60° C. for 30 minutes, of this mechanical pulp with 0.4% by weight of diethylene triamine pentaacetic acid (DTPA), relative to the total weight of dry mechanical pulp.
[0182] During the first step P (P1), the consistency of the mechanical pulp obtained at the end of step Q is adjusted to 14% by weight. Step P1 comprises the contacting, at a temperature of 70° C. for 120 minutes, of this mechanical pulp with a bleaching composition comprising 2.2% of hydrogen peroxide, 1.5% of sodium hydroxide, 1% of sodium silicate, 0.075% of magnesium sulfate, in percentages by weight relative to the total weight of dry mechanical pulp. The brightness of the five mechanical pulps is determined according to standard ISO 2470-2:2008.
[0183] During the second step P (P2), the consistency of the mechanical pulp obtained at the end of step P1 is adjusted to 20% by weight. Step P2 comprises the contacting, at a temperature of 70° C. for 120 minutes, of this mechanical pulp with a bleaching composition comprising 3.4% of hydrogen peroxide, 1.7% of sodium hydroxide, 1.6% of sodium silicate, 0.075% of magnesium sulfate, in percentages by weight relative to the total weight of dry mechanical pulp. The brightness of the five mechanical pulps is determined according to standard ISO 2470-2:2008.
[0184] The specific energy consumption of the method is calculated for each mechanical pulp, as described earlier on above.
[0185] The results are reported in table 4 below, following interpolation of the values to 300 mL CSF.
[0000] TABLE 4 CTMP Test 9 Test 10 Test 11 (ref) (inv) (inv) After Specific energy 1060 720 910 refining consumed (kWh/t) Energy saving/ref ref 32.1% 14.2% Brightness (%) (B R ) 37.2 41.6 43.2 After Brightness after QP 46.2 52 56.2 bleaching (%) (B QP ) Brightness after QPP 58.7 62 65.1 (%) (B QPP ) Brightness gain 24.2% 25.0% 30.1% (B QP − B R )/B R Brightness gain 57.8% 49.0% 50.7% (B QPP − B R )/B R
Concerning the specific energy consumption:
tests 10 and 11 (by comparison with test 9), especially test 10, show that the use of an impregnating composition according to the invention during refining produces a significant reduction in the specific energy consumption of refining in the CTMP process.
Concerning the brightness of the mechanical pulp:
tests 10 and 11 (by comparison with test 9) show that the use of an impregnating composition according to the invention during refining produces a brighter mechanical pulp CTMP both at the end of refining and at the end of subsequent bleaching of said pulp; the invention increases the brightness of the mechanical pulp obtained at the end of the first bleaching performed after refining.
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A method for producing mechanical paper pulp comprises: impregnating unprocessed wood, whereby unprocessed wood is exposed to an impregnating composition comprising at least a laccase enzyme and a formula mediator (I), wherein R 1 and R 2 are identical or different groups, chosen from among a hydrogen atom, a hydrocarbon chain, linear or branched, saturated or unsaturated, comprising 1 to 14 carbon atoms, wherein each hydrocarbon chain can be replaced by one or more functional groups chosen from among —OH, —SO 3 , benzyl, amino, mercapto, keto or carboxyl, wherein R 1 and R 2 in combination can form a cyclical structure, to achieve impregnation of the wood; and mechanically refining the impregnated wood, such that a mechanical paper pulp is obtained. The disclosure also relates to an impregnating composition used in this method and to the use thereof in a method for producing mechanical paper pulp, as well as to a method for producing paper.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention provides a device attached to the shaft of a golf club that reduces the effect of the user's dominant hand on his/her golf swing and at the same time helps to define the correct swing path and impact timing.
2. Description of the Prior Art
It is well known that one of the most important elements and a key to a successful golf swing is the golfer's grip. The art of positioning the fingers, hands and pressure applied to the grip has been described numerous times. In addition, there have been many devices invented for the purpose of teaching and achieving an improved golf grip or swing.
The placement of hand and fingers on grip of club is rather easily accomplished by careful observation and following instructions. But the feeling of gripping a club and the amount and placement of pressure is very difficult to describe to an individual since each interprets and feels differently.
As simple as gripping a club is, it is the most recognized and believed to be the leading cause of an inconsistent golf swing. For an efficient swing, the importance of placement of fingers and hands is fundamental. But knowing the fundamental alone does not cure problems in inconsistency; most problems may be cured by understanding how the sub-dominant and dominant hand work together.
It is known that the sub-dominant hand leads and controls the path of the golf swing. However, many golfers tend to utilize the dominant side over the sub-dominant side, consciously or unconsciously, more than necessary. This can be caused by an increase of the grip pressure, usage of wrist, turning of the hand or even the body movement. Nervousness, anxiousness, desire, lack of concentration, . . . etc. can also cause this type of problem. The actual golf swing takes a very short time from start to finish and problems can occur anytime during the swing.
What is required to overcome these mistakes is to provide a device that is simple to use and allows the user to practice conveniently as possible and not to interfere in anyway with the practice swing and to be able to compare one's own swing to the correct swing and be able to repeat the corrected swing consistently for trust and self confidence.
One of the most common and leading cause of mistake in golf is the grip. In many cases, the positioning of the hand and its pressure applied to the grip will determine the swing path and the angle of the club head, especially at the point of impact with the golf ball. A golf swing uses every part of the body sequentially and/or simultaneously in continuous motion. Therefore, when the mistake occurs during the motion, it most likely creates another mistake that leads to others. The grip connects the user's body and the club and it is one of the most important elements of the resultant golf swing. The grip has to be securely connected and at the same time, be sensitive to the club feel.
The following illustrates how the grip and pressure effects the golf swing.
A. Positioning of Fingers and Hands:
Strong grip, which promotes the dominant hand to be active and most likely closes club face at impact.
Weak grip, which promotes an open club face at impact.
B. Place of and Amount of Pressure Applied:
Excess pressure, resulting in active hands. Dominant hand takes authority of movement. Arm and hand dominated swing, over the top, under cutting. Premature turning of upper body. Decrease swing speed. Balance control. Reverse Pivot.
SUMMARY OF THE INVENTION
The most common problems in having a successful golf swing is caused by an active dominant hand.
An effective golf swing requires that parts of the body be utilized differently than normally used for everyday life especially the dominant side of the body. The dominant hand has to be relaxed and the sub-dominant hand lead the swing.
The logic and theory are told and explained to the date but in reality even seasoned players occasionally make mistakes by letting the dominant hand be more active than necessary, a natural instinct of a typical golfer.
To overcome this instinct and the golf swing accordingly, the present invention provides a device attached to the golf club grip that is simple in design and simple to use. It is portable and can be used to compare the feeling of swing and correct an improper swing.
The device of the present invention provides the following advantages:
Able to go back and forth with device for quicker comparison and for better and faster learning.
Able to hit ball with device.
Better concentration for swing.
Better feel of impact zone, clearly and easy to understand body and hand position.
Better control of club head.
Better balance throughout the swing.
Better understanding of the timing of releasing the dominant side for power.
Better understanding of the role and task for the positions of the dominant hand.
Better understanding of where and what amount of pressure to apply on the grip.
Better chance to achieve, smooth and natural swing that fundamentally fits to an individual.
Exercise the proper use of power.
Exercise the feel of power transition, from leading (sub-dominant hand) to dominant hand.
Increase club head speed that leads to distance and spin to control the ball flight.
Learn role and task of sub-dominant hand.
Learn and understand the task of dominant hand.
Teaches proper movement (sequence of motion) fit to an individual's physical capabilities for the golf swing, leading to consistency and playing successful golf Understanding of position, angle of club head, and its affect.
The present invention will benefit all players, from beginners to advanced players.
A. For Beginners:
Ease of achieving smooth swing, which fit individual's physical capabilities.
Correct premature take-back and downswing by active dominant hand.
Learn how to use hands properly.
Utilizing sub-dominant and dominant hand the correct way.
Better feel of swing.
Better balancing, smooth, and consistent swing.
B. For Advanced Player:
Better understanding of relationship between club head and hand.
Ease of working on shot making.
Ease of correcting one's problem by themselves.
Improvement of direction, distance and timing, and for consistent and better golf Trusting own swing for confidence.
The device has a mounting member enabling the device to be secured to the golf club grip. A positioning member is threadly engaged with a threaded post which is substantially perpendicular to the top surface of the mounting, the height of the positioner being adjustable to accommodate the hand size of a golfer.
DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention as well as other objects and further features thereof, reference is made to the following description which is to be read in conjunction with the accompanying drawing therein:
FIG. 1 is a perspective view of the device of the present invention;
FIGS. 2A-2D are plan and sectional views of a first embodiment of the device shown in FIG. 1 ;
FIGS. 3A-3D are plan and cross-sectional views of a second embodiment of the device shown in FIG. 1 ;
FIGS. 4A-4D illustrates the steps for attaching the device of the present invention to a golf club grip;
FIG. 5 illustrates the most common grip used by golfers, wherein the pinky of the golfers dominant hand over wraps and is positioned between the index and middle finger of the golfers sub-dominant hand;
FIG. 6 illustrates the device of the present invention attached to the grip of a golf club where the thumb and index finger of a golfer's dominant hand is positioned in the V formed thereby the remaining fingers being extended;
FIG. 7 illustrates the device of the present invention attached to the grip of a golf club wherein the thumb and index finger of a golfer's dominant hand is positioned in the V formed thereby, the index finger being hooked, the remaining fingers being extended;
FIG. 8 illustrates the device of the present invention used with the over wrap grip shown in FIG. 5 ; and
FIGS. 9A-9C illustrate a third embodiment of the present invention.
DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of the device 10 of the present invention.
Device 10 comprises a mount 12 with a post member 14 secured to the top surface of mount 12 , post member 14 having a threaded top portion 16 . An adjustable grip positioner 18 is movable via threaded portion 16 to a position where a user's hand can be comfortably positioned between lip 20 of the positioner 18 and the top surface 22 of mount 12 as will be set forth hereinafter. A stopper 24 prevents the separation of positioner 18 from mount 12 . Locking member 26 secures mount 12 in position on the golf club as will be described hereinafter.
Device 10 is designed to teach a player (left or right handed) the proper use of the sub-dominant and dominant hands, the relationship between hands, and the hand relationship between club-head and hands. These teachings enable a user to overcome many problems in his/her golf swing, help master the consistent swing that makes golf enjoyable and help users to concentrate on shot making instead of being worried about making contact with the golf ball.
A golf swing using the fundamental, or conventional, grip is conducted with both arms relaxed, extended and holding club lightly, the shoulder being turned to take back the golf club and letting the sub-dominant side (left for right handed and right for left handed) lead the swing.
The palm of the dominant hand is facing the target; at this position, the angle of the palm of the hand is the same angle as the leading edge of the club head. At the addressing stage, the club head is square to the direction of the target or perpendicular to its swing path. For the correct swing, as soon as the club head leaves the address position to the back swing, the golf club head starts to turn, or rotate, to the same angle as the swing path or plane and stays at the same angle.
The club head has to point to a certain direction during the swing such as the direction of the angle of the golf club leading edge, the same angle as of the swing plane and the same as the opened hand palm.
This open hand method is helpful to the learning process, since the player learns to concentrate only on the position or angle of the hand to know the position of the club head, instead of trying to adjust the club head by hand.
The device of the present invention does not control or maneuver the club or club head by hand but enables the club to act as the extension of the hand and thus enabling the club head react to or follow the hand.
Device 10 improves a golf swing by using a method of practicing the golf swing with an opened hand as shown in FIG. 6 , or partially opened as shown in FIG. 7 with a hooked index finger and the rest of the fingers extended as shown. This method prevents the dominant hand from controlling the golf club by making the sub-dominant hand work harder and take the leading role in the swing.
Device 10 is designed ergonomically to fit in the hand of a conventional golf grip, as shown in FIG. 8 , with minimum interference with the swing (the device is for practice purposes only, not for a regulated golf game).
By attaching the device 10 to the golf club grip in the manner shown in FIGS. 4A-4D , device 10 is ready for use (note that lock 26 may be unnecessary in cases where mount 12 fits securely on the golf club grip). Positioner 18 is adjusted by being moved up or down to a position individualized to a particular player such that the club will stay attached when a player's hands are opened but the “V” formed between the index finger and thumb of dominant hand is closed.
Device 10 is compact in size and can fit most clubs and the user need not carry any extra equipment to practice on his/her own. Device 10 , in addition to be used for practice, can be used to address and hit the golf ball on and off golf courses.
FIGS. 3A-3D illustrate a second embodiment of the present invention. In particular, device 100 comprises mount 102 , lock 104 , adjustable grip positioner 106 having an interior threaded portion 108 , stopper 110 , threaded screw 109 having portions 112 and 114 and short internally threaded post 116 protruding from the outer surface of positioner 102 .
In use, positioner 106 is rotated such that it moves along the threaded screw 109 to the proper user position.
Device 100 is portable and mount 102 and lock 104 can be positioned and remain on the club grip during practice.
Mount 102 , because of short post 116 , can remain secured to the golf club (preferably on the golf grip 103 as shown in FIG. 5 ) grip and stored in a conventional golf bag with minimum interference. When required for practice, post 109 is screwed on mount 102 via threaded portion 114 , post 109 already having been adjusted to the proper position within positioner 106 and practice conducted in the same manner as with device 10 , discussed hereinabove.
Lock 104 (identical to lock 26 shown in FIGS. 1 and 2 ) has curved portions 117 and 119 forming channels along their length. Cylindrically shaped mount 102 has lower foot shaped members 121 and 123 along its length.
FIGS. 4A-4D illustrate the sequence used in attaching and securing mount 12 to the grip of a golf club (the description that follows is the same for securing mount 102 ). In particular, device 10 is first positioned over the shaft 132 of golf club 130 ( FIG. 4A ) and then moved in direction of arrows 136 towards golf club grip 138 ( FIG. 4B ). Device 10 is then moved to an appropriate position on grip 138 ( FIG. 4C ) and, if necessary, lock 26 is moved in a manner ( FIG. 4D ) such that the channels formed by curved portions 27 and 29 therein engage foot shaped members 31 and 33 , respectively, on mount 22 as shown in FIG. 1 .
Referring not to FIGS. 9A-9C , a third embodiment of the present invention is illustrated. In essence, device 200 is similar to the version shown in FIGS. 3A-3D with the addition of a quick release post 202 in order to expedite the attachment/release of post to/from adjustable grip positioner 206 . Post 202 is L-shaped and comprises legs 208 and 210 , leg 208 sliding into a channel 212 formed in member 214 . The bottom surface of leg 208 has an opening 216 formed therein. The top surface of positioner 218 has a vertically movable protrusion, or dimple, 220 formed thereon. The post 202 is secured to the mounting plate by a user inserting leg 208 into channel 212 (direction of arrow 213 ) in a manner such that protrusion 220 clicks into opening 216 . A user can remove device post 202 by pulling the post in direction indicated by arrow 220 . In this case, protrusion 218 retracts enabling the post to be removed.
While the invention has been described with reference to its preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its essential teachings.
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A training device for use with a golf club. A mounting member enables the device to be mounted on the grip of a golf club. A positioning member is threadly engaged with a threaded post which is substantially perpendicular to the top surface of the mounting, the height of the positioner being adjustable to accommodate the hand size of the golfer.
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This application is a continuation of application Ser. No. 90/130,058, filed Aug. 6, 1998, now U.S. Pat. No. 6,070,214.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to data processing systems, and more particularly, to bridge systems including mechanisms for transferring information between buses.
2. Description of Related Art
Computers can use buses to transfer data between a host processor and various devices, such as memory devices and input/output devices. As used herein an “input/output” device is a device that either generates an input or receives an output (or does both). Thus “input/output” is used in the disjunctive. These buses may be arranged in a hierarchy with the host processor connected to a high level bus reserved for exchanging the data most urgently needed by the processor. Lower level buses may connect to devices having a lower priority.
Other reasons exist for providing separate buses. Placing an excessive number of devices on one bus produces high loading. Such loading makes a bus difficult to drive because of the power needed and the delays caused by signaling so many devices. Also, some devices on a bus may periodically act as a master and request control over a bus in order to communicate with a slave device. By segregating some devices on a separate bus, master devices can communicate with other devices on the lower level bus without tying up the bus used by the host processor or other masters.
The PCI bus standard is specified by the PCI Special Interest Group of Hillsboro, Oregon. The PCI bus features a 32-bit wide, multiplexed address-data (AD) Maintaining a high data throughput rate (e.g., a 33 MHZ clock rate) on the PCI bus leads to a fixed limitation on the number of electrical AC and DC loads on the bus. Speed, considerations also limit the physical length of the bus and the capacitance that can be placed on the bus by the loads, while future PCI bus rates (e.g., 66 MHZ) will exacerbate the electrical load and capacitance concerns. Failure to observe these load restrictions can cause propagation delays and unsynchronized operation between bus devices.
To circumvent these loading restrictions, the PCI bus standard specifies a bridge to allow a primary PCI bus to communicate with a secondary PCI bus through such a bridge. Additional loads may be placed on the secondary bus without increasing the loading on the primary bus. For bridges of various types see U.S. Pat. Nos. 5,548,730 and 5,694,556.
The PCI bridge observes a hierarchy that allows an initiator or bus master on either bus to complete a transaction with a target on the other bus. As used herein, hierarchy refers to a system for which the concept of a higher or lower level has meaning. For example, a PCI bus system is hierarchical on several scores. An ordering of levels is observed in that a high level host processor normally communicates from a higher level bus through a bridge to a lower level bus. An ordering of levels is also observed in that buses at equal levels do not communicate directly but through bridges interconnected by a higher level bus. Also, an ordering of levels is observed in that data is filtered by their addresses before being allowed to pass through a bridge, based on the levels involved. Other hierarchical systems exist that may observe an ordering of levels by using one or more of the foregoing concepts, or by using different concepts.
Some personal computers have slots for add-on cards. Because a user often needs additional slots, expansion cards have been designed that will connect between the peripheral bus and an external unit that offers additional slots for add-on cards. For systems for expanding a bus, see U.S. Pat. Nos. 5,006,981; 5,191,657; and 5,335,329. See also U.S. Pat. No. 5,524,252.
For portable computers, special considerations arise when the user wishes to connect additional peripheral devices. Often a user will bring a portable computer to a desktop and connect through a docking station or port replicator to a keyboard, monitor, printer or the like. A user may also wish to connect to a network through a network interface card in the docking station. At times, a user may need additional devices such as hard drives or CD-ROM drives. While technically possible to a limited extent, extending a bus from a portable computer through a cable is difficult because of the large number of wires needed and because of latencies caused by a cable of any significant length.
In U.S. Pat. No. 5,696,949 a host chassis has a PCI to PCI bridge that connects through a cabled bus to another PCI to PCI bridge in an expansion chassis. This system is relatively complicated since two independent bridges communicate over a cabled bus. This cabled bus includes essentially all of the lines normally found in a PCI bus. This approach employs a delay technique to deal with clock latencies associated with the cabled bus. A clock signal generated on the expansion side of the cabled bus: (a) is sent across the cabled bus, but experiences a delay commensurate with the cable length; and (b) is delayed an equivalent amount on the expansion side of the cabled bus by a delay line there, before being used on the expansion side. Such a design complicates the system and limits it to a tuned cable of a pre-designed length, making it difficult to accommodate work spaces with various physical layouts.
U.S. Pat. No. 5,590,377 shows a primary PCI bus in a portable computer being connected to a PCI to PCI bridge in a docking station. When docked, the primary and secondary buses are physically very close. A cable is not used to allow separation between the docking station and the portable computer. With this arrangement, there is no interface circuitry between the primary PCI bus and the docking station. See also U.S. Pat. No. 5,724,529.
U.S. Pat. No. 5,540,597 suggests avoiding additional PCMCIA connectors when connecting a peripheral device to a PC card slot in a portable computer, but does not otherwise disclose any relevant bridging techniques.
U.S. Pat. No. 4,882,702 and show a programmable controller for controlling industrial machines and processes. The system exchanges data serially with a variety of input/output modules. One of these modules may be replaced with an expansion module that can serially communicate with several groups of additional input/output modules. This system is not bridge-like in that the manner of communicating with the expansion module is different than the manner of communicating with the input/output modules. For the expansion module the system changes to a block transfer mode where a group of status bytes are transferred for all the expansion devices. This system is also limited to input/output transactions and does not support a variety of addressable memory transactions. See also U.S. Pat. Nos. 4,413,319; and 4,504,927.
In U.S. Pat. No. 5,572,525 another bus designed for instrumentation (IEEE 488 General Purpose Instrumentation Bus) connects to an extender that breaks the bus information into packets that are sent serially through a transmission cable to another extender. This other extender reconstructs the serial packets into parallel data that is applied to a second instrumentation bus. This extender is an intelligent system operating through a message interpretation layer and several other layers before reaching the parallel to serial conversion layer. Thus this system is unlike a bridge. This system is also limited in the type of transactions that it can perform. See also U.S. Pat. 4,959,833.
U.S. Pat. No. 5,325,491 shows a system for interfacing a local bus to a cable with a large number of wires for interfacing with remote peripherals. See also U.S. Pat. Nos. 3,800,097; 4,787,029; 4,961,140; and 5,430,847.
The Small Computer System Interface (SCSI) defines bus standards for a variety of peripheral devices. This CSI bus is part of an intelligent system that responds to high-level commands. Consequently, SCSI systems require software drivers to enable hardware to communicate to the SCSI bus. This fairly complicated system is quite different from bridges such as bridges as specified under the PCI standard. A variety of other complex techniques and protocols exist for transferring data, including Ethernet, Token Ring, TCP/IP, ISDN, FDDI, HIPPI, ATM, Fibre Channel, etc., but these bear little relation to bridge technology.
See also U.S. Pat. Nos. 4,954,949, 5,038,320; 5,111,423; 5,446,869; 5,495,569; 5,497,498; 5,507,002; 5,517,623; 5,530,895; 5,542,055; 5,555,510; 5,572,688; and 5,611,053.
Accordingly, there is a need for an improved system for transferring information between buses.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features, and advantages of the present invention, there is provided a bridge accessible by a host processor for expanding access over a first bus to a second bus. The first bus and the second bus are each adapted to separately connect to respective ones of a plurality of bus-compatible devices. Allowable ones of the devices include memory devices and input/output devices. The bridge has a link, together with a first and a second interface. The second interface is adapted to couple between the second bus and the link. The first interface and the second interface operating as a single bridge are operable to (a) send outgoing information serially through the link in a format different from that of the first bus and the second bus without waiting for an incoming acknowledgment over said link before inaugurating a transfer of said information over said link, (b) approve an initial exchange between the first bus and the second bus in response to a pending transaction having a characteristic signifying a destination across the bridge, and (c) allow the host processor, communicating through the first bus, to individually address different selectable ones of the bus-compatible devices on the second bus, including memory devices and input/output devices that may be present: (i) using on the first bus substantially the same type of addressing as is used to access devices the first bus, and (ii) without first employing a second, intervening one of the bus-compatible devices on the second bus.
In accordance with another aspect of the invention a bridge accessible by a host processor can expand access over a first bus to a second bus. The first bus and the second bus each are adapted to separately connect to respective ones of a plurality of bus-compatible devices. Allowable ones of the devices include memory devices and input/output devices. The bridge has a link, together with a first and a second interface. The first interface is adapted to couple between the first bus and the link. The second interface is adapted to couple between the second bus and the link. The first interface and the second interface are operable to (a) send information serially through the link in a format different from that of the first bus and the second bus, (b) exchange information between the first bus and the second bus according to a predetermined hierarchy giving the first bus a higher level than the second bus, and (c) allow the host processor, communicating through the first bus, to individually address different. selectable ones of the bus-compatible devices on the second bus, including memory devices and input/output devices that may be present: (i) using on the first bus substantially the same type of addressing as is used to access devices on the first bus, (ii) without first employing a second intervening one of the bus-compatible devices on the second bus, and (iii) without passing the information through an intervening hierarchical level.
In accordance with another, further aspect of the invention a bridge accessible by a processor can expand access over a first bus to a second bus. The first bus and the second bus each are adapted to separately connect to respective ones of a plurality of bus-compatible devices. The bridge has a link and a first and a second interface. The first interface is coupled between the first bus and the link. The second interface is adapted to couple between the second bus and the link. The first interface and the second interface operate as a single bridge and is operable to transfer information serially through the link in a format different from that of the first bus and the second bus without waiting for an incoming acknowledgment over the link before inaugurating a transfer of the information over the link.
By employing apparatus and methods of the foregoing type, an improved system is achieved for transferring information between buses. In one preferred embodiment, two buses communicate over a duplex link formed with a pair of simplex links, each employing twisted pair or twin axial lines (depending on the desired speed and the anticipated transmission distance). Information from the buses are first loaded onto FIFO (first-in first-out) registers before being serialized into frames for transmission over the link. Received frames are deserialized and loaded into FIFO registers before being placed onto the destination bus. Preferably, interrupts, error signals, and status signals are sent along the link.
In this preferred embodiment, address and data are taken from a bus one transaction at a time, together with four bits that act either as control or byte enable signals. Two or more additional bits may be added to tag each transaction as either: an addressing cycle; acknowledgment of a non-posted write; data burst; end of data burst (or single cycle). If these transactions are posted writes they can be rapidly stored in a FIFO register before being encoded into a number of frames that are sent serially over a link. When pre-fetched reads are allowed, the FIFO register can store pre-fetched data in case the initiator requests it. For single cycle writes or other transactions that must await a response, the bridge can immediately signal the initiator to wait, even before the request is passed to the target.
In a preferred embodiment, one or more of the buses follows the PCI or PCMCIA bus standard (although other bus standards can be used instead). The preferred apparatus then operates as a bridge with a configuration register that is loaded with information specified un er the PCI standard. The apparatus can transfer information between buses depending upon whether the pending addresses fall within a range embraced by the configuration registers. This scheme works with devices on the other side of the bridge, which can be given unique base addresses to avoid addressing conflicts.
In one highly preferred embodiment, the apparatus maybe formed as two separate application-specific integrated circuits (ASIC) joined by a cable. Preferably, these two integrated circuits have the same structure, but can act in two different modes in response to a control signal applied to one of its pins. Working with hierarchical buses (primary and secondary buses) these integrated circuits will be placed in a mode appropriate for its associated bus. The ASIC associated with the secondary bus preferably has an arbiter that can grant masters control of the secondary bus. This preferred ASIC can also supply a number of ports to support a mouse an keyboard, as well as parallel and serial ports.
When used with a portable computer, one of the ASIC's can be assembled with a connector in a package designed to fit into a PC card slot following the PCMCIA standard. This ASIC can connect through a cable to the other ASIC, which can be located in a docking station. Accordingly, the apparatus can act as a bridge between a CardBus and a PCI bus located in a docking station. Since the preferred ASIC can also provide a port for a mouse and keyboard, this design is especially useful for a docking station. Also, the secondary PCI bus implemented by the ASIC can connect to a video card or to a video processing circuit on the main dock circuit board in order to drive a monitor.
In some embodiments, one ASIC will be mounted in the portable computer by the original equipment manufacturer (OEM). This portable computer will have a special connector dedicated to the cable that connects to the docking station with the mating ASIC. For such embodiments, the existence within the preferred ASIC of ports for various devices can be highly advantageous. An OEM can use this already existing feature of the ASIC and thereby eliminate circuitry that would otherwise have been needed to implement such ports.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic block diagram showing a bridge split by a link within the bridge, in accordance with principles of the present invention;
FIG. 2 is a schematic block diagram showing a bridge in accordance with principles of the present invention using the link of FIG. 1;
FIG. 3 is a schematic block diagram showing the bridge of FIG. 2 used in a docking system in accordance with principles of the present invention;
FIG. 4 is a cross-sectional view of the cable of FIG. 3;
FIG. 5 is a schematic illustration of the bridge of FIG. 3 shown connected to a portable computer and a variety of peripheral devices; and
FIG. 6 shows a docking station similar to that of FIG. 5 but with the portable computer modified to contain an application-specific integrated circuit designed to support a link to the docking station.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a bridge is shown connecting between a first bus 10 and a second bus 12 (also referred to as primary bus 10 and secondary bus 12 ). These buses may be PCI or PCMCIA 32-bit buses, although other types of buses are contemplated and the present disclosure is not restricted to any specific type of bus. Buses of this type will normally have address and data lines. In some cases, such as wit the PCI bus, address and data are multiplexed onto the same lines. In a dition, these buses will have signaling lines for allowing devices on the bus to negotiate transactions. For the PCI standard, these signaling lines will in lude four lines that are used either for control or byte enabling (C/BE[ 3 : 01 ). Others signaling lines under the PCI standard exist for gaining control over the bus, for handshaking, and the like (e.g., FRAME#, TRDY#, IRDY#, STOP#, DEVSEL#, etc.)
Buses 10 and 12 are shown connecting to a first interface 14 and second interface 16 , respectively (also referred to as interfaces 14 and 16 ). Bus information selected for transmission by interfaces 14 and 16 are loaded into registers 18 and 20 , respectively. Incoming bus information that interfaces 14 and 16 select for submission to the buses are taken from registers 22 and 24 , respectively. In one embodiment, registers 18 - 24 are each 16×38 FIFO registers, although different types of registers having different dimensions may be used in alternate embodiments.
In this embodiment, registers 18 - 24 are at least 38 bits wide. Thirty six of those bits are reserved for the 4 control bits (C/BE#[ 3 : 01 ]) and the 32 address/data bits (AD[ 31 : 0 ]) used under the PCI bus standard. The remaining two bits can be used to send additional tags for identifying the nature of the transaction associated therewith. Other bits may be needed to fully characterize every contemplated transaction. Transactions can be tagged as: addressing cycle; acknowledgment of a non posted write; data burst; end of data burst (or single cycle). Thus outgoing write transactions can be tagged as a single cycle transaction or as part of a burst. Outgoing read requests can also be tagged as part of a burst with a sequence of byte enable codes (C/BE) for each successive read cycle of the burst. It will be appreciated that other coding schemes using a different number of bits can be use in other embodiments.
The balance of the structure illustrated in FIG. 1 is a link designed to establish duplex communications between interfaces 14 and 16 through registers 18 - 24 . For example, encode 28 can accept the oldest 38 bits from register 20 and parse it into five bytes (40 bits). The extra two bits of the last byte are encoded to signify the interrupts, status signals and error signals that may be supplied from block 34 .
Each of these five bytes is converted into a 10 bit frame that can carry the, information of each byte, as well as information useful for regulating the link. F or example, these frames can carry comma markers, idle markers, or flow control signals, in a well-known fashion. A transceiver system working with bytes that were encoded into such 10 bit frames is sold commercially by Hewlett Packard as model number HDMP-1636 or -1646. Frames produced by encoder 28 are forwarded through transmitter 44 along simplex link 46 to receiver 48 , which supplies the serial information to decoder 30 . Likewise, encoder 26 forwards serial information through transmitter 38 along simplex link 40 to receiver 42 , which supplies the serial information to decoder 32 .
Flow control may be necessary should FIFO registers 22 or 24 be in danger of overflowing. For example, if FIFO register 22 is almost full, it supplies a threshold detect signal 36 to encoder 26 , which forwards this information through link 40 to decoder 32 . In response, decoder 32 issues a threshold stop signal 50 to encoder 28 , which then stops forwarding serial information, thereby preventing an overflow in FIFO register 22 . In a similar fashion, a potential overflow in FIFO register 24 causes a threshold detect signal 52 to flow through encoder 28 and link 46 to cause decoder 30 to issue a threshold stop signal 54 , to stop encoder 26 from sending more frames of information. In some embodiments, the system will examine the received information to determine if it contains transmission errors or has been corrupted in some fashion. In such event the system can request a retransmission of the corrupted information and thereby ensure a highly reliable link.
In this embodiment, elements 14 , 18 , 22 , 26 , 30 , 38 and 48 are part of a single, application specific integrated circuit (ASIC) 56 . Elements 16 , 20 , 24 , 28 , 32 , 42 and 44 are also part of an ASIC 58 . As described further hereinafter, first ASIC 56 and second ASIC 58 have an identical structure but can be operated in different mode. It will be appreciated that other embodiments may not use ASIC's but may use instead alternate circuitry, such as a programable logic device, or the like. As shown herein, ASIC 56 is operating in a mode designed to service primary bus 10 , and (for reasons to be described presently) will be sending outputs to block 57 . In contrast block 34 of ASIC 58 will receive inputs from block 34 .
Encoders 26 and 28 have optional parallel outputs 27 and 29 , respectively, for applications requiring such information. Also for such applications, decoders 30 and 32 have parallel inputs 31 and 33 , respectively. These optional inputs and outputs may be connected to an external transceiver chip, such as the previously mentioned device offered by Hewlett Packard as model number HDMP-1636 or -1646. These devices will still allow the system to transmit serial information, but by means of an external transceiver chip. This allows the user of the ASIC's 56 and 58 more control over the methods of transmission over the link.
Referring to FIG. 2, previously mentioned ASIC's 56 and 58 are shown in further detail. The previously mentioned encoders, decoders, transmitters, receivers, and FIFO registers are combined into blocks 60 and 62 , which are interconnected by a duplex cable formed of previously mentioned simplex links 40 and 46 . Previously mentioned interface 14 is shown connected to primary bus 10 , which is also connected to a number of bus-compatible devices 64 . Similarly, previously mentioned interface 16 is shown connected to secondary bus 12 , which is also connected to a number of bus-compatible devices 66 . Devices 64 and 66 may be PCI-compliant devices and may operate as memory devices or input/output devices.
Interface 14 a shown connected to a first register means 68 , which acts as a configuration register in compliance with the PCI standard. Since this system will act as a bridge, configuration registers 68 will have the information normally associated with a bridge. Also, configuration registers 68 will contain a base register and limit register to indicate a range or predetermined schedule of addresses for devices that can be found on the secondary bus 12 . Under the PCI standard, devices on a PCI bus will themselves each have a base register, which allows mapping of the memory space and/or I/O space. Consequently, the base and limit registers in configuration registers 68 can accommodate the mapping that is being performed by individual PCI devices. The information on configuration registers 68 are mirrored on second configuration register 67 (also referred to as a second configuration means). This makes the configuration information readily available to the interfaces on both sides of the link.
In this embodiment, ASIC 58 has an arbiter 70 . Arbiters are known devices that accept requests from masters on secondary bus 12 for control of 25 the bus. The arbiter has a fair algorithm that grants the request of one of the contending masters by issuing it a grant signal. In this hierarchical scheme, secondary bus 12 requires bus arbitration, but primary bus 10 will provide its own arbitration. Accordingly, ASIC 56 is placed in a mode where arbiter 72 is disabled. The modes of ASIC's 56 and 58 are set by control signals applied to control pins 74 and 76 , respectively. Because of this mode selection, the signal directions associated with blocks 57 an 34 will be reversed.
In this embodiment, ASIC 58 is in a mode that implements a third bus 78 . Bus 78 may follow the PCI standard, but is more conveniently implemented in a different standard. Bus 78 connects to a number of devices that act as a port means. For example, devices 80 and 82 can implement PS/2 ports that 5 can connect to either a mouse or a keyboard. Device 84 implements an ECP/EPP parallel port for driving a printer or other device. Device 86 implements a conventional serial port. Devices 80 , 82 , 84 and 86 are shown with input/output lines 81 , 83 , 85 and 87 , respectively. Devices 80 - 86 may be addressed on bus 10 as if they were PCI devices on bus 12 . Also in this embodiment, a bus 88 is shown in ASIC 56 , with the same devices as shown on bus 78 to enable an OEM to implement these ports without the need for separate input/output circuits.
Referring to FIG. 3, previously mentioned ASIC 58 is shown in a 15 docking station 130 connected to an oscillator 91 for establishing a remote and internal clock. ASIC 58 has its lines 81 and 83 connected through a connection assembly 90 for connection to a keyboard and mouse, respectively. Serial lines 85 and parallel lines 87 are shown connected to transceivers 92 and 94 , respectively, which then also connect to connection assembly 90 for connection to various parallel and serial peripheral, such as printers and modems.
ASIC 58 is also shown connected to previously mentioned secondary bus 12 . Bus 12 is shown connected to an a adapter card 96 to allow the PCI bus 12 to communicate with an IDE device such as a hard drive, backup tape drive, CD-ROM drive, etc. Another adapter card 98 is shown for allowing communications from bus 12 to a universal serial port (USB). A network interface card 100 will allow communications through bus 12 to various networks operating under the Ethernet standard, Token Ring standard, etc. Video adapter card 102 (also referred to as a video means) allows the user to operate another monitor. Add-on card 104 may be one of a variety of cards selected by the user to perform a useful function. While this embodiment shows various functions being implemented by add-on cards, other embodiments may implement one or more of these function on a common circuit board in the dock (e.g., all functions excluding perhaps the IDE adapter card).
ASIC 58 communicates through receiver/transmitter 106 , which provides a physical interface through a terminal connector 108 to cable 40 , 46 . Connector 108 may be a 20 pin connector capable of carrying high speed signals with EMI shielding (for example a low force helix connector of the type offered by Molex Incorporated), although other connector types may used instead. The opposite end of cable 40 , 46 connects through a gigabit, terminal connector 110 to physical interface 112 , which acts as a receiver/transmitter. Interface 112 is shown connected to previously mentioned first ASIC 56 , which is also shown connected to an oscillator 114 to establish a local clock signal. This specific design contemplates sing an external transmitter/receiver (external SERDES of lines 27 , 29 , 31 , and 33 of FIG. 1 ), although other embodiments can eliminate these external devices in favor of the internal devices in ASIC's 56 and 58 .
This embodiment is adapted to cooperate with a portable computer having a PCMCIA 32-bit bus 10 , although other types of computers can be serviced. Accordingly, ASIC 56 is shown in a package 116 having an outline complying with the PCMCIA standard and allowing package 116 to fit into a slot in a portable computer. Therefore, ASIC 56 has a connector 118 for 25 connection to bus 10 . Cable 40 , 46 will typically be permanently connected to package 116 , but a detachable connector may be used in other embodiments, where a user wishes to leave package 16 inside the portable computer.
Power supply 120 is shown producing a variety of supply voltages used to power various components. In some embodiments, one of these supply lines can be connected directly to the portable computer to charge its battery. Referring to FIG. 4, the previously mentioned simplex links 40 and 46 are shown as twin axial lines 40 A an 46 A, wrapped with individual shields 40 B and 46 B. A single shield 122 encircles the lines 40 and 46 . Four parallel wires 124 are shown (although a greater number may be used in other embodiments) mounted around the periphery of shields 122 for various purposes. These wires 124 may carry power management signals, dock control signals or other signals that may be useful in an interface between a docking station and a portable computer. While twin axial lines offer high performance, twisted pairs or other transmission media may be used in other embodiments where the transmission distance is not as great and where the bit transfer speed need not be as high. While a hard wire connection is illustrated, in other embodiments a wireless or other type of connection can be employed instead.
Referring to FIG. 5, previously mentioned package 116 is shown in position to be connected to a PCMCIA slot in portable computer 126 . Computer 126 is shown having primary bus 10 and a host processor 128 . Package 116 is shown connected through cable 40 , 46 to previously mentioned connector 108 on docking station 130 .
Previously mentioned docking station 130 is shown connecting through PS/2 ports to keyboard 132 and mouse 134 . A printer 136 is shown connected to parallel port in docking station 130 . Previously mentioned video means 102 is shown connected to a monitor 138 . Docking station 130 is also shown with an internal hard drive 140 connecting to the adapter card previously mentioned. A CD-ROM drive 142 is also shown mounted in docking station 130 and connects to the secondary bus through an appropriate adapter card (not shown). Previously mentioned add-on card 104 is shown with its own cable 144 .
Referring to FIG. 6, a modified portable computer 126 ′ is again shown with a host processor 128 and primary bus. In this embodiment however, portable computer 126 ′ contains previously mentioned ASIC 56 . Thus there is no circuitry required (other than perhaps drivers) between ASIC 56 and cable 40 , 46 . In this case, the laptop end of cable 40 , 46 has a connector 142 similar to the one on the opposite end of the cable (connector 108 of FIG. 5 ).Connector 143 is designed to mate with connector 141 and support the highspeed link. As before, connectors 141 and 143 can also carry various power management signals, and other signal associated with a docking system.
An important advantage of this arrangement is the fact that ASIC 56 contains circuitry for providing ports, such as a serial port, a parallel port, PS/2 ports for a mouse and keyboard, and he like. Since portable computer 126 ′ would ordinarily provide such ports, ASIC 56 simplifies the design of the portable computer. This advantage is in addition to the advantage of having a single ASIC design (that is, ASIC's 56 and 58 are structured identically), which single design is capable of operating at either the portable computer or the docking station, thereby simplifying the ASIC design and reducing stocking requirements, etc.
To facilitate an understanding of the principles associated with the foregoing apparatus, its operation will be briefly described. This operation will be described in connection with the docking system of FIGS. 3 and 5 (which 20 generally relates to FIG. 2 ), although operation would be similar for other types of arrangements. For the docking system, a connection is established by plugging package 116 (FIG. 5) into portable computer 126 . This establishes a link between the primary bus 10 and SIC 56 (FIG. 3 ).
At this time an initiator (the host processor or a master) having access to primary bus 10 may assert control of the bus. An initiator will normally send a request signal to an internal arbiter (not shown) that will eventually grant control to this initiator. In any event, the initiator asserting control over primary bus 10 will exchange the appropriate handshaking signals and drive an address onto the bus 10 . Control signals simultaneously applied to the signaling lines of bus 10 will indicate whether the transaction is a read, write, or other type of transaction.
Interface 14 (FIG. 2) will examine the pending address and determine whether it represents a transaction with devices on the other side of the bridge (that is, secondary bus 12 ) or with the bridge itself. Configuration register 68 has already been loaded in the usual manner with information that indicates a range of addresses defining the jurisdiction of the interface 14 .
Assuming a write transaction is pending on bus 10 , interface 14 will transfer 32 address bits together with four control bits (PCI standard) to FIFO register 18 (FIG. 1 ). Encoder 26 will add at least two additional bits tagging this information as an addressing cycle. The information is then broken into frames that can carry flow control and other signals before being transmitted serially over link 40 .
Without waiting, interface 14 will proceed to a data cycle and accept up to 32 bits of data from bus 10 together with four byte enable bits. As before, this information will be tagged, supplemented with additional information and broken into frames for serial transmission over link 40 . This transmitted information will be tagged to indicate whether it is part of a burst or a single cycle.
Upon receipt, decoder 32 restore the frames into the original 38 bit format and loads the last two described cycles onto the stack of register 24 . Interface 16 eventually notices the first cycle as an addressing cycle in a write request. Interface 16 then negotiates control over bus 12 in the usual fashion and applies the address to bus 12 . A device on bus 12 will respond to the write request by performing the usual handshaking.
Next, interface 16 will drive the rite data stacked on register 24 into bus 12 . If this transaction is a burst, interface 16 will continue to drive data onto bus 12 by fetching it from register 24 . If however this transaction is a single cycle write, interface 16 will close the transaction on bus 12 and load an acknowledgment into register 20 . Since this acknowledgment need not carry data or address information, a unique code may be placed into register 20 , so that encoder 28 can appropriately tag this line before parsing it into frames for transmission over link 46 . Upon receipt, decoder 30 will produce a unique code that is loaded into register 22 and eventually forwarded to interface 14 , which sends an acknowledgment to the device on bus 10 that the write has 10 succeeded.
If the initiator instead sets its control bits during the address cycle to indicate a read request, interface 14 would also accept this cycle, if it has jurisdiction. Interface 14 will also signal the initiator on bus 10 that it is not ready to return data (e.g., a retry signal, which may be the stop signal as defined under the PCI standard). The initiator can still start (but not finish) a data cycle by driving its signaling lines on bus 10 with byte enable information. Using the same technique, the address information, followed by the byte enable information, will be accepted by interface 14 and loaded with tags into register 18 . These two lines of information will be then encoded and transmitted serially 20 over link 40 . Upon receipt, this information will be loaded into the stack of register 24 . Eventually, interface 16 will notice the first item as a read request and drive this address information onto secondary bus 12 . A device on bus 12 will respond and perform the appropriate handshaking. Interface 16 will then forward the next item of information from register 24 containing the byte 25 enables, onto bus 12 so the target device can respond with the requested data. This responsive data is loaded by in 16 into register 20 . If pre-fetching is indicated, interface 16 will initiate a number of successive read cycles to accumulate data in register 20 from sequential addresses that may or may not be requested by the initiator.
As before, this data is tagged, broken into frames and sent serially over link 46 to be decoded and loaded into register 22 . The transmitted data can include pre-fetched data that will be accumulated in register 22 . Interface 14 transfers the first item of returning data onto primary bus 10 , and allows the initiator to proceed to another read cycle if desired. If another read cycle is conducted as part of a burst transaction, the requested data will already be present in register 22 for immediate delivery by interface 14 to bus 10 . If these pre-fetched data are not requested for the next cycle, then they are discarded.
Eventually the initiator will relinquish control of bus 10 . Next, an initiator 10 on bus 12 may send a request for control of bus 12 to arbiter 70 (FIG. 2 ). If arbiter 70 grants control, the initiator may make a read or write request by driving an address onto bus 12 . Interface 16 will respond if this address does not fall within the jurisdictional range of addresses specified in configuration register 67 (indicating the higher level bus may have jurisdiction). In the same manner as before, but with a reversed flow over links 40 , 46 , interface 16 may accept address and data cycles and communicate them across link 40 , 46 . Before being granted bus 10 , interface 14 will send a request to an arbiter (not shown) associated with bus 10 .
In some instances, an initiator on primary bus 10 will wish to read from, or write to, port means 80 , 82 , 84 , or 86 . These four items are arranged to act as devices under the PCI standard. Interface 16 will therefore act as before, except that information will be routed not through bus 12 , but through bus 78 .
Other types of transactions may be performed, including reads and writes to the configuration registers 67 and 68 (FIG. 2 ). Other types of transactions, as defined under the PCI standard (or other bus standards) may be performed as well.
Interrupt signals may be generated by the ports or other devices in ASIC 58 . Also external interrupts may be received as indicated by block 34 . As noted before, interrupt signals may be embedded in the code sent over link 46 . Upon receipt, system 60 decodes the interrupts and forwards them on to block 57 , which may be simply one or more pins from ASIC 56 (implementing, for example, INTA of the PCI standard). This interrupt signal can either be sent over the bus 10 or to an interrupt controller that forwards interrupts to the host processor. System errors may be forwarded in a similar fashion to produce an output on a pin of ASIC 56 that can be routed directly to bus 10 or processed using dedicated hardware. The designer may wish to send individual status signals, which can be handled in a similar fashion along link 40 , 46 .
It is appreciated that various modifications may be implemented with respect to the above described, preferred embodiment. In other embodiments the illustrated ASIC's may be divided into several discrete packages using in some cases commercially available integrated circuits. Also, the media for the link may be wire, fiber-optics, infrared light, radio frequency signals, or other media. In addition, the primary and secondary buses may each have one or more devices, and these devices may be in one or more categories, including memory devices and input/output device. Moreover, the devices may operate at a variety of clock speeds, bandwidths and data rates. Furthermore, transactions passing through the bridge may be accumulated as posted writes or as pre-fetched data, although some embodiments will not use such techniques. Also, the bridge described herein can be part of a hierarchy using a plurality of such bridges having their primary side connected to the same bus or to buses of an equivalent or different level. Additionally, the illustrated ports 25 can be of a different number or type, or can be eliminated in some embodiments. Also, the illustrated arbiter can be eliminated for secondary buses that are not design to be occupied by a master. While a sequence of steps is described above, in other embodiments these steps may be increased or reduced in number, or performed in a different order, without departing from the scope of the present invention.
Obviously, many modifications an variations of the present invention are possible in light of the above teachings It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A bridge accessible by a host processor can expand access over a first bus to a second bus. The first bus and the second bus are each adapted to separately connect to respective ones of a plurality of bus-compatible devices. Allowable ones of the devices include memory devices and input/output devices. The bridge has a link, together with a first and a second interface. The first interface is coupled between the first bus and the link. The second interface is coupled between the second bus and the link. The first interface and the second interface are operable to (a) send information serially through the link in a format different from that of the first bus and the second bus, (b) approve an initial exchange between the first bus and the second bus in response to pending transactions having a characteristic signifying a destination across the bridge, (c) exchange information between the first bus and the second bus according to a predetermined hierarchy giving the first bus a higher level than the second bus, and (d) allow the host processor, communicating through the first bus, to individually address different selectable ones of the bus-compatible devices on the second bus, including memory devices and input/output devices that may be present: (i) using on the first bus substantially the same type of addressing as is used to access devices the first bus, and (ii) without first employing a second, intervening one of the bus-compatible devices on the second bus.
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TECHNICAL FIELD
This invention relates to liquid crystal and other electro-optical displays.
BACKGROUND
Commercially, it is highly desirable for an electronic display (e.g., a liquid crystal display) to be as thin and light as possible while still maintaining a high degree of ruggedness to withstand forces resulting from pressure, decompression, shear, and shock. In the area of mobile electronics, such as cell phones and personal digital assistants (PDAs), size and weight are critical factors to the commercial success of a product, but currently breakage of the displays within these devices remains the primary cause of repairs and product returns.
In addition, the need for electronic displays that can actually be bent has been acknowledged in several areas. So-called ‘electronic paper’ in which fiber paper is replaced with a display would be much more compelling as a product if the electronic display could be rolled up or folded like traditional paper. Wearable electronics, such as computers or multifunction watches, would be much more comfortable to the wearer if the display were conformable. Chip cards, which have strict flexure life-test performance standards, would be able to incorporate flexible displays and still conform to those standards.
One approach to achieving the desired rugged and flexible display is to substitute polymer (or other flexible) substrates for the glass substrates conventionally used. Achieving such a substitution of polymer for glass has been an area of active research within the display community for a number of years.
Polymer substrates have the property of not springing back into their original shape, as do glass substrates, following flexure of the display. This can result in a change in the separation between the two substrates, with resulting degradation of display quality. A solution to this problem is providing a structural bond between the polymer substrates. A structural bond is able to maintain the spacing by keeping the polymer substrates engaged against intervening spacing elements (e.g., tiny glass spheres or fibers) even during flexure of the display.
Display contrast is another area in which rugged and flexible displays have had difficulty matching the performance of conventional displays. One technique for increasing display contrast is to give the liquid crystal molecules a homeotropic alignment (i.e., the optical axis, or long dimension, of the molecules is generally perpendicular to the faces of the substrates) in the absence of an electric field. This gives the display the highest possible contrast because in the off state a homeotropic cell placed between crossed polarizers has extremely low transmission. In other words, the dark state is as dark as it can be (and depends on the extinction ratio of the polarizers used). When an electric field is applied to the liquid crystal in a selected area of the cell, the molecules in that area deviate from the homeotropic alignment towards an oblique or planar alignment, in which the molecules assume an orientation generally oblique and even parallel to the substrate (perpendicular to the substrate normal).
There are various known ways of achieving homeotropic alignment. The most common technique is to provide an alignment layer of, e.g., lecithin, on one or both of the substrates. Other alignment techniques have been attempted. E.g., a pre-manufactured layer of filter material with tiny pores (in which the molecules are received) can be inserted between the substrate faces. An electric field can be applied during manufacturing to position the molecules in homeotropic orientation, while slender tendrils of polymer are polymerized between the molecules to hold them in the desired alignment (sometimes referred to as a “polymer stabilized” display). But none of these approaches provided a structural bond between the substrates, and thus are ineffective for achieving a rugged or flexible display.
An early effort at providing a structural bond between substrates was the polymer dispersed liquid crystal (PDLC) display, in which the liquid crystal molecules were dispersed within a polymer matrix. After assembling the display, the polymer was cured, typically by ultraviolet light. During the polymerization the liquid crystal separated out from the polymer into microscopic droplets. The polymer provided a structural bond between the substrates. As the droplets of liquid crystal were not in contact with either substrate face, an alignment layer could not be used to orient the molecules, and the displays were operated in a different and less desirable “scattering mode”. Examples of PDLC displays and related technology are U.S. Pat. Nos. 4,688,900, 5,321,533, 5,327,271, 5,434,685, 5,504,600, 5,530,566, 5,583,672, 5,949,508, 5,333,074, and 5,473,450.
An improvement on the PDLC display was the Phase Separated Composite Organic Film (PSCOF) display (described in U.S. Pat. No. 5,949,508) in which the liquid crystal and polymer were disposed near opposite substrates, with widely separated support polymer dots extending fully across the gap between the faces. The dots provided an effective structural bond between the substrates and because in most locations one substrate face was exposed to the liquid crystal molecules, an alignment layer could be provided on one of the substrates. Typically, the alignment layer in PSCOF display positions the liquid crystal molecules in a homogeneous alignment (optical axis generally parallel with substrates), and the molecules are rotated to a homeotropic alignment by the presence of an electric field.
In both PDLC and PSCOF displays, the concentration of polymer was from 20 to 80 percent of the weight of the mixture of polymer and liquid crystal. In the polymer tendril (polymer stabilized) display, in which slender tendrils were formed while the molecules were held in homeotropic alignment by an applied electric field, the concentration of polymer was much less, e.g., about 3-5 percent by weight of the mixture of polymer and liquid crystal.
Other patents with potentially relevant background are: Rosenblatt et al., “Chiral Nematic Liquid Crystal with Homeotropic Alignment and Negative Dielectric Anistropy” (U.S. Pat. No. 5,477,358); Anderson et al., “Vertically Aligned Pi-Cell LCD having On-State with Mid-Plane Molecules Perpendicular to the Substrate” (U.S. Pat. No. 6,067,142); Patel, “Inverse Twisted and Super-twisted Nematic Liquid Crystal Device” (U.S. Pat. No. 5,701,168); Ogishima et al., “Liquid Crystal Display Device with Homeotropic Alignment in which Two Liquid Crystal Regions on the Same Substrate Have Different Pretilt Directions Because of Rubbing” (U.S. Pat. No. 5,757,454); Rosenblatt et al., “Cholesteric Liquid Crystal Devices” (U.S. Pat. No. 5,602,662); Kaufmann et al., “Homeotropic Nematic Display with Internal Reflector” (U.S. Pat. No. 4,492,432).
SUMMARY
We have discovered a form of in-situ polymerization that can achieve both a structural bond between the substrates and a homeotropic or other predetermined alignment.
In general the present invention provides a liquid crystal display device, containing two substrates facing and spaced from each other, at least one of the substrates being transparent, an electro-optical material filling a first portion of the space between the substrates, the electro-optical material comprising molecules whose spatial orientation can be altered by application of an electric field across the two substrates, and a polymeric material filling a second portion of the space between the substrates, the polymeric material having been polymerized in situ between the plates. The polymeric material forms a multiplicity of microscopic polymer columns extending between the two substrates. The columns provide both a structural bond between the two substrates for maintaining the spacing between the substrates and alignment of the molecules of the electro-optical material, with the alignment resulting from the close spacing of the microscopic columns.
The present invention also provides a method of manufacturing a liquid crystal display device. The method includes positioning two substrates that face each other, at least one of the substrates being transparent, and filling at least a portion of the space between the two substrates with a mixture of an electro-optical material and a polymeric material. The electro-optical material comprises molecules whose spatial orientation can be altered by application of an electric field across the two substrates. The polymeric material is then polymerized to form a multiplicity of microscopic polymer columns extending between the two substrates. The columns provide both a structural bond between the two substrates for maintaining the spacing between the substrates and alignment of the molecules of the electro-optical material, with the alignment resulting from the close spacing of the microscopic columns.
In some implementations of the invention, the invention may provide the following advantages (none of the following advantages will necessarily be achieved when practicing the invention, but the invention makes it possible to achieve some or all of these advantages in some implementations).
The structural bond between the substrates provided by the microscopic polymer columns can make the display insensitive to mechanical deformations and pressure, thus well suited for implementations requiring a rugged or flexible display.
Displays may be fabricated with high contrast. As homeotropic (perpendicular) alignment of the liquid crystal molecules may be achieved in the absence of an electric field, the OFF state of the display may be very dark, limited only by the quality of the polarizers used. The brightness of the ON state may be controlled by selecting liquid crystal material with suitable optical anisotropy or birefringence.
The displays may have fast response times, and require low operating voltages.
The details of one or more implementations or embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIGS. 1A and 1B are diagrammatic cross sectional views of two possible implementations of the invention.
FIGS. 2A and 2B are scanning microscope photographs showing the microscopic columns of one implementation of the invention.
FIGS. 3A , 3 B, 3 C, and 3 D are images of one implementation of the invention.
FIG. 4 is a plot of transmittance versus applied voltage for one implementation of the invention.
FIGS. 5A and 5B are photographs of a prototype display constructed according to one implementation of the invention.
DETAILED DESCRIPTION
In preferred implementations of the invention, one or more of the following may be incorporated (none of the following features is necessary to implementing the invention in its most general forms):
The alignment of the electro-optical material provided by the columns may be either a homeotropic alignment or an oblique alignment. As described in more detail below, a homeotropic alignment is provided when the polymeric material is polymerized in such a manner as to form columns that are perpendicular to the substrate surface. For example, when the polymeric material is a photocurable polymeric material, the cell may be illuminated in such a way that causes UV or other radiation to fall on the substrate, and consequently the mixture of electro-optical material and polymeric material, coincident with the normal. The photocurable prepolymer polymerizes in columns that are perpendicular to the substrate, providing a homeotropic alignment of the electro-optical material. An oblique alignment can be achieved by forming columns at an angle that varies from the normal, for example, by illuminating the cell with light at an angle that deviates from the normal of the substrate. The photocurable prepolymer polymerizes in columns that are oblique relative to the normal. The orientation of the columns provides an oblique alignment of the electro-optical material.
The polymerization of the polymeric material may be achieved by any means known in the art for polymerizing a polymeric material for use in an electro-optical display device. For example, when a photocurable polymeric material is used, polymerization may be induced by irradiating the cell with ultraviolet light. The ultraviolet radiation may be applied to one of the substrates from the side opposite the side facing the mixture of polymeric material and electro-optical material. In one implementation, the in-situ polymerization may occur in the absence of an electric field capable of aligning the molecules in a homeotropic alignment.
It has been observed that when the polymeric material polymerizes, caps of polymerized material may form on one or both ends of the polymer column. These caps comprise a thin layer of polymer that has a substantially greater lateral extent than the diameter of the column. It is preferred that when these caps are present, a majority of the caps are separated from adjoining caps, such that a substantially continuous layer of polymer is not formed on the face of the first or second substrates adjoining the caps. The caps may differ in size on each end of the polymer column. In other words, the average lateral extent of the caps on the first end of a polymer column may be greater than the average lateral extent of the caps on the second end of a polymer column.
In one implementation, the polymeric material is greater than about 10 percent by weight of the mixture of polymeric material and electro-optical material. In another implementation, the polymeric material is greater than about 20 percent by weight of the mixture of polymeric material and electro-optical material. The average spacing between polymer columns may also vary. In one implementation, the average spacing between the microscopic columns is greater than about 3 microns (3 micrometers) and less than about 30 microns (30 micrometers). In another implementation, the average spacing between the microscopic columns is greater than about 5 microns (5 micrometers) and less than about 15 microns (15 micrometers).
Additional elements may be added to the liquid crystal display of the present invention. For example, spacer elements may be positioned between the two substrates. An alignment layer for aligning the molecules of the electro-optical material in the presence of an electric field may optionally be present. The alignment layer may provide a homeotropic, planar or oblique orientation to the electro-optical material which may be a liquid crystal material. It is also envisioned that in some applications it may be desirable that no alignment layer is provided for aligning the molecules of the electro-optical material in the absence of an electric field.
When an oblique alignment is provided in the cell, a liquid crystal having positive or negative dielectric anisotropy may be used. When a homeotropic alignment is provided, a liquid crystal having positive dielectric anisotropy may be used.
The substrates may be of any material known in the art as being suitable for electro-optical displays. In one example, the substrates are polymeric.
In one particular implementation of the present invention, the polymeric material is a photocurable polymeric material, polymerization of the polymeric material is initiated by ultraviolet radiation, an alignment layer for aligning the molecules of the electro-optical material in a homeotropic alignment is not provided, the polymeric material is greater than about 20 percent by weight of the mixture of polymeric material and the electro-optical material, there are spacer elements positioned between the two substrates, and the electro-optical material is a liquid crystal material.
In another implementation of the present invention, the polymeric material is a photocurable polymeric material, polymerization of the polymeric material is initiated by ultraviolet radiation an alignment layer for aligning the molecules of the electro-optical material in a homeotropic alignment is not provided, the alignment provided by the columns is homeotropic, the polymeric material is greater than about 20 percent by weight of the mixture of polymeric material and the electro-optical material, there are spacer elements positioned between the two substrates, the electro-optical material is a liquid crystal material, and most of the polymer columns comprise a first cap on a first end of the column, the first cap being a thin layer of polymer of substantially greater lateral extent than the diameter of the column.
Described below in greater detail are some of the many possible implementations of the invention. As this is a discussion of implementations of the invention, many of the features and elements described in this section are not essential to practicing the invention.
One preferred implementation of the invention may be prepared as follows: Two glass substrates 22 , 26 ( FIG. 1A ) are coated with transparent indium tin oxide (ITO) electrodes 32 . These substrates are separated by glass fibers 30 of 3-5 micrometer diameter. A mixture of photocurable prepolymer (e.g., NOA65, NOA68, or NOA77 from Norland Products Inc.) and liquid crystal (MJ 991213 (MJ) with negative dielectric anisotropy from Merck Korea Ltd.) are mixed in the ratio 1:1, and then injected into the cell by capillary action at 95 degrees Celsius. The cell is then exposed (through one substrate) to collimated ultraviolet (UV) light 34 at the same temperature. The intensity of UV light (including 360 nm wavelength) at the glass surface is approximately 1.3 mW/cm 2 . Illumination by UV light initiates polymerization of pre-polymer molecules and, consequently, the phenomenon of phase separation, which, among other parameters, depends upon the interplay between the surface interactions and the inter-diffusion of liquid crystal and prepolymer at the molecular level. P. S. Drazaic, ed., Liquid Crystal Dispersions (World Scientific, Singapore, 1995). The prepolymer wets the indium tin oxide surface relatively faster than the liquid crystal molecules, and the microdroplets formed at the surface during photopolymerization act as nucleation sites for the development of polymer columns. During polymerization, more prepolymer molecules diffuse to these nucleation sites and undergo polymerization, thus forming columns. These polymer columns provide the necessary boundary condition for the homeotropic alignment of the liquid crystal molecules. The number, density, and size of the polymer columns are affected by the physiochemical nature of the liquid crystal material, prepolymer, polymer, cell thickness, and the rate of phase separation. By suitable adjustment of these physiochemical parameters and other external parameters such as the exposure temperature and UV intensity, one can obtain polymer columns that provide a structural bond between the two substrates while also providing homeotropic alignment of the liquid crystal molecules.
FIG. 1A shows a diagrammatic cross sectional view of one possible implementation of the invention. Microscopic polymer columns 24 extend downwardly toward the bottom substrate 26 . Most of the columns (i.e., more than 50%) have a cap 27 at one or both ends of the column. The caps are thin layers of polymer, with a lateral extent (i.e., parallel to the surfaces of the substrates) substantially greater than the diameter of the columns, themselves. Most of the caps do not contact adjacent caps, with the result that there is not the continuous layer of polymer adjacent a substrate (as was the case in PSCOF displays). The width of the columns may remain nearly uniform along the height of the columns (or the width of the columns may vary). There may be a range of column widths, with some columns being much narrower than others (or the columns may be nearly the same in width). Liquid crystal material 28 fills the spaces not occupied by the columns. Spacers 30 (e.g., glass fibers or spheres) space the two substrates 22 , 26 apart by a predetermined distance. The polymer columns provide a structural bond between the two substrates, holding the substrates against the spacers.
In another implementation, shown in FIG. 1B , one may use a collimated UV beam for oblique illumination of the cell during the polymerization-phase separation process. Then, the polymer columns 24 will be formed obliquely, which will, in turn, align the liquid crystal molecules in an oblique orientation. Application of an electric field will reorient the molecules to a planar or homeotropic orientation depending on whether the liquid crystal has negative or positive dielectric anisotropy.
FIG. 2A shows a scanning electron microscope (SEM) image of the polymer columns (NOA65-MJ mixture) after the liquid crystal has been washed away with hexane. FIG. 2B shows a tilted and magnified view of one of caps and one of the columns (partially visible below the cap).
FIG. 3A shows the microscopic texture of a 3-micron thick glass cell using a 1:1 NOA68-MJ mixture (50% by weight of each material) under crossed polarizers. The polymer columns appear dark under crossed polarizers, and liquid crystal defect lines interconnect them.
FIG. 3B is the conoscopic image of the same cell. A dark cross at the center of the field of view which is unaffected by rotation of the cell about its surface normal ensures the vertical alignment of the liquid crystal director.
FIG. 3C shows the microscopic texture of the same cell after a square wave electric field of amplitude 4 V at 1 kHz is applied across the cell. As the polymer columns extend vertically with no pretilt, the electric field reorients the liquid crystal director in the plane of the substrates with no preferential azimuthal orientation as indicated by the Schlieren.
FIG. 3D shows a prototype glass display fabricated using a 1:1 NOA68-MJ mixture. The indium-tin-oxide electrodes are etched away in the segmented area so that the application of the electric field across the cell switches the liquid crystals in the rest of the cell.
The performance of a liquid crystal display depends heavily upon its electrooptical properties. B.Bahadur, ed., Liquid Crystals: Application and Uses, Vol. 1 (World Scientific, Singapore, 1995). FIG. 4 shows the transmittance versus voltage (T-V) characteristics of a glass liquid crystal cell made by using a 1:1 NOA68-MJ mixture. The T-V characteristic of the cell is almost identical to a liquid crystal cell with a conventional homeotropic alignment layer. The gradual increase in the transmittance above approximately 5 V is due to the strong anchoring of the liquid crystal molecules on the walls of the polymer columns and small liquid crystal molecules trapped inside the polymer columns. The inset in FIG. 5 shows the switching time characteristic of the same cell under application of 2.25 V and 5.8 V corresponding to 10 and 90 percentage of the maximum transmittance. The response times of the cell, turn-on and turn-off times are 10 and 50 milliseconds, respectively, which are typical values for nematic liquid crystal displays.
Using a 1:1 NOA77-MJ mixture and 100 micron thick polymer (polyethersulphone) substrates separated by 5 micron thick spacers, a prototype display 2 in. by 3 in. was fabricated. FIG. 5A shows the display in the ON state. For this display, the active regions are the segments across which a square wave electric field with amplitude 6 V at 1 kHz has been applied. FIG. 5B shows the same display in the ON state flexed at the center with a radius of curvature of 1.25 inches. When flexed, the non-active area of the display appears gray at the edges due to the optical birefringence rendered by the inclined liquid crystal director (i.e., large viewing angle). However, at the normal view, the contrast ratio does not change by flexing the display. Because the plastic substrates are bonded together by polymer columns, application of an external pressure has minimal effect on the display and it returns to its normal performance almost immediately after the pressure is released.
A variety of factors may influence whether the in-situ polymerized columns of the invention are achieved. The relative viscosity and wetting capabilities of both the liquid crystal and the pre-polymer appear to be important factors. These factors affect the ability of the pre-polymer to separate from the mixture and wet the surface of a substrate to form nucleation sites, where the caps and columns begin to grow. As polymerization proceeds, with the polymer caps and columns growing in size, it appears to be important that the liquid crystal be capable of separating rapidly from the mixture, so as not to become trapped in pockets within the polymer (e.g., as occurs in PDLC displays). The amount of functionality of the oligomers (e.g., the number of locations at which polymer strands can attach) may also have an important effect on the manner and speed with which the polymer separates from the mixture.
A number of implementations of the invention have been described. Nevertheless, it will be understood that many and various modifications may be made without departing from the invention. For example: It may be possible to substitute a electro-optical polymer for the liquid crystal material. Alignment layers of appropriate but low anchoring energy may be used on one or both substrates to define the azimuthal direction for the molecular reorientation in the ON state (when the applied electric field causes planar orientation during operation of the display); such alignment layers are not relied on for achieving homeotropic alignment of the molecules in the OFF state, as the microscopic polymer columns provide that alignment. It may be desirable in some circumstances to use a homeotropic alignment layer in conjunction with the polymer columns, so that both the alignment layer and the polymer columns reinforce homeotropic alignment. More than one column may extend from a single cap (e.g., during polymerization a plurality of caps could merge together to form a single cap with multiple columns, or smaller-diameter columns could form along with a wider column). Not all of the columns need to provide a structural bond between the substrates, as the structural bond can be provided by the columns in the aggregate. A great many other examples exist, and thus many other implementations are within the scope of the following claims.
Some of the claims refer to “polymeric material,” which, depending on context, may be either a polymer or a pre-polymeric material that exists prior to polymerization.
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A liquid crystal display device comprises two substrates facing and spaced from each other, at least one of the substrates being transparent; an electro-optical material filling a first portion of the space between the substrates, the electro-optical material comprising molecules whose spatial orientation can be altered by application of an electric field across the two substrates; and a polymeric material filling a second portion of the space between the substrates, the polymeric material having been polymerized in situ between the plates, wherein the polymeric material forms a multiplicity of microscopic polymer columns extending between the two substrates, and the columns provide both a structural bond between the two substrates for maintaining the spacing between the substrates and alignment of the molecules of the electro-optical material, with the alignment resulting from the close spacing of the microscopic columns. A method to fabricate electro-optical displays having two facing substrates, electro-optical material in the space between the substrates, and in-situ polymerized microscopic columns extending between the substrates is also disclosed.
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TECHNICAL FIELD
The present invention relates generally to collapsible door structures for use with vehicle doors. More particularly, the present invention relates to collapsible door trim buckle initiator design in the armrest and grab handle region of the vehicle door. The collapsible door structures are strong and durable under normal use but demonstrate compromised lateral stiffness in the event of a side impact.
BACKGROUND OF THE INVENTION
Side impact events in vehicles have been identified as one of the top priorities for both research and regulation with government requirements continuing to become more stringent. These additional requirements make designs for door trim systems more challenging because they may impact the door trim at the door armrest supports and at the grab handle. It is known in vehicles to provide an armrest in a door typically having an integrated grab handle to allow the occupant to pull the door shut. According to known arrangements, the door armrest and grab handle are generally anchored to the vehicle door inner panel by a variety of structures. In addition to being anchored to the vehicle door inner panel, the grab handle is also solidly connected to the armrest substrate. This makes the area surrounding the grab handle quite stiff, which may negatively affect occupant injury results.
The known approaches to anchoring the armrest and door grab handle provide a good degree of lateral door function to the vehicle occupant while opening and, particularly, closing the door. Accordingly, a reduction in stiffness of the door trim panel in this area may improve side impact performance. But until now no solution has been available to this problem without compromising armrest and grab handle tensile and vertical strength.
Accordingly, as in so many areas of vehicle technology, there is room in the art of vehicle door design for an alternative configuration to known door armrest and door grab handle and adjacent support structures. The alternate configurations should allow the translation of horizontal force impacting the vehicle door in the event of an impact to vertical movement which deforms or buckles a portion of the armrest substrate to thereby prevent or minimize the movement of the armrest and its associated structure vehicle inward into the passenger area.
SUMMARY OF THE INVENTION
The present invention provides alternative arrangements to known vehicle door armrest and grab handle support structure designs. According to the present invention, a support structure design is provided which induces buckling in the door handle supports while continuing to provide acceptable durability and strength. To accomplish this two modifications to the door armrest and grab handle structures are made. First, an angled or curved section is added to the material flow strap of the armrest supporting structure to promote buckling. This approach overcomes the difficulty of known material flow straps which tend to be horizontal, thus introducing a strong compressive load path. By adding an angle to the flow straps the vertical motion is forced upon a lateral impact. Second, vertical components of the door handle support structure are removed while a buckle initiator in the door handle support is added.
This vertical motion contacts a buckle-line designed into the armrest substrate. This arrangement effectively provides the use of a secondary load path to pre-buckle the primary load path, insuring that the buckle will start a location defined by the buckle initiator, thus controlling the buckle and its development. By designing the armrest to buckle a reduction in the compressive strength is realized, while providing a load path for tensile forces.
Other advantages and features of the invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein:
FIG. 1 illustrates a perspective view of a door assembly viewed from the inside of the vehicle having a trim buckle initiator configuration according to the present invention;
FIG. 2 illustrates a perspective exploded view of the door frame, the grab handle back side plate, the armrest substrate, the energy-absorbing foam backing, and the armrest cover;
FIG. 3 illustrates a plan exploded view of the elements of FIG. 2 ;
FIG. 4 illustrates a sectional view of a conventional material flow strap assembly;
FIG. 5 illustrates a sectional view of a material flow strap assembly according to the disclosed invention shown in its pre-impact state;
FIG. 6 illustrates a sectional view of the material flow strap assembly of FIG. 5 illustrated in its post-impact state;
FIG. 7 illustrates a top sectional view of a portion of an armrest substrate according to an alternate embodiment of the disclosed invention prior to impact;
FIG. 8 illustrates the same view as shown in FIG. 7 but after a side impact;
FIG. 9 illustrates a perspective view of the grab handle back side plate of the disclosed invention;
FIG. 10 illustrates a lateral view of the grab handle back side plate of the disclosed invention; and
FIG. 11 illustrates a perspective view of a portion of the armrest substrate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for different constructed embodiments. These specific parameters and components are included as examples and are not meant to be limiting.
With reference to FIG. 1 , a perspective view of a door assembly of the present invention, generally illustrated as 10 , is shown. The door assembly 10 includes a frame 12 , an interior panel 14 , and an armrest and grab handle assembly 16 . It is to be understood that the configuration of the door assembly 10 shown in FIG. 1 is for illustrative purposes only and is not intended as being limiting. Particularly, the armrest and grab handle assembly 16 could be configured differently in terms of shape, size and overall configuration as well as in terms of placement of the grab handle itself.
With reference to FIGS. 2 and 3 , exploded views of the door assembly 10 are illustrated. The door assembly 10 includes the door frame 12 , a grab handle back side plate 18 , an armrest substrate 20 , an energy-absorbing foam backing 22 , and an armrest cover 24 . The energy-absorbing foam backing 22 is of known construction, as is the armrest cover 24 which may be of vinyl or another polymerized material as preferred and as is known in the art.
The door frame 12 includes a plurality of material flow straps 26 , 26 ′, 26 ″ and 26 ′″ to which the armrest substrate 20 is attached. The number and placement of the flow straps 26 , 26 ′, 26 ″, 26 ′″ . . . can be modified and adapted as required. However, according to the disclosed invention, the construction of the material flow straps 26 , 26 ′, 26 ″, and 26 ′″ is modified to allow them to buckle under compressive load.
A known material flow strap and associated elements are illustrated in FIG. 4 . With reference to that figure, a conventional material flow strap 30 , having an horizontal arm, is shown. The material flow strap 30 is continuous with a door trim substrate 32 . The door trim substrate 32 is adjacent a door inner sheet metal 34 .
A door handle support 36 is filled over the material flow strap 30 in a known manner and is fastened thereto by a first heat stake 38 and a second heat stake 40 . In the event of an impact situation the substantially horizontal portion of the material flow strap 30 may force the associated elements vehicle inward.
To improve on the situation possibly posed by the prior art, the material flow strap has been modified so that it buckles under compressive load. This structure is shown in FIGS. 5 and 6 . In FIG. 5 a sectional view of a supporting structure, generally illustrated as 40 , is shown. The supporting structure 40 includes a material flow strap 42 having a substantially horizontal portion 44 , an angled portion 46 , and a substantially vertical portion 48 . The substantially horizontal portion 44 is continuous with a door trim substrate 50 . Adjacent the door trim substrate 50 is a door inner sheet metal 52 .
Fitted to the material flow strap 42 is a door handle support 54 having a buckling initiator 56 formed therein. The buckling initiator 56 may be formed from a variety of methods, such as notching or slotting. The door handle support 54 is attached to the material flow strap 42 by a number of methods, such as by heat staking. As illustrated, attachment has been made by a heat stake 58 and by a heat stake 60 .
The supporting structure 40 is illustrated in FIG. 5 as the arrangement would appear prior to an impact event. In FIG. 6 , the arrangement is illustrated after the impact event. As is shown, the material flow strap 42 has buckled between the substantially horizontal portion 44 and the angled portion 46 . The buckling initiator 56 allows the substantially vertical movement of the material flow strap 42 and begins buckling in a specific, controlled location. By effecting upward, buckled movement of the material flow strap 42 and the door handle support 54 , the movement of the supporting structure and the lateral compressive stiffness is reduced.
An alternative arrangement for material flow straps is illustrated in FIGS. 7 and 8 . With reference first to FIG. 7 , an angled material flow strap 62 formed as set forth above in FIGS. 5 and 6 is provided and is shown prior to an impact event. Adjacent the angled material flow strap 62 is another angled material flow strap 64 which is provided at an angle which is generally perpendicular to the angled material flow strap 62 . Both the angled material flow strap 62 and the angled material flow strap 64 are fixed between a first portion of a door trim substrate 65 and a second portion of a door trim substrate 66 . A door inner sheet metal 67 is adjacent the first portion of the door trim substrate 65 . A handle closeout 68 is formed adjacent the angled material flow strap 64 . A switch area 69 is formed beside the handle closeout 68 .
The arrangement of FIG. 7 is shown after an impact event in FIG. 8 . As illustrated, both the angled material flow strap 62 and the angled material flow strap 64 are shown as having partially collapsed as has the handle closeout 68 . The impact energy is distributed away from the vehicle occupant and along the longitudinal axis of the vehicle through the armrest substrate and associated areas.
The invention disclosed herein also provides a modification to the grab handle back side plate 18 . This modification is illustrated in FIG. 9 in which the grab handle back side plate 18 is shown in perspective view. The grab handle back side plate 18 includes a pair of spaced apart side arms 70 and 72 which are joined by a curved bridge piece 74 . At the end of the side arm 70 is provided an attachment flange 76 having a door handle closeout attachment point 78 . At the end of the side arm 72 is provided an attachment flange 80 having a door handle closeout attachment point 82 .
In the event of a side impact event the rigid grab handle back side plate, as is known in the art, may be driven vehicle inward. To provide a potentially improved response, a plurality of buckling initiators are provided along each of the side arms 70 and 72 . Buckling initiators 84 , 84 ′, and 84 ″ are formed perpendicular to the long axis of the side arm 70 . Buckling initiators 86 , 86 ′ and 86 ″ are formed perpendicular to the long axis of the side arm 72 . Each of the buckling initiators 84 , 84 ′, 84 ″, 86 , 86 ′, and 86 ″ may be formed by notching, slitting or by any other known technique. An additional buckling initiator 88 may be formed at the corner of the side arm 70 and the attachment flange 76 . An additional buckling initiator 89 may also be formed at the corner of the side arm 72 and the attachment flange 80 . Furthermore, a buckling initiator 90 may be formed at the corner of the side arm 70 and the curved bridge piece 74 . An additional buckling initiator 92 may be formed at the corner of the side arm 72 and the curved bridge piece 74 .
FIG. 10 is a lateral view of the grab handle back plate 18 looking inward towards the center of the vehicle. This view illustrates the change in the thicknesses of the walls 70 and 72 over their respective vertical heights. The walls 70 and 72 are shown in broken lines at their attachment points to the attachment flanges 76 and 80 respectively. The thickness varies in order to accept tensile loads between the curved bridge piece 74 and the door handle closeout attachment points 78 and 82 during closing, while insuring that non-load bearing portions of the side walls 70 and 72 are effectively non-structural.
In addition to modifications being made to the material flow straps and to the grab handle back side plate as discussed above and shown in the related figures, further controlled buckling of the vehicle armrest can be established by making appropriate changes to the configuration of the armrest substrate. Such modifications are shown in FIG. 11 .
With reference to FIG. 11 , a perspective view of a portion of the armrest substrate 20 is illustrated. The armrest substrate 20 includes a grab handle cut out area 100 and a rearward armrest portion 102 . The rearward armrest portion 102 includes a top side 104 , a back end 106 , a front side 108 , and a front lip 110 . In general, slots, holes and apertures of a variety of shapes and sizes may be formed through the armrest substrate 20 according to the desired buckling path. The illustrated slots, holes and apertures are suggestive only and are not intended as being limiting, as other shapes and configurations may be formed in different places on the armrest substrate 20 .
By way of illustration, a plurality of elongated slots 112 and 112 ′ are formed along the top side 104 of the armrest substrate 20 . Ordinarily this area would be ribbed to provide structural integrity. The elongated slots 112 and 112 ′ are provided in lieu of the ribs without sacrificing structural integrity while providing an area for buckling initiation. In addition, a slot 114 may be provided along the front lip 110 . A plurality of vertical slots, for example, slots 116 and 116 ′, may be formed on the front side 108 of the armrest substrate 20 . To provide further or alternative buckling initiation a corner slot 118 may be formed as well.
The grab handle cut out area 100 may be strategically modified by removing the hard edge, by thinning the edge, or by forming an incline along the edge. Modifications may also include the formation of a buckling initiator slot 120 along the grab handle cut out area 100 . An upstanding vertical flange 122 is provided. The upstanding vertical flange 122 may be slotted, cut, or removed entirely, based upon the desired buckle kinematics. This embodiment shows the elongated slot 112 ′ to be approximately in-line with an upstanding vertical flange buckle initiator 124 . Each of these approaches would enable focused buckling initiation in the event of a side impact.
The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.
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A side impact door trim buckle initiator design is provided in a vehicle armrest and grab handle region. The disclosed support structure design induces buckling in the door handle supports while continuing to provide acceptable durability and strength. Two modifications to the door armrest and grab handle structures are made. First, an angled section is added to the material flow strap of the armrest supporting structure to promote buckling. This approach overcomes the difficulty of known material flow straps which tend to be horizontal, thus introducing a strong compressive load path. By adding an angle to the flow straps the vertical motion is forced upon a lateral impact. Second, vertical components of the door handle support structure are removed while a buckle initiator in the door handle support is added.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to the field of marine survey data acquisition and processing methods. More specifically, the invention relates to methods for attenuating strong marine seismic noise.
[0005] 2. Discussion of Related Art
[0006] To achieve high density surveys in regions having a combination of imaging and logistical challenges, a high trace density and closely spaced streamers may be used, however, this presents the potential of entangling and damaging streamer cables and associated equipment, unless streamer steering devices are closely monitored and controlled. Wide-azimuth towed streamer survey data is typically acquired using multiple vessels, for example: one streamer vessel and two source vessels; two streamer vessels and two source vessels; or one streamer vessel and three source vessels. Many possible marine seismic spreads comprising streamers, streamer vessels, and source vessels may be envisioned for obtaining wide- or rich-azimuth survey data. Assignee's U.S. Pat. No. 7,400,552 (Attorney Docket No. 594-25619-US), discusses some of these. This patent discusses shooting and acquiring marine seismic data during turns of linear marine surveys and during curvilinear paths. A great leap in acquisition technology was described in another assignee's co-pending application Ser. No. 12/121,324, filed on May 15, 2008 (Attorney Docket No. 594-25633-US2), which describes methods for efficiently acquiring wide-azimuth towed streamer seismic data, which is also known as the “coil shooting” technique. These non-linear survey methods deviate greatly from the traditional straight line surveys and frequently encounter a lot more noises from various sources, such as ocean current, towing mechanism, steering devices.
[0007] Regardless the acquisition methods used in seismic survey, the noise attenuation is always a major issue during data processing. There are many methods to attenuate noises. The methods could be classified into three categories:
methods to discriminate the noise from the signal based on apparent velocities; methods to discriminate the noise from the signal based on amplitudes; or methods that adaptively estimate the noises based on noise coherency.
[0011] Seismic data acquired in the presence of marine currents could be affected by very strong noise that could contaminate a large number of traces. When the noise energy is comparable to the signal energy, then the noise is referred to as strong noise; when the noise energy is greater than the signal energy, then the noise is very strong noise. The existent noise attenuation methods applied on such data do not perform well and the results typically have large amount of noise left and the signal amplitudes are not accurately preserved.
[0012] One way to handle these cases is to apply a combination of different methods that requires sorting the data in different domains, like common receiver domain or common offset domain and this could make the processing quite expensive.
[0013] While the Q suite of advanced technologies for marine seismic data acquisition and processing may provide detailed images desired for many reservoir management decisions, it is desirable to have methods that can improve the data quality and reduce the processing costs.
REFERENCES
[0000]
[1]. Peter W. Cary, Changjun Zhang, “Ground roll attenuation with adaptive eigenimage filtering”, SEG 2009, Houston, Tex.
BRIEF SUMMARY OF THE INVENTION
[0015] The methods proposed here are based on amplitude discrimination between signal and noise. We use a novel approach for noise estimation, where the methods attenuate strong marine noise that could be caused by marine currents, waves, equipment, seismic interferences, etc. The methods use singular value decomposition, determining noisiest traces and estimating noise components only from these traces, iteratively estimating the noise and protecting signal behind the noise.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] A better understanding of the invention can be had when the following detailed description of the preferred embodiments is considered in conjunction with the following drawings, in which:
[0017] FIG. 1 shows a flow diagram of an embodiment of the current invention.
[0018] FIG. 2 shows a flow diagram of another embodiment of the current invention.
[0019] FIG. 3 shows raw single sensor data.
[0020] FIG. 4 shows the same data as in FIG. 3 after removing noise using a method of the current invention.
[0021] FIG. 5 shows another example of comparing the input data, the data after noise attenuation and the noise removed.
[0022] FIG. 6 shows a typical computer system that may be used to implement the methods of the current invention.
[0023] It is to be noted, however, that the appended drawings are not to scale and illustrate only typical embodiments of this invention, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0024] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible. For example, in the discussion herein, aspects of the invention are developed within the general context of acquiring high quality marine seismic data in a more cost efficient manner, which may employ computer-executable instructions, such as program modules, being executed by one or more conventional computers. It is noted, however, that modification to the systems and methods described herein may well be made without deviating from the scope of the present invention. Moreover, those skilled in the art will appreciate, from the discussion to follow, that the principles of the invention may well be applied to other aspects of seismic data acquisition and data processing. Thus, the systems and method described below are but illustrative implementations of a broader inventive concept.
Mathematical Background
[0025] It is well known from linear algebra the operation of singular value decomposition for a given matrix D (m,n), where m=number of rows and n=number of columns. Singular value decomposition applied to the matrix D produces a diagonal matrix S (n, n) of dimension (n,n), and unitary matrixes U and V, so that:
[0000] D=U*S*V′ (1)
[0000] where V′ is the transpose of V. U has the dimension (m,n), S has the dimension (n,n) and V has the dimension (n,m). S is a diagonal matrix that has the elements S 11 ,S 22 , . . . Snn, and S 11 >S 22 >S 33 > . . . >.Snn. The elements of the matrix S are the eigenvalues of the matrix D.
[0026] If for the matrix D (m,n) we calculate only the largest k eigenvalues, than we can find the matrixes U 1 ( m,k ), S 1 ( k,k ) and V 1 ( k,n ) such that
[0000] N=U 1 *S 1 *V 1′ (2)
[0027] N matrix has the same dimension as the matrix D but the elements are different. Matrix N only has the largest k eigenvalues, S 11 through Skk, of Matrix D.
[0028] Consider a matrix D (ns, nt), which is the mathematical representation of a seismic shot gather that has ns samples in time and nt samples in space, i.e, the shot gather has nt traces and each trace has ns samples. The elements of the matrix D are the amplitude values of the seismic wavefield sampled in time and space.
[0029] The geophysical application of singular value decomposition for attenuation of the strong marine noise is based on two assumptions:
[0030] 1) D=S+N, where S=seismic signal and N=seismic noise
[0031] 2) We can discriminate the seismic amplitudes based on the selection of the eigenvalues: the largest eigenvalues correspond to the largest amplitude values. If we assume that we selected the largest k eigenvalues and these represent the noise part of the seismic data D, then the matrix N is an estimate of the noise. The estimated noise can be removed from the original data D by a simple matrix subtraction:
[0000] S 1 =D−N (3)
[0032] where S 1 is a representation of the seismic signal plus residual noise.
[0033] It can be difficult to determine the number of eigenvalues that can adequately represent the noise while preserving the signals. The “noise-free” matrix S 1 may still contain excessive residual noises.
[0034] FIG. 1 illustrates the overall flow diagram 100 of one of the methods to estimate and attenuate the noises while preserving the signals. The input data D 102 , go through the noise estimation or determination step 120 . The estimated noise is subtracted from the input data D at step 130 to generate output data 132 . The process is an iterative process. The output data 132 may be tested for its Signal/Noise ratio at step 140 . If the S/N reaches a preset threshold, the process stops at 152 . If not, the output data is treated as input data to step 120 to go through one or more iterations. Instead of testing S/N ration at each iteration, a total number of iteration may be set. Once the predetermined number of iterations has run, the process stops at 152 .
[0035] The number of iterations or the threshold S/N ratio is determined based on the evaluation of Signal/Noise ratio in the data. It is determined as a function of the noise level in each shot.
Energy Analysis
[0036] FIG. 3 illustrates a sample of raw data and FIG. 4 illustrates the data with noise attenuation method applied. An energy analysis may be done on the raw dataset which is to be processed.
[0037] In FIG. 3 , three windows are picked, one for noise window 310 , a second for signal window 320 and a third 330 for energy analysis window. The noise window 310 and signal window 320 may be selected based on their signal and noise contents. The noise window 310 is selected because the noise content predominates and the signal is almost invisible. The signal window 320 is just the opposite, where the noise content is small and signal amplitude is much larger than noise.
[0038] Using traces within noise window 310 , a noise matrix can be constructed and subject to singular value decomposition. Its eigenvalues (noise eigenvalues) can be calculated. Similarly, traces within signal window 320 , a signal matrix can be constructed and its eigenvalues (signal eigenvalues) computed. The noise eigenvalues and signal eigenvalues can be compared, their ranges are determined. A range of noise eigenvalues can be set to be used in later process. In an alternative, the number of iterations can be set, which is the number of iterations the noise attenuation procedures are applied to data to be processed.
[0039] Energy analysis window 330 is selected to be a window where parts of all traces are present. The window 330 contains no significant signals. It is typically chosen near the bottom of a seismogram, as shown in FIG. 3 . For each trace within window 330 , its total energy (amplitude) is calculated. The average of the trace energy is also calculated. Based on the average trace energy, noise/signal energy thresholds can be determined. If the trace energy is above the noisy threshold, then the trace is considered noisy, and will be treated with the noise attenuation method as described below. If the trace energy is below the signal energy threshold, the trace is considered clean, i.e. with little noise, and will be left alone. The clean trace is not subject to noise attenuation and all signal strength is preserved. For simplicity, the noise threshold and the signal threshold can be set as the same and same as the average trace energy. The two thresholds may also be set at different levels for better noise attenuation and/or signal preservation.
[0040] Based on the energy analysis or other knowledge of the particular dataset to be processed, a user may define other processing criteria which may affect the application of the noise attenuation methods described below.
[0041] The number of required iterations can be determined as described above in an “analysis” phase. The results, such as the energy of the noisy traces and/or the average energy values may be stored in the trace headers. The user can run singular value decomposition, estimate the noise, and determine the number of iterations that is required and the number of eigenvalues that have to be used to estimate the noise as a function of the noise level in each shot at this phase. When the data are actually processed, in an “execution” phase, the headers are examined and the number of iterations and/or the eigenvalue range for each shot are used. This optional energy analysis may be done before the “execution” phase, where the dataset is actually processed. It can be done during the “execution” step during some noise estimation and removal iterations. The energy analysis helps to determine whether the noise attenuation is adequately performed.
Description of the Strong Noise Estimation Method
[0042] FIG. 2 illustrates a flow diagram of the noise estimation process using singular value decomposition that is to attenuate strong noises in an input dataset D.
[0043] 1. Input data set is a shot gather represented by a matrix D 202 .
[0044] 2. In an optional step 212 , several windows may be selected to represent noises, signals as described above. The windows may be selected for full spectrum data or they may be selected later on within a band-limited data. From the windows, target Signal/Noise Ratio or number of iterations for the process are determined.
[0045] 3. In an optional step 213 , a frequency range (f 1 ,f 2 ) is determined, where the noise dominates the signal. Determine the frequency ranges where the noise is above the signal. This can be done by frequency analysis. The noise could be present in frequency ranges (f 1 ,f 2 ), (f 3 ,f 4 ), etc. The noise estimation and subtraction will be done for each frequency range. For simplicity, only one frequency range (f 1 , f 2 ) is discussed below.
[0046] 4. In an optional step 214 , where noise dominates within the frequency band (f 1 , f 2 ), a bandpass filter (f 1 ,f 2 ) is applied to the input data D and generate a filtered data set Df. Df contains signal and noise, primarily in the frequency band (f 1 , f 2 ). It will be used to find the noise in this frequency band.
[0047] 5. In step 215 , from Df determine the range of eigenvalues corresponding to the noise and the range of eigenvalues corresponding to the signal. This is done by calculating eigenvalues in a “noise” window, defined in space and time, where the noise is present, and a “signal” window, defined in space and time, where only the signal is present. FIG. 3 shows a shot gather and the windows selected for noise and signal.
[0048] The noise window and the signal window can be determined as described above or based on other user defined parameters.
[0049] From the matrix Df noisy traces are determined. This is typically done as discussed above, but in a bandpass filtered dataset Df. The trace energy for each trace in a window defined by the user as discussed above is calculated. The shot average energy is calculated and the energy of each trace is compared with the shot average energy. If the trace energy is larger than average energy the respective trace is considered a noisy trace. All noisy traces are collected in a matrix, Dnf. Unlike matrix Df, Dnf only contains noisy traces and does not contain clean signal traces.
[0050] 6. In step 216 , split the data Dnf in spatial gates, based on user defined parameters; each spatial gate is represented by a matrix Gi.
[0051] 7. In step 217 , apply singular value decomposition on each matrix Gi, using the range of eigenvalues for the noise and the signal determined in step 215 . From each matrix Gi, the noise Ni is estimated.
[0052] 8. In step 218 , all noise estimate matrices Ni are collected and assembled into a noise matrix N. This matrix N has the same dimension as the input matrix D, other matrices Df or Dnf all of which were derived from matrix D.
[0053] 9. In step 219 , the noise matrix N is subtracted from the input data matrix D; the result is a matrix D 1 . Since the noise matrix N is derived from data matrix Dnf, which is limited in frequency band (f 1 , f 2 ) and only the noisy traces, the signals in all other traces or other frequencies are not affected and preserved.
[0054] 10. In step 220 , the data matrix D 1 may be reviewed. In one method, the traces in data D 1 where the residual noise is still above the signal is determined. This can be done by evaluating the RMS amplitude in a window specified by the user. If yes, i.e. the noise level is high, make the D 1 matrix as original D matrix and repeat the steps above. If no, the process is done.
[0055] Alternatively, the total number of iteration, as discussed above, is set before hand, based on the noise/signal energy estimate. Unless the total number of iteration is reached, go to step 215 to repeat the noise estimation and removal process. Once the total number of iteration is reached, the process stops.
[0056] In each iteration in the above noise estimation and removal procedures, strong noises within noisy traces are estimated and removed. The traces having low or no noises are left alone and not touched. Therefore, the signals, however small, are preserved. The noise estimation is done within a frequency band. Similar to the treatment of noisy/clean traces, signals in frequency band not processed are not affected and preserved.
[0057] After each iteration, the strong noise in a trace within the frequency band is attenuated. So the noise level among the traces will change and the “noise” status of a trace may change as well. The traces have the highest noise level will be attenuated.
[0058] In the above example, only one frequency band (f 1 , f 2 ) is treated. If more frequency bands have strong noises, then the process is performed on each of those other bands. If strong noises are present in all spectra, then such noises may be attenuated first, without band filtering.
[0059] Noises from different sources typically only affect a particular frequency band or some traces. For example, the streamer towing noises are low frequency noise. The noised due to ocean waves are in another band but are present in all traces. The strong noises due to streamer turning may affect some traces but not all. Generally the marine noise due to streamer towing or marine currents dominates the very low frequencies from 0 Hz to 10 Hz.
[0060] An alternative to the fixed number of iteration, an adaptive process may be used, where in criteria to stop the noise attenuation may be based on the results of the last iteration. At the beginning of each iteration, noise/signal windows are determined by their energy level. From that, noise traces and signal traces are determined, which in term determines the target signal/noise ratio for the iteration. If the target signal/noise ratio is achieved, the noise attenuation is done.
[0061] Another possibility is to determine the level of noise estimated at iteration i'th with the level of noise estimated at the previous iteration, i−1. If the difference is negligible the process is stopped.
[0062] FIG. 5 shows another example: input data (left panel), data after noise attenuation (middle panel) and the difference between the input data and the data after noise attenuation, i.e. the noise that was removed. (right panel). It is clear that one of the current methods successfully attenuated strong noises in most of the traces, while preserved the low strength signals.
[0063] There are many benefits of the methods described above. They include at least the following:
use of singular value decomposition to evaluate the strong marine noise; determine the noisiest traces and estimate the noise component only from these traces; iterative estimation of the noise using singular value decomposition; protect the signal behind the noise; the method is applied only in the shot domain and does not require any data sorting; and the method is not sensitive to aliasing very efficient from computation point of view.
[0071] The methods described above can be and typically is used together with many other noise attenuation methods to achieve the desired objective in seismic data processing. They can be used first on the raw dataset in a data processing flow before all other data processing methods. This way, the signals, which may have much lower amplitudes, are not overwhelmed by the strong noises. Once the data are processed, they can be presented showing subsurface structures containing interested materials, such as hydrocarbon or minerals. The identified structures can be used to produce the interested materials, such as hydrocarbon.
[0072] The methods described above can be performed in an on-shore data processing office after a survey or in a geophysical surveying vessel during a survey. The on-board processing can provide immediate feedback on the data acquired during the survey and may cause some adjustments in the survey plan to optimize the survey results.
[0073] The methods described above are typically implemented in a computer system 1900 , one of which is shown in FIG. 6 . The system computer 1930 may be in communication with disk storage devices 1929 , 1931 , 1933 and 1935 , which may be external hard disk storage devices. It is contemplated that disk storage devices 1929 , 1931 , 1933 and 1935 are conventional hard disk drives, and as such, will be implemented by way of a local area network or by remote access. Of course, while disk storage devices are illustrated as separate devices, a single disk storage device may be used to store any and all of the program instructions, measurement data, and results as desired.
[0074] In one implementation, seismic data from the seismic receivers may be stored in disk storage device 1931 . Various non-seismic data from different sources may be stored in disk storage device 1933 . The system computer 1930 may retrieve the appropriate data from the disk storage devices 1931 or 1933 to process data according to program instructions that correspond to implementations of various techniques described herein. The program instructions may be written in a computer programming language, such as C++, Java and the like. The program instructions may be stored in a computer-readable medium, such as program disk storage device 1935 . Such computer-readable media may include computer storage media. Computer storage media may include volatile and non-volatile, and removable and non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules or other data. Computer storage media may further include RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid state memory technology, CD-ROM, digital versatile disks (DVD), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the system computer 1930 . Combinations of any of the above may also be included within the scope of computer readable media.
[0075] In one implementation, the system computer 1930 may present output primarily onto graphics display 1927 , or alternatively via printer 1928 (not shown). The system computer 1930 may store the results of the methods described above on disk storage 1929 , for later use and further analysis. The keyboard 1926 and the pointing device (e.g., a mouse, trackball, or the like) 1925 may be provided with the system computer 1930 to enable interactive operation.
[0076] The system computer 1930 may be located at a data center remote from an exploration field. The system computer 1930 may be in communication with equipment on site to receive data of various measurements. The system computer 1930 may also be located on site in a field to provide faster feedback and guidance for the field operation. Such data, after conventional formatting and other initial processing, may be stored by the system computer 1930 as digital data in the disk storage 1931 or 1933 for subsequent retrieval and processing in the manner described above. While FIG. 19 illustrates the disk storage, e.g. 1931 as directly connected to the system computer 1930 , it is also contemplated that the disk storage device may be accessible through a local area network or by remote access. Furthermore, while disk storage devices 1929 , 1931 are illustrated as separate devices for storing input seismic data and analysis results, the disk storage devices 1929 , 1931 may be implemented within a single disk drive (either together with or separately from program disk storage device 1933 ), or in any other conventional manner as will be fully understood by one of skill in the art having reference to this specification.
[0077] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope of the invention. Accordingly, the protection sought herein is as set forth in the claims below.
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Methods to attenuating strong marine seismic noises using singular value decomposition, determining noisiest traces and estimating noise components only from these traces, iteratively estimating the noise and protecting signal behind the noise. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72( b ).
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from Japanese Patent Application No. 2007-0791131, filed on Mar. 26, 2007, the entire subject matter of which is incorporated herein by reference.
FIELD
Aspects of the invention relate to printing apparatuses executing calibration to secure print image quality.
BACKGROUND
Known printing apparatuses, e.g., electrophotographic printers, execute a process designated as calibration to prevent degradation of image quality to result in printing due to environmental changes and consumption of components. In the calibration process, a toner image of a test pattern of each color is printed on a surface of an intermediate transfer belt, a position and toner density of the test pattern of each color are measured, and a color shift correction and a density adjustment are made for each color based on the measured results. The calibration process is executed automatically when it is determined that it is time to execute calibration, for example, after the expiration of a predetermined time interval from a previous calibration process.
The calibration process influences print quality during color printing more than during monochrome printing. However, if the calibration is started when print jobs are registered in a print queue, a monochrome print job, having a lower need for calibration when compared with a color print job, has to wait to start printing until after the calibration has been executed.
SUMMARY
Aspects of the invention provide a printing apparatus configured to avoid generating a waiting time due to calibration for a monochrome print job and to secure the print quality for a color print job.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative aspects of the invention will be described in detail with reference to the following figures in which like elements are labeled with like numbers and in which:
FIG. 1 is a side sectional view of a general structure of a printer according to an illustrative embodiment of the invention;
FIG. 2 is a block diagram showing an electrical structure of a printing system according to an illustrative aspect;
FIG. 3 illustrates a print data structure according to an illustrative aspect;
FIG. 4 is a flowchart of a job registration procedure according to an illustrative aspect;
FIG. 5 is a flowchart of printing processing according to an illustrative aspect; and
FIG. 6 illustrates a print job order change according to an illustrative aspect.
DETAILED DESCRIPTION
An illustrative embodiment of the invention will be described in detail with reference to FIGS. 1-6 . A printing apparatus according to aspects of the invention is applied to a color printer 1 . It will be appreciated that aspects of the invention apply to other types of printing apparatuses as well.
In the following description, the right side of FIG. 1 is referred to as the front of the printer 1 .
A general structure of the printer 1 will be described. As shown in FIG. 1 , the printer 1 includes a body casing 2 . A sheet supply tray 4 for placing a stack of recording sheets 3 is disposed on a bottom portion of the body casing 2 . A sheet supply roller 5 is disposed in an upper front portion of the sheet supply tray 4 . An uppermost sheet in the sheet supply tray 4 is fed in conjunction with the rotation of the sheet supply roller 5 to registration rollers 6 . The registration rollers 6 are configured to correct the skewing of the recording sheet 3 and then feed the sheet to a printing unit 10 .
The printing unit 10 includes a belt unit 11 , a scanner unit 17 , a process unit 20 , and a fixing unit 28 .
The belt unit 11 includes a pair of support rollers 12 disposed on the front and rear, and a belt 13 extended between the support rollers 12 . The belt 13 can be made of polycarbonate material. When the belt 13 is driven, the recording sheet 3 is fed rearward on the belt 13 . Transfer rollers 14 are disposed inside the belt 13 to face photosensitive drums 26 of the process unit 20 over the belt 13 . A sensor 15 is disposed in the vicinity of the rear support roller 12 . The sensor 15 is configured to detect a test pattern to be formed on the belt 13 .
The scanner unit 17 is configured to irradiate the surfaces of the photosensitive drums 26 with the corresponding lasers L emitted from a laser emitting portion (not shown).
The process unit 20 includes a frame 21 , and developing cartridges 22 (e.g., four) of yellow 22 Y, magenta 22 M, cyan 22 C, and black 22 K, each of which is detachably attached to the frame 21 . Each developing cartridge 22 includes a toner chamber 23 that stores toner of a corresponding one of colors, yellow, magenta, cyan, and black, a supply roller 24 , and a developing roller 25 . The frame 21 includes the photosensitive drums 26 and scorotron chargers 27 in association with the developing cartridges 22 .
Toner discharged from the toner chamber 23 is supplied to the developing roller 25 in conjunction with the rotation of the supply roller 24 , while being positively charged between the supply roller 24 and the developing roller 25 by friction. The surface of the photosensitive drum 26 rotating is uniformly charged positively by the charger 27 and exposed to the laser L that is emitted from the scanner unit 17 . An electrostatic latent image corresponding to an image to be printed on a sheet 3 is formed on the surface of the photosensitive drum 26 . As the developing roller 25 rotates, the toner on the developing roller 25 is supplied to the surface of the photosensitive drum 26 , and the latent image is developed with the toner to form a toner image. While the recording sheet 3 passes between the photosensitive drum 26 and the transfer roller 14 , the toner image is transferred to the recording sheet 3 by a transfer bias applied to the transfer roller 14 .
The recording sheet 3 having the toner image thereon is fed to the fixing unit 28 by the belt unit 11 , where the toner image is fixed onto the recording sheet 3 by heat. The recording sheet 3 is ejected onto an output tray 29 that is disposed at an upper surface of the body casing 2 .
A printing system between the printer 1 and a computer 40 connected to the printer 1 via a communication line 37 will be described with reference to FIG. 2 . Computer 40 can be connected to the printer 1 via the communication line 37 .
The printer 1 may include CPU 30 , ROM 31 , RAM 32 , non-volatile RAM (NVRAM) 33 , an operation unit 34 , a display unit 35 , the printing unit 10 , and a network interface 36 .
Various programs in the form of computer executable instructions for controlling the operation of the printer 1 can be stored in the ROM 31 . The CPU 30 acts as a controller and enables the RAM 32 and the NVRAM 33 to store results of processing executed according to a program read from the ROM 31 , while controlling the operation of the printer 1 .
The operation unit 34 includes buttons for user manipulation such as a print start button. The display unit 35 includes a liquid crystal display and a lamp, and is capable of displaying various setting screens and operation statuses. The network interface 36 is connected to the computer 40 via a communication line 37 to perform mutual data communications with the computer 40 .
The computer 40 can include CPU 41 , ROM 42 , RAM 43 , a hard disk 44 , an operation unit 45 constituting a keyboard and a pointing device, a display unit 46 constituting a liquid crystal display, and a network interface 47 connected to the communication line 37 . The hard disk 44 stores various programs having computer executable instructions such as application software for creating print data and printer drivers.
When the user inputs a print command to the computer 40 through the operation unit 45 , the CPU 41 causes application software to create data for printing, and causes a printer driver to convert the data into a page description language (PDL) to create print data shown in FIG. 3 .
The print data may have a data structure including a header section and a body section. Image data to be printed may be contained in the body section. The header section includes a print request (command) with an IP address of the computer 40 that is a source, and an IP address of the printer 1 that is a destination. The header further includes information such as a date of the print request, a user name, a document name, an application name, a data type, the number of pages, and the number of colors on each page (namely, color printing or monochrome printing). The CPU 41 sends the print data to the printer 1 via the network interface 47 .
When the printer 1 is turned on and becomes ready to print, the CPU 30 of the printer 1 starts a job registration processing ( FIG. 4 ) and printing processing ( FIG. 5 ). In the job registration processing, as shown in FIG. 4 , the CPU 30 regularly monitors reception of the print data (print request) (S 101 ). When the CPU 30 receives the print data and stores it in the RAM 32 (S 101 : Yes), it determines whether there is an empty place in a print queue (S 102 ). The print queue is a data structure for determining the order of execution of print jobs and is stored in the RAM 32 by the CPU 30 . Several print jobs (up to six jobs in this illustrative embodiment) can be registered in the print queue. The print jobs are numbered in order received from one. When there is an empty place in the print queue (S 102 : Yes), the CPU 30 registers the received print data in the print queue as a print job (S 103 ). The print job registered at this time is ranked last.
In the printing processing, as shown in FIG. 5 , the CPU 30 determines whether there is a registered print job in the print queue (S 201 ). When there is no registered print job (S 201 : No), the CPU 30 determines whether a flag indicating time to execute a color shift correction (as an example of the calibration) is turned on (S 202 ). The flag indicating the time to execute the color shift correction is stored in the NVRAM 33 . Although the value of the flag is normally off, it is turned on by the CPU 30 in advance when certain conditions are detected, such as when a fixed time elapses after the previous color shift correction, when designated pages are printed after the previous color shift correction, when the environment (e.g., temperature) changes, or when the remaining amount of toner is changed. The determination as to whether it is the time to execute the color shift correction may be made on reception of print data according to the status of the printer 1 . Records, such as a period of time elapsed after the previous color shift correction or the number of pages to be printed after the previous color shift correction, are stored in the NVRAM 33 and will not disappear even when the power is turned off.
When the flag is off or it is still not time to execute color shift correction (S 202 : No), the flow returns to S 201 and repeats S 201 and S 202 until a print job is registered in the print queue or the flag of the color shift correction is turned on. When the flag is on, that is, when it is the time to execute the color shift correction (S 202 : Yes), the CPU 30 executes color shift correction (S 203 ) and returns the flag to off. In this color shift correction, a test pattern of each color is printed on the belt 13 by the scanner unit 17 and the process unit 20 , the position of the test pattern is measured by the sensor 15 to find an amount of deviation from a transfer position by each color, and adjustments, e.g. exposure timing by the scanner unit 17 or exposure position on the photosensitive drum 26 , are made. After the color shift correction, the flow returns to S 201 .
When there is a registered print job or are registered print jobs in the print queue at S 201 (S 201 : Yes), a printing process for the first print job ranked in the print queue is executed (S 204 ). In this printing process, print data stored in the RAM 32 is subjected to image processing, for example, by converting the print data into bitmap data, and the bitmap data is sent to the printing unit 10 to perform printing. After printing is performed, the print job is deleted from the print queue, and print jobs remaining in the print queue are moved up one in the order. The CPU 30 determines whether there is an unexecuted print job in the print queue (S 205 ). When there is no unexecuted print job (S 205 : No), the flow returns to S 201 .
When there is an unexecuted print job in the print queue (S 205 : Yes), the CPU 30 determines whether it is the time to execute the color shift correction based on the value of the flag described above (S 206 ). When it is not the time to execute the color shift correction (S 206 : No), the flow returns to S 204 and the CPU 30 executes the subsequent print job that is the first in the current order in the print queue. While it is not the time to execute the color shift correction, print jobs registered in the print queue are executed successively.
When the flag indicating the time to execute color shift correction is on (S 206 : Yes), the CPU 30 changes the order of the print jobs registered in the print queue (S 207 ). In the order change process, the print jobs in the print queue are grouped into color print jobs and monochrome print jobs based on the headers of print data. A print job in which a color page is included in the print data is regarded as a color print job. A print job in which all pages in the print data are to be printed using only one color is regarded as a monochrome print job.
The print jobs are sorted in the order that each monochrome print job is higher than color print jobs in the order in the print queue. For example, as shown in FIG. 6 , six print jobs A to F are registered in a print queue. Before the job order is changed (on the left side of FIG. 6 ), the numbers 1 , 4 , and 6 are assigned to color print jobs A, D, and F, respectively, and the numbers 2 , 3 , and 5 are assigned to monochrome print jobs B, C, and E, respectively. After the job order is changed (on the right side of FIG. 6 ), the numbers 1 , 2 , and 3 are assigned to monochrome print jobs B, C, and E, respectively, and the numbers 4 , 5 , and 6 are assigned to color print jobs A, D, and F, respectively.
The CPU 30 determines whether the subsequent print job, that is, the current first print job in the print queue, is a monochrome print job (S 208 ). When it is a monochrome print job (S 208 : Yes), the CPU 30 executes the print job (S 209 ) and then deletes it from the print queue. The CPU 30 determines whether all monochrome print jobs in the print queue are finished (whether the subsequent print job is a monochrome print job) (S 210 ): When all monochrome print jobs are not finished (S 210 : No), the flow returns to S 209 and the CPU 30 executes the subsequent monochrome print job.
When all monochrome print jobs in the print queue are finished (S 210 : Yes) or there are no monochrome print jobs in the print queue (S 208 : No), the CPU 30 executes color shift correction (S 211 ) and returns the flag to off.
The CPU 30 determines whether the subsequent print job, that is, the current first print job in the print queue, is a color print job (S 212 ). When it is a color print job (S 212 : Yes), the CPU 30 executes the print job (S 213 ) and then deletes it from the print queue. The CPU 30 determines whether all color print jobs are finished (or the subsequent print job is a color print job) (S 214 ). When all color print jobs are not finished (S 214 : No), the flow returns to S 213 and the CPU 30 executes the subsequent color print job.
When all color print jobs in the print queue are finished (S 214 : Yes) or there is no color print job in the print queue (S 212 : No), the printing processing is finished, and the job registration processing is restarted.
According to the above illustrative embodiment, when the CPU 30 determines that it is the time to execute the color shift correction (an example of calibration), it executes printing of monochrome print job(s) in the print queue first, executes the color shift correction, and then executes printing of color print job(s), if the print queue includes both monochrome and color print jobs. As the monochrome print jobs, which are less susceptible to the color shift correction, are printed in preference to the color print jobs, waiting time due to the color shift correction can be avoided. As to the color print jobs, printing is performed after the color shift correction, so that print quality can be secured.
While color printing is performed with different color toners, e.g., magenta, yellow, cyan, and black, monochrome printing is performed with one of the different color toners. Printing of a monochrome print job(s) on a priority basis can avoid generating waiting time due to the calibration.
In the above illustrative embodiment, color shift correction is performed as an example of calibration. Aspects of the invention may be applied to a correction of other print characteristic, e.g., a density correction. The density correction may be performed by printing test patterns or patches on a belt, measuring densities of the test patterns by a sensor and adjusting the density based on measured results.
In the above illustrative embodiment, although a color laser printer of direct-transfer type is illustrated as an illustrative printing apparatus, a laser printer of intermediate transfer type may be applied. Alternatively, an inkjet printer may be applied.
At the time to execute the calibration, a notification that the order of print jobs is changed may be delivered to a computer that is a source of the print jobs. Alternatively, an instruction whether to perform the print job order change or whether to perform calibration may be input by a user, so that processing may be done in accordance with the input.
While the features herein have been described in connection with various example structures and illustrative aspects, it will be understood by those skilled in the art that other variations and modifications of the structures and aspects described above may be made without departing from the scope of the invention. Other structures and aspects will be apparent to those skilled in the art from a consideration of the specification or practice of the features disclosed herein. It is intended that the specification and the described examples only are illustrative with the true scope of the inventions being defined by the following claims.
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A printing apparatus includes a memory configured to store print jobs, a printing device configured to print an image based on each of the print jobs, a detector configured to determine when it is time to execute calibration to correct a printing characteristic of the printing device, and a controller. The controller is configured to cause the printing device to print each monochrome print job stored in the memory prior to each color print job stored in the memory when the detector determines that it is time to execute the calibration. Also, the controller is configured to execute the calibration when the detector determines that it is time to execute the calibration, and to cause the printing device to print each color print job stored in the memory after executing the calibration.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of intubating a patient, particularly a patient to be anesthetized, and to an introducer for use with such method.
In the course of surgery or other medical procedures, it is commonly necessary to anesthetize the patient, and this frequently requires that the patient be ventilated during the procedure, such ventilation is achieved by way of an endotracheal tube. Endotracheal intubation, placement of a breathing tube into the trachea, is commonly performed after induction of general anesthesia to maintain a patent airway and prevent aspiration of oral secretions or stomach contents into a patient's lungs. Usually, the tube is passed through the mouth and into the trachea under direct vision of the larynx at the tracheal opening. A specialized flashlight or laryngoscope is used to hold the tongue and airway structures out of the way, including the epiglottis, a structure above the larynx that functions to prevent entrance of food and liquid into the lungs as we swallow. Individual variation in patients' anatomy occasionally makes it difficult to see past the epiglottis even with proper use of the laryngoscope.
If a difficult intubation is encountered, one of several accepted methods may be used to facilitate correct tube placement despite inability to directly view the opening to the trachea. One of these methods involves using an introducer as a guide. The most common introducers are long, non-hollow and flexible, yet malleable enough to hold a curved shape in one end. With the introducer threaded through an endotracheal tube, the curved end of the introducer is used to probe gently behind the epiglottis until the trachea is entered by feel rather than under direct vision. The endotracheal tube is then guided over the introducer and into the trachea. The introducer is then removed and the position of the endotracheal tube is confirmed by the usual methods.
A common risk associated with introducer assisted difficult intubations is inadvertent esophageal placement of the endotracheal tube. Esophageal intubation itself, recognized and quickly corrected, is not likely to harm the patient. However, there exists the possibility of gastric distention, vomiting, and aspiration after attempts to ventilate through a tube placed in the esophagus. Also there may be a delay in providing adequate ventilation to the lungs. If one could reliably confirm that the introducer is in the trachea rather than the esophagus before passing the endotracheal tube over the introducer, these risks could be avoided.
One way to confirm tracheal rather than esophageal placement of an introducer, is sample gas through a hollow lumen from holes drilled in the side of the introducer near its curved tip. With rare exceptions carbon dioxide is present in exhaled gasses sampled from the trachea but not in the esophagus. This distinction is commonly used to confirm correct tracheal placement after an endotracheal tube has been placed, by whatever means, by measuring the amount of carbon dioxide in gas sampled through the tube. It thus became possible to distinguish tracheal from esophageal placement of an introducer by measuring carbon dioxide sampled through the hollow lumen of the introducer. However, reliance of this method in clinical practice is questionable because what was sampled was tracheal gas from introducers that were passed into the trachea through a previously placed endotracheal tube. In clinical practice, the position of the introducer would need to be confirmed before the endotracheal tube would be placed.
Hollow lumen tubes which are similar in size and shape to conventional introducers are available and are used for other purposes. One such tube is marketed as Jet Stylet or Endotracheal Tube Changer. This device is used when removing or changing a previously placed endotracheal tube when there is concern about the possibility of a difficult re-intubation. The Jet Stylet is placed into the Trachea through the lumen of a previously placed endotracheal tube. The tube is then withdrawn over the stylet and removed while the stylet remains in the trachea. If re-intubation is required, a new tube can then be placed over the stylet and into the trachea (using the stylet exactly as one would use an introducer that is already correctly placed in the trachea). A significant benefit of a Jet Stylet is the ability to give oxygen to the patients lungs through the hollow lumen if necessary. The term Jet Stylet is used because high pressure oxygenation through a small lumen catheter is known as jet ventilation and is one alternative that can be used when normal endotracheal intubation cannot be accomplished.
It will be seen from the above that even skilled anesthesiologists will at times be uncertain as to whether the introducer has in fact been placed into the trachea rather than the esophagus, and it is, therefore, the object of the present invention to provide a way of making certain that first the introducer, and ultimately the endotracheal tube, is in fact properly positioned in the patient's trachea rather than in his or her esophagus.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, the above object is achieved by measuring the carbo dioxide content of the gas flowing out of the patient through the introducer. This will give an indication as to whether the end of the introducer has been placed into the trachea or into the esophagus, because the carbon dioxide measurement will be greater if the gas comes from the patient's lungs through the trachea than from the patient's esophagus.
To allow the above method to be carried out in an efficacious manner, the present invention further provides an introducer for facilitating the placement of an endotracheal tube into the trachea of the patient, namely, an introducer incorporating a flexible tube and a removable stiffening element, so that when the stiffening element is in the tube, the introducer as a whole has the desired stiffness, whereas with the stiffening element removed, the remaining tube is sufficiently flexible to allow the introducer to be placed between the face of the patient and a face mask that is in contact with the face of the patient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a patient whose face is covered by a face mask.
FIG. 2 is a schematic illustration of a patient during insertion of the introducer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 shows the face F of patent P covered by a conventional ventilating mask 10 which has a stud 12 connected to hoses 14 leading a ventilator (not shown) for ventilating the patient during the procedure. The face mask 10 has a channel 16 which has two studs 18 and 20 as well as a three-way stop-cock or valve 22 which allows gas to flow from channel 16 to stud 20 or from stud 18 to stud 20. Stud 18 is connected to an introducer 24 which passes between the face mask 10 and the face of the patient. The stud 20 is connected to a hose 26 which is a sampling line leading to a capnograph (not shown) for measuring and displaying the levels of carbon dioxide content in the gas being sampled.
In one of the positions of the valve 22, gas flows from the mask 10 directly to the sampling line 26 leading to the capnograph and in the other position, gas flows to the capnograph from the introducer 24.
FIG. 2 shows a patient, without face mask, into whose mouth there has been placed the introducer 24 which is in the form of a flexible tube 24a preferably made of plastic and having inside it a removable reinforcing or stiffening element 24b, which was made of metal wire. The purpose of the wire 24b is to increase the rigidity of the plastic tube 24a during the insertion.
As shown in FIG. 2, one end of the reinforcing element 24b extends beyond one end of the flexible tube 24a to form a loop-shaped handle which allows withdrawal and insertion of element 24b from and into the tube 24a. The loop, which is preferably integral with the remainder of the reinforcing element, also serves as an abutment means for preventing the reinforcing element 24b from moving into a position where it would project outwardly from the other end of the tube, i.e., from that end which is inserted into the trachea, thus preventing contact between the wire element and the patient.
Element 24b is malleable so that when introducer is inserted into the flexible tube, as a whole can be bent into any desired configuration; this, in practice, will be one that allows the introducer to be best inserted into the trachea. The overall arrangement is such that the reinforcing element 24b provides the introducer as a whole with sufficient stiffness during insertion into the trachea whereas when the element 24b has been removed, the flexibility of the tube 24a is sufficient to allow the introducer, without the reinforcing element, to be easily placed between the face of the patient and the face mask when the same is placed on the patient.
As is also shown in FIG. 2, the leading end 24d of the introducer 24 has been moved past the patient's epiglottis and has just entered the upper end of the trachea.
In practice, the tubular introducer 24 will be inserted into the airway of the patient and such insertion will continue in anticipation that the introducer is actually inserted into the patient's trachea. After the introducer has been placed in what is believed to be the proper position, i.e., in the trachea, the reinforcing element is removed. The face mask is then placed on the patient's face, with the flexible tube 24a of the introducer being connected as shown in FIG. 1 and coming to lie between the patient's face and the face mask, and the patient is ventilated by the face mask.
In accordance with the present invention, the gas flowing out of the patient by way of the introducer is sampled, preferably continuously, for the purpose of determining the carbon dioxide content of the gas, thereby to obtain a determination of whether or not the end 24d of the introducer 24 has actually been placed into the patient's trachea. This is done by positioning the valve 20 into that position which places the introducer 24 into communication with the capnograph by way of the sampling line 26.
If the introducer has in fact been placed into the trachea, the capnograph will show a wave form having relatively large oscillations whereas if the introducer has been placed into the esophagus, the wave be generally flat or show only relatively small oscillations.
The following Table tabulates the capnograph measurements obtained as a consequence of an esophegeal and 33 tracheal placements:
TABLE I______________________________________CO.sub.2 WaveformAmplitude in Number of Esophageal Number of Trachealmm Hg Placements Placements______________________________________0 29 01 2 02 3 03 2 04 0 05 1 06 0 07 1 08 1 09 0 010 0 011 0 012 0 013 0 014 1 015 0 016 0 017 0 018 0 019 0 020 0 021 0 022 0 123 0 124 0 125 0 326 0 127 0 528 0 429 0 730 0 631 0 132 0 033 0 134 0 135 0 136 0 237 0 038 0 139 0 040 0 141 0 142 0 1______________________________________
As is apparent from the above Table, the carbon dioxide content of the gaseous medium which is obtained during ventilation when the introducer is placed in the trachea differs markedly from the carbon contents if the introducer is placed in the esophagus. Specifically, of the 79 capnograms tabulated above, carbon dioxide wave forms obtained during the 40 esophageal placements were well below 20 mm Hg, with the 29 being flat or 0, as compared to the carbon dioxide wave forms obtained during the 39 tracheal placements, each of which was above 20 mm Hg, with about half of them being in the 27 to 30 mm Hg range.
Thus, the anesthesiologist is readily able to ascertain whether or not the introducer has in fact been placed correctly, i.e., in the trachea. If it has, the next step is to pass the endotracheal tube (not shown) over the introducer until the endotracheal tube has been inserted into the patient's trachea. The introducer is then withdrawn and ventilation is continued through the endotracheal tube.
If, however, the carbon dioxide measurement indicates that the end of the introducer has been inserted into the esophagus, the tube 24a is at least partially withdrawn and is disconnected from the configuration shown in FIG. 1, the reinforcing element 24b is reinserted into tube 24a, and the thus reinforced introducer 24 is reinserted into what is now once again anticipated to be the trachea. This procedure is continued as described above, i.e., the carbon dioxide level of the gas flowing out of the introducer is again measured to determine whether or not its end has actually been placed in the patient's trachea. This step and the partial withdrawal and reinsertion of the introducer, are continued as often as necessary, until the carbon dioxide measurement indicates that the end of the introducer has in fact been inserted into the trachea, whereupon the endotracheal tube is inserted into the patient in the manner described above.
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 intubating a patient and an introducer for use with such method. The placement of the introducer is checked by measuring the carbon dioxide level of the gaseous medium flowing out of it, thereby giving an indication as to whether or not the introducer has been properly placed in the trachea of the patient. The introducer incorporates a flexible tube with a removable reinforcing element inside, which allows the introducer to be sufficiently stiff when being introduced into the patient and after removal of the reinforcing element, sufficiently flexible to be placed between the face of the patient and a face mask used to ventilate the patient.
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ORIGIN OF THE INVENTION
The invention described herein was made by employees of the U.S. Government and may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to check valves and to magnetically operated check valves and, in one aspect, to such a valve which is stable and durable in severe and extreme environments.
2. Description of Related Art
Check valves can be found in numerous industrial, aerospace and military applications where dependable operation, under demanding conditions, is critical. Such valves have an internal port or seat through which the fluid flows and a poppet, ball, reed, or gate that covers the seat to block flow in the reverse direction (see, e. g. the valve shown in FIG. 1). Fluid flow in the desired (forward) direction pushes the poppet open when the pressure differential across the valve is sufficient to overcome the force(s) restraining the poppet. Check valves utilize a spring, gravity, or magnetic force to return the poppet to the seated (blocking) position when there is no differential pressure. If the fluid flow attempts to reverse direction, the poppet is returned to the closed position, thus checking flow. All valves require a certain amount of seating stress to effect a seal when differential pressure in the reverse direction is low. The harder (more firm) that the seal material is the greater the load has to be to provide this stress. Reed poppets do not require a separate spring as the reed itself is a spring, and returns to the seated position when forward flow forces are no longer present. However, reed poppets are not found in fluid system check valve applications due to other performance limitations.
In a spring operated check valve, the valve's poppet and spring (see FIG. 1) form a classic spring-mass system that is subject to harmonic oscillation caused by flowing fluid. Harmonic motion (oscillations of the poppet) sustained for long periods of time can result in accelerated wear. Oscillations at frequencies even higher than the natural frequency are common in gaseous fluid service. A valve that ordinarily would be expected to operate for years can be ruined in a matter of hours when operating at conditions supporting this motion. Accelerated wear of the poppet and guide results in accelerated particulate generation. Companion components in the fluid system may be rendered inoperative by the abnormally high level of particulates generated by the check valve. Excessive particulates will contaminate fluids and increase the risk of decomposition or other adverse chemical reaction.
In certain prior art valves, self sustaining motion disturbs the fluid media flowing through the valve, setting the stage for undesirable secondary effects on other components or processes in the fluid system. In other prior art, gravity operated check valves must be positioned in a manner that permits gravitational forces to return the poppet to the seated position. This limitation eliminates many applications, especially aircraft and space flight. In certain spring-operated prior those in art valves, the load that provides the necessary seating stress with the valve seated/closed is imparted with the spring in the most extended position. Thus, as the valve strokes, this bias load is additive to the normal increase in spring load that occurs as the spring is compressed to provide a flow path and increases the differential pressure across the valve.
U.S. Pat. No. 3,026,903 to Roach discloses a magnetic check valve which includes a magnetically actuated return means for the valve element, a valve cage, a permanent magnet and a magnetically permeable closure member. The check valve incorporates a ball-type closure or poppet riding in a cage lined with longitudinal magnetic rods which urge the ball toward (in the same direction as reverse flow would occur) a valve seat to prevent reverse flow. The valve has a hard metal seat and a hard ball-type poppet that seal by direct contact with one another.
U.S. Pat. No. 3,495,620 to Raimondi et al. shows a magnetic valve which includes a movable valve member of magnetic material positioned between two magnetic inlet/outlet orifices. The valve incorporates dual magnets, one movable element and two fixed, one on either side of the movable element or poppet. Once a predetermined pressure has been established, the poppet is dislodged from the seated position and normal flow entering the valve passes through a port (that comprises the valve seat) in the first magnet and through matching holes in the poppet and final fixed magnet to the valve outlet. The magnet seats and the poppet seal by directly contacting one another. The magnet that comprises the seat is subject to deposition of magnetically attracted particles carried in the flow stream. The particles can lodge between the magnetic seat element and the magnetic movable element thus preventing closure of the valve.
U.S. Pat. No. 4,874,012 to Velie teaches a magnetically operated flow device which includes a movable member between magnets that define the flow passage. The valve has a magnet upstream of the seat area which may attract some but not all magnetic particles to itself before they reach the critical area of the seat/poppet interface where sealing takes place.
U.S. Pat. No. 2,539,316 to Jerman discloses a safety valve which includes a steel ball check valve positioned adjacent a magnet. The valve acts to close in case of excess flow in a line in which the valve is installed. A magnet holds a ball away from a seat through which flow must pass. Flow in excess of the normal range of flow dislodges the ball and carries it to the seat where it blocks flow. Thus it acts like a flow fuse rather than a check valve.
U.S. Pat. No. 2,646,071 to Wagner shows a magnetic check valve which includes a movable member having a magnet therein adjacent another magnet. The valve has a plastic seat and disc (poppet) sealing by direct contact with one another. The valve is configured to catch all particles as they enter the valve.
U.S. Pat. No. 2,667,895 to Pool et al. discloses a magnetically biased check valve which includes movable and stationary magnets. The magnetically actuated check valve incorporates dual magnets working in opposition to provide a separating force that moves one of the magnets toward the seat and sealing ring; the other magnet is anchored in the valve body. Flow in the direction that assists in separating the magnets (reverse to normal flow) also assists in placing the magnet against the seat and seal, thus checking flow. The seat o-ring is embedded in the valve body. The conventional way to embed or attach an o-ring to a surface is to use a dovetail groove into which an o-ring is forced. With this type of installation there is no room for the o-ring to grow in case of thermal expansion or in case of o-ring swell (due to exposure to certain fluids). When the o-ring is not allowed to grow uniformly, it will be distorted or damaged and will no longer be effective. The seating magnet is subject to deposition of magnetically attracted particles carried in the flow stream. The particles can lodge between the magnet and valve seat thus preventing closure of the valve. The seating forces in the valve are low, and therefore sealing forces are also low at low reverse differential pressures. The valve is not configured to provide maximum magnet seating forces at the seated position to reduce leakage at low reverse differential pressures. Since the seating forces in the valve increase with displacement of the magnet (poppet) from the seat, the valve can chatter as does a spring actuated valve. The valve will augment flow-induced harmonic motion since it stores and returns energy to the moving mass of the poppet as does the spring-mass system of the conventional spring loaded poppet.
U.S. Pat. No. 2,949,931 to Ruppright shows a magnetic check valve having a magnetic cage with the moving valve member contained therein. The valve has a magnet comprising the inlet flow path and seat of the valve, and a loosely guided disc that acts as the poppet to preclude reverse flow. The magnet that comprises the seat in this configuration is subject to deposition of magnetically attracted particles carried in the flow stream. The particles can lodge between the magnet and the valve disc (poppet) thus preventing closure of the valve. A magnetic seat and the disc seal by directly contacting each other.
There has long been a need for a magnetically operated check valve which does not augment flow-induced harmonic oscillation and in which poppet wear is reduced. There has long been a need for such a valve in which energy consumption is reduced and particulate generation is minimized. There has long been a need for such a valve in which required seating stresses are effectively achieved without adding to the differential pressure of the valve at full flow conditions.
SUMMARY OF THE INVENTION
In one embodiment of a valve according to this invention, a valve has a valve body with an inlet end or fitting, preferably a removable inlet fitting and an outlet end or fitting, preferably a removable outlet fitting. One or more magnets is removably held in a magnet holder which is removably disposed at the center of the inlet fitting, with flow channels which permit incoming fluid to flow into the inlet fitting and around the magnet. A poppet is movably disposed in a poppet chamber in the valve body so that the poppet is movable to contact a shoulder around the inlet fitting thus sealing off the flow channels around the magnet and closing the valve. The poppet or at least a portion thereof is made from magnetic material and the magnet holds the poppet against the inlet fitting's shoulder until the force of fluid flow through the valve overcomes the magnetic force holding the poppet to the magnet. Projections from the outlet fitting serve as stops to limit poppet movement away from the inlet fitting shoulder. Fluid flows between these projections and out from the outlet fitting. A sealing o-ring is provided between the inlet fitting and the valve body and between the outlet fitting and the valve body. A sealing o-ring is also provided between an edge of the poppet and the shoulder of the inlet fitting. The inlet fitting and poppet are designed and this o-ring is disposed so that a limited o-ring movement envelope is provided and so that an inclined edge of the centers the o-ring and guides it into position to contact both a sealing surface on the inlet fitting and a sealing surface on the poppet. The poppet chamber and the poppet are designed for a relatively close fit so that the poppet is prevented from binding against the cavity walls.
A magnetically operated check valve in another embodiment of the present invention has a valve body with a fluid flow channel therethrough and a cavity therein in communication with the fluid flow channel in which a valve poppet is movably disposed. The poppet has a magnetic portion which is attracted to and held by magnetic force against a body magnet secured in the valve body to close the valve. Once the force of fluid flow through the valve exceeds the force of magnetic attraction between the magnetic poppet and the body magnet the poppet is moved and the valve is opened permitting flow through the valve body. In one embodiment the poppet is configured and the magnets are positioned so that any magnetically-attracted particles flowing in the valve body are trapped in a magnetic field situated apart from a valve seating region. Also providing a tortuous flow path contributes to the trapping of particles before they reach the seating region.
Valves according to this invention do not require springs, but incorporate one or more permanent magnets to perform the functions of holding the valve closed until a certain flow level is reached and then returning the poppet to the seated position when flow again falls below that level. The basic material of the poppet can be either magnetic or nonmagnetic. A magnet is incorporated either into the body of the valve or into both the valve and the poppet. If only one component incorporates a magnet, the other incorporates a magnetic material to work in conjunction with the magnet. The poppet is magnetically attracted to the seat (inlet side of the valve body) to return the poppet to the seat in the absence of forward fluid flow, and unattracted to the outlet side of the valve.
In certain preferred embodiments, new generation ceramic, alnico, and rare earth elements provide a selection of magnets for use in valves according to this invention. Encapsulation of the magnet with a desired material (e. g. a material which will not be adversely affected by the fluid which will flow through the valve and/or which is chemically compatible with fluid to be passed through the valve) can be accomplished in cases where exposure of the magnet to the fluid media is not desirable.
Due to magnetic field limitations the stroke of a magnetically operated valve may be shorter than that of an equivalent flow capacity spring-operated valve, thus the seat diameter is increased to obtain the same flow area/capacity. Increasing the seat diameter increases the pressurized area of the poppet when in the seated position, This in turn beneficially reduces the pressure differential required to open the valve (cracking pressure) and increases the available seating force with low reverse pressure differential, thus aiding the flow-checking action of the valve. Under full rated flow conditions, the poppet will be farthest from the seat and the magnetic attraction will be the least. This is opposite to that of a spring operated check valve in which the spring is compressed to its maximum in the fully opened position. The magnetically operated valve thus offers less flow resistance at rated flow. The valve is designed to assure a small but significant differential pressure across the poppet, pinning it against the outlet portion of the housing, reducing or eliminating poppet instability. With magnets at the center of the inlet fitting and poppet, the magnetic field will assist in centering and guiding the poppet, thus reducing wear that would normally be expected at the interface of the poppet and the valve body during poppet stroking. The load that provides the necessary seating stress with the valve seated/closed is imparted by the magnetic field at the lowest magnetic gap, which is the strongest load imparted by the magnet(s). As the poppet strokes, this load is reduced as the poppet moves away from the seat to provide a flow path, thus minimizing differential pressure across the valve.
In order to obtain satisfactory sealing at very low reverse differential pressures with the lower seating forces obtainable in a reasonably compact design (which precludes large magnets) in certain preferred embodiments of check valves according to this invention, a magnetic check valve has naturally uniform, continuous contact between the o-ring and its mating surfaces. The o-ring is undistorted in order to provide such contact, otherwise perfect sealing will be not be achieved.
In the seat/poppet/o-ring sealing configuration of certain preferred embodiments, the poppet's axis when seated can float within the tolerances of the fit between the poppet and the seat ring. Such variation is tolerated because a primary sealing surface on the check valve body inlet fitting is at a right angle to a longitudinal axis of the check valve, thus displacement of the poppet axis away from the main check valve axis does not change the separation between the parts on any given circle concentric to the poppet axis. This allows the o-ring to naturally and uniformly contact both sealing surfaces without distortion. If the poppet tips on its axis, the magnet is strong enough to bring it into full contact with the o-ring and effect the seal. The poppet's leading edge (See FIG. 3) is a conical surface and is angled toward the sealing location so that as it approaches the seat the o-ring is moved into a mutually desirable sealing position following full excursion of the poppet from the full open position. Thus, the poppet contacts the o-ring before it is seated in metal-to-metal contact against another part of the valve. Metal-to-metal seating takes place under high differential pressures to assure there are no gaps into which the o-ring might be extruded. The o-ring is free to float within the confines of the seat/seat ring/poppet region until picked up by the poppet and carried to a seated position.
In preferred embodiment a magnetically operated check valve is provided which has a removable magnet holder.
Since there is no space required for spring installation, valves according to this invention may be relatively short (axial length) which is advantageous in certain applications where axial space is limited, and they may require a very low fluid volume which is advantageous for use in e.g., gas compressors. The unrestrained seat sealing o-ring and the extrusion preventing metal-to-metal final seating are designed to provide reliable sealing from zero pressure to thousands of pounds per square inch. The valve design minimizes the use of sliding fits and the related friction, wear, particle generation, and binding.
With the operating magnet incorporated in the entrance portion of the valve body, directly in the flow path, magnetic particulate carried by the fluid is trapped by the magnetic field before entering the seat area. The valve may thus double as a particulate filter in systems such as aircraft hydraulic systems where particulate control is very important.
It is, therefore, an object of at least certain preferred embodiments of the present invention to provide:
New useful, unique, efficient, and effective magnetically operated check valves;
Such valves with one or more permanent magnets to operate a check valve and to provide static sealing stress when there is inadequate fluid differential pressure to effect a perfect seal;
Such valves wherein no harmonic instability occurs during operation;
Such valves wherein the differential pressure across the valve that results from the seating mechanism of the valve is reduced as flow is increased, thus providing more flow capacity;
Such valves wherein particles of magnetic material are trapped in a magnetic field prior to reaching the sealing region of the valve;
Such valves in which a magnetic field assists in centering and guiding the poppet so that wear of the poppet and the valve body is reduced;
Such valves which offer less flow resistance at rated flow so that the differential pressure across the valve is reduced, saving energy in comparison to valves with higher pressure drop;
Such valves in which the level of particulate generated inherently by operation of the check valve is reduced, to a very low level, thus decreasing the effect on companion components in the fluid system as well as the risk of decomposition of liquid fuels and oxidizers, or other adverse chemical reaction; and
Such valves in which seating stresses of the magnetic operation valve are achieved without adding to the differential pressure of the valve at full flow conditions.
The present invention recognizes and addresses the previously mentioned problems and long-felt needs and provides a solution to those problems and a satisfactory meetings of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings and disclosures, other and further objects and advantages will be clear, as well as others inherent therein, from the following description of presently-preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. Although these descriptions are detailed to insure adequacy and aid understanding, this is not intended to prejudice that purpose of a patent which is to claim an invention no matter how others may later disguise it by variations in form or additions of further improvements.
BRIEF OF THE DRAWINGS
So that the manner in which the above-recited features, advantages and objects of the invention, as well as others which will become clear, are attained and can be understood in detail, more particular description of the invention briefly summarized above may be had by reference to certain embodiments thereof which are illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate certain preferred embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective equivalent embodiments.
FIG. 1 is a side view in cross-section of a prior art valve.
FIG. 2 is a side view in cross-section of a valve according to this invention.
FIG. 3 is an enlarged view of an inlet fitting, o-ring, and poppet of the valve of FIG. 2.
FIG. 4A is a side view in cross-section of an inlet fitting of a valve according to the present invention.
FIG. 4B is an end view of the fitting of FIG. 4A.
FIG. 5A is an end view of a poppet for the valve of FIG. 4A.
FIG. 5B is a side view of the poppet of FIG. 5A.
FIG. 6A is an end view of an outlet fitting for the valve of FIG. 4A.
FIG. 6B is a side view of the outlet fitting of FIG. 6A.
FIG. 7 is a side view, partially cut away, of a housing for the valve of FIG. 4A.
FIG. 8A is a side view in cross-section of a valve according to this invention. FIG. 8B shows an exploded view of the valve of FIG. 8A.
FIGS. 9 and 10 show various stages of operation of the valve of FIG. 8A.
FIG. 11 is a side cross-sectional view, enlarged, of a portion of the valve of FIG. 8A.
FIG. 12 is an end view of a poppet of the valve of FIG. 8A.
FIG. 13 is an end view of a magnet holder of the valve of FIG. 11.
FIG. 14 is a side cross-sect-ion view of the inlet fitting, poppet, and o-ring of the valve of FIG. 8A showing various o-ring positions with the poppet open.
FIG. 15 is an end view of the outlet fitting of the valve of FIG. 8A.
FIGS. 16A and 16B are end views of the inlet fitting of the valve of FIG. 8A.
FIG. 17 is an end view of the valve body or housing of the valve of FIG. 8A.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates a typical prior art spring-operated check valve V which has a valve body B, a poppet P, a spring S, an o-ring 0, an o-ring T, and a metal-to-metal seat M.
Referring now to FIGS. 2 and 3, a magnetically operated check valve 10 according to one preferred embodiment of the present invention has a valve body 12, a magnet 20 secured to an inlet fitting 28 threadedly and removably mounted in the body 12. Fluid flows into the valve body through an inlet 14 in the inlet fitting 28. A poppet chamber 16 in the valve body in fluid communication with the inlet 14 contains a poppet 18 movably disposed therein, and an outlet 21 in an outlet fitting 30 in fluid communication with the chamber 16 and from it fluid exits the valve body 12. A magnet 40 in the poppet 18 is attracted to the magnet 20. Central location of the magnet 20 in the inlet fitting and of the magnet 40 in the poppet provides for magnetic guiding of the movement of the poppet and for correct centering of the poppet. If no magnet 40 is used, a magnetically attractive portion can -be provided in its place on the poppet. A flow channel 22 includes a channel 24 through the inlet 14, the interior of the chamber 16, and a channel 26 through the outlet fitting 30. Arrows indicate flow path and direction. Fluid flows through indentations 49 on the inlet fitting and then around the poppet. It is within the scope of this invention to enlarge the clearance between the body 12 and the poppet 18.
A sealing o-ring 32 is disposed between the inlet fitting 28 and the valve body 12. A sealing o-ring 34 is disposed between the outlet fitting 30 and the valve body 12. A sealing o-ring 36 is disposed in the poppet chamber 16 between a shoulder 38 of the inlet fitting 28 and an edge 39 of the poppet 18. A protrusion 48 of the inlet fitting 28 is received within a recess 52 of the poppet 18 and serves to internally guide the poppet 18 in its movement.
As shown in enlarged detail in FIG. 3, the shoulder 38 and the poppet edge 39 present sealing surfaces to the o-ring 36. The edge 39 is inclined with respect to an edge 37 of the shoulder 38 so that as the poppet returns from a position apart from the shoulder 38, i. e., apart from the magnet 20, the edge 39 moves the o-ring 36 into position centering it on the poppet to seal against the edge 37 and against the edge 39 with little or no distortion of the o-ring 36. As the poppet is moving to close the flow, leading tip 42 of the poppet 18 does not make metal-to-metal contact with a sub-shoulder 44 of the shoulder 38 until the edge 39 has moved the o-ring into an effective sealing position.
FIGS. 4A-7 illustrate alternative parts for a valve according to this invention.
FIGS. 4A and 4B show an inlet fitting 228 with an inlet 214 and a magnet 220 disposed in a magnet holder 246. A protrusion 248 protruding from the inlet fitting assists in positioning and centering the poppet 218 as discussed below. Flow is permitted past the protrusion 248 via indented portions 249. A recess 257 holds an 0-ring 232.
Fluid flows into the inlet fitting 228 through inlet 214 and its inlet channel 224 and then into poppet flow channels 250 from which the fluid exits the inlet fitting and passes the protrusion 248.
FIGS. 5A and 5B show the poppet 218. The poppet 218 has an annular recess 252 around it which receives the protrusion 248 of the inlet fitting 228 when the poppet approaches a shoulder such as 38, FIG. 2. This assists in correctly positioning the poppet for encountering an o-ring such as 36, FIG. 2 and for centering the poppet 218. A recess 254 holds a magnet such as 40, FIG. 2. Fluid is permitted to flow in recesses 256 in the poppet 218. Clearance between the body and poppet can be enlarged by reducing the overall diameter of the poppet so as to eliminate the recesses 256.
FIGS. 6A and 6B show an outlet fitting 250 and an outlet channel 226. Protruding ribs 258 serve as a stop for the poppet 218 liiting its movement in a cavity in a cavity such as 16 in FIG. 2 Receiver 259 between the ribs 258 provide a flow path for fluids to enter the channel 226. A recess 255 holds an o-ring similar to 34, FIG. 2.
FIG. 7 illustrates a valve body 212.
A valve with the parts shown in FIGS. 4A - 7 is not as compact as the valve shown in FIG. 2. The valve of FIG. 2 has a relatively light- weight body shape and relatively stubby inlet and outlet connections, resulting in a more compact design.
A valve 100 according to this invention is shown in FIGS. 8A-10. Portions and parts of the valve 100 are shown in FIGS. 11-17. The valve 100 has a valve body 102, an inlet fitting 104, a magnet holder 106, a magnet 108, a movable poppet 110, and an outlet fitting 112. A sealing o-ring 60 is disposed between the inlet fitting 104 and the valve body 102 and a sealing o-ring 61 is disposed between the outlet fitting 112 and the valve body 102. The poppet 110 moves in a cavity 114 in the valve body 102. A sealing o-ring 63 is permitted limited movement in the cavity 114.
Fluid flows through the valve 100 as follows: fluid enters through an inlet channel 70 in the inlet fitting 104 and flows in flow channels 71 in the magnet holder 106 into the cavity 114 and then into a flow channel 72 in the outlet fitting 112 from which it exits the valve 100.
The inlet and outlet fittings are secured in place in the body 102 by welding, by a press fit, by threaded engagement, or by other suitable means.
FIGS. 9 and 10 show the poppet 110 in different positions. In FIG. 9 the poppet 110 is not in contact with a shoulder 74 of the inlet fitting 104, (see enlarged detail FIG. 11) but the force of the magnet 10B acts on the magnetically attractable material of the poppet 110 with sufficient force to hold the o-ring 63 against the shoulder 74 and against a surface 76 of the poppet 110 to close the valve 100. It is preferred that the surfaces 74 and 76 be parallel or substantially parallel to effect a good seal with the o-ring 63. (See FIG. 11) The cavity 114 is sized and a protrusion 78 of the outlet fitting 112 is size, shaped, and disposed so that binding of the poppet 110 in the cavity 114 is inhibited or prevented. By curving an end 80 of the poppet, binding of the poppet is also inhibited. An angled (conical) surface 79 of the poppet 110 is disposed and configured to move ("lift") the o-ring 63 upon initial contact therewith as the poppet 110 moves toward the magnet 108, moving the o-ring and centering it so that it contacts the sealing surface of the shoulder 74 and the surface 76 of the poppet 110 prior to contact of the poppet and inlet fitting.
FIG. 10 illustrates the valve 100 in full open position with the poppet 110 abutting the protrusion 78 of the outlet fitting 112. Of course, the poppet itself could have such protrusions or a stop member.
FIG. 12 illustrates an end view of the poppet 110 as seen from the left in FIG. 8A.
FIG. 13 illustrates an end view of the magnet holder 106 with the flow channels 71 which are not blocked when the magnet 108 is cylindrically shaped and fits within the inner circumference of the magnet holder 106. It is within the scope of this invention to provide either a magnet holder without flow channels and have a flow channel or channels formed in the body of the inlet fitting or to have a flow channel or channel of a shape different from that shown in FIG. 13 and/or a magnet of a different shape from that shown in FIG. 8B. The magnet holder 106 is secured within the inlet fitting by any suitable means.
FIG. 14 illustrates that the inlet fitting 104, poppet 110, and housing 102 are designed so that the o-ring 63 has a limited movement envelope (four possible positions shown for the 0-ring) and the angled surface 79 of the poppet will contact and move the o-ring to a desired sealing disposition between the poppet and the inlet fitting. As shown in FIG. 14, the o-ring 63 has a "lowest" possible position L and "high" position H. As the poppet moves toward the inlet fitting, the angled surface 79 contacts and moves the o-ring so that a positive seal will be created between the inlet fitting and the poppet. In a most preferred embodiment this is achieved with the parallel or nearly parallel shoulder 74 and surface 76, as well as with the angle from vertical of the angled surface 79 (vertical as viewed as in FIG. 14) and the position of the angled surface with respect to the body of the poppet. The space 114 is designed and configured so that, with the poppet in place, collapse of the o-ring is limited, inhibited, or most preferably totally prevented. It is also most preferred that the o-ring be sized so that it cannot pass through the space between an end of the poppet 81 and the shoulder 74 when the valve is in a full open position (as shown in FIG. 14).
The outlet fitting 112 is shown in FIG. 15, as seen from the left in FIG. 8A. Wrench flats 83 are provided for valve assembly and disassembly. Opposite end views of the inlet fitting 104 are shown in FIGS. 16A and 16B with wrench flats 85 for valve assembly and disassembly.
FIG. 17 shows an end view of the valve body 102 with its cavity 114 and flow channels 87 at the edge of the cavity 114. As the poppet 110 moves away from the inlet fitting 104 and the o-ring 63 moves out of contact with the shoulder 74 or the surface 76, flow is permitted around the poppet in the flow channels 87 to the outlet fitting 112.
The valve of FIG. 2 with its internally guided poppet has a relatively larger stroke than a valve (e. g. as shown in FIG. 8A) which has an externally guided poppet; but a lighter weight valve is possible when an externally guided poppet is used. Also, it is possible, by using an externally guided poppet, to achieve more effective magnetic pull for sealing stress application to 0-rings.
Both disposition of the magnet or magnets used with the valves described herein and the relatively tortuous path (e.g. fluid makes at least one, but preferably two or more turns, most preferably at least right angled turns, prior to passing a valve seating region) provided for fluid flow result in the trapping of particulates before they reach a valve seating region wherein they could impede closing off of the valve or otherwise adversely affect valve performance. The invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the described and in the claimed subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to all equivalent elements or steps.
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A magnetically operated check valve is disclosed having, in one aspect, a valve body and a movable poppet disposed therein, a magnet attracting the poppet to hold the valve shut until the force of fluid flow through the valve overcomes the magnetic attraction and moves the poppet to an unseated, open position; the poppet and magnet configured and disposed to trap magnetically attracted particulate and prevent it from flowing to a valve seating region.
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BACKGROUND OF THE INVENTION
This invention relates generally to the field of measuring an analyte in a liquid medium. More specifically, it relates to an immunoassay and reagents useful for the determination of an analyte in a biological sample, and in particular, for the determination of tricyclic antidepressant drugs.
SUMMARY OF THE INVENTION
The present invention relates to a new tricyclic antidepressant (TCA) immunogen useful for the generation of polyclonal and monoclonal antibodies to TCAs. The new immunogen is characterized by a saturated double bond on the amitriptyline portion of the molecule (dihydro amitriptyline). The invention also relates to TCA activated hapten derivatives useful for preparing tracers and conjugates for TCA immunoassays using an antibody produced from the immunogen of structure I derivatized at the C-2 position with either a conjugate derivatized at the N-1 position of imipramine or a conjugate derivatized at the C-2 position of dihydro-amitriptyline. The immunoassays of the present invention include a single, qualitative or semiquantitative toxicological screening assay which would broadly recognize tricyclic antidepressants as a class.
The present invention comprises the following embodiments:
a compound having the structure
where R 1 is a saturated or unsaturated, substituted or unsubstituted, straight or branched chain of 0-10 carbon or heteroatoms, X is a linker group consisting of 0-2 substituted or unsubstituted aromatic rings, and Y is an activated ester or NH—Z, where Z is a poly(amino acid);
an immunogen having the structure
where Z is a poly(amino acid);
an antibody produced in response to an immunogen of structure II;
an activated hapten having the structure
an activated hapten having the structure
an activated hapten having the structure
an activated hapten having the structure
an immunoassay for a tricyclic antidepressant drug utilizing an antibody produced from an immunogen of structure II and a drug conjugate derived from structure III, IV, V and VI,
an immunoassay for a tricyclic antidepressant drug utilizing an antibody specific for a tricyclic antidepressant and a drug conjugate derived from structure III, IV, V and VI; and
an immunoassay for a tricyclic antidepressant drug utilizing an antibody produced from an immunogen of structure II and a tricyclic antidepressant drug analog.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 ( a ), 1 ( b ) and 1 ( c ) are schematic diagrams illustrating the synthesis of two protein conjugates of the present invention, compounds 10 and 11 (structure II).
FIG. 2 is a schematic diagram illustrating the synthesis of compound 14 (structure IV).
FIG. 3 is a schematic diagram illustrating the synthesis of compound 16 (structure III).
FIGS. 4 ( a ) and 4( b ) are schematic diagrams illustrating the synthesis of compound 22 (structure V).
FIG. 4 ( c ) is a schematic diagram illustrating the synthesis of methyl 4-aminomethylbenzoate hydrochloride (compound 20) used in the synthesis of compound 22.
FIG. 5 is a schematic diagram illustrating the synthesis of compound 26 (structure VI).
FIG. 6 illustrates the structures for compounds 27, 28, 29 and 30.
FIG. 7 is a graph showing standard (dose response) curves generated from data obtained using conjugates and antibodies of the present invention in a microwell plate based enzyme immunoassay.
FIGS. 8 and 9 are graphs showing standard (dose response) curves generated from data obtained using conjugates and antibodies of the present invention in a lateral-flow immunoassay.
DETAILED DESCRIPTION OF THE INVENTION
Tricyclic antidepressant compounds which may be detected in an assay in accordance with the present invention include derivatives of dibenzazepine, dibenzocycloheptadiene and dibenzoxepine characterized by the formula
wherein V is CH 2 or CH═, W is CH 2 , O or ═CH, X 1 is N or C═, Y 1 , is CH 2 or ═CH— and R is H or CH 3 . Exemplary of such tricyclic antidepressant compounds are imipramine, desipramine, amitriptyline, nortriptyline, protriptylene, trimipramine, chlomipramine and doxepin.
In testing for small analytes such as drug molecules, immunoassays, particularly competitive binding immunoassays, have proven to be especially advantageous. In competitive binding immunoassays, an analyte in a biological sample competes with a labeled reagent, or analyte analog, or tracer, for a limited number of receptor binding sites on antibodies specific for the analyte and analyte analog. Enzymes such as β-galactosidase and peroxidase, fluorescent molecules such as fluorescein compounds, radioactive compounds such as 125 I, and microparticles are common labeling substances used as tracers. The concentration of analyte in the sample determines the amount of analyte analog which will bind to the antibody. The amount of analyte analog that will bind is inversely proportional to the concentration of analyte in the sample, because the analyte and the analyte analog each bind to the antibody in proportion to their respective concentrations. The amount of free or bound analyte analog can then be determined by methods appropriate to the particular label being used.
Various protein types may be employed as the poly(amino acid) antigenic material. These types include albumins, serum proteins, e.g., globulins, ocular lens proteins, lipoproteins and so forth. Illustrative proteins include bovine serum albumin, keyhole limpet hemocyanin, egg ovalbumin, bovine gamma-globulin and so forth. Alternatively, amino-polysaccharides, such as aminodextran, or synthetic poly(amino acid)s may be prepared having a sufficient number of available amino groups, e.g., lysines.
In the method of the invention, a sample suspected of containing imipramine, desipramine, amitriptyline, nortriptyline or a structurally related drug is combined with an antibody having specificity for imipramine, desipramine, amitriptyline, or nortriptyline and a labeled analyte analog which can interact with the combination of antibody and its corresponding analyte so as to detect the presence of the analytes at selected cutoff levels either alone or in combination. This invention can be used with any type of immunoassay format, e.g., turbidometric agglutination assay, radioimmunoassay, enzyme immunoassay, fluorescent polarization immunoassay or lateral flow immunochromatography. A potential use of the present invention is with agglutinometric formats susceptible to an instrumental method for the measurement of the changes brought about by the agglutination reaction. Both manual as well as automated apparatus testing may be suitably employed for such agglutinometric analysis. Typically, automated instrumentation will operate utilizing a multiplicity of reagent containers or reservoirs from which will be pipetted the appropriate amount of each reagent for addition to the sample. For immunoassays such as the subject agglutination assay, this will usually involve at least two such containers, typically, one for an antibody reagent and the other for the microparticles bound with the corresponding ligand. Alternatively, one container may comprise ligand analog conjugate reagent and the other comprises microparticles bound with antibody. Additional containers or reservoirs may be present in some instruments containing diluent, buffers or other additives for appropriate treatment of the sample.
The clinical analyzer pipettes the onboard reagents and samples into one cuvette where the competitive agglomeration reaction occurs and measurement of the turbidity is made. For example, using the HITACHI 917 analyzer (Roche Diagnostics) and the ABUSCREEN® OnLine drugs of abuse reagent kit (Roche Diagnostics), urine sample is pipetted with sample diluent into the cuvette, followed immediately by the appropriate amount of antibody reagent and mixing. An initial spectrophotometer reading is taken. Then the appropriate quantity of microparticle reagent is transferred to the cuvette and the reaction mixed. After a brief incubation, a final turbidity measurement is made. The overall change in turbidity (absorbance) in the reaction is compared to a calibration curve and results reported in ng/ml.
Microwell-plate based ELISA (enzyme-linked immunosorbent assay) is an established technology that has been widely applied to develop enzyme immunoassays for various analytes and proteins. Competitive ELISA has been applied for developing sensitive enzyme immunoassays for small analytes such as drug molecules. The present invention can be used in competitive ELISA for the quantification of TCAs in biological fluids. In the method of the invention, a sample suspected of containing, for example, imipramine or structurally related compounds, is diluted and added into microwell plates pre-coated with any of the TCA conjugates disclosed in the present invention, followed by pre-determined amount of anti-TCA antibody. After incubation, the wells can be processed with the standard ELISA procedure (appropriate enzyme-labeled secondary antibody, substrate, wash steps in between, and the measurement of optical densities). Optical densities can be plotted versus the final concentration of imipramine or TCA structurally-related compound selected as calibrator and calculated as a molar concentration.
Fluorescence polarization immunoassay procedures provide a quantitative means for measuring the amount of tracer-antibody conjugate produced in a competitive binding immunoassay. Such fluorescence polarization techniques are based on the principle that a fluorescent labeled compound, when excited by plane polarized light, will emit fluorescence having a degree of polarization inversely related to its rate of rotation. Accordingly, when a tracer-antibody conjugate having a fluorescent label is excited with plane polarized light, the emitted light remains highly polarized because the fluorophore is constrained from rotating between the time that light is absorbed and emitted. In contrast, when an unbound tracer is excited by plane polarized light, its rotation is much faster than the corresponding tracer-antibody conjugate and the molecules are more randomly oriented. As a result, the light emitted from the unbound tracer molecules is depolarized.
Lateral flow immunochromatography has been utilized to develop a rapid, non-instrument based strip assay for qualitative immunoassays. The immunochromatographic strip assay is based on the principle of competitive immunoassay whereby drug in the urine competes with a membrane-impregnated drug conjugate for the specific antibody on colored microparticles such as gold sol or dyed latex. The appearance of a colored bar at the detection region (drug impregnation area) for the drug indicates a negative result. No band is observed if the drug is present in the urine sample at or above the cutoff concentration for the corresponding assay. The present invention is useful for the development of membrane strip devices that serve as a toxicological screening immunoassay for the TCAs.
By tricyclic antidepressant (TCA) is meant any one of a group of drugs commonly used for treatment of depression, all of which have a similar chemical structure, a triple ring with a methylaminopropane side-chain. Exemplary of this group are imipramine, desipramine, amitriptyline, nortriptyline, protriptylene, trimipramine, chlomipramine, doxepin as well as biologically active or therapeutically active derivatives and metabolites thereof.
Analyte refers to the substance, or group of substances, whose presence or amount thereof in a liquid medium is to be determined and is meant to include any drug or drug derivative, hormone, protein antigen or oligonucleotide.
Analyte analog means any substance, or group of substances, which behaves essentially the same as the analyte with respect to binding affinity of the antibody for the analyte and is meant to include any tricyclic antidepressant drug or derivative and metabolites and isomers thereof.
Antibody or receptor means a specific binding partner of the analyte and is meant to include any substance, or group of substances, which has a specific binding affinity for the analyte to the exclusion of other substances. The term includes polyclonal antibodies, monoclonal antibodies and antibody fragments.
Haptens are partial or incomplete antigens. They are protein-free substances, mostly low molecular weight substances, which are not capable of stimulating antibody formation, but which do react with antibodies. The latter are formed by coupling the hapten to a high molecular weight carrier and injecting this coupled product into humans or animals. Examples of haptens include therapeutic drugs such as digoxin and theophylline, drugs of abuse such as morphine and LSD, antibiotics such as gentamicin and vancomycin, hormones such as estrogen and progesterone, vitamins such as vitamin B12 and folic acid, thyroxin, histamine, serotonin, adrenaline and others.
An activated hapten refers to a hapten derivative that has been provided with an available site for reaction such as by the attachment of a linking group for synthesizing a derivative conjugate.
A carrier, as the term is used herein, is an immunogenic substance, commonly a protein, that can join with a hapten, thereby enabling the hapten to stimulate an immune response. Carrier substances include proteins, glycoproteins, complex polysaccharides and nucleic acids that are recognized as foreign and thereby elicit an immunologic response from the host.
The terms immunogen and immunogenic as used herein refer to substances capable of producing or generating an immune response in an organism.
The term derivative refers to a chemical compound or molecule made from a parent compound or molecule by one or more chemical reactions.
Linking groups are used to activate, i.e., provide an available site on a drug derivative for synthesizing a hapten. The use of a linking group may or may not be advantageous or needed, depending on the specific hapten and carrier pairs. The term linker refers to a chemical moiety that connects a hapten to a carrier, immunogen, label, tracer or another linker. Linkers may be straight or branched, saturated or unsaturated carbon chains. They may also include one or more heteroatoms within the chain or at termini of the chains. By heteroatoms is meant atoms other than carbon which are chosen from the group consisting of oxygen, nitrogen and sulfur.
As used herein, a detector molecule, label or tracer is an identifying tag which, when attached to a carrier substance or molecule, can be used to detect an analyte. A label may be attached to its carrier substance or antibody directly or indirectly by means of a linking or bridging moiety. Examples of labels include enzymes such as β-galactosidase and peroxidase, fluorescent compounds such as rhodamine and fluorescein isothiocyanate (FITC), luminescent compounds such as dioxetanes and luciferin, and radioactive isotopes such as 125 I.
A peptide is any compound formed by the linkage of two or more amino acids by amide (peptide) bonds, usually a polymer of α-amino acids in which the α-amino group of each amino acid residue (except the NH 2 -terminal) is linked to the α-carboxyl group of the next residue in a linear chain. The terms peptide, polypeptide and poly(amino acid) are used synonymously herein to refer to this class of compounds without restriction as to size. The largest members of this class are referred to as proteins.
Any sample that is reasonably suspected of containing the analyte, i.e., a tricyclic antidepressant drug, can be analyzed by the method of the present invention. The sample is typically an aqueous solution such as a body fluid from a host, for example, urine, whole blood, plasma, serum, saliva, semen, stool, sputum, cerebral spinal fluid, tears, mucus or the like, but preferably is plasma or serum. The sample can be pretreated if desired and can be prepared in any convenient medium that does not interfere with the assay. An aqueous medium is preferred.
Calibration material means any standard or reference material containing a known amount of the analyte to be measured. The sample suspected of containing the analyte and the calibration material are assayed under similar conditions. Analyte concentration is then calculated by comparing the results obtained for the unknown specimen with results obtained for the standard. This is commonly done by constructing a calibration curve such as in FIGS. 6 and 7.
Various ancillary materials will frequently be employed in an assay in accordance with the present invention. For example, buffers will normally be present in the assay medium, as well as stabilizers for the assay medium and the assay components. Frequently, in addition to these additives, additional proteins may be included, such as albumin, or surfactants, particularly non-ionic surfactants, or the like.
Another aspect of the present invention relates to kits useful for conveniently performing the assay methods of the invention for the determination of an analyte. To enhance the versatility of the subject invention, reagents useful in the methods of the invention can be provided in packaged combination, in the same or separate containers, in liquid or lyophilized form so that the ratio of the reagents provides for substantial optimization of the method and assay. The reagents may each be in separate containers or various reagents can be combined in one or more containers depending on the cross-reactivity and stability of the reagents.
The present invention also encompasses a reagent test kit which comprises, in packaged combination, an antibody specific for imipramine, desipramine, amitriptyline, or nortriptyline, a complex comprising a ligand of a TCA derivative coupled to a labeling moiety, and may optionally also comprise one or more calibrators comprising a known amount of a substance selected from the group consisting of imipramine, desipramine, amitriptyline and nortriptyline. Such a test kit provides reagents for an assay with enhanced clinical sensitivity for imipramine, desipramine, amitriptyline, nortriptyline and structurally-related compounds.
In the examples that follow, boldface numbers refer to the corresponding structure in the drawings.
Example 1
Preparation of 3-(3-methoxy-benzylidene)-3H-isobenzofuran-1-one (1)
A mixture of 15 g (89 mmol) of m-methoxyphenyl acetic acid, 13.2 g (89 mmol) of phthalic anhydride and 246 mg (2.9 mmol) of sodium acetate was heated to 240° C. for 6 hours and water was continuously removed from the reaction. The solid formed in the reaction flask on cooling. This was recrystallized from absolute ethanol to obtain 15.6 g (62 mmol, 69%) of 1 as yellow powder.
Example 2
Preparation of 2-[2-(3-methoxy-phenyl)-ethyl]-benzoic Acid (2)
A solution of 15.6 g of 1 (62 mmol) in 300 ml of THF was added 30 g of 10% Pd-C, 40 g of ammonium formate and 17.2 ml of triethyl amine. The reaction mixture was heated at 70° C. for 6 hours and filtered. The filtrate was concentrated and redissolved in 500 ml of ethyl acetate and washed with 2×150 ml of 3% aqueous HCl and 2×100 ml of brine. The organic layer was concentrated and triturated with 1:1 ethyl acetate:hexane to give 8 g (31.2 mmol, 51%) of 2.
Example 3
Preparation of 2-methoxy-10,11-dihydro-dibenzo[a,d]cyclohepten-5-one (3)
To 5 g of phosphorous pentoxide was added 50 ml of methane sulphonic acid. The mixture was heated to 80° C. for 1 hour. The reaction mixture was brought down to 40° C. and 3 g (11.7 mmol) of 2 was added as solid. The mixture was heated at 40° C. for 1 hour and cooled down to room temperature. The reaction mixture was poured into 300 ml of ice/water and extracted with 200 ml of ethyl acetate. The organic layer was washed with 2×150 ml of water, 2×150 ml of saturated NaHCO 3 and 100 ml of water. The resulting organic layer was dried (Na 2 SO 4 ) and concentrated to give 2.6 g (11.7 mmol, 94%) of 3 as off-white powder.
Example 4
Preparation of 5-(3-dimethylamino-propyl)-2-methoxy-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-5-ol (4)
To 30 g of magnesium turnings was added 100 ml of freshly distilled THF and a catalytic amount of iodine. The reaction mixture was heated to reflux for 10 minutes and cooled to room temperature. To this reaction mixture 3.5 g (29 mmol) of 3-chloro-N,N-dimethylpropane was added and the reaction mixture was heated to reflux for 3 hours. The reaction mixture was cooled to room temperature and a solution of 2 g of 3 (8.3 mmol) in 20 ml of freshly distilled THF was added. The reaction was allowed to stir at room temperature for 2 hours and filtered. To the filtrate 10 ml of saturated solution of ammonium chloride was added and concentrated to remove THF. This was diluted with 100 ml of saturated ammonium chloride and extracted with ethyl acetate (3×150 ml). The combined organic layer was washed with 2×75 ml of saturated NaHCO 3 and 2×75 ml of water, dried (Na 2 SO 4 ) and concentrated. The crude product was purified by silica gel column chromatography using 10% methanol in dichloromethane to give 2.6 g (7.9 mmol, 95%) of 4 as white powder.
Example 5
Preparation of 10,11-dihydro-2-methoxy-N,N-dimethyl-5H-dibenzo[a,d]cyclohepten-5-propylamine (5)
To 65 mg (0.19 mmol) of 4 was added 5 ml of glacial acetic acid. The mixture was heated to 60° C. and allowed to stir until the mixture was homogeneous. The reaction mixture was cooled to room temperature and 300 mg of 10% Pd/C was added followed by 1 g of ammonium formate. The mixture was heated to 70° C. and allowed to stir at that temperature for 4 hours. The reaction mixture was cooled to room temperature and filtered. The residue was washed with 50 ml of dichloromethane. The combined filtrate was concentrated. The residue was dissolved in 100 ml of dichloromethane and washed with 2×50 ml of saturated NaHCO 3 followed by 2×50 ml of brine. The organic part was dried (Na 2 SO 4 ) and concentrated to give 50 mg (0.16 mmol, 82%) of 5.
Example 6
5-(3-dimethylaminopropyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-ol Hydrobromide (6)
To 35 ml of freshly distilled dichloromethane was added 1.98 ml of boron tribromide. The reaction mixture was placed in a water bath. To the reaction mixture was added a solution of 1.1 g (3.5 mmol) of 5 in 15 ml of dichloromethane dropwise. The mixture was allowed to stir at room temperature (23-26° C.) for 30 minutes and poured into 50 g of ice/water. An additional 50 ml of water was added and extracted with 3×100 ml of chloroform. The combined organic layer was dried (Na 2 SO 4 ) and concentrated to give 1.2 g (3.18 mmol, 90%) of 6 as an off-white solid.
Example 7
Preparation of 4-[5-(3-dimethylaminopropyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxy]-butyric Acid Ethyl Ester (7)
To 500 mg (1.32 mmol) of 6 was added 10 ml of freshly distilled acetone (distilled over anhydrous K 2 CO 3 ) and 10 ml of anhydrous DMF. To this reaction mixture was added 450 mg (3.0 mmol) of sodium iodide, 2 g of 4° A molecular sieves, 2 g (6.13 mmol) of cesium carbonate and a catalytic amount of 18-crown-6. To this reaction mixture was added 500 μl (3.38 mmol) of ethyl 4-bromobutyrate and the reaction mixture was heated on an preheated oil bath (90° C.) under argon atmosphere for 18 hours. The mixture was cooled to room temperature and filtered. The residue was washed with 30 ml of chloroform. The combined filtrate was concentrated under reduced pressure and redissolved in 100 ml of dichloromethane. This was washed with 2×100 ml of 5% NaOH followed by 2×100ml of water, dried (Na 2 SO 4 ) and concentrated. The residue was purified by silica gel column chromatography using 10% methanol in dichloromethane to give 450 mg (1.09 mmol, 83%) of 7 as a brownish oil.
Example 8
Preparation of 4-[5-(3-dimethylamino-propyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxy]-butyric Acid (8)
To a solution of 875 mg of 7 (2.1 mmol) in 10 ml of freshly distilled THF was added a solution of 875 mg of lithium hydroxide in 10 ml of water and 5 ml of methanol. The reaction was allowed to stir at room temperature 18 hours and concentrated to remove THF and methanol. The aqueous residue was adjusted to pH 6 with 6N HCl. This was extracted with 3×100 ml of dichloromethane. The pH of the aqueous part was readjusted to 6 again after first extraction. The combined organic part was dried (Na 2 SO 4 ) and concentrated to give 790 mg (2.0 mmol, 97%) of 8 as white amorphous solid.
Example 9
Preparation of 4-[5-(3-dimethylamino-propyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxy]-butyric acid 2,5-dioxo-pyrrolidin-1-yl Ester (9)
To a solution of 200 mg (0.52 mmol) of 8 in 40 ml of dichloromethane (distilled over calcium hydride) was added 92 mg (0.8 mmol) of N-hydroxysuccinimide and 152 mg (0.8 mmol) of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDC). The reaction mixture was allowed to stir at room temperature for 48 hours. The reaction mixture was diluted with 50 ml of dichloromethane and washed with 50 ml of brine, 2×50 ml of saturated sodium bicarbonate followed by 2×50 ml of brine. The resulting solution was dried (Na 2 SO 4 ) and concentrated to give 245 mg (0.51 mmol, 98%) of 9 as a white solid.
Example 10
Preparation of C-2 position TCA Immunogen (10)
To 738 mg of bovine thyroglobulin in 12 ml of 50 mM potassium phosphate (pH 7.5) was cooled in an ice-bath. To the solution was added 37 ml of dimethylsulfoxide dropwise and the reaction temperature was maintained below room temperature. To the protein solution was added a solution of 111 mg (0.23 mmol) of 9 in 1 ml of DMF dropwise. The mixture was allowed to stir at room temperature 18 hours. The resulting conjugate was placed in a dialysis tube (50,000 MW cut-off) and was dialyzed in 2 L of 70% DMSO in 50 mM potassium phosphate (pH 7.5, 3 changes, at least 3 hours each), 2 L of 50% DMSO in 50 mM potassium phosphate (at least 3 hours), 2 L of 30% DMSO in 50 mM potassium phosphate (at least 3 hours), 10% DMSO in 50 mM potassium phosphate (at least 3 hours) at room temperature followed by 6 changes with 50 mM potassium phosphate (pH 7.5) at 4° C. (2 L each for at least 6 hours each). The protein concentration was determined to be 3.9 mg/ml using Biorad Coomassie blue protein assay (Bradford, M., Anal. Biochem . 72, 248, 1976). A total of 100 ml of the conjugate was obtained. The extent of available lysine modification was determined to be 70% by the TNBS method (Habeeb AFSA, Anal. Biochem . 14, 328-34, 1988).
Example 11
Preparation of C-2 position TCA-BSA ELISA Screening Conjugate (11)
A solution of 1 g of bovine serum albumin (BSA) in 16 ml of 50 mM potassium phosphate (pH 7.5) was cooled in an ice-bath. To the solution was added 19 ml of DMSO dropwise and the reaction temperature was maintained below room temperature. To the protein solution was added a solution of 18.1 mg (0.038 mmol) of C-2 position TCA NHS ester derivative (9) in 1.5 ml of anhydrous DMF dropwise. The reaction mixture was allowed to stir at room temperature 48 hours. The resulting conjugate was placed in a dialysis tube (10,000 MW cut-off) and was dialyzed in 2 L of 60% DMSO in 50 mM potassium phosphate (3 changes, at least 3 hours each), 2 L of 50% DMSO in 50 mM potassium phosphate (at least 3 hours), 2 L of 30% DMSO in 50 mM potassium phosphate (at least 3hours), 2 L of 10% DMSO in 50 mM potassium phosphate (at least 3 hours) at room temperature followed by 6 changes with 50 mM potassium phosphate (pH 7.5) at 4° C. (2 L each for at least 6 hours each). A total of 70 ml of TCA-BSA conjugate was obtained. The protein concentration was determined to be 8.2 mg/ml using Biorad Coomassie blue protein assay. Overall drug:BSA ratio=2.5:1.
Example 12
Preparation of 4-[5-(3-dimethylaminopropyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxymethyl]benzoic Acid Methyl Ester (12)
A solution of 100 mg (0.34 mmol) of hydroxy TCA derivative 6 in 3 ml of DMF under argon was treated with 16 mg (0.4 mmol) of NaH (60% dispersion in mineral oil) and stirred at room temperature for 15 minutes. The mixture was then treated with 85 mg (0.37 mmol) of methyl-4-(bromomethyl) benzoate and stirred at room temperature for 4 hours. The reaction diluted with CH 2 Cl 2 and washed with 50 mM KPO 4 , pH 7. The aqueous portion was extracted once with CH 2 Cl 2 . The combined CH 2 Cl 2 portions were dried over Na 2 SO 4 and concentrated in vacuo to an oil. This was chromatographed on 20 g of silica gel using 3% MeOH in CH 2 Cl 2 as eluent to yield 46 mg (31%) of 12 as a pale yellow oil.
Example 13
Preparation of 4-[5-(3-dimethylaminopropyl-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxymethyl]benzoic Acid (13)
A solution of 46 mg (0.104 mmol) of 12 in 4.5 ml of MeOH and 0.5 ml of H 2 O under argon was treated with 28 mg (0.202 mmol) of K 2 CO 3 and heated to reflux for 4 hours. The reaction was concentrated in vacuo. The residue was dissolved in H 2 O and the pH adjusted to 6.5 with dilute HCl. A precipitate formed. This was extracted with 3×10 ml of CH 2 Cl 2 , dried over Na 2 SO 4 and concentrated in vacuo to yield 35 mg (79%) of 13 as an off-white amorphous solid.
Example 14
Preparation of 4-[5-(3-dimethylaminopropyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxymethyl]benzoic acid 2,5-dioxo-pyrrolidin-1-yl Ester
A solution of 35 mg (0.082 mmol) of acid 13 in 5 ml of CH 2 Cl 2 under argon was treated with 25 mg (0.217 mmol) of N-hydroxysuccinimide and 40 mg (0.209 mmol) of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide HCl and stirred at room temperature overnight. The reaction was washed with H 2 O, saturated NaHCO 3 and brine, dried over Na 2 SO 4 and concentrated in vacuo to give 30 mg (70%) of 14 as a white amorphous solid.
Example 15
Preparation of 4-({4-[5-(3-dimethylaminopropyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxy]butyrylamino}methyl)benzoic Acid (15)
A mixture of 32 mg (0.212 mmol) of 4-(aminomethyl)benzoic acid in 2 ml of H 2 O and 4 ml of THF was treated with approximately 0.1 ml of 2 N NaOH such that the pH of the mixture was about 9. This was then treated with a solution of 100 mg (0.209 mmol) of the TCA NHS ester 9 in 4.5 ml of THF. The pH was adjusted to about 8.5-9.0 with 2 N NaOH and the reaction was stirred at room temperature for 15 minutes. The reaction was neutralized to pH 6 with 2 N HCl, then extracted twice with CH 2 Cl 2 . The CH 2 Cl 2 portions were combined, dried over anhydrous Na 2 SO 4 and concentrated in vacuo to give 87 mg (81%) of the acid 15 as a pale yellow oil. This was used in the next step without further purification.
Example 16
Preparation of 4-({4-[5-(3-dimethylaminopropyl)-10,11-dihydro-5H-dibenzo[a,d]cyclohepten-2-yloxy]butyrylamino}methyl)benzoic acid 2,5-dioxo-pyrrolidin-1-yl Ester (16)
A solution of 87 mg (0.169 mmol) of the acid (15) in 10 ml of CH 2 Cl 2 was treated with 40 mg (0.348 mmol) of N-hydroxysuccinimide and 87 mg (0.454 mmol) of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide HCl and stirred at room temperature overnight. The reaction was washed with H 2 O, saturated NaHCO 3 and brine, dried over Na 2 SO 4 and concentrated in vacuo. The residue was chromatographed on silica gel using 10% ether in CH 2 Cl 2 as eluent to give 34 mg (33%) of 16 as a white amorphous solid.
Example 17
Preparation of 3-{[3-(10,11-dihydro-dibenzo[b,f]azepine-5-yl)-propyl]-methyl-amino}-propionic Acid Ethyl Ester (17)
A solution of 6.02 g (19.8 mmol) of desipramine hydrochloride was allowed to stir at room temperature for 5 minutes. This was extracted with 6×100 ml of chloroform. The combined organic part was washed with 100 ml of water, dried with anhydrous Na 2 SO 4 and concentrated to give 5.25 g of desipramine free base. A solution of 2.82 g (10.6 mmol) of desipramine free base in 100 ml of anhydrous acetone was added. To this reaction mixture 2.03 ml (15.8 mmol) of ethyl-3-bromopropionate, 3.65 g (26.4 mmol) of anhydrous potassium carbonate, 264 mg (1.76 mmol) of sodium iodide, 5 mg of 18-crown-6 and 0.7 ml of anhydrous DMF were added. The reaction mixture was allowed to reflux under argon overnight. The mixture was filtered and the residue was washed with 20 ml of acetone. The combined filtrate was concentrated and purified by silica gel column chromatography using 4% methanol in ethyl acetate to give 3.45 g (9.41 mmol, 89%) of the ethyl ester (17) as a thick oil.
Example 18
Preparation of 3-3{[3-(10,11-dihydro-dibenzo[b,f]azepin-5-yl)-propyl]-methyl-amino}-propionic Acid (18)
To 2.15 g (5.86 mmol) of the ethyl ester (17) was added 29.6 ml of freshly distilled THF, 29.6 ml of methanol and a solution of 4.7 g of lithium hydroxide in 63 ml of water. This mixture was allowed to stir at room temperature overnight and concentrated to remove methanol and THF. The pH of the aqueous solution was adjusted to 6. This was extracted with 6×100 ml of chloroform. The combined organic layers were washed with 100 ml of water, dried (anhydrous Na 2 SO 4 ) and concentrated to give 1.97 g (5.82 mmol, 99%) of 18 as white amorphous solid.
Example 19
Preparation of 4-[(3-{[3-(10,11-dihydro-dibenzo[b,f]azepin-5-yl)-propyl]-methyl-amino}-propionylamino)-methyl]-benzoic Acid Methyl Ester (19)
To a solution of 0.93 g (2.74 mmol) of 18 in 100 ml of anhydrous dichloromethane was added 446 mg (2.21 mmol) of methyl aminomethyl benzoate hydrochloride (20) followed by 1.05 g (5.47 mmol) 1-ethyl-3-(3-dimethylaminopropyl)-carbodiimide. The mixture was allowed to stir at room temperature overnight. To the reaction mixture was added 100 ml of water and 20 ml of dichloromethane. The organic layer was separated and the aqueous part was extracted with 4×75 ml of dichloromethane. The combined organic layer was washed with 2×100 ml of water, dried (Na 2 SO 4 ) and concentrated. The above reaction was repeated using 1.02 g of 18. The combined crude product was purified by silica gel column chromatography using 30% chloroform in methanol to give 1.2 g (2.47 mmol, 43%) of the methyl ester (19). An additional 760 mg of the product was also obtained containing small impurities.
Example 20
Preparation of Methylaminomethyl Benzoate Hydrochloride (20)
A magnetically stirred suspension of 6.05 g (40 mmol) of aminomethyl benzoic acid in 480 ml of methanol was cooled to −20° C. To the reaction mixture 12.3 ml of thionyl chloride was added for a period of 10 minutes. The reaction mixture was warmed up to 4° C. and was allowed to stir at that temperature overnight. The resulting solution was concentrated to give a solid. NMR analysis indicated that the reaction was not complete. This was again subjected to the above reaction conditions to give 7.8 g (38 mmol, 96%) of 20 as an off-white solid.
Example 21
Preparation of 4-[(3-{[3-(10,11-dihydro-dibenzo[b,f]azepin-5-yl)-propyl]-methyl-amino}-propionylamino)-methyl]-benzoic Acid (21)
To 1.2 g (2.47 mmol) of 18 were added 16.5 ml of THF, 16.5 ml of methanol and a solution of 2.63 g of lithium hydroxide in 38 ml of water. The mixture was allowed to stir at room temperature overnight. This was concentrated to remove methanol and THF. The pH of the solution was adjusted to 6 using 85% phosphoric acid. The resulting mixture was extracted with 5×100 ml of chloroform. The combined organic layer was washed with 100 ml of water, dried (Na 2 SO 4 ) and concentrated. The residue was purified twice by silica gel column chromatography using 7:3 methanol:ethyl acetate to give 550 mg (1.16 mmol, 47%) of 21.
Example 22
Preparation of 4-[3-{[3-(10,11-dihydro-dibenzo[b,f]azepin-5-yl)-propyl]-methyl-amino)-methyl-]benzoic acid 2,5-dioxo-pyrrolidin-1-yl Ester (22)
A solution of 55 mg (1.16 mmol) of 21 in 30 ml of dichloromethane was allowed to stir at room temperature under argon atmosphere. To the reaction mixture was added 575 mg (2.9 mmol) of 1-ethyl-3(3-dimethylaminopropyl)-carbodiimide) and 264 mg (2.29 mmol) of N-hydroxysuccinimide. The mixture was allowed to stir for 24 hours and was diluted with 15 ml of dichloromethane. The organic layer was separated and washed with 4×50 ml of water, 3×50 ml of saturated NaHCO 3 solution and 3×50 ml of water. The dichloromethane layer was dried (Na 2 SO 4 ) and concentrated to give 480 mg (0.8 mmol, 72%) of 22 as a white powder.
Example 23
Preparation of {2-[3-(10,11-Dihydro-dibenzo[b,f]azepin-5-yl)-propylamino]-ethyl]-carbamic Acid tert-butyl Ester (23)
To 6.02 g of desipramine hydrochloride was added 150 ml of 1N NaOH. The mixture was allowed to stir for 10 minutes. The aqueous mixture was extracted with 6×100 ml of chloroform. The combined chloroform layer was washed with 200 ml of water. The organic part was dried (Na 2 SO 4 ) and concentrated to give 5.25 g of desipramine free base.
To 3.23 g (12.04 mmol) of desipramine free base was added 80 ml of dry acetone, 3.6 g of anhydrous potassium carbonate, 3.0 g (13.45 mmol) of 2-(BOC-amino) ethyl bromide, 3 ml of anhydrous dimethylformamide, 15 mg of 18-crown-6 and 500 mg of sodium iodide. The mixture was allowed to reflux 18 hours under argon atmosphere. The reaction mixture was cooled to room temperature and filtered. The residue was washed with 10 ml of acetone. The filtrate was concentrated and the residue was purified by silica gel column chromatography using 4% methanol in ethyl acetate to give 4.8 g (11.7 mmol, 96%) of 23 as a thick oil.
Example 24
Preparation of N-[3-(10,11-Dihydro-dibenzo[b,f]azepin-5-yl)-N1-methyl-ethane-1,2-diamine (24)
To 1.0 g (2.44 mmol) of 23 was added 10 ml of CH2Cl2 and 10 ml of trifluoroacetic acid. The reaction mixture was allowed to stir at room temperature and concentrated. The residue was dissolved in CH 2 Cl 2 and concentrated. The above procedure was repeated twice and the residue was purified by silica gel column chromatography using 60% chloroform in methanol to give 1.02 g (2.40 mmol, 99%) of 24 as a thick oil.
Example 25
Preparation of N-(2-{[3-(10,11-Dihydro-dibenzo[b,f]azepin-5-yl)-propyl]-methyl-amino]-ethyl)-terephthalamic acid 2,5-dioxo-pyrrolidin-1-yl Ester (26).
To 500 mg (1.18 mmol) of TCA amine (24) was added 316 μl of triethyl amine and 30 ml of DMF. In a separate flask 1.16 g (mmol) of terephthalic acid di-N-hydroxysuccinimide ester (25) was mixed with 30 ml of anhydrous DMF. The previously prepared TCA amine solution was added to the terephthalic acid di-N-hydroxysuccinimide solution dropwise. The reaction mixture was allowed to stir at room temperature overnight and concentrated. The residue was dissolved in 75 ml of dichloromethane. The organic layer was washed with 2×50 ml of water, 2×50 ml of saturated solution of NaHCO 3 and 50 ml of water, dried (Na 2 SO 4 ) and concentrated. The residue was purified by silica gel column chromatography using 20% acetone in ethyl acetate to give 145 mg (0.26 mmol, 22%) of 26 as white powder.
Example 26
Preparation of N-1 position TCA Immunogen (28)
A solution of 96 mg of TCA NHS ester derivative (18) in 1.5 ml of anhydrous DMF was cooled to 0° C. To the reaction mixture was added 74 mg of dicyclohexyl urea (DCC) and 48 mg of N-hydroxysuccinimide. The mixture was allowed to stir at 4° C. for 24 hours. The N-hydroxysuccinimide ester prepared was used in situ in the protein conjugation.
Seven hundred mg of bovine thyroglobulin in 12 ml of 50 mM potassium phosphate (pH 7.5) was cooled in an ice-bath. To the solution was added 37 ml of dimethylsulfoxide (DMSO) dropwise and the reaction temperature was maintained below room temperature. To the protein solution was added dropwise the N-hydroxysuccinimide ester solution prepared in situ (as described above). The mixture was allowed to stir at room temperature 18 hours. The resulting conjugate was placed in a dialysis tube (50,000 MW cut-off) and was dialyzed in 2 L of 70% DMSO in 50 mM potassium phosphate (pH 7.5, 3 changes, at least 3 hours each), 2 L of 50% DMSO in 50 mM potassium phosphate (at least 3 hours), 2 L of 30% DMSO in 50 mM potassium phosphate (at least 3 hours), 10% DMSO in 50 mM potassium phosphate (at least 3 hours) at room temperature followed by 6 changes with 50 mM potassium phosphate (pH 7.5) at 4° C. (2 L each for at least 6 hours each). The protein concentration was determined to be 4.5 mg/ml using Biorad Coomassie blue protein assay (Bradford, M., Anal. Biochem . 72, 248 (1976). A total of 90 ml of the conjugate (28) was obtained. The extent of available lysine modification was determined to be 70% by the TNBS method, Habeeb AFSA, Anal. Biochem . 14, 328-34 (1988). Note: Reference for preparation of protein conjugate: Hubbard et al., J. Pharm. Sc . 67, 1571-1578 (1978).
Example 27
Preparation of C-2 position TCA-BSA (aromatic linker) Conjugate (29)
A solution of 550 mg of bovine serum albumin (BSA) in 11 ml of 50 mM potassium phosphate (pH 7.5) was prepared. A 10 ml solution was transferred into a RB flask and cooled in an ice-bath. To the solution was added 10 ml of DMSO dropwise and the reaction temperature was maintained below room temperature. To the protein solution was added a solution of 48.2 mg of C-2 position TCA NHS ester derivative (16) in 0.96 ml DMSO dropwise. The reaction mixture was allowed to stir at room temperature 16 h. The resulting conjugate was placed in a dialysis tube (10,000 MW cut-off) and was dialyzed against 500 ml of 50% DMSO in 50 mM potassium phosphate (at least 3 hours at room temperature), 500 ml of 30% DMSO in 50 mM potassium phosphate (at least 3 h at room temperature), 500 ml of 10% DMSO in 50 mM potassium phosphate (at least 3 h at room temperature) followed by 4 changes with 50 mM potassium phosphate (pH 7.5) at 4° C. (2 L each for at least 3 hours each). The resulting conjugate was filtered through a 0.45 μm filter. A total of 37 ml of TCA-BSA conjugate was obtained. The protein concentration was determined to be 14.4 mg/ml using Biorad Coomassie blue protein assay.
Example 28
Preparation of N-1-position TCA-BSA (aromatic linker) Conjugate (30)
A solution of 1 g of bovine serum albumin (BSA) in 16 ml of 50 mM potassium phosphate (pH 7.5) was cooled in ice-bath. To the solution was added 19 ml of DMSO dropwise and the reaction temperature was maintained below room temperature. To the protein solution was added a solution of 21 mg of TCA NHS ester derivative (22) in 1.5 ml of anhydrous DMF dropwise. The reaction mixture was allowed to stir at room temperature 24 h. The resulting conjugate was placed in a dialysis tube (10,000 MW cut-off) and was dialyzed in 2 L of 60% DMSO in 50 mM potassium phosphate (3 changes, at least 3 hours each), 2 L of 50% DMSO in 50 mM potassium phosphate (at least 3 h), 2 L of 30% DMSO in 50 mM potassium phosphate (at least 3 h), 2 L of 10% DMSO in 50 mM potassium phosphate (at least 3 h) at room temperature followed by 6 changes with 50 mM potassium phosphate (pH 7.5) at 4° C. (2 L each for at least 6 hours each). A total of 75 ml of TCA-BSA conjugate was obtained. The protein concentration was determined to be 11.4 mg/ml using Biorad Coomassie blue protein assay.
Example 29
Preparation of N-1-position TCA-BSA (short linker) Conjugate (27)
A solution of 12.8 mg of TCA NHS ester derivative (18) in 1.5 ml of anhydrous DMF was cooled to 0° C. To the reaction mixture was added 9.3 mg of dicyclohexyl urea (DCC) and 5.24 mg of N-hydroxysuccinimide. The mixture was allowed to stir at 4° C. for 24 h. The N-hydroxysuccinimide ester prepared was used in situ in the protein conjugation.
A solution of 1 g of bovine serum albumin (BSA) in 16 ml of 50 mM potassium phosphate (pH 7.5) was cooled in ice-bath. To the solution was added 19 ml of DMSO dropwise and the reaction temperature was maintained below room temperature. To the protein solution was added dropwise the N-hydroxysuccinimide ester solution prepared in situ (as described above). The reaction mixture was allowed to stir at room temperature 24 h. The resulting conjugate was placed in a dialysis tube (10,000 MW cut-off) and was dialyzed in 2 L of 60% DMSO in 50 mM potassium phosphate (3 changes, at least 3 hours each), 2 L of 50% DMSO in 50 mM potassium phosphate (at least 3 h), 2 L of 30% DMSO in 50 mM potassium phosphate (at least 3 h), 2 L of 10% DMSO in 50 mM potassium phosphate (at least 3 h) at room temperature followed by 6 changes with 50 mM potassium phosphate (pH 7.5) at 4° C. (2 L each for at least 6 hours each). A total of 100 ml of TCA-BSA conjugate was obtained. The protein concentration was determined to be 7.2 mg/ml using Biorad Coomassie blue protein assay.
Example 30
Development of Polyclonal Antisera to the C-2 Position Immunogen
Healthy, previously un-immunized rabbits of either sex were chosen for this work. Rabbits were housed and treated as approved by the vendor's IUACUC committee.
Primary immunization was with the 2-carboxypropyl-dihydroamitriptyline-BTG conjugate emulsified in complete Freund's adjuvant at a concentration of 1 mg/ml. Total dose administered to each rabbit was 0.2 ml or 0.2 mg, delivered by subcutaneous injection at multiple sites across the back. Four weeks later the immunization was repeated, substituting incomplete Freund's adjuvant, at different sites across the back, again via subcutaneous injection. Immunizations were then repeated at four-week intervals, using a total dose of 0.1 mg, administered via the same route as previously described, to week 16.
Antibody response was determined via ELISA of samples taken via ear vein bleeds. Serial dilutions of clarified serum were tested on both the C-2 position and N-1 position test protein (BSA) conjugates. The titers of the sera, expressed as the 50% of maximal response dilution, were generally similar with respect to the test conjugate used, approximately 5×105. Variations appeared to be more related to the individual animal than to the conjugate used for testing, in that high responders on the C-2 position test conjugate also were higher on the N-1 position conjugate, and the order of response among the animals, from highest to lowest, was generally the same as measured on each test conjugate.
Example 31
Immunization of Mice with C-2 Immunogen
The C-2 immunogen, compound 10, was prepared for primary immunization of mice by diluting to 0.2 mg/ml in physiological saline and emulsifying with an equal volume of Freund's Complete Adjuvant (Sigma Chemicals, St Louis, Mo.) by using two syringes and a double-hubbed 25 gauge needle. The emulsion was injected into the mice in each rear footpad and into the peritoneal area. A total dose of 0.1 ml per mouse was injected. A secondary injection using the same formulation with Freund's Incomplete Adjuvant was injected via the same routes four weeks later. The third injection was the same as the second and was administered 6 weeks following the second injection.
Blood samples were taken via retro-orbital bleeding 14 days after the second injection. Serum was separated via centrifugation and preserved via the addition of 1 μl of 10% thimerosal solution. The typical volume of serum was 10-20 μl.
Example 32
ELISA assay
To analyze the sera for antibody content an ELISA assay using the cognate antigen linked to a different protein (2-carboxypropyl-dihydroamitriptyline-BSA) (compound 11) was used. This antigen was diluted to 5 μg/ml in 0.1 M carbonate buffer, pH 9.5. A volume of 100 μl of this antigen solution was pipetted into wells of a polystyrene 96-well microplate (Costar, Cambridge, Mass.). This was incubated in a plastic bag at 37° C. for 1 hour. The solutions were then removed via suction, and wells were filled with a blocking solution. This consisted of gelatine hydrolysate, 1%, sucrose, 2%, Tris, 0.15 M, pH 7.4 (all reagents from Sigma Chemicals). This was allowed to block the plates for 1 hour at room temperature in plastic bags. Wells were then emptied via suction.
Dilutions of the sera were prepared by transferring 1 μl to a glass test tube containing 1 ml of phosphate buffered saline, with 0.1% Tween 20 (PBS-T). One hundred and fifty microliters of this dilution of each serum were transferred to wells in Row A of a polyvinyl chloride microplate. All other wells were filled with 100 μl of PBS-T. Serial three-fold dilutions were prepared by transferring 50 μl from Row A to Row B using a multi-channel micropipettor. Mixing was accomplished by re-pipetting 3 times. This was repeated from Row B to C and so on down each column of wells.
Once all dilutions were prepared, 95 μl of each, starting with Row H, was transferred to the same row in the coated plate. The plate was placed in a Ziploc plastic bag with a damp piece of paper towel and incubated at 37° C. for one hour. Following incubation, the wells were washed four times manually with 300 μl aliquots of PBS-T. A 1:5000 dilution of goat anti-mouse IgG AM-HRP conjugate (Kirkegaard & Perry, Gaithersburg, Md.) was prepared in PBS-T. 100 μl of this was then pipetted into each well, the plate again incubated as above. The plate was then washed 6 times with 300 μl of PBS-T manually, and 100 μl of K-Blue substrate (Neogen, Lexington, Ky.) was added to each well. This was allowed to develop in the dark for 5 minutes, and the reaction was then stopped by the addition of 100 μl of a 2 M phosphoric acid solution. The optical densities of the wells were read using a Molecular Devices Tmax plate reader and a Macintosh computer. The data suggested that all mice were sensitized to the immunogen, with some showing more of a response than others.
Example 33
Production of Monoclonal Antibodies from Murine Hybridomas
A mouse showing a high response to the immunogen via ELISA was chosen for use. This animal received a booster immunization of 100 μg of antigen in incomplete Freund's adjuvant four days before the fusion was performed. The myeloma cell line F0 (ATCC, Manassas, Va.) was used for the fusion. The fusion was performed by the method of de St Groth and Scheidegger, Journal of Immunol. Meth . 35, 1-21, 1980. Ten days later hybrid cell cultures were ready for screening. This was carried out by a process similar to the ELISA given above, with the addition of plates coated with an N-linked desipramine-BSA conjugate (compound 27) and a control plate coated only with BSA. Hybrid cells showing antibody capable of binding both the compound 11 and compound 27 but not the BS
A were chosen for further work. This consisted of immediate re-cloning as well as expansion of the culture for freezing in liquid nitrogen. Re-cloning was carried out by diluting the cells to 60 viable cells per 40 ml of culture media, distribution of 200 μl to each well in sterile 96-well culture plates, and incubation in a humidified CO 2 incubator until growth was observed.
Wells of the re-cloning plates showing growth were tested for antibody expression by the screening assay described earlier. Clones showing the desired reactions were expanded and stored in liquid nitrogen.
Monoclonal antibodies were produced by placing the desired hybridoma into tissue culture for expansion of cell number, followed by transfer to standard commercially available culture devices, such as the Miniperm (Hereaus, Germany). Antibody was used as a preserved culture supernatant for assay development.
Example 34
Immunoassay of Imipramine Using Monoclonal Antibody TCA 1.1
Hybridoma clone TCA 1.1 was placed into high-density culture and supernatant harvested. This preparation was preserved by the addition of thimerosal to a concentration of 0.02%. Antibody content was evaluated by a titer experiment in which varying dilutions of supernatant were placed into microplate wells coated with a constant amount of antigen conjugate. The dilution providing about 90% of maximal signal was used for further work in demonstrating an immunoassay.
Imipramine immunoassays were demonstrated by preparing various dilutions of a 1 mg/ml stock solution of the drug in PBS-T. Fifty microliters of these dilutions were pipetted into microplate wells coated with pre-optimized concentrations of either compound 11 or compound 27 conjugates, followed by 50 μl of the antibody supernatant diluted to one half of the previously determined dilution above. This provided a final dilution of supernatant equal to that previously determined and a final concentration of one-half of the drug level in the dilutions above. Incubation for 1 hour at 37° C. was followed by the same procedure as for the screening assays. Optical densities were plotted versus the final concentration of imipramine calculated as a molar (gram-molecular weight drug per liter) concentration. Standard curves with the following data were constructed (see FIG. 7 ):
TABLE 1
Imipramine
OD 450
OD 450
concentration
compound 11
compound 27
1.98 × 10 −6
0.056
0.037
6.6 × 10 −7
0.541
0.038
2.2 × 10 −7
1.35
0.276
7.43 × 10 −8
1.95
1.124
2.45 × 10 −8
2.325
1.719
8.15 × 10 −9
2.6
2.434
Based on these results, the lowest detectable amount of free drug by the assay using compound 11 conjugate is estimated to be 1.3×10 −6 M, or approximately 0.36 micrograms per ml. Using the compound 27 conjugate, a lower concentration of 4×10 −7 M, or about 0.11 micrograms/ml, was detectable. Background levels were reproducibly very low, suggesting that incorporation of a longer development time would probably provide lower detectable concentrations.
Furthermore, it was found that the other tricyclic antidepressant drugs also showed cross-reactivity with the binding of TCA 1.1 to both the compound 11 and the compound 27 conjugates. These data support the contention that immunization using the 2-carboxypropyl-dihydroamitriptyline-BTG conjugate (compound 10) is useful in the development of suitable antibodies for the purpose of determining concentrations of tricyclic antidepressants.
Example 35
Absorption of Antibodies to Microparticles
Carboxyl-modified blue polystyrene microparticles from Seradyn (0.3 micron) were first washed three times at 1% solids by centrifuging in 20 mM, pH 6.1 MES buffer (2-[N-morpholino]ethanesulfonic acid). The washed microparticles were then adjusted to 5% solids in MES, and the designated anti-TCA antibody was absorbed onto the microparticles as follows: To the solution of microparticles, an equal volume of 3 mg/ml anti-TCA antibody was added and allowed to stir for 16 hours at room temperature. The microparticles were then blocked with BSA solution in MES for 1 hour at room temperature and the mixture was washed for three times at 1% solids in MES by centrifugation. After the final wash, the microparticle solution was adjusted again to 10% solids. Before use, equal volumes of this latex and 35% w/v sucrose in MES were mixed.
Example 36
Preparation of Membrane Strip
Mylar-backed large pore size nitrocellulose (5-20 micron) was cut into pieces of 15 cm in length and 5 cm in width. Solutions of TCA-BSA conjugate (about 5 mg/ml) and anti-TCA monoclonal antibody (about 2 mg/ml), both in 50 mM potassium phosphate buffer pH 7.5, were dispensed using IVEK Corp. Digispense 2000™ system at the rate 1 μl/cm onto nitrocellulose at a distance respectively 2 cm and 1 cm from the 15 cm side. Nitrocellulose segments were allowed to dry for about 20 minutes at 37° C. and then were blocked with polyvinyl alcohol (PVA, MW 13,000-23,000) solution in 20 mM TRIS, pH 8, for 30 minutes at room temperature. The segments were then rinsed in water and dried.
Example 37
Immunochromatographic Assay of Imipramine using Polyclonal anti-TCA (C-2) Antibody
The same nitrocellulose as described above in this example was used as a separate membrane for microparticles (top membrane). The construction of the two-membrane strip configuration was done as described in detail in U.S. Pat. No. 5,770,458. In brief, the top membrane was blocked and washed using the same protocol as the main membrane. The top membrane that contains appropriate amount of microparticles was laminated to the main membrane with Adhesive Research Inc. adhesive mylar. After this, the segment was cut into 5 mm wide strips, sample pad and sink pad were placed respectively at the beginning and terminal ends of the strips. Cellulose from BioRad Laboratories (gel blotter) was used for both the sample receiving pads and the sink pads. A calibration curve was obtained by applying approximately 100 μl solutions containing predetermined amounts of the drug (TCA standards) onto the membrane strip. The signal strength was determined as follows: 2.5 to 3.0=dark blue, 1.5 to 2.0=medium blue, 1.0=light blue, 0.5=barely perceivable color, and 0=colorless. When the strip read colorless, a complete inhibition was achieved and the sample was indicated to contain 1000 ng/ml of TCA standard (e.g., imipramine). Results are presented in Tables 2-5 below and in FIG. 4 .
TABLE 2
Presented in Table 2 is the lateral-flow immunoassay standard curve for a
TCA assay using compound 27, 0.4 μg/strip, with antibody prepared from
the compound 10 immunogen (see FIG. 8).
Time of
Imipramine concentration (ng/ml)
testing
0
250
500
1000
2000
Experiment
2.00
2.00
1.50
0
0
1
Experiment
2.25
2.25
1.75
0
0
2
TABLE 3
Presented in Table 3 is the lateral-flow immunoassay standard curve for a
TCA assay using compound 30, 0.1 μg/strip, with antibody prepared from
the compound 10 immunogen (see FIG. 8).
Time of
Imipramine concentration (ng/ml)
testing
0
250
500
1000
2000
Experiment
3.00
2.50
2.00
1.00
0.50
1
Experiment
3.00
3.00
2.50
0.50
0
2
TABLE 4
Presented in Table 4 is the lateral-flow immunoassay standard curve for a
TCA assay using compound 27, 0.4 μg/strip, with antibody prepared from
the compound 28 immunogen (see FIG. 9).
Time of
Imipramine concentration (ng/ml)
testing
0
250
500
1000
2000
Experiment
2.50
2.00
0.50
0
0
1
Experiment
2.50
2.00
1.00
0
0
2
TABLE 5
Presented in Table 5 is the lateral-flow immunoassay standard curve for a
TCA assay using compound 30, 0.1 μg/strip, with antibody prepared from
the compound 28 immunogen (see FIG. 9).
Time of
Imipramine concentration (ng/ml)
testing
0
250
500
1000
2000
Experiment
3.00
3.00
2.50
0
0
1
Experiment
3.00
3.00
2.00
0
0
2
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The present invention is directed to novel tricyclic antidepressant drug derivatives synthesized for covalent attachment to proteins or polypeptide antigens for use in the preparation of antibodies or receptors to tricyclic antidepressant drugs and tricyclic antidepressant metabolites. The new derivatives are characterized by a saturated double bond on the amitriptyline portion of the molecule and are represented by the structure
where R 1 is a saturated or unsaturated, substituted or unsubstituted, straight or branched chain of 0-10 carbon or heteroatoms, X is a linker group consisting of 0-2 substituted or unsubstituted aromatic rings, and Y is an activated ester or NH—Z, where Z is a poly(amino acid). The novel tricyclic antidepressant activated hapten derivatives are useful for preparing tracers and conjugates for tricyclic antidepressant immunoassays, including an enzyme immunoassay and a microparticle capture inhibition assay using an antibody produced from the novel immunogen with a conjugate derivatized either at the N-1 position of imipramine or at the C-2 position of dihydroamitriptyline.
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CLAIM OF PRIORITY
This application claims the benefit of an earlier patent application entitled “Apparatus and Method for Photographing Image Using Digital Camera Capable of Providing A Preview Image,” filed in the Korean Intellectual Property Office on Aug. 23, 2007 and assigned Serial No. 2007-0085125, the content of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system and a method of photographing an image and automatically classifying the image, and more particularly to a system and a method of automatically classifying a facial image for each person, which includes a scheme for photographing images for classification and a scheme for classifying images.
2. Description of the Related Art
Due to a recent wide usages of a digital camera and a personal blog, a scheme is used in which an image photographed directly by a user is semi-automatically classified. In general, the scheme classifies the image for each person, or in reference to a scene or a background, such as the mountain and the sea. Here, the scheme for recognizing a face in the image and classifying the image requires registering many facial images for recognition in advance. Otherwise, there would be many errors, especially, in a case where the facial image is not a frontal image, or the facial image includes various facial expressions. That is, the photographed facial images with a natural pose include a face shape with various angles, but a rate of face recognition is lowered in the case of a non-front facial image, so that it is difficult to secure the accuracy of classification.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art and provides additional advantages, by providing an apparatus and a method for photographing and classifying a facial image while removing errors on recognizing and classifying the photographed image so as to accurately classify the image.
In accordance with an aspect of the present invention, an apparatus for photographing an image using a digital camera capable of providing a preview image includes: an image sensor for capturing an image of a subject; a first image signal processor for processing at least one captured image as a sequent image in order to display the captured image as a preview image on a display and detecting a face area from the captured image; a buffer for storing the image including at least one detected face area; a capture button for capturing a still image using outputting the sequent image as the preview image on the display window; a second image signal processor for processing the captured still image using the capture button; a controller for controlling to store the captured still image and information related on the face area detected from the first image signal processor prior to the input of the capture button; and a memory for storing the processed still image together with the information related on the detected face area.
In accordance with another aspect of the present invention, a method for photographing an image using a digital camera capable of providing a preview image includes: capturing at least one image of a subject; processing at least one captured image as a sequent image in order to display the captured image as a preview image on a display window; detecting a face area from the captured image, and storing the detected face area; capturing a photographed still image using a predetermined capture button; and storing the processed still image together with information related on the detected face area.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram illustrating an apparatus of photographing an image according to an exemplary embodiment of the present invention;
FIG. 2 is a diagram illustrating an image information unit and an image classifying unit according to an exemplary embodiment of the present invention; and
FIG. 3 is a flowchart illustrating a method for photographing and classifying a facial image according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings. In the following description, the same elements will be designated by the same reference numerals although they are shown in different drawings. For the purposes of clarity and simplicity, detailed explanation of known related functions and constitutions may be omitted to avoid unnecessarily obscuring the subject manner of the present invention.
FIG. 1 is a diagram illustrating an apparatus of photographing an image according to an exemplary embodiment of the present invention. As shown in FIG. 1 , the inventive apparatus of photographing the image includes a lens 101 , an image sensor 103 , a first image signal processor 105 , a controller 107 , a memory 111 , a buffer 113 , and a second image signal processor 109 .
The lens 101 optically receives an image of a subject. If the lens were included in a camera photographing the still image, the lens optically receives a still image as it is. If the lens were included in a camcorder photographing a moving image, the lens classifies the moving image into a plurality of still image and optically receives the still images in sequence. The image sensor 103 converts the image optically inputted by the lens 101 into an electrical signal. The second image signal processor 109 processes the electric signal converted-image based on a frame unit.
The memory 111 stores a photographed picture. The controller 107 shifts the lens 101 for adjusting focus on the subject.
The first image signal processor 105 selects the image including a face among the images processed based on the frame unit, determines the image, classifies, and stores the image. The classified facial image is stored in the buffer 113 . The description of the first image signal processor 105 will be described in details.
Even though not shown in the figures, the apparatus for photographing the image can further include a display unit capable of outputting the photographed image and have a function of providing a preview image. That is, the inventive apparatus for photographing the image is also equipped with the ability to provide preview images during a predetermined time period before and after a point of time of capturing in an image.
FIG. 2 is a diagram illustrating an image information unit and an image classifying unit according to an exemplary embodiment of the present invention. As shown, the first image signal processor 105 includes an image information unit 210 and an image classifying unit 230 . Note that FIG. 2 illustrates a state where the facial image is received from the camera and the connection state of each element. More particularly, the inventive apparatus for photographing image includes the image information unit 210 , an image storing unit 220 , and an image classifying unit 230 , and further includes a registered image DB 240 , and a person image DB 250 . Hereinafter, the configuration and operation thereof will be described, respectively.
The image information unit 210 photographs the image, extracts a specific area from the image, and collects information for classifying the extracted specific area according to a predetermined reference. In the present exemplary embodiment, the image information unit 210 photographs a facial image and extracts a face area. In order to classify the extracted face area for each person, the image information unit 210 collects facial image classification basis information from the extracted face area. To this end, the image information unit 210 includes an image selecting unit 222 , an image detecting unit 223 , an image tracking unit 224 , and a facial image classification basis information collecting unit 215 . The description of each configuration is as follows.
The image selecting unit 222 selects the facial image received from the image signal processor of a camera module. The image selecting unit 222 selects not only the image selected by the activation of the shutter of the camera, but also a predetermined number of preview images provided by the camera during before and after. The predetermined number of preview images can be determined by the user in advance. Note that the image can be passively selected by the user, or controlled to be automatically selected. For example, the user predetermines the number of preview images to be “5”, presses the shutter of the camera, and photographs the image. Here, the preview images are provided continuously before and after the photographing time point. The image selecting unit 212 selects not only the photographed image, but also the predetermined number of preview images photographed before and after the photographing time point. Since the predetermined number of preview images is set to be “5” in the present exemplary embodiment for illustrative purposes, the image selecting unit 212 selects and extracts the photographed image, two preview images right before the photographing time point, and two preview images right after the photographing time point. Therefore, a total of five images are selected and extracted, which are the facial images used for collecting the facial image classification basis information in the facial image classification basis information collecting unit 215 described later.
The image detecting unit 223 detects a facial area from the facial images selected in the image selecting unit 222 . Here, the face area can be detected by using the distribution of facial colors in the image, or by an active contour of the face, such as eyes, the nose, the mouth, or the like. Note that various methods known in the artisians can be applied to detect the face area.
The image tracking unit 22 tracks the movement of the face area detected in the image detecting unit 22 . That is, as shown in the above, the selected 5 facial images are the serial images, so that the face area moves when the person in the image moves. Therefore, the moving face area is tracked through the image tracking unit 224 It is reliable that the face areas detected according to the above tracking scheme are the face areas of the same person. In order to track the image, a tracking apparatus, such as a Kalman filter, or the like, can be employed by using the position similarity or the characteristic similarity between a present face and a previous face. The collected facial images for the same person are provided to the facial image classification basis information collecting unit 215 .
The facial image classification basis information collecting unit 215 collects information for classifying the facial images from the facial images of the same people collected in the image tracking unit 214 for each corresponding person according to a predetermined reference. The facial image classification basis information can include all information available for classifying the facial image for each person, e.g. information obtained through recognizing the image of the face area for comparing the pre-registered image, or Principle Component Analysis (PCA) feature vector. When a plurality of face areas are detected from a specific facial image, the facial image classification basis information collecting unit 215 can collect facial image classification basis information for each face area. That is, when three face areas are detected and tracked in the facial image, the facial image classification basis information is collected for every detected and tracked face area. In this case, the image classifying module 230 described later classifies the same image as each facial image of three people. The image storing module 220 stores the facial image and the preview images selected in the image selecting unit 222 together with the facial image classification basis information collected from them. The facial image and the preview images and the facial image classification basis information are provided to the image classifying module 230 .
The image classifying module 230 recognizes the facial images selected among the images photographed in the image information unit 210 , and classifies the recognized facial images according to the predetermined reference. The classification of tracked face area according to predetermine reference can be classified into a person individually or a group. The image classifying unit 230 is related to a classifying scheme through the image recognition. The image classifying module 230 includes an image recognizing unit 231 and an image classifying unit 232 , whose descriptions are as follows.
The image recognizing unit 231 recognizes the facial image and the preview image provided from the image storing unit 220 by using the facial image classification basis information. A lot of schemes for recognizing the facial image have existed conventionally, and in the present invention, the face shape can be recognized using the Support Vector Machine (SVM) or the artificial neural network.
In the meantime, the image classifying unit 232 classifies the facial image recognized in the image recognizing unit 231 for the corresponding person so as to store them in the facial image DB 250 . More particularly, the image classifying unit 232 compares the facial image classification basis information with the information extracted from the facial image previously registered in the registered image DB 240 , retrieves the person corresponding to the facial image and classifies the facial image for the corresponding person. If the registered facial image corresponding to the recognized facial image does not exist in the registered image DB 240 , the image classifying unit 132 classifies the recognized facial image as be a non-classified facial image so as to store it to the registered image DB 240 .
The afore-described each module and DB can be unified into a unit. However, the module, i.e. the image information unit 210 , the image storing unit 220 , and the image classifying unit 230 can be separated, respectively. For example, the image information unit 210 may be achieved by a camcorder, the image storing unit 220 may be achieved by a separate storing unit, and each of the image classifying module 230 , the registered image DB 240 , and the person image DB 150 may be achieved by either a separate unit or software installed in the computer.
In the meantime, the inventive apparatus can be designed to classify the image based on the reference of the mountain, the sea, the river, or the like, other than the facial image. The classification reference can be varied depending on the design.
FIG. 3 is a flowchart illustrating a method for photographing and classifying the facial image according to an exemplary embodiment of the present invention. Referring to FIG. 3 , the facial image is photographed by using the camera S 310 . Then, the image selecting unit 222 selects and extracts the photographed facial image and the predetermined number of preview images photographed before and after the photographing time point S 320 . The image detecting unit 223 detects the face area from the facial image, and the image tracking unit 224 tracks the movement of the face area in the detected face area S 330 . In this step, when the facial images include a plurality of people, a plurality of face areas can be separately detected and tracked. Alternatively, the plurality of face can be classified into a group.
In the meantime, the facial image classification basis information collecting unit 215 collects the respective facial image classification basis information in the detected and tracked face areas S 340 . The facial image classification basis information is basis information for classifying the facial images for each corresponding person. Next, the facial image and the preview images selected by the image selecting unit 222 , and the facial image classification basis information collected by the facial image classification basis information collecting unit 215 , are stored in the image storing module 220 S 350 . Then, the facial image classification basis information is compared with the information extracted from the registered facial image previously registered in the DB 240 , so that the selected facial image is recognized S 360 . Consequently, it is determined that the facial image recognized in the image recognizing unit 231 belongs to which registered facial image among the facial images previously registered in the registered image DB 240 S 370 . If the selected facial image has been previously registered, the image classifying unit 232 classifies the selected facial image as the facial image of the registered facial image, then stores the classified facial image to the facial image DB 150 S 380 . However, if the selected facial image has not been previously registered, the image classifying unit 232 classifies the selected facial image as the non-classified facial image, so as to store the non-classified facial image to the facial image DB 150 S 385 as a new entry.
As seen above, the present invention is effective in removing errors in recognition and classification of the photographed image, and in accurately classifying the photographed image according to a predetermined reference scheme. Especially, even though the non-front facial image with various angles due to the natural movement is photographed, the person can be accurately recognized and classified by the facial image classification basis information extracted from the facial image of the photographing time point and the preview images photographed before and after the photographing time point. Further, even if the user has registered a small number of facial images for recognizing the face, simulation can be performed based on the facial image classification basis information extracted from the photographed image and the predetermined number of preview images photographed before and after the photographing time point and stored together with the photographed image. Therefore, the system and method for photographing an image and classifying the image according to the present invention can increase the recognition rate of the face shape and the accuracy of the classification, as if the recognition were performed with a lot of registered facial images.
As described above, the input method, the configuration of the apparatus, and its action in the mobile communication terminal having the touch screen can be implemented according to the exemplary embodiment of the present invention. While the invention has been shown and described with reference to certain exemplary 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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Disclosed is an apparatus for photographing an image using a digital camera capable of providing a preview image, including: an image sensor for capturing an image of a subject; a first image signal processor for processing at least one captured image as a sequent image in order to display the captured image as a preview image on a display window and detecting a face area from the captured image; a buffer for storing the image including at least one detected face area; a capture button for capturing a still image during outputting the sequent image as the preview image on the display window; a second image signal processor for processing the captured still image using the capture button; a controller for controlling to store the captured still image and information related on the face area detected from the first image signal processor prior to the input of the capture button; and a memory for storing the processed still image together with the information related on the detected face area.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the right of priority under 35 U.S.C. §120, as authorized by 35 U.S.C. §365(c), to International Application No. PCT/JP2004/008991, filed on Jun. 25, 2004 by the same inventor (published under PCT Article 21(2) in Japanese and not English), which is incorporated herein by reference in it's entirety.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a medical image management system and a medical image management method. The present invention particularly relates to a medical image management system and a medical image management method that can add indices to the recorded medical movies according to the physiological data of a surgeon who performs medical treatment on a patient.
2. Description of the Related Art
Conventionally, movies of a surgery are captured by surgical cameras such as endoscopes and microscopes for ophthalmic surgeries. The in-vivo images are displayed on a screen of an output device while recorded in a recording medium as movie information. The movie of the medical treatment (medical movie) is recorded and saved for helping to recall important events during a surgery more vividly and accurately than other events among many surgical records.
Recently, a device capable of capturing still-image information (still image) from the recorded movie information (movie) during a surgery has been developed. When an event of high importance occurs, a person who performs medical treatment captures still images by operating some recording device.
The invention disclosed in Japanese Publication No. 2002-58641 includes a foot switch to be used for a surgeon to efficiently capture still images during a surgery. The surgeons can easily and efficiently capture the still images during their surgery by operating the foot switch with their foot.
The above-mentioned invention enables a surgeon to sample still images without any interruption during a surgery because they can capture desired still images by using the foot switch.
While the foot switch enables the surgeon to capture the desired still-images, if the surgeon forgets to operate the foot switch, the images cannot be obtained. Moreover, unless the surgeon decides to capture still images, nothing will be obtained.
The above-mentioned device for capturing still images depends on the surgeon's will whether to capture still images. However, the surgeon concentrating his attention to a surgery tends to forget to operate a footswitch or the like to capture still images.
The conventional imaging devices are not helpful in knowing how surgeons react to a specific situation.
Particularly, it is difficult to direct his attention to capturing still images with the conventional method while performing medical treatment, especially during such a stressful event that it causes changes in the physiological data of the surgeon.
It is also significantly difficult to tell stressful situations for an inexperienced surgeon. It is also difficult to tell what medical event makes him confused. Thus, he does not understand what stressful situation he will meet in a surgery room until he is involved in actual medical treatment.
Considering the above, there has been a need for a medical image management system configured to capture still images not depending on the surgeon's will but on the surgeons' physiological data corresponding to his stress level.
Furthermore, when the physiological conditions of the surgeons are measured, the resultant physiological data usually has non-linear changes rather than linear-changes in chronological order. Therefore, it is difficult to use the physiological data to make an accurate decision about when the surgeons become nervous.
The present invention relates to a medical image management system and a medical image management method that are capable of adding indices to a recorded medical movie according to the changes in the physiological data of a person who performs medical treatment.
SUMMARY OF INVENTION
According to the present invention, there is provided a medical image management system comprising: a medical imaging device configured to capture a medical movie of a patient who receives medical treatment, the medical movie consisting of a plurality of still images; a recording means configured to record the movie captured with the medical imaging device, wherein the medical image management system further includes: a measurement means configured to measure physiological conditions of a surgeon who performs medical treatment on the patient and to obtain physiological data; and an indexing means configured to add indices to the medical movie recorded by the recording means.
In one embodiment of the present invention, the indexing means comprises: a data receiving means configured to receive the physiological data from the measurement means; a comparison means configured to compare the physiological data received by the data receiving means with a predetermined threshold, and a first sampling means configured to sample still-image information from the movie if the first comparison means detects that the physiological data exceeds the threshold, wherein the still-image information is sampled by the first sampling means from a still image of the moment when the physiological data exceeds the threshold.
In one embodiment of the present invention, the indexing means further comprises a first start-and-end-index-recording means configured to record the still-image information sampled by the first sampling means as start-index information of the medical movie in the recording means, wherein, if the first comparison means detects that the physiological data falls below the threshold after the first sampling means samples the still-image information, the first start-and-end-index-recording means samples still-image information from the medical movie recorded in the recording means and records the still-image information as end-index information of the medical movie in the recording means, wherein the still-image information is sampled by the first start-and-end-index-recording means from a still image of the moment when the physiological data falls below the threshold.
In one embodiment of the present invention, the indexing means includes: a data receiving means configured to receive physiological data obtained by the measurement means; a physiological-data-saving means configured to save the physiological data received by the data receiving means in chronological order; a difference-value-calculating means configured to calculate a chronological difference-value based on adjacent two of the physiological data saved in the physiological-data-saving means; a second comparison means configured to compare the difference-value calculated by the difference-value-calculating means with a predetermined difference-value; and a second sampling means configured to sample still-image information from the medical movie if the second comparison means detects that the calculated difference-value exceeds the predetermined difference-value, wherein the still-image information is sampled by the second sampling means from a still image of the moment when the older physiological data of the adjacent two of physiological data that are used to calculate the difference-value.
In one embodiment of the present invention, the indexing means further comprises a second start-and-end-index-recording means configured to record the still-image information sampled by the second sampling means as start-index information of the medical movie in the recording means, wherein, if the second comparison means detects that the physiological data falls below the threshold after the second sampling means samples the still-image information, the second start-and-end-index-recording means ( 58 ) samples still-image information from the medical movie recorded in the recording means and records the still-image information as end-index-information of the medical movie in the recording means, and wherein the still-image information is sampled by the second start-and-end-index-recording means from a still image of the moment when the physiological data falls below the threshold.
In one embodiment of the present invention, the medical image management system further comprises an index-adjusting means configured to shift back the start-index information by a predetermined time length and to shift forward the end-index information by a predetermined time length.
In one embodiment of the present invention, still-image information to be recorded as the start-index information and/or after the end-index information is continuously sampled for a predetermined time length before and/or the first sampling means and the second sampling means ( 58 ) samples the still-image information.
In one embodiment of the present invention, the medical movie and/or the still-images saved in the recording means from when the start-index information is sampled and recorded in the recording means ( 4 ) to when the end-index information is sampled and recorded in the recording means.
In one embodiment of the present invention, the medical image management system further includes: a separating means configured to separate a plurality of chronologically-ordered still images from the medical movie recorded in the recording means; a calculating means configured to calculate coordinate values in a color space of each still image that is separated by the separating means; a selecting means configured to select adjacent two of the still images if the difference between the coordinate values of the two still images exceeds a predetermined threshold, an adding means configured to add image difference information to each of the still images selected by the selecting means.
In one embodiment of the present invention, the medical image management system further comprises an output means comprising: a first display configured to display the medical movie captured with the medical imaging device; and a second display configured to display the still images sampled by the first sampling means and the second sampling means.
In one embodiment of the present invention, the measurement means is configured to measure at least one physiological parameter selected from a group consisting of the surgeon's heart beat, blood pressure, sweat production, body temperature, electroencephalogram, grip strength, point of gaze, blink, pupil, eye movement, respiratory rate (including apneic period), pneumogram, number of swallowing, skin electric conductance, electric potential difference of muscle, neurotransmitter level, blood glucose level, blood flow rate, blood composition, amount of various hormones, chewing pressure, electrocardiogram, galvanic skin reflex, fingertip pulse wave, posture or position, tear production, tear composition, saliva production, saliva composition, gastric secretion, gastric fluid composition, facial expression (measurement in characteristic analysis), vocal change (measurement in characteristic analysis), lip reading (measurement in characteristic analysis), limb shivering, urine (protein level, sugar level, occult blood level).
In one embodiment of the present invention, all of the physiological data obtained by the measurement means is recorded in the recording means together with the medical movie that chronologically corresponds to the physiological data.
In one embodiment of the present invention, the medical image management system is further configured to select movies to which a larger number of the indices are added from the plurality of medical movies recorded in the recording means, and to carry out a predetermined process on the selected medical movies.
In one embodiment of the present invention, the medical image management further includes a manual indexing means configured to enable the surgeon to add indices to the medical movies.
According to the present invention, there is further provided a medical image management method of producing a medical movie of a patient who receives medical treatment and of managing the medical movie, the method including steps of: recording the medical movies while obtaining physiological data of a surgeon; and adding indices to the medical movie according to the physiological data of the surgeon.
In one embodiment of the present invention, the indices are added to the medical movies according to a comparison between the obtained physiological data and a threshold or according to a chronological change in the obtained physiological data.
In one embodiment of the present invention, the step of adding indices includes a step of sampling still-image information of still images contained in the medical movie.
In one embodiment of the present invention, the medical movie management method further includes steps of: calculating the moments to start sampling and to stop sampling the medical movie based on two of the sampled still-image information; and sampling and recording the medical movie or still images contained in the medical movie captured between the calculated moments.
In one embodiment of the present invention, the medical image management method further includes a step of simultaneously displaying the medical movie captured by the medical imaging device and the medical movie sampled according to the physiological data of the surgeon.
In one embodiment of the present invention, the physiological data of the surgeon includes at least one parameter selected from a group consisting of the surgeon's heart beat, blood pressure, sweat production, body temperature, electroencephalogram, grip strength, point of gaze, blink, pupil, eye movement, respiratory rate (including apneic period), pneumogram, number of swallowing, skin electric conductance, electric potential difference of muscle, neurotransmitter level, blood glucose level, blood flow rate, blood composition, amount of various hormones, chewing pressure, electrocardiogram, galvanic skin reflex, fingertip pulse wave, posture or position, tear production, tear composition, saliva production, saliva composition, gastric secretion, gastric fluid composition, facial expression (measurement in characteristic analysis), vocal change (measurement in characteristic analysis), lip reading (measurement in characteristic analysis), limb shivering, urine (protein level, sugar level, occult blood level).
In one embodiment of the present invention, information about events that occur during medical treatment is saved in the medical movies.
In one embodiment of the present invention, the medical image management method further includes a step of selecting a certain medical movie depending on the total number of the indices added to the medical movie.
In one embodiment of the present invention, the medical image management method further includes a step of adding indices to the medical movies according to the operation by the surgeon.
According to one embodiment of the present invention, the medical image management system adds indices to a medical movie according to changes in the physiological data of a surgeon who performs the medical treatment on a patient. Using the medical image management system, one can understand the changes in the surgeon's mental condition. For example, the indices added to the movie facilitate to pick up the stressful events for the surgeon. It is also possible to manage data about stressful events for an inexperienced surgeon. Such data can be used to give effective instructions to other surgeons. By using the device, it is further possible to know both important events and stressful events for the surgeon. This helps to provide safe medical treatment on patients and to improve the rate of successful treatment.
According to another embodiment of the present invention, the medical image management system adds indices to the medical movie if the obtained physiological data exceeds a predetermined threshold.
According to another embodiment of the present invention, the medical image management system provides the recorded medical movie with start indices and end indices that indicate supposedly important scenes of the medical treatment.
According to another embodiment of the present invention, the medical image management system uses chronological difference values to accurately detect changes in the physiological data and to add indices to the medical movie according to the detected changes.
According to another embodiment of the present invention, the medical image management system provides the recorded medical movie with start indices and end indices that indicate supposedly important scenes of the medical treatment.
According to another embodiment of the present invention, the medical image management system appropriately shifts indices to play a medical movie having an appropriate time length.
According to another embodiment of the present invention, the medical image management system samples a medical movie or a group of still images as start-index information and end-index information.
According to another embodiment of the present invention, the medical image management system saves a medical movie or a group of still images showing the important scenes of the medical treatment in the recording means ( 4 ) using the index information.
According to another embodiment of the present invention, the medical image management system detects changes in the still images contained in the medical movie by using coordinate values in color spaces of the still images.
According to another embodiment of the present invention, the medical image management system includes a first display (A) and a second display (C) so that the user can view the medical movies and the still images sampled from the medical movies.
According to another embodiment of the present invention, the medical image management system uses data of surgeon's heart beat, blood pressure, sweat production, body temperature, electroencephalogram, grip strength, point of gaze, blink, pupil, eye movement, respiratory rate (including apneic period), pneumogram, number of swallowing, skin electric conductance, electric potential difference of muscle, neurotransmitter level, blood glucose level, blood flow rate, blood composition, amount of various hormones, chewing pressure, electrocardiogram, galvanic skin reflex, fingertip pulse wave, posture or position, tear production, tear composition, saliva production, saliva composition, gastric secretion, gastric fluid composition, facial expression (measurement in characteristic analysis), vocal change (measurement in characteristic analysis), lip reading (measurement in characteristic analysis), limb shivering, urine (protein level, sugar level, occult blood level) to effectively estimate the physiological condition of the surgeon and to add index information to the medical movie.
According to another embodiment of the present invention, the medical image management system efficiently records and saves the medical movie based on various kinds of physiological data.
According to another embodiment of the present invention, the medical image management system prioritize medical movies based on the indices added to each medical movie. After being given priority, the medical movies are subjected to different processes according to their level of priority.
According to another embodiment of the present invention, the medical image management system enables the surgeon to sample medical images including still images and movies. Thus, both medical images sampled by the medical image management system and the medical movies sampled by the surgeon can be used to examine the importance of various scenes of the medical movie from different points of view.
According to another embodiment of the medical treatment method of the present invention, it is possible to add indices to a medical movie based on changes in the physiological data of the surgeon who performs the medical treatment on a patient. Using the medical image management method, one can estimate the changes in the surgeon's mental condition. For example, the indices added to the movie facilitate to pick up the stressful events for the surgeon. It is also possible to manage data about stressful events for an inexperienced surgeon. Such data can be used to give effective instructions to other surgeons. By using the device, it is further possible to know both important events and stressful events for the surgeon. This helps to provide safe medical treatment on patients and to improve the rate of successful treatment.
According to another embodiment of the medical image management method of the present invention, it is possible to add effective indices to the medical movie based on changes in the difference value of the physiological data.
According to another embodiment of the medical image management method of the present invention, what is sampled as indices are not the still images but the information (still image information) about the still images. This helps to reduce memory size engaged in the management of the medical images.
According to another embodiment of the medical image management method of the present invention, it is possible to sample a medical movie or still images from the medical movie showing the scenes that the user considers important by using still image information.
According to another embodiment of the medical image management method of the present invention, as a medical movie and still images to which indices are added are displayed simultaneously, the user can easily manage the medical images.
According to another embodiment of the medical image management method of the present invention, it is possible to effectively estimate the physiological condition of the surgeon and to add index information to the medical movie by using the data of surgeon's heart beat, blood pressure, sweat production, body temperature, electroencephalogram, grip strength, point of gaze, blink, pupil, eye movement, respiratory rate (including apneic period), pneumogram, number of swallowing, skin electric conductance, electric potential difference of muscle, neurotransmitter level, blood glucose level, blood flow rate, blood composition, amount of various hormones, chewing pressure, electrocardiogram, galvanic skin reflex, fingertip pulse wave, posture or position, tear production, tear composition, saliva production, saliva composition, gastric secretion, gastric fluid composition, facial expression (measurement in characteristic analysis), vocal change (measurement in characteristic analysis), lip reading (measurement in characteristic analysis), limb shivering, urine (protein level, sugar level, occult blood level).
According to another embodiment of the medical image management method of the present invention, it is possible to record information about the events that occur during the medical treatment, such as information about when the surgeon or medical personnel enters and leaves the room in which the medical treatment is carried out.
According to another embodiment of the medical image management method of the present invention, it is possible to prioritize the medical movies based on the indices added to each medical movie. After the prioritization, the medical movies are subjected to different processes according to their priority level.
According to another embodiment of the medical image management method of the present invention, the surgeon can sample medical images (i.e. still images and movies). Thus, both medical images sampled by the medical image management system and the medical images sampled by the surgeon can be used to examine the importance of various scenes of the medical movie from different points of view.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the medical image management system of the present invention will be described below referring to the accompanying drawings.
FIG. 1 is a view illustrating the medical treatment using the present invention.
FIG. 2 is a block diagram illustrating the configuration of the medical image management device of the present invention.
FIG. 3 is a block diagram illustrating the first indexing method.
FIG. 4 is a graph showing the moment when the still-image information is sampled based on the physiological data.
FIG. 5 is a block diagram illustrating the second indexing method.
FIG. 6 is a graph showing the moment when the still-image information is sampled based on the physiological data.
FIG. 7 is view illustrating the methods of using auxiliary indices to add index information to the medical movie.
FIG. 8 is a graph showing the moment when the still-image information is sampled based on the physiological data.
FIG. 9 is a block diagram illustrating the configuration for separating still images from the medical movie.
FIG. 10 is a view illustrating one embodiment of the display included in the output means.
FIG. 11 is a view illustrating one embodiment of the display included in the output means.
FIG. 12 is a view illustrating one embodiment of the display included in the output means. The display shows a graph of physiological data.
FIG. 13 is a flowchart illustrating the first indexing method.
FIG. 14 is a flowchart illustrating the second indexing method.
FIG. 15 is a flowchart illustrating the method of managing medical movies.
DESCRIPTION OF THE INVENTION
The term “surgeon” used herein refers to a person who performs medical treatment on a patient. Surgeons include any persons who are concerned in a surgery, such as persons who partake in a surgery (e.g. surgeons and anesthesists), persons who help the surgeon, nurses, and pharmacists, but not limited to these. In the description below, examples where one surgeon is involved are explained but the number of the surgeons is not particularly limited. If several surgeons are involved in a surgery, the physiological data of all of the surgeons is preferably obtained.
The term “physiological data” refers to data obtained by measuring at least one physiological parameter selected from a group consisting of surgeon's heart beat, blood pressure, sweat production, body temperature, electroencephalogram, grip strength, point of gaze, blink, pupil, eye movement, respiratory rate (including apneic period), pneumogram, number of swallowing, skin electric conductance, electric potential difference of muscle, neurotransmitter level, blood glucose level, blood flow rate, blood composition, amount of various hormones, chewing pressure, electrocardiogram, galvanic skin reflex, fingertip pulse wave, posture or position, tear production, tear composition, saliva production, saliva composition, gastric secretion, gastric fluid composition, facial expression (measurement in characteristic analysis), vocal change (measurement in characteristic analysis), lip reading (measurement in characteristic analysis), limb shivering, and urine (protein level, sugar level, occult blood level). The chronological changes in these physiological data are recorded with a measurement means described below.
The term “Measurements in a characteristic analysis” refers to the amount of chronological changes (difference value) in the physiological data. The change in this difference value represents the characteristics of the physiological data.
The medical image management system and the medical image management method of the present invention collect the physiological data from the surgeon. Preferably, physiological data of a patient is measured in addition to that of the surgeon. If there are several patients involved in the medical treatment, physiological data of all the patients is preferably collected.
The medial image management system ( 1 ) of the present invention includes a management unit ( 6 ). The management unit ( 6 ) includes a medical imaging device ( 2 ), a measurement means ( 3 ), a recording means ( 4 ), and an indexing means ( 5 ) (See FIG. 2 ).
The medical imaging device ( 2 ) includes, for example, an imaging device configured to capture a movie of medical treatment performed by the surgeon and an imaging device configured to capture a movie of the patient's body site subjected to the medical treatment. These medical imaging devices are preferably used for the present invention. The medical device ( 2 ) includes analog or digital medical imaging devices such as surgical microscopes and cameras configured to capture an operative field.
The measurement means ( 3 ) is used for measuring physiological conditions and for sending the data about the physiological conditions to the management unit ( 6 ) described below. The measurement means ( 3 ) is attached to the surgeon's body during the use. The measurement means ( 3 ) is designed not to disturb the surgeon's medical treatment.
The measurement means ( 3 ) shown in FIG. 1 includes measuring parts ( 31 ) configured to measure the surgeon's electroencephalogram and his blood pressure. After measuring the electroencephalogram and the blood pressure, the measuring parts ( 31 ) send these physiological data to a sending part (sender) ( 32 ). In the example of FIG. 1 , the sending part ( 32 ) sends these information to the management unit ( 6 ) using a radio system. However, the physiological data may be transmitted to the management unit ( 6 ) through any radio communication or any wired communication.
Any transmission mode may be also used as long as it does not disturb the surgeon. The measurement means ( 3 ) may be equipped elsewhere than the surgeon's body. In this case, any measuring instrument that accurately measures the physiological conditions is applicable.
The management unit ( 6 ) is comprised of a recording means ( 4 ) and an indexing means ( 5 ) described below. The management unit ( 6 ) may be a common commercial computer that includes an input device (e.g. a keyboard and a mouse); an arithmetic unit configured to perform calculations (e.g. addition, subtraction, multiplication and division) and comparison; a memory unit configured to temporarily save the calculation results; a display unit configured to displaying medical movies and medical still images; a control unit configured to control these units. These functionalities are helpful in performing the processes described below.
The recording means ( 4 ) in the management unit ( 6 ) may be either an internal main memory or an external memory. The recording means ( 4 ) receives and records therein the medical movies captured by the medical imaging device ( 2 ). The medical movies are recorded together with information about the time when the movies are recorded.
The indexing means ( 5 ) in the management unit ( 6 ) performs the following processes. The indexing means ( 5 ) adds indices to the medical movies recorded in the recording means ( 4 ) according to the physiological data obtained by the measurement means ( 3 ). The indices are recorded in the recording means ( 4 ) together with the medical movies.
Methods of adding indices to the medical movie with the indexing means ( 5 ) are described below.
Firstly, the first indexing method is described.
The indexing means ( 5 ) configured to perform the first indexing method includes a data-receiving means ( 51 ), a first comparison means ( 52 ), a first sampling means ( 53 ), and a first start-and-end-index-recording means (receiver) ( 54 ) (See FIG. 3 ).
The data-receiving means ( 51 ) receives the physiological data from the measurement means ( 2 ) successively and in chronological order.
The first comparison means (comparator) ( 52 ) compares the physiological data received by the data-receiving means ( 51 ) with a predetermined threshold. The user may arbitrarily set any threshold and vary the set threshold depending on the physiological condition measured by the measurement means ( 3 ). The threshold is adjusted so that physiological data exceeding the threshold should indicate an unusual state. For example, for a surgeon having a usual heart rate of 60 beats per minute, the threshold may be set as 100 beats per minute. In this case, a heart rate more than 100 beats per minute is considered as an unusual state. The threshold may be set as a value (usual value+α) that is slightly higher than the usual value. The usual value is previously calculated about the usual state of the surgeon in his daily life. Alternatively, the threshold may be equivalent to the physiological data obtained when the surgeon is in an unusual state.
If the physiological data exceeds the threshold, the first comparison means ( 52 ) allows for the first sampling means ( 53 ) (described below) to be activated. On the other hand, if the physiological data is below the threshold, the first comparison means ( 52 ) compares the next physiological data with the threshold.
If the first comparison means ( 52 ) detects that the physiological data is above the threshold, the first sampling means ( 53 ) samples still image information from the medical movie recorded in the recording means ( 4 ). First, the first comparison means ( 52 ) detects a physiological data that is above the threshold. At the same time, the first sampling means identifies the still image using the time information indicating the time when the physiological data exceeds the threshold. Once the still image is identified, the first sampling means ( 53 ) identifies still image information of this still image. The still image information includes, for example, the time information, index information, the address information, and the position information indicating where the still image is located in the medical movie. Although it is possible to sample the still images themselves, only the still image information is preferably sampled from the medical movie, considering the data volume of the still images and the fact that the medical movie which the still images belong to is recorded in the recording means ( 4 ).
The first start-and-end-index-recording means ( 54 ) records the still-image information sampled by the first sampling means ( 53 ) in the recording means ( 4 ) as start-index information of the medical movie. Further, if the first comparison means ( 52 ) detects that the physiological data is below the threshold after the first sampling means ( 53 ) samples the still-image information, the first start-and-end-index-recording means ( 54 ) enables the first sampling means ( 53 ) to sample still-image information from the medical movie recorded in the recording means ( 4 ). The first start-and-end-index-recording means ( 54 ) then records the still-images in the recording means ( 4 ) as end-index information of the medical movie. In this process, the still image information is sampled by the first start-and-end-index-recording means ( 54 ) from the still image of the moment when the physiological data falls below the threshold.
The first start-and-end-index-recording means ( 54 ) is designed to stay in the idling mode even if it receives an instruction to sample still-image information from the first comparison means ( 52 ), after the first sampling means ( 53 ) sampled still image information. Thus, the first sampling means ( 53 ) samples the still-image information of the moment when the physiological data exceeds or falls below the threshold (i.e. the moments when the chronological change curve intersects the threshold line).
For example, in the chronological change as shown in FIG. 4 , the physiological data first exceeds the threshold (x) at the moment A 1 . At the moment A 1 , the first comparison means ( 52 ) sends the first sampling means ( 53 ) an instruction to sample still-image information. Thus the still-image information of the moment A 1 is sampled. The first start-and-end-index-recording means ( 54 ) records the still-image information as the start-index information. Then, at the moment A 2 , the first comparison means ( 52 ) sends the first sampling means ( 53 ) an instruction to sample still-image information. Because the first sampling means ( 53 ) is in the idling mode, the first sampling means ( 53 ) ignores the instruction from the first comparison means ( 53 ). Then at the moment A 3 , the first comparison means ( 52 ) detects that the physiological data falls below the threshold (x) after the physiological data exceeds the threshold. The first comparison means ( 52 ) then urges the first sampling means ( 53 ) to sample still image information. The first start-and-end-index-recording means ( 54 ) records the still-image information sampled by the first sampling means ( 53 ) as the end-index information. During the time between the moments A 1 to A 3 , the first sampling means is in the idling mode.
In this way, the still-image information sampled from the still image of the moment A 1 is recorded as the start-index information while the still-image information sampled from the still image of the moment A 3 is recorded as the end-index information. Therefore, the time between A 1 to A 3 is marked as an important scene in the surgery based on the physiological data of the surgeon.
Next, the second indexing method is explained (See FIG. 5 ).
The indexing means ( 5 ) configured to perform the second indexing method includes a data-receiving means ( 51 ), a physiological-data-saving means ( 55 ), a difference-value-calculating means ( 56 ), a second comparison means ( 57 ), a second sampling means ( 58 ), and a second start-and-end-index-recording means ( 59 ).
The data-receiving means ( 51 ) receives the physiological data obtained by the measurement means ( 3 ) as described above. The physiological-data-saving means ( 55 ) saves the chronologically ordered physiological data received by the data-receiving means ( 51 ). Common recording devices may be used as the physiological-data saving means ( 55 ). The physiological data are saved in the physiological-data-saving means ( 55 ) successively and in chronological order. The difference-value-calculating means ( 56 ) calculates the chronological difference-value between two adjacent physiological data saved in the physiological-data-saving means ( 55 ). The time interval between the two adjacent physiological data is preferably 0.1 to 0.2 seconds, and more preferably 0.01 to 0.02 seconds, but may be set as other intervals that are appropriate for calculating difference values useful for accurately estimating changes in the physiological data. The difference value calculated by the difference-value-calculating means ( 56 ) may be the average value of the two data. The second comparison means ( 57 ) compares the difference-value calculated by the difference-value-calculating means ( 56 ) with a predetermined threshold. The predetermined threshold may be, for example, the average value calculated for older set of data. In this way, the threshold and the physiological data are compared.
If the second comparison means ( 57 ) detects that the difference-value is above the predetermined threshold, the second sampling means ( 58 ) samples still-image information of the moment (referred to below as “first sampling moment”) when the older physiological data of the two physiological data that are used to calculate the difference-value is measured. The second sampling means ( 58 ) samples still-image information from the medical movie in a basically similar manner to the first sampling means ( 53 ). The difference between the second sampling means ( 58 ) and the first sampling means ( 53 ) is that the second sampling means ( 58 ) samples the still-image information of the “first sampling moment”.
The second start-and-end-index-recording means ( 59 ) records the still-image information sampled by the second sampling means ( 58 ) in the recording means ( 4 ) as the start-index information of the medical images.
On the other hand, if the second comparison means ( 57 ) detects that the difference value is below the threshold after the second sampling means ( 58 ) samples still-image information, the second start-and-end-index-recording means ( 59 ) samples still-image information of the moment (“second sampling moment”) when the newer physiological data of the two physiological data that are used to calculate the difference value is measured The still-image information sampled by the second start-and-end-index-recording means ( 59 ) is then recorded in the recording means ( 4 ).
The second start-and-end-index-recording means ( 59 ) adds the start-index information and the end-index information to the medical movies in a similar manner to the first start-and-end-index-recording means ( 54 ). The difference between the first and the second start-and-end-index-recording means ( 54 ) and ( 59 ) is that the second start-and-end-index-recording means ( 59 ) samples the still image information contained in the still image of the “first sampling moment” as the start-index information and the still image information contained in the still image of the “second sampling moment” as the end index information. For example, if the change as shown in FIG. 6 occurs in the physiological data graph, the data-receiving means ( 51 ) receives physiological data at each of the moment B 1 , B 2 , B 3 , B 4 , and B 5 , and sends the physiological data to the physiological-data-saving means ( 55 ). The physiological-data-saving means ( 55 ) records therein the physiological data sent from the data-receiving means ( 51 ) and sends the recorded data to the difference-value-calculating means ( 56 ). The difference-value-calculating means ( 56 ) calculates the difference value for each time interval defined by adjacent two of B 1 to B 5 . Firstly, the average value of the physiological data between the moment B 1 and the moment B 2 is calculated. The average value is referred to as the first average value or the former average value.
Next, the difference-value-calculating means ( 56 ) calculates the average value of the physiological data between the moment B 2 and the moment B 3 . The average value is referred to as the second average value or the latter average value. The second comparison means ( 57 ) compares the first average value and the second average value.
If the second average value is greater than the first average value and if the difference between the second and the first average value is greater than a predetermined threshold, the second sampling means ( 58 ) is urged to be activated. The threshold may be set by the user as any value. Also, the predetermined threshold may be adjusted depending on the type of the physiological data or the surgeon subjected to the physiological measurement.
The above-described process is repeated for each time interval. In the example shown, the second difference value between the moment B 2 and the moment B 3 is significantly different from the first difference value of the moment B 1 and the moment B 2 . Therefore, the second sampling means ( 58 ) samples from the medical movie the still image information of the “first sampling moment”. In this example, the still-image information at the moment B 2 is sampled. The sampled still-image information is recorded in the recording means ( 4 ) as the start-index information.
Furthermore, the second start-and-end-index-recording means ( 59 ) obtains the end-index information. First, the difference-value-calculating means ( 56 ) calculates difference value (the third average value) between the moment B 3 and the moment B 4 as well as the difference value (the fourth average value) between the moment B 4 and the moment B 5 . Then the second comparison means ( 57 ) compares the third average value and the fourth average value. Detecting a significant difference between these values, the second comparison means ( 57 ) sends the second sampling means ( 58 ) an instruction to sample still-image information. The still-image of the “second sampling moment” (the moment B 4 in this example) is recorded in the recording means ( 4 ) as the end-index information. If the interval between B 1 and B 5 shown in FIG. 6 is shortened, it is possible to detect smaller changes in the physiological data, as well as to add a start-index and an end-index to the medical movie whenever these changes are detected.
The physiological data is saved in the physiological-data-saving means ( 55 ). In another embodiment, the physiological data previously saved in the physiological-data-saving means ( 55 ) may be used to calculate the start time and the end time of the changes in the physiological data. For example, if it is detected that one of the physiological data is above the predetermined threshold, the wave form of this physiological data is plotted (i.e. changes in this physiological data is monitored). Algorithms (e.g. genetic algorithm, neural network and fuzzy logic) for obtaining optimal solutions may be used to calculate the start time at which the physiological data start to deviate from the usual range and the end time at which the physiological data returns to the usual range. The data between the start time and the end time of one change is handled as one group of the physiological data. Among the groups of the physiological data saved in the physiological-data-saving means ( 55 ), a data group having unique characteristics is specified to detect changes in the physiological data.
In the first and second indexing method, an index-adjusting means ( 60 ) may be preferably used. The index-adjusting means ( 60 ) shifts back (with respect to the time vector) the start-index information by a predetermined time length and shifts forward the end-index information by a predetermined time length. Thus, when the user views the medical movie, the medical movie starts from the moment that is earlier than the start of a change in physiological data by a certain time length and ends at the moment that is later than the end of the change by a certain time length. The time length is not particularly limited but the user may choose any time length. If the start-index information and/or the end-index information are adjusted by the index-adjusting means ( 60 ), the adjusted index information is added to the medical movie and recorded in the recording means ( 4 ) together with the medical movie.
In another embodiment, still image information from a plurality of still images may be sampled as the start-index information and the end index information. Those still images from which the still image information is sampled include the still image of the moment when the comparison means ( 4 ) sends an instruction to sample still image information as well as several still images before and/or after that still image. In the examples described above, the index information is the still image information of one moment and the still image information indicates one moment. In the present example, the still image information is sampled from the still images corresponding to the time period that starts sometime before the moment when the index information is sampled and ends sometime after the moment when the index information is sampled. Therefore the index information in the present example samples a medical movie of an important scene continuing for a certain time length. For example, as shown in FIG. 7( a ), an auxiliary index is set to the position that is later than the sampled start index by a duration β. All the still images between the start-index information and the auxiliary index are labeled as index information. In an example shown in FIG. 7( c ), one auxiliary index is set to the position that is earlier than the sampled start-index information by a duration γ and another index is set to the position that is later than the sampled start-index information by the duration γ. All the still images between the two auxiliary indices (i.e. the medical movie between the two auxiliary indices) are labeled as index information. End-index information can be set in the same manner as the example shown in FIG. 7 . The user may set the duration β and γ as any duration. FIG. 7( c ) shows the example of the two auxiliary indices that are positioned symmetrically with respect to the start-index information but the auxiliary indices may not be necessarily positioned symmetrically. The index information that is sampled from a plurality of the still images may be recorded in the recording means ( 4 ).
The start-index information and the end-index information sampled by the first sampling means ( 53 ) and the second sampling means ( 58 ) may be used to sample the medical movie recorded between these index information. The still images between the start-index information and the end-index information may be sampled instead of the medical movie. In addition to sampling the medical movie and the still images between the start-index information and the end-index information, it is possible to sample the index information of the start- and the end-index information as well as to sample the index information, address information, time information of all the still images in the time duration. The sampled medical movie or still images, or their index information, address information, and the time information are displayed in the still image window described below.
Preferably, image property information is assigned to each of the sampled index information, the medical movie, and the still images. The image property information is helpful in a quick check on the property of the sampled information.
Preferably, a foot switch (foot-operated switch), a manual switch, a remote controller with manual buttons are available for the surgeon to add the above-described index information to the medical movie. Thus, it is possible to obtain the medical movies in either way, according to the surgeon's will or the physiological data.
As described above, medical image management system ( 1 ) is capable of adding the start-index information and the end-index information to the medical movie according to the changes in the physiological data. The physiological data includes at least one of physiological parameters selected from a group consisting of the surgeon's heart beat, blood pressure, sweat production, body temperature, electroencephalogram, grip strength, point of gaze, blink, pupil, eye movement, respiratory rate (including apneic period), pneumogram, number of swallowing, skin electric conductance, electric potential difference of muscle, neurotransmitter level, blood glucose level, blood flow rate, blood composition, amount of various hormones, chewing pressure, electrocardiogram, galvanic skin reflex, fingertip pulse wave, posture or position, tear production, tear composition, saliva production, saliva composition, gastric secretion, gastric fluid composition, facial expression (measurement in characteristic analysis), vocal change (measurement in characteristic analysis), lip reading (measurement in characteristic analysis), limb shivering, and urine (protein level, sugar level, occult blood level). In some examples as shown in FIG. 8 , several types of index information are assigned to one medical movie. In these examples, each type of index information is compared with the predetermined threshold in order to more accurately sample a medical movie showing an important scene of the medical treatment. In the dotted area shown in FIG. 8 , heart rate, blood pressure, sweat production, body temperature, and electroencephalogram simultaneously have an unusual value. This makes it possible to presume that the medical treatment in this scene is extremely stressful. The relative importance of the scenes constituting the medical treatment can be estimated by obtaining several different types of physiological data and calculating when these different types of physiological data simultaneously record an unusual value.
If data of grip strength is obtained among the physiological data, it is possible to record significant changes in grip strength in the medical movie as the index information. Checking the medical movie sampled by using such index information together with the changes in the grip strength data is helpful in understanding how instruments such as a surgical knife are used.
It is easy to sample a part of the medical movie that captures medical treatment such as skull drilling during a brain surgery by using the changes in grip strength because such medical treatment accompanies comparatively large hand motion and resultant significant changes in grip strength.
In surgeries (e.g. sclerotomy process during an ophthalmic operation using a microscope) that accompany smaller hand motion and resultant insignificant changes in grip strength, the changes in grip strength will not be a sufficient physiological data. In this case, electroencephalogram is used as physiological data in addition to grip strength. Electroencephalogram records muscle movement even in a hand motion that accompanies little change in grip strength. Data of grip strength and electroencephalogram as an auxiliary data cooperatively serve for accurate detection of changes in the physiological condition.
A surgeon with little experience in the medical treatment can study the important scenes in the medical treatment. This results in a effective simulation of the medical treatment so that the inexperienced surgeon can understand what scenes can be stressful before he actually performs the same treatment.
The medical image management system ( 1 ) further includes a separating means ( 61 ), a calculating means ( 62 ), a selecting means ( 63 ), and an adding means ( 64 ) configured to detect changes in the medical movie (See FIG. 9 ). The separating means ( 61 ) separates chronologically-ordered still images from the medical movie recorded in the recording means ( 4 ). The separating means ( 61 ) preferably separates still images from the medical movie at an interval of one frame, though the length of separating interval is not limited to this. Producing one still image per one frame is preferable considering the display device (described below) displays the medical movie frame by frame. In addition, still images produced for every one frame reveal extremely small changes in the medical movie.
The calculating means ( 62 ) calculates coordinate values in color space of each still image separated by the separating means ( 61 ). These coordinate values may be RGB (Red-Green-Blue) value, YUV (PAL-Phase Alternation by Line) value, YCbCr (ITU-R BT.601) value, and XYZ (CIE 1931) value and other values that are useful for detecting a difference in color of the still images.
The selecting means ( 63 ) compares the coordinate values in the color spaces of two chronologically adjacent still images. If the difference in the coordinate values in the color spaces of the adjacent two still images exceeds the predetermined threshold, the selecting means ( 63 ) selects these two still-images. In such comparison by the selecting means ( 63 ), first the still images contained in the medical movie are arranged in a chronological order and then chronologically adjacent still images are compared. A histogram obtained by calculating the coordinate values in the color spaces may be used in the comparison. If a set of coordinate values in color spaces results in a greater difference than a predetermined threshold, the selecting means ( 63 ) selects the still image having with this set of coordinate values. The threshold can be set to any value by a user.
Adding means ( 64 ) adds image-difference information to the still images selected by the selecting means ( 63 ). The image-difference information is added to the medical movie as the index information and recorded in the recording means ( 4 ) like the start-index information and the end-index information. In this way, when the still images are separated from the medical movie, coordinate values in the color space of the separated still images may be used to estimate the difference between the separated still images. The difference between the still images may be compared with the changes in the physiological data.
The medical image management system ( 1 ) of the present invention further includes an output means ( 7 ). As shown in FIG. 10 , the output means ( 7 ) includes a first display (A) and a second display (C). The first display (A) displays the medical movie captured by the medical imaging device ( 2 ). The second display (C) displays the still images from which the first and the second sampling means ( 53 ) and ( 58 ) sample the still-image information. The movie and the still images of the first display (A) and the second display (C) are displayed on the same screen. The output means ( 7 ) further includes an operating portion (B) and a movie display (D) configured to show the medical image saved in the recording means ( 4 ). The screen of the output device is divided into four sections and the four section has the first display (A), the operating portion (B), the second display (C), and the movie display (D), respectively. FIG. 10 shows the first display (A) in the upper left position, the operating portion (B) in the bottom left, the second display (C) in the upper right, and the movie display (D) in the bottom right but the arrangement of these is not limited to this. The arrangement shown in FIG. 10 is preferable to makes it easy to edit the movie on the screen. The resolution of the screen may preferably be ranged from 1024×768 pixels to 1280×1024 pixels considering that all of the first display (A), the operating portion (B), the second display (C), and the movie display (D) are shown in the screen, but the resolution range is not limited to this. In the example of FIG. 10 , above the second display (C) is the patient display (E) configured to display identification information of patients. A converting means (F) is arranged in the bottom of the screen.
The first display (A) shows and plays the medical movie and the still images recorded in the recording means ( 4 ). As the medical movie and the still images captured with the medical imaging device ( 2 ) are played on the first display (A), it preferably has the above-mentioned resolution and is capable of showing screen colors of more than 16 bits or 24 bits. The number of colors is not limited to these but can be selected according to the capacity of the medical imaging device ( 2 ).
In FIG. 11 , the second display (D) (described below) shows a medical movie (medical movie file) that is recorded in the recording means ( 4 ) while the first display (A) shows the beginning of the movie.
The operating portion (B) is used to operate the movie shown in the first display (A). The operating portion (B) is shown in the screen to be directly pointed with a coordinate input device (e.g. a mouse). The operating portion enables operations such as play, stop, rewind, and fast forward, pause, play at fast speed, rewinding play, and switch to another movie (B 1 ). The operating portion (B) facilitates viewing the medical movie. Preferably, the output means ( 7 ) further includes sampling portion (F) configured to sample a still image from the medical movie shown in the first display (A) by using the operating portion (B). The sampling portion (F) is pointed by a coordinate input device such as a mouse to sample a still image from the movie shown in the first display (A). In the figures (e.g. FIG. 11 ) of this embodiment, the sampling portion (F) is arranged between the first display (A) and the second display (C) because the still image is sampled from the movie shown in the first display and shown in the second display (C). However, the sampling portion (F) may be arranged in any position on the same screen of the output device ( 7 ) as the first display (A), the operating portion (B), and the second display (C). FIG. 11 shows a screen of the moment after sampling two still images from the movie files shown in the movie display (D). At this moment, the first display (A) shows one of the still images (the left image as shown in FIG. 11 ) listed in the second display (C). The second display (C) shows the still image with start-index information. If the still-image is selected, the first display runs a movie of the time duration from the time specified by the start-index information to the time specified by the nearest end-index information.
As shown in FIG. 10 , the operating portion (B) includes an auxiliary operating portion (B 3 ) for forwarding or rewinding the movie played (or displayed) in the first display (A) by a predetermined time length. The auxiliary operating portion (B 3 ) is capable of forwarding or rewinding the movie in the first display (A) by a predetermined time length and playing the movie after the forwarding or the rewinding in the first display (A). The auxiliary operating portion (B 3 ) shown in FIG. 10 is capable of forwarding and rewinding by 30 seconds, 15 seconds, one second, and one frame, but the time length is not limited to these. Shorter frame interval is preferable but the user can set any frame interval. If the auxiliary operating portion (B 3 ) is used, the first display shows a still image of a moment some time before/after the moment of the scene previously shown in the still image on the first display (A). If the function “rewinding for one second” is used while playing the movie of the time 1:30, the first display (A) shows the movie (still image) corresponding to the time 1:29. By accurately selecting the time of the movie or the still image to play in the display (A) in this way, desired movie or still image is played in the first display (A).
The second display (C) shows the still image to which the indexing means ( 5 ) added index information or the first still image contained in a sampled medical movie. The still image shown in the second display (C) includes information about the medical movie from which the still image is sampled. The information of the original movie may include information for linking the still image to the original movie. As the still images shown in the second display (C) includes the information about the original movie, the first display (A) shows the corresponding still image contained in the original movie, if the still image shown in the second display (C) is selected with an appropriate coordinate input device. The second display (C) also lists the still image obtained while playing the movie in the first display (A). The second display further includes a still-image-operating-portion (C 1 ) configured to handle the still images listed in the second display (C).
The movie display (D) shows the list of the movies recorded in the recording means ( 4 ) and of the sampled movie obtained according to the index information added by the indexing means ( 5 ). The list shown in the movie display (D) includes index information. Preferably, thumbnail-sized images or otherwise reduced images of the first still images of the movies are displayed in the movie display (D) to facilitate checking the content of each movie. However, the list of the movies may be displayed in other ways. The list shown in the movie display (D) may further include the playing time of each movie.
In the example of FIG. 10 , the movie display (D) includes a movie editing portion (D 1 ) configured to make a selection on the movies (or the movie files) listed in the movie display (D) and to edit the movies. The movie editing portion (D 1 ) enables selecting or deleting some of the movies from the listed movies.
The patient display (E) shows the identification information of the patient appearing in the movie or the still image shown in the first display (A). The identification information may include, though not limited to these, the patient's name, sex, and birth date. If it causes a privacy problem to show such information, the patient display (E) shows no information.
As shown in FIG. 10 , the output means ( 7 ) may include a printing means (G) configured to output a selected still image to a printer that prints out the still image. The output means ( 7 ) may further include a converting means (H) configured to convert the still images (still image files) or the movies (movie files) listed in the second display (C) and the movie display (D) to a given image format. The converting means (H) may convert the movies to common image formats, such as DICOM (Digital Imaging and Communications in Medicine) and JPEG (Joint Photographic Experts Group). The converting means (H) separately includes a DICOM converting means and other converting means (storage converting means). As shown in FIG. 12 , the output means ( 7 ) preferably shows graphs representing the changes in the physiological data synchronously measured with the medical movie shown in the first display (A). If the medical movie and the changes in the physiological data are synchronously displayed, it is possible to review the changes in the physiological data as the medical treatment progresses.
The output means ( 7 ) preferably shows a graph as shown in FIG. 8 . For each physiological parameter, the graph shows the moment when the start-index information and the end-index information are added to the medical movie while the medical movie is recorded. While viewing the screen that simultaneously shows the medical movie and the corresponding physiological data, the user can review the important scenes in the medical treatment.
Preferably, the output means ( 7 ) further shows information measured or obtained by medical devices in a graph showing the chronological changes in the information. The information from the medical devices is preferably displayed synchronously with the medical movie by the output means ( 7 ). Thus the output means ( 7 ) synchronously displays the medical movie, the information from the medical devices, the changes in the physiological data obtained from the surgeon and/or the patients. Such display of the output means ( 7 ) enables the user to easily understand accurate chronological changes.
The configuration and the operation of the medical image management system ( 1 ) have been described above. Next, the medical image management method of the present invention will be described below.
In the medical image management system of the present invention, indices are added to important scenes occurring in the medical movie that is captured by the medical imaging device ( 2 ) according to the changes in the physiological data of the surgeon and the patient during the medical treatment. After the medical treatment finishes, the indices are used to facilitate viewing the important scenes occurring in the medical treatment.
FIG. 13 shows a flow chart representing the first indexing method. The medical imaging device ( 2 ) captures a medical movie showing the medical treatment (S 1 ). At the same time, the measurement means ( 3 ) measures the physiological condition of the surgeon and the patient to obtain their physiological data (S 2 ). If the first indexing method is used, the data-receiving means ( 51 ) receives the physiological data, and the first comparison means ( 52 ) compares the physiological data with the predetermined threshold (S 3 ). When the comparison means ( 52 ) detects that the physiological data is above the threshold, the first sampling means ( 53 ) samples still image information from the medical movie as the start-index information (S 4 ). The still-image information is sampled from the still image of the moment when the physiological data exceeds the threshold. When the physiological data falls below the threshold again, the first sampling means ( 53 ) samples still image information from the medical movie as the end-index information (S 5 ). The still-image information is sampled from the still image of the moment when the physiological data falls below the threshold. The steps (S 2 ) to (S 5 ) repeat during the medical treatment. The index information is generated for each physiological data obtained. The index information is added to the medical movie and recorded in the recording means ( 4 ) (S 6 ).
As shown in FIG. 14 , if the second indexing method is used, the medical imaging device ( 2 ) captures a medical movie (S 11 ) and the measurement means ( 2 ) obtains physiological data (S 12 ).
The data receiving means ( 51 ) receives the measured physiological data and the physiological-data-saving means ( 55 ) saves the physiological data in chronological order (S 13 ).
Using the chronologically ordered physiological data saved in the physiological-data-saving means ( 55 ), the difference-value-calculating means ( 56 ) calculates the difference value at a predetermined time interval (S 14 ).
When the second comparison means ( 57 ) detects that the calculated difference value exceeds the threshold difference value, the second sampling means ( 58 ) samples still image information as the start-index information (S 15 ). The still-image information is sampled from the still image of the moment when the calculated difference value exceeds the threshold difference value. The still image information may be sampled from a plurality of still images as the start-index information.
When the difference value falls down the threshold difference value again, the second sampling means ( 58 ) samples still image information as the end-index information (S 16 ). The still-image information is sampled from the still image of the moment when the calculated difference value falls down the threshold difference value. The still image information may be sampled from a plurality of still images as the end-index information.
The processes (S 12 ) to (S 16 ) repeat during the medical treatment. The index information is generated for each physiological data obtained. The index information is added to the medical movie and recorded in the recording means ( 4 ).
In another embodiment, the index-adjusting means ( 60 ) may be used to shift back/forward the start-/end-index information.
In yet another embodiment, the medical movie existing between the start-index information and the end-index information may be saved as a separate movie file in the recording means ( 4 ). The medical movie may be saved as a group of the still images in the recording means ( 4 ). In this embodiment, the second display (C) and the movie display (D) show the oldest still image contained in the sampled medical movie or in the group of the still images.
While the medical movie is saved in the recording means ( 4 ), information about the medical treatment and other events occurring in the medical treatment room is recorded, in addition to the start- and end-index information described above. Such information about the events during the medical treatment is helpful for more accurate estimate of the changes that occur during the medical treatment.
The information about the events during the medical treatment includes, for example, information about the time when a medical process is carried out, information about when medicines are administered, the information about verbal instructions given by the surgeon, signals from medical devices such as various types of physiological monitors that measure physiological conditions, information when medical personnel (including the surgeon) enter or leave the medical treatment room, information about operation of various devices and the like. Such information is recorded in the medical movie. For example, information about when “the surgeon A sprayed 50 mL of physiological saline around the incision site” is added to the medical movie as the index information.
The time information related to the surgeon and the medical personnel as well as medicines and various devices may be managed by attaching radio IC tags and codes (e.g. barcodes and QR codes) to these persons, medicines and devices respectively.
In another embodiment, the medical image management system ( 1 ) can be used for recording medical movies of a plurality of patients and effectively managing a plurality of the medical movies. FIG. 15 shows a flowchart representing one example of methods of managing a plurality of the medical movies.
First, several medical movies are saved for a certain time period. The time period may be one day, one week, one month, or any other term set by the user.
The medical movies of patients are recorded (S 31 ). The index information is added to the medical movies using the medical image management system ( 1 ) while the movies are recorded (S 32 ).
If the set time period is passed, the recorded medical movies are edited. If the set time period is not yet passed, more medical movies are captured (S 33 ).
After the above-mentioned time period, the recorded movies are edited. Specifically, using the start-index information and the end-index information that are added to the medical movies according to changes in the physiological data, the time defined between each set of start- and end-index information is summed (S 34 ). The longer the summed time (characteristic value: value showing characteristics of the movie) a movie has, the more important it is considered to be.
The step S 33 is performed for every recorded medical movie of patients (S 35 ). In this step, the characteristic value of all the medical movies is calculated.
Once the characteristic value of the medical movies of patients is obtained, the characteristic value is processed in the following steps. The characteristic value of the medical movies is saved in the recording means ( 4 ) (S 36 ). Then the medical movies having a characteristic value that is above a predetermined threshold are selected from the medical movies (S 37 ). The medical movies with higher characteristic value are selected. The threshold characteristic value may be set to any value by the user.
The selected medical movies are marked as “high priority” medical movies among others (S 38 ). The “high priority” medical movies are subjected to processes enabling long-term storage. Such processes include, for example, lossless compression and compression with a low compression rate. Alternatively, the “high priority” medical movies may be kept uncompressed for a certain period.
The medical movies that remain unselected are saved as “low priority” medical movies (S 39 ). The “low priority” medical movies are subjected to processes that enable storage for a shorter term than “high priority” medical movies.
In calculating the characteristic value, the time defined between a pair of index information may be variously weighted based on the importance of the physiological data for which the index information is generated. For example, the time defined between the indices generated for an important physiological data is multiplied by a comparatively large factor while the time defined between the indices generated for a less important physiological data is multiplied by a comparatively small factor. The characteristic value calculated in this way may be used to analyze brief surgeries, technically easy surgeries, and surgeries easily done by an experienced surgeon.
The preferred embodiments of the medical image management method using the medical image management system of the present invention have been described above.
Still image information is sampled from a medical movie based on the physiological data obtained from a surgeon during medical treatment. The sampled still image information indicates important scenes of the medical treatment including the scenes the surgeon is not aware of. The still image information may also be used for classifying medical movies according to their level of importance.
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A medical image management system includes: a medical imaging device for imaging a patient to receive a medical treatment and creating a medical moving picture; and a recording unit for recording the medical moving picture imaged by the medical imaging device. The system further includes: a measurement unit for measuring biological information on a person who performs the medical treatment; and an indexing unit for adding an index to the medical moving picture recorded in the recording unit, according to the measurement result obtained by the measurement unit. By providing this system, it is possible to add an index to the medical moving picture recorded, according to the change of the biological information on the person who performs medical treatment on a patient.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to lens modules, and particularly, to a lens module having flexible lenses, and a camera module having the lens module.
[0003] 2. Description of Related Art
[0004] Currently, glass lenses and plastic lenses are two typical optical lenses. Usually, each of the two typical optical lenses has a given curvature when it is produced, such that a certain optical effect can be achieved soon after the lens is produced.
[0005] However, a method of producing such lenses each having a preformed curvature is usually complex or expensive, because a mold having the curvature is needed.
[0006] Therefore, what is needed, is a lens module and a camera module having the lens module, which can overcome the above shortcomings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Many aspects of the present lens module and camera module can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, the emphasis instead being placed upon clearly illustrating the principles of the present lens module and camera module. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0008] FIG. 1 is a schematic view of a lens module in accordance with a first embodiment, wherein the lens module includes a barrel.
[0009] FIG. 2 is a schematic, exploded view of the lens module of FIG. 1 .
[0010] FIG. 3 is a schematic view of the barrel of the lens module of FIG. 1 .
[0011] FIG. 4 is a schematic, exploded view of a lens module in accordance with a second embodiment.
[0012] FIG. 5 is a schematic view of a camera module having the lens module of FIG. 1 .
DETAILED DESCRIPTION
[0013] Reference will now be made to the drawings to describe in detail of the exemplary embodiments of the lens module and the camera module.
[0014] Referring to FIGS. 1 to 3 , a lens module 1 , in accordance with a first embodiment, includes a barrel 10 and three lenses 12 , 14 , 16 .
[0015] The barrel 10 is a columnar, and includes a first end 101 and an inner wall 102 . The first end 101 defines a through hole 103 to allow outside light beams passing through and enters the barrel 10 . The inner wall 102 defines a plurality of annular grooves 104 surrounding the inner wall 102 , configured for holding and fixing the at least one lens. The grooves 104 are spaced apart from each other and longitudinally defined in the barrel 10 . In the present embodiment, corresponding to the three lenses 12 , 14 , 16 , the barrel 10 has three grooves 104 for respectively holding and fixing the three lenses 12 , 14 , 16 .
[0016] The three lenses 12 , 14 , 16 are transparent, flexible circular lenses. The lenses 12 , 14 , 16 are flat lenses when they are produced and before they are mounted to the barrel 10 . The diameters of the lenses 12 , 14 , 16 are all greater than the inner diameter of the barrel 10 . Each of the lenses 12 , 14 , 16 can have a same diameter with each other. In the present embodiment, the three lenses 12 , 14 , 16 are made of transparent plastic with excellent flexibility. The three lenses 12 , 14 , 16 are bent about the central axis of the barrel 10 , and are respectively engaged with the three grooves 104 of the inner wall 102 of the barrel 10 . The centers of three lenses 12 , 14 , 16 are located on the central axis of the barrel 10 . Since the lenses 12 , 14 , 16 are flexible and the diameters of the lenses 12 , 14 , 16 are greater than the inner diameter of the barrel 10 , the lenses 12 , 14 , 16 are capable of being bent to form a certain curvature, for implementing a certain optical effect.
[0017] Assembly of the lenses 12 , 14 , 16 to the barrel 10 can be done by the following steps. Firstly, the lens 12 is bent to a certain curvature by a clamp (not shown). Secondly, the lens 12 is held by a suction device (not shown) with the suction device catching the convexity of the lens 12 to keep the lens 12 in a bent state. Thirdly, the lens 12 is put into the corresponding groove 104 of the barrel 10 by the suction device. Fourthly, the suction device exits the barrel 10 and the lens 12 is engaged with the groove 104 . Then, the lenses 14 , 16 can be assembled with the barrel 10 using the same method.
[0018] The three lenses 12 , 14 , 16 are flat lenses before assembly, such that the lenses 12 , 14 , 16 are easy to be produced and the cost of the product is relatively cheap. Meanwhile, the assembly of the lens module is simple and easy, such that the cost of the lens module is also relatively cheap.
[0019] Referring to FIG. 4 , a lens module 3 , in accordance with a second embodiment, includes a barrel 30 and three lenses 32 , 34 , 36 . Comparing with the first embodiment, the barrel includes a first barrel part 302 and a second barrel part 304 . The first barrel part 302 is symmetric with the second barrel part 304 about the central axis of the barrel 30 . The first barrel part 302 is a hollow semi-cylinder, and includes an inner wall 3021 and an end 3022 . The inner wall 3021 defines a plurality of group of annular protrusions 3023 surrounding the inner wall, for respectively fixing the three lenses 32 , 34 , 36 . One group of the annular protrusions 3023 includes two annular protrusions 3023 , and the two annular protrusions 3023 cooperatively form a receiving space 3025 for receiving a lens therein. The end 3022 defines a semi-circular hole 3024 configured for allowing outside light beams to enter the barrel 30 . The second barrel part 304 has the same structure with the first barrel part 302 . The two barrel part 302 , 304 engaged with each other and form the barrel 30 . The first barrel part 302 and the second barrel part 304 can be engaged with each other by adhesive.
[0020] Assembly of the lenses 32 , 34 , 36 to the barrel 10 can be done by the following steps, firstly, the three lenses 32 , 34 , 36 are bent to certain curvature and put into the three groups of annular protrusions 3023 of the first barrel part 302 by a clamp (not shown). Secondly, the second barrel part 304 is engaged with the first barrel part 302 by adhesive as well as the clamp is moved away. Then, the three lenses 32 , 34 , 36 are fixed in the barrel 30 .
[0021] It is understood that the number of lenses can be decided by practical need, and the number of grooves or groups of annular protrusions depends on the number of lenses. It is not limited to the present embodiments.
[0022] Referring to FIG. 5 , a camera module 5 includes the above lens module 1 , a holder 52 , a circuit board 54 and an image sensor 56 . The holder 52 is attached on the circuit board 54 , and a receiving cavity 58 is formed. The image sensor 56 is attached on the circuit board 54 and arranged in the receiving cavity 58 . The image sensor 56 is electrically connected with the circuit board 54 and the outer circuit (not shown). The lens module 1 is engaged with the holder 52 , configured for focusing light beams to the image sensor 56 .
[0023] While the present invention has been described as having preferred or exemplary embodiments, the embodiments can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the embodiments using the general principles of the invention as claimed. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains and which fall within the limits of the appended claims or equivalents thereof.
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An exemplary lens module includes a barrel and a plurality of deformable lenses received in the barrel. The barrel includes an inner wall. The inner wall has a plurality of circular retaining portions. The plurality of deformable lenses is deformed and retained in the plurality of circular retaining portions. Diameters of the lenses are greater than an inner diameter of the barrel. The lenses each has a curved surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
MICROFICHE/COPYRIGHT REFERENCE
Not Applicable.
FIELD OF THE INVENTION
This invention relates to exhaust gas aftertreatment and/or acoustic systems and the devices used therein that utilize external insulation blankets.
BACKGROUND OF THE INVENTION
Heat insulating batts and blankets are utilized in exhaust gas systems in order to provide heat insulation for acoustic and aftertreatment devices of the system to control the heat exchange to and from the devices. It is known, for example, to place heat insulating blankets between adjacent wall surfaces of such devices with the material of the heat insulation blanket being compressed to provide a desired installed density for the material to help maintain the heat insulating blanket in its mounted position via frictional forces between the blanket and the adjacent wall surfaces. Such a structure is shown in U.S. Ser. No. 12/696,347, filed Jan. 29, 2010 by Keith Olivier et al., entitled “Method of Producing an Insulated Exhaust Device”, the disclosure of which is hereby incorporated by reference.
It is also known to provide heat insulation blankets around the exterior of such exhaust gas system devices. However, such blankets have been found to encounter a variety of failure modes, including damage and cracking when removing and replacing insulation, damage due to exposure to vibration, damage due to loose or otherwise inappropriate fit due to thermal set, loss of insulation properties due to loose or otherwise inappropriate fit, and/or loss of insulation material.
The present invention is directed to overcoming one or more of the problems set forth above.
SUMMARY OF THE INVENTION
In one aspect of the present invention, a method of providing external insulation for an exhaust gas aftertreatment or acoustic device having a maximum operating temperature T MAX is provided, where the method includes (a) providing a blanket of silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, (b) calcining the blanket by heating all of silica fiber insulation material to a temperature T between T MAX , wherein T is less than the melting temperature of the silica fibers of the blanket; and (c) securing the blanket around the device after the calcining step.
In one form of this aspect of the invention, T is at least 1.05×T MAX .
In another form of this aspect of the invention, the method further includes encapsulating the blanket in a covering after the calcining step and prior to the securing step whereby the blanket is batting in the covering, wherein the covering between the blanket and the device is a selected one of foil, wire mesh, or high temperature textile. In a further form, the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber. In another form, the blanket is encapsulated in a covering before the calcining step.
In yet another form of this aspect of the present invention, during the calcining step the blanket is an uncompressed state.
In another form of this aspect of the present invention, T MAX is within the range of 300° C. to 1100° C.
In still another form, the securing step comprises installing the blanket so that the blanket encircles a core of the device through which the exhaust gas passes.
In yet another form, the silica fiber insulation material has a weight percentage of SiO 2 of greater than 95%.
In another aspect of the present invention, a method of producing an exhaust gas aftertreatment or acoustic device having a maximum operating temperature T MAX is provided, where the method includes (a) providing a blanket of alumina insulation material having a weight percentage of Al 2 O 3 of greater than 65%, (b) calcining the blanket by heating the alumina to a temperature T greater than T MAX , wherein T is less than the melting temperature of the alumina insulation material of the blanket, and (c) securing the blanket around the device after the calcining step.
In one form of this aspect of the invention, the method further includes encapsulating the blanket in a covering after the calcining step and prior to the securing step whereby the blanket is batting in the covering, wherein the covering between the blanket and the device is a selected one of foil, wire mesh, or high temperature textile. In a further form, the high temperature textile is a selected one of siliconized fiber glass or straight woven glass fiber. In another form, the blanket is encapsulated in a covering before the calcining step.
In still another form, the alumina insulation material has a weight percentage of Al 2 O 3 of greater than 95%.
Other objects, features, and advantages of the invention will become apparent from a review of the entire specification, including the appended claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of an exhaust system component employing the invention; and
FIG. 2 is a section view of a portion of the external blanket of the present invention encapsulated in a covering.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention may be used, for example, in an exhaust gas system such as a diesel exhaust gas aftertreatment system to treat the exhaust from a diesel combustion process (e.g., a diesel compression engine). The exhaust will typically contain oxides of nitrogen (NO x ) such as nitric oxide (NO) and nitrogen dioxide (NO 2 ) among others, particulate matter (PM), hydrocarbons, carbon monoxide (CO), and other combustion by-products. The system may include one or more exhaust gas acoustic and/or aftertreatment devices or components. Examples of such devices include catalytic converters, diesel oxidation catalysts, diesel particulate filters, gas particulate filters, lean NO x traps, selective catalytic reduction monoliths, burners, manifolds, connecting pipes, mufflers, resonators, tail pipes, emission control system enclosure boxes, insulation rings, insulated end cones, insulated end caps, insulated inlet pipes, and insulated outlet pipes, all of any cross-sectional geometry, many of which are known.
As those skilled in the art will appreciate, some of the foregoing devices may be strictly metallic components with a central core through which the exhaust flows, and other of the devices may include a core in the form of a ceramic monolithic structure and/or a woven metal structure through which the exhaust flows. These devices are conventionally used in motor vehicles (diesel or gasoline), construction equipment, locomotive engine applications (diesel or gasoline), marine engine applications (diesel or gasoline), small internal combustion engines (diesel or gasoline), and stationary power generation (diesel or gasoline).
FIG. 1 shows one example of such a device for use in a system such as described above, in the form of a catalytic unit 20 such as shown in Olivier et al. U.S. Ser. No. 12/696,347, the disclosure of which was heretofore incorporated by reference.
The catalytic unit 20 has a catalytic core 22 , a mount mat 24 , a cylindrical inner housing or can 26 , and heat insulating blanket or batt 28 , and a cylindrical outer housing or jacket 30 .
The core 22 may typically be a ceramic substrate having a monolithic structure with a catalyst coated thereon and will typically have an oval or circular cross section.
The mounting mat 24 is sandwiched between the core 22 and the can 26 to help protect the core 22 from shock and vibrational forces that can be transmitted from the can 26 to the core 22 . Typically the mounting mat 24 is made of a heat resistant and shock absorbing-type material, such as a mat of glass fibers or rock wool and is compressed between the can and the carrier in order to generate a desired holding force.
The heat insulating blanket 28 located inside the catalytic unit outer housing 30 may be made of a silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%. Such material is known and commercially available, with one suitable example being supplied by BGF Industries, Inc. under the trade name SilcoSoft®, and another suitable example being supplied by ASGLAWO technofibre GmbH under the trade name Asglasil®. Such material is typically supplied in rolls, with the individual blankets 28 being die cut to the appropriate length and width for the corresponding device 18 after the material has been taken from the roll.
In accordance with the present invention, an external blanket 40 is wrapped around the unit outer housing 30 so as to substantially encapsulate the housing 30 .
In one embodiment, the external blanket 40 may be advantageously made of a silica fiber insulation material having a weight percentage of SiO 2 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%. Such material is known and commercially available, with one suitable example being supplied by BGF Industries, Inc. under the trade name SilcoSoft®, and another suitable example being supplied by ASGLAWO technofibre GmbH under the trade name Asglasil®. Such material is typically supplied in rolls, with the individual blankets 40 being die cut to the appropriate length and width for the corresponding device 20 after the material has been taken from the roll. In one preferred form, the blanket 40 may have an average installed density of 0.18 grams/cubic centimeter to 0.30 grams/cubic centimeter of the silica fiber insulation material of the blanket 40 .
According to the invention, before the blanket 40 is installed into the device 18 , the blanket 28 is heat treated to achieve calcination of the silica fiber insulation material. In this regard, the blanket 40 is heated so that all of the silica fiber insulation material in the blanket 28 is raised to a temperature T greater than the maximum operating temperature T MAX of the device 20 . This heat treatment improves the resiliency and erosion resistance of the silica fiber insulation material and also eliminates the potential for a “thermoset” failure mode that can result if the silica fiber material were calcinated in-situ in the device 20 during operation of the system. Preferably, this heat treatment takes place with the blanket 40 in an uncompressed or free state wherein there are no compressive forces being applied to the silica fiber insulation material of the blanket 40 . The temperature T preferably has some margin of safety above the maximum operating temperature T MAX of the device 18 , with one preferred margin of safety being 1.05×T MAX .
This heat treatment improves the resiliency and erosion resistance of the silica fiber insulation material and also eliminates the potential for a “thermoset” failure mode that could result if the silica fiber material were to be calcinated in-situ on the device during operation of the system. Preferably, such heat treatment takes place with the external blanket 40 in an uncompressed or free state wherein there are no compressive forces being applied to the silica fiber insulation material of the external blanket 40 . The temperature T preferably has some margin of safety above the maximum operating temperature T MAX of the device 18 , with one preferred margin of safety being 1.05×T MAX .
By heat treating the silica fiber heat insulation material to the temperature T greater than T MAX before the external blanket 40 is installed on the device, the heat treated blanket can maintain suitable frictional engagement with the unit outer housing 30 over the desired life of the device because the silica fiber insulation material of the blanket 40 maintains its resiliency and does not take on a “thermoset” from the max operation temperature T MAX of the device.
The heat treatment may advantageously be accomplished using an in-line oven wherein the silica fiber heat insulation material is unrolled from a supply roll of the material and passed flat through an oven on a conveyor so that the external blanket 40 is planar during the heat treatment to reduce or prevent differential heating of the material of the blanket 40 and variation in thickness of the material in the blanket 40 . After heat treatment, individual blankets 40 can be die cut to the desired length and width before installing on a device. Alternatively, however, a complete supply roll of the silica fiber heat insulation material can be heat treated, with or without rotation of the roll in an oven, whereby individual blankets 40 can be die cut to the desired length and width after heat treatment and before installing on the device. As yet an another alternative, the silica fiber insulation material can be die cut before heat treatment, with the blanket being slightly oversized in length and width to account for shrinkage during heat treatment, and with the die cut blankets then heat treated in an oven while laying flat on a planar surface.
In accordance with a second embodiment, the external blanket 40 may also advantageously be a high alumina blanket. In one embodiment, the external blanket 40 may be advantageously made of an alumina insulation material having a weight percentage of Al 2 O 3 of greater than 65%, and in preferred embodiments greater than 95%, and in highly preferred embodiments greater than 98%. Such blankets are known and commercially available, with one suitable example being supplied by Saffil Ltd. of Cheshire, U.K. under the LDM trade name, and another suitable example being supplied by Mitsubishi under the MLS-2 trade name. In accordance with the present invention, these high alumina blankets 40 are also heat treated to achieve calcination prior to placement on the device 20 .
The calcined external blanket 40 of either embodiment is advantageously used as batting encapsulated in a covering 50 prior to placement on the device 20 , as illustrated in FIG. 2 . Calcination of the blanket 40 may be accomplished before encapsulating the blanket 40 in the covering 50 . However, calcination may also be accomplished in the covering 50 where the covering 50 will not be adversely impacted by the temperatures used in the calcinations. When installed on the device 20 , the side of the covering facing the heat side (e.g., the device 20 ) may advantageously be foil, wire mesh or a high temperature textile, such as siliconized fiber glass or straight woven glass fiber.
It should be appreciated that devices in exhaust gas systems having external blankets according to the present invention substantially reduce damage and cracking when removing and replacing insulation, damage due to exposure to vibration, damage due to loose or otherwise inappropriate fit due to thermal set, and/or loss of insulation properties due to loose or otherwise inappropriate fit, and/or loss of insulation material.
It should also be appreciated that while the invention has been described herein in connection with a diesel combustion process in the form of, for example, a diesel compression engine, the invention may find use in devices that are utilized in exhaust gas systems for other types of combustion processes, including other types of internal combustion engines, including, for example, internal combustion engines that use gasoline or other alternative fuels.
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A method is provided for producing an exhaust gas aftertreatment or acoustic device ( 20 ) having a maximum operating temperature T MAX . The method includes the steps of providing a blanket ( 40 ) of silica fiber or alumina insulation material having a weight percentage of SiO 2 or Al 2 O 3 of greater than 65%; calcining the insulating material by heating the blanket ( 40 ) so that all of silica fiber insulation material is raised to a temperature T greater than T MAX ; and securing the blanket ( 40 ) on the device ( 20 ) after the calcining step. The blanket is encapsulated in a covering prior to the securing step, and before or after the calcining step, with the covering between the blanket and the device being a selected one of foil, wire mesh, or siliconized fiber glass.
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FIELD OF THE INVENTION
[0001] This invention relates to solids exclusion. More particularly, this invention relates to a solids exclusion system that includes a filter characterized by porosity and permeability designed to optimize production at multiple specified intervals, and made of materials resistant to erosion by any solids and/or resistant against corrosion by any chemicals commonly used in drilling, or produced from, and/or injected into a well. In addition, the present invention makes it possible to circulate flow at the outside of the filter to remove any solids and/or fluids which can accumulate and prohibit flow; and, further, it can be employed to inject or produce any fluid and/or solids outside the filter. The invention can be used in any bore hole, lined or open hole, into any earth formation whether it is used for injection, production, and/or circulation of fluids, solids or any combination thereof.
BACKGROUND OF THE INVENTION
[0002] In the production of hydrocarbons from earth formations, wellbores are drilled into reservoirs or pay zones. Such wellbores are completed and perforated at one or more zones to recover hydrocarbons from reservoirs. Many oil and gas wells produce fluid from underground formations containing solid particles, which are loose and/or not strongly attached to each other and when hydrocarbon-containing fluid is produced, it tends to carry entrained solids with it. These solids can cause serious damage to well equipment due to erosion. Erosion is particularly bad when a disproportionate amount of flow is concentrated in a relatively small region, resulting in high velocities of the solids. These regions are called “hot spots”.
[0003] Filters, normally called sand screens of various designs, and slotted liners are commonly placed opposite the formation and below the production tubing in the well bore preventing entry of solid particulates into the tubing. Filters of different makes and configurations are commonly used as solids control devices. Filters currently available in the art typically erode substantially over time. In addition, they cannot effectively produce all zones because of the fact that the pressure differential required varies over the zones, which creates “hot spots” as mentioned above. Furthermore, there is currently no method available of filter cleaning by circulation of fluids, with or without additives, outside the filter.
[0004] Filters are commercially available that are made of multiple layers of woven material sintered together into a porous rigid medium, however they are only available in several mesh sizes with only one mesh size available per filter, and they are subject to corrosion and/or erosion.
[0005] There is a great need in the art for a solid filter assembly that is resistant to all erosive chemicals and production fluids known in the petroleum industry to cause problems and that can deal effectively with all sizes of solids to optimize production, even where optimal production requires different permeabilities and porosities of the filter for different intervals vertically or radially. It would constitute a great advance in the art if the same filter assembly were designed such that well intervention and cleaning were possible by circulation at the outside of the filter.
SUMMARY
[0006] In accordance with the foregoing the present invention provides a solids exclusion system with features not currently available in the art, including being constructed of material resistant to erosion by any known fluids with or without any form of solids, and characterized by porosity and permeability targeted for optimal production in multiple zones, and an overall design that makes possible circulation at the outside of the filter to enable cleaning, and which likewise makes possible the injection or production of any fluid and/or solids from outside the filter.
[0007] The present invention is a solids exclusion system for preventing migration of solid particles, of a certain size, into a production well comprising a filter having an upper surface and a lower surface, positioned in a lined or unlined hole, characterized by variable porosity and permeability properties designed to optimize production at one or more intervals, and further comprising the filter is constructed of a material resistant to erosion by any chemicals commonly used in the petroleum industry or any naturally occurring well bore fluids produced from earth formations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a longitudinal, cross-section view of one embodiment of the present invention.
[0009] [0009]FIG. 2 is an enlarged view of one section of FIG. 1 showing a seal.
[0010] [0010]FIG. 3 is a longitudinal, cross-section view of one embodiment showing a sub-section of the screen with connections, pin and box at each end.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The solids exclusion system of the present invention can be deployed in a well bore in an earth formation that is lined or unlined with steel or any other material.
[0012] The first embodiment and key part of the solids exclusion system is a filter made of erosion resistant material having porosity and permeability programmed for one or more specific intervals. The filter is manufactured in such a manner that the porosity and permeability can be programmed to have any given value in both radial as well as longitudinal direction. This will enable the free passage of solids through the body of the filter, after they have passed the wall of the filter.
[0013] There can be at least two versions of the solids exclusion system, one for allowing flow from outside in, having a lower porosity outside than inside, and one from inside out having a lower porosity inside than outside. Also porosity and permeability differences in the vertical direction can be achieved by the manufacturing process, thus allowing programmable flow resistance in longitudinal direction along the filter axis.
[0014] The filter is composed of materials that are erosion resistant to any naturally occurring well bore fluid produced from earth formations. Furthermore, the filter is resistant against all commercially available acids used in the petroleum and natural gas industry, including, but not limited to HCl and HF. Materials that would possess that level of erosion resistance include, but are not limited to metals, organic and/or non-organic porous permeable materials. Said metals, organic and/or non-organic porous permeable materials that are sintered and/or atomically bonded are particularly suitable. Examples of each of those are sintered and/or atomically bonded steel or copper, sintered and/or atomically bonded carbon and various sintered and/or atomically bonded ceramics.
[0015] Sintered and/or atomically bonded material has properties that make it a particularly desirable choice. These can be provided in tubular form and can be made to specific porosity and permeability specifications. Sintered and/or atomic bonded materials can be quite weak in tensile and shear. This can be resolved, if deemed necessary, by steel or other reinforcements stipulated by the design of the assembly.
[0016] Another very attractive embodiment is that the novel solids exclusion system design of the present invention is part of an assembly that makes it possible to circulate flow at the outside of the filter by opening ports above and below the filter that permit fluid communication from inside the filter to the outside of the filter, or visa versa, to allow cleaning at the outside and removal of any impairment by means of circulation. This cleaning operation can be set in motion, in part, by contacting a heating coil with shape memory metal alloy rods. In the specification and claims, the term “shape memory alloy” is used to refer to an alloy that exhibits a shape-memory effect, wherein complete recovery of a deformation undergone at a particular temperature takes place at heating. The skilled person is able to select a composition of the alloy material that exhibits the required effects at the temperature prevailing in the well.
[0017] The solids exclusion system contains an internal sealing arrangement above the filter and an internal sealing arrangement below the filter, allowing injection of fluids below the filter entering the annular space between the solids exclusion system and the lined or unlined well bore, thereby enabling fluid transport at the outside of the filter, taking the returns at the top of the filter through the sealing arrangement located at that position, or visa versa.
[0018] Also within the scope of the present invention it is contemplated that a larger solids exclusion system can be comprised of multiple filter sections vertically being pressure separated from each other in the annular space between the individual filters, or filter sections, and lined or not lined well bore in an earth formation. Each filter section can consist of several sub filter sections, which might have different physical properties.
[0019] Further, the present invention contemplates the use of an internal (over the filter) straddling arrangement enabling selective movement of fluids in- or outwards of the filter or filter parts. This enables localized cleaning and/or movement from fluids of any type and property.
[0020] Each filter can be fitted with one polished bore at the top of the filter or filter sections and one at the bottom thereby enabling full straddling of that section resulting in zero production or injection, thereby providing a method of reservoir management.
[0021] The solids exclusion system can have an external sealing design on top of the filter and/or filter subsections and one below the filter or filter subsections thereby sealing the annular space between the solids exclusion system and the lined or not lined well bore, thereby blocking annular communication along the filter top and bottom. The external seals can be activated in such a manner that vertical movement of the solid exclusion system is zero at any given time of the activation process. This activation is made possible by the use of shape memory alloy as an activation means. (See WO0111185, WO0138692, incorporated by reference herein in the entirety.)
[0022] Within the scope of the present invention, the design of the solids exclusion system and especially the design of the external seals (See FIG. 2) can be configured in such a manner that all external seals can be deactivated without drilling or so-called “over washing” of the solids exclusion system. The latter can be achieved by using a coiled tubing and/or wireline unit to cut the section 5 (FIG. 2) at the position between the arrows 22 b and 22 c until that point that the memory metal bars ( 22 c ) are being cut. This will release the force from the elastomeric seal element 22 b. The solids exclusion system can be held in place during its lifetime by at least one anchor, commonly a packer, at the bottom, and in case of tubing less completion, one non-rig/hoist intervention comprising an additional anchor, commonly a packer, at the top of the solids exclusion system.
[0023] It is desirable to obtain a water and/or hydrocarbon liquid flow through the permeable, porous and/or non-sealing parts of typically from 0 up to about 50 cubic meters liquid per day per meter of filter. It is desirable to obtain a flow of water and/or natural gas through the permeable, porous and/or non-sealing parts of typically from 0 to about 20,000 standard cubic meters gas per day per meter filter.
[0024] The solids exclusion system, and specifically the filter, should suitably allow passage of liquid of any density to a maximum of a density of typically 2.0 kg/litre at a maximum flow rate of typically 5 cubic meters per day per meter filter. Fluids of this type are typically used during installation and/or other well bore intervention activities.
[0025] The solids exclusion system is designed so that it can be installed and/or retrieved using state of the art industry rig and/or hoist equipment, procedures, and standards. The length of the solids exclusion system, or subsections thereof, will preferably not exceed the length of about typically 10 meters.
[0026] A suitable overall diameter of the solids exclusion system at any given position is less than the smallest drift diameter of the pipe through which the solids exclusion system must fully or partially pass. Sizes and tolerances for the pipe may vary.
[0027] In yet another embodiment of the present invention the solids exclusion system with circulation capabilities can be used to inject or produce any fluid and/or solids from the outside of the filter, as will be explained below.
[0028] The schematic drawing of FIG. 1 will serve to illustrate the invention disclosed herein. It is intended only as a means of illustration and should not be construed as limiting the scope of the invention in any way. Those skilled in the art will recognize many variations that may be made without departing from the spirit of the disclosed invention.
[0029] [0029]FIG. 1 demonstrates one embodiment utilizing the present invention in a well apparatus. Referring to FIG. 1 there is shown a solids exclusion system in a liner 1 , though, as mentioned the invention can be used in a lined or unlined hole. The liner 1 has perforations 12 to permit fluid flow. Perforations can be made using oil field standard perforation guns, or they can be pre-drilled, or they can be acidized (See, for example, U.S. Pat. No. 5,103,911). The filter 11 of the present invention is situated between the lower assembly 2 and the upper assembly 15 . The upper edge of the filter 11 is received into the upper assembly 15 and the lower edge of the filter 11 is received into the lower assembly 2 . The permeable filter is made of ceramic, metallic or organic material subjected to a sintering or atomic bonding process, as used for the production of nano materials, that provides for any type of porosity required.
[0030] The upper edge of the filter 11 terminates in a ring 13 which is in contact with memory metal rods 14 which change shape when temperature is applied and which, in turn, are in contact with shut off opening sleeve 17 which has a fishing and/or locator and/or activation recess 16 . In addition, sleeve 17 covers upper circulation port(s) 18 . A fishing and/or locator and/or activation recess is also represented by 19 .
[0031] In the lower assembly 2 a compression spring 3 holds disc 6 in the position to cover bottom port(s) 5 . The port(s) 5 allow flow from the outside inwards or from the inside outwards if the disc 6 is in the lower position. Disc 6 can be permeable or impermeable. A rod assembly to hold the spring in place is represented by 4 . A fixating plate for the rod assembly 4 is represented by 7 . A wire line lock assembly, which is a standard tool used in the oil industry, is represented by 8 - 10 , i.e. the latches, 8 , the body, 9 , and the fishing and locator groove, 10 .
[0032] [0032]FIG. 2 is an enlarged view, showing detail A, where sealing material is represented by 22 b, and memory metal rods 22 c, used to activate the seals. The numbering of FIG. 2, corresponds with the numbering of FIG. 1. The seal 22 consists of a ring 21 a connected to shape memory alloy rods 22 c connected to, ring 22 a. The sealing material 22 b is enclosed by ring 22 a and body 20 . By applying heat to the internal of body 2 , the shape memory alloy will contract and activate the seal. Length of contraction, varies typically between 4% and 8% of the length of the shape memory alloy bars. This allows someone knowledgeable in the art to dimension the seal material, seal length, and shape memory alloy rod length correctly.
[0033] Another very desirable embodiment of the present invention is that it is possible to circulate flow at the outside of the filter. Again, with reference to FIG. 1, this is achieved by running a heating coil to the position of the shape memory metal alloy rods 14 .
[0034] When the shape memory metal alloy rods 14 are heated they contract and shift the sleeve 17 , uncovering the upper port(s) 18 . These ports can be filled with a porous ceramic or metal material. At the same time, or in a separate operation, the bottom port(s) 5 are opened by stinging a pipe, such as coil tubing known from the oil industry, with seals into the body 9 . When pressuring this pipe up the disc 6 will move against the spring 3 and open up bottom port(s) 5 . The opening of the bottom port(s) can also be achieved by pulling the lock assembly comprising 3 , 4 , 6 , 7 , 8 , 9 , and 10 . An alternative method, not shown, is by mechanically pushing the disc 6 against the spring 3 . This allows cleaning of the filter at the outside or removal of any impairment outside the filter by means of circulation in either direction. The cleaning fluid can be any. Suitable fluids can be hydrocarbon-based fluids, acids, scavengers, water-based fluids, gases and/or solvents, or combinations thereof.
[0035] Circulation can take place through the inner tube, not shown, via bottom port(s) 5 to upper ports 18 after which the fluid is produced back through the annular space between the inner tube, not shown, and the upper assembly 15 . If reverse circulation is required then the mechanical lock open option of disc 6 needs to be used.
[0036] The port(s) 5 will automatically be closed as soon as the fluid flow through the ports stop and/or the pressure differential over element 6 counteracts the spring force.
[0037] A wire line tool is run to pull the sleeve 17 up, thereby covering the upper ports 18 . (See WO0138689, incorporated by reference herein in the entirety.) FIG. 1 shows the ports in closed and open position.
[0038] The third embodiment of the invention, as mentioned above, is that the filter assembly can be used to inject or produce any fluid and/or solids from the outside of the filter 11 by running the inner tube, not shown, and stinging this into the lock assembly. With reference to FIG. 1, in order to flow back, the total lock assembly comprising 3 , 4 , 6 , 7 , 8 , 9 , and 10 needs to be pulled, the mechanical push open (not shown) variation needs to be installed. Another alternative to this assembly is an oil industry standard wire line set plug.
[0039] To ensure that the fluids have a defined circulation path seals 22 are placed between the outer tube 1 and the upper 15 and lower 2 assembly (FIG. 1). The solids exclusion system can be kept stationary in the tube 1 (FIG. 1) by the use of oil industry standard tubular and/or formation packers.
[0040] [0040]FIG. 3 shows a sub-section of the screen of which multiples can be connected together with or without intermittent blanks and/or sealing elements. FIG. 3 shows a standard oil field pin 23 with threads 24 and 25 , which is screwed into embodiment 29 locking the screen 27 and filler ring(s) 26 in place. The top section of embodiment 29 shows a standard oil field box connection with threads allowing connection of multiple section and/or standard oil field tubular goods. The holes 28 (equal to item 20 of FIG. 1) allow passage of fluids whereby the number, dimension and position of the holes provide a certain spring force which can be controlled in combination with the dimensions of the filler ring(s) 26 and all other relevant dimensions, thus providing enhanced bending and/or axial tensile resistance of the assembly.
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Disclosed is a tool having an axial passage, a top and a bottom, and a sidewall portion possessing porosity and permeability properties and constructed of a material having equal or better erosion properties than any substances produced and/or injected into any earth formation, said tool functioning as a filter to permit solids to pass or not pass depending upon their size, characterized in that the porosity and permeability can be programmed to any given value radially and longitudinally, said tool further including a means for circulating from outside, inward or from the inside outward to enable cleaning, wherein optionally said tool can be used in multiples.
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TECHNICAL FIELD
1. Field of the Invention
The present invention relates to an engine cooling system, and more particularly to an engine cooling system mounted on construction machines.
2. Description of the Related Art
Of known art concerned with engine cooling system of the above-mentioned type, several conventional examples employing centrifugal fans are discussed below.
(1) “Internal Combustion Engine”, Vol. 31, No. 388, p. 9-27 (1992)
This known art intends to improve a cooling ability by using a centrifugal fan as a fan to supply cooling air in an engine cooling section of a construction machine, and to reduce noise of engine sound by separating an engine room and a cooling system section from each other.
(2) JP, A, 5-248239
This known art intends to improve a cooling ability by using a centrifugal fan as a fan to supply cooling air in an engine cooling section of a working vehicle such as a tractor.
(3) JP, U, 2-64799
This known art intends to eliminate a discharge duct, which has been required when using an axial fan, by using a centrifugal fan as a fan to supply cooling air in an engine cooling section of an automobile.
On the other hand, as known art concerned with engine cooling systems employing axial fans, there is an example set forth below.
(4) JP, A, 5-288053
According to this known art, in an engine cooling system for a hydraulic excavator, cooling air is supplied to a heat exchanger by an axial fan coupled to an engine crankshaft through a fan belt. Though not stated in detail in the Publication disclosing this known art, the engine cooling system has a structure, by way of example, as shown in FIG. 8 .
In FIG. 8, an engine cooling system is provided in an engine room 2 housing an engine 1 installed therein, and comprises an intercooler 3 for precooling combustion air supplied to the engine 1 , an oil cooler 4 for cooling a hydraulic working fluid for use in a hydraulic excavator, a radiator 5 for cooling cooling water supplied to the engine 1 , a cooling fan 8 in the form of an axial fan driven by a fan belt 7 to which power is transmitted from the crankshaft 6 of the engine 1 , and a suction duct 9 for introducing the cooling air to the suction side of the cooling fan 8 .
The cooling air enters the engine room 2 through a cooling air inlet port 10 from the outside of the engine room 2 , and is restricted by the suction duct 9 after passing the intercooler 3 , the oil cooler 4 and the radiator 5 which are each a heat exchanger, followed by reaching the cooling fan 8 . After being blown out axially to the downstream side of the cooling fan 8 , the cooling air flows around the engine 1 and an oil pan la below the engine 1 while cooling them, and is then discharged to the outside through cooling air outlet ports 11 , 12 disposed respectively in upper and lower portions of the engine room 2 . Additionally, the engine 1 is installed on a frame 13 , which is provided on a bottom surface 2 a of the engine room 2 , through vibration damping devices 14 , and partition members 15 , 16 are disposed so as to provide sealing between the suction duct 9 and an upper cover 2 b and the bottom surface 2 a of the engine room 2 .
Further, as known art concerned with engine cooling system employing obliquely axial fans, there is an example set forth below.
(5) JP, A, 4-269326
This known art is to achieve a higher pressure and a higher flow rate than obtainable with an axial fan by using an obliquely axial fan as a fan to supply cooling air in a cooling section of a diesel engine for vehicles, and by simultaneously forming a fixed shroud for introducing the cooling air in the shape of a suction duct.
Recently, there has been a tendency that resistance of a cooling flow passage in an engine room is increased due to the provision of an intercooler, a demand for improved enclosing of the engine room for noise reduction, and a demand for a more compact structure of the engine room. Because a comparable flow rate to a conventional device is demanded in spite of such a tendency, a cooling fan is required to provide a larger flow rate and a higher pressure.
Responding to those needs, in the known arts (1) to (3), a centrifugal fan capable of providing a larger flow rate and a higher pressure than an axial fan on condition the of having the same outer diameter and the same revolution speed under action of centrifugal forces is employed as the cooling fan in place of the axial fan which has been hitherto usually employed. In a centrifugal fan, cooling air is introduced to a impeller axially from a suction duct and blown out radially upon rotation of the vane wheel, but on that occasion there occurs a leakage of the cooling air in the radial direction through gaps between the suction duct and vanes. This increases loss and hence raises the problem that the fan efficiency expressed by (flow rate×pressure)/(power input to fan rotary shaft) is lowered and noise is increased.
Further, in the known arts (4) and (5), the use of an axial fan or an oblique axial fan makes it difficult to achieve a sufficient increase in flow rate and pressure. Accordingly, there has been a problem that when trying to ensure the same flow rate as usual under a condition where the resistance of the cooling flow passage in the engine room is increased for the above-mentioned reason, the revolution speed must be raised; hence noise is increased. Additionally, in the known art (5), because an air flow having passed the axial fan flows in such a direction as to strike against the engine, a pressure loss is increased and a reverse flow of the cooling air occurs around the engine and the oil pan in some cases. For these reasons, it is hard to ensure a sufficient flow rate of the cooling air. As a result, the revolution speed must be further raised from the standpoint of ensuring a sufficient flow rate of the cooling air; hence noise is increased.
To solve the problems stated above, the inventors of this application have proposed, in Japanese Patent Application No. 7-109483 (filed May 8, 1995), an engine cooling system comprising at least one heat exchanger provided in an engine room housing an engine installed therein, and including a radiator to cool cooling water supplied to the engine, a fan for cooling the heat exchanger, and a suction duct provided upstream of the fan and introducing the cooling air to the suction side of the fan, wherein the cooling fan is one of a mixed flow fan or a centrifugal fan, and includes an impeller provided with a plurality of vanes, and a rotary shroud fixed to the impeller and rotated together with the vane wheel.
In the proposed engine cooling system, however, the relationship in arrangement between the rotary shroud and the suction duct is not specified. There is disclosed such a structure that a suction-side end of the rotary shroud is positioned on the outer side and a downstream end of the suction duct is positioned on the inner side, and a structure that the suction-side end of the rotary shroud is positioned on the inner side and the downstream end of the suction duct is positioned on the outer side. The engine cooling system having the above structure accompanies another problem below.
In general, a largest part of the noise generated by the cooling system of the above-mentioned type is from the impeller of the cooling fan, and a largest part of the noise generated from the impeller is from front edges of vanes (inlet of vane). When the downstream end of the suction duct is positioned outside the suction-side end of the rotary shroud, the direction of a gap flow coming in through radial gaps between the suction duct and the rotary shroud is opposed to the direction of a main flow of cooling air coming in from the suction duct to the rotary shroud, and the flow of the cooling air is greatly disturbed due to eddies or the like in a joining area of both the gap flow and the main flow. A turbulent flow thus generated increases noise, in particular, at the vane front edges of the vane wheel. Further, in the above arrangement, to avoid contact between the suction duct and the rotary shroud in connection with the problem of vibration during work, the axial distance between the suction duct and the rotary shroud must be set long; hence it is difficult to meet the above-mentioned demand for a more compact engine room.
SUMMARY OF THE INVENTION
The present invention has been made to solve the various problems set forth above, and its object is to provide an engine cooling system which can produce cooling air at a large flow rate and a high pressure and can realize a reduction in noise and size without lowering the fan efficiency.
To achieve the above object, according to the present invention, in an engine cooling system comprising at least one heat exchanger provided in an engine room housing an engine installed therein, and including a radiator to cool cooling water supplied to the engine, a cooling fan for inducing cooling air to cool the heat exchanger, and a suction duct provided upstream of the cooling fan and introducing the, cooling air to the suction side of the cooling fan. The cooling fan is one of a mixed flow fan and a centrifugal fan, and includes an impeller provided with a plurality of vanes, and a rotary shroud fixed to the impeller and rotated together with the vane wheel. The suction duct has a downstream end with an opening diameter smaller than an opening diameter at a suction-side end of the rotary shroud, is being arranged such that the downstream end is positioned inside the suction-side end of the rotary shroud in overlapped relation.
Specifically, in the present invention, a mixed flow fan or a centrifugal fan is used as a fan. These fans can provide a larger flow rate and a higher pressure than an axial fan or an obliquely axial fan on the condition of having the same outer diameter and the same revolution speed under action of centrifugal forces. Accordingly, when designing an engine cooling system with a larger flow rate and a higher pressure to ensure a comparable flow that of a conventional device in a recent engine room where a cooling flow passage has increased resistance, noise can be reduced without increasing the revolution speed, unlike the case of using an axial fan or an oblique axial fan. In this connection, since the rotary shroud rotating together with the impeller is fixed to the vane wheel, cooling air is prevented from leaking radially through gaps between the suction duct and the vanes; hence the fan efficiency can be improved. As a result, noise can be further reduced correspondingly.
Also, by arranging the downstream end of the suction duct to a position inside the suction-side end of the rotary shroud in overlapped relation, the direction of a gap flow coming in through radial gaps between the suction duct and the rotary shroud is the same as the direction of a main flow of the cooling air. With this arrangement, the flow of the cooling air can be kept from being disturbed due to eddies or the like that are generated in the case of arranging the suction duct at a position outside the rotary shroud, and noise can be reduced correspondingly. In addition, with the arrangement that the downstream end of the suction duct is positioned inside the suction-side end of the rotary shroud in overlapped relation, the suction duct and the rotary shroud can be arranged closer to each other than the case of arranging the suction duct to position outside the rotary shroud on condition that a distance between the suction duct and the impeller in the axial direction of the fan is set to the same value. As a result, an engine room can be made more compact correspondingly.
In the above engine cooling system, preferably, an overlap amount between the downstream end of the suction duct and the suction-side end of the rotary shroud in the axial direction is not less than 0 mm, but not more than 40 mm.
The reason is as follows. Setting the overlap amount to be not less than 0 mm, i.e., not negative, makes it possible to avoid such problems that the downstream end of the suction duct and the suction-side end of the rotary shroud are separated from each other, thus increasing an amount of air sucked from the outside of the suction duct and lowering the fan efficiency, and a more compact engine room is difficult to realize. Conversely, if the overlap amount is too large, the suction duct and the rotary shroud are so close to each other and a distance from a joining position of the gap flow coming in through radial gaps between the suction duct and the rotary shroud and the main flow of the cooling air to a vane front edge of the impeller of the cooling fan is so short that flow disturbance caused upon joining of both the gap flow and the main flow adversely affects the performance of the cooling fan, thereby lowering the fan efficiency and increasing noise. With the above in mind, the overlap amount is optimally about 20 mm. In a case where the present invention is applied to construction machines such as hydraulic excavators, however, it is required to consider manufacturing tolerances and assembly errors because construction machines are each a large welded structure as a whole. In addition, it is also required to avoid contact between the suction duct and the rotary shroud even under vibration which occurs during work. In view of those points, an appropriate upper limit of the overlap amount is about 40 mm.
In the above engine cooling system, preferably, assuming that a radial clearance between the downstream end of the suction duct and the suction-side end of the rotary shroud is C and a maximum diameter of the impeller is Do, the relation of C≦0.05×Do is satisfied.
Specifically, if the clearance C is too large in comparison with the maximum diameter Do of the vane wheel, a proportion of the gap flow joining with the main flow of the cooling air is increased and the efficiency of the cooling fan is lowered. In other words, the smaller the clearance C, the higher is the fan efficiency. However, manufacturing tolerances, assembly errors and vibration have to be taken into consideration as with the setting of the clearance C stated above. Thus, an appropriate upper limit of the clearance C is C=0.05×Do.
In the above engine cooling system, preferably, the suction duct comprises a substantially box-shaped introducing plate and a ring member being substantially in the form of a circular tube and integrally formed on a rear wall of the introducing plate.
Specifically, it is desired that the suction duct has such a form as defining a flow passage shape to be as smooth as possible and causing no pressure loss. In order to obtain the smooth flow passage shape and improve the production efficiency, the suction duct is usually manufactured by, e.g., pressing using a die. The pressing method is effective in high-volume production, but it pushes up a cost in low-volume production because a die is relatively expensive. In the case of low-volume production, therefore, the suction duct is modified to have such a simpler structure that the ring member is attached to a rear wall of a substantially box-shaped introducing plate. This structure eliminates the need of a die and enables the suction duct to be manufactured at a reduced cost correspondingly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view showing a structure of an engine cooling system according to one embodiment of the present invention.
FIG. 2 is an enlarged side sectional view showing a detailed arrangement of a cooling fan and a suction duct.
FIG. 3 is a graph comparatively showing fan characteristics of an axial fan and a centrifugal fan on the condition of having the same revolution speed and the same outer diameter.
FIG. 4A is a side sectional view showing a detailed arrangement of principal part of an engine cooling system prepared for examining correlation of a noise reducing effect relative to the positional relationship between the suction duct and the rotary shroud.
FIG. 4B is a side sectional view showing a detailed arrangement of a principal part of an engine cooling system prepared for examining correlation of a noise reducing effect relative to the positional relationship between the suction duct and the rotary shroud.
FIG. 5 is a graph showing measured results of a noise value and an air flow rate at the same revolution speed.
FIG. 6 is a graph showing measured results of a noise value resulted when the revolution speed is adjusted so that the same air flow rate is produced.
FIG. 7 is a front and side view showing a structure of a suction duct according to a modification.
FIG. 8 is a side sectional view showing a structure of a conventional engine cooling system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereunder, an embodiment of an engine cooling system of the present invention will be described below in conjunction with the drawings.
One embodiment of the present invention will be described below with reference to the drawings.
FIG. 1 shows a structure of an engine cooling system according to this embodiment. It is to be noted that equivalent members to those in FIG. 8, which has been referred to above to explain the conventional structure, are denoted by the same reference numerals and are not explained here. Referring to FIG. 1, the structure of the engine cooling system according to this embodiment differs from the conventional structure shown in FIG. 8, particularly, in the type of a cooling fan 17 , arrangement of a rotary shroud 18 , and shape of a suction duct 19 . A detailed arrangement of the cooling fan 17 and the suction duct 19 is shown in FIG. 2 .
Referring to FIGS. 1 and 2, the cooling fan 17 is a centrifugal fan comprising a impeller 20 provided with a center plate 20 a and a plurality of vanes 20 b , and a rotary shroud 18 fixed to the impeller 20 and rotated together with the impeller 20 . The suction duct 19 has a downstream end 19 A with an opening diameter D 1 smaller than an opening diameter D 2 at a suction-side end 18 A of the rotary shroud 18 , and is arranged such that the suction duct downstream end 19 A is positioned inside the rotary shroud suction-side end 18 A in overlapped relation. Also, an overlap amount between the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A in the axial direction is d=20 mm. Given a maximum diameter of the impeller 20 (diameter of the center plate 20 a in this embodiment) being Do, a radial clearance C between the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A is given by C=0.03×Do. The suction duct 19 is manufactured by, e.g., pressing using a die in order to not only provide the suction duct 19 with such a form defining a smooth flow passage shape and causing no pressure loss, but also to improve the production efficiency.
In the above structure, similarly to that shown in FIG. 8, cooling air enters an engine room 2 through a cooling air inlet port 10 from the outside of the engine room 2 , and after passing an intercooler 3 , an oil cooler 4 and a radiator 5 which are each a heat exchanger, is introduced by the suction duct 19 to the cooling fan 17 comprising a centrifugal fan. After being blown out from a circumference of the cooling fan 17 , the cooling air flows around an engine 1 and an oil pan la below the engine 1 while cooling them, and is then discharged to the outside through cooling air outlet ports 11 , 12 disposed respectively in upper and lower portions of the engine room 2 .
Actions and effects of the present invention constructed as explained above will be described below one by one.
(A) Actions and Effects Based on Centrifugal Fan and Rotary Shroud
First, in the engine cooling system of this embodiment, a centrifugal fan is used as the cooling fan 17 . The use a centrifugal fan makes it possible to achieve a larger flow rate and a higher pressure than obtainable with a conventional structure using an axial fan or an obliquely axial fan on the condition of having the same outer diameter and the same revolution speed. This point will be described with reference to FIG. 3 .
FIG. 3 is a graph comparatively showing, by way of example, fan characteristics of an axial fan and a centrifugal fan on the condition of having the same revolution speed and the same outer diameter. In the graph of FIG. 3, the horizontal axis represents a flow rate and the vertical axis represents a static pressure. Characteristics curves of “axial fan” and “centrifugal fan” each indicate respectively a characteristic of a single axial fan alone and a single centrifugal fan alone (i.e., a characteristic of each fan alone measured without arranging it in a flow passage). Two resistance curves ( 1 ), ( 2 ) each indicate a characteristic of the cooling flow passage alone in the engine room (i.e, a characteristic uniquely determined by the flow passage structure). The cross points between the fan characteristic curves and resistance curves each imply an operating point effective when one of the fans is arranged in one of the flow passages, and represent a pressure and flow rate resulted in that case. Note that, of the resistance curves ( 1 ), ( 2 ), the resistance curve ( 1 ) indicates a characteristic of the cooling flow passage in the conventional engine room, and the resistance curve ( 2 ) indicates a characteristic of the cooling flow passage in the recent engine room adapted for the provision of an intercooler, a demand for improved enclosing of the engine room for noise reduction, and a demand for more compact structure of the engine room.
First, when the axial fan is arranged in the conventional engine room, the resulting flow rate and static pressure are given by a cross point A between the characteristic curve of “axial fan” and the resistance curve ( 1 ), i.e., Qprop1 and Pprop1, respectively. On the other hand, when the centrifugal fan is arranged in the conventional engine room, the resulting flow rate and static pressure are given by a cross point B between the characteristic curve of “centrifugal fan” and the resistance curve ( 1 ), i.e., Qturbo1 and Pturbo1, respectively. Thus, the centrifugal fan has a property capable of providing a higher pressure and a larger flow rate than the axial fan on the condition of having the same outer diameter and the same revolution speed under action of centrifugal forces (described later in more detail).
Next, if the conventional axial fan is arranged as it is in the recent engine room, the resulting flow rate and static pressure are given by a cross point C between the characteristic curve of “axial fan” and the resistance curve ( 2 ), i.e., Qprop2 and Pprop2, respectively. The static pressure Pprop2 is larger than the above Pprop1 resulted when arranging the axial fan in the conventional engine room, thus embalming a higher pressure to be achieved, but the flow rate Qprop2 is smaller than the above Qprop1 resulted when arranging the axial fan in the conventional engine room. Accordingly, in order to achieve a comparable flow rate to the conventional Qprop1, the revolution speed must be increased, which results in a remarkable increase of noise. On the other hand, when the centrifugal fan is arranged in the recent engine room, the resulting flow rate and static pressure are given by a cross point D between the characteristic curve of “centrifugal fan” and the resistance curve ( 2 ), i.e., Qturbo2 (Qprop1) and Pturbo2, respectively. Thus, a flow rate almost equal to the flow rate Qprop1 resulted when arranging the axial fan in the conventional engine room can be ensured, and a higher pressure twice or that more of the static pressure Pprop1 resulted when arranging the axial fan in the conventional engine room can be achieved.
Such characteristics of the centrifugal fan can be explained as follows.
Generally, a theoretical pressure rise Pth of a fan is expressed by the following formula:
Pth=P ( u 2 2 −u 1 2 )/2+ P ( v 2 2 −v 1 2 )/2+ P ( w 2 2 −w 1 2 )/2
where u is a circumferential speed of the fan, v is an absolute speed of a flow, w is a relative speed of the flow, and suffixes 1 , 2 represent that corresponding parameters indicate values at an inlet and outlet of the fan, respectively.
In the above formula, the first term P(u 2 2 −u 1 2 )/2 of the right member represents an effect of centrifugal forces, the second term P(v 2 2 −v 2 2 )/2 of the right member represents a change in kinetic energy (i.e., a rise in dynamic pressure), and the third term P(w 2 2 −w 1 2 )/2 of the right member represents an effect due to deceleration in the flow passage (i.e., a rise in static pressure). Considering now the first term, since the inlet and outlet of the axial fan have the same diameter, u 1 =u 2 holds and the first term=0 is resulted. On the other hand, since the outlet of the centrifugal fan has a lager diameter than the inlet thereof, the effect of centrifugal forces based on the second term is maximally developed. As compared with the axial fan, therefore, the centrifugal fan can achieve a higher pressure and hence a larger flow rate more easily. Note that while the characteristics of the centrifugal fan have been explained above in comparison with the axial fan, the above explanation is also equally applied to comparison with an obliquely axial fan.
By using a centrifugal fan as the cooling fan 17 , as stated above, it is possible to provide a higher pressure and a larger flow rate than using an axial fan or an obliquely axial fan on the condition of having the same outer diameter and the same revolution speed. Accordingly, when designing an engine cooling system with a larger flow rate and a higher pressure to ensure a comparable flow rate to that of a conventional device in the recent engine room where the cooling flow passage has increased resistance, noise can be reduced without increasing the revolution speed, unlike the case of using an axial fan or an obliquely axial fan. Further, in the cooling fan 17 , since the rotary shroud 18 rotating together with the impeller 20 is fixed to the impeller 20 , cooling air is prevented from leaking radially through gaps between the suction duct 19 and the vanes 20 b ; hence the fan efficiency can be improved. As a result, noise can be further reduced correspondingly.
(B) Actions and Effects Based on Positional Relationship Between Suction Duct and Rotary Shroud
In the cooling system of this embodiment, since the suction duct downstream end 19 A is positioned inside the rotary shroud suction-side end 18 A in overlapped relation, noise can be held down as compared with the case where the suction duct downstream end 19 A is positioned outside the rotary shroud suction-side end 18 A. This point will be described with reference to FIGS. 4A, 4 B, 5 and 6 .
For examining correlation of a noise reducing effect relative to the positional relationship between the suction duct and the rotary shroud, the inventors of this application prepared an engine cooling system wherein the suction duct downstream end 19 A was positioned inside the rotary shroud suction-side end 18 A in overlapped relation as shown in FIG. 4A, and an engine cooling system wherein the suction duct downstream end 19 A was positioned outside the rotary shroud suction-side end 18 A as shown in FIG. 4B, and then conducted experiments of measuring noise values of both the apparatus at the same revolution speed and noise values of both the apparatus resulted when the revolution speed is adjusted so that the same air flow rate is produced. FIG. 5 shows measured results of the former case and FIG. 6 shows measured results of the latter case. In the graphs of FIGS. 5 and 6, the horizontal axis represents a parameter given by a ratio (2C/Do) of twice a radial clearance (=tip clearance) between the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A to a fan maximum diameter. Further, the left half in the graph represents the measured values resulted for the structure of FIG. 4 A and the right half in the graph represents the measured values resulted for the structure of FIG. 4 B. FIG. 5 also shows air flow rates depending on measurement conditions as relative values with the air flow rate resulted at a minimum value of the clearance C being 100%.
In FIG. 5, ( a ) and ( b ) represent respectively the results of measuring air flow rates in the structures of FIG. 4A and 4B, whereas ( c ) and ( d ) represent respectively the results of measuring noise in the structures of FIG. 4A and 4B. As seen from ( a ) and ( b ), with the tip clearance C increasing, the air flow rate is reduced from 100% to 93% in the structure of FIG. 4 A and the air flow rate is reduced from 100% to 98% in the structure of FIG. 4B likewise. Thus, in any of the structures, the air flow rate is reduced as the tip clearance C increases. The reasons are that an increase in the clearance C enlarges an amount of air sucked from the outside of the suction duct 19 and hence lowers the fan efficiency in the structure of FIG. 4B represented by ( b ), and that an effective area on the suction side is reduced in the structure of FIG. 4A represented by ( a ). Also, at the same revolution speed and the same clearance C, the air flow rate in the structure of FIG. 4A is generally smaller than that in the structure of FIG. 4 B. Because of such a difference in air flow rate, as indicated by ( c ) and ( d ), noise generated on the condition of having the same revolution speed and the same clearance is smaller in the structure of FIG. 4A where the suction duct downstream end 19 A is positioned inside the rotary shroud suction-side end 18 A in overlapped relation than in the structure of FIG. 4B where the suction duct downstream end 19 A is positioned outside the rotary shroud suction-side end 18 A.
Next, FIG. 6 shows the results of measuring a noise level resulted when the revolution speed is adjusted so that the air flow rates in the structures of FIGS. 4A and 4B have no difference, i.e., they are equal to each other. Stated differently, FIG. 6 represents data resulted by increasing the revolution speed in the structure of FIG. 4A relatively over the revolution speed in the structure of FIG. 4B so as to establish the condition of the same air flow rate, and then measuring noise in that condition. In FIG. 6, ( e ) and ( f ) represent respectively the results of measuring noise in the structures of FIG. 4A and 4B. At the same revolution speed, as shown in FIG. 5, the air flow rate is reduced in both the structures of FIG. 4A and 4B with the tip clearance C increasing. To hold the same air flow rate, therefore, it is required to increase the revolution speed as the tip clearance C increases. As shown in FIG. 6, however, both ( e ) and ( f ) have such a tendency that noise also increases as the clearance C increases.
At this time, as is apparent from comparing ( a ) and ( b ) in FIG. 5, the air flow rate in the structure of FIG. 4A is reduced in a larger amount than in the structure of FIG. 4B as the tip clearance C increases. Accordingly, in the measurement for FIG. 6, the revolution speed in the structure of FIG. 4A is generally larger than that in the structure of FIG. 4 B. As is apparent from comparing ( e ) and ( f ) in FIG. 6, noise is smaller in the structure of FIG. 4A than in the structure of FIG. 4 B. The reason is as follows.
In general, a largest part of noise generated from the cooling system of the above-mentioned type is from the impeller 20 of the cooling fan, and a largest part of noise generated from the impeller 20 is from front edges of vanes 20 b (inlets of vane). In the structure of FIG. 4B, the direction of a gap flow 21 coming in through radial gaps between the suction duct 19 and the rotary shroud 18 is opposed to the direction of a main flow 22 of cooling air, as indicated by dotted arrows in FIG. 4B, and the flow of the cooling air is greatly disturbed due to eddies or the like in a joining area of both the gap flow and the main flow. A resulting turbulent flow increases noise at the front edges of the vanes 20 b . On the other hand, in the structure of FIG. 4A, the direction of a gap flow 21 coming in through radial gaps between the suction duct 19 and the rotary shroud 18 is the same as the direction of the main flow 22 of the cooling air. Accordingly, it is possible to keep the flow of the cooling air from being disturbed due to eddies or the like, and to reduce noise correspondingly.
Further, by positioning the suction duct downstream end 19 A inside the rotary shroud suction-side end 18 A in overlapped relation like the structure of FIG. 4A, the suction duct 19 can be arranged closer to the rotary shroud 18 than the case of positioning the suction duct downstream end 19 A outside the rotary shroud suction-side end 18 A like the structure of FIG. 4B on condition that a distance e between the suction duct 19 and the impeller 20 in the axial direction of the fan is set to the same value. This is because, as indicated in FIGS. 4A and 4B, the distance e is given by a distance from the suction duct downstream end 19 A to the front edge of the vane 20 b in the structure of FIG. 4A, while the distance e is given by a distance from the suction duct downstream end 19 A to a wall surface of the rotary shroud 18 in the structure of FIG. 4 B. As a result, the engine room 2 can be made more compact corresponding to a difference between both the distances.
In the engine cooling system of this embodiment, as stated above, the suction duct downstream end 19 A is positioned inside the rotary shroud suction-side end 18 A in overlapped relation similarly to the structure of FIG. 4 A. Accordingly, noise can be reduced down to a lower level and the engine room 2 can be made more compact than resulted from the case where the suction duct downstream end 19 A is positioned outside the rotary shroud suction-side end 18 A.
(C) Actions and Effects Based on Overlap Amount Between Suction Duct and Rotary Shroud
As a next step, the inventors of this application have studied the range of an optimum value for an overlap amount d (see FIG. 2) between the suction duct 19 and the rotary shroud 18 .
If the overlap amount is less than 0 mm (i.e., negative), the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A are separated from each other, thus causing the gap flow 21 to come in from the outside of the suction duct 19 in an increased amount and lowering the fan efficiency. Also, the separation of the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A poses a difficulty in realizing a more compact engine room. Conversely, if the overlap amount d is too large, the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A are so close to each other and a distance from a joining position of the gap flow 21 and the main flow 22 of the cooling air to the front edge of the vane 20 b is so short that flow disturbance caused upon joining of both the gap flow and the main flow adversely affects the performance of the cooling fan, thereby lowering the fan efficiency and increasing noise.
With the above in mind, the overlap amount d is optimally about 20 mm. It is however required to consider manufacturing tolerances and assembly errors in construction machines such as hydraulic excavators because they are each a large welded structure as a whole. In addition, because a body of a construction machine is subject to large vibration when the machine is traveling on a not-flat road surface or during work, it is also required to avoid contact between the suction duct 19 and the rotary shroud 18 . In view of those points, an upper limit of the overlap amount d is about 40 mm. Thus, an appropriate range of the overlap amount d between the suction duct 18 and the rotary shroud 19 is 0 mm≦d≦40 mm.
In this embodiment, the overlap amount between the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A in the axial direction is set to d=20 mm so that it is possible to prevent a lowering of the fan efficiency, realize a more compact engine room, and achieve a reduction in noise while allowing manufacturing tolerances and assembly errors.
(D) Actions and Effects Based on Radial Clearance Between Suction Duct and Rotary Shroud
As a further step, the inventors of this application have studied the range of an optimum value for the radial clearance C (see FIG. 4A) between the suction duct 18 and the rotary shroud 19 .
More specifically, if the clearance C is too large in comparison with the maximum diameter Do of the vane wheel, a proportion of the gap flow 21 Joining with the main flow 22 of the cooling air is increased and the efficiency of the cooling fan is lowered (as shown in FIG. 5, for example, the air flow rate is reduced to about 95.5% of the maximum value at 2C/Do≈0.05 and to about 93.5% of the maximum value at 2C/Do≈0.06). Thus, the smaller the clearance C, the higher is the fan efficiency. In the case where the present invention is applied to construction machines such as hydraulic excavators, however, it is required as with the above (3) to consider manufacturing tolerances and assembly errors in construction machines such as hydraulic excavators because they are each a large welded structure as a whole. In addition, it is also required to avoid contact between the suction duct 19 and the rotary shroud 18 even under vibration occurred during work. In view of those points, therefore, an appropriate upper limit of the clearance C is C=0.05 Do. Thus, an appropriate range of the radial clearance C between the suction duct 18 and the rotary shroud 19 is C<0.05 Do.
In this embodiment, the radial clearance between the suction duct downstream end 19 A and the rotary shroud suction-side end 18 A is set to C=0.03 Do so that it is possible to prevent a lowering of the fan efficiency while allowing manufacturing tolerances and assembly errors.
While a centrifugal fan is employed as the cooling fan 17 in the above embodiment, the present invention is not limited to the above embodiment, and an mixed flow fan may be used instead. This case can also provide similar advantages as mentioned above.
Further, in the above embodiment, the suction duct 19 is manufactured by, e.g., pressing using a die in order to not only provide the suction duct 19 with such a form as defining a smooth flow passage shape and causing no pressure loss, but also to improve the production efficiency. However, the suction duct 19 is not limited to such a shape, but may be replaced by a suction duct 23 having a simpler shape. This modification of the suction duct will be explained with reference to FIG. 7 .
The above-mentioned manufacture method by pressing is effective in high-volume production, but it conversely pushes up a cost in low-volume production because an expensive die is employed. In the case of low-volume production, therefore, the suction duct is modified to have such a simpler structure that a ring member 23 b substantially in the form of a circular tube is integrally attached by welding, for example, to a rear wall of a substantially box-shaped introducing plate 23 a , as shown in a side and front view of FIG. 7 . The suction duct 23 can be manufactured at a relatively inexpensive cost.
According to the present invention, since a rotary shroud is provided on a impeller of a mixed flow fan or a centrifugal fan, cooling air can be produced at a large flow rate and a high pressure without lowering the fan efficiency; hence noise can be reduced. Also, since a suction duct is positioned inside the rotary shroud, it is possible to keep a flow of the cooling air from being disturbed due to eddies or the like in contrast with the case of positioning the suction duct outside the rotary shroud, and to reduce noise correspondingly. Further, since the suction duct and the rotary shroud can be arranged closer to each other on condition that a distance between the suction duct and the impeller in the axial direction of the fan is set to the same value, an engine room can be made more compact correspondingly.
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In an engine cooling system which includes an intercooler for precooling combustion air supplied to an engine, an oil cooler for cooling a hydraulic working fluid for use in a hydraulic excavator, a radiator for cooling cooling water supplied to the engine, a cooling fan in the form of a centrifugal fan, and a suction duct for introducing the cooling air to the suction side of the cooling fan, an opening diameter of a suction duct downstream end is smaller than an opening diameter of a rotary shroud suction-side end, and the suction duct downstream end is positioned inside the rotary shroud suction-side end in overlapped relation.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from Japanese Patent Application No. 2010-230585 filed Oct. 13, 2010. The entire content of the priority application is incorporated herein by reference.
TECHNICAL FIELD
The invention relates to an image processor provided with correcting means for correcting image data based on a correction table.
BACKGROUND
Many conventional printing devices for printing images on paper or other printing media using colorants, such as toner or ink, execute a calibration process for maintaining uniform printing densities, and color balance. In the calibration process, the printing device forms density patches at a plurality of density levels with the colorant used for printing, measures the densities of these patches, and updates a correction table for correcting image data based on the measured densities. By executing this calibration process at appropriate times for updating the correction table and correcting image data based on the updated correction table, the printing device can maintain consistent quality in printed images, even when the performance of the printing device changes over time.
One such conventional printing device that performs this calibration process is configured to restrain toner consumption when the device is getting low on toner by either lengthening the interval between scheduled calibration processes or skipping the process entirely.
SUMMARY
Normally, printing devices that print images with colorant are designed to estimate the number of pages that can be printed with the amount of unused colorant remaining Naturally, it is desirable that this estimated number of printable pages does not differ greatly from the actual number of printable pages. It is particularly desirable that the actual number of printable pages be not greatly less than the estimated number of printable pages.
The estimated number of printable pages is determined by estimating the quantity of colorant used for printing one sheet of the printing media. However, this estimated quantity is determined based on a default correction table created before the calibration process is executed. If the quantity of colorant used for printing one sheet of the printing media increases in the correction table when the table is updated through the calibration process, there is a high likelihood that the printing device will run out of colorant before the actual number of printable pages reaches the estimated number of printable pages.
In addition, since this conventional printing device restricts execution of the calibration process when the amount of residual toner is low, aspects of printing quality such as printing density and color balance worsen. Moreover, since this conventional printing device does not account for the originally predicted number of printable pages, the device restricts execution of the calibration process when the quantity of toner runs low, even when the actual number of printable pages is greater than the estimated number.
In view of the foregoing, it is an object of the invention to provide an art capable of preventing the problem of colorant running out before the actual number of printable pages reaches the estimated number of printable pages.
In order to attain the above and other objects, the invention provides an image processing device includes a processing unit and a memory. The memory has instructions stored thereon that, when executed by the processing unit, cause the processing unit to function as an acquiring part, a color conversion part, a correction part, an update part, an amount determining part, and a modifying part. The acquiring part acquires image data indicating an image and having an input value. The image data is printed by using at least one color material. The color conversion part converts the input value to an output value by using a color profile that correlates the input value to the output value. The output value specifies an amount of a color material of the at least one color material. The correction part corrects the output value to a corrected value by using a correction table that correlates the output value to the corrected value. The update part updates the correction table based on a density patch formed by using the at least one color material. The amount determining part determines for each color material of the at least one color material whether a first amount is greater than a second amount. The first amount is an estimated amount of the each color material to be consumed when corrected image data corrected by using the updated correction table is printed. The second amount is an estimated amount of the each color material to be consumed when corrected image data corrected by using an initial correction table that is not updated is printed. When the amount determining part determines that the first amount is greater than the second amount for one color material of the at least one color material, the modifying part modifies the color profile such that the output value in the modified color profile specifies a less amount of color material corresponding to the one color material than an amount of color material specified by the output value in the unmodified color profile corresponding to the one color material.
According to another aspect, the invention provides a non-transitory computer readable storage medium storing a set of program instructions installed on and executed by a computer. The program instructions includes acquiring image data indicating an image and having an input value where the image data is printed by using at least one color material, converting the input value to an output value by using a color profile that correlates the input value to the output value where the output value specifies an amount of a color material of the at least one color material, correcting the output value to a corrected value by using a correction table that correlates the output value to the corrected value, updating the correction table based on a density patch formed by using the at least one color material, determining for each color material of the at least one color material whether a first amount is greater than a second amount where the first amount is an estimated amount of the each color material to be consumed when corrected image data corrected by using the updated correction table is printed, and where the second amount is an estimated amount of the each color material to be consumed when corrected image data corrected by using an initial correction table that is not updated is printed, modifying the color profile, when the determining determines that the first amount is greater than the second amount for one color material of the at least one color material, such that the output value in the modified color profile specifies a less amount of color material corresponding to the one color material than an amount of color material specified by the output value in the unmodified color profile corresponding to the one color material.
BRIEF DESCRIPTION OF THE DRAWINGS
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:
FIG. 1 is a block diagram showing a general structure of a printing system according to a first embodiment;
FIG. 2( a ) is an explanatory diagram illustrating a binary image data generation process according to the first embodiment;
FIG. 2( b ) is an explanatory diagram illustrating a calibration process and a color profile adjustment process according to the first embodiment;
FIG. 2( c ) is an explanatory diagram illustrating a binary image data generation process according to a second embodiment;
FIG. 3( a ) is an explanatory diagram illustrating input values in a color profile;
FIG. 3( b ) is an explanatory diagram illustrating output values in the color profile corresponding to input values shown in FIG. 3( a ) before the color profile is modified;
FIG. 3( c ) is an explanatory diagram illustrating corrected values obtained by correcting output values shown in FIG. 3( b ) according to a default correction table;
FIG. 3( d ) is an explanatory diagram illustrating corrected values obtained by correcting output values shown in FIG. 3( b ) according to an updated correction table;
FIG. 3( e ) is an explanatory diagram illustrating differences obtained by subtracting values in FIG. 3( c ) form values in FIG. 3( d );
FIG. 3( f ) is an explanatory diagram illustrating output values in a modified color profile corresponding to input values shown in FIG. 3( a );
FIG. 3( g ) is an explanatory diagram illustrating corrected values obtained by correcting output values shown in FIG. 3( f ) according to the updated correction table;
FIG. 3( h ) is an explanatory diagram illustrating differences obtained by subtracting values in FIG. 3( c ) from values in FIG. 3( g );
FIG. 4 is a graph showing a relation between the input color values and the output color values in the color profile;
FIG. 5( a ) is a flowchart illustrating the calibration process according to the first embodiment;
FIG. 5( b ) is a flowchart illustrating a color profile adjustment process according to the first embodiment;
FIG. 6 is a flowchart illustrating an active profile setting process according to the first embodiment;
FIG. 7( a ) is an explanatory diagram illustrating an image to be printed;
FIG. 7( b ) is a conceptual diagram showing an active profile setting region;
FIG. 8 is a flowchart illustrating the binary image data generation process according to the first embodiment;
FIG. 9 is a flowchart illustrating the binary image data generation process according to the second embodiment; and
FIG. 10 is a flowchart illustrating an excessive toner usage calculation process according to the second embodiment.
DETAILED DESCRIPTION
1. First Embodiment
1-1. Overall Structure of a Printing System
FIG. 1 is a block diagram showing the general structure of a printing system configured of a personal computer 1 and a printer 2 that are capable of communicating with each other.
The personal computer 1 is a general-purpose data processor and includes a control unit 11 , a communication unit 12 , an operating unit 13 , a display unit 14 , and a storage unit 15 .
The control unit 11 performs overall control of the components in the personal computer 1 . The control unit 11 includes a CPU 111 , a ROM 112 , and a RAM 113 .
The communication unit 12 is an interface enabling the personal computer 1 to communicate and exchange data with the printer 2 .
The operating unit 13 is an input device enabling the user to input commands through external operations. In the embodiment, the operating unit 13 includes a keyboard and pointing device, such as a mouse or touchpad.
The display unit 14 is an output device for displaying various information to the user as images that the user can interpret. In the embodiment, the display unit 14 is configured of a liquid crystal display.
The storage unit 15 is a nonvolatile storage device storing data that can be overwritten. In the embodiment, the storage unit 15 is configured of a hard disk drive. Various software programs are installed on the storage unit 15 , including an operating system (OS) 151 , an application program 152 such as a graphics tool, and a printer driver 153 that enables the personal computer 1 to use the printer 2 .
The printer 2 is an electrophotographic printing device and includes a control unit 21 , a communication unit 22 , an operating unit 23 , a display unit 24 , a storage unit 25 , an image-forming unit 26 , and a density sensor 27 .
The control unit 21 performs overall control of the components in the printer 2 . The control unit 21 includes a CPU 211 , a ROM 212 , and a RAM 213 .
The communication unit 22 is an interface that enables the printer 2 to communicate and exchange data with the personal computer 1 .
The operating unit 23 is an input device enabling the user to input commands through external operations. The operating unit 23 includes various operating buttons.
The display unit 24 is an output device for displaying various information to the user as images that the user can interpret. The display unit 24 includes a small liquid crystal display.
The storage unit 25 is a nonvolatile storage device for storing data that can be overwritten. In the embodiment, the storage unit 25 is configured of flash memory.
The image-forming unit 26 is a component for forming images expressed in binary image data as visible images according to an electrophotographic method that uses toner in the four colors cyan (C), magenta (M), yellow (Y), and black (K). The image-forming unit 26 includes four photosensitive members corresponding to the four toner colors. During image formation in the image-forming unit 26 , chargers apply an electric charge to the surfaces of the photosensitive members, and exposure devices such as LED heads irradiate light onto the charged surfaces of the photosensitive members to form electrostatic latent images thereon based on binary image data for each of the CMYK colors that altogether represent a color image. The electrostatic latent images formed on the photosensitive members are developed into visible toner images by toner in the CMYK colors supplied from developing devices. The toner images in each of the CMYK colors are transferred onto a sheet of paper or other recording medium conveyed by a conveying belt so as to be superposed on each other. Subsequently, the toner images are fixed to the printing medium by heat in a fixing unit, thereby completing the process of printing an image on the printing medium. The components used for this printing process are well known in the art and, therefore, have been omitted from the drawings.
When a calibration process described later is executed, the image-forming unit 26 also forms density patches directly on the conveying belt with the toner used for printing. The density patches represent a plurality of density levels for each of the CMYK colors. The image-forming unit 26 is also provided with a cleaning member for recovering the density patches formed on the conveying belt after the calibration process.
The density sensor 27 is used for measuring the densities of the density patches formed by the image-forming unit 26 on the conveying belt.
The CPU 21 estimates the number of sheets that can be printed with the amount of unused toner based on the predetermined quantity of toner for printing one sheet printed by using the default correction table.
1-2. Process Overview
Next, an overview of processes executed on the above printing system will be described.
The printer driver 153 is started when the user of the personal computer 1 initiates a print operation in the application program 152 while the application program 152 is executing. As a process of the application program 152 , the printer driver 153 passes image data representing an image to be printed to the control unit 11 of the personal computer 1 , and the control unit 11 converts the image data to binary image data for the CMYK colors so that the data can be rendered on the printer 2 , and transfers the converted binary image data to the printer 2 . Here, the image data represents the image and specifies the pixel values. The image data passed from the application program 152 is configured of draw commands. These draw commands can be classified as bitmap draw commands for drawing photo objects (hereinafter referred to as “photo draw commands”), text draw commands for drawing text objects, and graphics draw commands for drawing graphics objects.
Therefore, in the personal computer 1 according to the embodiment, the control unit 11 first develops the image data configured of draw commands into image data expressed in 256-level RGB values. Next, as indicated in FIG. 2( a ), the control unit 11 performs a color conversion process on the RGB image data for converting this image data into data expressed in CMYK values based on a color profile that specifies correlations between the input color values (RGB values) and the output color values (CMYK values). Note that the color profile according to the embodiment refers to a device link profile linking the device profile of the display unit 14 (an ICC profile) to the device profile of the printer 2 (an ICC profile).
FIG. 3( a ) shows an example of input color values for the color profile. In this example, the input color values range from white (RGB=255, 255, 255) to blue (RGB=0, 0, 255) and from blue to black (RGB=0, 0, 0). FIG. 3( b ) is an example of output color values in the color profile. Here, the output color values correspond to the input color values in FIG. 3( a ). For example, the output color values (CMYK values) for blue corresponding to the input color values for blue (RGB=0, 0, 255) are CMYK=237, 83, 0, 0. As shown in the graph of FIG. 4 , the color progression arrives at blue with a density of 100% just before the Y and K components are added. In the following description, the “dark region” refers to the range of densities greater than blue at 100% (primary blue), while the “light region” refers to the density range from 0 to 50% blue. The range of colors between 50 and 100% blue will be referred to as the “intermediate region”.
The personal computer 1 according to the embodiment is provided with three different color profiles for various types of objects (photos, text, and graphics). Specifically, a photo color profile is provided for photo objects, a text color profile for text objects, and a graphics color profile for graphics objects.
After undergoing the color conversion process, the image data is then subjected to a correction process based on a correction table, as shown in FIG. 2( a ). The correction table in the embodiment is a look-up table specifying correlations between input values configured of CMYK values, and output values configured of corrected CMYK values (denoted as C′M′Y′K′ values in FIG. 2( a ) to distinguish them from the input values). Therefore, the corrected image data is also expressed in 256-level CMYK values.
Following the correction process, the image data is further subjected to a thresholding process using the dither method to generate binary image data for each of the CMYK colors. The personal computer 1 then transmits this binary image data to the printer 2 , and the printer 2 prints the image represented by this binary image data.
A correction table to be used in the correction process is created when the calibration process is performed. However, prior to performing the calibration process, a default correction table is used. In other words, the correction table used in the correction process is updated each time the calibration process is performed.
In the embodiment, the control unit 11 compares the correction table newly created in each calibration process (hereinafter referred to as the “updated correction table”) to the default correction table and determines whether the quantity of toner usage in the updated correction table is greater than that in the default correction table for each color of toner, as shown in FIG. 2( b ). When the control unit 11 of the personal computer 1 determines that the quantity of toner usage in the updated correction table has increased from that in the default correction table for toner of one or more colors, the control unit 11 of the personal computer 1 adjusts one or more color profiles to reduce the output values for colors whose toner usage has increased.
1-3. Detailed Description of the Processes
Next, the calibration process executed by the control unit 11 of the personal computer 1 (and more specifically the CPU 111 of the control unit 11 ) will be described with reference to the flowchart in FIG. 5( a ). The control unit 11 executes the calibration process as a function of the printer driver 153 in response to a user request.
In S 101 at the beginning of the calibration process, the control unit 11 instructs the printer 2 to measure the densities of density patches. Accordingly, the printer 2 directly forms density patches on the conveying belt with toner used for printing and measures the densities of the density patches with the density sensor 27 . Here, the density patches represent a plurality of density levels for each of the CMYK colors.
In S 102 the control unit 11 receives measured densities for the density patches from the printer 2 . In S 103 the control unit 11 creates a new correction table (updated correction table) based on the measured densities and subsequently ends the calibration process. The new correction table is created such that the printer 2 can maintain consistent quality in printed imaged even when the performance of the printer 2 changes over time.
Next, a color profile adjustment process executed by the control unit 11 of the personal computer 1 (and more specifically the CPU 111 of the control unit 11 ) will be described with reference to the flowchart in FIG. 5( b ). The control unit 11 executes this color profile adjustment process after the calibration process described in FIG. 5( a ).
In S 201 at the beginning of the color profile adjustment process, the control unit 11 compares the updated correction table to the default correction table, and in S 202 determines for each color of toner whether the toner usage in the updated correction table is higher (greater in density) than that in the default correction table. Specifically, the control unit 11 compares the sum of the correction values (output values) for all input values in the updated correction table to the sum of the correction values (output values) for all input values in the default correction table for each color of toner, and determines that toner usage in the updated correction table has increased over that in the default correction table when there exists at least one color for which the sum of correction values in the updated correction table is greater than the sum of correction values in the default correction table.
If the control unit 11 determines in S 202 that toner usage in the updated correction table has increased over that in the default correction table, then in S 203 the control unit 11 calculates the amount of increase (difference) in toner usage for colors whose sum of correction values in the updated correction table exceeds the sum of correction values in the default correction table.
This difference may be calculated, for example, as the sum of differences obtained by subtracting values resulting from performing the correction process on output values in the color profile according to the default correction table from values produced in the correction process on these output values in the color profile according to the updated correction table. FIG. 3( c ) shows the values produced in a correction process on the output color values in FIG. 3( b ) using the default correction table, while FIG. 3( d ) shows the values obtained from the correction process performed on the output color values in FIG. 3( b ) according to the updated correction table. FIG. 3( e ) shows the differences obtained by subtracting the values in FIG. 3( c ) from the values in FIG. 3( d ). In this example, the sum of differences for the CMYK colors is found to be 64, 64, 28, and 22, respectively.
In S 204 the control unit 11 newly creates a modified photo color profile based on the original photo color profile by adjusting the output color values in the dark region of the original photo color profile so that the sum of output color values in the modified photo color profile for each color is equal to a value obtained by subtracting the sum of the differences for that color calculated in S 203 from the sum of the output values in the original photo color profile for that color.
FIG. 3( f ) shows the modified output color values obtained by reducing the output color values overall in the dark region so that the sum of output color values for each of the CMYK colors in the modified photo color profile is equal to a value obtained by subtracting the sum of the differences for that color shown in FIG. 3( e ) from the sum of the output values for that color shown in FIG. 3( b ). FIG. 3( g ) shows the values obtained by performing a correction process on the output color values in FIG. 3( f ) according to the updated correction table. FIG. 3( h ) shows the differences obtained by subtracting the values in FIG. 3( c ) from the values in FIG. 3( g ). Here, the sum of the differences is “0” for each of the CMYK colors. In other words, the increase in the CMYK values in the updated correction table is canceled by reducing the output color values in the color profile.
In the embodiment, the output color values in the dark region for each color shown in FIG. 3( g ) is obtained by subtracting a constant value (“4” for C′ values, for example) from the output color values in the dark region shown in FIG. 3( d ).
In S 205 the control unit 11 creates a modified text color profile based on the original text color profile by adjusting output color values in regions other than the light region of the text color profile (the region of densities greater than 50%; i.e., the intermediate region and the dark region) so that the sum of output color values for each color in the modified text color profile is equal to a value obtained by subtracting the sum of the differences for that color calculated in S 203 from the sum of output color values for that color in the original text color profile. The details of this process are essentially the same as the process described in S 204 for the photo color profile, except that output color values in the intermediate region are modified (reduced) in addition to the dark region. Note that the output color values in the light region depicting text are not modified because reducing the output color values in this region could make the light text so light as to be illegible.
In S 206 the control unit 11 creates a modified graphics color profile based on the original graphics color profile by adjusting all output color values in the graphics color profile so that the sum of output color values for each color in the modified graphics color profile is equal to a value obtained by subtracting the sum of the difference for that color calculated in S 203 from the sum of output color values for that color in the original graphics color profile. The details of the process to adjust the graphics color profile are similar to those for the photo color profile described in S 204 , except that the control unit 11 adjusts all output color values in the graphics color profile. Subsequently, the control unit 11 ends the color profile adjustment process.
However, if the control unit 11 determines in S 202 that toner usage in the updated correction table has not increased over that in the default correction table (S 202 : NO), the control unit 11 ends the color profile adjustment process without adjusting color profiles.
Next, an active profile setting process executed by the control unit 11 of the personal computer 1 (and specifically the CPU 111 of the control unit 11 ) will be described with reference to the flowchart in FIG. 6 . The control unit 11 executes the active profile setting process as a function of the printer driver 153 when the user has initiated a print operation for printing image represented by the image data in the application program 152 .
In S 301 at the beginning of the active profile setting process, the personal computer 1 initializes an active profile setting region. The active profile setting region is an area of the RAM 113 allocated for storing profile flags indicating the type of color profile to be used in a color conversion process (hereinafter referred to as the “active profile”) for each pixel in the image to be printed. Specifically, in S 301 the control unit 11 initializes the profile flags to “0” for all pixels in the active profile setting region. In subsequent processes (S 305 and S 308 ), the control unit 11 sets profiles flags to “1” for pixels whose active profile is the photo color profile, and “2” whose active profile is the text color profile. The profile flag is left unchanged at “0” for pixels whose active profile is the graphics color profile.
FIG. 7( a ) shows a sample image to be printed. As shown in FIG. 7( a ), the image includes a photo object A 1 , text objects A 2 , and graphics objects A 3 . FIG. 7( b ) is a conceptual drawing showing the active profile setting region storing profile flags for the image in FIG. 7( a ). In FIG. 7( b ), each pixel in a region B 0 depicted in white has been initialized to “0”, each pixel in a region B 1 has the profile flag “1” indicating a photo color profile, and each pixel in regions B 2 depicted in black has been set to the profile flag “2” indicating a text color profile.
Returning to FIG. 6 , in S 302 the control unit 11 acquires one draw command that has not yet been subjected to one of the draw processes in S 304 , S 307 , and S 309 described below. The draw command is acquired from all draw commands constituting the image data representing the image to be printed and set as the process target. That is, each draw command corresponds to one object. When objects in the image to be printed are arranged in overlapping positions, the control unit 11 acquires draw commands in overlapping positions in order with the command for the topmost object being last. Consequently, the active profile for areas with overlapping objects is set based on the draw command of the topmost object at each overlapping position.
In S 303 the control unit 11 determines whether the draw command acquired in S 302 as the process target is a bitmap draw command (photo draw command). That is, the control unit 11 determines whether the object of the process target is the bitmap. If the control unit 11 determines that the process target is a bitmap draw command (S 303 : YES), in S 304 the control unit 11 executes the draw process based on the draw command. Through this process, the process target is developed into 256-level RGB data representing the photo object.
In S 305 the control unit 11 sets the profile flag to “1” indicating the photo color profile for all pixels in the active profile setting region that correspond to the drawing region for the RGB data generated in S 304 . In other words, the control unit 11 sets the active profile for all pixels constituting the photo object developed in S 304 to the photo color profile. Subsequently, the control unit 11 advances to S 310 .
However, if the control unit 11 determines in S 303 that the process target is not a bitmap draw command (S 303 : NO), in S 306 the control unit 11 determines whether the process target is a text draw command. That is, the control unit 11 determines whether object of the process target is text. If the control unit 11 determines that the process target is a text draw command (S 306 : YES), in S 307 the control unit 11 executes a draw process based on the process target. That is, if the process target is graphics draw command (i.e. the object of the process target is the graphics), the profile flags is left unchanged at “0”. Through this draw process, the process target is developed into 256-level RGB data representing the text object.
In S 308 the control unit 11 sets the profile flag to “2” indicating the text color profile for all pixels in the active profile setting region that correspond to the drawing region for the RGB data generated in S 307 . In other words, the active profile for all pixels constituting the text object developed in S 307 is set to the text color profile. Subsequently, the control unit 11 advances to S 310 .
However, if the control unit 11 determines in S 306 that the process target is not a text draw command (i.e., that the process target is a graphics draw command; S 306 : NO), in S 309 the control unit 11 executes a draw process based on the process target. Through this draw process, the process target is developed into 256-level RGB data representing a graphics object. Subsequently, the control unit 11 advances to S 310 .
In S 310 the control unit 11 determines whether the draw process has been executed for all draw commands in the image data representing the image to be printed. The control unit 11 returns to S 302 upon determining that there remain draw commands for which the draw process has not yet been executed (S 310 : NO) and ends the active profile setting process upon determining that the draw process has been executed for all draw commands (S 310 : YES).
Next, a binary image data generation process executed by the control unit 11 of the personal computer 1 (and more specifically, the CPU 111 of the control unit 11 ) will be described with reference to the flowchart in FIG. 8 . The control unit 11 executes the binary image data generation process after completing the active profile setting process in FIG. 6 as a function of the printer driver 153 .
In S 401 at the beginning of the binary image data generation process, the control unit 11 acquires pixel data (256-level RGB values) for one pixel that has yet to be subjected to a thresholding process described later (S 409 ) from the pixels in the image to be printed.
In S 402 the control unit 11 acquires the active profile from the active profile setting region that has been set for the pixel data acquired in S 401 . In S 403 the control unit 11 determines whether the active profile acquired in S 402 is the photo color profile.
When the control unit 11 determines that the active profile is the photo color profile (S 403 : YES), in S 404 the control unit 11 executes the color conversion process using the photo color profile. If the control unit 11 creates the modified photo color profile in the color profile adjustment process shown in FIG. 5( b ), the control unit executes the color conversion process using the modified photo color profile. If the modified photo color profile was not created, the control unit 11 uses the original photo color profile. Subsequently, the control unit 11 advances to S 408 described below.
However, if the control unit 11 determines that the active profile is not the photo color profile (S 403 : NO), in S 405 the control unit 11 determines whether the active profile acquired in S 402 is the text color profile.
If the control unit 11 determines that the active profile is the text color profile (S 405 : YES), in S 406 the control unit 11 executes the color conversion process using the text color profile. If the control unit 11 creates the modified text color profile in the color profile adjustment process shown in FIG. 5( b ), the control unit executes the color conversion process using the modified text color profile. If the modified text color profile was not created, the control unit 11 uses the original text color profile. Subsequently, the control unit 11 advances to S 408 described below.
However, if the control unit 11 determines that the active profile is not the text color profile (i.e., that the active profile is the graphics color profile; S 405 : NO), in S 407 the control unit 11 executes the color conversion process using the graphics color profile. If the control unit 11 creates the modified graphics color profile in the color profile adjustment process shown in FIG. 5( b ), the control unit executes the color conversion process using the modified graphics color profile. If the modified photo color profile was not created, the control unit 11 uses the original graphics color profile. Subsequently, the control unit 11 advances to S 408 .
In S 408 the control unit 11 performs the correction process to correct the CMYK values produced from the color conversion process based on the correction table. In S 409 the control unit 11 executes the thresholding process for converting the 256-level CMYK values produced from the correction process into binary values (2-level values).
In S 410 the control unit 11 determines whether the thresholding process has been executed for all pixels in the image to be printed. The control unit 11 returns to S 401 upon determining that there remain pixels that have not been subjected to the thresholding process (S 410 : NO) and ends the binary image data generation process upon determining that all pixels have been subjected to the thresholding process (S 410 : YES).
1-4. Effects of the Embodiment
According to the first embodiment described above, the personal computer 1 can reduce the levels of toner used through the color conversion process by adjusting the color profiles so as to reduce output color values when the toner usage in the updated correction table is greater than that in the default correction table. As a result, the personal computer 1 can neutralize the increase in toner usage so that the printer 2 is less likely to run out of toner before the actual number of printed sheets reaches the number of printable sheets estimated based on the default correction table.
By adjusting the photo color profile to reduce output color values in the dark region in particular, the personal computer 1 can reduce toner usage without a likely drop in the quality of printed photo objects. Color balance and gradation levels are extremely important for photo objects, and changes in toner usage in light and intermediate regions can upset the CMYK color balance. However, since the dark region contains near-black colors, reducing output color values in the dark region does not dramatically change the color tones, despite there being a slight shift in the color balance.
Further, the personal computer 1 according to the embodiment adjusts the text color profile to reduce output color values in regions other than the light region. Accordingly, the personal computer 1 can reduce the quantity of toner usage while preventing light text from becoming so light as to be illegible.
Further, the personal computer 1 according to the embodiment adjusts the graphics color profile to reduce all output color values. Hence, the personal computer 1 can prevent a drop in quality in the printed images.
In addition, by making an overall determination as to whether the toner usage in the updated correction table is greater than that in the default correction table without regard for the image being printed, the personal computer 1 can reduce the process load required for this determination.
2. Second Embodiment
2-1. Differences from the First Embodiment
Next, a second embodiment of the invention will be described. The second embodiment has the same basic configuration as the first embodiment, but differs in the following points.
(1) The personal computer 1 according to the second embodiment determines whether toner usage in the updated correction table has increased over toner usage in the default correction table by comparing the sums of CMYK values for all pixels obtained when correcting the image data representing the image to be printed based on the default correction table to the sums of CMYK values for all pixels obtained when correcting the image data based on the updated correction table for each of the toner colors. In other words, the personal computer 1 determines whether toner usage in the updated correction table is greater than that in the default correction table based on the image to be printed.
(2) The personal computer 1 according to the second embodiment calculates the differences obtained by subtracting the sum of CMYK values for all pixels obtained when correcting the image data based on the updated correction table from the sum of CMYK values for all pixels obtained when correcting the image data based on the default correction table for each of the toner colors. These differences are accumulated for each color of toner as the total surplus (as described later in S 513 ) each time the image is printed.
(3) The personal computer 1 according to the second embodiment determines whether the quantity of toner usage in the updated correction table has increased over the quantity of toner usage in the default correction table for one or more colors. When this amount of increase, which is the amount of excessive usage, exceeds the total surplus calculated above, the personal computer 1 adjusts the color profile to reduce the output color values (CMYK values) for the colors whose toner usage has increased.
Specifically, as shown in FIG. 2( c ), the personal computer 1 according to the second embodiment calculates the total surplus of toner based on image data produced in the correction process. If the excessive usage is less than or equal to the total surplus, the personal computer 1 does not adjust the color profile, even though the toner usage in the updated correction table is greater than that in the default correction table. Hence, rather than performing the color profile adjustment process in FIG. 5( b ), the active profile setting process in FIG. 6 , and the binary image data generation process in FIG. 8 described in the first embodiment, the personal computer 1 according to the second embodiment performs a binary image data generation process shown in FIG. 9 and an excessive toner usage calculation process shown in FIG. 10 . The remaining configuration of the second embodiment is identical to that in the first embodiment and will not be described below.
2-2. Detailed Description of the Processes
Next, the binary image data generation process executed by the control unit 11 of the personal computer 1 (and more specifically, the CPU 111 of the control unit 11 ) will be described with reference to the flowchart in FIG. 9 . The control unit 11 executes the binary image data generation process as a function of the printer driver 153 in response to a print operation for printing the represented by the image data initiated by the user. The binary image data generation process is performed after the control unit 11 executes a draw process for image data including draw commands in the drawing region.
In S 501 at the beginning of the binary image data generation process, the control unit 11 executes the color conversion process using a normal color profile. In S 502 the control unit 11 executes an excessive toner usage calculation process. FIG. 10 is a flowchart illustrating steps in the excessive toner usage calculation process. In S 601 of the process in FIG. 10 , the control unit 11 corrects the CMYK image data according to the default correction table.
In S 602 the control unit 11 corrects the CMYK image data based on the current correction table. The “current correction table” is the default correction table before the calibration process has been executed once and is the updated correction table after the calibration process has been executed once.
In S 603 the control unit 11 sets a target toner color X to cyan (C). Here, X is a variable representing one of the colors C, M, Y, and K. In the following description, X will be treated as the color set as the process target.
In S 604 the control unit 11 sets a target pixel (i.e., a pixel to be processed) to the first pixel in the image (the pixel in the upper left, for example). In S 605 the control unit 11 compares the value of X toner in the image data created in S 601 (hereinafter referred to as the “default correction value”) to the value of X toner in the image data created in S 602 (hereinafter referred to as the “current correction value”) for the target pixel and calculates the difference between the two values (i.e., current correction value—default correction value).
In S 606 the control unit 11 updates the excessive usage of X toner by adding the difference calculated in S 605 to the quantity of excessive usage for X toner accumulated thus far and temporarily stored in the RAM 113 . Hence, the control unit 11 adds up the difference calculated for each target pixel in order to find the sum of differences for all pixels in the image, and sets this sum as the excessive usage. The control unit 11 updates the excessive usage in the RAM 113 such that the excessive usage indicates this sum.
In S 607 the control unit 11 determines whether the target pixel is the last pixel in the image (the pixel on the bottom right, for example). If the control unit 11 determines that the target pixel is not the last pixel of the image (S 607 : NO), in S 608 the control unit 11 sets the target pixel to the next pixel after the current target pixel, and subsequently returns to S 605 .
However, if the control unit 11 determines that the target pixel is the last pixel (S 607 : YES), in S 609 the control unit 11 determines whether the toner color X currently being processed is black (K). If the control unit 11 determines that the toner color X is not black (S 609 : NO), in S 610 the control unit 11 changes the toner color set as X to another color. Specifically, if the toner color X is currently cyan, the control unit 11 changes the process target to magenta. If the toner color X is currently magenta, the control unit 11 changes the process target to yellow. If the toner color X is currently yellow, the control unit 11 changes the process target to black. Subsequently, the control unit 11 returns to S 604 .
However, if the control unit 11 determines in S 609 that the process target of the toner color X is black (i.e., that all of the CMYK colors have been processed; S 609 : YES), the control unit 11 ends the excessive toner usage calculation process. Through the excessive toner usage calculation process described above, the control unit 11 calculates excessive toner usage (amount of increase in toner usage) for each of the CMYK colors.
In S 606 the difference (current correction value—default correction value) for the target pixel is added to the excessive usage for each toner color X. After the control unit 11 finishes the excessive toner usage calculation process that repeats S 605 and S 606 shown in FIG. 10 , the excessive usage for each color indicates a difference of a sum of the current correction value for all pixels and a sum of the default correction value for all pixels for each of CMYK colors.
Returning to the flowchart in FIG. 9 , in S 503 the control unit 11 sets the toner color X to the process target cyan. In S 504 the control unit 11 resets the X toner correction amount to “0”. In S 505 the control unit 11 determines whether the excessive usage of X toner calculated in S 502 is greater than “0”. In other words, the control unit 11 determines whether the amount of toner usage in the current correction table has increased over that in the default correction table.
When the control unit 11 determines in S 505 that the excessive usage of X toner is greater than “0” (S 505 : YES), in S 506 the control unit 11 determines whether the excessive usage of X toner is greater than the total surplus of X toner. If the control unit 11 determines that the excessive usage of X toner is greater than the total surplus of X toner (S 506 : YES), in S 507 the control unit 11 finds the X toner correction quantity by subtracting the total surplus of X toner from the excessive usage of X toner. In other words, the control unit 11 sets the correction quantity to the portion of the excessive usage not counterbalanced by the total surplus. Subsequently, the control unit 11 advances to S 508 .
However, if the control unit 11 determines in S 505 that the excessive usage of X toner is less than or equal to “0” (S 505 ; NO) or if the control unit 11 determines in S 506 that the excessive usage of X toner is less than or equal to the total surplus of X toner (S 506 : NO), then the control unit 11 advances directly to S 508 while leaving the correction quantity for X toner at “0”.
In S 508 the control unit 11 determines whether the current process target of the toner color X is black. If the toner color X is not black (S 508 : NO), in S 509 the control unit 11 changes the process target for the toner color X. That is, if the toner color X is currently cyan, the control unit 11 changes the process target to magenta. If the toner color X is currently magenta, the control unit 11 changes the process target to yellow. If the toner color X is currently yellow, the control unit 11 changes the process target to black. Subsequently, the control unit 11 returns to S 504 .
However, if the control unit 11 determines in S 505 that the process target of toner color X is black (i.e., that the above process has been performed for all CMYK colors; S 508 : YES), in S 510 the control unit 11 determines whether the toner correction quantity is no greater than “0” for all four CMYK colors.
If the control unit 11 determines that one or more toner colors have a correction quantity greater than “0” (S 510 : NO), in S 511 the control unit 11 creates a color profile that reduces the toner usage for each color by the toner correction quantity of the corresponding color. The same method described in the first embodiment may be used to correct the color profile. For example, the control unit 11 may adjust all output color values so that the sum of output color values for each color is reduced an amount equivalent to the toner correction quantity. As described in the first embodiment, the control unit 11 may perform separate processes based on the type of object.
In S 512 the control unit 11 performs the color conversion process using the new color profile created in S 511 . Subsequently, the control unit 11 returns to S 502 and repeats the process described above from S 502 using the adjusted color profile.
However, if the control unit 11 determines in S 510 that the toner correction quantity for each of the four CMYK colors is “0” or less (S 510 : YES), in S 513 the control unit 11 updates the total surplus by subtracting the excessive usage from the current total surplus for toner in each of the CMYK colors. Note that the total surplus is increased when the excessive usage is smaller than “0”. The excessive usage for each color indicated the difference of the sum of the current correction value for all pixels and the sum of the default correction value for all pixels. Thus, the total surplus indicates the accumulation of the negative value of the excessive usage. The total surplus resets to a prescribed initial value when a new toner (a toner cartridge (not shown), for example) is mounted.
In S 514 the control unit 11 executes a thresholding process for converting image data produced in the correction process based on the current correction table in S 602 to binary values. Subsequently, the control unit 11 ends the binary image data generation process.
2-3. Effects of the Second Embodiment
As described above, the personal computer 1 according to the second embodiment can make a relatively more accurate determination regarding whether toner usage in the updated correction table has increased over that in the default correction table since the personal computer 1 makes this determination for each printing operation using the image data representing the image being printed.
Moreover, the personal computer 1 according to the second embodiment does not adjust the color profile unless the excessive usage of toner has exceeded the total surplus, even when the toner usage in the updated correction table has increased over that in the default correction table. Hence, this method prevents the personal computer 1 from unnecessarily restricting toner usage when extra toner was left over from a previous printing operation.
3. Variations of the Embodiments
While the invention has been described in detail with reference to specific embodiments thereof, it would be apparent to those skilled in the art that many modifications and variations may be made therein without departing from the scope of the invention, the scope of which is defined by the attached claims.
(A) The personal computer 1 according to the first embodiment described above uses a photo color profile for photo objects, a text color profile for text objects, and a graphics color profile for graphics objects, but the invention is not limited to this configuration. For example, the personal computer 1 may share the same color profile for both text and graphics objects so that overall output color values in text objects are also adjusted, as with the graphics color profile.
(B) In the embodiments described above, the printer 2 forms density patches on the conveying belt used for conveying the printing media. However, if the printer 2 is configured to transfer toner images temporarily from the photosensitive members to an intermediate transfer belt and subsequently to transfer the full color image from the intermediate transfer belt to the printing medium, the printer 2 may form the density patches on the intermediate transfer belt. Alternatively, the printer 2 may form density patches on the printing medium.
(C) Although toner is used as an example of colorant (color material) in the embodiments, the colorant of the invention is not limited to toner, but may instead be ink, for example.
(D) While the process according to the invention is performed by the personal computer 1 in the embodiments, this process may be performed on the printer 2 side instead, for example.
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In the image processing device, the color conversion part converts the input value to an output value by using a color profile. The correction part corrects the output value to a corrected value by using a correction table. The update part updates the correction table based on a density patch. The first and second amount is an estimated amount of the color material to be consumed when corrected image data corrected by either using the updated correction table or using an initial correction table, respectively, is printed. When the amount determining part determines that the first amount is greater than the second amount, the modifying part modifies the color profile such that the output value in the modified color profile specifies a less amount of color material than an amount of color material specified by the output value in the unmodified color profile.
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FIELD OF THE INVENTION
The present invention relates to safety sports eyewear. More particularly, this invention relates to sports eyewear frames for use in sporting activities to prevent eye injury to a player from a ball, equipment, hands, or the like.
BACKGROUND OF THE INVENTION
In a large number of sporting activities, such as tennis, handball, squash, racquetball, basketball, soccer, and other sporting activities in which there is fast movement of players and the use of a ball, there is a continuing danger of a participant being struck in the eye by the ball, racket or hand of an opponent, which can result in severe injury or even, in some cases, loss of an eye. Thus, the use of protective eyewear is advisable.
Numerous types of safety sports eyewear are available, as exemplified by U.S. Pat. Nos. 4,367,561, and 4,229,837 to Solari; and U.S. Pat. No. 4,176,410 to Matthias.
Many of these sports frames have padding in the nose, forehead, and temple areas which make the eyewear safer and more comfortable for the participant. In most cases, however, the padding which is secured to the frame by adhesive detaches from the frame in a short time. This is partly because of the normal wear and tear, and partly because of moisture from the participant's perspiration.
Thus, there is a continuing need for a sports frame having padding which will not become detached from the frame even after extended wear.
SUMMARY OF THE INVENTION
Accordingly, the primary object of the present invention is to provide a sports frame which has padding that will not become detached from the frame even after extended wear and use.
The foregoing object is basically attained by providing a sports frame with at least one resilient pad comprising a rigid frame having first and second sides, at least one opening formed in the frame extending from the first side to the second side, and at least one resilient pad which has a tongue that is interlocked in the frame opening.
Other objects, advantages, and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the invention.
DRAWINGS
Referring now to the drawings which form a part of this original disclosure:
FIG. 1 is a front perspective view of a sports frame having several openings therein in accordance with the present invention;
FIG. 2 is a front perspective view of the sports frame of FIG. 1 after padding has been molded onto the frame;
FIG. 3 is a right side perspective view of a different sports frame having openings therein in accordance with the invention;
FIG. 4 is a top plan view in section of the sports frame of FIG. 3 taken along line 4--4, and padding having a tongue which is to be interlocked in the opening of the sports frame;
FIG. 5 is a top plan view in section of the sports frame and padding of FIG. 4 showing the tongue of the padding interlocked in the opening of the sports frame;
FIG. 6 is a rear perspective view of the sports frame of FIG. 3 after the nose pad and temple pads have been attached; and
FIG. 7 is a top plan view of the sports frame of FIG. 6 showing the positioning of the padding, the frame openings, and the interlocked tongues.
DETAILED DESCRIPTION OF THE INVENTION
As seen in FIG. 1, a sports frame 10 in accordance with the invention may take the form of an integrally molded, rigid frame having first and second sides 12 and 14, and including front portion 16 having a nose-area recess 17, and rearwardly extending side portions 18 and 20 connected thereto. The front portion 16 has two apertures therein 22 and 24 having inwardly opening peripheral recesses 26 and 28 therein which are designed to receive lenses that may be either refractive or non-refractive.
The front portion 16 of sports frame 10 has openings 30, 32, 34, and 36 which extend from the first side 12 to the second side 14 of the front portion 16. The side portions 18 and 20 also contain openings 38, 40, 42, and 44 which likewise, extend from the first side 12 to the second side 14 of the side portions 18 and 20. The front portion 16 of frame 10 also contains openings 46, 48, 50, and 52 extending from side to side.
As seen in FIG. 1, openings 30, 32, 34, and 36, as well as openings 46, 48, 50 and 52, comprise through-slots which extend from side to side of the frame 10, while openings 38, 40, 42, and 44 comprise through-apertures which extend from side to side of the frame.
The side portions 18 and 20, in the form of rearwardly extending members, contain additional openings 54 and 56, which are designed to receive retaining means for retaining the sports frame securely against the face of the wearer. The retaining means commonly comprises an elastic headband.
FIG. 2 shows the sports frame of FIG. 1 after resilient pads 58, 60 and 62 have been molded thereto. As seen in FIG. 2, slots 30, 32, 34, and 36 now contain tongues 64, 66, 68, and 70 which are interlocked in these slots by being attached to the resilient nose-area padding 58 on the first side 12 of sports frame 10, extending longitudinally through the slots and being attached to the padding 58 on the second side 14 of the frame. Similar tongues, not shown, are provided in slots 46, 48, 50 and 52.
As seen in FIG. 2, tongues 71 and 72 also extend from the padding 60 on the first side 12 through apertures 38 and 40 and are attached to the padding on the second side 14, thereby interlocking the tongues in the apertures and securing the temple-area padding to the side portion 18. Likewise, tongues extend from the padding 62 on the first side 12 of side portion 20 through apertures 42 and 44, and are attached to the padding on the second side 14, thereby securing the temple-area padding on the side portion 20.
The integrally molded frame 10 can be comprised of any material, but is advantageously comprised of a lightweight, moldable, shatterproof polymeric material, such as cellulose acetate.
The padding can also be comprised of any material which provides a cushioning effect for the wearer, and which is resilient, able to withstand normal wear and tear, and able to be molded onto the frame. A particularly advantageous padding which fulfills all of the above requirements is Kraton G, a proprietary product of Shell Chemical Co. which is comprised of a block copolymer of butadiene, isoprene, and styrene.
The process for making the padded sports frame shown in FIGS. 1-2 is relatively simple and straightforward. First, the frame is molded out of a polymeric material such as, for example, cellulose acetate. The frame is then removed from the first mold and placed in a second mold where the padding is molded around the frame and through the openings, thereby assuring the permanency of the pad.
EMBODIMENT OF FIGS. 3-7
Referring now to FIGS. 3-7, an alternate embodiment of the invention is shown comprising a frame 80 having first and second sides 82 and 84, and apertures 86 and 88 having peripheral recesses 90 and 92 therein for receiving lenses that are either refractive or non-refractive.
Also shown in FIG. 3 are openings 94, 96, and 98 which extend from the first side 82 to the second side 84 of frame 80. A nose recess 100 is also provided.
Referring now to FIGS. 4 and 5, the method by which modified resilient pads are attached to frame 80 is illustrated.
As seen in FIG. 4, temple-area resilient pad 102 is shown having a base portion 104, cylindrical tongue 106, enlarged frustoconical portion 108 and elongated cylindrical segment 110, all of which are integrally formed as one piece. Adjacent the pad 102 is opening 98 of sports frame 80, which is shown in FIG. 3.
In order to secure the pad 102 to frame 80 and interlock the tongue in the opening 98, elongated segment 110 is inserted through the opening 98 on the second side 84 of frame 80 until it protrudes through the opening on the first side 82. The elongated segment 110 is then pulled through the opening until the enlarged portion 108 is located entirely on the first side of the frame as shown in FIG. 5. Because the tongue 106 is approximately the same length as the length of the opening 98, the base 104 is held securely against the second side of the frame 84.
Once the pad 102 is secured to the frame 80, the elongated segment 110 may be removed by cutting along line x--x, thereby leaving only the enlarged portion 108 remaining on the first side 82 of frame 80.
FIGS. 6 and 7 show the sports frame after the temple pads 102 and 112, and nose and forehead pad 114 have been secured in the manner described above.
While two advantageous embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
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A sports eyewear frame having resilient padding attached to the frame by means of one or more tongues which are attached to the pads, and interlocked in openings provided in the frame. The pads, which can be molded-on or snapped-on, provide the sports frame with lifetime padding under normal wear and tear conditions.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of generating a hydrogen and oxygen gasses using electricity and more particularly to an apparatus and method that produces the gasses in an efficient manner while permitting continuous control of gas production.
[0003] 2. Description of the Related Art
[0004] Using electricity to decompose water into hydrogen and oxygen gas was discovered by William Nicholson in 1800. The process uses two electrodes, a cathode and an anode, immersed in water (not pure water). The electrodes are coupled to a direct current power source, the cathode to the negative power source and the anode to the positive power source. As current passes through the water, hydrogen is produced around the cathode and oxygen around the anode. The gasses may be left separate or allowed to mix, the mixed gasses often known as “Brown's gas,” hereby referred to as “brown gas.” Burning the brown gas produces an intense heat that can be used in welding, to heat buildings, or heat water. pollution and no negative health effects. During the burning of brown gas, heat and water are produced and virtually no pollutants, thereby allowing burning within occupied spaces without consuming air during the burning process and without the need for an exhaust. There are no known health issues with brown gas, in that handling the gas, a gas leak or exhausts from the burning process don't include CO or CO 2 or any other gas that will cause suffocation. Furthermore, because brown gas is lighter than air, any leakage will dissipate into the air, whereas other commonly used gasses such as propane are heavier than air, collect at ground level and can be inadvertently ignited. On the negative side, Hydrogen gas and brown gas are volatile and proper precautions must be taken to prevent explosion.
[0005] Current electrolysis techniques use a low-voltage, direct current passing through electrodes immersed in water (a mild acid may be added to increase current flow). Currently, tens to hundreds of ampere are required to produce brown gas in significant volume, requiring around 4 kWh of power to produce 1000 L of hydrogen. It has been measured that 1L of water produces 1234 L of hydrogen and 605 L of oxygen. Being that ⅔s of the earth's surface is covered with water; an almost limitless supply of brown gas (or hydrogen) is available given sufficient electrical input. It can be seen that the production of brown gas through electrolysis creates a greater volume of brown gas than the water used in the conversion process, hence, the as the process continues in a confined space, the brown gas becomes pressurized.
[0006] There is a need for using brown gas in a commercial embodiment. U.S. Pat No. 2,098,629, “Production of Gas and Combustion Thereof,” to Knowlton, describes a method of generating brown gas and burning the gas to heat water and is hereby incorporated by reference. This patent uses DC power derived by rectifying AC power using a full-wave bridge rectifier. In this, production of gas is regulated by mechanically monitoring the gas pressure and halting electrolysis by disconnecting the DC power source when the pressure exceeds a predetermined threshold set by a spring.
[0007] Unfortunately, the amount of electricity required for generating brown gas and the ability to discretely control the production of the gas in response to demands limits the efficiency of prior systems.
[0008] What is needed is a method and apparatus that will efficiently produce Brown gas with a robust control to modulate production to match consumption.
SUMMARY OF THE INVENTION
[0009] In one embodiment, an apparatus for producing brown gas is disclosed including a sealed tank with an exit for extracting the brown gas and a source of modulated direct current with a positive and a negative output; the source can vary the duty cycle of the outputs. At least one anode within the sealed tank is connected through an opening to the positive output and at least one cathode within the sealed tank is connected through a second opening to the negative output and both are at least partially immersed in water. A pressure sensor is coupled to the sealed tank for measuring a pressure of the brown gas and is connected to the source of modulated direct current. The source of modulated direct current changes the duty cycle of the outputs in response to changes in the pressure.
[0010] In another embodiment, a method of producing brown gas is disclosed including providing a sealed tank with an exit for extracting the brown gas and a source of modulated direct current with a positive and a negative output; the source is able to vary a duty cycle of its outputs. At least one anode is provided within the sealed tank and is connected through an opening in the sealed tank to the positive output of the source of modulated direct current. At least one cathode is provided within the sealed tank and is connected through a second opening in the sealed tank to the negative output of the source of modulated direct current. The at least one anode and at least one cathode are immersed in water. The pressure of the brown gas is measured and the duty cycle of the outputs are changed in response to changes in pressure.
[0011] In another embodiment, a means for producing brown gas is disclosed including a tank with an exit for extracting the brown gas and a direct current modulator having a positive output and a negative output. The modulator has a way to vary the duty cycle of the outputs. There is at least one anode within the tank connected through an opening to the positive output of the direct current modulator and at least one cathode within the tank connected through a second opening in the tank to the negative output of the direct current modulator. The anodes and cathodes are at least partially immersed in water. There is a pressure sensor coupled through an opening in the tank and connected to the direct current modulator for measuring the pressure of the brown gas. The direct current modulator changes the duty cycle of the outputs in response to the pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
[0013] FIG. 1 illustrates a schematic view of the apparatus of the present invention.
[0014] FIG. 2 illustrates a plan view of the present invention.
[0015] FIG. 3 a - FIG. 3 c illustrates power delivery waveforms of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. Throughout this specification, the term “brown gas” is used to describe the mixture of hydrogen (H 2 ) and oxygen (O 2 ) generated through the electrolysis of water. Brown gas is not limited to only hydrogen and oxygen, in that other impurities may exist in the gas without veering from the present invention. Furthermore, the same process and same system works equally well to generate oxygen (O 2 ) and hydrogen (H 2 ) and each may be stored separately and combined later as needed. Throughout this specification, the term water refers to water (H 2 O) with minerals and/or salts such as ordinary tap water, which is a conductor of electricity. Pure water cannot be used because it is an insulator and electricity would not flow and electrolysis would not occur.
[0017] Referring to FIG. 1 , a schematic of the apparatus of the present invention is shown. Although showing an alternating current power source 10 , the present invention works equally well with a direct current (DC) power source. The source power 10 is rectified by a rectifier 12 . Shown is a full-wave bridge rectifier 12 , though any suitable rectifier configuration works equally as well. The DC output 14 of the rectifier 12 is connected to a duty cycle and frequency modulator and high current driver 16 that modulates the DC voltage, and hence output current. The duty cycle and frequency modulator and high current driver 16 has an input from 22 from the pressure sensor 36 that is used to adjust the duty cycle in response to pressure changes as will be explained later. High current drivers 16 are known in the industry an example of which is a high-current power MOSFETs, silicon controlled rectifiers (SCRs), Triacs or other transistor or multiples of such configured in a parallel fashion, or any other type of high current amplifier including a fast-acting relay. Although, as shown, the AC power is converted to DC power by the rectifier 12 , then the DC power is modulated, there are other ways to modulate the duty cycle that work equally as well. Because of the high current and low voltage required, a step-down transformer (not shown) is often required. In an alternate embodiment, the duty cycle of the AC input to the step-down transformer is controlled using an SCR or Triac, in much the same way as a light dimmer operates. The low-voltage output of the transformer is rectified, resulting in a low-voltage, high-current variable pulse-width DC current.
[0018] The positive output 24 of the high current driver 16 is connected to a series of anodes 32 that are submerged in a tank 31 of water (not pure water). The negative output 26 of the high current driver 16 is connected to a series of cathodes 34 , also submerged in water within the tank 31 and alternately intermixed within the tank 31 , so as to provide a high amount of surface area to provide lower impedance to the flow of electricity between the cathodes 34 and the anodes 32 .
[0019] The area above the water level 30 allows for the collection of brown gas as current flows between the cathodes 34 and the anodes 32 . A valve 40 controls the flow of brown gas out of the tank 31 through a pipe or tube 42 . Not shown are various protection devices to prevent back flashes from reaching the tank 31 , potentially causing an explosion. A pressure sensor 36 monitors the pressure in the tank 31 and is coupled to the duty cycle and frequency modulator and high current driver 16 through signal path 22 . The duty cycle and frequency modulator and high current driver 16 reduces the duty cycle as the pressure increases, thereby limiting the gas pressure. Alternately, the duty cycle and frequency modulator and high current driver 16 increases the duty cycle as the pressure decreases, thereby supplying the needed gas pressure.
[0020] To understand the closed-loop operation of the system, assume the gas output 42 is connected to a hot-water heater (not shown). When the system is first started, no brown gas is present in the tank 31 ; therefore the pressure measured by the pressure sensor 36 is zero (roughly atmospheric pressure). When power is applied, the duty cycle and frequency modulator and high current driver 16 determines that there is no gas pressure and delivers power as in the waveform in FIG. 3 c , thereby producing brown gas at a high-volume output. As the pressure increases, the gas pressure sensor 36 relays this to the duty cycle and frequency modulator and high current driver 16 and a waveform with a 50% duty cycle (as in FIG. 3 b ) is generated, thereby producing a medium amount of brown gas. When the gas pressure reaches a high level, the duty cycle and frequency modulator and high current driver 16 delivers a waveform with a low duty cycle (as in FIG. 3 a ), thereby producing a very small amount of brown gas without stopping the reaction within the water. When the water heater requires gas, for example when water is being used, the valve 40 opens and gas flows from the tank 31 to the water heater, thereby reducing the gas pressure. As the sensor measures a lower pressure, the duty cycle and frequency modulator and high current driver 16 increases the duty cycle delivered to the anodes 34 and cathodes 32 , thereby increasing the production of brown gas. Therefore, only a small amount of brown gas is stored in the tank 31 and when needed, the duty cycle is increased causing production of brown gas to increase.
[0021] The relative gas production is charted against the duty cycle of the frequency modulator in Chart 1. The measurements in Chart 1 were taken using a 100 SCFH flow meter. The frequency modulator uses a full-wave rectifier producing unfiltered direct current of 120 pulses per second having an approximate period of 8.3 ms. The duty cycle is varied by delaying the application of power to the plates of the electrolyzer during each pulse by ⅛, 2/8, ⅜, 4/8, ⅝, 6/8, ⅞ and 8 / 8 , thereby generating duty cycles of 0, 12.5%, 25%, 37.5%, 50%, 62.5%, 75%, 87.5% and 100%. It can be seen in the chart that the gas production varies proportionately with the duty cycle. It can also be seen that the measured data (solid line) is substantially greater than the linear production (dashed line), showing the gas production is more efficient using pulsed direct current rather than using direct current. For example, at a 75% duty cycle, the measured gas production is 96% of the maximum, in that, reducing power input to the system to 75% yields gas production of 96% instead of 75%, producing much higher efficiencies than a system using direct current only. It should be noted that the first two data points of the measured data (0.125 and 0.25) are estimated because the gas production is too slow to accurately measure.
[0022] Referring to FIG. 2 a plan view of the present invention is shown. The tank 80 is filled with water to a level 86 high enough to at least partially cover the anodes 32 and cathodes 34 . A pipe or tube 43 provides a path for the brown gas to be transported to an appliance such as a heater or water heater. In practice, several safety systems (not shown) are attached to the pipe 43 before reaching the appliance to reduce the chances of a back flash reaching the tank 80 and causing an explosion. The top edge of the tank 80 has a flat surface with holes or threads 84 for attaching to the cover 90 through matching holes 94 (the fasteners are not shown for clarity purposes but can be any known in the industry). On the cover 90 , two holes 96 are provided to pass electricity into the electrolysis process. In embodiments where the cover 90 is made from a conductive material, insulators 97 are deployed between the positive 24 and negative 26 terminals of the electrolysis grid and the cover 90 . Each cathode 34 is connected to the negative terminal by a buss 27 and each anode 32 is connected to the positive terminal 24 by a second buss 25 . At the opposite end of each anode 32 and cathode 34 are insulating spacers 39 that keep the ends from getting too close and shorting against each other. Although two pairs of anodes 32 and cathodes 34 are shown, any number and any size is possible depending upon the brown gas output rate desired. Increasing the surface area of the anodes 32 and cathodes 34 , or spacing them closer or increasing their quantity reduces the impedance of the electrolysis grid, allowing higher current and, hence, higher production of brown gas. A pressure sensor/transducer 104 is connected through a pipe 88 into the tank 80 at a point above the water level 86 so gas pressure can be measured and transferred to the duty cycle and frequency modulator and high current driver 102 through wires 105 . In one embodiment, AC power is supplied to the duty cycle and frequency modulator and high current driver 102 by AC power cable 100 . The modulated DC output from the duty cycle and frequency modulator and high current driver 102 is delivered on a negative conductor 106 that connects to the cathodes 34 through the negative terminal 26 and a positive conductor 108 connecting to the anodes 32 through the positive terminal 24 .
[0023] Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
[0024] It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
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A method and apparatus for producing hydrogen and oxygen gas includes a tank for capturing the gas and holding anodes and cathodes submersed in water. An electrical supply is attached to the anodes and cathodes, providing direct current modulated at a duty cycle that is varied depending on the measured pressure of the produced gas.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a division of Ser. No. 09/892,037, filed Jun. 26, 2001, which is a division of pending application Ser. No. 09/007,599, filed Jan. 15, 1998, now U.S. Pat. No. 6,264,623, which is a division of Ser. No. 08/097,378, filed Jul. 23, 1993, now U.S. Pat. No. 5,753,227, the disclosures of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Atherosclerosis and cancer are the two major causes of morbidity and mortality in western societies. While there has been significant advance in the treatment of atherosclerosis there is still a great need for more effective treatment interventions.
[0003] The main mechanism by which atherosclerosis leads to morbidity and mortality is by narrowing the lumen of arteries and reducing the blood supply to the heart, brain and other vital organs. The factors associated with atherosclerosis include: High levels of cholesterol, triglycerides, low density lipoproteins (LDL) and low levels of high density lipoproteins (HDL).
[0004] Other factors are heredity, cigarette smoking, obesity, high blood pressure, reduced physical activity, high fat diets, and a high oxidation activity associated with the production of free radicals, leading to the oxidation of LDL, which accelerates the development of atherosclerotic lesions. Thus, J. Regnström et al., Lancet, Vol. 339, No. 8803 , May 16, 1992, pp. 1183-86, reported that the susceptibility of LDL to in vitro oxidation in the presence of copper, which acts as a catalyst in the oxidation process, was correlated with the severity of their coronary artery sclerosis. J. T. Salonen et al, Lancet, Vol. 339, No. 8798 , Apr. 11, 1992, pp. 883-87, found that the level of autoantibodies to oxidized LDL predicted the progression of atherosclerosis of the carotid artery (the artery that supplies blood to the brain). One likely mechanism in development of atherosclerotic lesions via the oxidation of LDL is the induction of an autoimmune process leading to the production of antibodies specific to oxidized LDL and propagation of the atherosclerotic lesion by the autoantibody binding to oxidized LDL. J. Regnström et al., supra, and T. Kita et al., Proceedings of the National Academy of Sciences USA, Vol. 84, 1987, pp. 5928-31. J. T. Salonen et al., Circulation, Vol. 86(3), September 1992, pp. 803-11 reported an association between the risk of heart attack and the level of iron in the blood, with the risk being particularly high when plasma levels of both iron and LDL were elevated.
[0005] A significant reduction in blood levels of LDL and cholesterol by diet and lipid reducing drugs was found to result in regression of atherosclerosis. G. Brown et al., New England Journal of Medicine, Vol. 323(19), Nov. 8, 1990, pp. 1289-1298. Oral lipid lowering drugs, such as Lovastatin, MSD (MEVACOR®, Merck), are risky and may cause liver damage. Their efficacy is relatively limited, even when they are taken in association with a strict diet. Lowering of LDL by extracorporeal treatment of blood, M. Strahilevitz, U.S. Pat. Nos. 4,375,414 and 4,813,924, and M. Strahilevitz, Atherosclerosis, Vol. 26, 1977, pp. 373-77, is significantly more effective in reducing blood cholesterol and LDL levels. H. Borberg et al., Journal of Clinical Apheresis, Vol. 4, 1988, pp. 59-65; R. L. Wingard et al., American Journal of Kidney Diseases, Vol. 18(5), 1991, pp. 559-65; V. Hombach et al., Dtsch Med. Wschr, Vol. 111(45), 1986, pp. 1709-15. LDL and cholesterol can be removed by affinity adsorption, utilizing as the adsorbent antibodies to LDL or other specific chemical adsorbents, such as dextran sulphate (M. Odaka et al., International Journal of Artificial Organs, Vol. 9, 1986, pp. 343-48) or heparin (D. J. Lupien et al., Pediatric Res., Vol. 14, 1980, pp. 113-17). LDL removal can also be achieved by heparin precipitation (D. Seidel et al., Journal of Clinical Apheresis, Vol. 4, 1988, pp. 78-81), and by double filtration plasmapheresis (S. Yokoyama et al., Arteriosclerosis, Vol. 5, November/December 1985, pp. 613-22) as well as by plasma exchange (G. R. Thompson, Lancet, 1981 I, pp. 1246-48).
[0006] The oral administration of vitamin E is associated with lower risk of coronary heart disease in men (E. B. Rimm et al., New England Journal of Medicine, Vol. 328(20), May 20, 1993, pp. 1450-56) and in middle aged women (M. J. Stampfer et al., New England Journal of Medicine, Vol. 328(20), May 20, 1993, pp. 1487-89). The mechanism of this protective effect is based on the antioxidant property of vitamin E, which inhibits the oxidation of LDL, thus exerting a protective effect from the development of atherosclerosis. The oxidation of LDL is catalyzed by heavy metals such as iron and copper. The removal of the metals by intravenous administration of chelating agents was reported to be effective in atherosclerotic vascular disease. E. Olszewer and J. P. Carter, Medical Hypotheses, Vol. 27(1), September 1988, pp. 41-49, and E. Cranton, “Bypassing Bypass,” Hampton Road Publishers, Norfolk, Va., 1992. Others did not confirm these reports. S. R. Wirebaugh and D. R. Gerates, DICP, Vol. 24(1), January 1990, pp. 22-24.
[0007] The apparent minimal effect, or lack of effect, of intravenous chelation in the treatment of atherosclerosis can be overcome by extracorporeal chelation which significantly increases chelation efficacy and reduces significantly its toxicity. M. Strahilevitz, Lancet, Vol. 340, Jul. 25, 1992, p. 235.
[0008] Extracorporeal chelation with desferoxamine was highly effective and safe in reducing blood iron in the treatment of hemochromatosis, a disease caused by the accumulation of excess iron in the blood and body stores. J. L. Held et al., Journal of American Academy of Dermatologists, Vol. 28, 1993, pp. 253-54. Ambrus and Horvath in U.S. Pat. No. 4,612,122 also describe a specific column configuration that can be used for extracorporeal chelation. In this column the chelating agent is physically immobilized in the spongy outer part of an anisotropic (asymmetrical) membrane.
[0009] Chelating agents can also be utilized with the extracorporeal affinity adsorption devices of Strahilevitz, U.S. Pat. No. 4,375,414.
[0010] Coronary bypass surgery is effective in reducing symptomatology, but its effect on mortality is limited. J. H. O'Keefe, Jr. and B. D. McCallister, Editorial, Mayo Clinic Proceedings, Vol. 67, 1992, pp. 389-91, R. D. Simari et al., Mayo Clinic Proceedings, Vol. 67, April 1992, pp. 317-22.
[0011] Bypass surgery has no curative effect on the atherosclerotic disease process. The problem of post surgery atherosclerosis progression and the development of coronary or graft restenosis are major problems associated with bypass surgery. The need for effective means for reducing progression and inducing regression of atherosclerosis in patients following bypass surgery is well recognized, as is the need to further develop effective nonsurgical treatments that would replace bypass surgery in a significant proportion of patients that are currently being treated with bypass surgery, because of the lack of alternative effective medical treatment.
[0012] This is particularly relevant for candidates for bypass coronary surgery with moderately severe coronary occlusion that may not exhibit significant fibrotic changes in the atherosclerotic coronary lesions. Similar limitations to those of bypass surgery apply to percutaneous transluminal coronary angioplasty. Simari et al., supra. In this procedure, an inflatable balloon is inserted into the coronary occlusion site. As with bypass surgery, this procedure also has no effect on the atherosclerotic disease process, thus restenosis is a significant problem. While the risks associated with angioplasty are lower than with bypass surgery, this is also an invasive procedure associated with morbidity and mortality risks.
[0013] While current medical treatments, particularly when combinations of conventional treatments are utilized, have significant effect in reducing progression and in inducing regression of the atherosclerotic process (Brown et al., supra), there is a need to have more effective treatment methods, particularly for those who can not be treated with oral lipid lowering drugs because of liver toxicity, who are unable to maintain a strict diet, or who fail to improve with conventional treatment, including oral lipid lowering drugs and diet.
[0014] The utilization of extracorporeal affinity adsorption of LDL (Strahilevitz, supra) can lead to marked reduction in LDL level, thus to significant regression of atherosclerotic coronary lesions. Hombach et al., supra. However, the effect of affinity adsorption of LDL and cholesterol, while aimed at a major factor in atherosclerosis, hyperlipidemia, is selectively targeted on this factor. Even when (as usually is the case) the affinity LDL adsorption is utilized with other measures (diet, exercise etc.) the quantitative impact of these conventional treatment methods may not be sufficient. The availability of non-surgical methods that will have a significantly larger quantitative effect on additional factors that are involved in the etiology and pathogenesis of atherosclerosis is of great importance, in order to optimize the non-surgical and post-surgical treatment of atherosclerosis.
SUMMARY OF THE INVENTION
[0015] One of the objects of the present invention is to provide effective non-surgical treatments of atherosclerosis.
[0016] Another object is to provide improvements in extracorporeal treatment methods for atherosclerosis and other diseases.
[0017] Another object is to provide improved specific affinity devices, particularly immunoadsorption devices, and methods.
[0018] Other objects will become apparent to those skilled in the art in light of the following description.
[0019] In accordance with one aspect of the present invention, methods and devices for treating atherosclerosis and other conditions are provided that are based on the utilization of specific affinity adsorption of several of the biological molecules that are etiological in the pathogenesis of the condition. The affinity adsorbents utilized in accordance with the present invention are both immunoadsorbents and non-immune-based specific affinity chemical adsorbents.
[0020] In some applications of extracorporeal combined treatment, one or both of the extracorporeal methods may be based on other principles than adsorption, for example use of extracorporeal double filtration for the removal of LDL. S. Yokoyama et al., supra.
[0021] The adsorbents are incorporated in an extracorporeal treatment device. The methods of the present invention will be usually utilized in conjunction with conventional treatment methods, both medical and, when indicated, surgical methods.
[0022] The novel treatment methods that are the subject of the present invention are based on and are specific improvements of extracorporeal affinity adsorption and extracorporeal affinity dialysis which are disclosed in Strahilevitz U.S. Pat. Nos. 4,375,414 and 4,813,924 and British provisional patent application No. 16001, May 20, 1971, and which are incorporated herein by reference.
[0023] It is one of the objects of the present invention to provide additional specific improvements and embodiments to further increase the effectiveness and utility of extracorporeal affinity adsorption treatment of atherosclerosis.
[0024] Many of the elements of the present invention, as it applies to the treatment of atherosclerosis, are discussed in M. Strahilevitz, Lancet, Vol. 340, Jul. 25, 1992, p. 235, which is incorporated herein by reference.
[0025] One aspect of the present invention is to provide novel extracorporeal treatments for atherosclerosis based on specific affinity adsorption. The present invention also improves the efficacy of extracorporeal LDL affinity adsorption by combining it with affinity adsorption of ligands other than LDL and other lipids, that are also etiological in atherosclerosis.
[0026] Another aspect of the present invention is providing means for reducing the level of oxidized LDL in the body, using as affinity adsorbents specific antibodies to oxidized LDL, or using as specific adsorbent enzymatic digestion fragments of such antibodies, or synthetic fragments of such antibodies.
[0027] Yet another aspect of the invention is improving the immunoaffinity adsorption of LDL through the utilization of specific synthetic fragments of antibody (G. W. Welling et al., Journal of Chromatography, Vol. 512, 1990, pp. 337-43), with synthetic fragments that are specific to LDL. Yet another aspect is providing means for extracorporeal affinity adsorption of autoantibodies to oxidized LDL, which may be etiological in atherosclerosis, by using as the specific adsorbent oxidized LDL (the antigen) such as malondialdehyde LDL (Salonen, Lancet, supra), or to use as the adsorbent of oxidized LDL autoantibodies, Staphylococcal Protein A (Strahilevitz, Lancet, supra). Rather than Staphylococcal Protein A, a recombinant Staphylococcal Protein A or Staphylococcal Protein A component, or other synthetic peptides of Staphylococcal Protein A may be utilized, as may Protein G or its components. Bensinger, U.S. Pat. No. 4,614,513; R. Lindmark et al., J. Immunological Methods, Vol. 62, 1983, p. 1. As used herein, except when the context clearly indicates otherwise, the terms “Protein A” and “Protein G” include all such variations.
[0028] When fragments of antibodies are used in the present invention as affinity adsorbents, they can be produced by enzymatic (e.g., papain or pepsin) digestion of the intact antibody to produce Fab, (Fab′)2, or FV antigen-binding fragments, or they can be produced by other methods known to those skilled in the art for the synthesis of peptides, such as solid phase synthesis (R. A. Houghten, Proc. National Academy of Science USA, Vol. 82, August 1985, pp. 5131-35; R. E. Bird et al., Science, Vol. 242, 1988, pp. 423-42) or through genetic engineering in a suitable vector such as E. Coli or phage (J. W. Larrick, Pharmacological Reviews, Vol. 41(4), 1989, pp. 539-57). The use of fragments, rather than intact antibodies, as the affinity adsorbent may increase the adsorption capacity and reduces side effects that may be associated with the Fc non-antigen binding part of the antibody molecule.
[0029] Another objective of the invention is to provide for extracorporeal chelation therapy for cancer, autoimmune diseases and degenerative diseases, such as rheumatoid arthritis.
[0030] An additional objective is to provide extracorporeal combined treatment of cancer based on combining extracorporeal chelation and extracorporeal adsorption of enhancing tumor antibodies and their complexes by utilizing one or more of the following specific adsorbents, (a) Tumor specific antigen and (b) Staphylococcal Protein A or Protein G.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] [0031]FIG. 1 is a diagrammatic view illustrating an affinity filtration device utilized for extracorporeal chelation therapy in accordance with the present invention.
[0032] [0032]FIG. 2 is a multi-hollow fiber dialyzer or diafilter utilized for extracorporeal chelation therapy in accordance with the present invention.
[0033] [0033]FIG. 3 is a detail of one hollow fiber of the device of FIG. 2.
[0034] [0034]FIG. 4 is a diagrammatic view of an extracorporeal affinity adsorption device for use with the present invention.
[0035] [0035]FIG. 5 is a diagrammatic view of two extracorporeal affinity adsorption devices connected in series for use in the present invention.
[0036] [0036]FIG. 6 is a diagrammatic view of two extracorporeal affinity adsorption devices connected in parallel for use in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] The following are examples of the preferred embodiments of devices and methods of the present invention. All of the examples utilize selective affinity binding of one ligand to another. The ligand which is held in an extracorporeal device will be referred to herein as a specific affinity “adsorbent,” even in cases in which that ligand is in solution or suspension, and the process of binding a chemical species carried in a fluid by means of the specific affinity adsorbent will be referred to as “affinity adsorption.”
[0038] Affinity Filtration Chelation
[0039] Referring now to the drawings, and in particular to FIG. 1, an apparatus is provided which corresponds to the apparatus of my U.S. Pat. No. 4,375,414, but in which a chelating agent is utilized as the specific affinity adsorbent. A column 1 is divided into a first compartment 2 and a second compartment 3 , by a semipermeable membrane 4 . Such membranes having various pore sizes and which are permeable to molecules of molecular weight below a particular weight only (“cut off”) are available commercially. Preferred is a membrane with a pore size of 0.001 micron to 0.01 micron, a suitable molecular weight cut off is 1,000 to 10,000 daltons. One suitable membrane is a polysulphone membrane (M. Amato et al., The International Journal of Artificial Organs, Vol. 11 (3), 1988, pp. 175-80. Another suitable membrane is made of modified Cuprophan (Hemophan). (S. K. Mujais and P. Ivanovich in “Replacement of Renal Function by Dialysis”, Third Edition. Kluwer Academic Pub., J. F. Maher Editor, 1989, pp. 181-98.
[0040] The membrane is preferably pleated to increase its surface area. The membrane is mechanically supported by a rigid mesh screen 5 , facing compartment 3 , thus avoiding contact of the mesh support material with the blood flow. Positive pressure pump 6 and negative pressure pump 7 are connected to compartments 2 and 3 and can be optionally operated when increased pressure across the membrane is needed for enhancing the mass transfer across the membrane between compartments 2 and 3 . The overall surface area of the membrane is between 0.5 m 2 -3 m 2 . The pumps are connected to a control 14 to enable automatic operation. Compartment 2 has an inlet 8 for a catheter 8 a , which is to be connected to a vein 8 b of the patient (when vein to vein connection is used, which is the preferred operation). Catheter 8 a may however be connected to an artery of the patient when desired. Outlet 9 is connected to a catheter 9 a , which is to be connected to another vein 9 b of the patient. Together they comprise a blood flow passage through compartment 2 . The second compartment 3 includes the chelating agent. Preferably the chelating agent is a multivalent chelating agent such as a biotechnology grade resin marketed by Biorad Corp. under the registered trademark CHELEX 100. This resin is a styrene divinylbenzene copolymer containing paired iminodiacetate ions, which act as chelating groups for binding polyvalent metal ions. Chelation is based on coordination binding between the chelating agent and the heavy metals, which is similar to a covalent bond, but in which both electrons are donated by the same atom. Chelating binding differs from ion exchange by its high selectivity for heavy (transition) metal ions and by its much higher bond strength. CHELEX 100 resin has the following selectivity for some cations (a higher number indicates greater affinity): Hg ++ =1060, Cu ++ =126, Na + =1×10 −7 .
[0041] The CHELEX 100 resin is obtained in 200 mesh size and is ground to particles with a diameter of 5 to 30 microns. The dialysis fluid is a standard renal dialysis fluid, preferably bicarbonate type buffered to pH 7.4.
[0042] While CHELEX 100 is preferred for some applications, other chelating agents can be used when bound to macromolecular organic or inorganic particles, such as triaminepenta acetic acid or deferoxamine bound to a suitable matrix, such as silica. Other chelating agents are derivatives of iminodiacetic acid such as EDTA and matrix bound glycine hydroxamic acid.
[0043] Peristaltic pumps 10 and 11 are optional and may be used as needed to accelerate blood flow into and out of compartment 2 . The blood flow through the device is in the range of 25 ml to 250 ml per minute. The system described thus far can be used without on-line regeneration, with the replacement of buffer and chelating agent as needed via inlet 12 and outlet 13 . This mode of treatment can be operated manually or automatically, by the use of control 14 to operate the valving of inlet 12 and outlet 13 , in conjunction with reservoir 15 that contains fresh CHELEX dialysis fluid suspension. Reservoir 16 collects “used up” CHELEX with its chelated heavy metals. Drain 17 can be used to clear reservoir 16 , for discarding, chemical analysis or off line regeneration of the chelating agent.
[0044] Optionally, the system can operate with either manual or automatic on-line regeneration of the chelating agent. The automatic regeneration is identical to Strahilevitz, U.S. Pat. Nos. 4,375,414 and 4,813,924, except for the use of a buffer pH 4 rather than pH 2.5.
[0045] Because the chelating agent specifically binds heavy metals such as Cu ++ and Fe ++ that are mass transferred across the membrane barrier, a continuous gradient is present for the heavy metals that continue to mass transfer from compartment 2 to compartment 3 across membrane 4 by diffusion and/or convection, as long as compartment 3 contains free chelating groups that are available to bind heavy metals. When pressure filtration is utilized, by operating the optional positive pressure pump 6 and/or negative pressure pump 7 , the process of mass transfer is accelerated by increased convection.
[0046] Optional means are provided for on-line continuous regeneration of the chelating agent. Preferably regeneration is achieved by use of a weak acid solution at pH 4 or higher. However, elution can also be achieved by use of a concentrated salt solution, or by the use of a low molecular weight free chelator, such as EDTA (specific elution). When on-line regeneration is used, the CHELEX bound heavy metals buffer solution is transferred through outlet 25 to compartment 18 with optional operation of peristaltic pump 27 . The buffer is pressure filtered through membrane 19 to compartment 20 (permeable to the buffer but not to the CHELEX). The positive pressure for filtration is provided by pump 28 . The elution (regeneration) buffer is then transferred from compartment 21 to compartment 18 and again positive pressure pump 28 transfers the heavy metals eluted from the CHELEX to compartment 20 and through outlet 23 to compartment 24 , from which it can be discarded or used for chemical analysis. Buffer pH 7.4 is added from reservoir 22 to compartment 18 and the regenerated CHELEX is returned to compartment 3 via conduit 26 . Optional peristaltic pump 29 is used to accelerate transfer. Alternatively, other configurations can be used for on-line regeneration, such as the one utilized in S. P. Halbert, U.S. Pat. No. 4,637,880.
[0047] While the method described thus far uses CHELEX with beaded, preferably regular spherical, form, other forms of matrix can be used such as irregular beads or fibers, either natural or synthetic, to which the chelating moiety can be covalently bound or physically trapped (immobilized).
[0048] The chelating moiety can also be covalently bound to semipermeable membrane 4 , when the membrane is made of synthetic polymer or from natural or modified polymer. The binding can be to the membrane side facing the blood flow, the membrane side facing the dialysis chelator flow, or to both sides. The physical configuration of the matrix is not limited to any particular form, as long as the matrix configuration and its particle size prevents the chelating agent from being substantially transferred from compartment 3 to compartment 2 .
[0049] The affinity chelation filtration can be utilized for affinity adsorption of a plurality of ligands, for example when free antibodies or antibodies bound covalently to a matrix or polymerized antibodies are included in compartment 3 and semipermeable membrane 4 is permeable to the antigen or hapten to which the antibodies are specific. An example for such antibodies are the antibodies to free cholesterol.
[0050] Affinity Adsorption Chelation
[0051] The configuration and process of this treatment is similar to affinity filtration chelation, except that the semipermeable membrane 4 and its mesh screen membrane support are excluded from the device of FIG. 1, along with pumps 6 and 7 . A chelating agent, CHELEX 100, ground to particle size of between 1-5 microns is encapsulated in a suitable microcapsule or macrocapsules. The macrocapsules used are those utilized by A. M. Wallace and A. Wood, Clinical Chimica Acta, Vol. 140, 1984, pp. 203-12, for encapsulating antibodies and have an average diameter of 30 microns, or they are thermoplastic based macrocapsules (P. Aebischer et al., J. Biomech. Eng., Vol. 113 (2), 1991, pp. 178-83) having a diameter of 560±65 microns. Another suitable encapsulation of CHELEX is by modification of the method of L. Marcus et al., American Heart Journal, Vol. 110, No. 1, Part 1, July 1985, pp. 30-39. The method used by Marcus et al. involved encapsulation of anti-digoxin antibodies in 0.2 micron polyacrolein microspheres, which are then encapsulated in 500-800 micron cross-linked agarose macrospheres. For encapsulation of CHELEX, the CHELEX is directly encapsulated in the cross-linked agarose macrospheres omitting the polyacrolein microencapsulation. Marcus et al. used their encapsulated antidigoxin antibodies in a column for extracorporeal adsorption treatment of digitalis intoxicated dogs. The same treatment was used in digitalis intoxicated humans. H. Savin et al., American Heart Journal, Vol. 113(5), May 1987, pp. 1078-84.
[0052] When CHELEX is used in free form, particles of about 30 to 300 microns are preferred. Other matrixes and other chelating agents bound to the matrixes can be used. The matrixes can be of various chemical composition including, for example: natural polymers such as cellulose and dextran; various synthetic polymers and copolymers such as polyacrylamide, polystyrene, and polyvinyl polystyrene copolymer, and glass and silica. One suitable matrix is heparinized silicone described in D. R. Bennett et al., U.S. Pat. No. 3,453,194. Various matrixes and methods for their activation for covalent ligand binding are described in P. D. G. Dean et al., Editors “Affinity Chromatography: A Practical Approach,” IRL Press, Oxford 1985, pp. 1-73. The configuration of the matrix is also not limited to a particular form; examples of suitable forms are beads (in particular, spherical in shape), fibrous matrixes, macroporous matrixes, and membranes including hollow fibers.
[0053] One possible configuration of the device is that of a typical multi-hollow fiber dialyzer or diafilter design. Such a design consists of a bundle of hollow fibers encased in a tubular housing.
[0054] In this configuration compartment 2 corresponds to the inner space of the hollow fibers and compartment 3 to the outer space of the hollow fibers.
[0055] In FIG. 2, blood flows from patient's vein through inlet 34 to compartment 32 (inner space of fibers). Heavy metals which pass across semipermeable membrane 40 are bound by chelation to CHELEX suspended in compartment 33 . The blood that flows out through outlet 35 is connected to another vein of the patient. This blood is relatively free from heavy metals. Inlet 36 is used to replace used up CHELEX suspension with new CHELEX suspension. The old CHELEX suspension is drained through drain 41 . This step is optional. Optionally also, CHELEX may be regenerated online by the same online regeneration means described with respect to FIG. 1. “Used up” CHELEX suspension is transferred from compartment 33 through outlet 39 to the regeneration unit. Regenerated CHELEX suspension is returned to compartment 33 from the regeneration unit through inlet 38 . Suitable pumps may be utilized if it is desirable to increase the blood pressure in compartment 32 and across membrane 40 , thus increasing the rate of mass transfer from compartment 32 to compartment 33 by a filtration process.
[0056] The space between fibers is sealed by sealing resin 37 .
[0057] [0057]FIG. 3 illustrates a single fiber in the unit. A typical fiber's membrane thickness is 6-30 microns. The combined inner membrane surface area is typically 0.75 to 1.2 meter 2 .
[0058] Commercially available dialysers that can be used are Fresenius model F60 or Asahi PAN 150 .
[0059] Another embodiment of affinity adsorption device for use in the present invention is shown in FIG. 4. The device of FIG. 4 can be used to treat either blood or plasma. Particularly suitable for direct blood treatments are devices in which the matrix-bound chelator is encapsulated or when the matrix is a spiral structure such as for example natural polymer or synthetic polymer membrane to which the chelating moiety is covalently bound. When plasma is treated in the device, a plasma separator is first used to separate on-line the patient's plasma from the cellular elements of blood. The physical configurations may include beads, in particular spherical beads, fibers, macroporous matrixes, membranes, and hollow fibers.
[0060] Blood may be directly treated, preferably when the matrix bound chelator is encapsulated. If plasma is treated, then the patient's blood flows via conduit 115 to plasma separator 103 (e.g., a centrifugal continuous plasma separator such as marketed by Cobe (Cobe IBM 2997) or preferably a membrane filtration plasma separator such as Kaneka Sulfox or Cobe TPE). The blood cells are returned to the patient via conduit 124 and the plasma is passed through conduit 117 , via inlet 105 to column 106 .
[0061] When encapsulation of matrix chelate is not utilized in the system and the method utilizes treatment of plasma, on-line manual or automatic regeneration can be used using a modification of the methods of Strahilevitz, U.S. Pat. No. 4,813,924 or the method of Halbert, U.S. Pat. No. 4,637,880.
[0062] In the on-line regeneration mode, with inlets 105 and 111 closed, outlet 112 to reservoir 136 closed, and either valve 119 or valve 139 closed, valve 130 is opened and buffer pH 7.4 is transferred from reservoir 125 to column 106 . This is an optional step utilized when it is desirable to wash some of the patient's plasma that is present in column 106 into the patient's circulation (with valve 119 open) or to drain this washed volume of plasma through drain 141 . This is done when it is desirable to reduce the amount of plasma proteins that is exposed to the eluting buffer. A small volume of buffer pH 7.4 is used, in order to minimize the volume of buffer introduced into the patient, when the option of returning the plasma to the patient is used. Alternatively the removal of plasma from column 106 back to the patient, can be accelerated by using positive pressure filtration with operation of pump 131 .
[0063] In the elution step, with all valves except valves 129 and 139 closed, eluting buffer pH 5 is transferred to column 106 from reservoir 127 ; after equilibration, valve 129 is closed, valve 139 is opened and the buffer, including the free heavy metal cations passes through drain 141 . Optionally, pressure filtration can be utilized with operation of pump 131 . Optional filter 134 is permeable to buffer, heavy metal cations, and plasma proteins about the size of LDL, but not to CHELEX and plasma proteins larger than LDL; the drained fluid is then collected in reservoir 135 and can be discarded or used for chemical analysis. In the next step column 106 is equilibrated with buffer pH 7.4, transferred from reservoir 125 through conduit 126 .
[0064] When on-line regeneration is not used, replacement of used adsorbent by fresh adsorbent can be done manually, or automatically by automatic control of valves 137 ′ and 138 with addition of fresh adsorbent from reservoir 137 and collecting used adsorbent in reservoir 136 .
[0065] Column 106 is then ready for re-use. Preferably vein to vein catheterisation is used, but when needed artery to vein catheterisation is utilized. When needed peristaltic pumps are used to accelerate fluid and mass transfer across the conduits 104 , 105 , 115 , 117 , 124 and 141 .
[0066] The affinity adsorption method is well adapted to the concurrent adsorption of a plurality of ligands. On-line regeneration can be used when needed, and is particularly simple when the regeneration of the various adsorption ligates can be regenerated by the same regeneration means, such as by an acidic pH buffer, for example. The various adsorbents can be present in free form or can be encapsulated in microcapsules. Free form adsorbents are preferable because of their mechanical strength and suitability for regeneration, when desired. Encapsulated adsorbents will generally not be suitable for regeneration.
[0067] In FIG. 4, column 106 contains a first adsorbent 107 and a second adsorbent 108 . Illustratively, the first adsorbent 107 is CHELEX 100 in bead form, with a bead diameter in the range of 5 to 30 microns when encapsulated and 30 to 300 microns when free. The bead is preferably in free form, but can be encapsulated as previously described. The microcapsule membrane, when present, is permeable to heavy metals but not to CHELEX or to plasma proteins. The CHELEX specifically adsorbs heavy (transition) metals which catalyze oxidation of LDL. The second adsorbent 108 is cyanogen bromide activated cross-linked agarose (SEPHAROSE, Pharmacia Fine Chemicals), with a bead diameter in the range of 212-300 microns, prepared according to R. E. Ostlund, Jr., Artificial Organs, Vol. 11(5), 1987, pp. 366-74. The SEPHAROSE is covalently bound to monoclonal antibodies to LDL. (R. L. Wingard et al., supra). According to Ostlund, supra, LDL is adsorbed by the antibodies. As previously described, rather than intact antibodies, antibody fragments can be used. The combined effects of significant reductions of both oxidant and LDL levels have a major impact on the atherosclerotic process.
[0068] Plasma which flows from column 106 though outlet 104 is substantially free of the species sought to be removed. Drains 111 and 112 can be used as needed for the removal of buffer and binding species, and for the addition of fresh binding species. Used binding species (e.g., anti-LDL antibodies and CHELEX) can be regenerated off line, if needed. It should also be recognized that antibodies or fragments, “humanized” or hybrid antibodies (or fragments) can be used rather than mouse antibodies. J. W. Larrick, supra. In synthesizing antibody fragments, solid phase peptide synthesis methods (R. A. Houghten, supra) or genetic engineering methods (R. E. Bird et al., supra) can be utilized.
[0069] The advantage of Ab fragments over intact antibody is the reduced likelihood of side effects of the immunoadsorption treatment, particularly when whole blood is used for adsorption and the antibody or fragment is not encapsulated thus enabling contact of the mouse antibody with the patient's immune cells.
[0070] Additional adsorbents that can be utilized in the treatment of atherosclerosis include oxidized LDL, which will adsorb autoantibodies to oxidized LDL (cf. Salonen et al., Lancet, supra; Strahilevitz, Lancet, supra). Instead of the oxidized LDL, autoantibodies to oxidized LDL and their complexes can be adsorbed by use of SEPHAROSE 4BCL Protein A, sold by Pharmacia Fine Chemicals. When Protein A is used as the adsorbent, the patient may need administration of replacement human gamma globulin. Additionally it may be desirable to adsorb oxidized LDL by using matrix bound antibodies to oxidized LDL as the adsorbent.
[0071] When affinity adsorption is used in accordance with the present invention for the adsorption of antigens or haptens, such as adsorption of LDL or oxidized-LDL in the treatment of atherosclerosis or adsorption of rheumatoid factor (autoantibodies to Human IgG) in the treatment of rheumatoid arthritis, for example, the application of the analytical method of J. Goding et al., J. Immunological Methods, Vol. 20, 1978, pp. 241-53, to extracorporeal affinity adsorption in accordance with the present invention, is a general method for the removal of antigens or haptens from the body. It should be clearly realized that any antigen or hapten can be removed from the body in accordance with this invention. In accordance with this method first Protein A or genetically engineered Protein A peptide (R. Lindmark et al., supra) is covalently bound to any of the matrixes described in the current invention, for example SEPHAROSE 4BCL. The antibody specific to the antigen, for example monoclonal antibody specific to LDL, is added to the SEPHAROSE-bound Protein A. It binds to Protein A through its Fc part, and its Fab antigen binding part is available to bind the antigen (LDL). The matrix bound Protein A-LDL-antibody is incorporated in the extracorporeal immunoadsorption (affinity adsorption) treatment column as described in the foregoing examples, for the treatment of atherosclerosis. Clearly it is possible to use Protein G instead of Protein A in this system.
[0072] When larger beads of cross linked SEPHAROSE are used as matrix, they are prepared according to Ostlund, supra.
[0073] In the treatment of cancer the affinity adsorbents can include for example: CHELEX 100 to reduce oxidation and Staphylococcal Protein A, or tumor specific antigens to remove enhancing tumor antibodies and their complexes.
[0074] An additional component of the combined treatment is to administer a radioactive drug or conventional drug conjugated to an antibody specific to a tumor antigen (such as Adriamycin conjugated to an antibody to Human-Alpha-Fetoprotein, R. Yang et al., Antibody, Immunoconjugates and Radiopharmaceuticals, Vol. 5, 1992, pp. 201-07), in conjunction with adsorption of the antibody-drug conjugate from blood. K. Norrgren et al., Antibody Immunoconjugates and Radiopharmaceuticals, Vol. 4(4), 1991, pp. 907-14.
[0075] The utilization of tumor-targeted radiolabeled antibody in conjunction with immunoadsorption of the radiolabeled antibody from the circulation to improve tumor imaging was reported by J. L. Lear et al., Radiology, Vol. 179, 1991, pp 509-12. The adsorbent they used was an antibody to the radiolabeled anti-tumor antibody. The adsorbing antibody was utilized in an extracorporeal column in which it was covalently bound to a matrix. C. Hartmann et al., Journal of Pharmacokinetics and Biopharmaceutics, Vol. 19(4), 1991, pp. 385-403, evaluated the removal of radiolabeled antibody by extracorporeal adsorption, also using antibody to the radiolabeled antibody as the adsorbent. They found that the method would be effective for enhancing tumor imaging and for increasing the efficacy and reducing the toxicity of antibody-targeted anti-tumor drugs. These authors also cite two additional groups reporting similar results.
[0076] In accordance with the present invention, the anti-tumor drug or radiolabeled anti-tumor antibody is adsorbed in an extracorporeal column utilizing Staphylococcal Protein A as the adsorbent. This is a simpler and less expensive adsorbent and has the additional advantage of adsorbing enhancing antibodies and immune complexes; this removal of enhancing antibodies and immune complexes has an important therapeutic effect on cancer. As previously mentioned, when Protein A is used as the affinity adsorbent, it may be necessary to administer intravenously, to the subject being treated, plasma or a plasma constituent such as gamma globulin.
[0077] It should be clearly understood that in enhancing tumor imaging utilizing antibody-targeted radioactive ligand, as disclosed in Hartmann et al., supra, Lear et al., supra, or Norrgren et al., supra, Protein A or Protein G can be utilized as the adsorbents.
[0078] Moreover, the radioactive imaging ligand may be incorporated in a hapten or antigen, preferably conjugated to the targeting antibody (or antibody fragment) by a spacer arm. The affinity adsorbent may then be an antibody to the free hapten or antigen, and all of the methods discussed above for binding drugs bound to targeting antibodies may be utilized. Engineered targeting antibody fragments are disclosed in D. J. King et al., Antibody, Immunoconjugates, and Radiopharmaceuticals, Vol. 5(2), 1992, pp. 159-70.
[0079] In the treatment of cancer the adsorption treatment will also be combined with conventional therapy such as chemotherapy.
[0080] Circulating immune complexes can also be adsorbed by C1q subcomponent of complement bound to specific antibodies to C1q, which are covalently bound to the matrix. T. Bratt and S. Ohlson, J. Clin. Lab. Immunol., Vol. 27, 1988, pp. 191-95. In combined treatment of degenerative diseases (such as rheumatoid arthritis, for example) the adsorbents include CHELEX 100 and Staphylococcal Protein A, or matrix immobilized human IgG to bind the rheumatoid factor which is an autoantibody to IgG.
[0081] When whole blood is treated in the column, the optional plasma separation system is bypassed and the blood flows from vein 102 A directly to column 106 via inlet 105 . Optional membrane 113 and membrane 114 are permeable to blood cells and plasma, but not to adsorbent-bound matrix, which in this application when used in particle form utilizes particles in the range of 300-800 microns in diameter to ensure free flow of blood cells. The matrix can be in various other configurations such as fibers, membrane, capillaries, open porosity cavernous structure and the like. The matrix can be made of blood compatible synthetic polymer, natural polymer and silica as examples. The filter 134 may be made of smaller pore size when molecules smaller than LDL, such as free cholesterol, are to be removed. When LDL is removed, filter 134 is permeable to molecules the size of LDL but not larger molecules.
[0082] [0082]FIG. 5 illustrates the use of two or more devices, either filtration adsorption or direct adsorption when each of the specific adsorbents is contained in its own column. The devices and treatment process can be operated manually or automatically. One or more of the devices can be regenerated on line or off line. Either whole blood or plasma is adsorbed. Pumps as needed are included in the system to optimize fluid flow through the system. Pumps are also utilized as needed to increase trans-membrane pressure, when the filtration adsorption process is used.
[0083] Referring to FIG. 5, a catheter 201 is inserted in vein 202 of patient 203 , optionally passed through continuous plasma cell separator 204 that is of either centrifugal or membrane type. The fluid (blood or plasma) is introduced into column 205 through inlet 206 . Heavy metals in the fluid are adsorbed to CHELEX 100 beads 218 . The fluid leaves column 205 via outlet 207 . It has a significantly reduced content of heavy metals such as Fe ++ and Cu ++ . The fluid is then introduced to column 208 via inlet 209 . IgG and antibodies as well as antibody complexes are adsorbed on beads of SEPHAROSE 4BCL/Protein A 210 . Suitable filters are positioned in the columns as described in reference to FIG. 4. The fluid leaving through outlet 211 has a reduced level of antibodies and complexes. The fluid is returned to the patient via catheter 212 and vein 217 . When the plasma cell separator is in use the cellular elements of the blood are returned to the patient via line 213 , catheter 214 and vein 215 .
[0084] The columns can be connected to the patient in parallel, rather than consecutively, as illustrated in FIG. 6.
[0085] With either the manual or automatic operation of valving, the patient's blood or plasma can be transferred to column 301 and 302 either consecutively, with valve 303 open when valve 304 is closed and vice versa, or concurrently with valves 303 and 304 both open at the same time.
[0086] The method of Halbert, U.S. Pat. No. 4,637,880 may be used to regenerate one of two extracorporeal devices while the other device continues to be used, without removing either device from the mammal being treated, using any of the devices of the present invention.
[0087] In the utilization of the methods of the invention, with or without the optional on-line regeneration step, heparin or another suitable anticoagulant may be administered intravenously or into the device as required, as is well known to those skilled in the art of extracorporeal treatment. See for example, Bensinger, U.S. Pat. No. 4,614,513.
[0088] Particularly when no regeneration of adsorbents is utilized, other columns can replace columns described in the current invention. For example, the column of Kuroda et al., U.S. Pat. No. 4,627,915 can be used to adsorb IgG and immune complexes, and the column of Ambrus et al., U.S. Pat. No. 4,612,122 can be used to remove heavy metals.
[0089] The present invention also includes the method of administering a drug bound (covalently or by other chemical binding) to an antibody such as an antibody specific to a tumor or to a tissue-specific antigen. Administration of the drug-antibody moiety is followed by a step of extracorporeally adsorbing the drug-hapten moiety by an antibody specific to the drug. The antibody in the extracorporeal device will thus adsorb both the drug-antibody moiety and the free drug in the circulation of the patient. The extracorporeal adsorption is preferably begun sufficiently long after the drug-antibody moiety is administered to permit the drug to reach a target in the mammal, although in some cases concurrent initiation of administration and adsorption is preferred. Generally, the time delay will typically be on the order of several minutes to forty-eight hours. An example of the drug is Adriamycin bound to a targeting antibody; the antibody in the extracorporeal specific affinity device will then be an antibody to Adriamycin. An example of the tissue specific antigens is thyroid gland specific antigen; an example of a tumor-specific antigen is human alpha-fetoprotein. Both the targeting antibody, to which the drug is initially bound, and the adsorbing antibody in the extracorporeal device may be an antibody fragment produced for example by synthesis or by enzymatic digestion treatment of a complete antibody. The adsorbent antibody is preferably linked to a matrix by a spacer arm of three to thirty carbon atoms; the targeting antibody is likewise preferably attached to the drug by a spacer. The adsorbing antibody may be made as a mirror image antibody, which binds to a site on the drug different from the site to which the targeting antibody is bound, by the method set out in my U.S. Pat. No. 4,375,414. Use of antibody to the drug in the extracorporeal device provides greater reduction in circulating drug (both bound and free), than does the antigen to which the targeting antibody is specific as used by Norrgren et al., supra.
[0090] Numerous other variations in the devices and methods of the present invention, within the scope of the appended claims, will occur to those skilled in the art in light of the foregoing disclosure.
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Extracorporeal affinity adsorption treatments which are aimed at the substantial removal of two or more compounds that are etiological in the pathogenesis of diseases in man provide effective therapeutic intervention means for these diseases. The methods are particularly suitable for the treatment of atherosclerosis, cancer, degenerative and autoimmune diseases. Extracorporeal chelation and immunotherapy for atherosclerosis, extracorporeal chelation treatment with on-line regeneration or replacement of chelant, extracorporeal immunotherapy with antibody fragments, and extracorporeal immunoadsorption utilizing antibodies bound to Protein A are also disclosed.
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CROSS-REFERENCES
This is a Continuation-In-Part of our co-pending Application Ser. No. 922,027, filed July 5, 1978, and now U.S. Pat. No. 4,214,151.
BACKGROUND OF THE INVENTION
The invention relates to a control instrument for electric hot plates with an adjustable power control device, which contains an expansion element with an electrical heating means, and with a time switch which, for a period of time, increases the output of the power control device in the initial cooking phase. The time switch contains an electronic counter as the timing member and at least one divider which, by means of an electronic switch element, reduces the power supplied to the heating means in a predetermined division ratio.
In such a control instrument known from U.S. Ser. No. 922,027 filed by Robert Kicherer and Wilfried Schilling on July 5, 1978 the complete time switch means is replaced by electronic components. All the mechanical parts for the timing member and the power switch are dispensed with, because the electronic switch element has only to switch the very limited power of the bimetallic member heating means for the power control device. However, the reliable quantizing power control device is retained for switching the high power to the hot plate. The hot plate only requires a single load heating resistance which is quantized by the power control device.
A pushbutton, which is operable independently of the adjusting toggle is provided for switching on the automatic initial cooking device formed by the time switch. It would also be possible to use an adjusting toggle which, in addition to its adjustment function, by rotation also assumes the pushbutton function by starting up the automatic initial cooking device on being depressed. Besides certain mechanical difficulties and the fact that the button requires a certain travel, the switching on of the automatic initial cooking device requires an additional operation, so that it is frequently not used.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention, particularly in the case of a control instrument as defined hereinbefore is to further simplify its operation and the arrangement thereof on a cooker or the like.
According to the invention this object is achieved in that the power switch, which can be switched on in a lower power range (continuous cooking range), can be automatically switched on by a manually operable adjusting means on setting a power level in the continuous cooking range. Thus, the operator no longer has to operate a separate button or knob. Installation is also simplified because there is no need to provide a separate switching-on knob or other separate operation measures.
According to the invention an embodiment in which the time switch can be automatically switched off by the adjusting means on exceeding the limit to the higher power range (frying range) is particularly advantageous. Thus, the automatic switching-on device, which is in any case only advantageous in the continuous cooking range, is switched off in the frying range, specifically on exceeding this limit in both directions. Thus, switching off does not only occur on switching from the continuous cooking range to the frying range, but also in the reverse direction, so that on switching down from the frying range to the continuous cooking range the automatic initial cooking device is no longer operating. It is also no longer necessary in this case, because the hot plate has already operated in the frying range, i.e. in the higher power range. In this way it is possible to bring about an intentional switching off of the automatic initial cooking device, either by briefly switching the adjusting means briefly over this limit from below and then back into the continuous cooking range or by the setting taking place directly from zero via the higher power range into the continuous cooking range.
Thus, according to an advantageous embodiment the adjusting means can be a per se known rotatable knob which, when rotated from the off position in the direction of increasing power, the time switch can be switched on, while the rotation in the opposite direction does not bring about the switching on of the time switch.
According to preferred embodiments a contactor can be operable for producing a switching-on pulse for the time switch between the off position and the lowest power stage and/or between the lower and upper power ranges (continuous cooking and frying ranges) a contact, which may be present in any case, produces an off pulse for the time switch. On regulating from the "0" position in the direction of increased relative switching-on period the contact is only briefly inched by means of trip cams before stage 1, i.e. there must be no permanent contact, because otherwise it would not be switched off at the end of the initial cooking period.
On further rotation from the continuous cooking range F into the frying range B in addition to the change in the division ratio the existing residual initial cooking time is cancelled out through the cams keeping the switch closed over the entire frying range.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described in non-limitative manner with reference to the drawings, wherein:
FIG. 1 is a diagrammatic circuit diagram of a control instrument according to the invention.
FIG. 2(a), FIG. 2(b) and FIG. 2(c) are each a diagram of the power pulses supplied to the power control device heating means in three different operating states of the control instrument according to the invention.
FIG. 3 is a diagram of the power pattern as a function of the power setting divided up from 1 to 12, the same type of lines being used in both FIGS. 2 and 3 for the individual operating modes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a control instrument 11 provided for the power control of an electrical hot plate 12 having a load heating resistance 13 and a temperature protection switch 14. The control instrument 11 is connected be means of terminal 15, 16 to the domestic mains and has a conventional quantizing power control device 17 switched into a terminal of the load heating resistance 13 and supplies to the latter the quantized power, i.e. in power pulses, whose relative switching-on period is dependent on the setting of the power control device and its heating means. The mechanically/thermally operating power control device contains a snap switch 18 operated by an expansion member, for example a bimetallic member 19. The latter is provided with a heating means 20 and by means of a setting cam 21 can be adjusted in its position relative to switch 18.
The heating means 20 is connected in parallel to the load heating resistance 13, i.e. as a potential winding and can be given a relatively high power, e.g. of 20 Watt, so that it can be easily produced even for higher mains voltages.
Setting cam 21 is mounted together with a trip cam 22 on a setting shaft 23, which can be manually rotated by an adjusting toggle 24. Trip cam 22 operates a switch contact 25 which is closed in the upper power range (frying range B).
The setting shaft 23 also carries a contact cam 40 which can operate a contactor 41 which is so arranged with respect to cam 40 that, in a manner to be described hereinafter, it can be operated at the start of the cooking range. Contactor 41 produces a switching-on pulse and contact 25 inter alia a switching-off pulse, which can switch on or off the counter 32. Contactor 41 can be a switch contact.
The control instrument 11 also contains an integrated circuit (IC) 28 which is supplied with the corresponding low voltage from the mains by means of a bridge circuit of a diode 29 with a resistance 30 on the one hand and a Zener diode 31 on the other. A capacitor 26 also forms part of the power supply system.
The IC contains an electronic counter 32 and two dividers 33, 34 which, as structural groups are indicated in block circuit manner. The counter forms a timing member, i.e. by counting the mains half-waves it permits the passage of a predetermined time of e.g. nine minutes before supplying an output signal to the divider 33 associated therewith. Counter 32 is started up by the switching-on contactor 41, while contact 25 controlling divider 34 can switch off counter 32 before it has completed its running time. From the dividers the IC output line leads to a thyristor 35, which is connected in series with the heating means 20 of the power control device 17. A diode 36 is connected in series therewith and serves as a protection against overvoltages.
Divider 33 is designed in such a way that during the operation of counter 32 it controls thyristor 35 so that the latter only permits the passage of every fifth half-wave of the mains current, while divider 34 is designed in such a way that, when switched on by closing contact 25, it controls the thyristor to permit the passage of every other half-wave on the alternating current.
The operation of the control instrument shown in FIG. 1 will be explained hereinafter relative to FIGS. 2 and 3.
In FIGS. 2 and 3 the single continuous line indicates operation without an automatic initial cooking device in the continuous cooking range F (FIG. 2c), the broken line indicates operation in the continuous cooking range with the automatic initial cooking device (FIG. 2b) and the double line operation in the frying range, i.e. the higher power range (FIG. 2a). The dot-dash line indicates the no-load limit, not illustrated in FIG. 2, by the response of the temperature protection switch 14.
If, as shown in FIG. 2a, the adjusting toggle 24 is rotated into the frying range, whereby said rotation can take place in either direction, contact 25 is closed. Divider 34 starts operating and ensures that thyristor 35 only permits the passage of every other half-wave of the alternating current, so that the design power of the heating means 20 is only 25% effective, i.e. there is an actual power of 5 Watt for a 20 Watt design power. The automatic initial cooking device is not switched on in this higher power range (frying range), because on rotation from the off position by the shortest route into the top power range (i.e. in counterclockwise direction in the drawing) the cam 40 has not passed the switching-on contactor 41 and the closed contact 25 keeps counter 32 switched off. On rotating in the clockwise direction to the same power value, i.e. through the lower power range (continuous cooking range F) the counter is initially switched on by the switching-on contactor 41, is immediately switched off by closing contact 25, which resets counter 32.
In FIG. 2b a power is set in the continuous cooking range F by rotating in the clockwise direction, i.e. from the off position and through the lowest power setting. Between the off position and the lowest power setting the switching-on contactor 41 is operated by the contact cam 40 which starts the counter 32 operating. The latter has started up and has activated the divider in such a way that the thyristor 35 only permits the passage of every fifth half-wave, i.e. only 10% of the design power or 20% of the power normally supplied to the heating means 20 in the continuous cooking range (FIG. 2c). Thus, the heating up of the bimetallic member 19 takes much longer and the relative switching-on period is increased by about five times, which means that when counter 32 is operating, the power set on toggle 24 is always increased five times (broken line in FIG. 3). When this cooking support lasts a constant time a power increased by a fixed amount is supplied, but is dependent on the control instrument setting. Here again the power dissipation is very low and can be a maximum of 2 Watt.
At the end of the fixed-programmed-in time, or the time set on counter 32, the automatic initial cooking device is switched off and thyristor 35 now permits the passage of every positive or negative half-wave of the alternating current, so that the heating means 20 of bimetallic member 19 is heated with 10 Watt. The power supplied to the hot plate 12 returns to 1/5 of the power, whose passage was permitted with respect to the automatic initial cooking device (continuous line in FIG. 3).
As shown in FIG. 2c the same effect is obtained if the adjusting toggle 24 is rotated in counterclockwise direction into the continuous cooking range, i.e. through the frying range towards a lower power setting. The switching-on contactor 41 is not passed by the contact cam 40 and the control instrument operates without the automatic initial cooking device. The same effect is also obtained if on clockwise rotation of the toggle, i.e. in the rising power direction, the limit between the continuous cooking range F and the frying range B is passed and then there is a return to the continuous cooking range. Although initially in this case the automatic initial cooking device (counter 32 and divider 33) is switched on, it is switched off again after passing the limit between F and B.
Thus, the invention provides a very advantageous operation of the control instrument. In the case of a normal power setting in the continuous cooking range there is generally a cold cooking product, so that an automatic initial cooking device with a time-limited power increase is advantageous. However, if for example after a frying operation the power is regulated down from the frying range to the continuous cooking range the automatic power increase, which would be disadvantageous, is switched off. This operating procedure also automatically takes account of the operation without knowing the function of the automatic initial cooking device. If, as is necessary with a conventional seven-speed circuit, someone initially sets a high power for initial cooking, i.e. in the frying range and then, after the cooking product has become heated, regulates down into the initial cooking range, as desired, the automatic initial cooking device remains inoperative.
The advantages resulting from the previous indentified patent application are fully retained here. A control instrument is provided, which can be manufactured with a minimum of mechanical costs, while high switching capacities are still not required of the electronic components. The invention can be used with particular advantage with the control device shown in FIG. 1 with electronic regulation and mechanical/thermal power switching. However, it can also be used with power control devices which operate purely mechanically or purely electronically.
The invention is not limited to the embodiments described and represented hereinbefore and various modifications can be made thereto without passing beyond the scope of the invention.
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A control instrument is used for the manually continuously adjustable supply of electric power to electric hot plates in the form of individual power pulses. The control instrument contains a switch, operated by a bimetallic member, whose heater is controlled by an electronic circuit and supplies current to the heating means in individual half-waves. An automatic initial cooking device with an electronic timing member is provided which, during the initial cooking phase, reduces the power supply to heater in a predetermined ratio and consequently correspondingly increases the power supplied to the electric hot plate. The automatic initial cooking device is automatically switched on by the control instrument knob. By rotating the control knob beyond a median power limit the automatic initial cooking device is switched off.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage application of International Application No. PCT/EP2011/071976 filed Dec. 6, 2011, which designates the United States of America, and claims priority to DE Application No. 10 2010 063 136.1 filed Dec. 15, 2010, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to a device and method for operating a plurality of fillable containers, in particular inflatable air cushions in a motor vehicle seat.
BACKGROUND
[0003] Such a device and such a method are known from the prior art for the operation of a plurality of air cushions which can be inflated with air or compressed air in a motor vehicle seat. The term “operation” means in this context that the air quantities or air pressures in the air cushions are adjusted in a desired manner, respectively. This requires the possibility of inflating or deflating the air cushions as required or of maintaining the air pressure therein. The known device comprises:
a plurality of container valves (air cushion valves) for connecting one of the containers (air cushions), respectively, and a filling channel arrangement (inflation channel arrangement) which is connected, on the one hand, to a media pressure source (air compressor) and is connected, on the other hand, to the container valves, respectively.
[0006] The container valves of the known device are electrically controllable, pneumatic 3/3-way valves, that is to say, comprising three valve connections (container, filling channel arrangement, atmosphere) and having three switching positions in order to close (“maintain”) the corresponding container (air cushion) as required or to connect it (“fill”) to the filling channel arrangement or to connect it (“discharge”) to atmosphere.
[0007] In order to be able to adjust a desired media pressure (air pressure) in the container as precisely as possible in this instance, one pressure sensor per container is necessary in the known device, for example, directly at each container or at a connection line leading from the associated container valve to the container.
[0008] However, pressure sensors which are suitable for this purpose (with adequate measurement precision) are relatively expensive. Another disadvantage of the known device is that, in the event of constant media pressure at the outlet of the media pressure source (air compressor), only one filling speed is possible. That filling speed particularly depends on the compressor output pressure and the technical flow conditions or properties of the device components, such as lines (for example, hoses), valves, etcetera.
SUMMARY
[0009] One embodiment provides a device for operating a plurality of containers which can each be filled with a medium, comprising: a plurality of container valves for connecting one of the containers, respectively, a filling channel arrangement which can be connected or is connected, on the one hand, to a media pressure source and is connected, on the other hand, to the container valves, respectively, and a discharge channel arrangement which is connected, on the one hand, to the container valves and which can be connected, on the other hand, to a pressureless media sink via a discharge channel valve.
[0010] In a further embodiment, the device comprises a control device for controlling the valves in accordance with an actuation parameter which is supplied to the control device, and wherein the control device is constructed to calculate the media pressure present in a specific container on the basis of a mathematical model taking into consideration a media pressure supplied by the media pressure source and the statuses of the valves.
[0011] In a further embodiment, the device comprises a filling channel pressure sensor for detecting a media pressure supplied by the media pressure source.
[0012] In a further embodiment, the device comprises a discharge channel pressure sensor for detecting a media pressure present in the discharge channel arrangement.
[0013] In a further embodiment, the discharge channel arrangement can further be connected to the filling channel arrangement via the discharge channel valve.
[0014] In a further embodiment, the connection which can be produced via the discharge channel valve between the discharge channel arrangement and the filling channel arrangement contains a throttle.
[0015] In a further embodiment, the devices comprising a filling channel valve, via which the filling channel arrangement can be selectively connected to the media pressure source directly or via a throttle.
[0016] Another embodiment provides a method for operating a plurality of containers which can each be filled with a medium, comprising controlling a plurality of container valves, to which, on the one hand, one of the containers is connected, respectively, and which are connected, on the other hand, to a filling channel arrangement which can be acted on with medium from a media pressure source, and controlling a discharge channel valve, by means of which a discharge channel arrangement connected to the container valves can be connected to a pressureless media sink.
[0017] In a further embodiment, the media pressure present in a specific container is calculated on the basis of a mathematical model taking into consideration a media pressure supplied by the media pressure source and the statuses of the valves.
[0018] In a further embodiment, the media pressure present in a specific container is established in that the container is connected to the discharge channel arrangement via the relevant container valve, the discharge channel arrangement is isolated from the pressureless media sink by means of the discharge channel valve, and the media pressure present in the discharge channel arrangement is measured.
[0019] In a further embodiment, the discharge channel arrangement can further be connected to the filling channel arrangement via the discharge channel valve and a throttle, and wherein there is provision for control of the discharge channel valve in order to produce that connection in order to achieve filling of a specific container which is connected to the discharge channel arrangement via the relevant container valve at a reduced filling speed.
[0020] In a further embodiment, the method comprises controlling a filling channel valve, via which the filling channel arrangement can be selectively connected to the media pressure source directly or via a throttle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Example embodiments are described below with reference to the drawings, in which:
[0022] FIG. 1 is a block diagram of a device (pneumatic system) for controllably inflating and deflating a plurality of air cushions in accordance with a first embodiment,
[0023] FIG. 2 is a block diagram of a device for controllably inflating and deflating a plurality of air cushions in accordance with a second embodiment,
[0024] FIG. 3 is a block diagram of a portion (filling channel arrangement) of a device for controlled filling and deflation of a plurality of air cushions in order to explain the use of a mathematical model in establishing the cushion pressure, and
[0025] FIG. 4 is an illustration of a mathematical model suitable for establishing the cushion pressure.
DETAILED DESCRIPTION
[0026] Embodiments of the present invention provide a device or a method of the type mentioned in the introduction, to reduce the complexity for measuring or establishing the media pressure in the individual containers and/or to allow different filling speeds.
[0027] One embodiment provides a discharge channel arrangement which is connected, on the one hand, to the container valves and which can be connected, on the other hand, to a pressureless media sink via a discharge channel valve.
[0028] Accordingly, the method may include control of a discharge channel valve, by means of which a discharge channel arrangement connected to the container valves can be connected to a pressureless media sink.
[0029] This construction advantageously allows a “central pressure sensor” or a central pressure measurement to be provided in the region of the discharge channel arrangement in order to establish, for example, the media pressures in the individual containers therewith. This construction further meets the requirement for a simple achievement of two different filling speeds (cf. also in this regard explanations set out below).
[0030] The filling channel arrangement may comprise, for example, a filling channel provided to connect the media pressure source and channel branches which branch off therefrom to the container valves, respectively.
[0031] The discharge channel arrangement may comprise, for example, a discharge channel provided for connecting the discharge channel valve and channel branches which branch off therefrom to the container valves, respectively.
[0032] The volume of the filling channel arrangement is preferably relatively small, as is the volume of the discharge channel arrangement. According to an embodiment, therefore, there is provision, for example, for such a volume to be smaller by at least a factor of 100 than the smallest of the volumes of the containers to be operated. If those last volumes change during operation (such as, for example, in air cushions which can be inflated so as to increase volume), the smallest container volumes in terms of operation must be considered regarding this embodiment (for example, the volumes of air cushions which are deflated, for example, at atmospheric pressure).
[0033] If the device constitutes a pneumatic system, that is to say, for example, is provided to operate air cushions in a seat of a motor vehicle and, in the simplest case, air is provided as the “medium”, for example, the atmosphere may be provided as the “pressureless media sink”.
[0034] The container valves are preferably, for example, electrically controllable 3/3-way valves, by means of which a container connection may selectively be closed (isolated) (“maintain”) or may be connected (“fill”) to the filling channel arrangement or may be connected (“discharge”) to the discharge channel arrangement.
[0035] One embodiment provides a control device to be used to control the valves of the device (for example, electronic programme-controlled control unit), which control device carries out that control action in accordance with an actuation parameter which is supplied to the control device.
[0036] The “actuation parameter” may result, for example, on the basis of an operating command of a user of the device, or may comprise such an operating command (example: the user actuates an operating knob in a motor vehicle in order to initiate specific inflation/deflation of an air cushion in a seat of the motor vehicle).
[0037] Alternatively or additionally, the actuation parameter may also originate from the device itself, in particular, for example, the control device mentioned, for instance, if a corresponding (re)filling requirement is established after a leakage of medium from a container has been detected in order to bring the media pressure in the relevant container back to the desired extent again.
[0038] In one embodiment, the device comprises a control device for controlling the valves in accordance with an actuation parameter which is supplied to the control device, and wherein the control device is constructed to calculate the media pressure present in a specific container on the basis of a mathematical model taking into consideration a media pressure supplied by the media pressure source and the statuses of the valves.
[0039] The “media pressure supplied by the media pressure source” is known in the simplest case in a manner dependent on the construction (depending on the specific construction of the media pressure source and/or the control thereof) or may be taken to be known to a given extent in a first approximation. With regard to the accuracy of that parameter used as an input variable for the mathematical model (algorithm), however, it is mostly preferable to use a pressure sensor for the purpose. According to one embodiment, the device comprises a filling channel pressure sensor for detecting a media pressure supplied by the media pressure source.
[0040] The filling channel pressure sensor can be arranged directly at a portion of the filling channel arrangement, in particular the filling channel already mentioned, or alternatively be connected to such a portion via a pressure measurement line.
[0041] The use of a mathematical model for establishing the pressure may also allow pressure sensors to be saved. For instance, the media pressures present in the containers can be established, for example, by means of one or a very small number of “commonly used” pressure sensor(s) (for example, filling channel pressure sensor) (cf. also in this regard explanations set out below).
[0042] In one embodiment, the device comprises a discharge channel pressure sensor for detecting a media pressure present in the discharge channel arrangement. The discharge channel pressure sensor can be arranged directly at a portion of the discharge channel arrangement, for example, the discharge channel mentioned, or be connected to such a portion via a pressure measurement line (for example, hose).
[0043] In one embodiment, the discharge channel arrangement can further be connected to the filling channel arrangement via the discharge channel valve. For that purpose, for example, the discharge channel valve may be, for example, an electrically controllable 3/3-way valve, by means of which the discharge channel arrangement may be selectively connected to the pressureless media sink or the filling channel arrangement, or may be closed (isolated).
[0044] In this embodiment, an additional possibility for filling the containers is advantageously provided, that is to say, via the discharge channel arrangement.
[0045] In one embodiment, the connection which can be produced via the discharge channel valve between the discharge channel arrangement and the filling channel arrangement contains a throttle.
[0046] As a result, a reduced filling speed is achieved when a container is filled via this path so that two different filling speeds are advantageously achieved depending on the filling path selected (either via the filling channel arrangement or via the filling channel arrangement and subsequently via the discharge channel arrangement).
[0047] In another embodiment, the device comprises a filling channel valve, via which the filling channel arrangement can be selectively connected to the media pressure source either directly or via a throttle.
[0048] FIG. 1 shows a device 10 which is provided for use in a motor vehicle in order to operate a plurality of inflatable air cushions 12 - 1 , 12 - 2 . . . 12 - n which are arranged in a “comfort seat” of the motor vehicle. The motor vehicle seat may contain, for example, at least three, in particular at least five such air cushions. In this application, each air cushion typically has a volume of approximately from 100 cm 3 to 1000 cm 3 .
[0049] Consequently, a user of the motor vehicle seat can adapt the properties of the seat to the current preferences by inflating or deflating the individual cushions 12 - 1 , 12 - 2 . . . 12 - n in a controlled manner or by maintaining cushion pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n, respectively.
[0050] The cushions 12 - 1 , 12 - 2 . . . 12 - n are connected in the example illustrated via hoses or connection lines 14 - 1 , 14 - 2 . . . 14 - n to one of a plurality of pneumatic valves 16 - 1 , 16 - 2 . . . 16 - n which are constructed as 3/3-way valves and which are also referred to below as “container valves”.
[0051] The container valves 16 - 1 , 16 - 2 . . . 16 - n are controlled by an electronic control unit ST (for example, controlled by microprocessor) which outputs inter alia corresponding control signals SV 1 , SV 2 . . . SVn to the container valves for this purpose.
[0052] The reference numerals of components which are provided repeatedly in one embodiment but which are similar in terms of their effect such as, for example, the air cushions 12 - 1 , 12 - 2 . . . , are numbered sequentially (each supplemented by a hyphen and a continuous number). Reference is also made below to individual examples of such components or to the entirety of such components by means of the non-supplemented reference numeral.
[0053] The associated cushion 12 , depending on the switching position of the valve 16 , can selectively be connected by means of each container valve 16 either to a filling channel arrangement 18 or to a discharge channel arrangement 20 or be closed (isolated).
[0054] In the illustrated example, the filling channel arrangement 18 comprises a filling channel supplied with compressed air by means of an air compressor 22 and filling channel branches which branch off from it to the container valves 16 , respectively. The air compressor 22 may be controlled with regard to its operation or its conveying output and is switched on and off or controlled with regard to its conveying output in this instance by a control signal SK supplied by the control unit ST.
[0055] In the Figure, a pressure present at the compressor output is designated PK and the pressures present in the filling channel branches are designated P1, P2 . . . Pn. Depending on the current operating status of the device 10 , the pressures P1, P2 . . . Pn can differ from each other or from the compressor pressure PK. In the application illustrated, the compressor pressure PK is typically approximately 1000 hPa (in relation to the environmental pressure, that is to say, atmospheric pressure).
[0056] The discharge channel arrangement 20 comprises in the illustrated example a discharge channel connected to a discharge channel valve VA and discharge channel branches which branch off from it to the container valves 16 , respectively. The valve VA is controlled by a control signal SVA supplied by the control unit ST.
[0057] The discharge channel valve VA could be, for example, a 2/2-way valve, by means of which the discharge channel can selectively be closed or connected to atmosphere (“pressureless media sink”).
[0058] In a preferable manner and as also provided for in the example illustrated, however, the discharge channel valve VA is a 3/3-way valve, by means of which the discharge channel arrangement 20 can further be connected to the filling channel arrangement 18 .
[0059] In the example illustrated, two air pressure sensors are further provided, that is to say, a filling channel pressure sensor 24 for measuring the compressor pressure PK at the output of the compressor 22 and a discharge channel pressure sensor 26 for measuring a pressure PA present in the discharge channel of the discharge channel arrangement 20 .
[0060] In the embodiment illustrated, a user instruction SB is supplied to the control unit ST (on the basis of actuation of an operating element by a user of the motor vehicle seat) and corresponding input signals are supplied to the measured pressures PK and PA. The control unit ST controls the valves 16 - 1 , 16 - 2 . . . 16 - n and VA of the device 10 on the basis of those variables in accordance with a control algorithm.
[0061] The operation of the device 10 is explained in greater detail below.
[0062] In order to fill (inflate) a specific one of the cushions 12 , the associated container valve 16 can be moved into a switching position “1” so that the relevant cushion 12 is connected via the relevant connection line 14 and the valve 16 to the filling channel arrangement 18 which is acted on with pressure by the air compressor 22 and consequently air flows from the filling channel arrangement 18 into that cushion 12 . It will be understood that such a filling action can also be carried out simultaneously for a plurality of the cushions 12 .
[0063] The specific construction of the device 10 illustrated further allows filling of one or more of the cushions 12 also to be brought about in that the relevant cushion 12 is connected to the discharge channel arrangement 20 via the associated container valve 16 (in the switching position “2”) and the discharge channel arrangement 20 is connected via the discharge channel valve VA (in the switching position “1”) to the filling channel arrangement 18 which is acted on with pressure. In that switching position combination, compressed air flows from the compressor 22 via the valve VA and the relevant valve(s) 16 (in the switching position “2”) into the relevant cushions 12 .
[0064] In this instance, a particular advantage is produced owing to a throttle 28 which is inserted in the connection path between the discharge channel arrangement 20 and the filling channel arrangement 18 and which ensures that a reduced filling speed results during this filling method so that two different filling speeds can be achieved for one and the same compressor pressure PK.
[0065] Advantageously, the two different filling methods can also be carried out simultaneously, that is to say, it is possible to fill, for example one or more of the cushions 12 simultaneously directly via the filling channel arrangement 18 (“first filling method”) and simultaneously one or more of the remaining cushions 12 via the valve VA and the discharge channel arrangement 20 (“second filling method”).
[0066] The arrangement of the throttle 28 at the side of the filling channel arrangement 18 (and not at the side of the discharge channel arrangement 20 ) has the particular advantage that the speed of the discharge of individual cushions 12 , as will be described below, is not influenced (reduced) as a result.
[0067] The throttle 28 can be combined structurally with the valve VA in a structurally particularly simple manner, for example, as a suitably dimensioned cross-section contraction in the region of the connection of the valve VA connected to the filling channel arrangement 18 .
[0068] In time phases in which the discharge channel arrangement 20 is not used to carry out the “second filling method”, it is possible to discharge (deflate) one or more of the cushions 12 via that discharge channel arrangement 20 by the relevant valve(s) 16 being moved into the switching position “2” thereof and consequently being connected to the discharge channel arrangement 20 and the discharge channel arrangement being connected to atmosphere via the valve VA in the switching position “2”.
[0069] At any time during operation of the device 10 , each of the cushions 12 may also be closed (isolated) by the associated container valve 16 being moved into the switching status “0”. The internal cushion pressure P_cushion then remains constant in those cushions 12 .
[0070] With the device 10 described, apart from the description of a plurality of filling speeds already explained, extremely simplified monitoring and adjustment of the air pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n in the cushions 12 - 1 , 12 - 2 . . . 12 - n can also be achieved in relation to the prior art.
[0071] In the example illustrated, pressure sensors associated individually with the individual cushions 12 are dispensed with. Accordingly, pressure sensors are saved or the number thereof reduced in the device 10 .
[0072] A pressure monitoring carried out by the control unit ST is instead carried out on the basis of the pressures PK and PA measured by the two pressure sensors 24 and 26 . A mathematical model, in which the individual cushion pressures are calculated from specific peripheral conditions (compressor pressure PK, flow resistances of the relevant lines or channels, volumes of the cushions 12 , etcetera), the start condition (“start pressure” in the individual cushions 12 ) and the switching statuses “0”, “1” or “2”) of the valves 16 - 1 , 16 - 2 , . . . 16 - n , VA, can be used to monitor the pressure.
[0073] The compressor pressure PK is measured by means of the pressure sensor 24 in the example illustrated and is consequently known to a high degree of accuracy. The remaining peripheral conditions such as line lengths, line diameters, etcetera, are known in any case.
[0074] A defined start condition at a relative cushion pressure of 0 hPa can be produced, for example, after sufficiently long prior deflation of the relevant cushion 12 .
[0075] The switching statuses of all the valves 16 - 1 , 16 - 2 , . . . 16 - n , VA are further known in the region of the control unit ST.
[0076] For example, the analogy of an electrical RC member can be used as a simple mathematical model, the resistance “R” representing the relevant flow resistance (by valve(s) and line(s)) and the capacity C representing the relevant cushion volume. The implementation of such a model places only small requirements on the resources of the control unit ST.
[0077] Such a mathematical model or the control algorithm which is processed in the control unit ST therefor is discussed again below with reference to FIGS. 3 and 4 .
[0078] The additional pressure sensor 26 in the common discharge channel arrangement 20 brings about additional advantageous possibilities for pressure measurement which can be used in the context of or in addition to the mathematical model mentioned during operation of the device 10 . For example, the pressure PA measured by the pressure sensor 26 during the pressure monitoring in the context of the model can be taken into consideration during deflation by means of the discharge channel arrangement 20 .
[0079] Furthermore, the pressure sensor 26 may be used, for example, to detect a leakage of the system (in order thereby to initiate, for example, a suitable refilling operation).
[0080] The pressure sensor 26 further allows the individual cushion pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n to be measured successively with great precision by the valve VA being moved into the switching position “0” and the valve 16 associated with the relevant cushion 12 being moved into the switching position “2”.
[0081] At a start of operation, for example, a test for any leaks can initially be carried out in order subsequently to measure all the cushion pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n successively and subsequently to use the measured values, for example, for the “start condition” of the mathematical model.
[0082] In order to avoid a pressure loss in the relevant cushion 12 brought about by the discharge channel arrangement 20 being flooded in this pressure measurement method, the discharge channel arrangement 20 is preferably briefly filled by means of the compressor 22 before this measurement by the valve VA being moved briefly into the switching status “1”.
[0083] In the device 10 of FIG. 1 , if a specific example of the cushions 12 - 1 , 12 - 2 . . . 12 - n and the associated example of the container valves 16 - 1 , 16 - 2 . . . 16 - n and the commonly used discharge channel valve VA are considered, a total of 3×3=9 possible combinations of the valve switching positions are produced.
[0084] The following table again sets out the 9 possible statuses (switching position combinations) “A” to “I”, the resultant behavior with regard to the cushion 12 considered being set out for each status:
[0000]
Switching
Switching
Behavior of the cushion
position of
position of
pressure P_cushion
the container
the valve
(1 . . . n) or device
Status:
valve 1 . . . n:
VA:
functionality:
A
0
0
Maintain cushion
pressure
B
1
0
Fill cushion (normal
filling speed or “first
filling method”)
C
2
2
Deflate cushion
D
2
1
Fill cushion (reduced
filling speed or “second
filling method”)
E
2
0
Measure cushion pressure
F
0
1
Fill measurement channel
(reduced filling speed)
and maintain cushion
pressure
G
1
1
Fill measurement channel
(reduced filling speed)
and fill cushion
(normally) and measure
H
0
2
Discharge measurement
channel and maintain
cushion pressure
I
1
2
Discharge measurement
channel and fill cushion
(normally)
[0085] In the status “E”, the discharge channel arrangement 20 functions to a degree as a “measurement channel” connected to the relevant cushion 12 in order to measure the cushion pressure by means of the pressure sensor 26 .
[0086] Before that measurement, the measurement channel can be filled via the valve VA to the expected cushion pressure P_cushion (status “F” or “G”) in order to avoid a pressure loss in the relevant cushion 12 owing to the subsequent measurement.
[0087] Except for such measurements of the cushion pressures P_cushion carried out, for example, from time to time, the actual pressure monitoring and pressure adjustment based thereon are carried out by means of a mathematical model.
[0088] During the pressure adjustment, an increase or decrease of the cushion pressures P_cushion may be carried out, for example, in a time-controlled manner, that is to say, by the relevant inflation or deflation operation being carried out for a predetermined time; the resultant cushion pressure change results on the basis of the mathematical model.
[0089] In the simplest case, the supply pressure (compressor pressure PK) necessary for the model as an input variable already results from the properties of the pressure source specifically used (in this instance: compressor 22 ).
[0090] However, this supply pressure may optionally also be measured by an additional pressure sensor, the pressure sensor 24 in the example of FIG. 1 , or a pressure sensor 24 ′ which is illustrated with broken lines in FIG. 1 and which is arranged further downstream in the path of the filling channel. As a result, the peripheral condition “supply pressure” necessary for the mathematical model for use can be measured with greater accuracy.
[0091] If only one cushion 12 is being deflated (status “C”), the cushion pressure P_cushion can also be measured during that deflation with the central pressure sensor 26 . Furthermore, if only one cushion 12 is filled at the reduced filling speed (status “D”), the relevant cushion pressure P_cushion can also be measured during that filling operation with the central pressure sensor 26 . If only one cushion 12 is being filled (at normal filling speed) in the status “G”, a measurement of the cushion pressure P_cushion can be carried out at the same time.
[0092] In the case of such pressure measurements during the deflation/filling, a deviation which is more or less large occurs in this instance between the actual cushion pressure P_cushion and the pressure PA measured by the pressure sensor depending on the technical flow conditions (flow resistances of the used lines, hoses, valves, etcetera). However, this can readily be taken into account by the mathematical model in order to calculate the cushion pressure P_cushion on the basis of the measured pressure PA taking into account all other relevant variables, and consequently to improve the adjustment accuracy. This consideration may take place, for example, in the form of a “correction” described in the publication DE 10333204A1 (cf. particularly, for example, claim 1 and paragraphs [0006], [0009], [0032], [0033] of DE10333204A1). In some embodiments, such a correction of the pressure PA measured by the pressure sensor 26 may also be carried out in order to obtain the cushion pressure P_cushion.
[0093] In the following description of additional embodiments, the same reference numerals supplemented by a lower case letter in order to distinguish the embodiment are used for components having the same effect. Substantially only the differences in relation to the embodiment(s) already described are discussed and reference is hereby expressly further made to the description of the preceding embodiments.
[0094] FIG. 2 shows a device 10 a according to a second embodiment.
[0095] Unlike in the above-described embodiment, pressure sensors 17 a - 1 , 17 a - 2 . . . 17 a - n which are arranged on the connection lines 14 a of the relevant cushions 12 a are provided in the device 10 a.
[0096] Another difference in relation to the first embodiment is that a discharge channel arrangement common to the container valves 16 a - 1 , 16 a - 2 . . . 16 a - n is not associated in the device 10 a but instead the corresponding valve connections are directly connected to atmosphere (“pressureless media sink”).
[0097] A peculiarity of the device 10 a is that there is provided a filling channel valve VB by means of which a filling channel arrangement 18 a can be selectively connected to an air compressor 22 a directly or via a throttle 30 a . In the example illustrated, the valve VB is a 3/2-way valve.
[0098] Consequently, two different filling speeds can advantageously be achieved by the filling channel valve VB (control signal SVB) being controlled accordingly.
[0099] In a switching position “0”, the compressor pressure PK is applied directly to the filling channel arrangement 18 a (normal filling speed), whereas the flow takes place via the throttle 30 a in a switching position “1” (reduced filling speed).
[0100] A reduced filling speed achieved in the context of the present disclosure particularly allows imperceptible or relatively small correction operations, for example, in order to compensate for gradual pressure changes by, for example, leaks, temperature changes, etcetera.
[0101] The throttle 30 a can be combined, for example, structurally with the valve VB, that is to say, in particular integrated in the valve VB.
[0102] FIGS. 3 and 4 again illustrate the already-mentioned possibility of calculating cushion pressures on the basis of a mathematical model in order thereby to be able to dispense with pressure sensors which are individually associated with the individual cushions (generally: containers) and which measure in a precise manner.
[0103] FIG. 3 shows a filling channel arrangement 18 b , to which a corresponding plurality of air cushions 12 b - 1 , 12 b - 2 . . . 12 b - n are connected via container valves 16 b - 1 , 16 b - 2 . . . 16 b - n and connection hoses 14 b - 1 , 14 b - 2 . . . 14 b - n.
[0104] The filling channel arrangement 18 b may be, for example, the filling channel arrangement of one of the embodiments already described ( FIGS. 1 and 2 ).
[0105] The filling channel arrangement 18 b is supplied with a compressor pressure PK (for example, 1000 hPa) at an input of a filling channel, from which channel branches branch off to the individual valve inputs. The filling channel arrangement 18 b forms to a degree a “pressure distributor” (illustrated with broken lines in FIG. 3 ). The pressures present at the valve inputs are designated P1, P2 . . . Pn in FIG. 3 .
[0106] If the valves 16 b illustrated in FIG. 3 are closed (switching status “0” or “2”), the pressures P1, P2 . . . Pn all take on the value of the supply pressure PK. The individual cushion pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n remain unchanged in the case of the switching status “0” (“maintain”).
[0107] If at least one of the valves 16 b is opened, however, deviations, on the one hand, of the pressures P1, P2 . . . Pn relative to each other and in comparison with the pressure PK occur. If a plurality of the cushions 12 b are filled, there is in principle an effect on the pressures P1, P2 . . . Pn. This effect is dependent on the overall switching status of the valves 16 b and the individual cushion pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n because the flow decreases when the cushions 12 b become fuller. The longer a specific one of the valves 16 b is open, the more the pressure at the corresponding valve input and in the corresponding cushion conform to the supply pressure PK.
[0108] It is readily apparent to the average person skilled in the art that, taking into consideration the physical conditions and the technical flow properties of the device components used, it is readily possible to formulate a mathematical model which supplies the values of the pressures P1, P2 . . . Pn resulting at the valve inputs as output variables on the basis of the (for example, measured) supply pressure PK, the switching statuses of the valves 16 b known in any case and the current cushion pressures P_cushion as input variables.
[0109] A partial model M1 of a corresponding model is indicated in FIG. 4 .
[0110] At any time (during a filling phase), the actual pressures P1, P2 . . . Pn at the inputs of the valves 16 b - 1 , 16 b - 2 . . . 16 b - n are established with the model M1. At the input side, the values of the last cushion pressures established P_cushion-1, P_cushion-2 . . . , P_cushion-n, the current compression pressure PK and the current “overall valve status” VS, that is to say, the switching statuses of all the valves of the device, are supplied to the model M1.
[0111] On the basis of that detection result (and taking into consideration the valve statuses), a change in the individual cushion pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n can subsequently be calculated on the basis of an additional partial model M2 (see FIG. 4 ). Consequently, the model M2 uses the previously established pressures P1, P2 . . . Pn. The cushion pressures updated on the basis of the cushion pressure changes can subsequently be used again as input variables of the model M1 (cf. FIG. 4 ).
[0112] Consequently, the partial models M1 and M2 form a mathematical model or a calculation algorithm for establishing the cushion pressures P_cushion-1, P_cushion-2 . . . , P_cushion-n with regard to operating phases in which filling is carried out via the filling channel arrangement 18 . The time progression of the pressures at the valve inputs is advantageously taken into consideration when the cushion pressures are calculated. Therefore, they do not have to be constant (or be assumed to be constant).
[0113] If additional information concerning individual pressures of the cushion pressures is available, it can also be taken into consideration. Such information is available, for example, if a cushion 12 b has been deflated for a relatively long period of time. Such information is also available, for example, if one or more cushion pressures has/have been measured by means of a pressure sensor. A corresponding measurement method has already been described above with reference to FIG. 1 (measurement of the cushion pressures by means of the central pressure sensor 26 ). The corresponding information can be used to re-initialize the cushion pressure calculated on the basis of the model (see FIG. 4 , input variable “P_cushion — 1 . . . n_init”).
[0114] Model parameters which are necessary for formulating the models M1 and M2 are substantially produced from the geometry data of the device components used (line lengths, line cross-sections, flow resistances of the valves, etcetera).
[0115] Since individual cushions 12 b are also deflated during operation of the device, where applicable, the mathematical model illustrated in FIGS. 3 and 4 merely for the case of filling must ultimately be further supplemented with a completely similarly derivable model for the case of deflation. The deflation of individual valves 12 b can be carried out via the corresponding lines 14 b and valves 16 b , for example, directly to atmosphere (cf. also the embodiment according to FIG. 2 ) or, for example, via a discharge channel arrangement (cf. also the embodiment according to FIG. 1 ). In both cases, it is again possible to determine a mathematical model or a mathematical model which is similarly combined from partial models and to use it to calculate the cushion pressures in phases of a deflation operation.
LIST OF REFERENCE NUMERALS
[0000]
10 Device
ST Control unit
12 Inflatable air cushions
14 Connection lines
16 Container valves
VA Discharge channel valve
VB Filling channel valve
17 Pressure measurement sensors
18 Filling channel arrangement
20 Discharge channel arrangement
22 Compressor
24 Filling channel pressure sensor
26 Discharge channel pressure sensor
28 Throttle
30 Throttle
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A device for operating a plurality of containers fillable with a medium may include a plurality of container valves each connected to of one of the containers, and a filling channel arrangement connectable or connected at one end to a media pressure source and connected at the other end to the respective container valves. In order to simplify determination of the media pressure in the individual containers and, furthermore, to permit different filling speeds, an emptying channel arrangement is connected at one end to the container valves and connectable at the other end to an unpressurized media hollow via an emptying channel valve. The media pressure in one of the containers can be calculated using a mathematical model. A filling channel valve may be provided for selectively connecting the filling channel arrangement to the media pressure source either directly or via a throttle in order to permit different filling speeds.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/412,879, filed Nov. 12, 2010, which is incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to leisure and amusement slides, and particularly to water slides.
BACKGROUND
[0003] Water slides in general are fabricated from rigid material configured into twists and turns to provide variety and entertainment for the user. A rider travels down the slide on a body of water and, because of the rigidity of the slide, travels in a predetermined slide track which is repeated on subsequent uses.
[0004] Water slides can be classified as either a body ride where the rider travels on or in a body of water, or a tube ride where the rider travels in a craft or inner tube which itself travels on or in a body of water. In both cases, the water provides lubrication and a sliding enhancement medium. In some cases, water may be replaced by polishing the sliding surface of the slide so as to make a slippery surface on which to slide. Other sliding aids may also be used. Examples include a waxed bag, mat, or special suit.
[0005] Known slides have distinct disadvantages. They are rigid over their entire length and therefore, once constructed, cannot be varied or changed as to slope, height, bumps, curves, or other features. The slide path is the same in each use; ultimately, users may lose interest in such static, unchanging rides. Thus, slides are frequently updated or replaced in order to provide variety and maintain user interest.
SUMMARY OF INVENTION
[0006] The present inventions relate to sections of an amusement slide which are designed to move in different ways. Some of the embodiments described below provide a potentially different slide track with each use. The rider will also be subject to the sensation of movement within the ride itself, which has little or no precedent in the prior art.
[0007] Since it is possible to use the start and finish of existing rides while incorporating movable sections disclosed herein, old slides may be retrofitted with new moving sections; of course, completely new installations may also be made using moving slide sections.
[0008] In one embodiment, an amusement slide includes a first stationary section having a rider passageway therein and a movable section having a rider passageway therein. The movable section passageway is in communication with the first section passageway such that a rider may pass from one of the passageways to the other of the passageways. A first slide path passes through the passageways. At least one actuator is configured to move the movable section. A processor in data communication with the at least one actuator is included for causing the movable section to move from a first state to a second state. Movement of the movable section from the first state to the second state alters the first slide path to a second slide path passing through the passageways. The second slide path is different from the first slide path.
[0009] In another embodiment, an amusement slide includes a first section, a second section, and at least one actuator for moving the first section from a first state to a second state. The first section has a rider passageway therein, and the second section has a rider passageway therein. The second section passageway is in communication with the first section passageway such that a rider may pass from one of the passageways to the other of the passageways. A first slide path is defined while the first section is at the first state, and a second slide path is defined while the first section is at the second state. The second slide path is different from the first slide path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 a shows a plan view of part of a slide having a rotating section according to one embodiment.
[0011] FIG. 1 b shows a cross sectional view taken from FIG. 1 a along line A-A.
[0012] FIG. 1 c shows a diagram of a processor in data communication with the actuator of FIG. 1 a.
[0013] FIG. 2 shows a plan view of part of a slide having a rotating section according to another embodiment.
[0014] FIG. 3 shows a plan view of part of a slide having rotating sections according to yet another embodiment.
DETAILED DESCRIPTION
[0015] FIGS. 1 a and 1 b show a rotating section 6 installed as part of a tubular slide having an upstream section 4 and a downstream section 5 . The rotating section 6 rotates about axis B-B and includes an interior rider passageway that is aligned with and smoothly transitions to an interior rider passageway 4 a ( FIG. 1 b ) of the upstream section 4 and to an interior rider passageway of the downstream section 5 . Alignment and transition of the interior rider passageways may be desired to minimize (at least to an acceptable extent) discomfort and opportunity for bodily injury when a rider passes between the interior rider passageways as discussed further below. In some embodiments, alignment and transition may be such that the rider experiences no noticeable affects from moving between the sections 4 , 5 , 6 .
[0016] Collars 1 a , 1 b may maintain the alignment between the rotating section 6 and the upstream and downstream sections 4 , 5 , and the collars 1 a , 1 b may include bearings that interact with one or more of the sections 4 , 5 , 6 . In some embodiments, gearing, pistons (or “rams”), and/or other actuators may be formed with one or both of the collars 1 a , 1 b , such that force is operatively imparted on one or both ends 6 a , 6 b of the rotating section 6 . In the embodiment shown in FIG. 1 a , movement of the rotating section 6 may be caused by a suitable powered mechanism 3 providing necessary drive energy to slide bearings in the collar 1 b . However, those skilled in the art will appreciate that numerous actuating devices may be used to rotate the rotating section 6 whether at one or both ends 6 a , 6 b , or at a central area of the rotating section 6 .
[0017] If the sections 4 , 5 , 6 are coupled together in a generally watertight manner, water may be introduced into the upstream section 4 and flow through the interior rider passageways of the sections 4 , 5 , 6 . In other embodiments, water may be introduced into each of the sections 4 , 5 , 6 and may cycle out of the slide without proceeding from one section to the next. And in still other embodiments, the rotating section 6 may be used with dry slides that do not utilize water or other lubricants.
[0018] As the rotating section 6 , the collars 1 a , 1 b , the sections 4 , 5 , and/or other elements may be undesirably stressed (especially while the rotating section 6 rotates), it may be desirable to include a weighted unit (or “counter balance”) 2 . The counter balance 2 may have various aesthetic configurations, and may be intended (if employed) to reduce undesirable stresses acting on the overall system. FIG. 1 a shows the counter balance 2 configured very similar to the rotating section 6 , and the counter balance 2 may or may not have an interior rider passageway similar to the interior passageway of the rotating section 6 . If the counter balance 2 does include an interior rider passageway, diverters may be used to direct riders into the counter balance 2 or the rotating section 6 .
[0019] In use, at least one rider enters the slide at the upstream section 4 (i.e., in the interior rider passageway 4 a ) or even further upstream than the section 4 . The rider may enter the slide with or without a carrying vehicle; or in other words, the rider may enter feet-first, head-first, on a raft, et cetera. After travelling through a traditional (i.e., non-rotating) upstream portion, the rider passes from the interior rider passageway 4 a of the upstream section 4 and into the interior rider passageway of the rotating section 6 .
[0020] The rotating section 6 may be caused to rotate (clockwise and/or counterclockwise) in various manners. For example, a processor 110 ( FIG. 1 c ) may activate the actuator 3 , and exemplary rotation of the movable slide section 6 is shown by arrows C in FIG. 1 b . The rotating section 6 may be continuously, intermittently (either at times such that the rotating sections 6 rotates while used by a rider, or at times such that the rotating section 6 rotates while no riders are present), or randomly rotated (e.g., by the processor 110 activating the actuator 3 ), or may for example be rotated to correspond to the rider entering or approaching the rotating section 6 (e.g., by using a predetermined time interval from when the rider entered the slide, by employing sensors to detect the rider's location, et cetera). Further, the rotating section 6 may be rotated at different (or even varying) speeds. In some embodiments, the rider may select the direction and/or speed of rotation (e.g., before entering the slide). The processor 110 may include hardware and/or software for controlling actuators as described. Those skilled in the art will appreciate that other embodiments may omit the processor 110 and use operators (e.g., employees) to manually activate the actuators, for example.
[0021] Gravity may bias the rider toward the lowermost point of the interior rider passageway of the rotating section 6 , regardless of the position of the rotating section 6 . Accordingly, the rider may remain generally in whatever part of the interior rider passageway of the rotating section 6 is lowest when he encounters it—regardless of the position of the rotating section 6 (e.g., below axis B-B, above axis B-B, et cetera). As such, the rider may sometimes travel in the interior rider passageway adjacent side 6 c of the rotating section 6 , and may at other times travel in the interior rider passageway adjacent side 6 d of the rotating section 6 . Due to the curved configuration of the interior rider passageway and the rotation of the rotating section 6 , the rider may encounter a different slide path inside the rotating section 6 each time the slide is used. From the rotating section 6 , the rider proceeds to the interior rider passageway of the downstream section 5 .
[0022] The rotating section 6 may be constructed from any suitable material, such as GRP or any other appropriate materials now known or later developed. In addition, the rotating section 6 may be incorporated into various existing (or later developed) slides, with the unique features of each combining to provide different overall experiences. For example, U.S. patent application Ser. No. 13/080,452 (published as US 2011/0183768), the contents of which are incorporated herein by reference, discloses a “bowl” type slide having two tubular entrances 205 , 207 and two tubular exits 514 , 514 ′. The rotating section 6 may be incorporated, for example, into one or both tubular entrances 205 , 207 and/or one or both tubular exits 514 , 514 ′. It should also be appreciated that a slide (or even a portion of a slide) may include multiple rotating sections 6 that a rider will encounter.
[0023] FIG. 2 shows a rotating section 7 according to another embodiment which may be used in conjunction with, or instead of, the rotating section 6 . The rotating section 7 may be curved (as shown, for example) or may extend generally straight, and is hinged (at axis 9 ) to rotate. In some embodiments, the axis 9 may extend generally horizontally. The rotating section 7 may include a supporting frame (or “spine”) 8 made of steel or other suitable material or combination of materials, and ram(s) 12 , gearing, and/or other actuators may cause the frame 8 to rotate about the axis 9 . It may be desirable for the axis 9 to be at (or closely adjacent) a proximal end 7 a of the rotating section 7 . Those skilled in the art will appreciate that, if a ram 12 is used, the ram 12 may be powered by various existing or later-developed devices, such as hydraulic devices, pneumatic devices, electric motors, balancing devices that use fluid or solid weights, et cetera.
[0024] In the embodiment shown in FIG. 2 , the rotating section 7 is located at the beginning of the slide and feeds into non-rotating section 10 . In this embodiment, a rider 11 may enter the slide at the section 10 . Instead of initially travelling toward the end of the slide (i.e., in leftward direction E), the rider 11 may instead be launched in the opposite direction (i.e., in rightward direction F), such that the rider 11 travels down the rotating section 7 (at position 7 ′). As the rider 11 reaches a distal end 7 b of the rotating section 7 , or at some other determined time, the ram 12 (or other actuator) may cause the rotating section 7 to pivot upwardly (to position 7 ″) such that the rider 11 is higher than the section 10 . Curve in the rotating section 7 and/or the rotation of the rotating section 7 may cause the rider to stop moving away from the section 10 , and gravity may cause the rider 11 to slide back down the rotating section 7 and to pass into the non-rotating section 10 .
[0025] By incorporating the rotating section 7 at the beginning of the slide, riders may be allowed to choose whether to use the rotating section 7 or to proceed directly to the non-rotating section 10 . For riders utilizing the rotating section 7 , the amount of time on the slide may be increased without increasing the height of the entry stairway or the starting platform of the slide, and without extending the length from the starting platform to the end of the slide. Moreover, by using the rotating section 7 , a rider's momentum may be increased.
[0026] In other embodiments that incorporate the rotating section 7 at the beginning of a slide, riders may enter the rotating section 7 at the distal end 7 b while the rotating section 7 is at the lowered position 7 ′. This may be advantageous in that the height of the entry stairway and the starting platform may be lower than it would otherwise be. And, in some embodiments, it may be possible for the distal end 7 b to reach all the way down to a ground level such that an entry stairway is not required.
[0027] Particularly in such embodiments, it may sometimes be necessary to use a series of rotating sections 7 to enable riders to reach certain heights without the length of each section 7 being undesirably long. Such a configuration may resemble the configuration shown in FIG. 3 , but the actuators would be operated to move the rider in directions opposite those shown in FIG. 3 . In other words, the rider 13 in FIG. 3 could enter at distal end 20 b of rotating section 20 , and ram 21 could be used to move the rotating section 20 from lowered position 20 ″ to above raised position 20 ′, causing the rider 13 to travel to proximal end 20 a of rotating section 20 and onto distal end 17 b of rotating portion 17 . Ram 19 could then be used to move the rotating section 17 from lowered position 17 ″ to above raised position 17 ′, causing the rider 13 to travel to proximal end 17 a of rotating section 17 and onto distal end 13 b of rotating portion 13 . This pattern could be repeated until the rider is sufficiently high and introduced into a non-rotating section (e.g., section 10 in FIG. 2 ), or the rider could descend on the same sections as described below regarding FIG. 3 .
[0028] FIG. 3 shows additional rotating sections 15 , 17 , 20 according to another embodiment which may be used in conjunction with, or instead of, the rotating section 6 and/or the rotating section 7 . The rotating sections 15 , 17 , 20 may each be substantially similar to the rotating section 7 , and may differ primarily in their location along the overall slide.
[0029] The rotating sections 15 , 17 , 20 are arranged such that a rider progresses from one of the sections to another following vertical and/or horizontal movement of each of the sections 15 , 17 , 20 . If a section 15 , 17 , 20 moves both vertically and horizontally, attachment between the frame of the section and a respective actuator (e.g., ram 16 , 19 , 21 ) may for example include a ball and socket joint, and an additional element (e.g., another actuator) may cause the angle (i.e., orientation) of the actuators to adjust. Control of the actuators may be mechanical, manual, or computer controlled, and may be linked to other parts of the ride for safety and/or operational reasons.
[0030] In use, the rider 13 may launch from start area 14 at the top of an access tower and travel along the movable section 15 . As the rider 13 progresses down the section 15 , the ram 16 moves the section 15 to engage with the next movable section 17 or an intermediary section. The rider 13 then progresses down the section 17 , while the section 15 may return to a beginning orientation for the next rider. As the rider 13 progresses down the section 17 , the ram 19 moves the section 17 to engage with the next movable section 20 or an intermediary section. The rider 13 then progresses down the section 20 , while the section 17 may return to a beginning orientation for the next rider. As the rider 13 progresses down the section 20 , the ram 21 moves the section 20 to offload the rider 13 (e.g., in a splash pool). This sequence may of course be abbreviated or extended by using fewer or additional moving sections. The speed and/or amount of rotation caused by the actuators may be generally unchanging, or may vary to alter riders' experiences.
[0031] If water is used with the embodiment shown in FIG. 3 , the water may be provided at the start area 14 , may be introduced (e.g., by spray nozzles) at strategic locations along the sections 15 , 17 , 20 , and/or may be introduced at other desired locations.
[0032] Those skilled in the art will appreciate that the hinge and actuator positions may be varied to provide a “see saw” motion and allow different slide configurations. For example, the hinge and actuator can be placed in such a way as to allow the rotating section to pivot about a central point so that the rider could be launched from a start point into the rotating sections, and the section could then rotate to direct the rider to a different slide.
[0033] Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.
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Amusement slides having moving sections are disclosed. In one embodiment, an amusement slide includes a first section, a second section, and at least one actuator for moving the first section from a first state to a second state. The first section has a rider passageway therein, and the second section has a rider passageway therein. The second section passageway is in communication with the first section passageway such that a rider may pass from one of the passageways to the other of the passageways. A first slide path is defined while the first section is at the first state, and a second slide path is defined while the first section is at the second state. The second slide path is different from the first slide path.
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[0001] This application claims the benefit of earlier filed U.S. Provisional Application No. 61/701,399, filed on Sep. 14, 2012, which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to improvement of human endothelial function and cardiovascular parameters through use of the herbo-mineral Shilajit.
BACKGROUND
[0003] Cardiovascular disease (CVD) is the number one cause of death globally. Smoking, hypertension, high LDL cholesterol, low HDL cholesterol and diabetes mellitus (DM) are the five major risk factors for CVD. Diabetes is associated with an increased risk of atherosclerosis, which may result in coronary artery disease (CAD) (A. Pandolfi, et al., “Chronic hyperglycemia and nitric oxide bioavailability play a pivotal role in proatherogenic vascular modifications,” Genes & Nutrition (2007) 2 (2): 195-208). Physiological impairments that link DM with a marked increase in atherosclerotic vascular disease include platelet hyper-reactivity, a tendency for negative arterial remodeling, impaired fibrinolysis, increased inflammation, and endothelial dysfunction.
[0004] Endothelial dysfunction, present at disease onset, may be the cause of atherogenesis that is present throughout the course of DM and associated with late-stage adverse outcomes (Panwar, et al., “Atherothrombotic risk factors & premature coronary heart disease in India: A case-control study,” Indian J. Med. Res . (July 2011) 134: 26-32). The endothelial dysfunction results from reduced bioavailability of the vasodilator nitric oxide (NO) mainly due to accelerated NO degradation by reactive oxygen species (J. A. Beckman, “Pathophysiology of Vascular Dysfunction in Diabetes,” Cardiology Rounds (December 2004) Volume 8, Issue 10). A currently favored hypothesis is that oxidative stress, through a single unifying mechanism of superoxide production, is the common pathogenic factor leading to insulin resistance, β-cell dysfunction, impaired glucose tolerance (IGT) and ultimately to Type 2 DM (T2DM). Furthermore, this mechanism has been implicated as the underlying cause of both the macrovascular and microvascular complications associated with Type 2 DM. It follows that therapies aimed at reducing oxidative stress would benefit both patients with T2DM and those at risk for developing diabetes (Potneza, et al., “Endothelial Dysfunction in Diabetes: From Mechanism to Therapeutic Targets,” Current Medicinal Chemistry (2009) 16: 94-112; S. E. Inzucchi, “Oral Antihyperglycemic Therapy for Type 2 Diabetes. Scientific Review and Clinical Applications,” Journal of American Medical Association (Jan. 16, 2002-Vol 287, No. 3, pp. 360-372; and Wright, et al., “Oxidative stress in type 2 diabetes: the role of fasting and postprandial glycaemia,” Int. J. Clin. Pract . (2006 March) 60(3): 308-314).
[0005] Many natural products possess potent antioxidant, anti-inflammatory and cardio-protective properties and are used by patients with increased risk of cardiovascular morbidity and mortality in order to treat or prevent disease and/or reduce symptoms.
[0006] Among them, Shilajit is an herbo-mineral drug, which oozes out from a special type of mountain rocks in the peak summer months. It is found at high altitudes ranging from 1000-5000 meters. The active constituents of Shilajit contain dibenzo-alpha-pyrones and related metabolites, small peptides (constituting non-protein amino acids), some lipids, and carrier molecules (fulvic acids). See, Ghosal, S., et al., “Shilajit Part 1—Chemical constituents,” J. Pharm. Sci . (1976) 65:772-3; Ghosal, S., et al., “Shilajit Part 7—Chemistry of Shilajit, an immunomodulatory ayurvedic rasayana,” Pure Appl. Chem . (IUPAC) (1990) 62:1285-8; Ghosal, S., et al., “The core structure of Shilajit humus,” Soil Biol. Biochem . (1992) 23:673-80; and U.S. Pat. Nos. 6,440,436 and 6,869,612 (and references cited therein); all hereby incorporated by reference herein.
[0007] Shilajit (PrimaVie®) finds extensive use in Ayurveda, for diverse clinical conditions. For centuries people living in the isolated villages in Himalaya and adjoining regions have used Shilajit alone, or in combination with, other plant remedies to prevent and combat problems with diabetes (Tiwari, V. P., et al., “An interpretation of Ayurvedica findings on Shilajit,” J. Res. Indigenous Med . (1973) 8:57). Moreover being an antioxidant it will prevent damage to the pancreatic islet cell induced by the cytotoxic oxygen radicals (Bhattacharya S. K., “Shilajit attenuates streptozotocin induced diabetes mellitus and decrease in pancreatic islet superoxide dismutase activity in rats,” Phytother. Res . (1995) 9:41-4; Bhattacharya S. K., “Effects of Shilajit on biogenic free radicals,” Phytother. Res . (1995) 9:56-9; and Ghosal, S., et al., “Interaction of Shilajit with biogenic free radicals,” Indian J. Chem . (1995) 34B:596-602). It has been proposed that the derangement of glucose, fat and protein metabolism during diabetes, results into the development of hyperlipidemia. In one study, Shilajit produced significant beneficial effects in lipid profile in rats (Trivedi N. A., et al., “Effect of Shilajit on blood glucose and lipid profile in alloxan-induced diabetic rats,” Indian J. Pharmacol. (2004) 36(6):373-376). However, some drugs elicit a response in animals but may not do so in humans. Thus, the present invention relates to evaluating the effect of Shilajit on endothelial function and cardiovascular morbidity in humans.
[0008] In view of the above, it would be desirable to provide a method of using Shilajit for improvement of endothelial function and other cardiovascular parameters, and to help reduce cardiovascular morbidity in a human patient.
SUMMARY OF THE INVENTION
[0009] An objective of the present invention is to develop a method of using Shilajit compositions for improving endothelial function and cardiovascular health in patients with Type 2 diabetes mellitus as well as in healthy subjects.
[0010] In one embodiment, a method of treating or preventing endothelial dysfunction is provided including administering to an individual in need thereof an effective amount of a composition comprising Shilajit and a pharmaceutically acceptable carrier, wherein endothelial function is improved.
[0011] In another embodiment, a method of treating a diabetic individual suffering from type 2 diabetes mellitus is provided including administering to an individual in need thereof an effective amount of a composition comprising Shilajit and a pharmaceutically acceptable carrier, wherein endothelial function is improved.
[0012] In yet another embodiment, a method of treating a diabetic individual suffering from type 2 diabetes mellitus is provided including administering to an individual in need thereof an effective amount of a composition comprising Shilajit and a pharmaceutically acceptable carrier, wherein a blood lipid parameter is improved.
DETAILED DESCRIPTION
[0013] In one aspect, the present invention reveals the usefulness of Shilajit compositions in improving endothelial function and cardiovascular health in patients with Type 2 diabetes mellitus as well as in healthy subjects.
[0014] Patients with diabetes have vascular complications and endothelial dysfunction is one of the early prognostic markers of atherosclerosis which may eventually result in cardiovascular disease. Studies have reported that endothelial dysfunction occurs in patients with diabetes much earlier than clinical manifestations of diabetic vascular complications (Schalkwijk, et al., “Vascular complications in diabetes mellitus: the role of endothelial dysfunction,” Clinical Science (2005) 109: 143-159). Diabetes is associated with accelerated atherosclerosis and microvascular complications which may be major causes of morbidity and mortality, as discussed above. Endothelial cell dysfunction is emerging as a key component in the pathophysiology of cardiovascular abnormalities associated with diabetes mellitus.
[0015] Increased arterial stiffness, as measured by pulse wave analysis, is associated with cardiovascular risk factors and established coronary artery disease. Pulse wave analysis is simple and reproducible to stratify cardiac risk in diabetes. Whilst arterial compliance is determined predominantly by structural factors, the vascular endothelium is also involved. The vascular endothelium contributes to vascular tone and endothelial dysfunction is implicated as an early functional alteration predating structural changes of the vasculature. Conventional cardiac risk factors such as dyslipidemia, hypertension, smoking, and Type 2 diabetes are associated with impaired endothelial function. The intact endothelium promotes vasodilatation principally via the release of NO—originally also called endothelium derived relaxing factor. Endothelium dependent vasodilators reduce pulse wave velocity suggesting nitric oxide (NO) plays a role in determining arterial distendability. Free radical NO has emerged as a fundamental signaling device regulating virtually every critical cellular function and is a potent mediator of cellular damage in many conditions. Nitric oxide is produced in endothelial cells from the substrate L-Arginine via endothelial Nitric oxide synthatase (eNOS). Elevated asymmetric dimethylarginine levels cause coupling, a mechanism which leads to decreased NO bioavailability. The endothelial dysfunction associated with diabetes has been attributed to lack of bioavailable nitric oxide due to reduced ability to synthesize NO from L-Arginine. New basic research insights provide possible mechanisms underlying the impaired NO bioavailability in Type 2 diabetes.
[0016] Use of herbs and/or herbo-minerals for the treatment of cardiovascular diseases and diabetes in Ayurveda, Chinese and Unani systems of medicine has provided new leads to understanding the pathophysiology of these diseases. Therefore, it is rational to use our natural resources for identifying and selecting inexpensive and safer approaches for the management of cardiovascular disease along with current therapy.
[0017] As discussed above, Shilajit may be a useful component for therapeutic treatment of vascular conditions and for palliative treatment of endothelial dysfunction.
[0018] Study in Diabetic Subjects
[0019] A prospective, randomized, double blind clinical study was conducted with twenty-five diabetic patients enrolled in the study. Patients included in the study were of either sex, aged 18-75 years, fasting plasma glucose of ≧110 mg/dL, a glycosylated haemoglobin (HbA1c) between 7% and 9% and taking a stable dose of anti-diabetic treatment (Metformin 1500-2500 mg/day) for the past 8 weeks prior to the screening visit; and having endothelial dysfunction defined as ≦6% change in reflection index (RI) on post salbutamol challenge test. Patients with severe uncontrolled hyperglyceamia, uncontrolled hypertension, cardiac arrhythmia, impaired hepatic or renal function, history of malignancy or stroke, smoking, chronic alcoholism, or any other serious disease requiring active treatment and treatment with any other herbal supplements, were excluded from the study.
[0020] Study design.
[0021] After screening, all the eligible subjects were randomized to receive either one of the two treatments for a duration of 12 weeks: Group 1 received one capsule containing 250 mg Shilajit (PRIMAVIE® 250 mg capsules) twice daily orally, and Group 2 received one capsule of Placebo twice daily orally. Subjects were asked to report for follow up visits at 4, 8, and 12 weeks of therapy. At each visit, they were evaluated for efficacy and safety. Pharmacodynamic evaluation for endothelial function was conducted at every visit. Blood samples were collected for evaluation of biomarkers before and at end of the treatment. Inhibition of platelet aggregation was also studied with the two treatments. Safety lab investigations for hematological, hepatic and renal biochemical parameters were conducted before and at the end of the study, and also as and when required (in case of any adverse drug reaction (ADR)). Subjects were interviewed for the presence of ADRs and the same was recorded in the case report form. Compliance to therapy was assessed by pill count method.
[0022] The active ingredients used in the capsules may have the following compositions.
[0023] Shilajit (PrimaVie®, available from Natreon, Inc., New Brunswick, N.J.) is a standardized dietary supplement ingredient extracted and processed from Shilajit bearing rocks, containing not less than about 50% to 60% by weight fulvic acids (FAs), at least about 10% by weight dibenzo-α-pyrone chromoproteins, and at least 0.3%, or more, by weight total dibenzo-α-pyrones (DBPs). Water content is about 6%, or less, by weight. Water-soluble extractive value is about 80% (w/w), or greater.
[0024] Procedure for Assessment of Endothelial Function.
[0025] A salbutamol (albuterol) challenge test employing digital volume plethysmography was used to assess endothelial function as reported by Chowienczyk et al., “Photoplethysmographic assessment of pulse wave reflection: blunted response to endothelium dependant beta 2-adrenergic vasodilation in type 2 diabetes mellitus,” J. Am. Coll. Cardiol . (1999 Dec) 34(7):2007-14; and Naidu, et al., “Comparison of two β 2 adrenoceptor agonists by different routes of administration to assess human endothelial function,” Indian J. Pharmacol . (2007) 39:168-9. The patients were examined in supine position after 5 minutes of rest. A digital volume pulse (DVP) was obtained using a photo plethysmograph (Pulse Trace PCA2, PT200, Micro Medical, Gallingham, Kent, UK) transmitting infrared light at 940 nm, placed on the index finger of the right hand. The signal from the plethysmograph was digitized using a 12 bit analogue to digital converter with a sampling frequency of 100 Hz. DVP waveforms were recorded over 20 second period and the height of the late systolic/early diastolic portion of the DVP was expressed as a percentage of the amplitude of the DVP to yield the reflection index (RI), per the procedure described in detail by Millasseau et al., “Determination of age related increases in large artery stiffness by digital pulse contour analysis,” Clinical Science (2002) 103: 371-377. After DVP recordings had been taken, three measurements of reflection index (RI) were calculated and the mean value was determined. Patients were then administered 400 μg of salbutamol by inhalation. After 15 minutes three measurements of RI were obtained again and the difference in mean RI before and after administration of salbutamol was used for assessing endothelial function. A change of ≦6% in RI post salbutamol was considered as endothelial dysfunction.
[0026] Measurement of Wave Reflection Indices
[0027] Augmentation index (AIx) and augmented pressure of the central (aortic) pressure waveform were measured as indices of wave reflections. Augmented pressure is the pressure added to the incident wave by the returning reflected one and represents the pressure boost that is caused by wave reflection and with which the left ventricle must cope.
[0028] Augmentation pressure (AP) is the contribution that wave reflection makes to systolic arterial pressure, and it is obtained by measuring the reflected wave coming from the periphery to the centre. Reduced compliance of the elastic arteries causes an earlier return of the ‘reflected wave’, which arrives in systole rather than in diastole, causing a disproportionate rise in systolic pressure and an increase in pulse pressure (PP), with a consequent increase in left ventricular afterload and impaired coronary perfusion.
[0029] The augmentation index (AIx) is an indirect measure of arterial stiffness and increases with age, and it is calculated as AP (augmentation pressure) divided by PP×100 to give a percentage. With an increase in stiffness there is a faster propagation of the forward pulse wave as well as a more rapid reflected wave. AP and AIx both increase with age. Augmentation index is commonly accepted as a measure of the enhancement (augmentation) of central aortic pressure by a reflected pulse wave.
[0030] Augmentation index is calculated from pulse waves of the common carotid artery recorded by applanation tonometry (SphygmoCor; AtCor Medical, Sydney, Australia). The systolic part of central arterial waveform is characterized by two pressure peaks. The first peak is caused by left ventricular ejection, whereas the second peak is a result of wave reflection. The difference between both pressure peaks reflects the degree to which central arterial pressure is augmented by wave reflection. Augmentation index (%) is defined as the percentage of the central pulse pressure which is attributed to the reflected pulse wave and, therefore, reflects the degree to which central arterial pressure is augmented by wave reflection.
[0031] Augmentation index is a sensitive marker of arterial status, in that:
[0032] Augmentation index has been shown to be a predictor of adverse cardiovascular events in a variety of patient populations, and higher augmentation index is associated with target organ damage, and
[0033] Augmentation index can distinguish between the effects of different vasoactive medications when upper arm blood pressure and pulse wave velocity do not.
[0034] The augmentation index is thus a composite measure of the magnitude of wave reflections and arterial stiffness, which affects timing of wave reflections. Because the augmentation index is influenced by changes in heart rate (HR), it was also accordingly corrected (AIx@75). The augmentation index was measured by using a validated, commercially available system (SphygmoCor; AtCor Medical, Australia) that employs the principle of applanation tonometry and appropriate acquisition and analysis software for noninvasive recording and analysis of the arterial pulse. In brief, from radial artery recordings, the central (aortic) arterial pressure was derived with the use of a generalized transfer function that has been shown to give an accurate estimate of the central arterial pressure waveform and its characteristics.
[0035] The subendocardial viability index, an indicator of myocardial workload and perfusion (O 2 supply vs. demand) was calculated as the ratio of the integral of diastolic pressure and time to the integral of systolic pressure and time. Low SEVR (Subendocardial viability ratio) has been shown to be associated with coronary artery disease, decreased coronary flow reserve in patients with healthy coronary arteries, severity of type I and type II diabetes, decreased renal function, and a history of smoking
[0036] Assessment of Arterial Stiffness (baPWV, ABI)
[0037] Brachial-ankle pulse wave velocity (baPWV) is also used to evaluate arterial stiffness. Pulse wave velocity is the speed at which the blood pressure pulse travels from the heart to the peripheral artery after blood rushes out during contraction. It is mainly used to evaluate stiffness of the artery wall. Pulse wave velocity increases with stiffness of the arteries. The PTT (Pulse Transit Time) of each segment is calculated from the waveform taken from each sensor. Pulse wave velocity is defined in Equation (1):
[0000]
PWV
=
L
(
distance
)
PTT
(
Pulse
Transit
Time
)
Equation
(
1
)
[0038] This method calculates heart-brachial PWV of both upper limbs, heart-ankle PWV of both lower limbs, brachial-ankle PWV of both right and left limb pairs, and effective estimated carotid-femoral PWV is calculated. See Equations (2), (3), and (4):
[0000]
ha
PWV
(
heart
ankle
PWV
)
-
Lha
PTTha
Equation
(
2
)
hb
PWV
(
heart
brachial
PWV
)
-
Lhb
PTThb
Equation
(
3
)
ba
PWV
(
brachial
ankle
PWV
)
-
Lba
PTTba
Equation
(
4
)
[0039] Where
[0040] Lha=Distance between heart and respective ankle
[0041] Lhb=Distance between heart and respective brachium.
[0042] Lba=Distance between respective brachium and ankle
[0043] Brachial Ankle Pulse Wave Velocity (baPWV), Ankle Brachial Index (ABI) and Blood Pressure (BP) were measured using an automatic waveform analyzer (model BP-203 RPE; Colin Medical Technology, Komaki, Japan). Measurements were taken with patients lying in a supine position after 5 minutes of rest in that position. Occlusion and monitoring cuffs were placed snugly around both sites of the upper and lower extremities of patients. Pressure waveforms of the brachial and tibial arteries were then recorded simultaneously by an oscillometric method. Measurement of right and left baPWV was obtained for an average of 10 seconds. The average of left and right baPWV will be used for analysis.
[0044] Method for Recording of Cardiac Output (Lt/Min)
[0045] Recording of cardiac output (CO) was performed using L&T Nivomon monitor (Larsen & Toubro Ltd., Mumbai, India). Noninvasive continuous cardiac output monitor with peripheral blood flow measurement option. This equipment is very useful and versatile. It calculates many cardiac parameters directly including cardiac output. It works on the features of impedance plethysmography principle and has tetrapolar configuration. One advantage is that this equipment directly calculates the cardiac output along with other parameters using the pulse wave.
[0046] Biomarker Evaluation
[0047] Nitric oxide, MDA, Glutathione and levels were estimated spectrophotometrically and HsCRP (high sensitivity C-reactive protein) by ELISA method. Malondialdehyde (MDA) levels were determined as described in Vidyasagar, et al., “Oxidative stress and antioxidant status in acute organophosphorous insecticide poisoning,” Indian J. Pharmacol . (April 2004) 36(2): 76-79. Glutathione (GSH) levels were determined as described in G. L. Ellman, Arch. Biochem. Biophys . (1959) 82: 70-77 (original determination). Nitric oxide levels were estimated spectrophotometrically as described in Miranda, et al., “A Rapid, Simple Spectrophotometric Method for Simultaneous Detection of Nitrate and Nitrite,” NITRIC OXIDE: Biology and Chemistry (2001) Vol. 5, No. 1, pp. 62-71.
[0048] Method For Evaluating Platelet Function
[0049] The effect of Shilajit (PrimaVie®) and Placebo on platelet function was determined by the following procedure. After assessing the eligibility of the subject by performing the evaluation of endothelial dysfunction, i.e., a change of ≦6% in RI post salbutamol, the platelet function test was carried in a dual channel platelet aggregometer instrument (Wheecon chronologue dual channel platelet aggregometer, Wheecon Instruments Pvt. Ltd., Chemai, Tamilnadu, India).
[0050] About 9 ml of blood sample was collected in a 10 ml plastic test tube containing 1 ml of 3.8% sodium citrate from the cubital vein of the subject at baseline and after post treatment in both the groups. The test was performed immediately within a time period of one and a half hour from collection. The samples were centrifuged at 800 rpm for 15 minutes to obtain a platelet rich plasma. The same sample was centrifuged at 2500 rpm for 10 minutes so as to get a poor platelet plasma sample. The aggregometer was switched about 30 minutes before the test to allow the heating block to warm up to 37° C. Then the test was performed in duplicate by taking 0.5 ml of platelet rich plasma using 5 μA of ADP (adenosine di-phosphate) (2 μm/ml) in cuvettes containing stir bars. The speed of the stir bars was adjusted to 1200 rpm so as to facilitate the aggregation of the platelets. The platelet-poor plasma sample was kept as a reference. The readings were recorded at baseline and after treatment with ADP. The percentage aggregation at baseline and the percentage inhibition of platelet aggregation on post treatment with the two treatments was calculated.
[0051] Safety Assessments
[0052] All the subjects had undergone complete physical examination, safety lab evaluations at baseline and at the end of the treatment. Samples were collected after an overnight fast of 12 hrs after the last dose of medication for determination of haemoglobin, HbA1c, blood urea and serum creatinine, liver function test, and lipid profile (Total cholesterol, High density lipoprotein cholesterol (HDL-C), low density lipoprotein cholesterol (LDL-C)). Plasma glucose, liver function test, blood urea, serum creatinine and HbA1c were measured using appropriate standard techniques.
[0053] Efficacy and Safety Parameters
[0054] The primary efficacy measure was a change in endothelial dysfunction as assessed by more than 6% change in reflection index at 12 weeks in all the treatment groups. Secondary efficacy measures include change in oxidative stress markers, serum levels of nitric oxide at 12 weeks in all the treatment groups and also evaluation of safety and tolerability of the test medications.
[0055] Data Analysis
[0056] Data are expressed as mean±SD (standard deviation). ANOVA and paired and unpaired t-test were performed for within group and between groups analysis respectively. A p-value <0.05 was considered to be statistically significant. All statistical analysis were performed using the Prism Graphpad 4 (GraphPad Software, Inc., La Jolla, Calif., USA).
[0057] Results of Study
[0058] Total of 25 subjects were screened and 20 eligible subjects completed the study. Ten subjects each in Shilajit (PrimaVie®) 250 mg and Placebo groups completed the study, as shown in Table 1.
[0000]
TABLE 1
Demographic characteristics of the two study Groups
Parameter
Shilajit (PrimaVie ®)
Placebo
Total No.
n = 10
n = 10
Gender (M/F)
8/2
7/3
Age (yrs)
55.40 ± 10.71
56.90 ± 8.81
Weight (Kg)
65.50 ± 8.99
66.30 ± 6.46
BMI (Kg/m 2 )
24.73 ± 3.17
25.48 ± 2.10
[0059] The detailed demographic characteristics of the two study groups are shown above in Table 1. There was no significant difference between treatment groups in baseline characteristics including age, weight & body mass index (BMI).
[0000]
TABLE 2
Effect of Shilajit (PrimaVie ®) & Placebo on pharmacodynamic cardiovascular
parameters after 12 weeks of treatment - All values expressed as Mean ± SD
Shilajit (PrimaVie ®) n = 10
Placebo n = 10
Parameter
Pretreatment
Post treatment
Pretreatment
Post treatment
RI (%)
−2.54 ± 1.72
−8.61 ± 2.51 $
−2.01 ± 0.71
0.07 ± 3.17
AIx (%)
145.8 ± 13.88
137.3 ± 9.82 #
142.8 ± 15.32
143.5 ± 15.14
SEVR (%)
144.0 ± 27.90
154.3 ± 27.47 #
146.6 ± 21.94
147.3 ± 21.20
ABI
1.05 ± 0.04
1.06 ± 0.05 NS
1.04 ± 0.05
1.05 ± 0.06
PWV (cm/s)
1560 ± 203.4
1478 ± 128.8 NS
1601 ± 141.1
1603 ± 146.2
CO (Lt/min)
5.09 ± 1.31
5.29 ± 1.12 NS
4.44 ± 0.63
4.33 ± 0.58
#—p < 0.05 compared to baseline
$—p < 0.001 compared to baseline
NS—nonsignificant compared to baseline
[0060] As shown in above Table 2, there was significant improvement observed in endothelial function after 12 weeks of treatment with Shilajit (PrimaVie®) compared to baseline. With Shilajit (PrimaVie®) treatment there was significant reduction in augmentation index and significant increase in sub-endocardial ratio; whereas changes recorded in ABI, PWV and CO were not statistically significant compared to baseline values.
[0000]
TABLE 2A
Comparison of Absolute change in Pharmacodynamic parameters
after 12 weeks of treatment with Shilajit (PrimaVie ®) &
Placebo - All values expressed as Mean ± SD
Parameter
Shilajit (PrimaVie ®)
Placebo
RI (%)
−6.07 ± 2.81 $
2.08 ± 3.00
AIx (%)
−8.59 ± 10.61 #
0.69 ± 1.31
SEVR(%)
10.25 ± 13.76 #
0.72 ± 2.29
ABI
0.01 ± 0.07 ns
0.01 ± 0.01
PWV(cm/s)
−82.5 ± 146 ns
2.50 ± 33.44
CO (Lt/min)
0.2 ± 0.44 ns
−0.11 ± 0.24
$—RI - p < 0.001 Shilajit (PrimaVie ®) Vs Placebo
#—AIx - p < 0.05 Shilajit (PrimaVie ®) Vs Placebo
#—SEVR - p < 0.05 Shilajit (PrimaVie ®) Vs Placebo
ABI - Non-significant between the two treatments
PWV - Non-significant between the two treatments
CO - Non-significant between the two treatments
[0000]
TABLE 3
Effect of Shilajit (PrimaVie ®) & Placebo on biomarkers after 12 weeks of
treatment - All values expressed as Mean ± SD
Shilajit (PrimaVie ®) n = 10
Placebo n = 10
Parameter
Pretreatment
Post treatment
Pretreatment
Post treatment
NO (μMol/L)
29.40 ± 13.21
35.69 ± 13.75 #
31.31 ± 8.20
30.81 ± 7.04
MDA (nMol/ml)
3.27 ± 0.78
2.65 ± 0.70 #
3.22 ± 0.79
3.26 ± 0.72
GSH (μMol/L)
510.3 ± 120.4
639.4 ± 113.6*
503.1 ± 47.29
502.7 ± 47.17
HsCRP (mg/L)
1.94 ± 0.89
0.87 ± 0.21 #
2.11 ± 0.97
2.16 ± 0.96
*p < 0.05 compared to baseline
#—p < 0.01 compared to baseline
[0061] As shown in above Table 3, there were significant increases recorded in nitric oxide and glutathione levels in the Shilajit (PrimaVie®) treatment group compared to baseline. On treatment with Shilajit (PrimaVie®) there were also significant decreases in malondialdehyde and HsCRP levels observed compared to baseline.
[0000]
TABLE 3A
Comparison of Absolute change in Biomarkers after 12 weeks of
treatment with Shilajit (PrimaVie ®) & Placebo -
All values expressed as Mean ± SD
Parameter
Shilajit (PrimaVie ®)
Placebo
NO (μMol/L)
6.30 ± 5.82 @
−0.50 ± 2.98
MDA (nMol/ml)
−0.63 ± 0.55 #
0.05 ± 0.77
GSH (μMol/L)
129.09 ± 169.90 #
−0.34 ± 5.78
HsCRP (mg/L)
−1.08 ± 0.89 $
0.05 ± 0.11
@—NO - p < 0.01 Shilajit (PrimaVie ®) Vs Placebo
#—MDA - p < 0.05 Shilajit (PrimaVie ®) Vs Placebo
#—GSH - p < 0.05 Shilajit (PrimaVie ®) Vs Placebo
$—HsCRP - p < 0.001 Shilajit (PrimaVie ®) Vs Placebo
[0000]
TABLE 3B
Mean Percent change in Biomarkers after 12 weeks of treatment with
Shilajit (PrimaVie ®) & Placebo - All values expressed as Mean ± SD
Parameter
Shilajit (PrimaVie ®)
Placebo
NO (%)
24.26 ± 24.63 @
−0.45 ± 10.45
MDA (%)
−18.28 ± 16.77
−0.35 ± 27.08
GSH (%)
33.02 ± 43.18 #
−0.07 ± 1.15
HsCRP (%)
−44.71 ± 36.16 $
2.56 ± 6.73
@—NO - p < 0.01 Shilajit (PrimaVie ®) Vs Placebo
MDA - Non-significant Shilajit (PrimaVie ®) Vs Placebo
#—GSH - p < 0.05 Shilajit (PrimaVie ®) Vs Placebo
$—HsCRP - p < 0.001 Shilajit (PrimaVie ®) Vs Placebo
[0000]
TABLE 4
Effect of Shilajit (PrimaVie ®) & Placebo after 12 weeks of treatment on lipid profile
Shilajit (PrimaVie ®) n = 10
Placebo n = 10
Parameter
Pretreatment
Post treatment
Pretreatment
Post
Total
174.2 ± 26.68
139.4 ± 39.50 #
173.2 ± 21.03
180.1 ± 18.65
cholesterol (mg/dl)
HDL (mg/dl)
39.20 ± 4.63
44.40 ± 6.81*
40.60 ± 4.64
39.20 ± 4.59
LDL (mg/dl) (mg/dl)
105.5 ± 20.58
91.40 ± 18.06 #
109.5 ± 24.19
112.0 ± 22.17
Triglycerides (mg/dl)
130.2 ± 42.08
104.7 ± 23.13 #
145.0 ± 12.48
148.5 ± 15.46
VLDL (mg/dl)
29.40 ± 16.55
22.90 ± 8.64*
31.00 ± 4.59
30.70 ± 4.85
*p < 0.05 compared to baseline
#—p < 0.01 compared to baseline
[0062] The above Table 4 indicates that, in the Shilajit (PrimaVie®) treatment group there were significant reductions in Total cholesterol, LDL-C, Triglycerides, and VLDL-C, compared to a significant increase in HDL-C levels compared to baseline.
[0000]
TABLE 4A
Comparison of Absolute change in Lipid profile after 12 weeks
of treatment with Shilajit (PrimaVie ®) & Placebo -
All values expressed as Mean ± SD
Parameter
Shilajit (PrimaVie ®)
Placebo n = 10
Total cholesterol (mg/dl)
−34.80 ± 23.52 $
6.9 ± 12.28
HDL (mg/dl)
5.20 ± 6.92 #
−1.4 ± 2.59
LDL (mg/dl)
−14.10 ± 11.33 $
2.5 ± 5.66
Triglycerides (mg/dl)
−25.46 ± 24.30 @
3.5 ± 7.81
VLDL (mg/dl)
−6.50 ± 8.80 #
−0.3 ± 2.00
$—Total cholesterol - p < 0.001 Shilajit (PrimaVie ®) Vs Placebo
#—HDL - p < 0.05 Shilajit (PrimaVie ®) Vs Placebo
$—LDL - p < 0.001 Shilajit (PrimaVie ®) Vs Placebo
@—Triglycerides - p < 0.01 Shilajit (PrimaVie ®) Vs Placebo
#—VLDL - p < 0.05 Shilajit (PrimaVie ®) Vs Placebo
[0000]
TABLE 4B
Mean Percent change in Lipid Profile after 12 weeks of treatment
with Shilajit (PrimaVie ®) & Placebo -
All values expressed as Mean ± SD
Parameter
Shilajit (PrimaVie ®)
Placebo n = 10
Total cholesterol (%)
−20.67 ± 14.16
4.35 ± 6.93
HDL (%)
14.02 ± 19.51
−3.24 ± 6.54
LDL (%)
−12.90 ± 10.67
2.87 ± 5.44
Triglycerides (%)
−16.19 ± 15.15
2.38 ± 5.24
VLDL (%)
−16.52 ± 13.75
−0.90 ± 6.45
[0000]
TABLE 5
Effect of Shilajit (PrimaVie ®) & Placebo after 12 weeks of treatment on HbA1c (%)
Shilajit (PrimaVie ®) n = 10
Absolute
Mean percentage
Placebo n = 10
Absolute
Mean percentage
Parameter
Pre treatment
Post treatment
change
change
Pre treatment
Post treatment
change
change
HbA1c (%)
7.73 ± 0.54
6.78 ± 0.43 $
−0.95 ± 0.49
−12.10 ± 5.63
7.48 ± 0.47
7.52 ± 0.51
0.04 ± 0.18
0.54 ± 2.35
$ -p < 0.001 compared to baseline
In Absolute change
p < 0.001 Shilajit (PrimaVie ®) Vs placebo
[0063] The above Table 5 shows that, in the Shilajit (PrimaVie®) treatment group there was a significant decrease in glycosylated hemoglobin A1c levels (HbA1c) observed compared to baseline. When a comparison between Shilajit (PrimaVie®) and placebo was performed there was statistical significance observed in absolute change.
[0000]
TABLE 6
Effect of Shilajit (PrimaVie ®) and Placebo on Platelet Function-
Percentage decrease in inhibition of Platelet aggregation
(All values expressed as Mean ± SD)
Group
Pretreatment
Post treatment
% Inhibition
Shilajit
77.40 ± 11.64
66.50 ± 9.20 # $
13.73 ± 6.88
(PrimaVie ®)
n = 10
Placebo
69.20 ± 5.26
70.10 ± 6.31
1.97 ± 2.89
#—p < 0.001compared to baseline
$—p < 0.001 Shilajit (PrimaVie ®) Vs Placebo
%
Inhibition
calculation
=
(
Pre
treatment
Aggregation
-
Post
treatment
Aggregation
)
Pre
treatment
Aggregation
×
100
[0064] As shown in above Table 6, there was a significant decrease in platelet aggregation after treatment with Shilajit (PrimaVie®) compared to baseline. There was a statistically significant change in percentage decrease in platelet aggregation observed when a comparison was performed between Shilajit (PrimaVie®) and placebo.
[0000]
TABLE 7
Effect of Shilajit (PrimaVie ®) and Placebo on safety parameters (all values expressed as Mean ± SD)
Shilajit (PrimaVie ®) n = 10
Placebo n = 10
Parameters
Pretreatment
Post treatment
Pretreatment
Post treatment
Systolic BP (mmHg)
119.40 ± 4.01
118.20 ± 2.39
116.60 ± 3.13
117.20 ± 3.01
Diastolic BP (mmHg)
76.20 ± 5.37
77.00 ± 4.92
74.40 ± 4.09
75.20 ± 3.43
Heart rare (bpm)
77.40 ± 3.78
75.20 ± 4.02
74.40 ± 4.50
76.20 ± 3.19
Hemoglobin (gm/dl)
12.93 ± 1.18
13.43 ± 1.01
13.15 ± 1.23
14.05 ± 1.22
WBC Count (/mm 3 )
7190.00 ± 1198.56
6980.00 ± 784.29
6530.00 ± 1064.63
7010.00 ± 938.62
Platelet Count (lakh/mm 3 )
2.28 ± 0.66
2.65 ± 0.70
2.10 ± 0.80
2.34 ± 0.72
Blood Urea (mg/dl)
24.60 ± 8.38
26.60 ± 5.82
22.10 ± 7.17
25.10 ± 6.12
S. Creatinine (mg/dl)
0.98 ± 0.12
1.00 ± 0.11
1.03 ± 0.16
1.05 ± 0.16
AST (SGOT) (U/L)
19.60 ± 8.49
21.50 ± 8.67
24.20 ± 7.54
26.20 ± 7.07
ALT (SGPT) (U/L)
24.70 ± 6.50
25.30 ± 5.25
23.70 ± 6.40
26.20 ± 6.75
Alkaline Phosphatase (U/L)
184.60 ± 46.07
189.60 ± 29.35
163.00 ± 42.83
158.40 ± 38.06
Total Bilirubin (mg/dl)
0.54 ± 0.26
0.49 ± 0.18
0.52 ± 0.27
0.55 ± 0.16
[0065] As shown in above Table 7, at post treatment, there were no significant changes in hematological, renal and hepatic functions. There was no serious adverse event recorded in the study.
[0066] The nutraceutical compositions of the present invention may be administered in combination with a nutraceutically acceptable carrier. The active ingredients in such formulations may comprise from 1% by weight to 99% by weight, or alternatively, 0.1% by weight to 99.9% by weight. “Nutraceutically acceptable carrier” means any carrier, diluent or excipient that is compatible with the other ingredients of the formulation and not deleterious to the user. In accordance with one embodiment, suitable nutraceutically acceptable carriers can include ethanol, aqueous ethanol mixtures, water, fruit and/or vegetable juices, and combinations thereof.
[0067] The pharmaceutical compositions of the present invention may be administered in combination with a pharmaceutically acceptable carrier. The active ingredients in such formulations may comprise from 1% by weight to 99% by weight, or alternatively, 0.1% by weight to 99.9% by weight. “Pharmaceutically acceptable carrier” means any carrier, diluent or excipient that is compatible with the other ingredients of the formulation and not deleterious to the user.
[0068] Delivery System
[0069] Suitable dosage forms include tablets, capsules, solutions, suspensions, powders, gums, and confectionaries. Sublingual delivery systems include, but are not limited to, dissolvable tabs under and on the tongue, liquid drops, and beverages. Edible films, hydrophilic polymers, oral dissolvable films or oral dissolvable strips can be used. Other useful delivery systems comprise oral or nasal sprays or inhalers, and the like.
[0070] For oral administration, a Shilajit composition may be further combined with one or more solid inactive ingredients for the preparation of tablets, capsules, pills, powders, granules or other suitable dosage forms. For example, the active agent may be combined with at least one excipient such as fillers, binders, humectants, disintegrating agents, solution retarders, absorption accelerators, wetting agents, absorbents, or lubricating agents. Other useful excipients include magnesium stearate, calcium stearate, mannitol, xylitol, sweeteners, starch, carboxymethylcellulose, microcrystalline cellulose, silica, gelatin, silicon dioxide, and the like.
[0071] The components of the invention, together with a conventional adjuvant, carrier, or diluent, may thus be placed into the form of pharmaceutical compositions and unit dosages thereof. Such forms include solids, and in particular tablets, filled capsules, powder and pellet forms, and liquids, in particular aqueous or non-aqueous solutions, suspensions, emulsions, elixirs, and capsules filled with the same, all for oral use, suppositories for rectal administration, and sterile injectable solutions for parenteral use. Such pharmaceutical compositions and unit dosage forms thereof many comprise conventional ingredients in conventional proportions, with or without additional active compounds or principles, and such unit dosage forms may contain any suitable effective amount of the active ingredient commensurate with the intended daily dosage range to be employed.
[0072] The components of the present invention can be administered in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise, as the active component, either a chemical compound of the invention or a pharmaceutically acceptable salt of a chemical compound of the invention.
[0073] For preparing pharmaceutical compositions from a chemical compound of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
[0074] In powders, the carrier is a finely divided solid, which is in a mixture with the finely divided active component. In tablets, the active component is mixed with the carrier having the necessary binding capacity in suitable proportions and compacted in the shape and size desired.
[0075] The powders and tablets preferably contain from five or ten to about seventy percent of the active compound(s). Suitable carriers are magnesium carbonate, magnesium state, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethlycellulose, a low melting wax, cocoa butter, and the like. The term “preparation” is intended to include the formulation of the active compound with encapsulating material as carrier providing a capsule in which the active component, with or without carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid forms suitable for oral administration.
[0076] Liquid preparations include solutions, suspensions, and emulsions, for example, water or water-propylene glycol solutions. For example, parenteral injection liquid preparations can be formulated as solutions in aqueous polyethylene glycol solution. The chemical compound according to the present invention may thus be formulated for parenteral administration (e.g. by injection, for example bolus injection or continuous infusion) and may be presented in unit dose for in ampoules, pre-filled syringes, small volume infusion or in multi-dose containers with an added preservative. The compositions may take such forms as suspensions, solutions, or emulsions in oily or aqueous vehicles, and may contain formulation agents such as suspending, stabilising and/or dispersing agents. Alternatively, the active ingredient may be in powder form, obtained by aseptic isolation of sterile solid or by lyophilization from solution, for constitution with a suitable vehicle, e.g. sterile, pyrogen-free water, before use.
[0077] Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents, as desired. Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, or other well known suspending agents.
[0078] Compositions suitable for administration in the mouth include lozenges comprising the active agent in a flavored base, usually sucrose and acacia or tragacanth; pastilles comprising the active ingredient in an inert base such as gelatin and glycerine or sucrose and acacia; and mouthwashes comprising the active ingredient in suitable liquid carrier.
[0079] Solutions or suspensions are applied directly to the nasal cavity by conventional means, for example with a dropper, pipette or spray. The compositions may be provided in single or multi-dose form. In compositions intended for administration to the respiratory tract, including intranasal compositions, the compound will generally have a small particle size for example of the order of 5 microns or less. Such a particle size may be obtained by means known in the art, for example by micronization.
[0080] The pharmaceutical preparations are preferably in unit dosage forms. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packaged tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenges itself, or it can be the appropriate number of any of these in packaged form.
[0081] Tablets, capsules and lozenges for oral administration and liquids for oral use are preferred compositions. Solutions or suspensions for application to the nasal cavity or to the respiratory tract are preferred compositions. Transdermal patches for topical administration to the epidermis are preferred.
[0082] Further details on techniques for formulation and administration may be found in the latest edition of Remington's Pharmaceutical Sciences (Mack Publishing Co., Easton, Pa.).
[0083] Solid nutritional compositions for oral administration may optionally contain, in addition to the above enumerated nutritional composition ingredients or compounds: carrier materials such as corn starch, gelatin, acacia, microcrystalline cellulose, kaolin, dicalcium phosphate, calcium carbonate, sodium chloride, alginic acid, and the like; disintegrators including, microcrystalline cellulose, alginic acid, and the like; binders including acacia, methylcellulose, sodium carboxymethylcellulose, polyvinylpyrrolidone, hydroxypropyl methylcellulose, ethyl cellulose, and the like; and lubricants such as magnesium stearates, stearic acid, silicone fluid, talc, waxes, oils, colloidal silica, and the like. The usefulness of such excipients is well known in the art.
[0084] In one embodiment, the nutritional composition may be in the form of a liquid. In accordance with this embodiment, a method of making a liquid composition is provided.
[0085] Liquid nutritional compositions for oral administration in connection with a method for preventing and/or endothelial dysfunction or cardiovascular disorders including diabetes can be prepared in water or other aqueous vehicles. In addition to the above enumerated ingredients or compounds, liquid nutritional compositions can include suspending agents such as, for example, methylcellulose, alginates, tragacanth, pectin, kelgin, carrageenan, acacia, polyvinylpyrrolidone, polyvinyl alcohol, and the like. The liquid nutritional compositions can be in the form of a solution, emulsion, syrup, gel, or elixir including or containing, together with the above enumerated ingredients or compounds, wetting agents, sweeteners, and coloring and flavoring agents. Various liquid and powder nutritional compositions can be prepared by conventional methods. Various ready-to-drink formulations (RTD's) are contemplated.
[0086] Routes of Administration
[0087] The compositions may be administered by any suitable route, including but not limited to oral, sublingual, buccal, ocular, pulmonary, rectal, and parenteral administration, or as an oral or nasal spray (e.g. inhalation of nebulized vapors, droplets, or solid particles). Parenteral administration includes, for example, intravenous, intramuscular, intraarterial, intraperitoneal, intranasal, intravaginal, intravesical (e.g., to the bladder), intradermal, transdermal, topical, or subcutaneous administration. Also contemplated within the scope of the invention is the instillation of a pharmaceutical composition in the body of the patient in a controlled formulation, with systemic or local release of the drug to occur at a later time. For example, the drug may be localized in a depot for controlled release to the circulation, or for release to a local site.
[0088] Pharmaceutical compositions of the invention may be those suitable for oral, rectal, bronchial, nasal, pulmonal, topical (including buccal and sub-lingual), transdermal, vaginal or parenteral (including cutaneous, subcutaneous, intramuscular, intraperitoneal, intravenous, intraarterial, intracerebal, intraocular injection or infusion) administration, or those in a form suitable for administration by inhalation or insufflations, including powders and liquid aerosol administration, or by sustained release systems. Suitable examples of sustained release systems include semipermeable matrices of solid hydrophobic polymers containing the compound of the invention, which matrices may be in form of shaped artices, e.g. films or microcapsules.
[0089] While in the foregoing specification this invention has been described in relation to certain embodiments thereof, and many details have been put forth for the purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.
[0090] All references cited herein are incorporated by reference in their entirety. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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Shilajit in a standardized composition produces a significant improvement in several cardiovascular parameters including RI, AIx and SEVR. Further, significant reductions in malondialdehyde and increases in nitric oxide levels are provided suggesting improvement in endothelial function. Shilajit may be used to reduce inflammatory biomarker HsCRP levels significantly compared to baseline and placebo. Additionally, Shilajit can provide significant improvement in lipid parameters including total cholesterol, LDL-C, and HbA1c (%) Inhibition of platelet aggregation using Shilajit performed using ADP as aggregant also provides highly significant inhibition of platelet aggregation compared to baseline and with placebo. Thus, Shilajit may be used for improvement of endothelial function and to help reduce cardiovascular morbidity, particularly for the diabetic individual.
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TECHNICAL FIELD
The present disclosure relates to thermal systems for converting thermal energy, specifically systems utilizing organic Rankine cycles.
BACKGROUND
An Organic Rankine cycle (ORC) is named for its use of an organic, high molecular mass fluid with a liquid-vapor phase change, or boiling point, occurring at a lower temperature than the water-steam phase change. The fluid allows Rankine cycle heat recovery from lower temperature sources such as biomass combustion, industrial waste heat, and waste heat from various small-scale heat engines, fuel cells or electric devices, geothermal heat, solar ponds, energy from combustion or decomposition of biodegradable materials. The low-temperature heat is converted into useful work that can itself be converted into electricity.
An idealized Clausius-Rankine cycle, also known as Rankine cycle, is characterized by an isentropic expansion, a heat dissipation at constant temperature, isentropic compression and an isobaric heating, which may be followed by a superheating. In a real Rankine cycle, the steps of expansion and compression are not exactly isentropic but the entropy increases slightly.
In the case of a “dry fluid”, the Rankine cycle can be improved by the use of a regenerator. In a temperature—entropy diagram, a dry-fluid is characterized by an overhanging mixed phase to vapour phase boundary. The dry fluid, which has not reached the two-phase state at the end of the expansion, has a temperature that is higher than the condensing temperature. The higher temperature fluid can be used to preheat the work fluid before it enters the evaporator.
SUMMARY
It is an object of the application to provide an improved ORC cycle system for operation under high and low temperature conditions.
The application discloses an organic Rankine Cycle system with a generating unit, a condenser for condensing an organic work fluid, a feeder pump for circulating the organic work fluid, and an evaporator for evaporating the organic work fluid. It is advantageous to use organic work fluids for low temperature applications. By choosing suitable organic compounds, they can be tailored to the application with respect to the boiling point and other thermal properties. Organic liquids are also usually less corrosive than water.
According to the application, the generating unit comprises a high-pressure screw expander and a low-pressure screw expander which are connected in series. Thereby, the heat can be used effectively without the need to make the expanders very big. Screw expanders are often better than turbines for use in compact machines rather as compared to large scale steam engines for atomic power plants, for example. The high-pressure screw expander and the low-pressure screw expander are mechanically connectable to a generator which is provided between the high-pressure screw expander and the low-pressure screw expander. The arrangement of the generator between the expanders according to the application yields a compact and robust design.
The ORC system further comprises a by-pass line for bypassing the high-pressure screw expander, wherein the bypass line comprises a control valve for opening and closing the by-pass line. Under conditions when the temperature of a heat source to which the evaporator is connected is low it can be advantageous to disconnect the high-pressure turbine and to use just the low-pressure turbine.
In a waste recovery system for an engine such a condition can occur, for example, when the engine has just started and does not provide sufficient exhaust heat to drive both of the expanders. On the other hand, it can also be advantageous to disconnect a previously closed bypass and use both expanders in situations when a temperature of a heat source is higher than it was before. This could occur in a geothermal power station, when a bore hole is drilled to a greater depth with a higher temperature or when the ORC machine is moved or connected to a different geothermal heat source. If heat from volcanic heat sources or from geysers is harnessed, the temperature may also change over time. These changes may be periodic changes, especially for geysers, or also long-term changes.
According to the one embodiment, the high-pressure expander is mechanically connectable to the generator via a freewheeling device. This provides a simple way of disconnecting from the high-pressure expander from the low-pressure expander.
According to the application, the bypass can be activated and deactivated by providing an input control valve and an output control valve. The high-pressure expander is arranged in the flow path of the work fluid between the input control valve and the output control valve. The high-pressure expander can be shut off from the work flow current from the input and the output side by closing the input control valve and the output control valve.
Furthermore, the Organic Rankin Cycle system may comprise one or more gear sets in order to adapt the generator speed to the output speed of the expanders for operating the generator close to a desired working point.
According to one embodiment, the generating unit comprises a first spur gear that is connected to the high-pressure expander and a second spur gear ( 64 ) that is connected to the low-pressure expander ( 24 ).
According to another embodiment the ORC system comprises a first planetary gear set that is connected to the high-pressure expander a second planetary gear set that is connected to the low-pressure expander. While a spur gear is easy to realize, a planetary gear can provide a higher reduction ratio for a given dimension.
In yet another embodiment of the ORC system, the generating unit comprises a planetary gear set, wherein a sun gear of the planetary gear set is connected to the high-pressure expander and a planetary carrier of the planetary gear set is connected to the low-pressure expander. With a planetary gear set which is connected in this way, the output of the two expanders can be used simultaneously.
According to one embodiment, the ORC system comprises a work fluid which is an azeotropic mixture, the azeotropic mixture comprising a first organic fluid with a normal boiling point in a temperature above 35° C. and a second organic fluid which is of low flammability. The boiling point of above 35° C. is advantageous when the temperature of the cooling fluid is as warm as 30° or even slightly warmer. This situation occurs for a ship in tropical latitudes. The low flammability is important for security reasons to prevent a fire on board a ship in which the ORC system is installed. This also applies to other environments, in which flammable substances such as oil are close to the ORC system.
In order to achieve these desired properties, the first organic fluid of the work fluid may comprise a pentafluorobutane and the second organic fluid may comprise a perfluoropolyether.
In particular, the condenser and/or the evaporator may comprise a plate heat exchanger. This type of heat exchanger is advantageous for situations in which the ORC engine is moving around. Movements of the fluid within the heat exchanger are constrained by the geometry of the plate heat exchanger.
In particular, the expanders may be realized as oil-free expanders. Thereby, it is not necessarily to mix oil into the working fluid which could deteriorate the properties of the working fluid.
Furthermore, the application discloses a ship engine with an aforementioned ORC system wherein the evaporator of the ORC system is connected to an exhaust of the ship engine via a pipe. The pipe may be filled with a circulating thermal oil that acts as a heat transporter.
In another embodiment, the application discloses a geothermal power station with the aforementioned ORC system wherein the evaporator of the ORC system is connected to a pipe for a brine of the geothermal power station, the pipe being connected to the geothermal heat source via a borehole. The brine is injected into the heat source or, in the case of a geyser, it may also be provided by the geothermal heat source itself.
Moreover, the application discloses a method for operating an ORC system with a high-pressure expander and a low-pressure expander. Therein, the ORC system comprises a bypass line that extends, in a flow direction of the working fluid, from a branching point before the high-pressure expander to the low-pressure expander. The ORC system furthermore comprises an input control valve before the high-pressure expander.
In a high temperature operating mode the bypass line is closed and the input control valve is opened. In a low temperature operating mode the bypass line is opened and the input control valve is closed. Thereby, the ORC system can be adapted to different temperature conditions without the need to provide to different ORC systems.
Furthermore, the method may comprise steps of measuring a temperature of a heat source and automatically selecting one of the high-pressure operation mode and the low-pressure operation based on the temperature of the heat source. This embodiment is advantageous, when a temperature of the heat source can change more rapidly.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter of the application will now be explained in further detail with reference to the following Figures in which
FIG. 1 shows an ORC system according to the application,
FIG. 2 shows the ORC system of FIG. 1 in a high-pressure operation mode,
FIG. 3 shows the ORC system of FIG. 2 in a low-pressure operation mode,
FIG. 4 shows a generation unit with a clutch,
FIG. 5 shows a generation unit with a clutch with an alternative orientation of the low-pressure expander,
FIG. 6 shows a generation unit with two freewheeling devices,
FIG. 7 shows a generation unit with two freewheeling devices with an alternative orientation of the low-pressure expander,
FIG. 8 shows a first view of an evaporator,
FIG. 9 shows a second view of an evaporator,
FIG. 10 shows a first view of a condenser,
FIG. 11 shows a second view of a condenser,
FIG. 12 a schematic process diagram of the ORC system of FIG. 1 ,
FIG. 13 shows a further embodiment of an ORC system having a separator chamber between first and second expander stages,
FIG. 14 shows a generation unit with a spur gear,
FIG. 15 shows a generation unit with two planetary gearsets, and
FIG. 16 shows a generation unit with a planetary type overriding drive.
DETAILED DESCRIPTION
In the following description, details are provided to describe the embodiments of the application. It shall be apparent to one skilled in the art, however, that the embodiments may be practised without such details. In the following description, the same reference numbers refer to the same or similar parts and primed reference numbers refer to similar parts. The expression “generating unit ( 11 , 111 )” refers to all embodiments of the generating unit.
Similar parts have the same reference numbers. Different embodiments of similar parts are marked with primes.
FIG. 1 shows an Organic Rankine Cycle (ORC) system 10 . The ORC system 10 comprises, in the sense of a work fluid flow, a generating unit 11 , a condenser 12 , a feed pump 13 , and an evaporator 14 . Respective work fluid pipes connect a work fluid outlet 15 of the generating unit 11 with a work fluid inlet 16 of the condenser 12 , a work fluid outlet 17 of the condenser 12 with a work fluid inlet 18 of the feeder pump 13 , a work fluid outlet 19 of the feeder pump 13 with a work fluid inlet 20 of the evaporator 14 and a work fluid outlet 21 of the evaporator 14 with a work fluid inlet 23 of the generating unit 11 such that a closed work flow loop is formed.
The expander screws are oriented such that the high-pressure expander 23 and the low-pressure expander 24 turn in the same direction when they are pressurized via their respective work fluid inputs. The freewheel clutch 27 is connected such that the freewheel clutch is disengaged when the low-pressure expander 24 turns faster than the high-pressure expander 23 and is engaged when the high-pressure expander 23 turns faster than the low-pressure expander 24 .
The generating unit 11 comprises a high-pressure expander 23 and a low-pressure expander 24 . The high-pressure expander 23 and the low-pressure expander 24 are connected to a generator 25 via a shaft 26 . According to the application, the generator 25 is provided by an alternating current generator 25 , for example by a three phase generator such as a cylindrical rotor generator, a salient pole generator, or a claw pole generator.
The generator 25 is arranged between the high-pressure expander 23 and the low-pressure expander 24 . A freewheeling device 27 is provided between the generator 25 and the high-pressure expander 23 . The shaft 25 comprises at least a first section, which connects the high-pressure expander 23 and a first input of the freewheeling device 27 , and a second section, which connects a second input of the freewheeling device 27 and the generator 25 .
At a first branching point 28 behind the work fluid input 22 of the generating unit 11 , the fluid pipe branches off into a high-pressure supply line 29 that is connected to a work fluid input of the high-pressure expander 23 and into a low-pressure supply line 30 that is connected to a work fluid input of the low-pressure expander 24 . A high-pressure exhaust line 31 that is connected to a work fluid output of the high-pressure expander 23 leads into the low-pressure supply line at a second branching point 32 . A bypass control valve 33 is provided between the first branching point 28 and the second branching point 32 at the low-pressure supply line 30 . An input control valve 34 is provided between the first branching point 28 and the work fluid input of the high-pressure expander 23 . An output control valve 35 is provided between the work fluid output of the high-pressure expander 23 and the second branching point 32 . A flow direction of the work fluid is indicated by arrows.
The condenser 12 is realized as a plate heat exchanger that comprises one or more channels 39 for cooling water and one or more channels 40 for the work fluid. The channel for cooling water 39 is connected to a cooling water source 36 at one end and to a cooling water sink 37 at the other end. For a ship, the cooling water source and sink can be realized by input and output ports which are connected to sea water. For a geothermal energy plant, the cooling water can be provided by a freshwater source or by circulating cooling water, which is recycled after it has cooled down. The cooling process of the cooling fluid may be accelerated by using a cooling tower or other heat exchangers.
Similar to the condenser 12 , the evaporator 14 is realized as a plate heat exchanger that comprises a heating fluid inlet 43 , one or more channels 41 for a heating fluid, a heating fluid outlet 44 and one or more channels 42 for the work fluid. For waste energy recuperation, the heating fluid can be provided by a thermal oil which takes up heat from a heat source 38 and which is circulated in a closed loop. In the case of a geothermal heat source, the heating fluid, also known as “injection brine”, is provided by a heated water or steam which is pumped out from the geothermal heat source and injected back into it.
According to the application, the expanders 23 , 24 are preferentially realized as essentially oil-free expanders. In this context “oil-free” expanders refers to expanders in which the screw surfaces are lubricated through the work fluid. In one embodiment, the freewheeling device 27 is realized as a sprag type freewheel which has low friction. In addition or alternatively, a clutch may be provided, for example an electromagnetic clutch to decouple the motion of the low-pressure expander 24 from the motion of the high-pressure expander 23 .
By using a two-stage expander, the expanders can be made smaller, such that they fit into the limited space of a ship's engine room. When a work fluid according to the application is used, the dimensions of the expanders can be made such that they each provide an expansion ratio of about 5.
In FIG. 1 , measuring locations for thermodynamic state quantities of the work flow are marked by squared numbers “1” to “4”. The thermodynamic state quantities comprise directly measurable state quantities, such as pressure and temperature, as well as derived state quantities, such as specific enthalpy and entropy. A “1” denotes a measuring location between the generating unit 11 and the condenser 12 , a “2” denotes a measuring location between the condenser 12 and the feeder pump 13 , a “3” denotes a measuring location between the feeder pump 13 and the evaporator 14 and a “4” denotes a measuring location between the evaporator 14 and the generating unit 11 . The measuring locations correspond to start and end points of process sections of a Clausius-Rankine cycle.
FIG. 2 shows the ORC system 10 of FIG. 1 in a high-pressure mode, also referred to as high temperature mode. The high-pressure mode is especially advantageous for waste heat recovery from heat sources which have substantially higher temperatures than 100° C. These conditions apply to combustion motors but also to some geothermal heat sources, for example.
In the high-pressure mode, the bypass valve is closed and the input valve and the output valve of the high-pressure expander 23 are open. During operation, work fluid in the gaseous phase is supplied to the high-pressure expander 23 , the work fluid, which is still in the gaseous phase, is expanded in the high-pressure expander 23 and discharged through the output valve of the high-pressure expander. Then, the work fluid flows to the low-pressure expander 24 and is expanded in the low-pressure expander. The work fluid, which is still in the gaseous state, is then discharged from the generating unit 11 . The faster revolving one of the high-pressure expander 23 and the low-pressure expander 24 drives the shaft 26 and there by the rotor of the electricity generator 25 .
If the high-pressure expander 23 turns faster than the low-pressure expander 24 , the freewheel 27 engages and the high-pressure expander 23 turns the rotor of the generator and the low-pressure expander 24 . If, on the other hand, the low-pressure expander 24 turns faster than the high-pressure expander, the freewheel 27 disengages and the low-pressure expander 24 turns the rotor of the generator. Thereby, the low-pressure expander 24 , which is now under load, will slow down again.
The remaining cycle of the work fluid is similar to a standard ORC cycle and is omitted here for brevity.
FIG. 3 shows the ORC system 10 of FIG. 1 in a low-pressure mode, also referred to as low temperature mode. The low-pressure mode is especially advantageous for waste heat recovery from heat sources which have temperatures of only about 100° C. or lower. These conditions apply, for example, to low temperature geothermal sources or to the decomposition of biodegradable substances.
In the low-pressure mode, the bypass valve is opened whereas the input valve and the output valve of the high-pressure expander is closed.
During operation, work fluid in the gaseous phase is supplied to the low-pressure expander 24 . The work fluid, which is still in the gaseous phase, is expanded in the low-pressure expander 24 and discharged through the output valve of the low-pressure expander. The remaining cycle of the work fluid is similar to a standard ORC cycle and is omitted here for brevity.
The work fluid of the Rankine cycle system according to the application is an organic fluid in the form of an azeotropic mixture. Preferentially, the working fluid fulfils the following criteria.
1. non-toxic 2. non-flammable 3. non-corrosive and fouling resistant 4. material compatibility and suitable fluid stability limits 5. high latent heat and high density 6. low environmental impact 7. acceptable pressure range for screw expanders 8. safety
In particular, SES36 is a suitable work fluid according to the application. SES36 is an azeotropic mixture of 365 mfc (1,1,1,3,3 pentafluorobutane) and PFPE (perfluoropolyether). While 365 mfc on its own already provides a good efficiency as an ORC work fluid, the addition of PFPE to 365 mfc has the benefit of reducing the reactiveness significantly.
The following table lists thermodynamic properties of SES36:
Liq.
Tem-
Liq.
Vap.
Liq.
Vap.
Entropy
Vap.
perature
Pressure
Density
Density
Enthalpy
Enthalpy
[kJ/(k
Entropy
[° C.]
[bar]
[kg/m3]
[kg/m3]
[kJ/kg]
[kJ/kg]
gK)]
[kJ/(kgK)]
0
0.263
1422.04
2.00
200.00
349.88
1.000
1.549
10
0.395
1400.14
2.89
207.26
359.64
1.026
1.564
20
0.579
1377.21
4.12
215.92
369.63
1.056
1.580
30
0.833
1353.24
5.77
226.05
379.70
1.090
1.597
40
1.174
1328.22
8.00
237.62
389.66
1.127
1.613
50
1.622
1302.16
10.97
250.50
399.25
1.168
1.628
60
2.200
1275.04
14.90
264.36
408.23
1.210
1.642
70
2.932
1246.85
20.08
278.74
416.31
1.252
1.653
80
3.845
1217.59
26.82
293.04
423.29
1.293
1.662
90
4.964
1187.26
35.45
306.69
429.05
1.331
1.668
100
6.316
1155.82
46.31
319.35
433.67
1.365
1.671
110
7.929
1123.24
59.79
331.04
437.38
1.396
1.673
120
9.831
1089.48
76.45
342.12
440.51
1.424
1.674
130
12.055
1054.38
97.20
353.16
443.37
1.451
1.675
140
14.636
1017.66
123.68
364.78
446.20
1.479
1.676
150
17.622
978.55
158.94
377.61
449.10
1.509
1.678
160
21.072
934.72
209.17
392.33
451.93
1.542
1.680
170
25.067
875.19
289.01
410.03
454.18
1.582
1.681
Further characteristics of the work fluid SES36 are summarized in the following table, in which “NBP” denotes the normal boiling point, cp′ the liquid heat capacity for constant pressue, cp″ the vapour heat capacity for constant pressure and cv″ the vapour heat capacity for constant volume.
Physical Property
Unit
Value
Molecular mass
g/mol
184.53
NBP
° C.
35.64
Tcrit.
° C.
177.55 ± 0.5
pcrit.
Bar
28.49 ± 0.24
crit. Density
kg/m_3
538
liq. density @ NBP
kg/m_3
1339.25
vap. density @ NBP
kg/m_3
6.95
cp′ @ NBP
J/(kg K)
1167.2
cp″ @ NBP
J/(kg K)
641.9
cp″/cv″@ NBP
—
1.01
heat of vaporisation
kJ/kg
152.94
By using SES36, which has a high boiling point of over 35° C., it is possible to use sea water as cooling fluid in a condenser, even under tropical conditions where the sea water may have temperatures as high as 30° C. Moreover, SES36 has a high vapour density. Thereby the expanders can be made more compact and with smaller expansion ratios.
In a first example, the ORC system in the high-pressure configuration of FIG. 2 is used in a ship to produce electric current from waste heat of a ship engine using SES36 as work fluid. In this example, the work fluid has a temperature T — 1 of 40.15° C., a pressure p — 1 of 1.26 bar and a specific enthalpy h — 1 of 389.66 kJ/kg between the low-pressure expander 24 and the condenser.
Assuming typical water conditions in the tropics, the condenser takes in seawater at a temperature of 30° C. and ejects heated sea water at a temperature of about 35° C. Between the condenser and the feeder pump, the work fluid has a temperature T — 2 of about 35.64, a pressure p — 2 of 1 bar and a specific enthalpy h — 2 of 236.72. These conditions correspond to the normal boiling point (NBP) of the work fluid SES36. Here, the specific enthalpy h — 2 is the liquid enthalpy under the assumption that the condenser liquefies all of the work fluid.
The feeder pump circulates work fluid at about 0.345 liter/sec. Between the feeder pump and the evaporator, the work fluid has a temperature of 35.64° C., a pressure of 25 bar and a specific enthalpy h — 3 of 239.62. The evaporator is fed by a thermal heat transfer oil which is heated up by the ship engine to about 230° C. When the thermal oil is ejected again from the evaporator it has an outlet temperature of about 80° C. The high-pressure expander 23 and the low-pressure expander 24 drive the generator such that an output power P_gen of about 20 kW=20 kJ/sec is produced.
A first estimate of the thermal efficiency η_th under the conditions of the first example is given by the quotient
η
th
≈
P
gen
(
h
4
-
h
2
)
*
m
.
pump
Assuming a work fluid temperature T — 4 of 170° C., a pressure p — 4 of 25.06 bar and a corresponding specific vapour enthalpy of 454.18 kJ/kJ at the inlet of the high-pressure expander 23 , and with a liquid density of 1339.25 kg/m 3 at NBP, the quotient yields an approximate thermal efficiency of:
η
th
≈
20
kJ
sec
(
454.18
-
236.72
)
kJ
kg
*
0.345
l
sec
*
1.33925
kg
l
≈
20
%
In a second example, the ORC system in the low-pressure configuration of FIG. 3 is used in a geothermal energy plant to produce electric current geothermal heat using SES36 as work fluid. It is assumed here that the geothermal heat is sufficient to heat water to the boiling point. Higher or lower temperatures may be achieved as well, depending on the nature of the geothermal source and the water injection process.
In this example, the work fluid has a temperature T — 1 of 40.15° C., a pressure p — 1 of 1.26 bar and a specific enthalpy h — 1 of 389.66 kJ/kg between the low-pressure expander 24 and the condenser. Between the condenser and the feeder pump, the work fluid has a temperature T — 2 of about 35.64° C., a pressure p — 2 of 1 bar and a specific enthalpy h — 2 of 236.72. These conditions correspond to the normal boiling point (NBP) of the work fluid SES36. Here, the specific enthalpy h — 2 is the liquid enthalpy under the assumption that the condenser liquefies all of the work fluid. Between the feeder pump and the evaporator, the work fluid has a temperature of T — 3 of 35.64° C., a pressure p — 3 of 6.136 bar and a corresponding specific enthalpy h — 3 of 239.62 kJ/kg. Between the evaporator and the inlet of the low-pressure expander 24 , the work fluid has a temperature T — 4 of 100° C., a pressure of 6.136 bar and a corresponding specific enthalpy of 433.67 kJ/kg. A work fluid mass flow through the low-pressure expander is 0.4544 kg/sec.
These enthalpy values yield a theoretical thermal efficiency of
η
th
=
(
h
4
-
h
1
)
-
(
h
3
-
h
2
)
(
h
4
-
h
3
)
=
(
433.67
-
389.66
)
-
(
239.62
-
236.72
)
(
433.67
-
239.62
)
≈
21
%
For the real process one needs to consider that the feeder pump and the expanders have efficiencies below 1, for example the pump may have an efficiency of only 0.8 and the expander an efficiency of only 0.75. This yields
η
th
=
(
433.67
-
389.66
)
*
0.75
-
(
239.62
-
236.72
)
*
10
/
8
(
433.67
-
239.62
)
≈
15
%
In summary, the thermal efficiency of the ORC system using SES36 fluid according to the application is as high as 20% for the high temperature example and still at about 15% for the low temperature example.
FIG. 4 shows another embodiment of a generating unit 11 ′ in which a clutch 50 is provided between the generator 25 and the high-pressure expander 23 and a freewheel device is provided between the generator 25 and the low-pressure expander.
FIG. 5 shows an embodiment of a generating unit 11 ″ which is similar to the embodiment of FIG. 4 but in which the low-pressure side of the low-pressure expander 24 ′ faces towards the generator.
FIG. 6 shows an embodiment of a generating unit 11 ′″ in which a first freewheel device 27 is provided between the generator 25 and the high-pressure expander 23 and a second freewheel device 27 ′ is provided between the generator 25 and the low-pressure expander 24 .
FIG. 7 shows an embodiment of a generating unit 11 ″″ which is similar to the embodiment of FIG. 4 but in which the low-pressure side of the low-pressure expander 24 ′ faces towards the generator.
FIG. 8 shows an evaporator 14 for use in the embodiments of the application. The evaporator 14 comprises a plate heat exchanger 51 with a preheater portion 52 or first heat exchanger 52 and an evaporator portion 53 or second heat exchanger 53 as well as a separator chamber 54 , also referred to as liquid receiver tank 54 . The separator chamber 54 comprises a liquid outlet 55 at the bottom, a liquid inlet 56 and a vapour inlet 57 at the top. According to the embodiment of FIG. 8 , the height of the separator chamber 54 is higher than the height of evaporator 53 . Thereby, the vapour region remains separate from the liquid region under movements of a ship.
The liquid outlet 55 is connected to a liquid inlet 58 at the bottom of the evaporator section 53 . The liquid inlet 56 is connected to a liquid outlet 59 at the bottom of the evaporator portion 53 . The vapour inlet 57 is connected to a vapour outlet 60 at the top of the heating portion 53 . Furthermore, the evaporator 14 comprises an inlet 43 and an outlet 44 for a heating fluid such as thermo oil, water steam or hot water.
FIG. 9 shows a side view of the evaporator 14 of FIG. 8 . A work fluid in a liquid state is referred to in FIGS. 8 and 9 as “SES 36 Liquid” and a work fluid in a coexistence region of liquid and vapour is referred to as “SES 36 vapour+ liquid”.
During operation of the evaporator 14 , a feeding liquid, also known as work fluid, is pre-heated by the first heat exchanger 52 up to the boiling temperature and is fed to the liquid receiver tank 54 . The work fluid is then fed to the second heat exchanger 53 and converted into vapour. The vapour is fed back to the top of the receiver tank 54 and the vapour from the top of the receiver tank 54 is supplied to the expander 23 or 24 via the outlet 21 .
A flow of the work fluid through the evaporator is as follows: From the first heat exchanger inlet 20 to the outlet 59 to the tank inlet 56 to the tank outlet 55 via the second heat exchanger inlet 58 and the outlet 60 to the tank inlet 57 to the tank vapour outlet 21 to an inlet of a turbine or expander. A flow of a heating oil, which is referred to as “thermo 32 oil” in FIGS. 8 and 9 , extends from the inlet 43 via pipes of the evaporator to the outlet 44 .
FIG. 10 shows a condenser 12 for use in the embodiments of the application. The condenser 12 comprises a cooling fluid inlet at a lower left portion, a cooling fluid outlet at an upper right portion, a work fluid inlet 16 at a top portion and a work fluid outlet 17 at a bottom portion.
For use in a ship, it is advantageous if the condenser and evaporator comprise plate heat exchangers due to conditions in the ship. However, for a geothermal or other ground based power station or waste recovery system, the ORC system is not moving and other types of heat exchangers may be used as well.
FIG. 11 shows a side view of the condenser 12 in which the cooling fluid outlet is shown in a frontal view. In the interior of the heat exchanger, the fluid channels of the work fluid and/or of the cooling fluid may branch off into several channels which are in thermal contact with each other. Another embodiment comprises undulating channels. While many undulations and/or fluid channels improve the heat exchange, fewer undulations and/or fluid channels have a smaller flow resistance.
FIG. 12 shows a schematic view of an idealized Clausius-Rankine cycle of the ORC system of FIG. 1 . In FIG. 12 , the boundary of the vapour liquid coexistence region is indicated by a line 49 . In an isentropic expansion step 4 - 1 , the work fluid is expanded to a lower density while mechanical work is generated. In a cooling step 1 - 2 the work fluid is cooled down to the liquid phase. In the coexistence region, the heat loss is provided by removing the condensation heat such that this portion of the cooling step is isothermal. In an isentropic pumping step 2 - 3 , the temperature of the work fluid is increased isentropically. In a heating step 3 - 4 the work fluid is heated until it reaches the vapour phase. In the coexistence region, the heat increase is absorbed by the vaporization heat such that this portion of the heating step is isothermal.
FIG. 13 shows a second embodiment of an ORC engine, in which the outlet of the high-pressure expander 23 is connected to an inlet of a second separator chamber 54 ′ in a vapour region of the separator chamber 54 ′, and a vapour outlet of the separator chamber 54 ′ in the vapour region is connected to an inlet of the low-pressure expander 24 . A liquid outlet of the separator chamber 54 ′ in the liquid region is connected to a supply line for the feeder pump 13 at a branching point. A control valve 62 is provided between the liquid outlet of the separator chamber 54 ′ and the branching point 61 . Furthermore, a second feeder pump 13 ′ is provided between the branching point 61 and the outlet 17 of the condenser 12 .
FIG. 14 shows a further embodiment of a generating unit 111 in which a first spur gear 63 is provided between an output shaft of the high-pressure expander 23 and a generator shaft, an a second spur gear 64 is provided between an output shaft of the high-pressure expander 24 and the generator shaft.
FIG. 15 shows a further embodiment of a generating unit 111 ′ in which a first planetary gear set 65 is provided between an output shaft of the high-pressure expander 23 and a generator shaft, and a second planetary gear set 66 is provided between an output shaft of the low-pressure expander 24 and the generator shaft.
In the first planetary gear set 65 , a ring gear is connected to a casing of the generating unit 111 ′, a planetary carrier is connected to the output shaft of the high-pressure expander 23 , and a sun gear is connected to the generator shaft. Likewise, in the second planetary gear set 66 , a ring gear is connected to a casing of the generating unit 111 ′, a planetary carrier is connected to the output shaft of the low-pressure expander 24 , and a sun gear is connected to the generator shaft.
FIG. 15 shows a further embodiment of a generating unit 111 ″ in which a rotor of the generator is connected to a hollow shaft. The hollow shaft is connected to a ring gear of a planetary gear set 67 . A planetary carrier of the planetary gear set 67 is connected to an output shaft of the low-pressure expander 24 and a sun gear of the planetary gear set 67 is connected to an output shaft of the high-pressure expander 23 which passes though the hollow shaft. A brake clutch 68 is provided to fix the sun gear of the planetary gear set 67 when the high-pressure expander 23 is not in operation.
During operation in a high temperature configuration in which valves 34 and 35 are open and the bypass valve 33 is closed, the planetary gear is driven as an overriding gear by both the sun gear and the planetary carrier. The direction of rotation of the expanders is designed such that the rotation speed of the hollow shaft is increased.
During operation in a low temperature configuration in which valves 34 and 35 are closed and the bypass valve 33 is closed, the planetary gear is driven by the planetary carrier and the sun gear is fixed by the brake clutch 68 .
Reference numbers
10
ORC system
11-11″″,
Generating unit
111-111′″
12
condenser
13
feeder pump
14
evaporator
15
work fluid outlet
16
condenser inlet
17
condenser outlet
18
feeder pump inlet
19
feeder pump outlet
20
evaporator inlet
21
evaporator outlet
22
generating unit inlet
23
high-pressure expander
24, 24′
low-pressure expander
25
generator
27, 27′
freewheel device
29
high-pressure supply line
30
low-pressure supply line
32
branching point
34
input control valve
35
output control valve
36
cooling fluid source
37
cooling fluid sink
38
heat source
39
cooling water channel
40
work fluid channel
41
heating fluid channel
42
work fluid channel
43
heating fluid inlet
44
heating fluid outlet
49
coexistence region boundary
50
coupling/clutch
51
plate heat exchanger
52
preheater portion
53
evaporator portion
54, 54′
separator chamber
55
liquid outlet
56
liquid inlet
57
vapour outlet
58
liquid inlet
59
liquid outlet
60
vapour outlet
61
branching point
62
control valve
63
first spur gear
64
second spur gear
65
first planetary gear
66
second planetary gear
67
planetary gear
68
brake clutch
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The application discloses an organic Rankine Cycle system with a generating unit, a condenser for condensing an organic work fluid, a feeder pump for circulating the organic work fluid and an evaporator ( 14 ) for evaporating the organic work fluid. The generating unit comprises a high-pressure screw expander and a low-pressure screw expander, which are connected in series, wherein the high-pressure screw expander and the low-pressure screw expander are mechanically connectable to a generator, which is provided between the high-pressure screw expander and the low-pressure screw expander. The ORC system comprises a by-pass line for bypassing the high-pressure screw expander. The bypass line comprises a control valve for opening and closing the by-pass line.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for enabling the operation of a conventional gasoline engine by an auxiliary fuel source such as liquefied propane gas.
2. Discussion of Related Art
The increasingly high cost of conventional gasoline fuels and the increating incidence of low availability of the gasoline leading to long gas lines and short tempers has produced a need for a means of using an auxiliary fuel in a conventional gasoline vehicle.
Furthermore, in view of the high pollution consciousness of society, it is desirable to provide a means of fueling a conventional internal combustion engine which is capable of reducing exhaust gas pollutants to a minimum.
U.S. Pat. No. 3,184,295, issued May 18, 1965 to Baverstock, shows an LPG fuel system for internal combustion engines which includes a vaporizer having a heated metal base member with an inlet for liquid and an outlet for gas. The system utilizes an engine manifold vacuum sensor to control gas pressure. When the vacuum falls below a predetermined level, the regulator pressure is increased. U.S. Pat. No. 3,718,000, issued Feb. 27, 1973 to Walker, shows a dual fuel motor using liquid fuel such as gasoline and a gaseous fuel such as LPG. The Walker system includes exhaust treating devices in the exhaust system that operate efficiently when above a predetermined temperature. A thermally sensitive control change-over from gas to gasoline is effected when the treater reaches a desired temperature and switches back to gas fuel when below a desired temperature. U.S. Pat. No. 3,982,516, issued Sept. 28, 1976 to Abernathy, shows a standby system to provide a gaseous fuel to an internal combustion engine in the event of the failure of a primary source of fuel. The Abernathy system includes a primary source of fuel and a standby source of fuel and a normally open pressure switch which is responsive to a predetermined lower-than-normal pressure in a primary source of fuel to indicate a failure thereof. A vacuum sensor is responsive to engine vacuum and communicates the standby source of fuel to the engine fuel-air mixer when the primary source fails and fuel is demanded by the engine.
While various types of systems have heretofore been provided, as for example those discussed above, for providing auxiliary fuel sources or reduced emissions engine operation, considerable operating problems have been encountered with their use. Also, considerable expense is involved in adapting an existing engine to utilize these systems.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a relatively inexpensive, efficient system for utilizing a gaseous fuel in a conventional internal combustion engine.
A further object of the present invention is to provide a system for the use of LPG which system includes components readily adapted to be retrofit onto existing vehicle internal combustion engine components with a minimum of effort and alteration to the existing components. The elements of the present invention can be mounted at convenient locations within the vehicle and require a minimum of space due to the compact nature of each component.
Another object of the present invention is to provide a system for supplying LPG to an internal combustion engine which system includes a regulator which gasifies the LPG and supplies the gaseous fuel through a first regulator for engine idling and through a second regulator for high speed engine operation. The second regulator emits fuel to the carburetor in proportion to air drawn through the carburetor throat. This proportionate relationship is modified in response to engine manifold vacuum and can be further optionally modified in response to oxygen content in the exhaust gases of the engine in order to increase efficiency and reduce pollutants admitted to the atmosphere.
Another object of the present invention is to provide a liquefied propane system including a fuel tank designed expressly for use in the motor vehicle, incorporating a safety cut-off valve, sensors for an electronic fuel level gauge, and an outer seal of the shell for use when the tank is mounted inside the vehicle, the outer shell being vented to the atmosphere thereby preventing gas from leaking into the vehicle interior.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of the liquefied propane system;
FIG. 2 is a vertical sectional view of the regulator unit of the system;
FIG. 3 is a vertical sectional view of the LPG storage tank;
FIG. 4 is a vertical sectional view of the fuel-air mixer;
FIG. 5 is a plan view of a second form of mixer;
FIG. 6 is a vertical sectional view taken substantially upon the section line 6--6 of FIG. 5;
FIG. 7 is a plan view of a third form of mixer; and
FIG. 8 is a vertical sectional view taken substantially upon the section line 8--8 of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now with reference to the drawings, a liquefied propane carburetor modification system incorporating the principles and the concepts of the present invention will be described in detail. With specific reference to FIG. 1, it can be seen that the system includes a gas regulator unit 10 which receives liquefied propane through line 12 from storage tank 14. The gaseous propane is channeled from the regulator unit 10 through supply tube 16 to carburetor 17 for supplying the internal combustion engine (not shown) connected to the carburetor with fuel. The propane supply can be interrupted manually by operating switch 20 mounted on the indicator and the control panel 22. Switch 20 controls a solenoid valve 24 located in liquid propane supply line 12. A second switch 23 operates a second solenoid valve 26 contained within gasoline supply line 28 from the engine fuel pump (not shown). Accordingly, by moving the switch 20 to the "on" position, valve 24 is opened allowing liquid propane from tank 14 to enter the regulator 10. At the same time, switch 21 would be moved to the "off" position thereby causing solenoid valve 26 to shut-off gasoline flow through supply tube 28 to the carburetor. Reverse actuation of each of these switches would of course return conventional gasoline supply and operation to the internal combustion engine.
With reference to FIG. 2, it can be seen that the gas regulator unit 10 comprises a liquid propane inlet 30 for connection to supply line 12. The liquid propane entering inlet 30 is channeled to chamber 32 of pressure regulator 34. Pressure regulator 34 lowers the pressure of the liquid propane to 5 psi in a conventional manner by balancing the pressure of the liquid propane contained in upper chamber 36 against the force of spring 38. The pressure of the liquid propane acts against diaphragm 40 to which spring 38 is connected. Valve member 42 is also connected to the diaphragm and stops communication between chambers 32 and 36 when the appropriate pressure causes displacement of the diaphragm.
The liquid propane in chamber 36 is allowed to flow through vertically oriented port 46 onto heater unit 48 contained in liquid-to-gas conversion chamber 50. Heater 48 is supplied with hot engine cooling fluid through inlet 52 and outlet 54 which are connected in the internal combustion engine heating system by use of heater hoses, standard connectors and the like. The liquefied propane is gasified by contact with the heater unit 48 and fills chamber 50. Excess gas pressure in chamber 50 may be vented by relief valve 56 which is a standard spring-biased relief valve allowing communication with overflow tube 58 which can release the gaseous propane into the atmosphere or into a low pressure storage tank as desired. It is noted that the chamber 50 is formed from an upper casting 60 which is bolted to a lower casting 62. The heater unit 48 is mounted in casting 60 by the use of nuts 63 which attach to threaded surfaces formed around the inlet 52 and outlet 54 of the heater unit 48. Accordingly, the heater unit 48 can be formed separately and incorporated in the device upon assembly. Also formed in the casting 60 is an outlet port 64 which is connected by a gas supply tube 66 to the intake manifold 69 shown in FIG. 1. Gas flow through tube 66 is controlled by regulator 68 which comprises a diaphragm 70 and a valve member 72. The pressure of the gas is properly regulated to ensure adequate supply for engine idling purposes. The regulator is a standard type wherein the diaphragm is displaced downwardly thereby opening valve 72 when engine demand is sensed through a reduction in pressure in chamber 74 below the diaphragm. Sufficient fuel is fed through valve 72 to supply the engine. When engine demand for a supply of idle fuel is reduced, the pressure in chamber 74 is increased and the valve is closed by operation of diaphragm 70.
The lower casting 62 comprises an upper half 76 and a lower half 78 which are attached by bolts extending between flanges 80 and 82 to form chamber 84. Chamber 84 is divided by a diaphragm 86 which is secured between flanges 80 and 82. The diaphragm 86 attaches to actuation rod 90 so that displacement of the diaphragm opens valve 92 through attachment of rod 90 to lever arm 94 which connects to valve arm 96. Engine demand is sensed by a change in pressure in chamber 84 above the diaphragm through outlet port 98 which connects through supply tube 16 to the carburetor 17 as will be discussed hereinafter. When the pressure in chamber 84 above the diaphragm 86 falls below zero psi, the diaphragm is displaced upwardly thus opening valve 92 against the force of spring 100 which extends between offset spring mount 102 formed by the lever rod 94 and cup 104 which is attached to the end of adjustment screw 106 which extends through the wall of casting 62. Accordingly, it can be seen that when demand is sensed by lowering of the pressure, gas is allowed to enter the engine via valve 92 and outlet port 98.
An additional feature of the invention includes vacuum controlled regulator unit 108 which comprises diaphragm 110 dividing the regulator into upper chamber 112 and lower chamber 114. The diaphragm 110 is attached to actuator rod 90 through coil spring 116 which provides additional tension against the upward displacement of lever arm 94. Accordingly, if a low pressure is sensed in lower chamber 114, the diaphragm 110 is displaced downwardly thus increasing the force against which the low pressure in the upper portion of chamber 84 must act in order to allow additional gaseous vapor to enter the engine. This produces an economizing effect upon the use of fuel when the lower chamber 114 is connected through port 120 to the intake manifold 69 by line 122 shown in FIG. 1. Additionally, as depicted schematically in FIG. 1, a vacuum actuated valve 124 is included in line 122. Valve 124 closes completely during engine idling. The maximum effect of the regulator 108 can be controlled by adjustment screw 126 disposed through the bottom of the regulator housing. Adjustment screw 126 is threadedly connected to the housing and can be moved up or down in order to act as a stop against which connector 128 abuts during the vertical downward displacement of diaphragm 110. As is apparent from FIG. 2, connector 128 passes through the diaphragm and actually mounts the spring 116 to the diaphragm. In this manner, the maximum effect of regulator 108 can be limited by properly setting adjustment screw 126. It is also noted that the regulator connects to the lower portion 78 of casting 62 by threaded engagement comprising threads formed on the upper portion of regulator neck 130 which engage internal threads formed on mounting boss 132. A port 134 communicates the area below diaphragm 86 in chamber 84 with the upper chamber 112 of the regulator in order to balance the movement of the regulator in accordance with pressure in the lower portion of chamber 84.
When the engine is initially started, it is sometimes desirable to prime the engine with a free flow of fuel for a short period of time. In order to accomplish this result, a solenoid coil 140 is mounted about neck 130 of the regulator 108. The coil can be actuated by depression of switch 142 seen in FIG. 1 on panel 22. Energization of coil 140 causes upward movement of cylindrical member 144 which is attached to rod 90 and surrounds the spring 116. Member 144 acts as the solenoid armature and naturally should be formed of a magnetic material. Member 144 moves upwardly centering itself axially of the coil and at the same time forces rod 90 up to open valve 92. Valve 92 is kept open thus allowing a free flow of gas to the engine as long as the prime switch 142 is depressed. Naturally, switch 142 could be a time delay switch which releases after a predetermined time to ensure that an excess of fuel does not enter the engine.
The fuel exiting outlet 98 flows through supply line 16 into the carburetor 17 via mixer 150 shown in detail in FIG. 4. The mixer is actually an adapter comprising cylindrical housing 152 which fits into the throat 154 of the existing automobile carburetor 17. The housing 152 fits within a recess in throat 154 and is held therein by a threaded knob 156 which fits over and threadedly engages shaft 158. Shaft 158 threadedly connects to boss 160 which is a conventional fixture formed in the carburetor throat. The knob 156 also mounts cover plate 162 which retains air filter 164 on the lower filter mounting plate 166. The lower mounting plate threadedly attaches to the cylindrical housing 152. The cover plate 162 overlies three equilaterally spaced braces two of which are shown at 168. Braces 168 screw onto annular gas dispersion chamber housing 170 which is fixedly mounted in an upper recess of the housing 152. An O-ring 172 is fitted into an annular groove in housing 170 to ensure no leakage of gas from gas dispersion chamber 174 to the atmosphere. Chamber 174 communicates with the outlet port 98 of regulator unit 62, shown in FIG. 2 through inlet port 176 which is attached to supply tube 16. The lower surface of the housing 170 comprises a radially inward extending upwardly inclined wall 178 having a plurality of gas dispersion ports 180 formed therein circumferentially spaced about the wall. Gas is drawn through ports 180 from inlet 176 in proportion to the airflow through the carburetor throat by use of a floating spring-balanced meter element 182. Meter element 182 is a frustum shaped element having a central aperture slidably mounted on sleeve 184. Element 182 is biased upwardly against nut 186 by spring 188 which rests in cup 189 on boss 160. Accordingly, the element 182 can move downwardly against the force of spring 188 as airflow drawn into the carburetor throat increases. The frustum shape of the element 182 ensures that incoming air is channeled past apertures 180 thus drawing propane gas from the apertures at a rate in proportion to the airflow.
In order to guard against damage to the mixer components during engine backfire through the carburetor, the sleeve 184 is slidably mounted on shaft 158 and held in spaced relation thereto by a spacer 187. Above and below the spacer 187 are coil springs 190 and 192, respectively, which abut against the base 194 of the spacer and are held on the shaft at the upper end by knob 156. Thus, the spacer can move upwardly against the force of springs 190 and 192 when pressure is applied from below as through backfiring. This allows the element 182 to move upwardly thus clearing the area inward of housing 170 for the combustion gases to exit through upon backfire.
Now again with reference to FIG. 1 and with reference to FIG. 3, the tank 14 designed for use in the present system will be described in detail. Tank 14 includes an outer shell 200 which surrounds and mounts inner shell 202 which contains the liquid propane fuel. Shell 200 contains vent openings 204 and 206 which vent the space between shells 200 and 202 to the atmosphere when the tank 14 is to be contained within a vehicle. A plurality of mounts such as shown at 208 space the tank 14 inwardly of shell 200. Pressure sensors 210 and 212 are mounted respectively through the upper and lower portions of the shell 202 and measure the pressure within the shell. The sensors communicate with electronic circuit 214 which detects the difference between the pressures measured by the sensors to give an indication of fuel level which is displayed on gauge 215 of panel 22. Naturally, when the fuel level in shell 202 becomes low, the tank should be filled through filler tube 216 which extends from the tank to a convenient location. An overflow and vent tube 217 is also connected to the shell 202 and is disposed in a convenient location on the vehicle. Fuel line 12 is connected to the shell 202 through valve 218 which is a commercially available safety valve which shuts off fuel flow through the line 12 in the event that the tube is ruptured.
It can be seen that the outer shell 200 can be formed in two portions which are bolted together as shown at 196. The tank can also contain mounting supports 198 for holding it level on a surface. Other features of the tank such as the material from which it is made and the exact shape of each of the tank shells can be varied according to the area in which it is to be mounted.
An optional feature to further enhance the economy and usability of the invention includes the connection of an oxygen sensor 230 to the engine exhaust line 232 as depicted schematically in FIG. 1. The oxygen sensor 230 can be a commercially available device as sold by the Ford Motor Company as part No. D8FZ9F4728. The output of sensor 230 is proportional to the oxygen level in the exhaust gases and is directed to an electronic circuit 234 which causes actuation of solenoid 236 shown schematically in FIG. 1 and in further detail in FIG. 2. Actuation of solenoid 236 causes downward displacement of a needle valve 238 which is mounted therein. Normally, the needle valve 238 is biased upwardly into port 240 by a spring 242. Thus, port 240 is normally closed off. When the solenoid is actuated, the port effective area is increased thus allowing communication of vacuum from the engine intake manifold 69 through line 122, line 244 and port 246 to lower the pressure in the lower portion of chamber 84 below diaphragm 86. This lowered pressure is of course dependent upon the vacuum in the manifold and increases the force against which the diaphragm 86 must move to increase gas flow to the carburetor. Thus, when increased emissions are detected in the exhaust by an increased level of oxygen and the engine manifold vacuum is at a maximum indicating lower fuel demand by the engine, the diaphragm 86 is pulled downwardly with the greatest force by a vacuum disposed below it thereby reducing gas flow to the engine. Whenever the oxygen level is higher than desired, the solenoid 236 is actuated thus increasing the resistance against which the diaphragm 86 must be moved thereby reducing gas flow to the engine. Obviously, the additional force against which diaphragm 86 must move is determined by the manifold vacuum level and thus is dependent on engine demand.
While the actual structure of the needle valve configuration can vary, as shown, the housing 248 slidably mounts the needle valve 238 and the spring 242. The housing contains upper external threads which mate with internal threads of an aperture formed through the wall of casting 78.
In operation, initially switches 20 and 21, shown on panel 22 of FIG. 1, should be moved to the "on" and "off" positions, respectively. This then opens solenoid valve 24 and closes solenoid valve 26. In the absence of a rupture in line 12, valve 218 would also be open allowing liquid propane to pass through line 12 into regulator 34 shown in FIG. 2. That regulator reduces the pressure of the liquid propane to 5 psi. The liquid propane then flows through port 46 onto the heater 48 which vaporizes the propane.
When the engine is to be started, switch 142, again shown on panel 22 of FIG. 1, is depressed thereby actuating solenoid 140, shown in FIG. 2. This causes upward movement of lever arm 94 opening valve 92 allowing a free flow of gaseous propane through chamber 84 and port 98 into the carburetor through ports 180, shown in FIG. 4. The engine thus is provided with sufficient fuel to start when cold. Once the engine is started and idling, the solenoid 140 is deactuated and fuel for engine idling is supplied through regulator 68 shown in FIG. 2 and line or supply tube 66 shown in FIG. 1 directly to the intake manifold 69. During engine idle, vacuum valve 124 is closed off thereby eliminating any effect on regulator 108. When the vehicle accelerator is depressed the vacuum in intake manifold 69 is reduced and the valve 124 is opened thus communicating the vacuum to regulator 108. At the same time, propane is drawn from chamber 84, shown in FIG. 2, through port 176, shown in FIG. 4, into the carburetor in proportion to the airflow through the carburetor port by action of the metering device 182. An increase in airflow indicating a increased demand by the engine draws additional fuel from the chamber 84 by causing upward displacement of diaphragm 86 opening valve 92 of the regulator unit, shown in FIG. 2. Balanced against this force, is the vacuum sensed by regulator 108 from the intake manifold. Large manifold vacuum indicates small engine demand and thus diaphragm 110 of regulator 108 is moved downwardly allowing less gas to exit from chamber 84. As engine demand increases, the vacuum also decreases thus reducing the force against which diaphragm 86 must move.
In the event that oxygen sensor 230 of FIG. 1 is also included in the system, when high oxygen levels are sensed in the exhaust gases, a reduction in gas flow to the engine is effected via solenoid 236 which opens allowing vacuum from the engine manifold to communicate with chamber 84 below the diaphragm thus increasing the resistance against which that diaphragm must move.
Referring now more specifically to FIGS. 5 and 6 of the drawings there may be seen a modified form of mixer referred to in general by the reference numeral 250 and which may be mounted on the carburetor throat 154 in lieu of the mixer 150. The mixer 250 includes a hollow housing referred to in general by the reference numeral 252 including a removable top wall and a bottom wall 256 through which first and second small and large diameter ports 258 and 260 are formed. The top wall 254 has a pair of small and large diameter rounded edge openings 262 and 264 formed therein in registry with the ports 258 and 260 and a spring-biased meter element 266 corresponding to the meter element 182 is supported for shifting between positions opening and closing the port 260 by a support frame 268 carried by the top wall 254 and a compression spring 270. The bottom and top walls 256 and 254 include central vertical passages therethrough for receiving the carburetor air cleaner hold-down bolt 272 corresponding to the shaft 158 and the interior of the housing 252 defines a pair of hollow chamber portions 274 and 276 disposed about the ports 258 and 260. A narrow annular passage 278 extends about and opens into the port 258 below the opening 262 and communicates the chamber portion 274 with the port 258 in the venturi area defined by the port 258. A slightly wider annular passage 280 is disposed about and opens into the inlet end of the port 260 beneath the top wall 254 and communicates the chamber portion 276 with the port 260 in a venturi area defined by the port 260.
The mixer 250 receives a source of primary vaporized fuel through a supply line 282 extending from a regulator and vaporizer assembly similar to that indicated as at 10, but somewhat modified in that the modified regulator unit supply vaporized fuel to the mixer 250 does not include the components 64, 68, 70 and 74 of the unit 10. The supply line 282 opens into the chamber portion 276 through a gaseous fuel flow opened restrictor valve 284 having an adjustable stop member 286 operatively associated therewith for limiting movement of the valve 84 toward the open position.
In addition, a supply line 288 extends from the aforementioned modified regulator unit and opens into the chamber portion 274, the outlet end of the line 288 having an adjustable throttle valve 290 threadedly engaged with the top wall 254 operatively associated therewith. Also, the aforementioned modified regulator may supply an adjustably throttled amount of gaseous fuel to a fuel idle port of the associated carburetor. However, the port 258 is utilized, in conjunction with the conventional throttle valve 292 of the associated carburetor 17 for supplying a primary supply of vaporized fuel to the primary inlet port 58. During periods of high engine demand for air and fuel, the valve 266 is opened against the closing action of the spring 270 and a secondary supply of vaporized fuel is supplied to the port 260 from the chamber portion 276 through the annular slot 280. Thus, it may be seen that the mixer 250 comprises a simplified unit as compared to the mixer 150.
With attention now invited more specifically to FIGS. 7 and 8 of the drawings, there will be seen a third form of mixer referred to in general by the reference numeral 300 and which is to be utilized in conjunction with the inlet passages of a diesel engine. The mixer 300 defines an inlet port 302 corresponding to the port 258 and a hollow chamber portion 304 corresponding to the hollow chamber portion 274 to which vaporized fuel may be supplied from a modified regulator unit for vaporizing liquefied fuel. The vaporized fuel may be admitted into the hollow chamber portion 304 corresponding to the hollow chamber portion 274 in any convenient manner (not shown) and may be discharged from the hollow chamber portion 304 through the annular slot 306 surrounding the port 302. When the mixer 300 is utilized in conjunction with a diesel engine, the diesel engine is supplied induction air in the usual manner and diesel fuel is injected into the combustion chambers of the diesel engine through utilization of conventional diesel fuel injectors. However, the mixer 300 is disposed upstream in the diesel engine induction system from the air flow controlling throttle valve or valves thereof and is operative to admit gaseous fuel into the induction system of the diesel engine at a rate equal to approximately 20% of the usual fuel-to-air ratio. Although the total amount of fuel which is therefore provided to the engine at any given throttle setting thereof is greater, the amount of power developed by the engine is in excess of 20% more than would be developed without the gaseous fuel mixer, resulting in an over-all greater efficiency of operation of the engine. Further, by admitting vaporized liquefied gas into the induction system of a diesel engine, the diesel fuel being burned in the engine is more completely burned and the exhaust gases being discharged from the diesel engine are considerably more free of air pollutants.
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 system which can be retrofit into an existing conventional gasoline powered vehicle for enabling the vehicle to operate on either gasoline or liquefied propane fuel. The system includes a mixer in the form of an adapter to fit on the top of an existing carburetor. The mixer has a unique spring balanced metering device which controls flow of gaseous propane to the carburetor in proportion to airflow through the carburetor. The mixer is connected to a regulator assembly which receives liquid propane in a first chamber, heats the liquid propane to form a vapor, and feeds the vapor through an idle valve to control idling of the engine. The vapor is also passed to a second chamber of the regulator assembly in response to demand from the metering device which is sensed by a diaphragm actuated gas flow valve. From the second chamber, the gaseous propane is fed to a high speed inlet of the mixer. Engine manifold vacuum is also used to provide additional control for the gas flow valve to increase efficiency of the system. Other features include a special purpose fuel tank and an optional exhaust system oxygen sensor for further regulating gas flow to the engine.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/427,792 filed Apr. 22, 2009, now U.S. Pat. No. 8,128,642 which claims benefit of application No. 61/049,820 filed May 2, 2008, and the disclosures of each of the above-identified applications are hereby incorporated by reference in their entirety.
BACKGROUND
1. Technical Field
The present disclosure relates to a fluid delivery system for surgical instruments. More particularly, the present disclosure relates to a fastener for releasing treatment material to clamped tissue.
2. Background of Related Art
During certain surgical procedures as is often necessary to clamp tissue, such as, vascular tissues, to prevent leakage therethrough during surgeries. The procedure typically involves placing clips or clamps within an applicator device and applying the clamps to the tissue on one side of an area, for example a diseased section of vascular tissue or colonic tissue, and placing another set of clamps on the opposing side of the diseased section. Thereafter, the diseased section can be excised and the resulting free ends of the tissue reattached.
During surgery certain problems may arise. For example, manipulation of surrounding tissue, as well as fluid pressure within the tissue, may cause loosening of the clamp and resulting leakage or even possible detachment of the clamp. Additionally, it is often desirable to provide certain medicament or treatment materials such as, for example, biomechanical mediums or antimicrobials solutions to the tissues during the surgery.
Therefore, it is desirable to provide a mechanical fastening device having a securing mechanism for maintaining the fastening devices in a closed position during the surgery. It is further desirable to provide a mechanical fastening device capable of applying medicament or treatment materials to the tissues during the surgery.
SUMMARY
There is disclosed a toothed fastener for securing tissue. The toothed fastener generally includes an upper leg and a lower leg, each of the upper and lower legs having a row of teeth, each tooth having a proximal face and a distal face. The toothed fastener further includes a longitudinally extending securing member. A hole of predetermined diameter is formed in each of the proximal and distal faces and is of sufficient size to allow passage of the securing member therethrough. The upper or lower legs are movable from an open position to a closed position s placing all the holes in longitudinal alignment such that the securing member can pass through all the holes in the teeth of the upper and lower legs.
In a specific embodiment, each tooth has a pair of spaced apart holes formed in each of the distal and proximal faces. In this embodiment, the securing member has first and second legs for passage through the pair of spaced apart holes. The securing member includes a backspan such that the first and second legs extend distally from the backspan.
In one embodiment, the hole formed in the distal face of the distal most tooth is sized to engage the securing member in a friction fit fashion.
In a particular embodiment, each of the teeth are hollow or define a receptacle for receipt of material such that passage of the securing member through the holes of the teeth releases the material into the space between the first and second legs. The material may be contained within a puncturable capsule.
In the disclosed toothed fastener each leg has a base, each base having an opening to the interior of the tooth for passage of material into the tooth. A membrane is provided covering the openings in each leg to retain the material within the teeth.
In one embodiment, a connector is affixed to a proximal end of each of the first and second legs. In a specific embodiment, the connector is a living hinge. In a more specific embodiment, the living hinge is formed integrally with the proximal ends of the first and second legs.
There is also disclosed a system for applying a fastener to tissue including an applicator having a first and a second jaw and a toothed fastener positionable within the first and second jaws. The toothed fastener includes an upper leg and a lower leg, each of the upper and lower legs having a row of transverse, longitudinally extending teeth, each tooth having a proximal face and a distal face. The toothed fastener also includes a longitudinally extending securing member. A hole of predetermined diameter is formed in each of the proximal and distal faces and is of sufficient size to allow passage of the securing member therethrough. The upper or lower legs are movable from an open position spaced apart to a closed position substantially adjacent each other placing all the holes in longitudinal alignment such that the securing member passes through all the holes in the teeth of the upper and lower legs. The first and second jaws of the applicator are operable to move the upper and lower legs between the open and closed positions.
In one embodiment of the system, each tooth has a pair of spaced apart holes formed in the proximal and distal faces and the securing member is a staple bar having a backspan and first and second legs extending distally from the backspan. The first and second legs being configured to pass through the pairs of spaced apart holes to secure the upper and lower legs in the closed position.
The applicator further includes a pusher, engageable with the backspan of the staple bar, to drive the staple bar distally relative to the toothed fastener.
The present disclosure contemplates a fluid delivery system having an actuating handle assembly, a pair of jaws operably connected to the handle assembly, the pair of jaws each having teeth defining openings, and a puncturing member receivable in the openings of the teeth, the teeth defining at least one receptacle containing a fluid. In certain embodiments, the pair of jaws includes a first jaw and a second jaw arranged for clamping onto tissue. The fluid may be a medicament, tissue sealant or tissue adhesive. The fluid may be disposed in a puncturable capsule, the securing member having a tip for puncturing the puncturable capsule.
The present disclosure contemplates a tissue fastener having a first leg and a second leg pivotably connected to one another, the first leg and second leg each having teeth defining openings, and a securing member receivable in the openings of the teeth. A surgical instrument for applying the tissue fastener to tissue includes a pair of jaws and a handle assembly operably arranged to move the jaws between a closed position for clamping tissue and an open position for releasing the tissue. The jaws of the instrument are arranged to receive the tissue fastener and securing member. The surgical instrument includes a pusher for advancing the securing member through the openings in the teeth of the fastener. The teeth may define at least one receptacle containing a fluid. The fluid may be a medicament, tissue sealant or tissue adhesive.
In a further aspect, a toothed fastener comprises an upper leg and a lower leg, each of the upper and lower legs having a row of transverse longitudinally extending teeth, each tooth having a proximal face and a distal face; a longitudinally extending securing member; and a hole of predetermine diameter formed in each of the proximal and distal faces. The upper or lower legs are movable from an open position spaced apart to a closed position wherein all of the holes are in longitudinal alignment enabling the securing member to pass through the holes to maintain the fastener in the closed position.
In certain embodiments, each of the teeth are hollow for receipt of material such that the material is released into spaces defined between the upper and lower legs. The material may be contained within a puncturable capsule. Each of the upper and lower legs may have a base, each base having an opening to the interior of the tooth for passage of material into the tooth. In certain embodiments, a membrane covering the openings in each leg to retain the material within the teeth.
DESCRIPTION OF THE DRAWINGS
Various embodiments of the presently disclosed toothed fastener are disclosed herein with reference to the drawings, wherein:
FIG. 1 is a perspective view of one embodiment of a toothed fastener and applicator instrument;
FIG. 2 is a perspective view of the toothed fastener of FIG. 1 ;
FIG. 3 is a perspective view of an alternative, two part toothed fastener;
FIG. 4 is a perspective view of the toothed fastener of FIG. 1 with parts separated;
FIG. 5 is a side sectional view taken along line 5 - 5 of FIG. 2 ;
FIG. 6 is an end sectional view taken along line 6 - 6 of FIG. 5 ;
FIG. 7 is a perspective view of the distal end of one leg of the toothed fastener of FIG. 1 ;
FIG. 8 is a perspective view of the toothed fastener of FIG. 1 in an initial position on the applicator;
FIG. 9 is a perspective view similar to FIG. 8 during initial puncturing and securement;
FIG. 10 is a side sectional view taken along line 10 - 10 of FIG. 9 ;
FIG. 11 is a perspective view of the toothed fastener during final puncturing and securement; and
FIG. 12 is a side sectional taken along line 12 - 12 of FIG. 11 .
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiments of the presently disclosed fluid delivery system will now be described in detail with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views. As is common in the art, the term ‘proximal” refers to that part or component closer to the user or operator, i.e. surgeon or physician, while the term “distal” refers to that part or component further away from the user.
Referring to FIG. 1 there is disclosed a toothed fastener for use in a surgical instrument 12 . Surgical instrument 12 can be of the type for open surgery or laparoscopic surgery. In the present disclosure, surgical instrument 12 generally includes a handle 14 having an elongate tubular member 16 extending distally from handle 14 . The surgical instrument has an end effector at a distal end of the tubular member 16 , including an upper jaw 18 and a fixed jaw 20 that are movable with respect to one another. An actuator or trigger 22 is movably mounted on handle 14 and is operable to drive a securing and puncturing mechanism of fastener 10 into position as described in detail herein below. The handle 14 has a clamping handle 15 for moving the upper and lower jaws 18 and 20 to clamp tissue therebetween. Surgical instrument 12 additionally includes a rotation collar 24 , affixed to elongate tubular member 16 , to orient upper and lower jaws 18 and 20 during surgery.
Referring now to FIG. 2 , fastener 10 generally includes an upper leg 26 and a lower leg 28 . In this embodiment, upper leg 26 and lower leg 28 are connected by a flexible, living hinge 30 . Living hinge 30 allows upper leg 26 and lower leg 28 to move between an open position substantially spaced apart to a closed position wherein upper leg 26 is substantially adjacent to lower leg 28 . Upper leg 26 generally includes a base 32 having a row of transverse teeth 34 extending lengthwise along base 32 . The teeth 34 are hollow so as to define a receptacle in each tooth. Upper leg 26 additionally includes a distal most tooth 36 (or differ slightly to incorporate a locking mechanism as described in more detail herein below). Base 32 includes a plurality of base openings 38 that communicate with a corresponding receptacle in a corresponding tooth, and distal most tooth 36 . Openings 38 are provided to receive materials to be dispensed to tissue as described in more detail herein below.
Lower leg 28 also includes a base 40 having a row of transverse teeth 42 . The teeth 42 are also hollow so as to define a receptacle in each tooth. Lower leg 28 also includes a distal most tooth 44 on base 40 . It should be noted here in that, while the following specific descriptions of configurations, features and/or components of legs 26 and 28 may be given with respect to one of legs 26 and 28 , legs 26 and 28 may have the same or different configurations, features and components and are identical in all respects. Teeth 42 of lower leg 28 each include a distal face 46 and proximal face 48 . Similarly, distal most tooth 44 includes a distal face 50 and a proximal face 52 . Pairs of holes 54 are provided through distal face 46 and proximal face 48 of hollow teeth 42 . Living hinge 30 is also provided with a pair of holes 56 which are similar in size and spacing to holes 54 . Additionally, in a particular embodiment, distal most tooth 44 has a pair of spaced apart holes 58 in proximal face 52 . Distal face 50 of distal most tooth 44 as a pair of spaced apart holes 60 which can differ from holes 54 and 58 in size and may form part of a locking mechanism as described in more detail herein below. In the alternative, holes 60 may be similar to holes 54 and 58 and the pair of spaced apart holes in a distal face of distal most tooth 36 in upper leg 26 may differ from the pairs of spaced apart holes in teeth 34 to form the disclosed locking mechanism.
Upper leg 26 may be provided with a longitudinally extending membrane 62 which serves to cover base openings 38 and secure materials within hollow teeth 34 and 36 .
Referring for the moment to FIG. 3 , there is disclosed an alternative, two-part toothed fastener 64 which is substantially identical to toothed fastener 10 except for the lack of a living hinge. Fastener 64 generally includes an upper leg 66 and a lower leg 68 . Upper leg 66 includes a base 70 and a row of transverse, hollow teeth 72 . Upper leg 66 also includes a hollow distal most tooth 74 . A membrane 76 is provided across base 70 and functions similar to membrane 62 described hereinabove. Similarly, lower leg 68 includes a base 78 having rows of transverse, longitudinally extending hollow teeth 80 and a hollow distal most tooth 82 . Each of hollow teeth 80 includes a distal face 84 and a proximal face 86 . Hollow distal most tooth 82 also includes a proximal face 88 and a distal face 90 . A pair of spaced apart, holes 92 are provided in distal faces 84 and proximal faces 86 of teeth 80 . Likewise, proximal face 88 of distal most tooth 82 includes a pair of spaced apart holes 94 . In a specific embodiment, distal face 90 includes a pair of spaced apart distal holes 96 which differ in size from holes 94 and 92 and serve as a locking mechanism which functions similar to that which will be described herein below with respect to toothed fastener 10 . As shown, upper leg 66 includes a membrane 76 . As noted hereinabove, descriptions of the upper and lower legs of the various embodiments of the toothed fastener include similar components, such as the addition of a membrane to lower leg 68 , except for variations in distal most tooth 74 and distal most tooth 82 . Additionally, the operation of toothed fastener 64 , with the exception of a living hinge, functions the same as that described with respect to toothed fastener 10 hereinbelow.
Referring now to FIG. 4 , toothed fastener 10 also includes a securing member 100 which serves several functions. Securing member 100 has a backspan 102 and a pair of legs 104 and 106 extending distally from backspan 102 . Legs 104 and 106 terminate in distal tips 108 and 110 . Securing member 100 is provided to secure upper leg 26 and lower leg 28 in the closed position. Specifically, in the closed position, holes provided in teeth 34 and 36 of upper leg 26 are in direct longitudinal alignment with holes 54 , 58 and 60 in lower leg 28 . Thus, by driving securing member 100 , and specifically legs 104 and 106 , distally through holes 56 in backspan 30 and through holes 54 , 58 and 60 in lower leg 28 and the corresponding holes in upper leg 26 , upper leg 26 is secured in the closed position relative to lower leg 28 . Additionally, as tips 108 and 110 , of legs 104 and 106 , passed through the holes of the teeth as described herein, tips 108 and 110 puncture capsules of material, such as capsules 112 in upper leg 26 and capsules 114 ( FIG. 4 ) in lower leg 28 , to release materials contained therein onto tissue captured between upper leg 26 and lower leg 28 . Capsules 112 and 114 may contain a variety of materials for treatment or joining of tissue, such as, for example, biomedical mediums, antimicrobial solutions, etc. Materials disclosed in WO 2006/044800, the disclosure of which is hereby incorporated by reference herein, may be used. Lower leg 28 is provided with a membrane 116 to secure capsules 114 within hollow teeth 42 and 44 . Finally, tips 108 and 110 , in conjunction with smaller diameter holes 60 in distal face 50 of distal most tooth 44 , may act as a locking mechanism to prevent staple bar 100 from “backing out of” upper leg 26 and lower leg 28 as described below. The leg 104 and leg 106 may be sized to functionally engage the interior surface of the fastener teeth inside holes 60 , or the leg 104 and/or leg 106 have a textured surface for engaging inside the holes 60 , or both.
Referring now to FIGS. 5-7 , the details of teeth 34 and 36 of upper leg 26 will now be described. As noted hereinabove, upper leg 26 includes a distal face 118 of teeth 34 and proximal and distal faces, 120 and 122 , respectively, of teeth 36 . Teeth 34 include holes 124 which are similar in size to holes 54 in teeth 42 of lower leg 28 . Similarly, distal most tooth 36 includes a pair of spaced apart holes 126 formed in proximal face 120 which are also substantially the same as holes 54 . Distal face 122 of distal most tooth 36 includes a pair of spaced apart holes 128 which, together with tips 108 and 110 of securing member 100 , may form a locking mechanism to secure staple bar 102 within upper and lower legs 26 and 28 . Specifically, holes 124 and 126 may have a diameter d 1 which is greater than the diameter d 2 of pair of holes 128 in distal face 122 of distal most tooth 36 . Diameter d 1 of holes 124 and 126 are sized to be greater than the diameter of legs 104 and 106 of staple bar 100 so as to allow materials released from capsules 112 and 114 into the space between upper leg 26 and lower leg 28 in the closed position. Diameter d 2 of pair of holes 128 may be sized so as to grasp tips 108 and 110 of staple bar 100 in friction fit fashion thereby locking staple bar 100 in position within upper leg 26 and lower leg 28 . The teeth of upper leg 26 define receptacles for a fluid material. The lower leg 28 has teeth defining receptacles and holes that are similar to those discussed above.
Referring now to FIGS. 1 and 8 - 12 , the use of toothed fastener 10 in applicator 12 will now be described. As shown in FIG. 1 , toothed fastener 10 is attached to jaws 18 and 20 of applicator 12 , such as, for example, by a snap-fit. Once jaws 18 and 20 have been properly positioned around tissue (not shown), clamp handle 15 can be actuated to initially move the jaws to the closed position relative to one another. As best shown in FIG. 8 , this brings upper leg 26 into close cooperative alignment with lower leg 28 . In this position, teeth 34 of upper leg 36 interengage or interdigitate with teeth 42 of lower leg 28 . Depending upon the longitudinal orientation of upper leg 26 relative to lower leg 28 within upper jaw 18 and lower jaw 20 , one of distal most tooth 36 of upper leg 26 or distal most tooth 44 of lower leg 28 will become a distally most extending tooth of toothed fastener 10 . It should be noted that, depending upon which distal most tooth 36 or 44 becomes the distally most extending tooth, that tooth may be provided with holes of the smaller diameter d 2 in the distal face thereof to secure securing member 100 . Securing member 100 is in a proximal most position within elongate tubular member 16 . Applicator 12 is provided with a pusher 130 positioned against backspan 102 of securing member 100 .
Referring now to FIG. 9 , as trigger 22 is actuated, pusher 130 urges securing member 100 distally within elongate tubular member 16 . As securing member 100 moves distally, tips 108 and 110 of legs 104 and 106 pass through holes 56 in living hinge 30 . Referring specifically to FIG. 10 , as legs 104 and 106 (not shown) moves distally tips 108 and 110 passed through holes 54 in teeth 42 of lower leg 28 and holes 124 of teeth 34 of upper leg 26 . As legs 104 and 106 pass through holes 54 and 124 , tips 108 and 110 of legs 104 and 106 penetrate or puncture capsules 112 and 114 of material M thereby releasing material M into the spaces defined between teeth 42 and 34 . In this manner, toothed fastener 10 is capable of delivering material M to tissues captured between upper leg 26 and lower leg 28 . Additionally, the passage of legs 104 and 106 through holes 54 and 124 serve to secure upper leg 26 in the closed position relative to lower leg 28 .
Referring now to FIGS. 11 and 12 and initially with regard to FIG. 11 , as pusher 130 advances securing member 100 completely through upper leg 26 and lower leg 28 , tips 110 and 108 passed through holes 128 in distal face 122 of distal most tooth 36 . As noted hereinabove, holes 128 may have a diameter d 2 which is sufficiently small to engage tips 110 and 108 in friction fit fashion. In this manner, securing member 100 is “locked” into position within upper or lower legs 26 and 28 , respectively, thereby preventing staple bar 100 from inadvertently pulling out of upper and lower legs 26 and 28 . Additionally, the friction fit of tips 110 and 108 within holes 128 serves to seal holes 128 against any leakage of material M therethrough.
Referring to FIG. 12 as leg 106 passes through holes 126 in proximal face 120 , capsule 112 is punctured and material and is released. As shown, when distal most tooth 44 of lower leg 28 is not the distally most extending tooth of tooth fastener 10 , holes 60 in distal face 50 are of the same diameter as holes 54 in proximal face 52 to allow passage of material M therethrough as capsule 114 is penetrated. When the jaws of the surgical instrument are released from the tissue, through operation of the clamp handle 15 , the toothed fastener is secured onto the tissue, as the securing member 100 is retained in the teeth of upper leg 26 and teeth of lower leg 28 . Further, the material has been deployed to the tissue site.
It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the teeth of the legs may be formed with a single hole in each of the proximal and distal faces for receipt of a single bar therethrough. Further, the tips of the staple bar may be enlarged to engage the distal most hole in rivet fashion. Additionally, the holes of the teeth may be covered be a penetratable membrane and the material provided as a fluid within the teeth. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
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There is provided a penetratable toothed fastener for clamping tissue during surgery. The toothed fastener includes first and second legs each having longitudinal rows of transverse teeth and a securing member configured to pass through the transverse teeth to hold first and second legs closed relative to each other and about tissue. A locking mechanism is provided to retain the securing member within the first and second legs of the toothed fastener. The toothed fastener additionally includes receptacles for the receipt of medicant materials and holes in the teeth to dispense the materials to clamped tissue.
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TECHNICAL FIELD
[0001] The technical field of the disclosed technology relates to a RF-lightwave system for temporal compression of RF pulsed waveforms. This allows a radar system to have a longer detection range and also improved range resolution.
BACKGROUND INFORMATION
[0002] Most radar systems, especially those that have lower probability of interception (LPI), operate at limited average transmit powers. LPI systems also may involve wideband transmit waveforms (spread spectrum) instead of single-frequency waveforms. In order to increase the detection range of these radar systems, transmit pulses of longer duration, or even continuous (cw) waveforms, are often used. However, the range resolution is reduced as the pulse is lengthened. Pulse compression techniques are available that sub-divide the pulse into a number of shorter intervals in which the waveform frequency or phase is coded in a way that makes those intervals distinct. The radar return waveform is processed in such a way that the various intervals are overlaid in time to create a much shorter effective pulse of higher energy. For example, many radar systems employ transmit pulses that have a duration of 10 to 500 microseconds. In comparison, the pulse needs to be compressed to approximately 2 nanoseconds to achieve a range resolution of 1 foot. Pulse compression ratio is defined as the ratio of the transmit pulse duration and the sub-divided pulse interval. Thus, there is a desire to achieve large pulse compression ratios since that improves the processing gain of the radar system.
[0003] Phase coding is one way to achieve large pulse-compression ratios and is used in many radar systems. Presently, phase coding has only been used for narrow-band radar systems, partly because of the difficulty of generating and processing wideband waveforms by electronic means.
[0004] The RF-lightwave approach disclosed herein is compatible with wideband uncompressed waveforms that may be useful for LPI systems. In fact, this approach can be used with a variety of waveforms. The disclosed approach also can potentially achieve shorter sub-divided pulse intervals, which could lead to larger pulse compression ratios and finer range resolutions or improved processing gain. Because the short sub-divided pulse interval can be achieved, the approach disclosed herein also can be used to compress, by phase coding, individual pulses in the pulse bursts that often are employed in radar systems. Bursts of short pulses have high pulse-repetition frequencies, with each burst separated by longer intervals. This can reduce the range and Doppler ambiguities.
[0005] The disclosed approach preferably combines the benefits of large pulse-compression ratios, short compressed pulses and compatibility with a variety of wideband waveforms.
[0006] Improved range resolution allows the radar system to not only detect the presence of objects but also to identify them by detecting their features. The disclosed approach makes possible the achievement of pulse compression with wideband LPI waveforms.
[0007] The prior art includes electronic methods for pulse compression by phase coding, and a large number of pulse compression phase codes are known as are the radar systems that employ phase-coded pulse compression. The presently disclosed technology makes use of conventional phase codes and likely can also make use of future phase coding techniques as well. Examples of conventional phase codes are discussed in a book chapter on Phase-Coding Techniques by Cohen and Nathanson in Radar Design Principles, 2nd Ed., SciTech, 1999.
[0008] Prior art approaches for using phase encoding in radar systems typically involve direct changes of the phase at the microwave carrier frequency. Microwave “magic-tee” transmission line structures provide anti-phase outputs and “hybrids” provide 0 and 90° phase shifts over bandwidths in excess of 20 percent of the carrier frequency. Semiconductor diode switches, which can have switching speeds of a few nanoseconds, are typically used to select the phase. Thus, the sub-divided pulse intervals are at least many nanoseconds in duration. Digital approaches also can be used to generate phase-shifted waveforms. Digital synthesizers, however, are generally limited to frequencies of several hundred megahertz or lower.
[0009] The processing of radar return signals is typically done using analog microwave tapped delay lines or by using digital shift registers. The tapped delay lines can operate at the microwave carrier frequency or at a lower, intermediate frequency. Some prior tapped delay lines operate after the return signal has been down-converted to video frequencies. Typically, lengths of microwave cable or transmission lines are used as the delay lines. The tapped delay-line function also can be accomplished by surface acoustic wave (SAW) devices. For each tapped signal, an appropriate phase shift, using the approaches described in the preceding paragraph, is applied to counteract the phase shift produced at the encoder. The outputs from the various re-shifted taps are then summed together. For high-frequency signals, the microwave implementations of the tapped delay line approaches can limit the cumulative delay (the delay increment times number of taps) because of the attenuation of the delay lines. Also, the phase re-shifts generally cannot be changed quickly. Digital techniques typically involve sampling and quantizing the return signal and then moving that sampled data down a shift register. The sampler and shift register can be clocked at the sub-divided interval. The phases of the data samples in the register are then compared with a template pattern to determine a match. Since only the phase or sign of the data samples are compared, the quantizer can be quite coarse in terms of resolution. The fastest digital samplers are capable of clock rates of several gigahertz.
[0010] The presently disclosed technology also preferably makes use of tapped delay line paths, similar to some of the decoding architectures. A new way to accomplish delays for time-delay encoding/decoding, by using switched optical delay lines, is disclosed. A key advantage of the photonic approach for encoding described herein is that the subdivided pulse interval can be fractions of a nanosecond long. This leads to improved range resolution. Likewise, the counteracting time-delay shifts (the time-delay re-shifts) applied to the tapped signals in the decoder can be changed quickly—at speeds in excess of several gigahertz. This can allow the decoder to be reconfigured or adapted rapidly to account for effects such as Doppler shifts from closely spaced targets.
[0011] Switched optical delay lines have been used for RF antenna beam forming. Tapped optical delay lines have been used for constructing RF filters as well as for beam forming. It is not believed that there exists any prior use of switched or tapped optical delay lines to construct RF time-delay encoders or decoders for pulse compression.
[0012] Switched optical delay lines have been used in the past for phase-shift keying of signals for communications applications. These phase modulators are described by Fukushima, Doi, et al., in articles published in J. Lightwave Technology, v. 18, p. 301 (2000) and in IEEE Photonics Technol. Letters, v. 11, p. 1036 (1999). The architecture of these prior phase modulators is somewhat similar to the architecture of the time-delay encoders disclosed herein. For these prior phase modulators, however, a single-frequency microwave signal is impressed on the lightwave carrier. In contrast, the time-delay encoder disclosed herein may be used with both single-frequency and wideband RF waveforms.
BRIEF DESCRIPTION OF THE PRESENTLY DISCLOSED TECHNOLOGY
[0013] The RF radar transmit and return waveforms are modulated onto lightwave carriers. A RF-photonic encoder and a decoding preprocessor are used to phase-encode the Transmit waveform and partially decode the return signal. The encoder contains switched optical delay-lines to produce the desired RF phase shifts. The decoding preprocessor is based on a tapped optical delay line. The taps can be weighted to accomplish objectives such as reduction of side lobes in the compressed pulse. By using RF-lightwave encoders and decoders, one can achieve shorter compressed pulses and larger pulse-compression ratios than can be obtained using conventional electronic approaches. The presently disclosed technology is applicable to wideband transmit waveforms since it uses switched optical delay lines and, unlike prior approaches, is not restricted to single-frequency waveforms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1 a and 1 b are block diagrams of a RF lightwave time-delay coding system, FIG. 1 a depicting a phaser encoder while FIG. 1 b depicts a phase decoder;
[0015] FIG. 2 illustrates the basic elements and operation of the RF-lightwave encoder;
[0016] FIG. 3 illustrates an example of an encoder containing directional coupler switches;
[0017] FIG. 3 a depicts the shifting of the phase of a single frequency waveform by steps of ±180°;
[0018] FIG. 4 a illustrates the operation of a tapped delay line as the decoding preprocessor;
[0019] FIG. 4 b illustrates the decoding of a two-layer concatenated Barker code when the electronic processor uses a tapped-delay line;
[0020] FIG. 4 c illustrates a two-layer concatenation comprising a length 3 basic Baker code that is concatenated according to a length 5 Baker sequence to form a length 15 code;
[0021] FIGS. 5 a - 5 d illustrate some of the signals occurring in electronic pulse-compression processor;
[0022] FIG. 6 illustrates an embodiment of a decoding preprocessor that provides a tapped delay line without suffering from significant attenuation; and
[0023] FIG. 7 depicts an integrated optic implementation of an encoder and a decoding preprocessor.
DETAILED DESCRIPTION
[0024] The RF lightwave time-delay coding system disclosed herein includes a RF-lightwave phase encoder 100 and a phase decoder 200 . The phase decoder 200 contains a RF-lightwave time-delay decoding preprocessor 220 . Both the encoder 100 and the decoder 200 can have RF inputs and outputs. One or more of their inputs and/or outputs can alternatively be a RF-lightwave port instead of a RF port. For a RF-lightwave port, the signal is in the form of a RF-modulated lightwave carrier. A block diagram of an embodiment of the RF-lightwave phase encoder is depicted by FIG. 1 a while the phase decoder is depicted by FIG. 1 b. For RF inputs and outputs, the system also includes optical modulators and photodetectors that transduce the signal from the RF domain into the RF-lightwave domain.
[0025] A phase-code control signal data stream or sequence is supplied via a control input 110 to the RF lightwave encoder 120 . The control signal 218 on this control input 110 can be a binary data stream if the phase code is a binary code. The binary data stream could be the phase code itself, amplified to the voltage needed to control the encoder. However, the data stream is normally established by a phase-encoding processor. The phase code can be changed from pulse to pulse. The phase-select control lines 210 for the decoding preprocessor 220 set the phase shifts that are applied to the return signal 240 . The sequence of phase shifts that are determined by this set of control lines 210 normally would be an inverse of the phase code. This sequence can be changed to accommodate different phase codes. The photodetector 250 after the decoding preprocessor 220 has a single RF output 260 that is a series of short RF sub-pulses. These sub-pulses are supplied to the electronic pulse-compression processor 230 and are used for two different purposes. They indicate the time intervals (clk) during which a code match should be considered by the processor 230 . They also contain the partially decoded phase information (data). The phase of the RF waveform in each sub-pulse is still partially encoded. Examples of the operation and preferred embodiments of the RF-lightwave encoder 120 and decoding preprocessor 220 are described below.
[0026] The basic elements and operation of the phase encoder 100 are illustrated with reference to FIG. 2 . The lightwave source 102 ; optical modulator 104 and photodetector 122 are optional components of the encoder 100 , depending on whether the desired inputs and outputs of the encoder are signals in the RF domain or the RF-lightwave domain. The basic elements of the encoder are one or more sets of phase-selector switch structures 108 , 116 and at least two optical delay paths 112 . The phase-selector switches 108 , 116 determine which of the optical delay paths 112 is selected for the signal to undergo. One of the optical delay paths is a reference path. The other paths are longer than the reference path by specific increments that produce successively greater RF phase shifts by having the signal propagate for successively longer durations of time in those paths. The length increments are determined by the approximate frequency of the RF signal and the desired amounts of phase shift. These phase shifts represent different fractions of the approximate period of the RF waveform. For example, a 180° phase shift at 4 GHz requires a time delay of 125 psec. Such a delay can be realized with silica waveguides having lengths of 25 mm. Given the relatively short waveguide lengths needed, the encoder 100 can be implemented with reasonable loss using integrated-optics technologies such as III-V semiconductors or lithium niobate that are capable of rapid switching.
[0027] The phase selector switches 108 , 116 can be implemented in several ways. In one way, the input signal is divided into all of the delay paths. The delayed signal from only one of those paths is coupled to the output. This approach was used in the prior-art modulators for phase-shift keying (described in the aforementioned articles by Fukushima, Doi, et al.). The on/off path switching can be accomplished by means of optical intensity modulators such as Mach-Zehnder modulators or electro-absorption modulators, both of which are known in the art. Mach-Zehnder modulators have been constructed from III-V semiconductor or lithium niobate materials. Electro-absorption modulators have been constructed from III-V semiconductor materials. Another implementation makes use of optical-path routing switches such as directional couplers. Such switches typically have one or two inputs and one or two outputs. They direct the light from an input into one of the outputs, according to the level of an electrical control signal. Directional coupler switches are known and have been constructed from III-V semiconductor or lithium niobate materials.
[0028] An example of an encoder containing directional coupler switches is illustrated in FIG. 3 . An encoder 120 that is capable of producing four different phase states is shown. The switch structure 108 at the input is constructed from three 1×2 directional couplers or switches 108 - 1 , 108 - 2 and 108 - 3 . The switch structure 116 at the output likewise is constructed from three 2×1 directional couplers 116 - 1 , 116 - 2 and 116 - 3 . The states of these directional couplers 108 , 116 are set so that light is routed through the desired delay waveguide 112 . The state of a directional coupler can be changed very rapidly, at rates in excess of 10 GHz. These couplers or switches 108 , 116 are reconfigured at each phase-code interval. It should be noted that any net phase shift between 0° and 360° could be selected by switching of the delay paths. Also, if an input waveform consists of several frequency components, those frequency components need not undergo the same phase shift, although those phase shifts will be produced by the same delay. For example, a signal component at 8 GHz may receive a phase shift of 90° while a component at 7 GHz receives a phase shift of 77°. Since the switching can be done so rapidly, the phase-code intervals can be very short. For example, a 10 GHz switching speed corresponds to a phase-code interval of only 100 psec. This means that very short compressed pulses can be achieved. Obviously, the duration of the compressed pulse should be appropriately greater than the period of the wave associated with the approximate frequency of the RF waveform.
[0029] Phase-code control signals 218 are used to set the states of the switches 108 , 116 . These signals can have data that change at a rate as high as the phase coding rate. For a binary phase code, only two optical paths are needed. One pair of directional-coupler switches can provide the phase selection when there are only two possible optical paths. A control signal equivalent to an amplified version of the zero/one phase-code sequence is used to control the states of the switches. A “zero” switches the light through the reference delay path and a “one” switches the light through the phase A delay path. The phase A delay path, in this case, is set to produce some desired phase, typically near 180°, in the RF waveform. A digital processor can be used to generate the desired code sequence. The electrical waveform of the code sequence can then be frequency upconverted, if necessary, to the desired phase coding rate before being applied to the encoder.
[0030] The desired phase-coded waveform is obtained by selecting different RF phase shifts for each phase-code interval according to a specified phase code sequence ( 218 1 , 218 2 , . . . 218 n-1 , 218 n ) supplied to control input 110 . Different numbers of possible delay paths and different delay-path lengths can be chosen to accommodate different phase shift formats (e.g., binary or quadrature phase codes) and/or different approximate frequency ranges of the RF waveform (e.g., 2, 8, 16, 35 GHz). This shifting of the phase is illustrated in FIG. 3 a , for a single-frequency RF signal (using only the reference path and another delay path). Additional delay paths could enable the same encoder to be used for other RF-waveform frequency ranges.
[0031] The decoding preprocessor 210 is based on a tapped delay line 212 , an embodiment of which is illustrated by FIG. 4 a . Each time delay interval ΔT of the delay line 212 is equal to the phase-code interval for the radar pulse. The RF radar return signal 240 is first modulated by a modulator 205 onto a lightwave carrier generated by a laser diode 204 . The RF-lightwave signal is then fed to the tapped optical delay line 212 . Optical-waveguide taps are located after each time delay segment 214 and each diverts a portion of the signal to a set of phase selectors 216 , the diverted portions being appropriately delayed copies of the RF lightwave radar return signal. The first tap 224 n is associated with the last digit of the code 218 n , the second tap 224 n-1 with the second to last digit of the code 218 n-1 , and so on. The phase selector is preferably similar to the phase encoder discussed above and illustrated in FIGS. 2 and 3 . For example, in the phase encoder phase A is a short delay (e.g. 0.1 nsec), phase B is a longer delay (e.g. 0.2 nsec) and phase C is a longer still delay (e.g. 0.3 nsec). However, for the phase selector, phase A corresponds to the longest delay (e.g. 0.3 nsec). Phase B is of medium delay (e.g. 0.2 nsec) and phase C is of shorter delay (e.g. 0.1 nsec). Thus, when used in the decoding preprocessor 220 , each return phase selector 216 counteracts the time delay applied to that particular phase-code interval by the transmit phase encoder 112 . The result of this decoding is that all phase-code intervals undergo the same total time delay when a combination of the transmitter and receiver imposed time delays is considered.
[0032] The duration ΔT of the desired time delay and the length of the delay line 214 between taps 224 is determined by the desired compressed-pulse width. For example, a 0.5 nsec compressed-pulse width translates to a waveguide length of 10 cm in silica and 6.8 cm in lithium niobate. This inter-tap delay length limits the number of taps and delay segments that can be integrated on a single substrate. A maximum of 6-13 delay segments may be reasonable, given typical waveguide losses of <0.1 dB/cm for silica and <0.2 dB/cm for lithium niobate.
[0033] The selection of an appropriate phase code for a given radar application depends on the characteristics of the target to be detected and/or identified. These characteristics include the target's radial velocity (Doppler shift) and the presence of multiple targets or of clutter. For slowly moving targets, binary phase codes such as Barker code (or sequences) are sometimes preferred because they result in compressed pulses that have low temporal side lobes. Although the longest known Barker code has a length of thirteen, phase codes having lengths up to 10,985 have been derived by concatenating or overlaying multiple Barker codes (or other codes), as discussed in the book chapter by Cohen and Nathanson. For example, each higher layer of a combined-Barker code is essentially a Barker coded super-interval of Barker coded intervals. FIG. 4 c illustrates a two-layer concatenation comprising a length 3 basic Baker code (the first layer) that is concatenated according to a length 5 Baker sequence (the second layer) to form a length 15 code. This multilayer overlay or concatenation approach is especially suitable for RF-lightwave decoder 200 . The decoding preprocessor 220 may be used to compress the basic Barker-coded interval (i.e., the first layer of the code). The partially compressed output of that preprocessor 220 can then be further compressed by an electronic pulse-compression processor 230 (see FIG. 1 ). The data is supplied to the electronic processor 230 at a slower rate than the pulse-code rate. Thus, the electronic processor 230 has sufficient speed to perform the additional phase decoding, using the higher layers of the code. For example, assume that the compressed pulse interval has a one nanosecond duration and that the first-layer code has a length of seven. The data is then supplied to the electronic processor 230 at a rate of 143 MHz, which is compatible with many processors 230 having high dynamic range. By way of an example, see FIG. 4 b , which illustrates the decoding of a two-layer concatenated Barker code when the electronic processor 230 likewise uses a tapped-delay line format. The function of the combined RF-lightwave preprocessor 220 and the electronic processor 230 can be illustrated as a nested arrangement of the tapped delay lines. It should be noted that FIG. 4 b provides a functional representation rather than a physical representation of the decoder 220 . Functionally, the electronic summing node 222 of the RF-lightwave preprocessor 220 produces an output pulse 260 1 at the occurrence of each code match in a basic (first layer) Barker-coded interval. The sequence of output pulses ( 260 1 , 260 2 , . . . 260 k ), one for each basic Barker-coded interval, can be illustrated functionally as being produced by a cascade of tapped-delay line preprocessors (e.g. 220 10 , 220 20 , . . . , 220 k0 ). Note that those output pulses are actually preferably produced, at different times, by the same physical preprocessor 220 as opposed to by separate processors as functionally depicted by FIG. 4 b . Each output pulse 260 ′ shown in FIG. 4 b is given, by a phase selector 236 , an additional, compensating phase shift Δθ 1 , . . . , Δθ k that is associated with the Barker code of that super-interval (i.e., the second code layer). The time delays applied by those phase selectors are controlled by phase-select control signals 238 . The output of phase selectors 236 are then summed together at a summing point 290 . A strong pulse results when the phases of those outputs are matched with each other.
[0034] The output of summing node 222 is detected by a photodetector and produces the partially compressed RF output 260 . A “clk” signal and a “data” signal are derived from output 260 . This output 260 is described in more detail below.
[0035] To further describe the decoder 200 , some of the signals of the electronic pulse-compression processor 230 , are illustrated in FIGS. 5 a - 5 d. The “clk” signal (see FIG. 5 a ) is the series of partially compressed pulses supplied by the decoding preprocessor 220 . These pulses have the desired compressed-pulse width. There are a number of such “clk” pulses within the duration of the radar return from a single target scatterer. Essentially, one “clk” pulse occurs within each basic Barker-coded interval. The second processor, the electronic processor 230 , essentially determines which of these “clk” pulses corresponds to the actual range of the target. The “clk” signals also are expanded in duration (see FIG. 5 b ), typically accompanied by a low pass or temporally integrating filter, to form the “data” inputs for the electronic processor 230 . This expansion allows the “data” to be handled more easily by the lower-bandwidth processor. The electronic processor 230 decodes by overlaying the “data” into the appropriate temporal interval, perhaps by using electronic tapped delay lines 252 and compensating for the phase shifts produced by using phase selectors 236 , and summing them at a summing node 290 as shown by FIG. 4 b . The result of this operation is illustrated by FIG. 5 c . The desired output of the phase decoding processor 200 is the logical “and” of the electronically decoded signal with the “clk” pulse duration (i.e., when the “clk” envelope coincides with an envelope of the decoded “data”), as illustrated by FIG. 5 d.
[0036] Other types of codes also could be used. For example, some polyphase codes can approximate linear frequency modulation of the transmit waveform. Such codes may have improved performance when the target is moving. The disclosed encoder and the disclosed phase selector in the decoding preprocessor are compatible with polyphase codes. If only binary phase codes are used, any additional delay paths available in the switched encoder and phase selector (in the decoding preprocessor) can be employed to match transmit waveforms that are at other frequency ranges. They also can be used to provide slightly different phase shifts that compensate for Doppler shifts in the return signal.
[0037] In general, a tapped delay line suffers from attenuation of the signal, because that signal power is divided among the multiple taps and then recombined. FIG. 6 illustrates a decoding preprocessor 220 that provides a tapped delay line 212 without suffering from such attenuation. With this approach, the RF return signal is modulated onto multiple lightwave carriers, which are at different optical wavelengths λ 1 , λ 2 , . . . , λ n generated by laser diodes 204 1 - 204 n and combined in a wavelength division multiplexer (WDM) 205 . Each optical wavelength is associated with a given tap. Light from multiple lasers 204 1 - 204 n is supplied into a single optical modulator 206 , to which the radar return signal 240 is applied. The preprocessor 220 makes use of various wavelength dropping filters (WDF) 228 to tap off light from the time delay waveguide 212 . Wavelength λ n undergoes a delay of one time interval ΔT. Wavelength λ n-1 undergoes a delay of two time delay intervals (2ΔT), and so on. Wavelength λ 1 undergoes all of the time delays. A multi-wavelength combiner (WDM) 232 located at the output end of the taps can combine these time-delayed and phase-adjusted signals without incurring the typical loss of 3 dB per 2:1 combination that is associated with conventional optical waveguide or RF waveguide power combiners. The laser wavelengths can be selected to correspond to commercial telecommunications standards so that commercially available WDF and WDM components can be used.
[0038] The entire decoding preprocessor as well as the encoder could be implemented on a common substrate of electro-optic material such as III-V semiconductor or lithium niobate. An embodiment of such an integrated optic implementation is illustrated in FIG. 7 . Additional components that may be needed in the phase-coding system, but are not shown in FIG. 7 , are the lightwave sources, optical modulators and photodetectors. These additional components need not be co-located with the integrated optic subsystem shown in FIG. 7 . The integrated optical implementation illustrated by FIG. 7 is most suitable for short compressed pulses and phase codes having a relatively short length (at its first level). As an example, a 0.5 nsec compressed pulse interval corresponds to a lithium niobate waveguide length of 6.8 cm. The length of the phase code (first level) determines the maximum delay line length. For a length seven code at this compressed pulse interval, a maximum delay line length of 47.6 cm would be needed. Silica waveguides of such length have been fabricated on a single substrate and lithium niobate waveguides should be achievable, given the large refractive index difference of such lithium niobate waveguides. The resulting optical losses, approximately 10 dB neglecting the residual loss of the WDF 228 and WDM 232 and the phase selector 116 , may still be acceptable for many radar applications. If lower losses are desired, optical fiber segments might be used instead for the delay lines between the taps.
[0039] Various phase codes could be used with the disclosed system. The disclosed technology is not restricted to having only particular phase codes. Generally, a larger preprocessor with more taps is needed for longer codes. A combined approach is disclosed herein for processing long phase codes that comprise concatenations of shorter-length codes. This combined approach processes smaller portions of the code (i.e., the shorter-length codes) in the RF-lightwave domain and completes that processing (i.e., of the concatenated combination) in the digital-electronic domain.
[0040] The encoder and the decoding preprocessor can be implemented as photonic guided-wave structures. Such structures can be fabricated using conventional photonic-device processing techniques.
[0041] Having described this technology in connection with preferred embodiments thereof, modification will now suggest itself to those skilled in the art. As such, the technology is not to be limited to the disclosed embodiments, except as specifically required by the appended claims.
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An apparatus for preparing a RF radar transmit waveform and for decoding RF return waveforms comprising: a RF-lightwave encoder and a decoding preprocessor to phase-encode the RF radar transmit waveform and partially decode the return signal, the encoder including switched optical delay lines for producing desired RF phase shifts, and the decoding preprocessor including a tapped optical delay line and optical delay lines that counteract the delays imposed by the delay lines of the encoder, wherein the RF-lightwave encoder and the decoders allow shorter compressed pulses and larger pulse-compression ratios to be achieved than can be obtained using conventional electronic approaches. Wideband transmit waveforms can be generated due to the use of the switched optical delay lines and, unlike prior art approaches, is not restricted to single-frequency waveforms. The taps can be weighted to accomplish objectives such as reduction of side lobes in the compressed pulse.
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This is a division of application Ser. No. 466,643 filed May 3, 1974, which, in turn, is a continuation-in-part of Ser. No. 372,125, filed June 21, 1973, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods of cold forming, more particularly, backward and forward extrusion of ferrous metal workpieces using as a lubricant a coating composition of a film-forming, chlorine-containing polymer and a destabilizing agent, said coating being deposited from a liquid composition directly on the metal surface to form an essentially integral film thereon.
2. Description of the Prior Art
The use of lubricant materials as surface treatment for metals in cold forming, including backward and forward extrusion procedures, is well known in the art. The simplest known methods involve the use of ordinary lubricating oils which have been utilized on various metal materials in die-forming and drawing procedures for a substantial period of time. Lubricating oils, however, have one drawback and that is they fail to provide satisfactory performance under extreme pressure conditions, especially as are encountered in the forming of harder metals such as steel with the result that the failure of the lubricant under these conditions results in scoring of the metal during the forming step. It is believed that this failure of the lubricants under these high-stress conditions is attributable to the squeezing out of the lubricant from between the work and the die under the high pressures used. Improved phosphate coating processes for these so-called impact extrusions, specifically relating to mild steels, were developed in the 1930's. These traditional processes, still widely used, employ a phosphate (zinc, iron, manganese) coating chemically applied to the surface of the workpiece or blank. The phosphate coating served a dual purpose, that of a separating layer and partial lubricant and as a lubricant absorbent and carrier. The lubricants employed and still in current application were soap such as sodium stearate soaps and other additives such as graphite or other extreme pressure lubricant additives. For other applications, compositions have been employed which contain pigment type additives which may be generally described as infusible. These pigments are intended to separate the die and the workpiece at the points of extreme deformation when the pressure or temperature during the drawing or forming process is too great to be withstood by conventional lubricating materials. Examples of such pigment additives are materials such as clay, lime, calcium carbonate, molybdenum disulfide, titanium dioxide and graphite. In this practice there is thus provided a dry lubricant composition which primarily consists of a high pressure lubricant material such as the insoluble or infusible pigment described above. For more severe application, this pigment technology has been added to the phosphate coating so that typical lubricant systems would consist of phosphate coatings, soap films and an infusible pigment such as molybdenum disulfide. These compositions and procedures are described in U.S. Pat. No. Re. 24,017.
The method described in the aforenoted Reissue Patent involves three basic co-acting factors which include formation of an integral coating directly on the work, application of an organic binder coating on the integral coating, said organic binder containing a dispersion of fusible pigments. The integral coating formed on the ferrous metal workpieces is brought about by electrochemical reaction of the iron with reactive materials to form chemical coatings such as iron sulfide, iron phosphate, iron oxalate, or iron fluoride. The organic binder material employed may include various synthetic and natural resins such as acrylics, alkyl resins, cellulose nitrate polymers, asphaltum, shellac, polyvinyl chloride, polyvinyl acetate, and styrene polymers and the like. The fusible pigments employed are those which have a Moh hardness of less than 5 and melt below the melting point of the work or the die, whichever is lower. The melting range is described as generally above 500°C. Examples of fusible pigments include aluminum stearate, antimony oxide, copper powder, lead borate, sulfur, etc.
In the process described in the U.S. Pat. No. Re. 24,017, the ferrous metal workpiece is provided with an integral, chemically bonded coating (i.e., ferrous sulfide) formed on the surface thereof which is then further coated with a composition of a fusible organic resin binder containing admixed therein an inorganic, fusible solid material as a secondary or high or extreme pressure lubricant. However, the phosphate methods are expensive and cumbersome to employ since the described procedures involve a chemical treatment of the metal surface which is difficult to control due to normal acid bath depletion, and the subsequent application of an organic coating represents a separate coating and handling operation.
More recently, organic polymers have been employed as the lubricant in the drawing of metals, particularly mild steel workpieces. Polymers which have been considered include polymethylmethacrylate polymer, polyethylene, polypropylene, polyvinyl chloride and nylon in solvent solutions. These procedures are described in Sheet Metal Industries, July, 1963. Solvents obviously present a toxicity and a flammability hazard.
In Sheet Metal Industries, October, 1967, Rao also describes the use of polyethylene as a lubricant in the deep drawing of workpieces. The application of the polyethylene to the workpiece was by a variety of procedures, including hot-dip, adhesives, cold spraying, flame spraying, extrusion coating, emulsion coats, and solution coating from solids.
Blake, et al. in Meltallurgia and Metal Forming, January, 1972, pp. 30 and 31, disclose the attempted use as lubricants of polyvinyl chloride films laid down from solvent systems. This procedure, however, did not give satisfactory results.
While these prior art procedures appear to have functioned satisfactorily in many respects, they do not produce the desired results under all conditions, especially the severe conditions encountered in backward and forward extrusion of metal and, more particularly, steel workpieces.
SUMMARY OF THE INVENTION
The present invention relates to a method of cold-forming a ferrous metal workpiece which comprises applying to a ferrous metal workpiece, free from other coatings or surface treatments, a coating of a lubricant drawing composition containing a film-forming, chlorine-containing polymer and a soluble or dispersible destabilizing agent. The coating is applied to the metal workpiece, dried, and the coated workpiece subjected to the forming process.
The present invention also relates to cold-forming lubricant compositions employed in said process, including liquid lubricant coating compositions suitable for direct application to a metal workpiece without the necessity of chemical preparation or special treatment applied thereto, said liquid coating compositions containing a liquid carrier, a film-forming, chlorine-containing polymer and a destabilizing agent. In one preferred form the liquid coating composition includes a water or aqueous vehicle as the carrier and the chlorine-containing polymeric material is in latex or dispersion form. The liquid carrier may also include liquid solvents which may be typified by organic solvents such as, for example, xylene, toluene or the like. While solvents may be employed in the broadest aspects of this invention, it should be understood that they present a problem with respect to flammability, toxicity of fumes to workers, recovery problems and an air pollution liability, difficulties which are not associated with the compositions which employ aqueous vehicles as the liquid carrier.
Broadly, the film-forming polymeric materials employed in the coating composition include chlorine-containing polymers or copolymers of monomers such as vinyl chloride, vinylidene chloride and epichlorohydrin. Other suitable polymeric materials which can be used include chlorinated polymers such as chlorinated polyethylene or other chlorinated polyolefins.
The film-forming copolymers of vinyl chloride or vinylidene chloride may include, in addition to the vinyl chloride and vinylidene chloride component, non-chlorinated comonomers such as acrylates and methacrylates which may be typified by acrylates such as ethyl, methyl and butyl, hexyl or octyl acrylates or other derivatives thereof, or by the use of other non-chlorine containing comonomeric constituents as are well known in the art such as ethylene, which form polymers which form films. Preferred polymers are copolymers which are film-forming at room temperature. The film-forming copolymers of vinyl chloride and alkyl acrylates are a preferred embodiment. Externally plasticized film-forming polymeric compositions are also contemplated for use herein, as well as internally plasticized copolymers such as the vinyl chloride. External plasticizers can include those conventionally used in this art such as dioctyl phthlate, dioctyl sebacate, dibutyl phthalate, succinic acid esters, and so-called polymeric plasticizers such as copolymers of succinic acid and glycols (e.g. ethylene glycol).
In addition to the copolymers recited above, particularly useful compositions are terpolymers such as those of vinyl chloride which contain a small amount, generally from between about 0.5 to 5% of an acidic comononmer such as, for example, acrylic acid or substituted acrylic acid, methacrylic acid, itaconic acid, and maleic acid, which improve the adhesion properties of the coating to the metal.
The polymeric material may be broadly described as having film-forming properties and, more particularly, film-forming properties from the latex form when the latex is dried at room temperatures. It should be also understood that the film-forming capacity relates to the ability of the polymeric materials to form a film when deposited from solvent solutions and includes polymer compositions that are externally plasticized.
The latices which are employed in the preferred form of forming lubricant composition may include broadly both those which are formulated as neutral latices or as basic or acidic latices.
In the formulation of the latices the polymer latex is customarily further diluted by the addition of water. Generally, the polymer is present in the latex to the extent of about 5 to 50% by weight thereof. Preferably, the polymeric material is present on a solids basis in an amount of from about 10 to 30% by weight of the aqueous latex. The chlorine in the latex composition may be present in amounts ranging from about 1.5 to 30%, preferably 3 to 18% chlorine.
The destabilizing agent employed in the present invention is a compound which is characterized as being preferably completely soluble or at least highly dispersible in water or whatever solvent may be employed in forming the liquid coating compositions of the present invention. Solubility or high dispersibility is desired in these compositions to assure that the destabilizing agent is adequately and uniformly throughout the composition and in the resulting film. It should be understood, however, that destabilizing agents which are soluble are preferred.
Broadly, the destabilizing agent is a compound or salt of a transition metal such as, for example, iron, cobalt, nickel, copper, zinc, chromium and manganese or salts of tin or aluminum. Salts may be in the form of halides, sulfates, nitrates, acetates, propionates, butyrates, citrates or the like. The most preferred salts are those which have anions formed from organic acids and nitrates. Other inorganic anions such as the chlorides and sulfates, while usable, appear to have some corrosion liability, which although minor in the present context, may limit their applicability in some applications. The destabilizing agent is generally present in amounts of from 0.25 to 10% based on polymer and preferably from 0.5 to 5%. Of the destabilizing agents formed from transition metals the most preferred are zinc acetate or zinc nitrate or mixtures thereof. In those situations where a basic or neutral latex is employed, it has been found that to prevent the precipitation of the destabilizing agent as the hydroxide or basic salt where such a reaction may occur, it is necessary to add a chelating agent. Chelating agents well known in the art are amino polycarboxylic acids such as EDTA and its salts, diethylene triamine pentaacetic acid and its salts (DTPA), gluconic and heptagluconic acids and their salts, citric acid, etc.
In addition to the destabilizing agents referred to above, non-metallic destabilizing agents such as free radical catalysts may be used. These include the preferred water soluble peroxides such as potassium persulfate and the water soluble hydroperoxides. Hydroperoxides such as cumene hydroperoxide, can be used and these are preferably employed in a redox system that includes ferrous sulfate. Less preferred catalysts include water dispersible catalysts such as benzoyl peroxide, lauroyl peroxide or the like and azo catalysts such as 2,2'-azo-bis-(isobutyronitrile) (AIBN).
The present invention contemplates application of the liquid coating composition on the workpiece to produce a dried coating weight thereon, which will range from about 0.1 to 2 grams per/sq.ft. and preferably from between about 0.5 to 1.5 grams per/sq.ft.
One of the objects of the present invention is to provide a lubricant system for the extrusion of ferrous metal workpieces which would eliminate the use of the phosphate treatment of the workpiece prior to drawing.
Other objects include the provision of coating compositions which may be easily applied directly to the work without the necessity of intervening coatings such as the phosphate treatment referred to above, but permit quick and easy removal of the coating from the workpiece after extrusion.
Moreover, it is a further object to provide a lubricant coating composition which will not produce residue build-up in the die which might intefere with continuous, repeated formings.
Further objectives are the provision of an extrusion lubricant coating composition which has minimal corrosive properties when applied to ferrous metal workpieces; has good stability in the liquid and particularly in the emulsion form; is relatively non-toxic and non-irritating (cutaneous); is simple to apply; and does not have objectionable odors.
While not wishing to be limited by any particular theory of operation, it is believed that the compositions of the present invention provide a system whereby an extreme pressure lubricant is generated in situ during the extrusion operations and under the temperature and pressure conditions encountered in the extrusion operation which prevents welding of the metal work to the die and consequent scoring of the work. While termed "destabilizing agent" it should be understood that the destabilization effect which occurs is limited to destabilization during the forming operation per se. The compositions in the solution or emulsion form, or as dry coatings applied to the workpieces, are essentially, completely stable materials.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples will illustrate the compositions prepared in accordance with the present invention and will describe the formulations and procedures employed in coating and forming metal workpieces.
I. formulations
the following describes four types of latex emulsion systems of the invention: (a) acidic latex with metal salt; (b) neutral or basic latex with metal salt; (c) neutral or basic latex with free radical initiator; and (d) neutral or basic latex with free radical initiator in redox system. The following also illustrates typical procedures used to make the formulations:
______________________________________A. Acidic Laytex with Metal SaltZinc Nitrate 1 pt.*Add to Water 75 pts.then add 50 pts. copolymer of vinyl chloride-alkyl acrylate and acrylic acid [ B.F. GoodrichGeon 460X2, 50% solids, pH 2.2] latex to abovesolution.B. Neutral or Basic Latex with Metal SaltZinc Nitrate 1 pt.Dissolve in Water 50 pts.Add disodium salt of EDTA (Geigy Ciba SequestereneNA.sub.2) 2 pts. to solutionAdjust pH, if necessary, to about 8 to 9 with ammoniumhydroxide (or equivalent), then add 50 pts. copolymerof vinyl chloride-alkyl acrylate [B.F. Goodrich Geon450X3] latex to above.C. Neutral or Basic Latex with Free Radical InitiatorCumene Hydroperoxide 1 pt.Add to water 50 pts.Adjust pH to above 8 to 9 then add Geon 450X3 latex50 pts. to above. D. Neutral or Basic Latex with Free Radical Initiator in Redox SystemFerrous Sulfate 0.05 pt.Dissolve in Water 50 pts.Add EDTA 0.10 pt.Add Cumene Hydroperoxide 1 pt.Adjust pH to about 8 to 9 with ammonium hydroxideor equivalent, then add Geon 450X3 latex, 50 pts.to above.______________________________________ *pt. = part
Ii. coating procedure
a. emulsion Systems
The coating procedure used for small parts is barrel coating. Parts are rotated slowly in an open mesh barrel and dipped into the emulsion. After the steel is wetted by the emulsion, the barrel is lifted from the emulsion tank and drained over it. An air blast is directed over the parts to accelerate drying. Air temperatures used have been from ambient room temperature up to 100°F. with little influence of temperature on drying time which is about 5 to 10 minutes. By tumbling the parts during drying, sticking is prevented.
On large parts the procedure would be to dip the parts into the emulsion using an open mesh tray. Although the bottom of the part does not receive full coating, large parts are carried to the press and inserted with the coated face towards the punch.
It should be noted that the lubricant coating is adherent and not readily damaged. Small parts are dumped into hoppers and the lubricant must resist the impact experienced in transfer of the steel parts.
With emulsions, the preferred and practical bath temperature and part temperature during coating is room temperature, although higher temperatures can be used.
B. Solvent Systems
With solvent systems the bath temperature often has to be higher than ambient to maintain solubility of the polymer and to put down a uniform coating of the proper thickness on the steel.
Iii. evaluation of lubricants
the lubricant formulations were evaluated by back extrusion of SAE 1018 steel slugs coated with the lubricant. Testing was done using a 60-ton capacity mechanical press with automatic ejection of the formed pieces. Slugs were fed into the press manually and the forming rate was about 10 to 12 pieces per minute. The criterion of acceptability used was the lack of score marks on the inner surface of the formed part when examined at 7× magnification. A lubricant must provide this scoring resistance at the severest conditions of test which are: ##EQU1##
Criteria A and B represent about the severest conditions experienced in industrial extrusion of steel. Criterion C was established by experience as a lower limit needed to heat the tooling up to steady state conditions. If a lubricant remains promising after 25 slugs, it would usually prevent scoring on the one-hundredth slug, the practical limit on the number tested.
In testing a new lubricant, it was first evaluated at less severe conditions:
A. reduction of area could be 50%
B. height : Diameter = 2:1
C. number of slugs = 5 to 10
Since the die diameter was fixed, A was varied by changing the punch diameter and B by changing the height of the steel slug to be formed. A lubricant passing these lower conditions would then be evaluated under more severe conditions until it would be either passed or rejected. Under the less severe conditions of test, tool steel punches could be used; however, under the severest conditions, the tool steel deformed under the heat generated and carbide punches had to be used. Besides providing scoring resistance, the lubricant must not build-up in the die cavity. Build-up results in difficulties in the insertion and injection of slugs.
Iv. specific examples
example 1
an aqueous emulsion lubricant coating composition was prepared by diluting a B.F. Goodrich 460X2 latex about 50% solids as received with water to a 20% solids latex basis. The chlorine content of the polymer is approximately 30% which corresponds to about 53% vinyl chloride and the remainder being alkyl acrylate and acrylic acid (less than 5%) monomers. The latex as received has a pH of about 2.2.
To the diluted 20% solids latex was added 0.8% of zinc nitrate (polymer solids basis) which represents approximately 0.16% of zinc nitrate destabilizing agent in the final product. The pH of final emulsion was 2.
The aqueous emulsion was applied to a workpiece at a coating weight of about 0.7 gms. per/sq.ft. The mild steel (SAE 1018) slugs employed for coating purposes had a diameter of 0.687 inch, and a height of 0.669 inch. These slugs were backward extruded into a cup form to an inner wall height to a punch diameter ratio of about 3:1 by a die having a ring diameter of 0.698 inch. The plunger used in the forming operation had a diameter of 0.575 inch and the resulting reduction in cross-sectional area was about 70%. The head of the punch or plunger portion of the die is provided with a land which is approximately 0.005 inch greater than the diameter of the punch.
The coated slugs were drawn with good results and exhibited no scoring or marking of the product or die build-up.
The following Table will illustrate additional examples of latex or aqueous emulsion type lubricant coating compositions employing various polymers and destabilizing agents.
TABLE I__________________________________________________________________________EX. NO. Polymer Emulsion pH Polymer Solids % Destabilizing %.sup.(2)__________________________________________________________________________2 Vinyl chloride-alkyl 9 20 Cumene Hydroperoxide 4acrylate copolymer.sup.(1) FeSO.sub.4 0.2(B.F. Goodrich Geon 450X3) EDTA 0.43 Vinyl chloride-alkyl acrylate 8 20 Cumene Hydroperoxide 4copolymer (Borden's POLYCO- FeSO.sub.4 0.22607) EDTA 0.44 Vinyl chloride-alkyl acrylate 8 25 Cumene Hydroperoxide 4copolymer (National Starch Co. FeSO.sub.4 0.2VYNACLOR 2523) EDTA 0.45 Vinyl chloride-alkyl acrylate 3 20 Zinc Acetate 0.4copolymer (Geon 460X2)6 Vinyl chloride-alkyl acrylate 1 20 ZnCl.sub.2 4copolymer (Geon 460X2)7 Vinylidene chloride copolymer, 1 20 ZnCl.sub.2 460% chlorine (Geon 660x1)8 Vinyl chloride-alkyl acrylate 8 25 Zinc Nitrate 4copolymer (Geon 450X3) EDTA 89 Vinyl chloride-alkyl acrylate 8 25 Potassium Persulfate 4copolymer (Geon 450X3)10 Vinyl chloride-alkyl acrylate 5 31 Zinc Acetate.sup.(3) 5.4copolymer (Geon 460X2) (1 part)plusAcrylic polymer Hycar 2671(1 part)11 Vinyl chloride-alkyl acrylate 9 20 Zinc Nitrate 2copolymer (Bordens Polyco 2607) Tetrasodium EDTA 812 Vinyl chloride-alkyl acrylate 3 20 Cobaltous Acetate 1copolymer (Geon 460X2)13 Vinyl chloride-alkyl acrylate 9 20 Cobaltous Acetate 2copolymer (Polyco 2607) Tetrasodium EDTA 814 Vinyl chloride-alkyl acrylate 2 20 Stannous Chloride 2copolymer (Geon 460X2) Disodium EDTA 415 Vinyl chloride-alkyl acrylate 2 20 Aluminum Nitrate 1copolymer (Geon 460X2) Disodium EDTA 216 Ethylene-vinyl chloride 5 25 Zinc Nitrate 1copolymer (Monsanto Monflex 4500) Disodium EDTA 217 Plasticized vinyl chloride-alkyl 10 20 Zinc Nitrate 2acrylate copolymer with 35 phr Tetrasodium EDTA 8dioxtyl phthalate (Geon 576)18 Mixture of two vinyl chloride-alkyl 10 20 Zinc Nitrate 2acrylate copolymers (Polyco 2607, Tetrasodium EDTA 80.85 part; Polyco 2612, 0.15 part)19 Chlorinated polyethylene 5 Nickel Acetyl 4(48% chlorine) in xylene Acetonate20 Epichlorohydrin polymer 5 Nickel Acetyl 3(B.F. Goodrich Co. Hydrin Acetonate200) in MEK21 Polyvinyl chloride resin 5 Molybdenum 3(GEON 103) in cyclohexanone Naphthenate__________________________________________________________________________ .sup.(1) 50/50 vinyl chloride, alkyl acrylate .sup.(2) Based on polymer solids .sup.(3) Based on vinyl chloride copolymer solid
On testing, all formulations gave no scoring or die build-up where tested in accordance with procedures.
V. industrial evaluation
in addition to the pilot plant tests, the lubricant has been evaluated in a production test in a commercial plant. Parts coated with the lubricant were evaluated on a 500-ton capacity mechanical press. The parts were slugs of SAE 1016B steel which were sent through the first step of manufacture, a heading operation. The pieces were then coated with lubricant and dried. The slugs were back extruded under production conditions. This forming operation is part of the sequence used to manufacture track link bushings.
The following summarizes the information on this production evaluation:
______________________________________LubricantGeon 460X2 100 partsWater 100 partsZinc Nitrate 0.33 parts(with respect to polymer solids 0.67%)Coating ProcedureBarrel coating followed by warm air drying.SlugsTotal Number 25Diameter 2-9/32 inchHeight 2-7/8 inchExtrusion ConditionsBack extrusion using carbide punchA. Reduction in area = 42% Inner wall heightB. = 2.8:1 Punch Diameter______________________________________
The first step of evaluation involved insertion of a series of 10 slugs manually into the press and forming. It was found that no scoring of the inner surface of the formed parts had occurred. The next step was to insert 15 slugs into the press conveyor which feeds the press. The press was then started and the slugs fed at the normal production rate of 22 parts per minute.
On inspection of the slugs coated with the latex lubricant, no scoring was found.
As noted above, it has also been determined that the lubricant composition can be applied to to a workpiece or blank from a solvent solution rather than as an emulsion or latex. In such a composition, 5 parts of a polymer such as Geon 103 (polyvinyl chloride) is dissolved in 95 parts of cyclohexanone to which is added 0.1 part of benzoyl peroxide to form a 5% solution. The destabilizing agent employed should be soluble in the solvent used in forming the solution. For this purpose, metal compounds of the class described should be metal-organic compounds with sufficiently large organic groups to permit solubilization in the organic solvent. Organic solvents other than xylene, such as toluene, chlorinated solvents, etc. may also be used. It should be understood that while solvent systems may be employed, they are not preferred in view of flammability hazard, cost, pollution factors and the like.
It should be understood that for best performance, the compositions should include the destabilizing agent in a soluble form to assure distribution throughout the system. The free radical catalysts employed should also be either soluble or dispersible in the system, again to assure uniform distribution.
The coating compositions of this invention are capable of application to the workpiece, stable in the emulsion form as well as a dried coating on the workpiece item, form a uniform film or coating on the workpiece when applied from the liquid coating bath, are essentially non-corrosive and readily removed from the piece after forming. They provide lubrication and good results on ferrous metal cold extrusions (backwards and forwards) without scoring or die build-up at high deformation, i.e., in back extrusion with height to diameter ratios of say 3:1. Further, no intervening phosphate or other metal surface treatment is required, but application of the lubricant may be directly to the surface of the clean metal workpiece.
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A method of cold forming ferrous metals is disclosed employing as a cold-forming lubricant a dry solid coating comprising a film of a chlorine-containing, film-forming polymer and a destabilizing agent applied to the surface of a ferrous metal workpiece, which surface is free from other coatings or surface treatment, said coating being applied as a liquid composition and to particular coating compositions.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a process for preparing sterile Cefepime dihydrochloride monohydrate.
[0003] 2. Discussion of the Related Art
[0004] U.S. Pat. No. 4,910,301 (column 11) and its related patents (e.g. U.S. Pat. No. 4,994,451) describe the preparation of cefepime dihydrochloride monohydrate from cefepime sulphate. The process comprises precipitating the sulphate as a means of purifying the cefepime obtained in the synthesis, its subsequent transformation into the zwitterion and its passage from this to cefepime dihydrochloride monohydrate by acidification with HCl and dilution with acetone until precipitation of the dihydrochloride monohydrate is complete.
SUMMARY OF THE INVENTION
[0005] It has now been surprisingly discovered that the aforedescribed process can be simplified by avoiding precipitation of the cefepime sulphate derived from the synthesis and instead precipitating the cefepime dihydrochloride monohydrate directly. In this respect, the aqueous solution containing the cefepime derived from the synthesis is decolorized with carbon, filtered, washed with water and methanol, then acidified with concentrated HCl to crystallize the aforesaid dihydrochloride by diluting with acetone. The dihydrochloride thus obtained is dissolved in methanol or water, filtered sterilely and added dropwise to acetone. The sterile product is obtained by filtering the suspension containing acetone and methanol or acetone and water.
[0006] Specifically, the process of the invention is characterised in that a solution of cefepime obtained from the synthesis is decolorized with carbon, treated with concentrated HCl to pH 0.4-0.6 at a temperature between 15° and 30° C., then allowed to crystallize for 15-60 minutes and subsequently diluted by adding a water miscible organic solvent over 60-90 minutes at 20°-30° C. until complete precipitation of the crude cefepime dihydrochloride monohydrate, which is then filtered off, redissolved in a solvent chosen from the group consisting of methanol and water at 15°-25° C., filtered sterilely, diluted with the same organic solvent used previously over 30-60 minutes, in order to induce crystallization, and finally diluted again with the same solvent over 90-150 minutes to complete crystallization of the sterile cefepime dihydrochloride monohydrate, which is filtered off, washed with acetone and dried under vacuum to a K.F. between 3.0% and 4.5%. It is therefore evident that the process of the present invention provides some considerable advantages, such as an appreciable reduction in working hours, no sodium sulphate to dispose of, absence of ash in the final product because sulphuric acid is not used.
[0007] It was also observed that by using very pure materials for the synthesis together with very careful and attentive monitoring of the process, a final synthesis aqueous solution can be obtained which is so pure as to enable cefepime dihydrochloride monohydrate to be obtained of such purity that a simple sterile filtration of the final synthesis aqueous solution enables sterile cefepime dihydrochloride monohydrate to be precipitated, thus avoiding the second step of purification and sterilization, with an immense yield advantage of a 10% increase, which is added to the already indicated advantages for the process in the two aforedescribed steps.
[0008] A further and unexpected advantage is the fact that the sterile cefepime dihydrochloride monohydrate prepared in accordance with the process of the present invention, presents a density almost double that of sterile cefepime dihydrochloride monohydrate obtained by known methods. This fact represents an undoubted advantage because filtration and washing are facilitated, as is its dispensing into sterile containers, with the sterile product occupying less space in the warehouse and during transport, before its distribution into the sterile containers used in clinical practice.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The process outlined above will now be described in detail with the examples that follow:
Example 1
Crude Cefepime Dihydrochloride Monohydrate
[0010] 290 of a solution of rich liquors derived from the synthesis and containing about 65 g of cefepime as internal salt, are decolorized with 1.5 g of carbon while agitating for 20 minutes at ambient temperature. The mixture is filtered and washed with 43 ml of water and 10 ml of methanol. Agitation is maintained between 25° and 30° C. while concentrated HCl (91.5 g) is added dropwise. The mixture is then seeded and allowed to crystallize for 30 minutes. Completion of the crystallization is achieved by adding acetone (3.3 l) dropwise over 60 minutes at 25° C. The product is filtered off, washed with acetone and dried at 40° C. under vacuum. Yield: 74 g of crude cefepime dihydrochloride monohydrate, equal to 90% of the theoretical on the starting nucleus, with 84.7% purity.
Example 2
Sterile Cefepime Dihydrochloride Monohydrate
[0011] 20 g of crude cefepime dihydrochloride monohydrate are dissolved in methanol (85 ml) at ambient temperature. The solution obtained is filtered sterilely then maintained between 18° and 22° C. under agitation while acetone (50 ml) is added dropwise over 45 minutes. The mixture is seeded and allowed to crystallize for 2 hours; further acetone (450 ml) is added over 2 hours, then the product is filtered off, washed with acetone and dried at 45° C. under vacuum to a K.F. between 3.0% and 4.5%.
[0012] Yield: 18.6 g of sterile cefepime dihydrochloride monohydrate, equal to 93% of the theoretical relative to the crude product. The density of the product obtained is 0.55 g/ml, while under the same conditions the density of a sample prepared inn accordance with the known art is less than 0.3 g/ml.
[0013] Superimposable results can be obtained by dissolving the crude cefepime dihydrochloride monohydrate in water instead of methanol and using a final synthesis aqueous solution obtained from very pure raw materials, then by conducting the synthesis with scrupulous care the sterile cefepime dihydrochloride monohydrate is obtained with yields of 90% on the starting nucleus.
[0014] The yields obtained by operating in accordance with the known method are 90% of cefepime sulphate on the original nucleus, whereas, with the transformation of cefepime sulphate into sterile cefepime dihydrochloride monohydrate, a yield of 90% is obtained: it is therefore evident that although in the first step of the process there is exact equivalence between the known art and the process of the present invention, in the second and final step a clear increase in the yield (3%) is obtained if operating in accordance with the present invention. Differences between the two products at the analytical level have not been found other than the different densities of the crystals and the absence of ash in the product obtained in accordance with the process of the present invention.
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An amino acid in solution is precipitated with concentrated hydrochloric acid and isolated as the dihydrochloride monohydrate. Said dihydrochloride is redissolved and reprecipitated by adding a solvent.
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[0001] This application claims the benefit of U.S. provisional application Ser. No. 60/891,098 filed on Feb. 22, 2007, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Aspects of the present invention relate generally to saddles for anchoring and supporting insulated and uninsulated pipes. Saddles are typically used in building construction to anchor and support pipes to suspend the pipes from the structure of the building. Saddles typically spread the force of a hanger across a portion of the pipe to minimize the force applied to a particular spot. Arcuate flat saddles and saddles with 180° arcuate ribs ( FIG. 1 ) are well known in the art. An improved saddle is desired.
SUMMARY
[0003] Embodiments of the present invention relate to arcuate saddles with partial ribs typically used to anchor and suspend insulated or non-insulated pipes. Partial ribs on the lower face of the saddle inhibit the saddle from sliding relative to the hanger when engaged and provide strengthening force to the saddle.
[0004] In certain embodiments of the present invention, an arcuate saddle comprises a saddle which has a length and a width formed into an arc defined by a radius. The arcuate saddle further includes an exterior face on the saddle and a pair of partial ribs with closed ends protruding from the exterior face.
[0005] Objects, features and advantages of the present invention shall become apparent from the detailed drawings and descriptions provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a prior art saddle with 180° arcuate ribs.
[0007] FIG. 2 is an example of a hanger assembly usable to suspend saddles according to embodiments of the present invention.
[0008] FIG. 3 illustrates a hanger assembly and saddle supporting a pipe according to a preferred embodiment of the present invention.
[0009] FIG. 4 is lower perspective view of an arcuate saddle according to one embodiment of the present invention.
[0010] FIG. 5 is a lower view of the saddle of FIG. 4 .
[0011] FIG. 6 is side view of the saddle of FIG. 4 .
[0012] FIG. 7 is a downward or interior view of the saddle of FIG. 4 .
[0013] FIG. 8 is a die usable to make arcuate saddles according to embodiments of the present invention.
[0014] FIG. 9 is an enlarged partial view of the die of FIG. 8 .
[0015] FIG. 10 is a cross-sectional view of a die assembly usable to make arcuate saddles according to embodiments of the present invention.
[0016] FIG. 11 is a cross-sectional view of a die assembly usable to make arcuate saddles according to embodiments of the present invention.
[0017] FIG. 12 is a framed view of a roll bending machine to make arcuate saddles according to embodiments of the present invention.
[0018] FIG. 13 is a framed view of an optional sensor assembly on the machine of FIG. 12 .
[0019] FIG. 14 is a perspective view of the die assembly of FIG. 10 with a sensor.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated 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, such alterations, modifications, and further applications of the principles of the invention being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0021] Embodiments of the present invention relate to arcuate saddles with partial ribs typically used to anchor and suspend insulated or non-insulated pipes. As illustrated in FIGS. 2 and 3 , in a typical assembly 10 a hanger assembly 20 wraps around a pipe or insulated pipe 15 with a saddle 30 situated between the lower portion of the hanger and the pipe. According to an embodiment of the present invention, partial ribs 50 on the lower face of the saddle inhibit the saddle from sliding relative to the hanger when engaged and provide strengthening force to the saddle.
[0022] When putting together assembly 10 , an installer takes saddle 30 and slides it through lower bracket 24 of hanger 20 either independently or with the introduction of pipe 15 into the hanger. Partial ribs 50 are generally on the lower face or side of saddle 30 and do not extend upward to the vertical sides. The vertical sides of saddle 30 have a width in a close tolerance with the interior of hanger lower bracket 24 to transfer suspension force from the pipe to the hanger once in place. Typically the ribs in a prior art saddle, such as 180° ribs shown in FIG. 1 , have a higher profile and larger radius than the interior of hanger particularly on the sides, making sliding introduction of the prior art saddles into the hanger difficult. Omitting rib portions from the sides of the saddle allows the saddle to be introduced with a slight lifting above the lower hanger portion to clear the lower ribs, but without concern for side rib portions which might otherwise require lifting or twisting of the saddle relative to the hanger sides.
[0023] Partial ribs 50 according to certain preferred embodiments are considered closed at their ends, for example with the ends tapered into the face of the saddle. Closing the ends and omitting rib portions from the sides of the saddle allows the lower hanger portion to engage the sides of the saddle and pipe 15 in a flush or no-gap arrangement between the saddle side and hanger and between the saddle side and pipe and preferably with a friction fit once engaged. This flush arrangement substantially closes and seals the hanger to the saddle side and the saddle to the pipe and prevents the accumulation or retention of moisture or debris in the rib, such as water, dust, mold, or bacteria, which could accumulate in an open ended rib, such as in the 180 degree arcuate ribbed saddle of FIG. 1 .
[0024] Hanger 20 , for example the clevis hanger illustrated in detail in FIG. 2 , typically includes an upper portion or bracket 22 which can be suspended from a building structure, a lower bracket 24 for receiving and engaging the saddle and pipe and optionally includes a pivot 26 between the upper and lower brackets to allow some relative movement of the hanger portions, if necessary due to vibration, expansion or contraction. Alternately, the hanger can be one piece or a strap which suspends a pipe and saddle.
[0025] FIGS. 4-7 illustrate saddle 30 according to one preferred embodiment. Saddle 30 is formed typically from a metal sheet 32 pressed or rolled into approximately a 180° arcuate bend about a radius R, forming a length L and a width W. Saddle 30 includes two ends 33 and 34 at opposing ends of the saddle length. Ends 33 and 34 are optionally slightly outwardly flared 35 at each end to facilitate introduction of the pipe into the saddle and to minimize any abutment of sharp edges against the pipe or insulation. The exterior face of saddle 30 includes a generally lower portion or lower face 38 and opposing vertical sides 39 . “Vertical” and “lower” references herein refer to arcuate or curved portions of the saddle which may include generally vertical or horizontal tangents and are not intended to imply planar or flat portions.
[0026] The outer diameter or width W of saddle 30 is preferably sized to closely correspond to the inner diameter or width W C of the lower bracket 24 of hanger 20 . As examples, pipe sizes may range from 0.5 to 24 inches. More typical saddle sizes have outer diameters of 1.5 to 12 inches, optionally available in half-inch increments, although other outer diameter sizes can be made as desired. Example lengths are 8 or 12 inches
[0027] An interior channel 42 extends through the interior 44 of saddle 30 along channel axis C. In use, the interior diameter of channel 42 is sized to receive and engage an outer diameter of a corresponding pipe or insulated pipe.
[0028] Partial ribs 50 are defined on the lower face 38 of saddle 30 . Ribs 50 typically have an arcuate bend corresponding in shape to the arcuate curve of lower face 38 . Partial ribs 50 are generally transverse to the length L of saddle 30 and parallel to the width W. Ribs 50 preferably extend a sufficient height and width to inhibit saddle 30 from moving relative to the lower bracket 24 of hanger 20 once installed. Ribs 50 are preferably primarily oriented on lower face 38 and do not substantially extend to side portions 39 . In certain preferred embodiments, the arcuate bend of ribs 50 is approximately 60° or less.
[0029] Ribs 50 each include a central peak section 52 and opposing slanted or curved sides extending from face 38 to peak 52 . Peak section 52 may be sharp, blunted or rounded. Ends 56 of the ribs may be sharply defined, but preferably are tapered into saddle 30 at each end to form a closed end. Ribs 50 could be mounted to lower face 38 with an attachment process, but preferably are formed into the metal.
[0030] In one method of manufacture, a piece or “blank” of metal sheet either to be bent or pre-bent into a saddle is placed into a stamping machine which receives the piece. The stamping machine compresses the sheet between mating portions. During the compression, one piece of the press includes protruding partial ribs which stamp corresponding rib sections into the saddle. Optionally, the sheet is bent into an arcuate shape in the same step.
[0031] In an alternate method of manufacture, partially ribbed saddles can be made using a roll bending process using, for example, an Acrotech Model 1618 roll bending machine. A die 130 usable in a roll bending machine 400 ( FIG. 12 ) is illustrated in FIGS. 8 and 9 .
[0032] Die 130 includes opposing ends 131 which are engaged and driven by the roll bending machine. A central portion of the die has a length L D corresponding to the length of the saddle piece to be formed. The central portion has opposing ends 133 and 134 along length L D to form corresponding ends in the saddle. Optionally, ends 133 and 134 are flared 135 on the die to impart a flare to the end portions of the saddle.
[0033] In the embodiment of FIGS. 8 & 9 , die 130 is a solid cylinder which can be mounted at opposing ends to a roll bending machine to be driven. In an alternate embodiment shown in FIG. 10 , die 230 is a two piece die with an outer sleeve 235 surrounding an inner cylinder 240 . Inner cylinder 240 has opposing ends which are mountable to a roll bending machine. The outer diameter of inner cylinder 240 preferably forms a close fit with the inner diameter of outer sleeve 235 such that rotation of the inner cylinder by the machine transmits a corresponding rotation to outer sleeve 235 .
[0034] In a still further embodiment illustrated in FIG. 11 , die 330 includes an outer sleeve 335 with an outer and inner diameter and an inner roller 340 . Inner roller includes a mandrel shaft 344 with opposing ends mountable to a be driven by roll bending machine. Two bearing rollers 348 are mounted to shaft 344 and engage channels 337 defined adjacent opposing ends on the inner diameter of outer sleeve 335 . As inner roller 340 is turned, it causes sleeve 335 to rotate at a rate proportional to the ratio between the channel diameter C D and the diameter R D of bearing rollers 348 .
[0035] The die diameter is preferably sized to the diameter of a desired arcuate saddle, with different sizes usable for different sized saddles. By way of example only, a solid die, such as die 130 , can be used for saddles up to approximately four (4) inches in diameter. A two-piece die with an inner cylinder, such as die 230 , may be preferred for saddles from approximately four (4) inches in diameter to five (5) inches in diameter. A two-piece die with an inner shaft driving a sleeve, such as die 330 , may be preferred for saddles with a diameter of approximately five (5) inches or larger.
[0036] The outer surface of the die defines partial ribs which press corresponding rib portions into the saddle during the roll bending process. For example, in dies 130 , 230 and 330 the partial ribs are 150, 250 and 350 respectively. The ribs of die 130 are described in detail, with ribs 250 and 350 being similar yet appropriately sized to the corresponding die diameter. As shown in detail in FIG. 9 , ribs 150 preferably include a transverse length with a peak 152 and opposing side portions 154 . The ends of the partial ribs 156 are preferably tapered into the curve of die 130 . Partial ribs 150 are preferably formed on a face of die 130 to correspond in placement to a lower portion of saddle 30 , with blank portions on opposing sides of the ribs on die 130 to form corresponding non-ribbed side portions in the saddle.
[0037] A portion of an example roll bending machine 400 is shown in FIG. 12 . To form a piece of sheet metal into an arcuate saddle, a blank piece is preferably fed between two rollers, one of which is die 130 , with the length placed to correspond to the central portion of the die. Preferably the die is arranged and timed to rotate and form the partial ribs in the lower face of the arcuate saddle while bending each saddle. One method of arranging such timing is to start the die at a specific rotational point relative to the introduction of each blank sheet to form a saddle. An alternate method uses an automated or timed feeding mechanism to introduce blanks only at specified points relative to the rotation of die 130 while the die is in continuous rotation.
[0038] In certain embodiments, for example those shown in FIGS. 13 and 14 , a roll bending machine incorporates a sensor to consistently start the die at a specific rotational point relative to the introduction of each blank sheet to form a saddle. The sensor can be mechanical, such as a cam, wheel or lever, or electrical such as a light sensor or an electrical circuit.
[0039] In one embodiment, illustrated with die 130 in FIG. 13 , a cam 170 is mounted to an end of die 130 . A lever 175 is eccentrically pivotally mounted to cam 170 offset from the die axis, and extends through a bracket 177 towards a two-position switch 180 . Lever 175 is pulled and pushed through bracket 177 during rotation of die 130 . In use, a saddle blank is arranged at a feed point into the roll bending die with lever 175 at its extended position relative to switch 180 . The switch is then activated, for example by pushing handle 184 inward to push switch 180 to engage the roll bending machine to feed and bend the saddle blank into an arcuate saddle with rib portions while simultaneously pulling and then pushing lever 175 during the rotation cycle. When the die has made one complete revolution, lever 175 returns to its extended position and pushes switch 180 outward to disengage the rolling process. Preferably, at the end stopping point of the die rotation the protruding ribs on the die are positioned to be synchronized with the desired rib placement for when the next saddle blank is fed into the machine.
[0040] In an alternate embodiment, illustrated on die 230 in FIG. 14 yet usable in various die sizes, a registry point is defined on the die, and a sensor disengages the rolling process when the registry point reaches a desired position. In the example illustrated, die 230 includes a hole or depression 250 adjacent an end, for example on the exterior face or shoulder of sleeve or on an end face of the sleeve. A sensor 450 is arranged to detect when the hole or depression reaches a desired registry point. In one example, sensor 450 is a spring-biased wheel 452 mounted on a stalk 455 extending from machine 400 . In use, the process is engaged with a manual switch or sensor when a blank is in place or with an automated feed process. The wheel 452 is pushed outward by the die face during rotation of the die, and is biased to move slightly inward to engage the hole or depression when aligned with the registry point. The slight inward movement of wheel 452 preferably disengages the rolling process. Preferably, at the end stopping point of the die rotation the protruding ribs on the die are positioned to be synchronized with the desired rib placement for when the next saddle blank is fed into the machine.
[0041] 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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Embodiments of the present invention relate to arcuate saddles with partial ribs typically used to anchor and suspend insulated or non-insulated pipes. Partial ribs on the lower face of the saddle inhibit the saddle from sliding relative to the hanger when engaged and provide strengthening force to the saddle.
Objects, features and advantages of the present invention shall become apparent from the detailed drawings and descriptions provided herein.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of application Ser. No. 11/359,730, filed Feb. 22, 2006, now U.S. Pat. No. 7,470,638, issued Dec. 30, 2008. The disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to methods and systems for removing liquids from surfaces of semiconductor substrates such as wafers. More particularly, the present invention relates to systems and methods for reducing or eliminating the presence of residues on a substrate surface following the removal of liquids therefrom by selective manipulation of the liquids on the substrate surface.
2. Discussion of Related Art
Integrated circuit devices such as microprocessors and memory devices are typically fabricated upon a semiconductor substrate, such as a full or partial wafer of semiconductor material (e.g., silicon, indium phosphide, gallium arsenide, etc.), or other substrate including one or more layers of semiconductor material thereon, such as a silicon-on-insulator (SOI) type substrate (such as, a silicon-on-glass (SOG), silicon-on-sapphire (SOS), silicon-on-ceramic (SOC), etc.), or any other suitable fabrication substrate. A large number of identical integrated circuit devices typically are fabricated on a single substrate, and the substrate is then diced, sawed, or cut, to physically separate individual semiconductor devices from one another.
Semiconductor substrates are subjected to a significant number of individual processes during the fabrication of integrated circuitry thereon. These processes often include growth or deposition of material layers, ion doping or implanting, photolithography processes, etc. These processes may be preceded or followed by cleaning steps that involve, for example, scrubbing, spray cleaning, and other such processes. At the completion of cleaning, the substrate may be further processed to remove the cleaning agents and contaminant materials from the surface of the substrate to prevent the formation of contaminating residue on the substrate surface. Often, the last step in a cleaning process includes a rinsing step using clean, de-ionized water followed by a drying process.
For example, it is known in the art to spin a fabrication substrate about a rotational axis extending through the center of the substrate and perpendicular to a major plane thereof, while directing a stream of clean de-ionized water onto a surface of the substrate. A substrate may be placed in a spin rinse drier (SRD) that includes a platform coupled to a drive motor. The drive motor may cause the platform to spin at a velocity of, for example, up to 4,000 revolutions per minute (rpm). A stream of water may be directed onto the surface of the substrate while it is spinning to rinse contaminants from the surface of the substrate.
Typically, a rinse liquid is applied to an entire surface of the substrate, including the center of rotation thereof, which is a point on the surface at which the axis about which the substrate is rotated intersects the surface of the substrate to which liquid is applied and removed. As the substrate spins, centrifugal forces cause the liquid to fan out across the surface of the substrate, thereby forming a substantially continuous sheet or film of liquid covering the surface of the substrate. To dry the surface of the substrate, the substantially continuous sheet or film of liquid is removed from the surface of the substrate by interrupting the flow of liquid onto the surface of the substrate while continuing to spin the substrate. Centrifugal forces acting on the liquid cause it to slide off from (or otherwise be removed from) the surface of the substrate in a generally radially outward direction from the center of rotation toward the lateral edges of the substrate.
Often, traces or residue of contaminant material or other unwanted matter, which may be referred to as “water marks” or “doilies,” are left behind on the surface of the substrate after the liquid has been removed from the substrate. These traces or residue may include solid matter such as, for example, silica or other materials left behind by prior processing of the substrate, and generally are undesirable as they may interfere with subsequent processing of the substrate. For example, if the rinse process is followed by an etch process in which a portion of the substrate underlying a water mark is to be etched, the solid matter forming the water mark may act as a mask to prevent or block the etch process on the underlying surface of the subject, thereby generating a defect in the structure being defined by the etch on the substrate. If the rinse process is followed by an ion implant process, in which ions of a selected material are to be implanted in a portion of the substrate underlying a water mark, the solid matter forming the water mark may prevent or block the ion implant process, thereby generating a defect in the portion of the substrate, such as a source or drain region, being implanted.
In view of the foregoing, it would be desirable to provide methods and systems for rinsing and drying a semiconductor substrate such as a wafer that minimizes water marks or other contaminant residue or matter left behind on the surface of the substrate.
BRIEF SUMMARY OF THE INVENTION
In one aspect, the present invention includes a method for processing a semiconductor substrate which, for the sake of convenience, may also be termed a “fabrication substrate” herein to signify its status as a semiconductor substrate under fabrication. The fabrication substrate is continuously spun about an axis of rotation while a stream of liquid is directed onto a surface of the fabrication substrate and, in so doing, a substantially continuous annular-shaped sheet or film of the liquid is formed on the surface of the fabrication substrate. The annular-shaped sheet or film of liquid has an inner diameter defining a substantially liquid-free void. The substantially continuous annular-shaped sheet or film of liquid is then manipulated by one or more techniques to reduce a size of the inner diameter of the annular-shaped sheet or film. The substantially liquid-free void may then be enlarged until the surface is substantially dry.
In yet another aspect, the present invention includes a method for processing a semiconductor substrate with a liquid. The semiconductor substrate is continuously spun about a rotational axis, and liquid is introduced onto a contact area on a surface of the semiconductor substrate. The area or region on the surface of the semiconductor substrate onto which the stream of liquid is directed is referred to herein as a “contact area.” The contact area is positioned at a first position on the surface of the semiconductor substrate that includes an intersection between the surface of the substrate and the rotational axis. The contact area is moved in a radially outward direction from the first position to a second position to form a substantially annular-shaped sheet or film of the liquid on the surface of the semiconductor substrate. The contact area does not include the intersection between the surface of the semiconductor substrate and the rotational axis in the second position. The contact area is then moved in a radially inward direction from the second position to a third position located radially between the first position and the second position to reduce an inner diameter of the substantially annular-shaped sheet or film of the liquid. The contact area does not include the intersection between the surface of the semiconductor substrate and the rotational axis in either the second position or the third position.
In an additional aspect, the present invention includes a system for processing a fabrication substrate. The system includes a rotatable support member configured to support a fabrication substrate to be processed using the system, a rotation actuator device coupled to the support member and configured to rotate the support member about a rotational axis, and means for dispensing liquid onto a contact area on a surface of the fabrication substrate. The means for dispensing liquid may include at least one liquid-dispensing device that is configured and located to dispense liquid onto a contact area on the surface of the fabrication substrate to be carried by the support member. The system further includes a computer device in communication with the means for dispensing liquid, and the computer device is configured under control of a program to provide the contact area in a first position that includes an intersection between the surface of the fabrication substrate as carried by the support member and the rotational axis, to move the contact area in a radially outward direction from the first position to a second position, and to move to the contact area in a radially inward direction from the second position to a third position radially between the first position and the second position. The contact area does not include the intersection between the surface of the fabrication substrate and the rotational axis in either the second position or the third position.
The features, advantages, and alternative aspects of the present invention will be apparent to those skilled in the art from a consideration of the following detailed description taken in combination with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming that which is regarded as the present invention, the advantages of this invention can be more readily ascertained from the following description of the invention when read in conjunction with the accompanying drawings in which:
FIG. 1 is a cross-sectional side view of a system for removing liquid from a fabrication substrate in accordance with teachings of the present invention;
FIGS. 2A-2D are top plan views of the fabrication substrate shown in FIG. 1 illustrating sequential contact areas of liquid directed toward the surface of the fabrication substrate by at least one liquid-dispensing element of the system shown in FIG. 1 ;
FIGS. 3A-3D are top plan views like those shown in FIGS. 2A-2D illustrating an additional contact area resulting from the direction of additional liquid toward the surface of the fabrication substrate;
FIG. 4A is a side view of a fabrication substrate and another embodiment of a liquid-dispensing element that may be used in the system shown in FIG. 1 ;
FIG. 4B is a top plan view of the fabrication substrate and the liquid-dispensing element shown in FIG. 4A ; and
FIG. 5 is a top plan view of a fabrication substrate and another embodiment of a liquid-dispensing element that may be used in the system shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
In the description which follows, like features and elements have been identified by the same or similar reference numerals for ease of identification and enhanced understanding of the disclosure hereof. Such identification is by way of convenience for the reader only, however, and is not limiting of the present invention or an implication that features and elements of various components and embodiments identified by like reference numerals are identical or constrained to identical functions.
An illustrative system 10 that embodies teachings of the present invention is shown in FIG. 1 . By way of example and not limitation, the system 10 may function as a spin, rinse, dry (SRD) system. The system 10 may include a rotatable support member 12 that is configured to support a fabrication substrate 14 such as, for example, a full or partial semiconductor wafer or other bulk semiconductor substrate that is to be processed using the system 10 . For example, the support member 12 may comprise a substantially planar member. The fabrication substrate 14 may be secured to the support member 12 by, for example, using a vacuum chuck or one or more mechanical clamps. In other embodiments, the rotatable support member 12 may include a plurality of structurally supported rollers configured to contact and grip the fabrication substrate 14 substantially along the peripheral edges thereof, as known in the art. The particular shape or configuration of the support member 12 does not contribute to the present invention, and as such, systems including any type or configuration of a support member 12 are within the scope of the present invention.
The system 10 may further include a rotation actuator device 16 that is operatively coupled to, or otherwise associated with, the support member 12 and configured to cause the support member 12 to rotate about a rotational axis 20 . By way of example and not limitation, the rotation actuator device 16 may include an electrical motor configured to spin a shaft 18 at a selectively variable speed, and the shaft 18 may be structurally coupled to the support member 12 . The rotation actuator device 16 may be configured to spin the shaft 18 and the support member 12 in either a clockwise or counter-clockwise direction, as indicated by the directional arrow 17 shown in FIG. 1 . In additional embodiments, the rotation actuator device 16 may be directly coupled to the support member 12 without the use of an intermediate shaft 18 or other element for transmitting the kinetic energy generated by the rotation actuator device 16 to the support member 12 .
The system 10 also includes one or more liquid dispensers 22 , each of which may be configured and located to direct at least one stream of liquid 24 selectively toward a surface 15 of the fabrication substrate 14 . By way of example and not limitation, each liquid dispenser 22 may include a simple open-ended tube or conduit or a liquid-dispensing nozzle coupled to an outlet of a tube or conduit in communication with a liquid source. The stream of liquid 24 may include a substantially continuous column of liquid 24 , or a spray or drip of substantially discontinuous droplets of liquid 24 . Systems that embody teachings of the present invention, however, may include any other type or configuration of a liquid-dispensing element as long as the liquid-dispensing element is configured and oriented to direct a stream of liquid 24 onto at least one surface 15 of the fabrication substrate 14 .
In one particular embodiment shown in FIG. 1 , the system 10 may include two liquid dispensers 22 , each configured, located and oriented to direct a stream of liquid 24 toward a surface of the fabrication substrate 14 . Liquid supply lines 30 may be used to supply liquid 24 from a liquid source (not shown) to the one or more liquid dispensers 22 . Selectively controllable flow valves 32 may be provided in the liquid supply lines 30 for selectively controlling the flow of liquid 24 through the liquid supply lines 30 to the liquid dispensers 22 .
A liquid dispenser actuator 26 may be coupled to or otherwise operatively associated with each liquid dispenser 22 and configured to cause the liquid dispenser 22 to dispense a stream of liquid 24 onto a selected, or desired, contact area on the surface of the fabrication substrate 14 (e.g., by selectively moving the liquid dispenser 22 ), as discussed in further detail below.
By way of example and not limitation, each liquid dispenser actuator 26 may be configured to move a liquid dispenser 22 in a linear direction relative to the fabrication substrate 14 as indicated by the directional arrows 27 in FIG. 1 . Additionally, and without limiting the scope of the present invention, each liquid dispenser actuator 26 may be supported by and cooperate with a stationary member 28 , such as that shown in FIG. 1 . The stationary member 28 may include, for example, a simple horizontally extending arm that is structurally coupled to an outer housing 54 of the system 10 . Any other type or configuration of stationary member 28 may be used in the system 10 . By way of example and not limitation, each liquid dispenser actuator 26 may include an electromechanical device comprising an electrically driven gear set cooperative with teeth on the stationary member 28 , a stepper motor cooperative with stationary member 28 , or a pneumatically or hydraulically driven piston attached at one end to the stationary member 28 .
In additional embodiments, systems that incorporate teachings of the present invention may include liquid dispensers 22 that move in any other manner (e.g., nonlinear) or direction relative to the fabrication substrate 14 or liquid dispensers 22 that are stationary relative to the fabrication substrate 14 but capable of altering the position at which a stream of liquid 24 dispensed thereby contacts the surface 15 of the fabrication substrate 14 . For example, systems that embody teachings of the present invention may include liquid dispensers 22 that are stationary relative to fabrication substrate 14 and configured to selectively vary the position at which the stream of liquid 24 dispensed thereby contacts the surface of the fabrication substrate 14 in response to selective variations in the liquid pressure at which the liquid 24 is dispensed from the liquid dispensers 22 . Furthermore, systems that incorporate teachings of the present invention may be configured to move a fabrication substrate in a lateral direction in the X-Y plane parallel to the major plane of the fabrication substrate relative to a stationary liquid dispenser 22 and/or stream of liquid 24 dispensed thereby.
The system 10 may include a liquid container 36 positioned to laterally surround the fabrication substrate 14 and configured to capture liquid 24 dispensed from the liquid dispensers 22 as the liquid 24 is spun off of the fabrication substrate 14 . For example, the liquid container 36 may include a bottom wall 38 and at least one lateral sidewall 40 . At least a portion of the lateral sidewall 40 may be configured to deflect liquid 24 into the container 36 toward the bottom wall 38 as the liquid 24 is spun off of the fabrication substrate 14 and impinges against the lateral sidewall 40 . As shown in FIG. 1 , the liquid container 36 may be generally configured as a bowl having a bottom wall 38 , a sidewall 40 , and a top opening 42 through which a fabrication substrate 14 may be positioned on the support member 12 . At least a portion of the sidewall 40 may be disposed at an angle with respect to the fabrication substrate 14 and oriented to deflect liquid 24 spinning off from the fabrication substrate 14 towards the bottom wall 38 and into the liquid container 36 . The liquid container 36 also may include a drain 44 for removing liquid 24 from the container 36 for disposal, recycling, or further processing.
The liquid container 36 may be configured to move relative to the support member 12 between a first position in which the support member 12 is substantially disposed outside the liquid container 36 and a second position in which the support member 12 is substantially disposed inside the liquid container 36 . In such a configuration, placement of a fabrication substrate 14 onto the support member 12 may be facilitated while the liquid container 36 is in the first position, and capture of the liquid 24 spun off of the fabrication substrate 14 by the liquid container 36 may be facilitated while the liquid container 36 is in the second position during processing.
By way of example and not limitation, the system 10 may include a container actuator 46 such as, for example, an electromechanical device or motor, or a pneumatically or hydraulically actuated cylinder that is operatively coupled to a drive shaft 48 . The drive shaft 48 may be structurally coupled to the liquid container 36 . In this configuration, the container actuator 46 may be configured to selectively move the liquid container 36 in a vertical direction (as indicated by the directional arrow 50 ) back and forth between a first position in which the support member 12 is substantially disposed outside the liquid container 36 and a second position in which the support member 12 is substantially disposed inside the liquid container 36 . The liquid container 36 is shown in the second position in FIG. 1 .
In additional embodiments, the rotatable support member 12 may be configured to move up and down in the vertical direction relative to the liquid container 36 instead of, or in addition to, the liquid container 36 being configured to move up and down in the vertical direction as previously discussed. Furthermore, the rotatable support member 12 and the liquid container 36 may be stationary relative to one another.
Optionally, an outer housing 54 may be used to substantially enclose the various components of the system 10 .
The system 10 also may include a computer device such as, for example, a programmable logic controller 58 or other electronic controlling device including, for example, at least one processor operably coupled to communicate with at least some of the active, controllable elements or components of the system 10 . By way of example and not limitation, the programmable logic controller 58 may communicate with and be configured to selectively control the liquid dispenser actuators 26 for moving the streams of liquid 24 dispensed by the liquid dispensers 22 , the flow control valves 32 , the rotation actuator device 16 for rotating or spinning the support member 12 , and the container actuator 46 for moving the position of the liquid container 36 . The programmable logic controller 58 also may communicate with and be configured to selectively control other active, controllable elements or components of the system 10 that are not shown in FIG. 1 or described herein.
In this configuration, the programmable logic controller 58 may be programmed by way of computer software or code to spin, rinse, and dry a fabrication substrate 14 in accordance with a method that embodies teachings of the present invention and facilitates rinsing and drying of a fabrication substrate 14 while minimizing or eliminating water marks or other residues or matter left behind on the surface of the fabrication substrate 14 .
In at least a portion of a processing sequence, the programmable logic controller 58 may be programmed to continuously rotate, or spin, a fabrication substrate 14 about the rotational axis 20 while directing at least one stream of liquid 24 onto a contact area 62 on the surface 15 of the fabrication substrate 14 . Referring to FIG. 2A in combination with FIG. 1 , the programmable logic controller 58 may be programmed to cause at least one liquid dispenser 22 to direct a stream of liquid 24 onto the surface 15 of the fabrication substrate 14 such that the contact area 62 is in a first, central position that includes an intersection between the surface 15 of the fabrication substrate 14 and the rotational axis 20 . This intersection between the surface 15 of the fabrication substrate 14 and the rotational axis 20 (see FIG. 1 ) may define a center of rotation 21 on the surface 15 of the substrate 14 , illustrated in FIGS. 2A-2D . The surface 15 of the fabrication substrate 14 may be substantially covered by a sheet or film of the liquid 24 dispensed from the liquid dispenser 22 ( FIG. 1 ) as the liquid 24 flows from the contact area 62 in a radially outward direction toward the peripheral edges 34 (e.g., circumference) of the fabrication substrate 14 . In this manner, the liquid 24 rinses the surface 15 of the fabrication substrate 14 . Optionally, at least one additional stream of liquid 24 may be directed onto one or more additional contact areas on the surface 15 of the surface of the fabrication substrate 14 , as discussed in further detail below.
Referring to FIG. 2B in combination with FIG. 1 , the programmable logic controller 58 may be programmed to move the liquid dispenser 22 (while continuing to dispense liquid 24 from the liquid dispenser 22 ) such that the contact area 62 moves in a radially outward direction from the first position shown in FIG. 2A to a second position shown in FIG. 2B to form a substantially circular, substantially dry region 68 on the surface 15 of the fabrication substrate 14 that is centered about the rotational axis 20 .
In this second position shown in FIG. 2B , the contact area 62 does not include the center of rotation 21 . The contact area 62 may be moved in a radially outward direction from the first position shown in FIG. 2A to the second position shown in FIG. 2B by a distance at which an outer periphery 63 of the contact area 62 is separated from the rotational axis 20 by a distance X 1 that is illustrated in FIG. 2B . A substantially continuous annular-shaped sheet or film of liquid 24 may cover the regions on the surface 15 of the fabrication substrate 14 surrounding the substantially circular, substantially dry region 68 as the liquid 24 flows from the contact area 62 in a radially outward direction toward the peripheral edges 34 of the fabrication substrate 14 . The substantially continuous annular-shaped sheet or film of liquid 24 may have an inner diameter 72 that defines a void in the sheet or film of liquid 24 through which the substantially circular, substantially dry region 68 on the surface 15 of the fabrication substrate 14 is exposed.
By forming the substantially circular dry region 68 , the liquid 24 in the annular-shaped sheet or film of liquid 24 may be more readily spun off from the surface 15 of the fabrication substrate 14 relative to liquid 24 in a substantially continuous sheet or film substantially covering the surface 15 of the fabrication substrate 14 . Any finite area or region of liquid 24 on the surface 15 of a spinning fabrication substrate 14 may be subjected to both centrifugal forces and surface tension forces exerted on the area or region of liquid 24 by the surrounding liquid 24 . A finite area or region of liquid 24 located on the surface 15 of the fabrication substrate 14 may be subjected to surface tension forces by a portion of liquid 24 on the surface 15 of the fabrication substrate 14 radially inward thereof, relative to the rotational axis 20 . These surface tension forces may work against the centrifugal forces acting on the finite area or region of liquid 24 . By forming the substantially circular substantially dry region 68 , the surface tension acting on the liquid 24 that directly counteracts the centrifugal forces may be minimized or eliminated, thereby facilitating removal of the liquid 24 from the surface 15 of the fabrication substrate 14 by the centrifugal forces.
As a non-limiting example, the distance X 1 may be greater than about five percent (5%) of the distance across the surface 15 of the semiconductor fabrication substrate 14 (e.g., the diameter D shown in FIG. 2A ). Accordingly, the inner diameter 72 of the annular-shaped sheet or film of liquid 24 may be greater than about ten percent (10%) of the distance across the surface 15 of the semiconductor fabrication substrate 14 (e.g., the diameter D shown in FIG. 2A ).
As the contact area 62 is moved from the first position shown in FIG. 2A to the second position shown in FIG. 2B , droplets of liquid 24 may splash onto the regions of the surface 15 of the fabrication substrate 14 radially inward from the contact area 62 (i.e., on the substantially circular, substantially dry region 68 ). These droplets of liquid 24 may leave water marks, residue, or other unwanted matter on the surface 15 of the fabrication substrate 14 . To minimize deposition of such water marks, residue, or other unwanted matter on the surface 15 of the fabrication substrate 14 by these droplets, the programmable logic controller 58 may be programmed to cause the liquid dispenser 22 or dispensers 22 to move the contact area 62 radially inward from the second position shown in FIG. 2B to a third position shown in FIG. 2C that is radially between the first position shown in FIG. 2A and the second position shown in FIG. 2B , thereby reducing (but not eliminating) the diameter of the substantially circular, substantially dry region 68 and the inner diameter 72 of the annular-shaped sheet or film of liquid 24 . In the third position shown in FIG. 2C , the outer periphery 63 of the contact area 62 may be separated from center of rotation 21 by a distance X 2 that is illustrated in FIG. 2C . Thus, the contact area 62 does not include the center of rotation 21 in the third position shown in FIG. 2C .
It may be desirable to provide a distance X 2 that is as small as possible without causing the liquid 24 to cover the center of rotation 21 and forming a substantially continuous sheet of liquid 24 that substantially covers the surface 15 of the fabrication substrate 14 . By way of example and not limitation, the distance X 2 shown in FIG. 2C may be less than about five percent (5%) of the distance across the surface 15 of the fabrication substrate 14 (e.g., the diameter D shown in FIG. 2A ), and, accordingly, the inner diameter 72 of the annular-shaped sheet or film of liquid 24 may be less than about ten percent (10%) of the distance across the surface 15 of the fabrication substrate 14 (e.g., the diameter D shown in FIG. 2A ). Furthermore, the diameter of the substantially circular, substantially dry region 68 and the inner diameter 72 of the annular-shaped sheet or film of liquid 24 may be less than about one centimeter (1 cm) in the third position shown in FIG. 2C .
If the contact area 62 is moved from the first position shown in FIG. 2A directly to the third position shown in FIG. 2C , the surface tension of the liquid 24 may prevent the formation of the relatively smaller substantially circular dry region 68 shown in FIG. 2C . Therefore, the contact area 62 may be moved from the first position shown in FIG. 2A to the second position shown in FIG. 2B by a distance that is large enough to cause formation of the substantially circular dry region 68 . The contact area 62 may then be moved to the third position shown in FIG. 2C , at which the size of the substantially circular dry region 68 may be minimized without causing the liquid 24 to substantially cover the surface 15 of the fabrication substrate 14 (entirely removing the substantially circular, substantially dry region 68 ). Moreover, as the contact area 62 is moved from the first position shown in FIG. 2A to the second position shown in FIG. 2B , droplets of liquid 24 may be spattered or sprayed or otherwise deposited onto the substantially circular, substantially dry region 68 . By moving the contact area 62 from the second position shown in FIG. 2B to the third position shown in FIG. 2C , these droplets of liquid 24 may be captured by or incorporated into the annular-shaped sheet or film of liquid 24 , thereby facilitating complete removal of the liquid 24 from the surface 15 of the fabrication substrate 14 .
The programmable logic controller 58 may be programmed to cause the liquid dispensers 22 to direct a stream of liquid 24 toward the first position shown in FIG. 2A , the second position shown in FIG. 2B , and the third position shown in FIG. 2C for predetermined amounts of time ranging from about zero seconds to several minutes or longer, as necessary or desired.
After the liquid dispensers 22 have been caused to position the contact area 62 of a stream of liquid 24 in the third position shown in FIG. 2C , contact between the stream of liquid 24 impinging on the contact area 62 and the surface 15 of the fabrication substrate 14 may be interrupted while continuing to spin the fabrication substrate 14 to remove the liquid 24 from the surface 15 of the fabrication substrate 14 . For example, the programmable logic controller 58 may be configured to close one or more flow control valves 32 after the liquid dispensers 22 have positioned the contact area 62 in the third position shown in FIG. 2C . As the fabrication substrate 14 continues to spin after interrupting the stream of liquid 24 impinging on the contact area 62 , the inner diameter 72 of the annular-shaped sheet or film of liquid 24 may progress in a radially outward direction towards the peripheral edge 34 (e.g., circumference) of the fabrication substrate 14 , as indicated by the directional arrows 74 in FIG. 2D , until substantially all the liquid 24 has been spun off of the surface 15 of the fabrication substrate 14 . In other embodiments, the contact area 62 may be moved from the third position shown in FIG. 2C in a radially outward direction towards and beyond the peripheral edge 34 of the fabrication substrate 14 instead of closing one or more flow control valves 32 to interrupt the flow of liquid 24 onto the contact area 62 .
By way of example and not limitation, the fabrication substrate 14 may be spun at a rate greater than about 500 revolutions per minute while directing a stream of liquid 24 onto the surface 15 of the fabrication substrate 14 . More particularly, the fabrication substrate 14 may be spun at a rate of greater than about 4,000 revolutions per minute while directing a stream of liquid 24 onto the surface 15 of the fabrication substrate 14 . Furthermore, the fabrication substrate 14 may be spun at a rate or rates greater than about 2,000 revolutions per minute while the contact area 62 is in each of the first position shown in FIG. 2A , the second position shown in FIG. 2B , and the third position shown in FIG. 2C , and at a rate or rates between about 500 revolutions per minute and about 1,000 revolutions per minute after interrupting contact between the stream of liquid 24 impinging on the surface 15 of the fabrication substrate 14 at the contact area 62 . In general, an optimum rate of rotation may be at least partially a function of the size of the fabrication substrate 14 , with smaller fabrication substrates 14 possibly requiring greater rates of rotation.
Optionally, at least one additional stream of liquid 24 may be directed onto the surface 15 of the fabrication substrate 14 . For example, as liquid 24 spreads out across the surface 15 of the fabrication substrate 14 , voids in the sheet or film of liquid 24 may occur near the peripheral edges 34 of the fabrication substrate 14 . Such voids may contribute to the deposition of water marks, residue, or other unwanted matter on the surface 15 of the fabrication substrate 14 , and may be undesirable. Referring to FIG. 3A in combination with FIG. 1 , the programmable logic controller 58 may be programmed to concurrently direct at least one additional stream of liquid 24 onto at least one additional contact area 64 on the surface 15 of the fabrication substrate 14 to prevent or reduce the occurrence of voids in the sheet or film of liquid 24 near the peripheral edges 34 of the fabrication substrate 14 .
FIGS. 3A-3D are similar to FIGS. 2A-2D respectively, and illustrate the use of an additional stream of liquid 24 to rinse the surface 15 of the fabrication substrate 14 to prevent or minimize the occurrence of voids in the sheet or film of liquid 24 proximate the peripheral edges 34 of the fabrication substrate 14 . Referring to FIG. 3A , the programmable logic controller 58 may be programmed to cause at least one liquid dispenser 22 to direct a stream of liquid 24 onto an additional contact area 64 on the surface 15 of the fabrication substrate 14 . The second contact area 64 may be positioned on the surface 15 of the fabrication substrate 14 so as not to include or cover the center of rotation 21 .
As illustrated in FIGS. 3A-3C , the additional stream of liquid 24 may be directed onto the surface 15 of the fabrication substrate 14 while the first contact area 62 is in one or more of the first position shown in FIG. 3A , the second position shown in FIG. 3B , and the third position shown in FIG. 3C . The additional stream of liquid 24 may be directed onto the surface 15 of the fabrication substrate 14 while the first contact area 62 is in each of the first position shown in FIG. 3A , the second position shown in FIG. 3B , and the third position shown in FIG. 3C . Additionally, the additional liquid 24 may be directed onto the surface 15 of the fabrication substrate 14 while the first contact area 62 is in only the second position shown in FIG. 3B and the third position shown in FIG. 3C , or only while the first contact area 62 is in the third position shown in FIG. 3C . Furthermore, the position of the additional contact area 64 on the surface 15 of the fabrication substrate 14 may vary as the first contact area 62 moves between the first position shown in FIG. 3A , the second position shown in FIG. 3B , and the third position shown in FIG. 3C .
As shown in FIG. 3A , the fabrication substrate 14 may have a diameter D. By way of example and not limitation, an outer periphery 65 of the second contact area 64 may be separated from the rotational axis 20 by a distance X 3 that is greater than about fifty percent (50%) of the diameter D ( FIG. 2A ) of the fabrication substrate 14 while the first contact area 62 is in the first position shown in FIG. 3A , the second position shown in FIG. 3B , and the third position shown in FIG. 3C .
As shown in FIG. 3D , a stream of liquid 24 may continue to be directed onto the additional contact area 64 until the inner diameter 72 of the annular-shaped sheet or film of liquid 24 approaches or reaches the additional contact area 64 after closing a flow control valve 32 to interrupt the stream of liquid 24 being directed at the first contact area 62 of the surface 15 of the fabrication substrate 14 . As the inner diameter 72 of the annular-shaped sheet or film of liquid 24 approaches or reaches the outer periphery 65 of the additional contact area 64 , the stream of liquid 24 being directed at or impinging on the additional contact area 64 on the surface 15 of the fabrication substrate 14 may also be interrupted while continuing to spin the fabrication substrate 14 until the liquid 24 has been substantially completely removed from the surface 15 of the fabrication substrate 14 .
In the systems and methods previously described in relation to FIGS. 1 , 2 A- 2 D, and 3 A- 3 D, the contact area 62 is moved relative to the surface 15 of the fabrication substrate 14 along a substantially linear path disposed along a line that includes the center of rotation 21 . As an alternative or in addition, the contact area 62 may be moved relative to the surface 15 of the fabrication substrate 14 along a curved or curvilinear path or any other nonlinear path.
Another embodiment of a liquid dispenser 76 is shown in FIG. 4A that may be used in the system 10 shown in FIG. 1 . The liquid dispenser 76 may be configured to dispense a stream of liquid 24 in a lateral or horizontal direction relative to the surface 15 of the fabrication substrate 14 , as shown in FIG. 4A . By way of example and not limitation, the liquid dispenser 76 may include a tube or conduit portion 78 and an outlet portion 80 configured to dispense a stream of liquid 24 in a lateral direction relative to the surface 15 of the fabrication substrate 14 . The liquid 24 may fall onto a contact area 62 on the surface 15 of the fabrication substrate 14 that is laterally spaced from the liquid dispenser 76 , as shown in FIG. 4A . In this configuration, the position of the contact area 62 may be selectively moved across the surface 15 of the fabrication substrate 14 by, for example, rotating the liquid dispenser 76 about a dispenser axis 86 . Referring the FIG. 4B , in such a configuration, the contact area 62 may be moved to a first position, from the first position to a second position, and from the second position, to a third position in accordance with the method described in reference to the first contact area 62 shown in FIGS. 2A-2C , by selectively rotating the liquid dispenser 76 about the dispenser axis 86 .
The liquid dispenser 76 is shown in FIG. 4B rotated to a position about the dispenser axis 86 such that the contact area 62 is disposed in a first position that includes or covers the center of rotation 21 . In at least a portion of a processing sequence, a programmable logic controller 58 ( FIG. 1 ) may be programmed to rotate the liquid dispenser 76 about the dispenser axis 86 from the first position to a second position 88 such that the contact area 62 moves in a radially outward direction from the first position to a second position 90 to form a substantially circular, substantially dry region on the surface 15 of the fabrication substrate 14 having an outer diameter approximately represented by dashed line 92 . Moreover, the programmable logic controller 58 ( FIG. 1 ) may be programmed to rotate the liquid dispenser 76 about the dispenser axis 86 from the second position 88 to a third position 94 such that the contact area 62 moves in a radially inward direction from the second position 90 to a third position 96 to reduce the diameter of the substantially circular, substantially dry region to a size approximately represented by dashed line 98 .
In this manner, the liquid dispenser 76 may be selectively rotated or moved about the dispenser axis 86 to selectively move the contact area 62 to a first position including the center of rotation 21 , from the first position radially outward to a second position 90 , and from the second position 90 radially inward to a third position 96 in accordance with the method previously described in reference to FIGS. 2A-2C .
In the systems and methods previously described herein, the contact area 62 is moved relative to the surface 15 of the fabrication substrate 14 by moving the position of the one or more liquid dispensers 22 , 76 relative to the surface 15 of the fabrication substrate 14 . In other examples of systems and methods that embody teachings of the present invention, the contact area 62 may be moved relative to the surface 15 of the fabrication substrate 14 by means other than a moveable liquid dispenser 22 , 76 .
For example, the system 10 ( FIG. 1 ) may include a liquid dispenser 99 as shown in FIG. 5 , which may be configured to have a size and shape similar to the liquid dispenser 76 shown in FIG. 4A . The liquid dispenser 99 may be positioned relative to the surface 15 of the fabrication substrate 14 radially outward from the center of rotation 21 , and oriented such that an outlet portion 80 of the liquid dispenser 99 directs a stream of liquid 24 (not shown in FIG. 5 ) emitted thereby in a radially inward direction toward the center of rotation 21 . In such a configuration, the liquid dispenser 99 may be configured to selectively vary the position of the contact area 62 between the stream of liquid 24 and the surface 15 of the fabrication substrate 14 by selectively varying the pressure of the liquid 24 inside the liquid dispenser 76 . The system 10 ( FIG. 1 ) may include a selectively variable pressure control valve (not shown) in or along the fluid liquid supply lines 30 , and the programmable logic controller 58 may communicate with and be configured to selectively control the selectively variable pressure control valve.
In this configuration, the programmable logic controller 58 ( FIG. 1 ) may be programmed to vary the pressure of the liquid 24 inside the liquid dispenser 99 , thereby selectively moving the contact area 62 on the surface 15 of the fabrication substrate 14 . The programmable logic controller 58 may be programmed to move the contact area 62 (by varying the pressure of the liquid 24 in the liquid dispenser 99 ) to a first position that includes the center of rotation 21 (which may allow liquid 24 to substantially cover the surface 15 of the fabrication substrate 14 ), from the first position radially outward to a second position 100 , and from the second position 100 radially inward to a third position 102 , in a manner substantially similar to those previously described in reference to FIGS. 2A-2D . As such, it may not be necessary to displace (e.g., move or rotate) the liquid dispenser 99 relative to the surface 15 of the fabrication substrate 14 in order to move the contact area 62 according to methods that incorporate teachings of the present invention.
Each of the methods described herein includes forming a substantially continuous annular-shaped sheet or film of liquid 24 on the surface 15 of a spinning fabrication substrate 14 , the annular-shaped sheet or film of liquid 24 having an inner diameter 72 defining a void in the sheet or film of liquid 24 , as well as reducing the size of the inner diameter 72 of the annular-shaped sheet or film of liquid 24 , then subsequently enlarging the inner diameter 72 of the annular-shaped sheet or film of liquid 24 until substantially no liquid 24 remains on the surface 15 of the fabrication substrate 14 .
In any of the previously described systems and methods, a stream of air or gas (such as, for example, clean dry air, nitrogen or another inert gas, etc.) may be directed at the surface 15 of the fabrication substrate 14 to facilitate the formation of a substantially circular, substantially dry region, such as the substantially circular, substantially dry region 68 shown in FIGS. 2B-2D . Referring to FIGS. 2A and 2B , and by way of example and not limitation, a stream of air or gas may be directed at the surface 15 of the fabrication substrate 14 at or proximate to the center of rotation 21 of the fabrication substrate 14 as the contact area 62 is moved from the first position shown in FIG. 2A to the second position shown in FIG. 2B . The stream of air or gas may continue to be directed at the surface 15 of the fabrication substrate 14 while the contact area 62 is in the second position shown in FIG. 2B , the third position shown in FIG. 2C , and until the liquid 24 has been substantially removed from the surface 15 of the fabrication substrate 14 after interrupting the flow of liquid 24 onto the contact area 62 .
The inventors of the present invention have discovered, however, that by moving a contact area 62 in the manners and sequences previously described herein, the deposition of water marks, residue, or other unwanted matter on the surface 15 of a fabrication substrate 14 may be substantially minimized or eliminated. In this manner, the methods and systems of the present invention may facilitate rinsing and drying of a fabrication substrate while minimizing the deposition of water marks, contaminant residue, or other unwanted matter onto the surface of the substrate. Furthermore, methods and systems that embody teachings of the present invention may allow the liquid to be removed from the surface of a fabrication substrate faster than conventional methods and systems, and as a result, may reduce the amount of time required to dry semiconductor substrates. For example, methods and systems that embody teachings of the present invention may allow the liquid to be removed from the surface of a fabrication substrate up to twenty-percent (20%) faster than conventional methods and systems.
While systems that embody teachings of the present invention have been described in relation to what are referred to as spin, rinse, and dry (SRD) systems, the teachings of the present invention may be equally applicable to other semiconductor fabrication processes and systems in which a liquid is dispensed onto and removed from at least one surface of a spinning fabrication substrate. This may be particularly so in fabrication processes that involve liquids in which the surface tension of the liquid affects the removal of the liquid from the surface of the spinning fabrication substrate. By way of example and not limitation, wet etch systems and chemical-mechanical polishing (CMP) systems may also embody teachings of the present invention. As such, liquids dispensed from systems that embody teachings of the present invention may include clean de-ionized water, acids, solvents, or any other single- or multi-component liquid, solution, suspension or emulsion.
While the present invention has been described in terms of certain illustrated embodiments and variations thereof, it will be understood and appreciated by those of ordinary skill in the art that the invention is not so limited. Rather, additions, deletions and modifications to the illustrated embodiments may be effected without departing from the spirit and scope of the invention as defined by the claims which follow.
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A semiconductor substrate undergoing processing to fabricate integrated circuit devices thereon is spun about a rotational axis while introducing liquid onto a surface of the substrate. An annular-shaped sheet of liquid is formed on the surface, the sheet of liquid having an inner diameter defining a liquid-free void. The size of a diameter of the void is reduced by manipulation of the annular-shaped sheet of liquid. The void may then be enlarged until the surface is substantially dry. The annular-shaped sheet of liquid may be formed and altered by selectively moving a contact area on the surface of the substrate on which the liquid is introduced. Systems for processing a substrate and configured to deposit and manipulate a sheet of liquid thereon are also disclosed.
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FIELD OF THE INVENTION
[0001] This invention pertains to mooring ropes and cables and more particularly it pertains to an anchor rode having an extensible segment built therein and a method for manufacturing this extensible segment.
BACKGROUND OF THE INVENTION
[0002] Stretchable cordage are used as mooring cables and anchor rodes for partly absorbing the stresses caused by wave actions on small boats, on buoys or on similar floating structures, for preventing damage to these crafts and floating structures and for preventing the loosening of their anchors. Stretchable cordage are also used as tow ropes for dampening the shocks of pulling an object from rest. Some of the stretchable cordage of the prior art are described in the following documents:
[0003] U.S. Pat. No. 4,258,608 issued on Mar. 31, 1981 to John L. Brown;
[0004] U.S. Pat. No. 4,426,908 issued on Jan. 24, 1984 to Martin Ullmann;
[0005] U.S. Pat. No. 4,534,262 issued on Aug. 13, 1985 to Richard C. Swenson;
[0006] U.S. Pat. No. 4,597,351 issued on Jul. 1, 1986 to Edward C. Brainard, II;
[0007] U.S. Pat. No. 5,483,911 issued on Jan. 16, 1996 to Ronald N. Kubli, and
[0008] CA 1,087,930 issued on Oct. 21, 1980 to Bertil Brandt.
[0009] Generally, the stretchable ropes of the prior art are made of a rubber rod or tube enclosed in the central portion of a rope. A tension on the rope causes the braided outside layer of the rope to compress the rubber core radially, which causes the rope to elongate, thus providing the rope with elastic properties. The length and diameter of the rubber core is proportional to these elastic properties.
[0010] An anchor rode is often partially wound on a capstan or around sheaves, and has shackles or knots at both ends thereof. Therefore, an anchor rode needs to be non-elastic along the segments thereof which are used for tying and along the segments susceptible to slippage and sharp bending. Hence, it is often desirable to make only a short segment of the anchor rode extensible as opposed to its full length.
[0011] In the past, this characteristic has raised difficulties in preventing the longitudinal movements of rubber core inside the base rope during repeated elongations and retractions of the rope. The methods of the prior art to retain the rubber core inside the base rope consists of using high strength tape and ring clips to squeeze the base rope at each end of the rubber core. It is believed that theses tapes and clips are subject to deterioration from fatigue stress and exposure to the harsh environment in which these ropes are used. Consequently, the ropes must be inspected often and repaired in order to maintain their integrity.
[0012] Moreover, the rubber cores in the stretchable ropes of the prior art are generally not subject to elongation with the outside layer of the base rope. The relative movement of the outside braided layer over the rubber core during repeated elongations and retractions causes friction and wear of the outside braided layer and of the rubber core. It will be appreciated that all relative movements between the outside braided layer and the rubber core have an adverse effect on the useful life of the rope.
[0013] Although the elastic cordage of the prior art deserve undeniable merits, it is believed that a need still exists for an extensible segment in an anchor rode, in which the rubber core does not move inside the braided outside layer of the base rope and consequently reduces the friction wear inside the base rope in order to prolong the useful life of the anchor rode.
SUMMARY OF THE INVENTION
[0014] In the present invention, there is provided an extensible segment in an anchor rode in which the rubber core is held longitudinally along the central axis of the base rope, to reduce friction related wear of the base rope and of the rubber core.
[0015] Broadly, the extensible segment in an anchor rode comprises a rubber core enclosed in a braided base rope along the central axis of the base rope. A braided cover further encloses an intermediate portion of the rubber core inside the base rope. The braided cover is made of braided cover strands embedded in the rubber core, and un-braided cover strands extending over the two ends of the rubber core. The un-braided cover strands are weaved into the base rope to retain the rubber core longitudinally inside the base rope.
[0016] The extensible segment according to the present invention is advantageous to disperse peak load in an anchor rode. Its construction prevents the rubber core to move along the base rope during repeated elongation and retractions of the rope, and enhances the resiliency of the extensible segment by applying tension as well as compression stresses to the rubber core. Friction generated by relative movement between the rubber core and the base rope is practically eliminated due the encapsulated braided cover being in contact with the braids of base rope.
[0017] Still another feature of the present invention is that it is susceptible of a low cost of manufacture with regard to both materials and labour, and which accordingly is then susceptible of low prices of sale to the consumer, thereby making such extensible segment economically available to the public.
[0018] Other advantages and novel features of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] One embodiment of this invention is illustrated in the accompanying drawings, in which like numerals denote like parts throughout the several views, and in which:
[0020] [0020]FIG. 1 is a perspective view of a rubber rod used to manufacture the extensible segment according to the preferred embodiment of the present invention;
[0021] [0021]FIG. 2 is a perspective view of the rubber rod enclosed in a braided cover;
[0022] [0022]FIG. 3 is a perspective view of the encapsulated rubber rod inserted into a base rope;
[0023] [0023]FIG. 4 is a perspective view of the encapsulated rubber rod inserted into the base rope, wherein the braided cover has been undone over a nominal distance at both ends of the rubber rod;
[0024] [0024]FIG. 5 is a partial view of the base rope with the encapsulated rubber rod inserted completely into the base rope, and the un-braided strands extending outside the base rope;
[0025] [0025]FIG. 6 is a partial view of the base rope with the encapsulated rubber rod inserted completely into the base rope, and the un-braided strands weaved into and with the braids of the base rope.
[0026] [0026]FIG. 7 is a partial view of an anchor rode having an extensible segment according to the preferred embodiment built therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will be described in details herein a specific embodiment, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and is not intended to limit the invention to the embodiment illustrated and described.
[0028] Referring to FIGS. 1 - 7 , the extensible segment 20 in an anchor rode according to the preferred embodiment comprises broadly, a rubber rod 22 encapsulated in a braided cover 24 . The braided cover 24 is embedded into the surface of the rubber rod 22 . The encapsulated rubber rod 26 forms the core of the extensible segment of a base rope 28 . The strands 30 of the braided cover 24 , at both ends of the encapsulated rubber rod 26 , are weaved into and with the braids 32 of the base rope 28 for retaining the rubber rod 22 firmly into and along the base rope 28 .
[0029] The preferred extensible segment 20 in an anchor rode comprises a rubber rod 22 having a diameter of about twenty-five (25) mm., and a length of about five (5) meters.
[0030] The preferred braided cover 24 embedded into the surface of the rubber rod 22 is made of high module polyethylene fibers which are applied at maximum pitch angle. The preferred braiding is referred to in the industry as twenty-four (24) carrier by two (2) ply, meaning there are forty-eight (48) strings of fibers that are paired; one half are left-handed, the other half are right-handed.
[0031] The preferred base rope 28 in which the rubber rod 22 is inserted is a twenty-five (25) mm., twelve (12) strand rope made of high module polyethylene.
[0032] A preferred method for manufacturing the extensible segment 20 is described as follows:
[0033] A. Obtaining an extruded rubber rod 22 as represented in FIG. 1. The preferred rubber rod is crude natural rubber, non-vulcanized, and having a durometer value of seventy (70).
[0034] B. Applying a tack coat on the rubber rod 22 and allow the coat to dry.
[0035] C. Passing the rubber rod through a braiding machine, and forming the braided cover 24 at maximum pitch angle over the rubber rod 22 .
[0036] D. After the braided cover 24 is formed over the rubber rod 22 , as illustrated in FIG. 2, the encapsulated rubber rod 26 , is placed in an oven and vulcanized to give the rubber its resilience and to cause the fibers of the braided cover 24 to sink into and become embedded into the surface of the rubber rod 22 . The encapsulated rubber rod 26 has an outside diameter of about thirty (30) mm.
[0037] E. A coat of urethane marine finish paint is then applied to the encapsulated rubber rod and is allowed to dry completely.
[0038] F. The encapsulated rubber rod 26 is then inserted into the base rope 28 as illustrated in FIG. 3. This is achieved by squeezing the base rope like an accordion to make room for the encapsulated rubber rod 26 to fit inside the base rope, and inserting the encapsulated rubber rod through the braids 32 of the base rope 28 without cutting any of the braids 32 of the base rope 28 .
[0039] G. Before completely inserting the encapsulated rubber rod 26 into the based rope 28 , a section ‘A’ of about half a meter of braiding at each end of the encapsulated rubber rod is undone to liberate six (6) strands 30 containing eight (8) strings of fibers per strand, as illustrated in FIG. 4.
[0040] H. The entire length of the encapsulated rubber rod 26 is then pulled inside the base rope 28 , until the un-braided strands 30 are entirely within the base rope 28 .
[0041] I. The base rope 28 is pulled tight over the encapsulated rubber rod 26 to remove and wrinkle in the base rope 28 and to smoothen the base rope 28 over the encapsulated rubber rod 26 .
[0042] J. The un-braided strands 30 are then extracted from the base rope 28 , as illustrated in FIG. 5, using a pointed tool. The strands 30 of the braided cover are extracted at equal intervals around the circumference of the base rope 28 . The strands 30 of the braided cover are extracted through the base rope at the same place ‘A’ they leave the rubber rod 22 .
[0043] K. Once the strands 30 of the braided cover 24 have been extracted, these are pulled firmly and evenly.
[0044] L. The six (6) un-braided strands 30 are then weaved into the base rope 28 as illustrated in FIG. 6, by a process referred to as “over and under”. This process is carried out until all the un-braided strands 30 are tucked into the base rope 28 .
[0045] M. The other end of the extensible segment 20 is done in a same manner by repeating the steps J, K and L.
[0046] The extensible segment 20 according to the preferred embodiment is made relatively quickly, without cutting any braid in the base rope or otherwise affecting the tensile strength of the base rope 28 . The rubber rod 22 is held firmly inside the base rope 28 by the un-braided strands 30 such that there is no movement of the rubber core 22 inside the base rope 28 .
[0047] Furthermore, the weaving of the strands 30 of the braided cover 24 into the braids 32 of the base rope 28 transmits some of the longitudinal stresses in the base rope 28 to the rubber rod 22 causing the rubber rod 22 to stretch with the rope. Hence the rubber rod 22 is subject to both tensile stresses and compression stresses. The stiffness of the extensible segment 20 is thereby increased.
[0048] It will be appreciated that rubber rods and base ropes with other dimensions will provide extensible segments with different properties. Therefore, a rubber rod and a base rope must be selected according to the intended purpose of the rope. The extensible segment 20 described herein with a rubber rod length ‘B’ of about five (5) meter, as illustrated in FIG. 7, has been found convenient for use as anchor rodes for retaining small fishing boats, small sailing crafts, buoys and floating docks.
[0049] While one embodiment of this invention has been illustrated in the accompanying drawings and described hereinabove, it will be evident to those skilled in the art that changes and modifications may be made therein without departing from the essence of this invention, as set forth in the appended claims.
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The extensible segment in an anchor rode comprises a rubber core enclosed in a base rope along the central axis of the base rope. A braided cover further encloses an intermediate portion of the rubber core inside the base rope. The braided cover is made of braided cover strands embedded in the rubber core, and un-braided cover strands extending over the two ends of the rubber core. The un-braided cover strands are weaved into the base rope to retain the rubber core longitudinally inside the base rope.
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BACKGROUND
The present invention generally relates to image comparison, and more particularly to a bitmap comparator for comparing bitmaps of images.
In optical character recognition (OCR), a computer identifies or recognizes printed characters in a bitmap representing, for example, a portion or all of a scanned document and obtains their ASCII values. In one approach, the words within the scanned image are identified, the identified words are divided into characters and each character is then identified by the computer running an OCR program or program module. Scanner limitations and noise in the document being scanned make character recognition from a scanned image of printed text difficult.
Characters to be recognized are normally represented as bitmaps obtained from scanning printed text. In the recognition process, a bitmap of an unknown character may be compared to a bitmap of a known character to determine whether they match and if so, how well. One conventional method of comparison aligns the two bitmaps and then forms the Boolean exclusive-OR (XOR) of their corresponding bits to use as a measure of the equivalency or non-equivalency of the two images.
A more recent technique uses a Euclidean distance map. The two bitmaps are aligned and then XORed to form a comparison bitmap. The Euclidean distance map is generated by replacing each black pixel in the comparison bitmap with its distance to the closest white pixel in the comparison bitmap. A value may be computed from this distance map to represent the difference between the two images, which can be compared against a threshold value to determine whether the two images corresponding to the two original bitmaps likely are equivalent.
Although this approach can distinguish meaningful blobs from random noise, it requires the generation of a Euclidean distance map, which is computation-intensive.
Thus, there is a need for a more practical, less computation-intensive image comparison technique to distinguish meaningful differences from those caused by noise.
SUMMARY OF THE INVENTION
Broadly, the invention provides a bitmap comparison technique that is able to compare bitmap images quickly while discounting differences between the images due to noise. The invention can be implemented in numerous ways, including as an apparatus, as a method implemented in a general--or special-purpose computer, or as a program stored on a computer-readable medium.
One aspect of the invention features an apparatus for comparing a first bitmap with a second bitmap, each having an outline mask, that includes: (a) a comparator for comparing the first and the second bitmaps to produce a difference map of the bits which differ between the two bitmaps; (b) a divider for dividing the difference map of bits into multiple pluralities of bits of differing importance using the respective outline masks of the first and second bitmaps; and (c) a comparison score calculator for deriving a score of a match between the two images using the difference map and weighting differently the multiple pluralities of bits of differing importance.
In general, in another aspect, the invention features a method for comparing first and second bitmaps of images, each having an outline mask, that includes the steps of: (a) comparing the first and the second bitmaps to produce a difference map of the bits which differ between the two bitmaps; (b) dividing the difference map of bits into multiple pluralities of bits of differing importance using the respective outline masks of the first and second bitmaps; and (c) deriving a score of a match between the two images using the difference map and weighting differently the multiple pluralities of bits of differing importance. Preferably, the weights of the bits of differing importance are assigned based upon factors such as bitmap size, number of bits, noisiness of the page and ASCII value.
In another aspect, the invention features a computer program, residing on a computer-readable medium, having instructions for causing a computer to: a) compare first and second bitmaps of images, each having an outline mask, to produce a difference map of the bits which differ between the two bitmaps; b) divide the difference map of bits into multiple pluralities of bits of differing importance using the respective outline masks of the first and second bitmaps; and c) derive a score of a match between the two images using the difference map and weighting differently the multiple pluralities of bits of differing importance. Preferably, the bits not falling on the outline masks are weighted to a lesser extent than the remaining bits when determining the score so that the influence of noise is diminished.
Although the invention is generally applicable to comparing bitmaps and generating an indication of their similarities or dissimilarities, the invention is particularly well suited for a character recognition system where character bitmaps are compared and a comparison score is generated and used to determine whether the bitmaps represent the same character.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary computer system for comparing bitmaps according to the invention.
FIG. 2 is a block diagram showing a bitmap comparator of the invention.
FIG. 3 is a flowchart of a method of bitmap comparison processing.
FIG. 4 is a flowchart of a method of comparison score generation.
FIG. 5 is an illustration of the use of an embodiment of the method of bitmap comparison.
FIG. 6 is a flowchart of a method of bitmap outline processing.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention are discussed below with reference to FIGS. 1-6. However, those skilled in the art will readily appreciate that this detailed description is for explanatory purposes only, as the invention extends beyond these limited embodiments.
The embodiments employ various computer-implemented operations involving data stored in data storage and processing elements of computer systems. These operations manipulate electrical signals that are stored, transferred, combined, compared, or otherwise manipulated. These signals are referred to as bits, values, elements, variables, characters or data structures. These and similar terms associated with the appropriate physical quantities are merely convenient labels.
The manipulations performed are often referred to as producing, generating, identifying, determining, dividing, deriving, smearing, inverting or comparing. These operations are computer operations. The present invention also relates to the computer apparatus for performing these operations. The apparatus may be or include a general-purpose computer selectively activated or configured by a computer program stored in the computer, or it may be or include a special-purpose computer so configured. One such exemplary structure is described below.
FIG. 1 is a block diagram of a computer system 10 programmable for comparing images in accordance with the invention. Computer system includes a digital computer 11, a display screen (or monitor) 22, a printer/scanner 24, a floppy disk drive 26, a hard disk drive 28, a network interface and a keyboard 34. The digital computer 11 includes a processor 12, a memory bus 14, random access memory (RAM) 16, read only memory (ROM) 18, a peripheral bus and a keyboard controller (KBC) 32. Digital computer 11 can be a personal computer (such as an IBM compatible personal computer), a workstation computer (such as a Sun Microsystems or Hewlett-Packard workstation), or other type, size or configuration of computer.
The processor 12 is a general purpose digital processor that controls the operation of the computer system 10. The microprocessor 12 can be a single-chip microprocessor or can be implemented with multiple components. Executing instructions read from memory, the processor 12 controls the reading and manipulation of input data and the output and display of data on output devices. When programmed according to the invention, a particular function of processor 12 is to compare bitmaps of images in a novel way so that meaningful differences are distinguished from differences due to noise.
The memory bus 14 is used by the processor 12 to access the RAM 16 and the ROM 18. The RAM 16 is used by the processor 12 as a general storage area and as scratch-pad memory, and can also be used to store input data and processed data. The ROM 18 can be used to store instructions or program code executed by the processor 12 as well as image descriptions and character outlines used to display images. Alternatively, such image descriptions and character outlines can be included in ROM or RAM within a peripheral device.
The peripheral bus is used to access the input, output and storage devices used by the digital computer 11. These devices may include the display screen 22, the printer/scanner device 24, the floppy disk drive 26, the hard disk drive 28 and the network interface 30. The keyboard controller 32 is used to receive input from keyboard 34 and send decoded symbols for each pressed key to processor 12 over bus 33.
The display screen 22 is an output device that displays images of data provided by the processor 12 via the peripheral bus or provided by other components in the computer system 10. The display screen 22 may be a raster device that displays images on a screen in rows and columns of pixels corresponding, for example, to bits of a bitmap. Raster display screens such as CRT's, LCD displays, and so on are suitable for use as the display screen 22.
The printer/scanner device 24 when operating as a printer may provide an image of a bitmap on a sheet of paper or a similar surface. The printer 24 can be a laser printer, which, like display screen 22, is fundamentally a raster device. Laser printers can be configured to display pixels derived from bitmaps and to print images derived from coded data such as found in a page description language file. The printer/scanner device 24 when operating as a scanner scans documents or similar surfaces to produce bitmaps of the images thereon. Other output devices such as a plotter, typesetter and so on can be used in place of, or in addition to, the printer/scanner device 24.
The floppy disk drive 26 and the hard disk drive 28 can be used to store bitmaps, image descriptions (coded data), and character outlines, as well as other types of data. The floppy disk drive 26 facilitates transporting such data to other computer systems, and hard disk drive 28 permits fast access to large amounts of stored data such as bitmaps, which tend to require large amounts of storage space.
The processor 12, generally under control of an operating system (not shown), executes computer code (instructions) to produce and use data. The computer code and data may reside on the RAM 16, the ROM 18 or the hard disk drive 28. The computer code and data may also reside on a removable program medium and be loaded or installed onto the computer system when needed. Removable program media include, for example, CD-ROM, PC-CARD, floppy disk and magnetic tape.
The network interface is used to send and receive data over a network connected to other computer systems. An interface card or similar device and appropriate computer programs can be used to connect the computer system to a network and transfer data according to standard protocols.
The keyboard 34 is used by a user to input commands and other instructions to programs running on the computer system 10. Images displayed on the display screen 22 or accessible to the computer system can be edited, searched, or otherwise manipulated in response to instructions entered by the user on the keyboard 34. Other types of user input devices can also be used in conjunction with the present invention, including pointing devices such as a computer mouse, a track ball, a stylus or a tablet.
FIG. 2 is a block diagram showing a bitmap comparator in accordance with an embodiment of the invention. The bitmap comparator 36 may be implemented by a computer system, such as the computer system illustrated in FIG. 1, programmed in accordance with the methods of the invention.
The bitmap comparator 36 compares two bitmaps A and B (38 and 40), which have been aligned. An input bitmap may be derived from a scanned image of text from which a character recognition system is asked to recognize characters or it may be a stored image of a character. However, a bitmap could, more generally, be of a word or words, symbols, logos, designs or other images. The bitmap comparator 36 operates to identify differences between bitmap A and bitmap B and then to analyze these differences to determine if the two bitmaps match.
When documents are scanned, it is not uncommon for images to shift or to lose or gain one bit (or pixel) in a given direction because of the limitations of the scanner which scans the image. Note that the use of the term "bit" with respect to a bitmap is used, as context requires, to refer to a set bit (usually a `1`) that corresponds to a pixel (usually a black pixel) in the rendered image. Consequently, corresponding bits that differ between bitmaps, but are only one pixel from where they should be for a match to occur, are likely caused by noise associated with the scanning process.
Bitmap comparator 36 includes a difference map generator 48 that receives as input bitmap A 38 and also bitmap B 40; the latter bitmap could be a template, for example, in an OCR application. These inputs may be received over busses of the kind shown in FIG. 1, or through programmed process interfaces of code modules running on computer system (FIG. 1). The difference map generator 48 then identifies those bits that are different between the bitmap A and the bitmap B, which will be referred to as the "different bits". Preferably, the difference map generator 48 XOR's corresponding bits of bitmap A and bitmap B, producing a difference map (which may be a bitmap or may be created and used incrementally) containing only the bits that are different between bitmap A and bitmap B.
Difference map bit divider 52 operates to differentiate those bits that differ between bitmap A and the bitmap B by a tolerance of only a single bit from those bits that differ by more. Alternatively, multiple-bit noise tolerances could be used instead of single bit tolerances. In addition to receiving bitmaps A and B, difference map bit divider 52 receives outline A 39 and outline B 41 (each of which is a bitmap) and also receives the difference map from the difference map generator 48. (Outlines are illustrated in FIG. 5, which will be described below.) Using the original two bitmaps, the difference map and the two outlines, the difference map divider 52 counts all the bits that are what will be called "very different" between bitmap A 38 and bitmap B 40. In making this count, divider 52 does not count any of the bits that are common to either outline A 39 or outline B 41. Divider 52 also counts the number of "outline bits", defined as those bits that were not counted as very different bits because they fell on outlines A or B.
Divider 52 also counts all bits "gained". A bit gained is one that is on the bitmap A 39 but not on the bitmap B 40, unless it falls on either of the outlines 39 or 41.
Divider 52 also counts all bits "lost". A bit lost is one that is on the bitmap B 40 but is not on the bitmap A 38. Again, bits lost do not include any bits that fall on either outline A or outline B.
Finally, divider 52 counts the "outline bits gained" and the "outline bits lost". The outline bits gained are bits that are on either of the outlines and are on the bitmap A but are not on the bitmap B. The "outline bits lost" are bits that are on either of the outlines and on the bitmap B, but are not on the bitmap A.
Because of the asymmetry of the definition of bits gained and lost between bitmaps A and B, the former may be referred to as the "input" bitmap and the latter, as the "template" bitmap.
The information calculated by difference map bit divider 52 is passed to comparison score calculator 54. Comparison score calculator 54 determines a score reflecting how closely the input bitmap A matches the template bitmap B. Those bits in the difference map that are likely caused by differences between the images within the bitmaps being compared, but are unlikely to have been caused by scanning noise, were identified as "very different bits" by divider 52. Comparison score calculator 54 then produces a comparison score for the match between the two images represented by the bitmaps A and B using the counts produced by divider 52, weighting differently the counts of the categories of bits of differing importance.
In one embodiment, comparison score calculator 54 calculates a "net bits different". This calculation uses a count of the "outline bits", which are those different bits that fall on either outline A or outline B. The net bits different is obtained by adding the count of very different bits (which does not include any outline bits) to the count of outline bits. Before adding the count of outline bits, the count is multiplied by an outline discount 43, which is provided as an input to the calculator 54. The discount is a factor in the range of zero to one. An outline discount is a weight that determines how much weight to give the outline bits in comparison to the very different bits. The value zero indicates that the outline bits have no importance; the value one indicates that the outline bits are just as important as the very different bits. An outline discount will be determined empirically and may depend on several things, including the character represented by the template being matched. For example, matching against a template for the letter "c", it is very easy for a bitmap of an "e" to lose the cross bar and look like a "c". On the other hand, matching against a template for the capital letter "A", even if an input "A" lost its crossbar, it still generally will be recognizable as an "A". That is not true of an "e". For that reason, the outline discount for an "A" template would generally be smaller than one for an "e" template, other things being equal. Other factors that may also affect the outline discount include the number of bits in the character template map and the height and width (the size in bits) of the character template map.
The comparison score calculator 54 preferably also uses a weight table 42. Like the outline discount, the weight table is also determined empirically and may depend on the character represented by the template being matched ("c" vs. "A", as in the example above), as well as on the number of bits in the character bitmap and the height and width of the character bitmap.
The comparison score calculator 54 uses the weight table 42 to calculate the score based on the net bits different.
______________________________________EXAMPLE WEIGHT TABLENet Bits Different Comparison Score______________________________________2 1.005 0.9020 0.40______________________________________
Interpreting the above Example Weight Table, if the net bits different is less than or equal to 2, comparison score calculator 54 returns a comparison score of 1.00, indicating a match success on output 46. If the net bits different is greater than 20, comparison score calculator 54 will return a score of zero (0), indicating a match failure. If the net bits different score is between 2 and 20, calculator 54 performs a linear interpolation from the Example Weight Table to obtain a score between 1.00 and 0.40. For example, if the net bits different is 10, calculator 54 does a linear interpolation between 5 and 20 to obtain a comparison score of 0.73.
If the net bits gained and the net bits lost are both above a minimum net bits different threshold 44, the score can be heavily discounted or even rejected entirely (see step 197, FIG. 4). A difficult match showing both black noise and white noise indicates that likely no match exists between the bitmaps. Like the outline discount and the weight table, the minimum net bits different threshold 44 is also determined empirically and may depend on the character represented by the template being matched ("c" vs. "A", as in the example above), as well as on the number of bits in the character bitmap and the height and width of the character bitmap.
Referring to FIG. 3, a method for comparing bitmaps 94 receives, at step 96, first and second bitmaps to be compared, along with outlines of the first and second bitmaps. Generally, the first bitmap is an input bitmap of an image to be recognized or compared and the second bitmap is a template bitmap with which the input bitmap is compared. These correspond to the bitmaps and outlines A and B, respectively, of FIG. 2 (38, 40, 39 and 41). The input and template bitmaps are XORed to generate, at step 100, a difference map of bits that differ between the first and second bitmaps.
The total number of very different bits contained in the difference map is determined at step 104. This is done by excluding from the bits of the difference map all bits that fall on either of the outlines received at step 96. The excluded bits are those which have been called "outline bits"; their number is determined at step 105.
The number of bits gained by the input bitmap (bits that are not on the template bitmap but are on the input bitmap) is determined at step 106. The number of bits lost from the input bitmap (from the template bitmap) is determined at step 108. The bits lost or gained do not include any of the outline bits.
Next, the number of outline bits gained by the input bitmap is determined at step from the input bitmap, the template bitmap and the two outlines. These are bits that fell on either outline but were not on the template bitmap. The outline bits lost are determined at step 112. These are bits on the template bitmap that fell on either outline but were not on the input bitmap.
Thereafter, a comparison score is generated at step 114.
Referring to FIG. 4, a method of generating a comparison score 186 multiplies the outline discount by the number of outline bits at step 190. At step 192, the product from step 190 is added to the number of very different bits to obtain the "net bits different".
At step 195, the number of net bits lost is calculated by multiplying the outline bits lost, which are the bits in the template that fall on the template outline but are not on the input bitmap, multiplied by the outline discount. The result is then added to the total number of bits lost determined at step 108 of FIG. 3.
Next, in a similar manner, at step 196, the net bits gained is obtained by multiplying the outline bits gained by the outline discount. The outline bits gained are those bits that are on either of the outlines and are on the input bitmap, but are not on the template bitmap. The result of this multiplication is added to the number of bits gained obtained at step 106 of FIG. 3.
Next, in step 197, a check is made as to whether the net bits lost, calculated at step 195, and the net bits gained, calculated at step 196, are greater than the threshold 44 (FIG. 2). If both the net bits lost and the net bits gained are greater than the threshold, at step 198 the comparison is rejected: the method has concluded there is no match. If neither the net bits lost nor the net bits gained are greater than the threshold, a percentage score adjustment is calculated at step 199 from the weight table 42 (FIG. 2) as has been described. In an alternative embodiment, gained or lost outline bits are weighted differently using different discount factors from gained or lost very different bits.
FIG. 1 is a diagram illustrating an example of a bitmap comparison according to an embodiment of the methods of the invention where a first input bitmap 130 is compared to a second template bitmap 132. Here, the first and second bitmaps 130 and 132 are images of the character "n" that resulted from a scanning operation on a text document. Notice that neither image is perfectly formed and that white noise corrupts the stem portion of the first input bitmap 130.
After the first and second bitmaps 130 and 132 are received at step 96 of FIG. 3, the comparison method 94 produces a difference map of differing bits 134. The number of differing bits is also determined at step 104 of FIG. 3 by counting the bits in the difference map 134. A first outline 136 and a second outline 138 are received at step 96 in FIG. 3. The first outline 136 outlines the first input bitmap 1and the second outline 132 outlines the second template bitmap 132. The first outline 136 is itself a bitmap of those bits that touch a bit in the first input bitmap 130. The second outline 138 is a bitmap of those bits that touch a bit in the second template bitmap 132. The term "bit" with respect to a bitmap refers to a set bit (usually a "1") that corresponds to a pixel (usually a black pixel) in the rendered image. For example, in FIG. 5, the set bits are shown as black pixels in the rendered images, such as image 130. Next, a combined outline mask 140 is produced from the first and second outlines 136 and 138, by Boolean ORing corresponding bits of the first and second outlines 136 and 138 to produce a combined outline, and then inverting the combined outline to produce the combined outline mask 140. Thereafter, a bitmap of very different bits 142 (which were not on either outline 136 or outline 138) is produced by Boolean ANDing the difference map of differing bits 134 and the combined outline mask 140. The total number of outline bits within the difference map of differing bits 134 is determined by subtracting the number of bits in the bitmap of very different bits 142 from the total number of differing bits in the difference map of differing bits 134.
Bits gained is calculated by ANDing bitmap 142 with bitmap 1and counting the bits. Bits lost is calculated by subtracting bits gained from the number of very different bits in bitmap 142. Outline bits gained is found by ANDing bitmap 134 with bitmap 136 and counting the bits. Outline bits lost is found by subtracting outline bits gained from the total number of outline bits.
The comparison score formed at step 114 of FIG. 3 discounts those bits within the difference map of differing bits 134 that are likely to have been caused by noise. The resulting comparison score is thus a better indicator of the similarity or dissimilarity of the two images. By using such an improved comparison score, a character recognition system, for example, is better able to determine that the first input image is the same character as the second template image. A character recognition system not using the invention is likely more often to fail to recognize the first input bitmap 1 as representing an "n" or as showing the second template bitmap 132, or to mis-recognize or the first input bitmap 1 as representing another character, or to fail completely to recognize any character at all.
In each of the above embodiments and examples, additional comparison information (besides the total number of differing bits and the number of outline bits or very different bits) can be used to facilitate or enhance comparison evaluation. The number of outline bits gained, the number of outline bits lost, the total number of bits gained and the total number of bits lost can be determined and used to aid in character identification. Some information is directly obtainable from other previously calculated information. For example, the number of outline bits gained could be determined by Boolean ANDing the first input bitmap with the second template outline, and the number of outline bits lost can be similarly determined by Boolean ANDing the second template bitmap with the first outline of the input bitmap. The comparison score can be produced using any or all of the comparison information, including the number of differing bits, the number of very different bits, the number of bits gained or lost by the input bitmap, the number of outline bits gained or lost and the number of outline bits. The comparison score could also be produced using the number of bits in the images themselves as another source of information.
Referring to FIG. 6, the method for creating an outline bitmap 116 begins by receiving the outline prepared at step 118. Next, the bitmap is smeared at step 120. To produce a one bit (or pixel) noise filter, the bitmap is smeared by one bit (pixel), as will be described. The smearing is a Boolean-OR of the original bitmap and a copy of the bitmap moved up one bit. The Boolean-OR may be performed by long operations (e.g., 32 bits) of the processor 12 (FIG. 1), so that many bits are operated on concurrently.
Next, the once-smeared bitmap is smeared down at step 122. This smearing is achieved by a Boolean-OR of a copy of the bitmap received at step 118, moved down one bit, and the once-smeared bitmap.
Next, the twice-smeared bitmap is smeared left at step 124. Then the three-times smeared bitmap is smeared right at step 126. At this point, if it is desired to filter or discount more than one bit or pixel (e.g., two bits or pixels) to discount noise, the steps 118-126 can be repeated using a four-times smeared bitmap as the original. Thereafter, the resulting bitmap from the four-smear operations is Boolean-ANDed to the inverse of the original image bitmap to produce the outline at step 128.
When the processing associated with the invention is performed by an apparatus, such as a general purpose computer that provides long logical operations, the invention is preferably implemented using the long operations so that multiple bits of the bitmaps being processed can be processed simultaneously. When this can be done, it is not necessary that intermediate bitmaps be temporarily stored or even completely formed. It is enough that their bits be processed in accordance with the invention.
The bitmap comparator has been described in terms of particular inputs in the form of outlines and numerical parameters such as discounts, weights and thresholds. The bitmap comparator may be constructed to receive what is substantively the same information but in different forms. A threshold, for example, may be expressed as a percentage of an image or bitmap size rather than as an absolute value without changing the way the comparator operates or the results it achieves.
The many features and advantages of the present invention are apparent from the written description, and thus, it is intended by the appended claims to cover all such features and advantages of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents should fall within the scope of the invention.
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A bitmap comparison technique that is able quickly to compare two bitmap images while discounting differences between the images likely due to noise. The bitmap comparison technique includes the operations of: comparing the first and second bitmaps, producing a difference map identifying differing bits between the first and second bitmaps, producing outline masks based on the outlines of the first and second bitmaps, identifying certain very different bits within the difference map that are to be weighted differently from the remaining bits within the difference map based upon the outline mask, and determining a comparison score to indicate the extent to which the first and second images differ by differently weighting the very different bits and the remaining bits. The certain bits are normally weighted to a lesser extent than the remaining bits when determining the comparison score so that the influence of noise in the comparison score is diminished. The above bitmap comparison technique can be implemented in numerous ways, including as an apparatus, a method or as a computer-readable medium.
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PROBLEM & PRIOR ART
Many handicapped persons, particularly those who are paralyzed, and/or who have suffered injuries to one or both hands and/or who suffered the loss of both arms or who are quadopedics, and/or are otherwise rendered physically helpless, are dependant upon other persons for their simplest needs, e.g., controlling or directing a wheelchair, turning the pages of a book, etc. Heretofore, efforts have been made to provide such handicapped persons with mechanical aids which can be entirely controlled by the handicapped person himself. Control means for such mechanical aid have been conceived whereby such aids are controlled by touch. However, severely handicapped persons, such as quadrapedics and/or totally paralyzed persons, cannot satisfactory operate such touch type control devices.
OBJECTS
It is an object of this invention to provide a positive and negative pressure sensitive control device whereby mechanical aids can be controlled by a totally handicapped or helpless person.
Another object is to provide a breath control device for a mechanical aid in which a totally paralyzed person can personally control a device by blowing and sucking only.
Another object is to provide a breath control device which is rendered responsive to a plurality of different negative or positive pressure conditions.
Another object is to provide a breath control device in which the mechanical advantage necessary for actuation of the control device is reduced as either the positive or negative pressure respectively is increased.
BRIEF SUMMARY OF THE INVENTION
The foregoing objects and other features and advantages are attained by a pressure sensitive control device which is particularly adapted for use as a breath control device whereby a handicapped person can readily control a mechanical aid. The breath control device comprises essentially of a base member having a lever pivotally connected at one end to the base member. A chamber capable of expanding and contracting is disposed between the base member and the free end of the lever. A suitable hose or conduit is connected in communication with the chamber whereby blowing into the hose causes the chamber to expand and by sucking on the hose causes the chamber to contract. By controlling the air pressure exerted by blowing or sucking the lever is pivoted relative to the base member.
A bracket is mounted on the base and it is provided with an opening. An actuating arm pivotally connected at one end to the lever is extended through the opening, and in the neutral or inoperative position the arm is centered within the opening.
A plurality of micro switches having an actuating plunger are disposed on opposite sides of the actuating arm. The switches are arranged so that a soft blow and hard blow switch are diagonally disposed on opposite sides of the actuating arm. The switches also include a soft suck and a hard suck switch which are also diagonally disposed on opposite sides of the actuating arm. The arragement is such that the hard blow switch functions as the pivot for the actuating arm when the expandible chamber is expanded to a first soft blow position whereby the lever arm provides a mechanical advantage greater than 1, and whereby the bracket because the falcrum or pivot for the actuating arm when the chamber is expanded to a second or hard blow position whereby the lever effect of the actuating arm produces a leverage of 1 to 1. When a negative pressure is applied to the chamber, a converse result is achieved; i.e., a soft suck effects the displacement of the actuating arm with a mechanical advantage greater than 1, and whereby a hard suck effects displacement of the actuating arm with a 1 to 1 mechanical advantage.
FEATURES
A feature of this invention resides in the provision of a breath control device in which appropriate switches are rendered responsive in predetermined sequence in which multiple postive and negative pressure positions are obtainable.
Another feature resides in the provision of a pneumatic control device in which the mechanical advantage of the switch actuator can be varied in a predetermined manner in response to the applied negative or positive pressure.
Other features and advantages will become more readily apparent when consiered in view of the drawings and specifications in which:
FIG. 1 is a side elevation view of a control device embodying the invention illustrating a plurality of positive pressure conditions.
FIG. 2 is a top plan view of FIG. 1.
FIG. 3 is a sectional view taken along line 3--3 on FIG. 2.
FIG. 4 is an enlarged detail of construction having portions shown in section.
FIG. 5 is an end view taken along line 5--5 on FIG. 3.
FIG. 6 is a side elevation view of the control device illustrating a first and second positive pressure position.
FIG. 7 is a side elevation view similar to that of FIG. 6 illustrating a first and second negative pressure position.
DETAILED DESCRIPTION
Referring to the drawings, there is shown in FIGS. 1 to 5 a positive and negative pressure sensitive control device 10. The control device is particularly useful as a breath control device for controlling a mechanical aid simply by one's breath; i.e., by a person sucking and blowing. The mechanical aids have reference to wheelchairs, page turning devices and other aids useful to handicapped person. The breath control device 10 is particularly adapted as a control for person who are severely handicapped; e.g., paralyzed persons, quadrapedic and the like. With the control device 10 to be described, a handicapped person can control a particular air; e.g., a wheelchair simply by lowing and sucking on the control device, which it will be understood is operatively connected to the drive of a wheelchair.
The control device 10 comprises a base member 11 having a horizontal leg 11A and a connected vertical leg 11B to define a generally L shaped base. As best seen in FIG. 5, the vertical leg 11B is provided with opposed slots 11C adjacent the upper end thereof. A pivoting lever 12 is pivotally connected to leg portion 11B. As seen in FIGS. 1 to 5, the pivoting lever 12 is pivotally connected to the vertical leg 11B by the interengagement of complementary slots 11C formed in leg 11B and notches 13 formed in the bifurated ends 14--14 of pivot lever 12.
The pivoting lever 12 includes a free end portion 12A which is connected to an overlie expandible chamber formed in the form of a bellows 15. As best seen in FIGS. 1 and 2, the bifurated ends 14--14 of lever 12 is connected to the free end 12A portion by an offset 12B.
Connected to the base member is a U shaped bracket 16. Mounted on each of the arms 16A, 16B of the bracket 16 are a pair of micro switches S 1 , S 2 , S 3 and S 4 respectively. Each micro switch S 1 , S 2 , S 3 , and S 4 is provided with an actuating button or plunger 17 which closes or opens to circuit in which the respective micro switches are connected.
Each arm 16A, 16B of the bracket intermediate the ends thereof is provided with an opening 18 which is disposed in alignment.
On the free end 12A of the pivoting lever 12 there is provided a bracket 19 to which an actuating arm 20 is pivotally connected. As best seen in FIGS. 1 to 3, the actuating arm extends through aligned opening 18, 18 in the arms 16A, 16B of bracket 16 and between the plunger 17 of switches S 1 to S 4 .
In the neutral position as shown in FIG. 2, i.e., when the bellows 15 is neither expanded or contracted, the actuating arm is centered in openings 18, 18 with the plunger 17 of the respective switches S 1 to S 4 in an inactive or inoperative position.
Connected to the bellows 15 which defines an expandible chamber when subjected to a positive pressure and a collapsed position when subjected to a negative pressure in a hose 21.
The control device 10 described is arranged so as to effect sequential opration of switches S 1 , S 2 , S 3 , and S 4 by either one blowing or sucking on hose 21 to subject the chamber or bellows 15 to either a positive or negative pressure.
In accordance with this invention, provisions are provided for the actuation of the control device by either a soft blow or hard blow or by a soft suck or a hard suck, i.e., the control device is rendered responsive to a first or second positive pressure condition or a first or second negative pressure condition. This is attained by subjecting the actuating arm to predetermined mechanical advantages so as to insure positive actuation between the respective position of soft and hard blow position and the soft and hard suck position.
Referring to FIGS. 1, 6 and 7, the operation of the control device is as follows:
In the neutral position as seen in FIG. 1, the actuating arm 20 is centered in opening 18, 18 and the switch plungers 17 are in an inoperative position. As shown S 1 is a soft blow switch, S 2 is a hard blow switch. Conversely, S 3 and S 4 are soft suck and hard suck switches respectively.
If one softly blows into hose 21, the bellows is expanded to a first position as shown by the solid line showing in FIG. 6. In this position, the actuating arm is displaced so that the soft positive pressure switch S 1 is actuated. In this position, the plunger 17 of switch S 2 acts as fulcrum for actuating arm to produce a 2:1 mechanical advantage for for the bellows 15 with respect to switch S 1 . When switch S 1 is actuated, the actuating arm engages the edge of the opening 18 in arm 16A whereby the edge of hole 18 in arm 16A becomes the fulcrum for continued displacement of the actuating arm 20. The arragement is such that greater positive pressure is required to activate switch S 2 since the shifting of the fulcrum for the actuating arm reduces the mechanical advantage to 1:1. Thus, upon blowing hard on hose 21, the bellows 15 is expanded to the dotted line position to activate the hard blow switch S 2 .
Conversely, when a soft suck or first negative pressure position is imparted on the bellows 15 to cause it to contract to a first position A as seen in FIG. 7, plunger 17 of switch S 3 becomes the fulcrum of the actuating arm 20 to produce a 2:1 mechanical advantage in actuating the soft blow switch S 3 . When switch S 4 is actuated, the actuating arm engages the upper edge of hole 18 in arm 16B so that this edge now becomes the fulcrum for any continued displacement of the actuating arm 20. Because of the shifting of the fulcrum as described, the mechanical advantage of the arm in effecting the actuating of switch S 3 has been reduced to 1:1. Thus a greater negative pressure or hard suck is required to be imparted on the bellows to effect displacement thereof of a sufficient amount for the actuating arm 20 to activate the hard suck switch S 3 .
With the control device described it will be noted that the arrangement is such that a definite positive displacement of the actuating arm 20 can be effected to distinguish between a soft and hard blow and a soft and hard suck so as to control a mechanical aid accordingly.
While the invention has been described with respect to a particular embodiment thereof, it will be appreciated and understood that variations and modifications may be made without departing from the spirit or scope of the invention.
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This disclosure is directed to a positive and negative pressure operated control device for use as a breath control device. The device includes a plurality of micro switches which can be sequentially actuated or rendered responsive to a person blowing or sucking on an expandible chamber whereby the change in pressure effected thereby will actuate the respective switches accordingly.
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FIELD OF THE INVENTION
The present invention concerns a process for improving doxorubicin production by means of a recombinant strain bearing a mutation in a gene of daunorubicin metabolism.
BACKGROUND OF THE INVENTION
Anthracyclines of daunorubicin group such as doxorubicin, carminomycin and aclacinomycin and their synthetic analogs are among the most widely employed agents in antitumoral therapy (F. Arcamone, Doxorubicin, Academic Press New York, 1981, pp. 12-25; A. Grein, Process Biochem., 16: 34, 1981; T. Kaneko, Chimicaoggi May 11, 1988; C. E. Myers et al., "Biochemical mechanism of tumor cell kill" in Anthracycline and Anthracenedione-Based Anti-cancer Agents (Lown, J. W., ed.) Elsevier Amsterdam, pp. 527-569, 1988; J. W. Lown, Pharmac. Ther. 60: 185-214, 1993). Anthracyclines of the daunorubicin group are naturally occurring compounds produced by various Streptomyces species and by Actinomyces carminata. Doxorubicin is mainly produced by strains of Streptomyces peucetius while daunorubicin is produced by many other Actinomycetes. In particular daunorubicin and doxorubicin are synthesized in S. peucetius ATCC 29050 and 27952 from malonic acid, propionic acid and glucose by the pathway summarized in Grein (Advan. Applied Microbiol. 32: 203, 1987) and in Eckart and Wagner (J. Basic Microbiol. 28: 137, 1988). Aklavinone (11-deoxy-e-rhodomycinone), e-rhodomycinone and carminomycin are established intermediates in this process. The final step in this pathway involves the hydroxylation of daunorubicin to doxorubicin by the DoxA enzyme ({U.S. Ser. No. 08/396,218, WO96/27014}; M. L. Dickens and W. R. Strohl, J. Bacteriol. 178: 3389 (1996)), which is reported to occur only in S. peucetius.
13-Dihydrodaunorubicin may be an intermediate in the conversion of e-rhodomycinone to daunorubicin via rhodomycin D (FIG. 1) according to Dickens et al. (J. Bacteriol. 179: 2641 (1997)). Daunorubicin is bioconverted to (13S)-13-dihydrodaunorubicin when added to cultures of S. peucetius and some other streptomycetes (N. Crespi-Perellino et al., Experientia, 38: 1455, 1982; T. Oki et al., J. Antibiotics, 34: 1229, 1981; G. Cassinelli et al., Gazz. Chim. Ital. 114: 185, 1984). It is not known whether the 13-dihydrodaunorubicin that may be an intermediate of daunorubicin and doxorubicin production in S. peucetius is identical to the (13S)-13-dihydrodaunorubicin formed by this bioconversion. Since these two compounds can differ in their C-13 stereochemistry, one diastereomer of 13-dihydrodaunorubicin might be a substrate for DoxA and the other one would not. In the latter case, C-13 reduction of daunorubicin would block its further oxidation to doxorubicin.
Several genes for daunorubicin and doxorubicin biosynthesis and resistance have been isolated from S. peucetius 29050 and 27952 by cloning experiments. The S. peucetius dnrU gene identified herein is a homolog of the Streptomyces sp. strain C5 gene ORF1 (syn. dauU) described by Dickens and Strohl (J. Bacteriol. 178: 3389 (1996)). Since the predicted protein products of the dnrU and dauU genes resemble enzymes known to reduce ketone groups, the DnrU and DauU proteins may catalyze the reduction of daunorubicin, formed in vivo or added to cultures exogenously, to 13-dihydrodaunorubicin.
SUMMARY OF THE INVENTION
The present invention concerns a process for preparing doxorubicin by means of a bacterial recombinant strain bearing a mutation blocking the function of a gene of daunorubicin metabolism. With this process the amount of doxorubicin is greatly increased, relative to the amount of daunorubicin formed. The relative amounts of e-rhodomycinone, daunorubicin and 13-dihydrodaunorubicin may also be altered, as an incidental consequence of the mutation. Preferably the bacteria is a strain of Streptomyces sp. producing daunorubicin and doxorubicin, having a mutation blocking the function of a gene of daunorubicin metabolism. Said blocked gene is preferably comprised in the DNA fragment having the configuration of restriction sites shown in FIG. 3 or in a fragment derived therefrom containing a gene, dnrU SEQ ID NO:1!, coding for a protein involved in the metabolism of daunorubicin. The present invention provides a mutant strain of S. peucetius, obtained from S. peucetius ATCC 29050, having a mutation blocking the function of the dnrU gene. This mutation greatly increases the doxorubicin production level relative to the amount of daunorubicin, and by coincidence may also increase the amount of e-rhodomycinone and reduce the amount of 13-dihydrodaunorubicin formed.
Genes for daunorubicin and doxorubicin biosynthesis and resistance have been obtained from S. peucetius 29050 and S. peucetius 27952 by cloning experiments as described in Stutzman-Engwall and Hutchinson (Proc. Natl. Acad. Sci. USA, 86: 3135 (1988)) and Otten et al., (J. Bacteriol. 172: 3427 (1990)).
The dnrU mutant can be obtained by disrupting the dnrU gene, obtained from the S. peucetius 29050 anthracycline production genes described by Stutzman-Engwall and Hutchinson (Proc. Natl. Acad. Sci. USA, 86: 3135 (1988)) and Otten et al. (J. Bacteriol. 172: 3427 (1990)), by insertion of the neomycin/kanamycin resistance gene (aphII) into the BalI restriction site located at the beginning of dnrU. This disrupted dnrU::aphII gene is used to replace the normal dnrU gene in the 29050 strain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a summary of the biosynthetic pathway to daunorubicin and doxorubicin in S. peucetius.
FIG. 2 shows the DNA and deduced protein sequences of the dnrU gene and part of the dnrV gene. SEQ ID 1 is a schematic illustration of the dnrU DNA nucleotide sequence. Said DNA corresponds to that encoding a protein for daunorubicin metabolism. The sequence covers the region between the SstI and the AatII restriction sites and shows the coding strand in the 5' and 3' direction. The derived amino acid sequence of the translated open reading frame encoding a protein required for daunorubicin metabolism is shown below the nucleotide sequence of the dnrU gene as SEQ ID 2.
FIG. 3 is a restriction map analysis of the DNA of the invention. Said DNA is a 4.8-kb BamHI-NruI fragment containing dnrU and dnrV, subcloned from the cosmid clone pWHM335 described in Stutzman-Engwall and Hutchinson, (Proc. Natl. Acad. Sci. USA, 86: 3135 (1988)) and Otten et al. (J. Bacteriol. 172: 3427 (1990)). The location and direction of transcription of the two genes are indicated by arrows. The fragment was inserted into the unique BamHI and NruI restriction sites of the polylinker region of plasmid pSE380 (Invitrogen Corp.). The map shown in FIG. 3 does not necessarily provide an exhaustive listing of all restriction sites present in the DNA fragment. However, the reported sites are sufficient for an unambiguous recognition of the DNA segment. (Restriction site abbreviations: Ba, BamHI; Sa, SalI, Kp, KpnI; No, NotI; B, BalI, Nr, NruI; Aa, AatII, Ss, SStI and Pv, PvuII).
FIG. 4 is the structure of KC515 and phWHM295 containing the disrupted copy the dnrU gene. ΔattP and cos indicate the relative locations of the deletion in the phage attachment site and the cohesive end of KC515, respectively; tsr, vph and aphII are the thiostrepton, viomycin and neomycin resistance genes, respectively. (Restriction site abbreviations: Ba, BamHI; Bg, BglII; Hp, HpaII; No, NotI; Nr, NruI; Ps PstI; Pv, PvuII; SS, SstI and Xh, XhoI).
DESCRIPTION OF THE INVENTION
The present invention provides a bacterial recombinant strain bearing a mutation inactivating the function of the daunorubicin metabolism gene dnrU. The bacterial strain may be one that is daunorubicin- or doxorubicin-sensitive, i.e. cannot grow in the presence of a certain amount of daunorubicin or doxorubicin, or that is daunorubicin- or doxorubicin-resistant. Strains belonging to the Streptomyces genus constitute a preferred embodiment of the invention; a Streptomyces peucetius strain constitutes a particularly preferred embodiment of the invention. Most preferred is the S. peucetius strain WMH1658. The strain WMH1658 was deposited on Jul. 3, 1997 at the American Type Culture Collection, 10801 University Boulevard, Manassas, Va. 20110-2209, USA, under the accession number ATCC 55994. The WMH1658 strain has been obtained from S. peucetius ATCC 29050 strain by replacing the dnrU gene with a mutated dnrU gene into which the neomycin/kanamycin resistance gene (aphII) from the pFDNEO-S plasmid described by F. Danis and R. Brzezinski, (FEMS Microbiology Letters 81: 261 (1991) has been inserted. The aphII gene has been inserted into the BalI restriction site located at the beginning of dnrU to disrupt the function of dnrU, as better explained in Example 1.
The expert in the art will recognize that any other technique to inactivate the gene can be suitably employed in the present invention.
The bacterial recombinant strain may be any other microorganism transformed with plasmids or transfected with phage DNA containing an anthracycline gene cluster able to produce daunorubicin and/or doxorubicin and/or baumycins.
In another aspect, the present invention provides a process for preparing doxorubicin, which process comprises:
(i) culturing a bacterial recombinant strain of the invention, and
(ii) isolating doxorubicin from the culture.
In this process the bacterial recombinant strain may be cultured at from 20 to 40° C., for example from 26 to 37° C. The culture is preferably carried out with agitation. In order to obtain the bacterial recombinant strain of the invention, the dnrU gene was isolated from clones described in Stutzman-Engwall and Hutchinson, (Proc. Acad. Sci. USA 86: 3135 (1989) and Otten et al., (J. Bacteriol. 172: 3427 (1990).
The dnrU gene is contained in a 4.8-kb BamHI-NruI fragment obtained from the cosmid clone pWHM335 described in Stutzman-Engwall and Hutchinson (Proc. Natl. Acad. Sci. USA, 86: 3135 (1988)) and Otten et al. (J. Bacteriol. 172: 3427 (1990)).
This 4.8 kb BamHI-NruI fragment can be further digested to give the 1.55 kb SstI-AatI fragment whose sequence is shown in FIG. 2. The 1.55 kb SstI-AatI fragment includes the dnrU gene and part of the dnrV gene.
The dnrU gene consists essentially of the sequence of SEQ ID NO 1, which sequence will be referred to as the "dnrU" sequence. The deduced amino acid sequence of the daunorubicin and doxorubicin metabolism protein encoded by SEQ ID NO 1 is shown in SEQ ID NO 2. The isolated dnrU gene was subsequently subcloned into an appropriate DNA cloning vector. Any autonomously replicating and/or integrating agent comprising a DNA molecule to which one or more additional DNA segments can be added may be used. Typically, however, the vector is a plasmid. Preferred plasmids are pUC19 (Yanish-Perron et al., Gene 33: 103 (1985)) and pWHM3 (Vara et al., J. Bacteriol. 171: 5872 (1989)). Any suitable technique may be used to insert the DNA into the vector. Insertion can be achieved by ligating the DNA into a linearized vector at an appropriate restriction site. For this, direct combination of sticky or blunt ends, homopolymer tailing, or the use of a linker or adapter molecule may be employed. The recombinant plasmid is then digested with a suitable restriction enzyme and ligated with the aphII gene. This construction is transferred into a suitable vector for homologous integration. Among the possible vectors that can be used, KC515 (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985)) or pKC1139 (M. Bierman et al., Gene 116: 43-49 (1992)) are preferred. KC515 is a derivative of φC31 and can only transduce a host to antibiotic resistance if the vector carries a segment of homologous DNA, and pKC 1139 is an E. coli-Streptomyces shuttle vector that contains a temperature-sensitive replicon that functions well at temperature below 34° C. and bears the apramycin resistance gene. The recombinant vector thus obtained is used to transform, typically with KC515 by transduction with infective phage particles or with pKC119 by protoplast transformation, an appropriate Streptomyces strain; the final step in this inactivation protocol is the isolation of kanamycin resistant transformant in which the recombinant plasmid has recombined with the dnrU gene and inactivated it (see also Example 1).
On the basis of the information provided herein, the expert in the art can easily obtain the 1.55 kb SstI-AatII DNA fragment by:
a) preparing a library of the genomic DNA of S. peucetius 29050 or a strain derived therefrom:
b) screening the library for clones positive to a labelled probe, of at least 24 nucleotides, synthesized according to the sequence of SEQ ID NO: 1;
c) obtaining an insert DNA, from a recombinant vector, that forms part of the library and that has been screened as positive for the ability to metabolize daunorubicin to doxorubicin in the S. peucetius dnrU mutant.
To obtain the DNA fragment, the library may be prepared in step a) by partially digesting the genomic DNA of S. peucetius 29050 or a strain derived therefrom; or by screening a library of Streptomyces genomic DNA that has been enriched for the cluster of daunorubicin and doxorubicin biosynthesis genes. Generally the restriction enzyme MboI is preferably used for genomic DNA, but for the libraries containing the cluster of daunorubicin biosynthesis genes, the restriction enzymes BamHI is preferred. The DNA fragments thus obtained can be size fractionated; fragments from 1 to 7 kb in size are preferred for libraries containing the cluster of daunorubicin and doxorubicin biosynthesis genes. These fragments are ligated into a linearized vector such as pWHM3 or pKC505 ((M. A. Richardson et al, Gene 61: 231 (1987)). E. coli DH5a and DH1 are respectively transformed or transfected with the ligation mixtures.
In step b) the colonies obtained by the transformations are transferred to nylon membranes and screened by colony hybridization for plasmids or cosmids which hybridized to the labelled probe, of at least 24 nucleotides, synthesized according to the sequence of SEQ ID No:1
In step c) plasmid DNA from the clones which hybridized to the probe is isolated and used to transform protoplasts of host cells. The hosts may be microorganisms that produce less doxorubicin than daunorubicin. The S. peucetius dnrU mutant strain (ATCC 55994) that produces more doxorubicin than daunorubicin and, coincidentally, more e-rhodomycinone than the 29050 strain, represents a particularly suitable host.
Clones containing DNA fragments which include the 1.55 kb SstI-AatII DNA fragment of the invention, when introduced into the S. peucetius dnrU mutant strain (ATCC 55994), are recognized by the appearance in fermentation cultures of decreased levels of doxorubicin relative to daunorubicin and, coincidentally, e-rhodomycinone.
MATERIALS AND METHODS
Bacterial strains and plasmids: E. coli strain DH5a (Sambrook et al., Molecular cloning. A laboratory Manual, 2nd ed. Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989), which is sensitive to ampicillin, is used for subcloning DNA fragments. S. peucetius ATCC 29050 and a S. peucetius dnrU mutant that produces more doxorubicin than daunorubicin and, coincidentally, more e-rhodomycinone than the 29050 strain are used for disruption and expression, respectively, of the dnrU gene. Streptomyces lividans TK24 (D. A. Hopwood et al., J. Gen. Microbiol. 129: 2257 (1983)) and S. lividans TK24(φC31) lysogen are used in transferction experiments (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985) and for screening of phage carrying a cloned chromosomal DNA fragment (N. D. Lomovskaya et al., J. Bacteriol. 178: 3238 (1996) or N. D. Lomovskaya et al. Microbiology 143: 875 (1997)).
The plasmid cloning vectors are pUC18/19 ((Yanish-Perron et al., Gene 33: 103 (1985)), pSE380 (Invitrogen Corp.), pSP72 (Promega), and pWHM3 (Vara et al., J. Bacteriol. 171: 5872 (1989)). The integrative vector is KC515, a derivative of phage φC31 (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985). The pFDNEO-S plasmid described by F. Danis and R. Brzezinski, (FEMS Microbiology Letters 81: 261-264 (1991)) is used to get the neomycin/kanamycin aphII resistance gene.
Media and buffer: E. coli strain DH5a is maintained on LB agar (Sambrook et al., Molecular cloning. A laboratory Manual, 2nd ed. Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989). When selecting for transformants, ampicillin is added at a concentration of 100 micrograms/ml. S. peucetius 29050 and dnrU::aphII strains are maintained on ISP4 agar (Difco Laboratories, Detroit, Mich.) for the preparation of spores and on R2YE agar (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985) for regeneration of protoplasts. When selecting for transformants overlay with 20 micrograms/ml thiostrepton is used. R2YE agar without sucrose is used when S. peucetius 29050 is infected with phage phWHM295.
Subcloning DNA fragments: DNA samples are digested with appropriate restriction enzymes and separated on agarose gel by standard methods (Sambrook et al., Molecular cloning. A Laboratory Manual, 2nd ed. Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989). Agarose slices containing DNA fragments of interest are excised from a gel and the DNA is isolated from these slices using the GENECLEAN device (Bio101, La Jolla, Calif.) or an equivalent. The isolated DNA fragments are subcloned using standard techniques (Sambrook et al., Molecular cloning. A Laboratory Manual, 2nd ed. Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989) into E. coli for routine manipulations, including DNA sequencing, and E. coli-Streptomyces shuttle vectors for expression experiments and fermentations.
Transformation of E. coli and Streptomyces species: Competent cells of E. coli are prepared by the calcium chloride method (Sambrook et al., Molecular cloning. A Laboratory Manual, 2nd ed. Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989) and transformed by standard techniques (Sambrook et al., Molecular cloning. A Laboratory Manual, 2nd ed. Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989). S. peucetius dnrU::aphII mycelium is grown in R2YE medium (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985) and harvested after 24 hr. The mycelial pellet is washed twice with 10.3% (wt/vol) sucrose solution and used to prepare protoplasts according to the method outlined in the Hopwood manual (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985). The protoplast pellet is suspended in about 300 microlitres of P buffer (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985) and 50 microlitres aliquot of this suspension is used for each transformation. Protoplasts are transformed with plasmid DNA according to the small scale transformation method of Hopwood et al. (Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985), Stutzman-Engwall and Hutchinson (Proc. Natl. Acad. Sci. USA, 86: 3135 (1988) or Otten et al. (J. Bacteriol. 172: 3427 (1990)). After 17 hr of regeneration on R2YE medium at 30° C., the plates are overlayed with 20 micrograms/ml of thiostrepton and allowed to grow at 30° C. until sporulated.
Doxorubicin and daunorubicin production: S. peucetius dnrU::aphII is inoculated into 25 ml of liquid R2YE medium with 40 micrograms/ml of kanamycin sulfate in a 300 ml flask and incubated at 30° C. and 300 rpm on a rotary shaker. After 2 days of growth 2.5 ml of this culture are transferred to 25 ml of APM production medium: ((g/l) glucose (60), yeast extract (8), malt extract (20), NaCl (2), 3-(morpholino)propanesulfonic acid (MOPS sodium salt) (15), MgSO4.7H2O (0.2), FeSO4.7H2O (0.01), ZnSO4.7H2O (0.01), added with 40 micrograms of kanamycin, and incubated in a 300 ml flask at 30° C. and 300 rpm on a rotary shaker for 96-120 hr. The culture is acidified with 250 mg oxalic acid and incubated at 30° C. over night and then extracted with an equal volume of acetonitrile:methanol (1:1) at 30° C. and 300 rpm for 2 hr. The extract is filtered and the filtrate is analyzed by reversed-phase high pressure liquid chromatography (RP-HPLC). RP-HPLC is performed by using a Vydac C18 column (4.6×250 mm; 5 micrometers particle size) at a flow rate of 0.385 ml/min. Mobile phase is 0.2% trifluoroacetic acid (TFA, from Pierce Chemical Co.) in H2O and mobile phase B is 0.078% TFA in acetonitrile (from J: T: Baker Chemical Co.). Elution is performed with a linear gradient from 20 to 60% phase B in phase A in 33 minutes and monitored with a diode array detector set at 488 nm (bandwidth 12 micrometers). ε-rhodomycinone, daunorubicin and doxorubicin (10 micrograms/ml in methanol) are used as external standards to quantitate the amount of these metabolites isolated from the cultures.
EXAMPLES
Example 1
Disruption of dnrU: pWHM555 is constructed by subcloning the 6.0-kb BamHI fragment containing the dnrU and dnrV genes from the pWHM335 cosmid clone described by Stutzman-Engwall and Hutchinson (Proc. Acad. Sci. USA 86: 3135 (1988)) and Otten et al. (J. Bacteriol. 172: 3427 (1990)) in the pUC18 plasmid vector. pWHM289 is constructed by subcloning the 4.8-kb BamHI-NruI fragment containing the dnrU and dnrV genes from pWHM555 in the pSE380 vector, from which a 4.8-kb BamHI-XhoI fragment was cloned into the pSP72 vector to create pWHM290. Then the aphII gene, obtained as a 1.0 kb SalI fragment from pFDNeoS, was inserted into the BalI site located in the beginning of the structural part of dnrU to create pWHM293. A 4.0-kb AatII-XhoI fragment containing the aphII gene was cloned blunt-ended from pWHM293 into the PvuII site of pSP72 to create pWHM294, from which a 4.0-kb BamHI-Xhol fragment containing the disrupted copy of dnrU was cloned into the KC515 phage vector to create phWHM295 (FIG. 3).
Cloning of the dnrU gene: Cloning of S. peucetius 29050 DNA fragments into the phage integrative vector KC515 and screening of the phage carrying a disrupted copy of the dnrU gene are performed as described by Lomovskaya et al. (J. Bacteriol. 178: 3238 (1996) or Microbiology 143: 875 (1997)). The phage plaques obtained after transfection of S. lividans TK24 protoplasts are screened by selection for neomycin resistance with neomycin (10 micrograms/ml) added to R2YE growth medium. The presence or absence of the neomycin (aphII) and viomycin (vph) resistance genes in the phage vector is tested by adding neomycin (10 microgram/ml) and viomycin (200 microgram/ml) to R2YE medium. In this way the phage phWHM295 is characterized as containing aphII and vph resistance genes. The presence of the cloned DNA containing the disrupted dnrU::aphII gene was confirmed by restriction endonuclease digestion analysis.
S. peucelius 29050 is infected with phWHM295 (5×10 7 spores and 1 to 2×10 8 phage). After 16 h the plates are overlaid with an aqueous neomycin solution to give a final concentration of 10 microgram/ml, then after further growth for 6 d until sporulation, the plates are replicaplated on minimal medium (Hopwood et al., Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985) containing neomycin (10 micrograms/ml). Primary neomycin-resistant clones are isolated and their phenotype is determined after a second round of single colony isolation. Selection for gene replacement is carried out on minimal medium with neomycin (10 micrograms/ml) and viomycin (30 micrograms/ml). In this way, clones are obtained that are resistant to neomycin and sensitive to viomycin. Two colonies with the neomycin-resistance, viomycin-sensitive phenotype are examined by Southern analysis to verify the disruption of the dnrU gene. Chromosomal DNA from the 29050 strain and the WM1658 dnrU mutant strain are digested with BamHI and probed with the 1.1-kb PstI-BamHI fragment of pFDNeoS containing the aphII gene. The probe hybridizes to a 7.0-kb BamHI fragment for the dnrU mutant, which is consistent with the insertion of the aphII gene in the dnrU gene.
Example 2
Enhanced ε-rhodomycinone and doxorubicin production in the fermentation broth of the WHM1658 dnrU::aphII mutant: The dnrU::aphII mutant is grown for 10 days at 30° C. on slants of ISP4 agar medium (Difco) supplemented with 40 micrograms of kanamycin sulfate. The spores of this culture are collected and suspended in 300 ml Erlenmeyer flasks containing 25 ml of R2YE liquid medium containing 40 micrograms of kanamycin sulfate and the flasks are shaken for 2 days at 30° C. on a rotary shaker running at 300 rpm in a 5 cm diameter circle. A 2.5 ml portion of this culture is used to inoculate 25 ml of APM medium containing 40 micrograms of kanamycin sulfate in 300 ml Erlenmeyer flasks. The flasks are incubated at 30° C. for 96 hr under the same conditions described for the seed cultures. The metabolites are extracted from the cultures according to the methods described in the Materials and Methods section. The production values are indicated in Table 1.
TABLE 1______________________________________Amount (micrograms/ml) of ε-rhodomycinone, daunorubicin anddoxorubicin produced by the S. peucetius ATCC 29050 andWMH1658 dnrU::aphII strains in the APM medium at 96 h. ε-rhodomy- doxo-Strain cinone rubicin daunorubicin doxo/dauno ratio______________________________________290950 11.6 6.6 10.1 0.65WMH1658 39.4 31.7 8.9 3.56______________________________________
Example 3
Complementation of the dnrU::aphII mutation with the dnrU and dnrU+dnrV genes: To confirm that the high production value of ε-rhodomycinone and doxorubicin in the fermentation broth of the dnrU::aphII mutant is due to dnrU disruption, the WMH1658 dnrU mutant is transformed separately with pWHM299 and pWHM345. These two plasmids are made as follows. A 1.55-kb AatII-SstI fragment from pWHM555 containing the dnrU gene is cloned into pSE380 to create pWHM298. A 1.55-kb EcoRI-HindIII fragment from pWHM298 is cloned into pWHM3 to create pWHM299. A 3.1-kb PvuII-SstI fragment from pWHM555 containing the dnrU and dnrV genes is cloned into pSP72 to create pWHM343. A 3.1-kb EcoRI-XhoI fragment from pWHM343 is cloned into pSE380 to create pWHM344. A 3.1-kb EcoRI-HindIII fragment from pWHM344 is cloned into pWHM3 to create pWHM345. pWHM299 and pWHM345 are introduced separately into the S. peucetius WMH1658 dnrU mutant by the protoplast-mediated transformation method described above, using thiostrepton (20 micrograms/ml) for selection of the transformants. S. peucetius WMH1658 transformants are verified by reisolation of pWHM3, pWHM299 or pWHM345 according to the plasmid isolation protocol described by Hopwood et al. (Genetic Manipulation of Streptomyces. A Laboratory Manual, John Innes Foundation, Norwich, UK, 1985) and analysis of the DNA of these plasmids by restriction endonuclease digestion according to standard protocols (Sambrook et al., Molecular cloning. A Laboratory Manual, 2nd ed. Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989). Transformants are grown in the APM medium in the presence of thiostrepton (10 micrograms/ml) and culture extracts are checked for production of ε-rhodomycinone, daunorubicin and doxorubicin production according to the procedure described above. HPLC analysis shows a decrease in the amount of ε-rhodomycinone and doxorubicin produced by the WMH1658(pWHM299) recombinant strain containing the dnrU gene and the WMH1658(pWHM345) recombinant strain containing the dnrU and dnrV genes, compared with the amounts of these metabolites produced by the WMH1658(pWHM3) transformant (typical values are shown in Table 2). As can be seen from Table 2, the complementation experiment with plasmid pWHM345 resulted in a complete restoration of doxorubicin production level. This result is not unexpected since, as already described in Solari et al., Cloning and Expression of Daunorubicin C-14 Hydroxylase Gene from a Streptomyces peucetius Mutant, the Sixth Conference on the Genetics and Molecular Biology of Industrial Microorganisms, Oct. 20-24, 1996, Bloomington, Ind., (USA), the presence of the dnrV gene has the effect of increasing the conversion from daunorubicin to doxorubicin in Streptomyces.
TABLE 2______________________________________Amounts (micrograms/ml) of ε-rhodomycinone, daunorubicin anddoxorubicin produced by the S. peucetius WMH1658 dnrU::aphIIrecombinant strain bearing either pWHM3, pWHM299 or pWHM345 inthe APM medium at 120 h. ε-rhodomy- doxo-Strain cinone rubicin daunorubicin doxo/dauno ratio______________________________________WMH1658 75.1 70.2 30.0 2.34(pWHM3)WMH1658 60.3 49.4 44.1 1.12(pWHM299)WMH1658 42.8 52.1 19.3 2.70(pWHM345)______________________________________
__________________________________________________________________________# SEQUENCE LISTING- <160> NUMBER OF SEQ ID NOS: 5- <210> SEQ ID NO 1<211> LENGTH: 864<212> TYPE: DNA<213> ORGANISM: Streptomyces peucetius<220> FEATURE:<221> NAME/KEY: CDS<222> LOCATION: (1)..(864)- <400> SEQUENCE: 1- atg acg gcc tcc acc ccg cac cac ggg aca cc - #a cgc ggc ggc ctg tcg 48Met Thr Ala Ser Thr Pro His His Gly Thr Pr - #o Arg Gly Gly Leu Ser# 15- ggc cgg acg gtg ctg gtc acc ggg gcc acg tc - #c ggc atc ggc cgg gcg 96Gly Arg Thr Val Leu Val Thr Gly Ala Thr Se - #r Gly Ile Gly Arg Ala# 30- gcg gcc ctc gcg gtc gcc cgc cag ggg gcc cg - #c gtc gtg ctc gtc ggc 144Ala Ala Leu Ala Val Ala Arg Gln Gly Ala Ar - #g Val Val Leu Val Gly# 45- cgg gac ccc gag cgt ctg cgg acc gtc acg aa - #c gag gtg gcc cgg acc 192Arg Asp Pro Glu Arg Leu Arg Thr Val Thr As - #n Glu Val Ala Arg Thr# 60- gcc ggc ccg gcc ccg gac gcc ttc cgc gcg ga - #c ttc gcc gag ctg cgc 240Ala Gly Pro Ala Pro Asp Ala Phe Arg Ala As - #p Phe Ala Glu Leu Arg# 80- cag gta cgc gac ctg ggg gag cgg ctg cgg ga - #c cgg tac ccg cgc atc 288Gln Val Arg Asp Leu Gly Glu Arg Leu Arg As - #p Arg Tyr Pro Arg Ile# 95- gat gtc atg gcc agc aac gcc ggc ggc atg tt - #c tgg tcg cgc acc acg 336Asp Val Met Ala Ser Asn Ala Gly Gly Met Ph - #e Trp Ser Arg Thr Thr# 110- acc cag gac ggg ttc gag gcc acc atc cag gt - #c aat cac ctc gca ggc 384Thr Gln Asp Gly Phe Glu Ala Thr Ile Gln Va - #l Asn His Leu Ala Gly# 125- ttc ctg ctg gca cgg ctg ctg cgg gag cgg ct - #c gcg ggc ggg cgg ctg 432Phe Leu Leu Ala Arg Leu Leu Arg Glu Arg Le - #u Ala Gly Gly Arg Leu# 140- atc ctc acc tcg tcc gac gcg tac acc cag gg - #c cgg atc gac ccg gac 480Ile Leu Thr Ser Ser Asp Ala Tyr Thr Gln Gl - #y Arg Ile Asp Pro Asp145 1 - #50 1 - #55 1 -#60- gac ctc aac ggc gac cgt cac cgc tac agc gc - #c ggc cag gcg tac ggc 528Asp Leu Asn Gly Asp Arg His Arg Tyr Ser Al - #a Gly Gln Ala Tyr Gly# 175- acg tcc aaa cag gcc aac atc atg acc gcg gc - #g gag gcc gcc agg cgc 576Thr Ser Lys Gln Ala Asn Ile Met Thr Ala Al - #a Glu Ala Ala Arg Arg# 190- tgg ccg gac gtg ctg gcg gtc agc tat cac cc - #c ggt gag gtc cgc acc 624Trp Pro Asp Val Leu Ala Val Ser Tyr His Pr - #o Gly Glu Val Arg Thr# 205- cgc atc gga cgg ggc acg gtc gcc tcg tcc ta - #c ttc cgg ttc aac ccc 672Arg Ile Gly Arg Gly Thr Val Ala Ser Ser Ty - #r Phe Arg Phe Asn Pro# 220- ttc ctg cgc tcc gcg gcg aag ggc gcc gac ac - #c ctc gtg tgg ctg gcg 720Phe Leu Arg Ser Ala Ala Lys Gly Ala Asp Th - #r Leu Val Trp Leu Ala225 2 - #30 2 - #35 2 -#40- tcc gcg ccg gcc gag gag ttg acc acg ggc gg - #c tac tac agc gac cgg 768Ser Ala Pro Ala Glu Glu Leu Thr Thr Gly Gl - #y Tyr Tyr Ser Asp Arg# 255- cgg ctg tcc ccg gtg agc ggc ccg acc gcc ga - #c gcc ggc ctc gcg gcg 816Arg Leu Ser Pro Val Ser Gly Pro Thr Ala As - #p Ala Gly Leu Ala Ala# 270- aag ctc tgg gag gcc ggc gcg gcc gcc gtc gg - #c gac acc gcg cac tga 864Lys Leu Trp Glu Ala Gly Ala Ala Ala Val Gl - #y Asp Thr Ala His# 285- <210> SEQ ID NO 2<211> LENGTH: 287<212> TYPE: PRT<213> ORGANISM: Streptomyces peucetius- <400> SEQUENCE: 2- Met Thr Ala Ser Thr Pro His His Gly Thr Pr - #o Arg Gly Gly Leu Ser# 15- Gly Arg Thr Val Leu Val Thr Gly Ala Thr Se - #r Gly Ile Gly Arg Ala# 30Ala Ala Leu Ala Val Ala Arg Gln Gly Ala Ar - #g Val Val Leu Val Gly# 45- Arg Asp Pro Glu Arg Leu Arg Thr Val Thr As - #n Glu Val Ala Arg Thr# 60Ala Gly Pro Ala Pro Asp Ala Phe Arg Ala As - #p Phe Ala Glu Leu Arg# 80- Gln Val Arg Asp Leu Gly Glu Arg Leu Arg As - #p Arg Tyr Pro Arg Ile# 95Asp Val Met Ala Ser Asn Ala Gly Gly Met Ph - #e Trp Ser Arg Thr Thr# 110- Thr Gln Asp Gly Phe Glu Ala Thr Ile Gln Va - #l Asn His Leu Ala Gly# 125Phe Leu Leu Ala Arg Leu Leu Arg Glu Arg Le - #u Ala Gly Gly Arg Leu# 140- Ile Leu Thr Ser Ser Asp Ala Tyr Thr Gln Gl - #y Arg Ile Asp Pro Asp145 1 - #50 1 - #55 1 -#60Asp Leu Asn Gly Asp Arg His Arg Tyr Ser Al - #a Gly Gln Ala Tyr Gly# 175- Thr Ser Lys Gln Ala Asn Ile Met Thr Ala Al - #a Glu Ala Ala Arg Arg# 190Trp Pro Asp Val Leu Ala Val Ser Tyr His Pr - #o Gly Glu Val Arg Thr# 205- Arg Ile Gly Arg Gly Thr Val Ala Ser Ser Ty - #r Phe Arg Phe Asn Pro# 220Phe Leu Arg Ser Ala Ala Lys Gly Ala Asp Th - #r Leu Val Trp Leu Ala225 2 - #30 2 - #35 2 -#40- Ser Ala Pro Ala Glu Glu Leu Thr Thr Gly Gl - #y Tyr Tyr Ser Asp Arg# 255Arg Leu Ser Pro Val Ser Gly Pro Thr Ala As - #p Ala Gly Leu Ala Ala# 270- Lys Leu Trp Glu Ala Gly Ala Ala Ala Val Gl - #y Asp Thr Ala His# 285- <210> SEQ ID NO 3<211> LENGTH: 1569<212> TYPE: DNA<213> ORGANISM: Streptomyces peucetius<220> FEATURE:<221> NAME/KEY: CDS<222> LOCATION: (1)..(255)<220> FEATURE:<221> NAME/KEY: CDS<222> LOCATION: (1219)..(1569)- <400> SEQUENCE: 3- atg gct gag ctc agc ctg gcg gaa ctg cgg ga - #g atc atg cgg cag agc 48Met Ala Glu Leu Ser Leu Ala Glu Leu Arg Gl - #u Ile Met Arg Gln Ser# 15- ctg ggg gag gac gag gtc ccc gac ctt gcg ga - #c gcg gac acc gtg acc 96Leu Gly Glu Asp Glu Val Pro Asp Leu Ala As - #p Ala Asp Thr Val Thr# 30- ttc gag gac ctc ggg ctc gac tcc ctg gcc gt - #c ctg gaa acg gtc aac 144Phe Glu Asp Leu Gly Leu Asp Ser Leu Ala Va - #l Leu Glu Thr Val Asn# 45- cac atc gag cgg acc tat ggc gtg aag ctg cc - #c gag gag gaa ctg gcg 192His Ile Glu Arg Thr Tyr Gly Val Lys Leu Pr - #o Glu Glu Glu Leu Ala# 60- gag gtc agg acg ccg cat agc atg ctg atc tt - #c gtc aac gag agg ctg 240Glu Val Arg Thr Pro His Ser Met Leu Ile Ph - #e Val Asn Glu Arg Leu# 80- cga gcg gcg gca tga cggcctccac cccgcaccac gggacacca - #c gcggcggcct 295Arg Ala Ala Ala- gtcgggccgg acggtgctgg tcaccggggc cacgtccggc atcggccggg cg - #gcggccct 355- cgcggtcgcc cgccaggggg cccgcgtcgt gctcgtcggc cgggaccccg ag - #cgtctgcg 415- gaccgtcacg aacgaggtgg cccggaccgc cggcccggcc ccggacgcct tc - #cgcgcgga 475- cttcgccgag ctgcgccagg tacgcgacct gggggagcgg ctgcgggacc gg - #tacccgcg 535- catcgatgtc atggccagca acgccggcgg catgttctgg tcgcgcacca cg - #acccagga 595- cgggttcgag gccaccatcc aggtcaatca cctcgcaggc ttcctgctgg ca - #cggctgct 655- gcgggagcgg ctcgcgggcg ggcggctgat cctcacctcg tccgacgcgt ac - #acccaggg 715- ccggatcgac ccggacgacc tcaacggcga ccgtcaccgc tacagcgccg gc - #caggcgta 775- cggcacgtcc aaacaggcca acatcatgac cgcggcggag gccgccaggc gc - #tggccgga 835- cgtgctggcg gtcagctatc accccggtga ggtccgcacc cgcatcggac gg - #ggcacggt 895- cgcctcgtcc tacttccggt tcaacccctt cctgcgctcc gcggcgaagg gc - #gccgacac 955- cctcgtgtgg ctggcgtccg cgccggccga ggagttgacc acgggcggct ac - #tacagcga1015- ccggcggctg tccccggtga gcggcccgac cgccgacgcc ggcctcgcgg cg - #aagctctg1075- ggaggccggc gcggccgccg tcggcgacac cgcgcactga cggcggcggc cc - #gccccgcc1135- cgcatgtccg tctcatccgc gagatgtccg tctcatccgc gagcgcagac gc - #tcgtgtgc1195- cgatccatcg aaaggaacga ttc gtg acc agg ttc gcg cc - #c ggc gcc ccc gca1248#Gly Ala Pro Ala Arg Phe Ala Pro# 90- tgg ttc gac ctc ggt tcg ccc gat gtc gcc gc - #c tcg gcc gac ttc tac1296Trp Phe Asp Leu Gly Ser Pro Asp Val Ala Al - #a Ser Ala Asp Phe Tyr#110- acc ggc ctg ttc ggc tgg acc gcc acc gtg gt - #c agc gac ccg ggc gcc1344Thr Gly Leu Phe Gly Trp Thr Ala Thr Val Va - #l Ser Asp Pro Gly Ala# 125- ggg gga tac acg acg ttc agc tcc gac ggg aa - #g ctg gtc gcc gcg gtc1392Gly Gly Tyr Thr Thr Phe Ser Ser Asp Gly Ly - #s Leu Val Ala Ala Val# 140- gcc cgc cac cag atc gac acc ccc tac cac cg - #g ccg tac ggg ccc ggg1440Ala Arg His Gln Ile Asp Thr Pro Tyr His Ar - #g Pro Tyr Gly Pro Gly# 155- aac gac cag cac ggc atg ccg gcc atc tgg ac - #c gtg tac ttc gcc acc1488Asn Asp Gln His Gly Met Pro Ala Ile Trp Th - #r Val Tyr Phe Ala Thr# 170- gac gac gcc gac gca ctg acc aag cgg gtc ga - #g acg gcg ggc ggc gag1536Asp Asp Ala Asp Ala Leu Thr Lys Arg Val Gl - #u Thr Ala Gly Gly Glu175 1 - #80 1 - #85 1 -#90# 1569g act ccg atg gac gtc ctc ggc ct - #cVal Ile Met Thr Pro Met Asp Val Leu Gly Le - #u# 200- <210> SEQ ID NO 4<211> LENGTH: 84<212> TYPE: PRT<213> ORGANISM: Streptomyces peucetius- <400> SEQUENCE: 4- Met Ala Glu Leu Ser Leu Ala Glu Leu Arg Gl - #u Ile Met Arg Gln Ser# 15- Leu Gly Glu Asp Glu Val Pro Asp Leu Ala As - #p Ala Asp Thr Val Thr# 30- Phe Glu Asp Leu Gly Leu Asp Ser Leu Ala Va - #l Leu Glu Thr Val Asn# 45- His Ile Glu Arg Thr Tyr Gly Val Lys Leu Pr - #o Glu Glu Glu Leu Ala# 60- Glu Val Arg Thr Pro His Ser Met Leu Ile Ph - #e Val Asn Glu Arg Leu# 80- Arg Ala Ala Ala- <210> SEQ ID NO 5<211> LENGTH: 117<212> TYPE: PRT<213> ORGANISM: Streptomyces peucetius- <400> SEQUENCE: 5- Val Thr Arg Phe Ala Pro Gly Ala Pro Ala Tr - #p Phe Asp Leu Gly Ser# 15- Pro Asp Val Ala Ala Ser Ala Asp Phe Tyr Th - #r Gly Leu Phe Gly Trp# 30- Thr Ala Thr Val Val Ser Asp Pro Gly Ala Gl - #y Gly Tyr Thr Thr Phe# 45- Ser Ser Asp Gly Lys Leu Val Ala Ala Val Al - #a Arg His Gln Ile Asp# 60- Thr Pro Tyr His Arg Pro Tyr Gly Pro Gly As - #n Asp Gln His Gly Met# 80- Pro Ala Ile Trp Thr Val Tyr Phe Ala Thr As - #p Asp Ala Asp Ala Leu# 95- Thr Lys Arg Val Glu Thr Ala Gly Gly Glu Va - #l Ile Met Thr Pro Met# 110- Asp Val Leu Gly Leu 115__________________________________________________________________________
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The present invention concerns a process for improving doxorubicin production by means of a recombinant Streptomyces peucetius strain bearing a mutation in the gene dnrU coding for a protein involved in the metabolism of daunorubicin.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH OR DEVELOPMENT
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to clothes washing machines and particularly to a washing machine having high pressure angled air jets that introduce air into the wash water in a stationary tub to establish a circular swirl flow-pattern within the wash water to agitate and clean the clothes without the need for a mechanically rotated drum, and sediment from the laundry is removed from the water by drains both at the top and the bottom of the washing machine; at the end of the wash cycle the high pressure air is used to drain and dehydrate the clean clothes.
[0006] 2. Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98
[0007] During operation, a conventional clothes washing machine proceeds through a series of wash and rinse cycles requiring a substantial amount of time and detergents and other cleaning products to get clothes clean. Each rinse cycle includes a spin cycle portion wherein a clothes article containing tub is spun at a very high speed in order to extract water from the clothes. A drain pump is typically run during the spin cycle in order to remove water from the washer.
[0008] Prior art washers present a host of problems. Tangling of garments is common with traditional washing through agitation made by a cylinder. Residue from the detergent and loose fabric in the garments is caused by tangling in prior art washers. Prior art washers produce off-balanced tumbling noise and even vibration and movement of the prior art washing machines from the prior art washer's spinning cycle. Floating particles are typically not removed by prior art washers.
[0009] U.S. Pat. No. 1,878,825, issued Sep. 20, 1932 to Caise, shows a washing machine which uses submerged laterally mounted water jet nozzles to agitate the garments in a vertical axis.
[0010] U.S. Pat. No. 2,649,706, issued Aug. 25, 1953 to Kemp, describes a washing machine in which the clothes are agitated and washed using jets of water. The jets are arranged in the wall of the tub so as to cause a swirling effect in the cleaning water.
[0011] U.S. Pat. No. 1,790,902, issued Feb. 3, 1931 to Cowles, indicates a washing machine with agitation which is provided by a jet or jets of liquid.
[0012] Two U.S. Pat. Nos. 2,651,191 issued Sep. 8, 1953 and No. 2,575,039 issued Nov. 13, 1951 both to Barnes, are for a washing machine which uses air jets submerged in the cleansing liquid for agitating clothes and the cleansing liquid. U.S. Pat. No. 655,717, issued Aug. 14, 1900 to Kuppelmann, provides a machine generally used by brewers to wash fibrous or loose material which comprises a tank in which pulp is placed. Cold water and air are introduced into the tank through ports to cause the mass of pulp to whirl and thereby be agitated.
[0013] U.S. Pat. No. 3,293,890, issued Dec. 27, 1966 to Valdespino, shows an aspir-jet washer which uses aspirator nozzles to introduce air into the tank through ports to cause the garments and cleaning water to be agitated.
[0014] U.S. Pat. No. 3,418,832, issued Dec. 31, 1968 to Valdespino, claims a small portable apparatus connected to an external source of water under pressure which injects water and air from the atmosphere through a venture-type nozzle arranged generally tangentially of the apparatus.
[0015] U.S. Pat. No. 1,474,277, issued Nov. 13, 1923 to Martel, discloses a washing machine having a continuous whirling action of water which is imparted by streams of water forcibly delivered through apertures at varying elevations.
[0016] U.S. Pat. No. 2,529,802, issued Nov. 14, 1950 to Glass, puts forth a cleaning machine for dry or wet cleaning of garments which comprises an upstanding container having washing liquid therein which is agitated by compressed air which passes through a pipe that encircles the container, through risers up to and through lateral ports, thereby causing a swirling effect.
[0017] U.S. Pat. No. 2,270,805, issued Jan. 20, 1942 to Evans, concerns a washing machine which uses compressed air passing through laterally mounted and submerged jets in intermittent blasts to agitate the clothes in a clockwise or counterclockwise fashion.
[0018] What is needed is a jet-washer for washing clothes which uses a series of spaced and variously angled jets of air in a stationary sealed tank of water to swirl the water under pressure and clean clothes faster and better than prior art washing machines without the need for detergents, thereby eliminating problems caused by prior art washing machines.
BRIEF SUMMARY OF THE INVENTION
[0019] An object of the present invention is to provide a jet-washer for washing clothes which uses a series of spaced and variously angled jets of air in a stationary sealed tank of water to swirl the water under high pressure and clean clothes faster and better than prior art washing machines without the need for detergents, thereby eliminating problems caused by prior art washing machines.
[0020] In brief, a pressurized jet-washer has four air jets at four different levels and directions creating clockwise and spiral movement in the water to wash garments. Air jets force the non-dissolved particles and stains to be separated from the garments and float the particles to the top of the water in the bubbles made by the jets. The pressure in the wash tank is built up by the air jets and the temperature of warm wash water to increase the dissolving rate of water soluble particles. The jet-washer of the present invention washes garments by air jets, clockwise and spiral movement, pressure, and temperature.
[0021] The oxygen level is increased in the water by the air jets making the water “fresher” to control the bacteria growth.
[0022] There is no need for detergent, only spray stain remover and bleach might be needed for tough stains.
[0023] The jet-washer of the present invention reduces tangling of garments common with traditional washing through agitation made by a cylinder, and reduces the residue of detergent and loose fabric in the garments caused by tangling.
[0024] With the jet-washer of the present invention there is no more off-balanced tumbling noise from traditional washer's spinning cycle. The jet-washer of the present invention drains and dehydrates the garments by forcing water out of garments through pressurized air.
[0025] The traditional washer fails to remove floating particles. The new jet-washer has one drain for floating particles on top and another drain for the sediment at bottom.
[0026] With no detergent, less tangling, and less wash time, the jet-washer of the present invention prolongs the life and color of garments and saves energy and money.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0027] These and other details of my invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the invention, and in which drawings:
[0028] FIG. 1 is a diagrammatic side elevation partial cross-sectional view of the air jet pressurized washer of the present invention showing the perforated wall of the inner drum and the air jets and pump, the upper and lower drains, and the outer drain pipe;
[0029] FIG. 2 is a top plan view of the air jet pressurized washer of FIG. 1 showing the air tight sealed steel lid and locking arm;
[0030] FIG. 3 is a diagrammatic top view in partial section of the air jet pressurized washer of FIG. 1 showing the air jets around the perimeter and the perforations on the bottom of the inner drum.
DETAILED DESCRIPTION OF THE INVENTION
[0031] In FIGS. 1-3 , the present air jet washing machine invention 20 comprises a vertical double cylindrical drum comprising a perforated stationary inner drum 8 and a solid stationary outer drum 17 having a circular top opening, a bottom drain 11 to drain water and substances settling in the water which substances were removed from the clothes, and a top drain 18 from the perforated walls of the inner drum for draining water and substances floating on the water which substances were removed from the clothes, an air tight steel lid 1 over the top opening with an annular rubber seal 6 and a pin hinge 3 on each side, a steel arm locking device 2 on a pivot hinge 5 , a spring loaded air pressure balance device 4 to release air beyond designed pressure for safety, an air pump 14 , a series air jet nozzles 9 protruding into the wash tank spaced apart around the interior cylindrical wall, each nozzle angled acutely vertically and horizontally away from the cylindrical wall so that air entering the pressurized wash tank through the series of air jet nozzles produces a swirling high velocity vortex motion in the water in the wash tank to agitate and clean the clothes in the water in the pressurized wash tank and to rinse and air dry the clothes with the water removed from the pressurized wash tank, the air jet nozzles each comprising a backflow prevention device to prevent water and air from escaping the pressurized wash tank. A warm/cold water inlet 7 with a backflow preventer fills the washer tank with a desired level of water for the size of the wash. Preferably there are four air jets 9 at four different levels and directions to create the clockwise and spiral swirling movement to wash the clothes. All these features pressurize the wash tank at higher pressure during washing cycle, and according to the laws of physics, the higher the pressure, the higher dissolving rate of soluble particles for cleaner clothes.
[0032] A drainpipe from the washer tank has a perforated end 13 of the drainpipe inserted into a drain trap below to relieve air pressure exiting the pressurized air tank from destroying the water prime in the drain trap during drain and dehydration cycles.
[0033] The inner tank 8 further comprises a perforated bottom 10 slanted toward the center of the tank to receive garments resting thereon during a dehydration cycle to assist in forcing the water from the damp garments by the air pressure into drain.
[0034] The present invention has an insulation blanket which wraps around the wash tank to prevent the heat lost of warm/hot water during washing & rinsing cycles, and according to the laws of physics, the higher the temperature, the higher dissolving rate of soluble particles. All prior art washers do not have insulation to retain the heat.
[0035] The present invention has a pressured air outlet 16 into wash tank above maximum washing water line, a lower tank drain with open-close solenoid 12 , an air pump 14 , and an outer tank drain with open-close solenoid 18 . All these features pressurized the wash tank at higher atmospheric pressure during drain & dehydrate cycles, and it forces water out off garments into drain(s) at normal atmospheric pressure. Some washers of prior arts use “vacuum” function to suck out water from the drain side, but the “vacuum” fails to apply even suction pressure on all garments in the wash tank to remove water from the garment efficiently, but the present invention applies constant higher pressure onto every inch of the garments in the wash tank during the entire dehydration cycle which will efficiently “dry” or dehydrate the garments.
[0036] The present invention has an outer stationary tank drain with an open-close solenoid 18 which will open first during drain cycle to discharge floating particles at top of wash tank, following that a lower tank drain with open-close solenoid 12 will open to discharge sediments at bottom of wash tank. All prior art washers fail to remove floating particles by discharge water from holes at the bottom or/and sidewalls of wash tank linked to a drain.
[0037] The present invention has a preset washing water table level to be adequately higher than the selected wash load of garments (small, medium, high) and to insure the garments are freely moving in the washing liquid.
[0038] A pressured air inlet 16 , as shown in FIG. 3 , into the wash tank above the maximum washing water line increases the pressure in the wash tank and pushes particles/water into the drain trap during drain and dehydration cycles.
[0039] In use, during the wash cycle drop garments (spray stain remover as needed) into the washer tank 8 and add bleach into the softener and/or bleach filler & dispenser 19 if desired (no detergent required). Close the lid I and lock the pressure locking arm 2 and program the washing function, water level & push start. Fill the washer tank 8 with warm/cold water thru inlet 7 to desired water level and start the air pump 14 and solenoid switch 15 to open the air jet nozzles 9 . The air jets 9 create a clockwise and spiral washing movement and pressurize the tank to the desired pressure. The air jets 9 create the swirling flow to separate particles from the garments and pressure and temperature increase the dissolving rates of the particles into the water. The air pump 14 runs for the programmed time of the wash load. During the drain cycle, which may be part of the wash or rinse cycles, the outer tank drain solenoid 18 opens first and the lower tank drain solenoid 12 opens later to drain particles and water and the air pump 14 runs and the solenoid 15 switch open to the air inlet 16 above the maximum washing water line to increase the pressure in the wash tank and push floating particles/water into the outer tank 17 and through the drain solenoid 18 to the drain trap. The air pressure in the wash tank pushes sediments/water into the lower drain 11 and through the drain solenoid 12 to the drain trap. Then, the two drain solenoids 12 and 18 switch to close per programmed time and the air pump 14 stops. Then, the rinse cycle, drain cycle and the dehydration cycle follows. In the rinse cycle cold water is input through the inlet 7 to a programmed water level. The air pump 14 starts and the solenoid 15 switch is opened to the air jet nozzles 9 . The air jets 9 create clockwise and spiral rinsing movements and pressurize the wash tank to the designed pressure. The air pump 14 runs per the programmed time of the rinse load. Then the drain cycle is repeated. In the dehydration cycle, the air pump 14 runs and the solenoid 15 switch stays opened to the air outlet 16 above the maximum washing water line.
[0040] When the pressure in the tank 8 builds up to a desired pressure at the programmed time, the lower tank solenoid 12 switch opens. Higher pressure at the top of tank than the lower tank suck outs the water from the piled damp garments downward into lower tank perforated drain 11 and pushes the pressed out water through the drain solenoid 12 to the drain trap. The lower tank drain solenoid 12 switches to close at the programmed time.
[0041] The rinse and drain and dehydration steps may be repeated depending upon the programmed wash load. The air pump 14 stops per the programmed time of the wash load and the remaining pressure is released through the air pump to the atmosphere to complete the programmed wash.
[0042] An emergency stop, if necessary, is made by pressing a stop button and during wash and rinse cycle, the air pump 14 stops and the solenoid 15 is switched open to the air outlet 16 to release the air pressure through the air pump to the atmosphere, and during the drain and dehydration cycle, the air pump 14 stops and the solenoid 15 is already open to the air outlet 16 , which will reverse the air flow and release the air pressure through the air pump to the atmosphere. The locking arm 2 is unlocked, the steel lid 1 lifted to open the wash tank. Then the steel lid is closed the locking arm 2 locked, and a start button is pressed to resume the previous function.
[0043] It is understood that the preceding description is given merely by way of illustration and not in limitation of the invention and that various modifications may be made thereto without departing from the spirit of the invention as claimed.
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A washing machine having high pressure angled air jets that introduce air into the wash water in a stationary pressurized tub. A circular swirl flow-pattern and air pressure within the warm wash water agitates and cleans the clothes without the need for a mechanically rotated drum or detergent. Sediment from the laundry is removed from the water by drains both at the top and the bottom of the tub. At the end of the wash cycle, the high pressure air is used to drain and dehydrate the clean clothes.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No. 11/733,542 filed on Apr. 10, 2007 and entitled “SLING RELEASE MECHANISM.” U.S. Ser. No. 11/733,542 is a non-provisional of U.S. Provisional No. 60/790,653 filed on Apr. 10, 2006, and entitled “SLING RELEASE MECHANISM.” The entire contents of all of the foregoing applications are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates to release mechanisms for releasing a deployed parachute from a suspended load in a controlled manner.
BACKGROUND
[0003] Aerial delivery is a means frequently used for transporting cargo quickly to areas of limited or hostile access, without the availability of any nearby airports. At times, people in isolated areas, such as jungles, deserts, mountains, polar regions, or combat zones, are in need of essential supplies, including food and medical supplies, but are not within access to an airport at which a supply plane could land. In these instances, aerial delivery of cargo from in-flight aircraft is the sole option. These aerial delivery systems involve the use of parachute systems to slow the descent and gently land the cargo platforms on the ground.
[0004] Similar parachute systems are further utilized for recovery of aeronautical and astronautical vehicles, including rocket boosters, experimental aircraft and space capsules, returning back to the earth's surface from flights in the upper atmosphere or outer space.
[0005] In these aerial delivery or recovery systems, a series of parachute deployments is often used to progressively slow the descent velocity of the payload. Use of a series of parachute deployments is often necessary because the force and impulse on the suspension lines and straps of a main parachute (i.e., one large enough to slow the cargo platform to an acceptable landing velocity) deploying at the terminal, free-fall velocity of the cargo platform would be excessive, causing the parachute system to fail. Instead, the cargo platform is typically slowed in a series of stages using subsequently larger parachutes.
[0006] A drogue parachute is typically deployed first from the parachute system. The drogue is a small parachute which can be easily deployed from its container by a tether attached to the launching cargo plane or by an easily deployed stored energy means such as a spring launched pilot parachute. As the drogue parachute is deployed and inflated, it moderately decelerates the suspended cargo platform, as well as orientating the cargo platform into its desired upright attitude, without excessive strain on the slings and parachute canopy from which the cargo platform is suspended. After a predetermined time period, the drogue parachute is released from the suspended cargo platform. The drag provided by the released drogue parachute is then utilized to pull and deploy the next, larger parachute. This next parachute may be the final, main parachute, or another intermediary parachute prior to another subsequent deployment of the main parachute, depending upon the size of the cargo platform and the design of the parachute system.
[0007] To accomplish this release design, the drogue parachute is attached to the suspended cargo platform by a release mechanism. The suspended cargo platform is suspended from the release mechanism typically by a series of suspension slings. The suspension slings maintain the suspended cargo platform in a stable, level attitude. The number of suspension slings is typically four, with one routed to each corner of a square or rectangular cargo platform supporting the suspended cargo. For larger platforms, a greater number of suspension slings may be used. The suspension slings converge at a point above the suspended load to the release mechanism, located at the apex of the pyramid formed by the suspension slings.
[0008] The drogue parachute may be attached to the release mechanism by a single sling or riser. From the top end of this sling, a number of suspension lines radiate to the perimeter of the drogue parachute canopy.
[0009] One common release mechanism is a pyrotechnic cord cutter powered by an explosive or pyrotechnic charge. This mechanism utilizes the detonation of a small explosive charge to drive a cutting blade through the suspension sling. For example, Norton, U.S. Pat. No. 4,493,240, disclosed a pyrotechnic cord cutter comprising an elongated cylindrical body with a lateral aperture proximate to one end of the body, through which passes the suspension line or other support line in the parachute system. A chamber is located at the other end of the body, containing an explosive charge. An opening is provided in the medial end of the chamber, into which is registered the rear end of a cutting blade. Upon detonation of the explosive charge in the chamber, the cutting blade is propelled through the aperture, severing the cord within.
[0010] The pyrotechnic cord cutters are typically usable only for relatively small-diameter cords. As the weight of a platform and payload increases, the size of the cord or strap between the parachute and payload platform increases. A pyrotechnic cord cutter for payloads above a moderate size becomes too large for practical handling and would incorporate an explosive charge too large and powerful for safe handling by personnel.
SUMMARY
[0011] A sling release mechanism is provided for installation between an aerially descending cargo platform and its drogue parachute. The sling release mechanism is disposed on the platform or pallet supporting the delivery load. The parachute release mechanism has a body with a connection means located at its upper portion for connection to the sling of a drogue parachute. The release mechanism has one or more pivot arms. Each pivot arm is situated within the body and pivots about a common axle or pivot pin located in the body. Each pivot arm has a free end section with a shaped end section which engages with a latch apparatus.
[0012] In one embodiment, the latch mechanism is comprised of an inner and an outer hinge plate, each having a flat plate section with parallel inner and outer flat faces which articulate with the body. The inner face of the inner hinge plate has a receiver defined therein, which is shaped and adapted to receive the shaped end section of the pivot arm. The inner hinge plate will typically articulate with the body at its lower end, while the outer hinge plate will conversely hinge from its upper end. The two hinge plates are adapted and disposed on the body such that the inner latch plate can articulate to a point where its receiver is engaged by the shaped end section of the pivot arm, after a sling end loop has been placed thereon, and, in this position, the outer hinge plate can articulate to have its inner face lie flush against the outer face of the inner hinge plate. The outer hinge plate is then secured to the body with a retainer, and the retainer is provided with a release means.
[0013] In this configuration, the leverage provided by the two hinge plates allows the retainer to exercise a significantly augmented force to hold the shaped end section of the pivot arm in place within the receiver of the inner latch plate. This significantly reduces the necessary size of the retainer and the means to release the retainer from the outer hinge plate. In one embodiment, the retainer is a cut loop and the release means is a cord cutter. Because the cut loop in this invention needs only to be sufficiently strong to resist the torque on the outer hinge plate imparted by the pivot arm, which is only a small fraction of the weight of the platform, and not the entire weight of the payload platform, a much smaller cord, and thus a much smaller cord cutter may be used than in conventional release means.
[0014] The following detailed description is not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an isometric view of the preferred embodiment of the sling release mechanism.
[0016] FIG. 2 is another isometric view of the preferred embodiment.
[0017] FIG. 3 is a plan view of the preferred embodiment.
[0018] FIG. 4 is a plan view of the preferred embodiment, illustrating the operation of the sling release mechanism.
[0019] FIG. 5 is of another embodiment of the invention, showing an alternate torsion means, retainer and release means.
[0020] FIG. 6 is an elevational view of another embodiment of the invention, showing an alternate retainer and release means.
[0021] FIG. 7 is an illustration of an alternate embodiment of the invention, illustrating multiple pivot arms.
DETAILED DESCRIPTION
[0022] As shown in FIGS. 1 and 2 , a preferred embodiment of a sling release mechanism is comprised, first, of a body 10 , which serves as the base or foundation upon which all other components are assembled. The base can be fabricated of any commonly known, structurally strong material, such as metal, including but not limited to steel, stainless steel, cast iron, aluminum, aluminum alloys, titanium or titanium alloys.
[0023] Attached to the body is a pivot arm 12 . The pivot arm 12 has an elongated section 14 . At one end of the elongated section 14 is a shaped end section 16 and at the other, a means for articulating with the body 10 . This means for articulating with the body 10 comprises, preferably, an aperture 18 . A first pin 20 or the like passes through the aperture 18 with minimal clearance and conjoins at one or both of its ends with the body 10 . The pivot arm 12 can then freely articulate around the first pin 20 . The shaped end section 16 is disposed at the opposite end of the elongated section 14 from the aperture 18 .
[0024] The sling release mechanism further comprises an inner hinge plate 22 . The inner hinge plate 22 generally is of the shape of an elongated flat plate 26 having one enlarged end section. The enlarged end section has an aperture 24 defined within it, the axis of the aperture 24 normal to the longitudinal axis of the flat plate and parallel to the width dimension of the flat plate. A second pin 28 registers with the inner hinge plate aperture 24 and secures with the body 10 , permitting articulation of the inner hinge plate 22 about the second pin 28 . The longitudinal axis of the second pin 28 is parallel to that of the first pin 20 , so that the pivot arm 12 and the inner hinge plate 22 articulate within the same plane, with the inner hinge plate 22 inner face proximate to the pivot arm 12 .
[0025] In the inner hinge plate 22 inner face is or is defined a receiver 30 for the shaped end section 16 of the pivot arm 12 . The shaped end section 16 and the receiver 30 are complementarily shaped so that the shaped end section 16 registers with the receiver 30 when the inner hinge plate 22 is articulated towards the pivot arm 12 . Once the shaped end section 16 registers with the receiver 30 and the inner hinge plate 22 is restrained in place, the pivot arm 12 is likewise secured in place and precluded from any further articulation until the inner hinge plate 22 is released and allowed to articulate. In one embodiment, the complementary shapes are simply a rounded, convex hemispherical tip on the shaped end section and a concave, hemispherical cavity in the inner face of the inner hinge plate 22 . In another embodiment, the complementary shapes are of a conical frustrum. Other shapes to the shaped end section 16 and receiver 30 are within the scope of the invention, including but not limited to one or more tongue-and-groove slots disposed parallel to the axes of the pivot arm 12 and inner hinge plate 22 , so long as the shaped end section 16 and the receiver 30 can freely engage and disengage with little force to the inner hinge plate 22 , but, when engaged, will restrain articulation of the pivot arm 12 .
[0026] The sling release mechanism further comprises an outer hinge plate 36 . The outer hinge plate 36 is constructed similar to the inner hinge plate 22 , being again in the preferred embodiment a flat plate 38 with an expanded end section and an aperture 40 defined in the expanded end section normal to the longitudinal axis and parallel to the width dimension of the flat plate 38 . A third pin 42 registers with the outer hinge plate aperture 40 and is secured to the body 10 , permitting articulation of the outer hinge plate 36 about the axis of the third pin 42 . The axis of articulation of the outer hinge plate 36 , the inner hinge plate 22 and the pivot arm 12 are parallel, and the three components articulate substantially within the same plane.
[0027] The third pin 42 , about which the outer latch plate 36 articulates is disposed on the body 10 at a point where an imaginary line through the third pin 42 and the second pin 28 is parallel to the longitudinal axis of the inner hinge plate 22 , when the shaped end section 16 of the pivot arm 12 has registered with the inner latch plate receiver 30 . The inner and outer hinge plates 22 , 36 are constructed such that, when the pivot arm 12 has engaged with the receiver 30 in the inner face of the inner hinge plate 22 , the inner face of the outer hinge plate 36 can engage flush with the outer face of the inner hinge plate 22 .
[0028] As shown in FIG. 3 , the sling release mechanism further comprises a first torsion means, provided on the inner hinge plate 22 , which applies a torque to the inner hinge plate 22 about the axis of its articulation in a direction away from the pivot arm 12 . In the preferred embodiment, the first torsion means is a compression spring 32 which is disposed within a cavity or well 34 in the body 10 . The depth of the cavity 34 is slightly less than the length of the compression spring 32 , such that, when inserted into the well 34 , one end of the compression spring 32 protrudes slightly beyond the edge of the well 34 . A foot 35 is provided on the inner hinge plate 22 to engage and compress the protruding end of the compression spring 32 when the inner hinge plate 22 rotates to a position of engagement with the pivot arm 12 . The first torsion means facilitates disengagement of the receiver in the inner hinge plate 22 from the shaped end section 16 of the pivot arm 12 , when the inner latch plate 22 is intentionally released and allowed to articulate.
[0029] A second torsion means is further provided on the outer hinge plate 36 , applying a torque to the outer hinge plate 36 about the axis of articulation in a direction away from the pivot arm 12 , similar to the first torsion means on the inner hinge plate 22 . However, since the outer hinge plate 36 is oriented inversely from the inner hinge plate 22 , the second torsion means will apply a torque to the outer hinge plate 36 in a direction opposite from the first torsion means. If the inner hinge plate 22 is disposed as shown in FIG. 1 , with its axis of articulation to the left and below the pivot arm 12 , the first torsion means will apply an anticlockwise torque to the inner hinge plate 22 , while the second torsion means will apply a clockwise torque to the outer hinge plate 36 .
[0030] Like the first torsion means, the second torsion means in the preferred embodiment is a compression spring 44 , which is disposed in a cavity or well 46 in the body 10 , which protrudes slightly from the well 46 , and which engages with part of the outer hinge plate 36 as the outer hinge plate 36 contacts the inner hinge plate 22 , while the inner hinge plate 22 has been engaged by the pivot arm 12 .
[0031] Once the inner hinge plate 22 has engaged the pivot arm 12 , and the outer hinge plate 36 has engaged the inner hinge plate 22 , a releasable retainer is provided to temporarily secure the outer hinge plate 36 in place against the torque applied to the outer and inner hinge plates 22 , 36 , as well as any force applied to the pivot arm 12 from a sling disposed thereon. However, because of the lever arms provided by both the outer and inner hinge plates 22 , 36 , the force on the retainer is significantly less than the external force applied on the pivot arm 12 .
[0032] In the preferred embodiment, again shown in FIG. 3 , the retainer is an explosive bolt 48 securing the end of the outer hinge plate 36 , distal from its aperture 40 , to the body 10 . This can be accomplished by drilling aligned holes in the outer hinge plate 36 and the body 10 and tapping the hole in the body 10 to accept the threads of an explosive bolt 48 . An explosive bolt 48 is well known in the art of aerial parachute delivery systems, and is comprised of a frangible bolt with an embedded explosive charge which, when ignited, severs the bolt laterally. The explosive charge may be ignited by a remote or an automatic controller, which delivers an igniting electrical charge or current to the explosive at a predetermined time for release of the outer hinge plate 36 .
[0033] Once the release means releases the retainer securing the two hinge plates to the body, the two are free to articulate. As shown in FIG. 4 , upon detonation of the explosive bolt (not shown), the outer hinge plate 36 is free to articulate clockwise, assisted in part by the force provided by the compressed compression spring 44 . The outer hinge plate 36 then articulates, in the case in the layout shown in FIG. 4 , clockwise. This then releases the inner hinge plate 22 , which then articulates anti-clockwise, propelled in part by the force exercised by the compression spring 32 against the foot 35 . Once the inner hinge plate begins to articulate, the receiver 30 disengages from the shaped end section 16 of the pivot arm 12 , and the pivot arm 12 is then free to articulate, in this case, clockwise. Once the pivot arm has sufficiently articulated, a sling secured onto the pivot arm 12 is free to slide off and release from the mechanism.
[0034] In other embodiments of the present invention, alternative devices may be used for the first and second torsion means. As shown in FIG. 5 , torque may be provided by torsion springs 62 , 64 disposed coaxially on the second and third pins 28 , 42 respectively, with one end secured to the respective hinge plate 22 , 36 and the other to the pin 28 , 42 or body 10 . However, this embodiment is less desirable because the spring would not unload and would continue to impart a torque to the respective hinge plate even after the engagement with the pivot arm 12 was released.
[0035] FIG. 5 also shows another embodiment of the retainer and release means. Here, the retainer comprises a piece of cord in a loop, commonly called a “cut loop” 50 in the art, which circumscribes the outer and inner hinge plates 22 , 36 and, optionally, part or all of the body 10 . A pyrotechnic cord cutter 52 , well known in the art, is disposed on the cut loop 50 . The cord cutter 52 has an aperture through which passes the cord of the cut loop 50 . Within the cord cutter 52 is a knife edge which is propelled by a small pyrotechnic charge. The charge can be detonated by an electric signal sent automatically or remotely. When an electric signal is provided to the cord cutter 52 , the pyrotechnic charge ignites, propelling the knife edge through the cord and severing the cut loop 50 . The two hinge plates 22 , 36 are then free to articulate away from engagement with the pivot arm 12 .
[0036] FIG. 5 further shows a sling 58 secured to the pivot arm 12 by a loop 60 at the end of the sling 58 .
[0037] In another embodiment, shown in FIG. 2 , the first and second torsion means are found in and as part of the second and third pins 28 , 42 , wherein the second and third pins 28 , 42 are rigidly secured to the respective inner and outer hinge plates 22 , 36 and are fabricated of an elastic material, such as a polymeric elastomer or spring steel, in part or in toto, which can elastically twist and provide a torque on the respective hinge plates as those hinge plates are articulated on the two pins 28 , 42 . This is commonly referred to in the art as a torsion bar. This torsion bar has a similar disadvantage of the other alternative embodiments, in that a torque is still applied even when the respective hinge plates 22 , 36 rotates at angles beyond that sufficient to disengage the pivot arm 12 from the inner hinge plate 22 , but the torsion bars 28 , 42 have the advantage of providing the capability of holding the two hinge plates 22 , 36 , after release, at a fixed angle away from the pivot arm 12 , rather than freely flapping and articulating uncontrolled after release from the pivot arm 12 . This can be provided by securing the two torsion bars 28 , 42 to the body with the respective hinge plates 22 , 36 at a desired angle after release. The torsion bars 28 , 42 will provide the necessary torque when the two hinge plates 22 , 36 are articulated to the position of engagement with the pivot arm 12 but, when released, will only articulate sufficiently to release the pivot arm 12 . Any further articulation of either of the hinge plates 22 , 36 will be corrected by the reverse torque imposed by the torsion bar 28 , 42 twisted in the reverse direction.
[0038] In another embodiment, shown in FIG. 6 , the retainer is a sliding pin 54 which engages a hasp 55 mounted on the outer hinge plate 36 with either the body 10 or the inner hinge plate 22 . The sliding pin 54 is translationally operated by an electric solenoid 56 . When the inner hinge plate (hidden from view) and outer hinge plates 36 are positioned to engage the pivot arm (hidden from view), the solenoid 56 is de-energized to register the sliding pin 54 with the outer hinge plate 36 . When the pivot arm (hidden from view) is desired to be released, the electrical power to the solenoid 56 is energized on, the sliding pin 54 withdraws from the hasp 55 and the outer hinge plate 36 is released.
[0039] Another embodiment of the invention comprises a plurality of the single sling mechanism described above. In this embodiment, shown in FIG. 7 , a body 10 has a plurality of pivot arms 12 disposed therein, preferably on a common or concentric axis. A set of inner and outer hinge plates 22 , 36 as described above, can be provided for each of the plural pivot arms 12 . Each outer hinge plate 36 may have its own, dedicated retainer and release means, such as a separate explosive bolt. This would allow release of each pivot arm 12 and its associated sling independently. Alternatively, one set of inner and outer hinge plates 22 , 36 may be provided. The single inner hinge plate 22 would have multiple receivers disposed in its inner face, the number of which equaling the number of pivot arms 12 .
[0040] Another alternative of this plural sling embodiment is one having a plurality of pivot arms 12 , capable of securing and then releasing multiple slings. This may find use where several drogue parachutes may be deployed and then released in series, to decelerate a cargo incrementally. The plurality of pivot arms may be secured by a plurality of inner and outer hinge plates 22 , 36 operating in a similar manner as a single sling release mechanism, in which each inner hinge plate has one receiver 30 securing one pivot arm 12 , and each outer hinge plate 36 secures one inner hinge plate 22 . Alternatively, large inner and outer hinge plates 22 , 36 can be provided which can individually secure multiple pivot arms 12 or inner hinge plates 22 , respectively. As shown in FIG. 7 , one embodiment has two pivot arms 12 articulating on a common first pin 20 . The pivot arms 12 each engage with an individual inner hinge plate 22 with a single receiver 30 . However, as shown, the two inner hinge plates 22 , shown in hidden view, would be secured by a single outer hinge plate 36 . This outer hinge plate 36 can be held in place with the various retainers and release means described in the other embodiments.
[0041] While various embodiments of the invention have been described above, it should be understood that they have been presented by way of example, and not of limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail may be made therein without departing from the spirit, scope or application of the invention. This is especially true in light of technology and terms within the relevant art that may be later developed. Thus, the present invention should not be limited by any of the above-described exemplary embodiments, but should only be defined in accordance with the appended claims and their equivalents.
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A sling release mechanism for releasing the sling of a drogue parachute from a descending aerially delivered cargo pallet. The sling release mechanism has a body, with which a pivot arm, an inner and outer hinge plate articulate. The inner and outer hinge plates articulate in opposite directions when in use. The inner hinge plate has a cavity or receiver into which the end tip of the pivot arm may engage. The end of a parachute sling is placed over the pivot arm, and the pivot arm and inner hinge plate are articulated to engage the pivot pin end with the receiver of the inner hinge plate. The outer hinge plate is then articulated to engage the inner hinge plate, and is held in place with a releasable retainer. The parachute sling is released by releasing the retainer, allowing the outer and then the inner hinge plates to articulate, thereby releasing the pivot arm to articulate, after which the end of the parachute sling slides off the pivot pin. Other embodiments include multiple mechanisms for releasing a plurality of slings.
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TECHNICAL FIELD
This invention relates to engine exhaust driven turbochargers and more particularly to a turbocharger rotor having alignment couplings and a fastener rod joining compressor and turbine wheels with a connecting shaft.
BACKGROUND OF THE INVENTION
It is known in the art relating to exhaust driven engine turbochargers to provide a rotor including a turbine wheel and a compressor wheel connected by a shaft for rotation together about an axis. In some cases, the shaft is formed as an extension of the turbine wheel. Separate shaft and wheel components may be welded together before final machining. Alternatively, a steel shaft may be connected to the turbine and to the compressor wheel by separate connecting means. Commonly, the impeller or compressor wheel is made of aluminum alloy to minimize the rotating mass.
Various types of connecting means have been provided for aligning and connecting the wheels and the shaft for axial rotation. Where the connecting means extend through the compressor wheel and clamp the wheel in compression against the shaft, the design should avoid excessive variations in clamping load due to differential thermal growth and the effects of centrifugal force on the steel and aluminum during varying operating and stationary conditions. The means for connecting the compressor impeller wheel and the turbine wheel to the shaft are also important because the rotor must be disassembled after balancing in order to assemble the rotor into the turbocharger. Upon reassembly of the rotor, the repeat balance must preserve the original balance as far as possible without actually rebalancing the rotor in the turbocharger assembly. Connecting means that allow separation and reassembly of the components without changing the balance are therefore desired.
SUMMARY OF THE INVENTION
The present invention provides a rotor including a turbine wheel and a compressor wheel connected by a shaft for rotation together about an axis. Novel connecting means extend between the compressor and turbine wheels and limit the clamp load, or retaining force, variation applied to the compressor wheel under varying thermal expansion conditions experienced during operation and shutdown. The connecting means also provide for coaxially aligning or centering the compressor and turbine wheels on the axis of the connecting shaft with the capability of simple and repeatable reassembly.
The connecting means include a single long fastener rod, such as a stud or bolt, which extends through both the compressor wheel and the connecting shaft to engage the turbine wheel and place both the compressor wheel and the connecting shaft in compression. Preferably the fastener rod is threaded into the turbine wheel and carries a nut or head that clamps the compressor wheel and shaft in assembly with the turbine wheel. Optionally, the fastener rod could also extend through the turbine wheel and be secured to the turbine wheel by a nut or head.
The connecting means also include first and second joints between the shaft and the compressor wheel at one end and the turbine wheel at the other end. The joints are configured to maintain coaxial alignment of the compressor and turbine wheels with the shaft while providing high axial and bending stiffness and torque transmitting capability. Various forms of joints could be provided to meet these requirements. Examples include piloted shoulders and polygon connections as well as toothed couplings, among others. A presently preferred embodiment uses toothed couplings with so-called CURVIC™ coupling teeth.
Another preferred feature of the invention includes use of a steel adapter which is press fitted onto a stub of the aluminum alloy compressor wheel to provide a joint material similar to that of the connecting shaft. The adapter may also provide an oil sealing surface. A similar adapter may also be provided on the turbine wheel if desired.
The shaft may include one or more radial thrust surfaces preferably located inboard of associated bearing journals to limit oil sealing requirements. The thrust surfaces preferably face outward and are formed on flanges integral with the shaft.
These and other features and advantages of the invention will be more fully understood from the following description of certain specific embodiments of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a cross-sectional view of an engine turbocharger having a rotor including features in accordance with the invention;
FIG. 2 is a side view partially in cross section of the rotor in the embodiment of FIG. 1;
FIG. 3 is an end view from the plane of the line 3 — 3 of FIG. 2 showing a toothed coupling portion of the compressor wheel;
FIG. 4 is an enlarged end view of the compressor wheel coupling teeth shown in the circle 4 of FIG. 3;
FIG. 5 is an enlarged end view of the rotor shaft coupling teeth configured for mating with the compressor wheel coupling teeth; and
FIG. 6 is a view similar to FIG. 2 but showing a modified embodiment of the invention;
FIG. 7 is a fragmentary cross-sectional view showing an alternative rotor having an exemplary piloted shoulder coupling;
FIG. 8 is a view similar to FIG. 7 but showing a polygon coupling; and
FIG. 9 is an end view from line 9 — 9 of FIG. 8 showing the shape of the polygon recess in the shaft coupling.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, numeral 10 generally indicates an exhaust driven turbocharger for an engine, such as a diesel engine intended for use in railway locomotives or other applications of medium speed diesel engines. Turbocharger 10 includes a rotor 12 carried by a rotor support 14 for rotation on a longitudinal axis 16 and including a turbine wheel 18 and a compressor wheel 20 . The compressor wheel is enclosed by a compressor housing assembly 22 including components which are supported on an axially facing first side 24 of the rotor support 14 . An exhaust duct 26 has a compressor end 28 that is mounted on a second side 30 of the rotor support 14 spaced axially from the first side 24 .
The exhaust duct 26 is physically positioned between the rotor support 14 and the turbine wheel 18 to receive exhaust gases passing through the turbine wheel and carry them to an exhaust outlet 32 . A turbine end 34 of the exhaust duct 26 and an associated nozzle retainer assembly 35 are separately supported by an exhaust duct support 36 that is connected with the exhaust duct 26 at the turbine end 34 . The exhaust duct support 36 also supports a turbine inlet scroll 38 which receives exhaust gas from the associated engine and directs it through a nozzle ring 40 to the turbine wheel 18 for transferring energy to drive the turbocharger compressor wheel 20 .
The rotor support 14 includes a pair of laterally spaced mounting feet 42 which are rigidly connected to an upstanding mounting portion 44 of the rotor support 14 and are adapted to be mounted on a rigid base, not shown. The rotor support 14 further includes a tapering rotor support portion 46 having bearings 48 , 50 that rotatably support the rotor 12 . Bearing 48 is a combination sleeve and thrust bearing while bearing 50 is primarily a sleeve bearing.
Referring particularly to FIG. 2, the rotor 12 includes a shaft 52 connected with the turbine wheel 18 at one end and the compressor wheel 20 at the opposite end. The shaft 52 includes a pair of axially spaced bearing supported portions or journals 54 , 56 , respectively adjacent the compressor and turbine wheel ends of the shaft. A flange 57 , inboard of journal 54 , carries a radial thrust reaction surface 58 . A second flange 59 , inboard of journal 56 , carries a radial anti-thrust reaction surface 60 . Journals 54 , 56 are respectively supported in bearings 48 , 50 (FIG. 1 ). Radial surface 58 carries thrust forces to the sleeve/thrust bearing 48 and radial surface 60 limits axial movement of the rotor 12 .
A particular advantage of the invention is gained by having the thrust reaction surface 58 and the anti-thrust reaction surface 60 both face outward toward the ends of the shaft 52 . This is made possible by separating the shaft from the compressor and turbine wheels and allows both flanges 57 , 59 to be made integral with the shaft, which avoids separate thrust flanges and simplifies machining of the shaft itself. The separation also benefits design modification and rebuild functions because modification or replacement of the turbine or compressor portions need not affect the bearings or the shaft portion.
In accordance with the invention, the rotor elements including the compressor wheel 20 , shaft 52 and turbine wheel 18 are retained in assembly by connecting means including a fastener rod, preferably comprising a stud 62 and nut 64 . The stud 62 extends through axial openings in the compressor wheel 20 and the shaft 52 and is threaded into a threaded recess in an inner end 66 of the turbine wheel 18 . The nut 64 is threaded onto an opposite end of the stud and engages a washer 68 on an outer end of the compressor wheel. The nut 64 is tightened a predetermined amount to place under compressive load additional elements of the connecting means, including connections or first and second joints 70 , 72 between the shaft 52 and the compressor wheel 20 and turbine wheel 18 respectively.
The stud 62 is sized to resiliently stretch a desired amount as the nut is tightened to compress the rotor elements. In this way, variations in the compressive force on the rotor elements due to axial dimensional changes in the rotor components, in operation or while stationary, are limited by stretching of the stud 62 so that excessive variations in compressive load are not encountered. This is particularly desirable, since the compressor wheel is made of aluminum alloy, which has a greater thermal coefficient of expansion than the stud 62 and other elements of the rotor made of steel. If desired, another suitable form of fastener rod, such as a long bolt with a head, could be used in place of the stud 62 and nut 64 , as long as the force limiting feature of the fastener rod is retained. Use of a fastener rod to load and connect the rotor elements axially requires only a relatively small axial opening through the compressor wheel and a small threaded recess in the turbine wheel. Thus, stresses in the wheels are reduced as compared to other connecting methods and increased maximum rotor speeds are permitted.
In accordance with the invention, the first and second joints 70 , 72 of the connecting means are provided for aligning and connecting the compressor and turbine wheels on their respective ends of the shaft 52 . The joints 70 , 72 must maintain coaxial alignment of the compressor and turbine wheels with the shaft while providing high axial stiffness under compression, high bending stiffness, and torque transmitting capability. Many joint configurations exist that could meet the above requirements and are intended to be included within the broad scope of the invention. Accuracy, reliability and cost are also factors to be considered in selecting a suitable joint configuration.
Presently preferred embodiments of joints 70 , 72 are illustrated in FIGS. 2-5. The compressor wheel 20 includes on an inner end a stub 74 carrying a pressed-on steel adapter 76 having a ring shaped end face 78 of the compressor wheel that engages a compressor end 80 of the shaft 52 at the first joint 70 . Adapter 76 also includes a generally cylindrical seal surface 81 , for cooperating with a compressor oil seal of the turbocharger to control oil leakage toward the compressor wheel 20 . The turbine wheel 18 similarly includes on its inner end 66 a steel adapter 82 having a ring shaped end face 84 that engages a turbine end 86 of the shaft 52 at the second joint 72 . Adapter 82 also includes a generally cylindrical seal surface 87 for cooperating with a turbine oil seal to control oil leakage toward the turbine. The inboard location of the thrust flanges and their reaction surfaces 58 , 60 of shaft 52 also helps control oil seal leakage, because oil flowing from the thrust flanges is directed away form the oil seal surfaces 81 , 87 .
FIGS. 3-5 show details of the first joint, which are similar to those of the second joint. The end face 78 of the compressor wheel 20 mounts an axially centered first ring of coupling teeth 88 extending axially inward from the end face 78 toward the compressor end 80 of the shaft 52 . The shaft 52 similarly has on the compressor end 80 a second ring of mating coupling teeth 90 extending axially outward into engagement with coupling teeth 88 of the first ring. Preferably, the coupling teeth take the form of a so-called CURVIC™ coupling in which the first ring of teeth 88 of the compressor wheel are formed with concave sides separated by convexly sided spaces 92 and the mating teeth 90 on the shaft have convex sides separated by concavely curved spaces 94 . These configurations are best shown in FIGS. 4 and 5.
The second joint 72 similarly includes an axially centered third ring of coupling teeth 88 extending axially inward from the end face 84 of the turbine toward the turbine end 86 of the shaft 52 . The shaft similarly has on the turbine end 86 a fourth ring of mating coupling teeth 90 extending axially outward into engagement with coupling teeth 88 of the third ring. These teeth also preferably take the form of a CURVIC™ coupling as described above. The toothed couplings at the first and second joints meet the requirements of the joints by maintaining coaxial alignment of the compressor and turbine wheels with the shaft while providing high axial stiffness when under compression with high bending stiffness, and torque transmitting capability.
The rotor 12 is first assembled outside the turbocharger as shown in FIG. 2 . It is balanced, marked to show the locations of the mating coupling teeth and subsequently disassembled for reassembly with other components in the buildup of a complete turbocharger. Upon reassembly within the turbocharger, the rotor components are axially aligned by the toothed couplings and angularly positioned with the same phase angles maintained during balancing by aligning the marked teeth of the couplings. The reassembled rotor is thus maintained in essentially the same balance condition as originally provided by the original balance operation outside of the turbocharger.
Referring now to FIG. 6 of the drawings wherein like numerals indicate like parts or features, numeral 100 indicates a turbocharger rotor similar to that of FIG. 2 . Rotor 100 differs from rotor 12 in that the turbine adapter is replaced by a seal collar 102 , which forms a cylindrical seal surface 104 but does not form an inner face of the turbine wheel 106 . Instead, a stub 108 of the wheel 106 has an inner end 110 integral with a ring shaped inner face 112 and a third ring of coupling teeth 114 integrally formed on the inner face 112 . Teeth 114 may be configured like teeth 88 on the turbine wheel adapter 82 of the embodiment of FIG. 2, and so the turbine wheel 106 may be made interchangeable with turbine wheel 18 illustrated in FIGS. 1 and 2. The coupling teeth may be formed on the turbine wheel because the turbine wheel material has a hardness similar to the shaft 52 to which it is coupled. The aluminum material of the compressor wheel makes use of the adapter 76 necessary, or at least desirable, to avoid having aluminum teeth on the compressor wheel 20 engaging steel teeth on the shaft 52 .
FIGS. 7-9 illustrate two examples of alternative joint configurations that could be selected for use in a turbocharger rotor of according to the invention. These examples are not meant to limit the scope of the invention, but only to show some considered alternatives.
FIG. 7 illustrates one form of piloted shoulder coupling joint 116 located at the inner end of compressor wheel 20 but also usable at the joint between the shaft and turbine wheel, not shown. Joint 116 includes a male coupling 118 formed on an adapter 120 fixed on the inner end of the compressor wheel 20 . Coupling 118 includes an annular shoulder 122 surrounding a protruding cylindrical pilot 124 formed with a circular cross section. A mating female coupling 126 is formed in an end of the connecting shaft 128 and includes an annular abutment 130 engaging the shoulder 122 . A cylindrical recess 132 is axially centered on the shaft end and receives the pilot 124 of coupling 118 with a close fit. The pilot 124 and surrounding shoulder 122 and the mating recess 132 and abutment 130 of the couplings assure coaxial alignment of the compressor wheel 20 with the shaft 128 when the components are compressed by the stud 62 and nut 64 comprising the fastener rod. A similar coupling joint, not shown, may be applied at the turbine end of the shaft 128 . Preferably, a dowel 134 connects the adapter 120 with the shaft 128 to maintain angular positioning of the components upon reassembly of the rotor.
FIGS. 8 and 9 illustrate one form of so-called polygon coupling joint 136 . The polygon joint is similar to the piloted shoulder joint 116 just described and may be used in the same locations. The adapter located polygon coupling 138 differs in that the protruding pilot 140 and the mating recess 142 of the shaft coupling 144 of shaft 146 have polygon shaped cross sections as shown, for example, by recess 142 in FIG. 9 . The shoulder 148 of the male coupling 138 and the mating abutment 150 of the shaft coupling 144 differ in configuration but have the same purpose as the similar features 122 , 130 of joint 116 . With the polygon joint 136 , a locating dowel is not needed, since marking the assembled rotor components allows reassembly in the same location determined by the polygon pilot. In other ways, coupling joints 136 and 116 may be essentially the same.
While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiments, but that it have the fall scope permitted by the language of the following claims.
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A turbocharger rotor includes a turbine wheel, a compressor wheel, a shaft extending between the turbine and compressor wheels for rotation together about an axis, and connecting means. The connecting means include first and second joints including alignment couplings joining opposite ends of the shaft with adjoining inner ends of the compressor wheel and the turbine wheel. The couplings are configured to coaxially align and drivingly engage the shaft with the compressor and turbine wheels. A fastener rod extends through the shaft and the compressor wheel, engaging the turbine wheel to retain the rotor components together under compressive load. The rod is resiliently stretchable to limit changes in the retaining force changes in axial dimensions during operating and stationary conditions. Additional features and variations are disclosed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention relates to and claims priority of U.S. provisional patent application (“Provisional Application”), Ser. No. 61/251,428, entitled “An Adaptive Beamforming and Space-Frequency Block Coding Transmission Scheme for MIMO-OFDMA Systems,” filed on Oct. 14, 2009. The Provisional Application is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to high data rate wireless communication. In particular, the present invention relates to high data rate wireless communication using beam-forming and coding schemes.
[0004] 2. Discussion of the Related Art
[0005] Wireless communication systems are developing in the directions of higher data rates and more reliable communication in diverse propagation environments. An important aspect of a good communication system design is efficient utilization of available diversity in the system. The principles of multiple-input-multiple-output (MIMO) and orthogonal frequency division multiple access (OFDMA) allow a flexible system design in which frequency and spatial diversities of the channel can be exploited. When the channel is frequency-selective, frequency diversity can be exploited by assigning each mobile station (MS) to its best channel out of the available subchannels (also known as “multiuser diversity”). On the other hand, multiple antennas can be used in a variety of ways to improve the link quality. For example, when channel knowledge at the transmitter is available, beam-forming (BF) and precoding techniques provide array gain. Alternatively, space-frequency coding schemes can be exploited for spatial diversity in the channel without requiring channel information at the transmitter.
[0006] Channel information can be acquired either through feedback from the receiver in both frequency-division duplex (FDD) and time-division duplex (TDD) systems or by measuring the uplink channel in a TDD system. At the transmitter, channel knowledge imperfections due to estimation errors, quantization errors, or feedback delays are important factors affecting a system design. In recent years, researchers have focused on optimizing multiple antenna transmission with imperfect channel knowledge at the transmitter. Such studies are published, for example, in (a) “Transmitter optimization and optimality of beamforming for multiple antenna systems,” S. A. Jafar and A. Goldsmith, IEEE Trans. Wireless Commun ., vol. 3, no. 4, pp. 1165-1175, July 2004; (b) “Space-time transmit precoding with imperfect feedback,” by E. Visotsky and U. Madhow, IEEE Trans. Inform. Theo ., vol. 47, no. 6, pp. 2632-2638, September 2001; (c) “Robust transmit eigen beamforming based on imperfect channel state information,” by A. Abdel-Samad, T. N. Davidson and A.-B. Gershman, IEEE Trans. Sig. Process ., vol. 54, no. 5, pp. 1596-1609, May 2006; and (d) “Robust power allocation designs for multiuser and multiantenna downlink communication systems through convex optimization,” by M. Payaro, A. Pascual-Inserte and M. A. Lagunas, IEEE Journal Select. Area. Commun ., vol. 25, no. 7, September 2007. These examples illustrate optimum transmission strategies when partial channel knowledge is available at the transmitter.
[0007] Alternatively, space diversity schemes may be combined with BF to provide robust transmission based on channel quality. Examples of such an approach are reported, for example, in (a) “Combining beamforming and orthogonal space-time block coding,” by G Jongren and M. Skoglung, IEEE Trans. Inform. Theory , vol. 48, no. 3, pp. 611-627, Mar. 2002; (b) “Optimal transmitter eigen-beamforming and space-time block coding based on channel mean feedback,” by S. Zhou and G B. Giannakis, IEEE Trans. Sig. Process ., vol. 50, no. 10, pp. 2599-2613, October 2002; and (c) “Combining beamforming and space-time coding using quantized feedback,” S. Ektabani and H. Jafarkhani, IEEE Trans. Wireless Commun ., vol. 7, no. 3, pp. 898-908, March 2008. In BF space diversity schemes, a quasi-static fading assumption is made in which the channel is considered fixed throughout the frame. Hence, these analyses are based on constant channel imperfection, which may not be valid for a long frame or at high Doppler frequencies. In fact, varying channel imperfection conditions are often experienced by mobile users.
[0008] Numerous techniques have been reported which focus on either a space-time coding or space-frequency coding design, or a BF design. However, a design which switches between space-frequency coding and BF within a transmission frame is not known. For instance, U.S. Pat. No. 7,522,673, entitled “Space-time coding using estimated channel information,” to G. Giannakis, S. Zhou, issued on Apr. 21, 2009, discloses techniques for space-time coding only in a wireless communication system with multiple transmit antennas. In such a system, the transmitter uses channel information fed back from a receiver.
[0009] U.S. Patent Application Publication 2008/0144738, entitled “Beam space time coding and transmit diversity,” by A. Naguib, filed on Jun. 19, 2008, discloses methods and apparatus for increasing diversity gain at a receiver by applying BF to transmit diversity space-time coded signals. Using this technique, transmit diversity can be exploited at a signal source by space-time coding the signal. A transmit signal is space-time coded over multiple space-time antenna groups that are each associated with a specific space-time code. The signal at each space-time antenna group is then beam-formed over the antennae in the space-time antenna group. Each antenna in a space-time antenna group is weighted with a distinct weight, relative to other antennae in the space-time group.
[0010] U.S. Patent Application Publication 2008/0101493, entitled “Method and system for computing a spatial spreading matrix for space-time coding in wireless communication systems,” by H. Niu, C. Ngo, filed on May 1, 2008, discloses a method and system for wireless communication that combine space-time coding with statistical transmit BF. The statistical transmit BF uses an optimal spreading matrix as a function of a transmit correlation matrix, without requiring instantaneous channel state information (CSI). In a high mobility environment, the wireless channel gains can vary within the transmission frame, causing substantial performance degradation in BF approaches.
[0011] However, the techniques discussed above do not address channel temporal variations within the transmission frame, and hence suggest neither the desirability of, nor the means for, a switching mechanism between space-time coding and BF within a frame.
[0012] U.S. Pat. No. 7,280,604, entitled “Space-time doppler coding schemes for time-selective wireless communication channels,” to G Giannakis, X. Ma, issued on Oct. 9, 2007, discloses, for time-selective and high Doppler spread channels, a space-time Doppler (STDO) coding technique. In particular, a STDO coded system is capable of achieving a maximum Doppler diversity for time-selective frequency-flat channels. U.S. Pat. No. 7,224,744, entitled “Space-time multipath coding schemes for wireless communication systems,” by G. Giannakis, X. Ma, issued on May 29, 2007, discloses space-time multipath (STM) coding techniques for frequency-selective channels. The described STM coded system guarantees full space-multipath diversity, and achieves large coding gains with high bandwidth efficiency. Despite frequency diversity in the STM, however, none of the techniques disclosed are able to exploit frequency and multiuser diversities simultaneously.
[0013] U.S. Patent Application Publication 200/0227249, entitled “Adaptive transmission method and a base station using the method” (“Ylitalo”), by J. Ylitalo, filed on Sep. 10, 2009, relates to a technique for selecting a spatial transmission method for a next downlink transmission in a BS. In Ylitalo, the BS makes a selection between BF, space-time coding (STC) or MIMO for a next downlink frame. The selection is based on uplink measurements and feedback from a particular MS to which the next downlink frame is to be transmitted. Ylitalo, however, does not consider channel temporal variations within the transmission frame which represents high mobility environments. As BF approaches are sensitive to channel knowledge mismatches, the channel variations within the frame will cause performance degradation under the Ylitalo's approach.
SUMMARY OF THE INVENTION
[0014] The present invention provides numerous methods for allocating alternative multiple antenna transmission modes based on the signal-to-noise ratio (SNR), modulation order and Doppler frequency, These methods increase reliability (i.e., decrease the bit-error-rate (BER))
[0015] Unlike methods of the prior art, the methods of the present invention allow different transmission modes during a single frame, in response to channel variations within the frame. In one embodiment of the present invention, a method takes advantage of available channel knowledge in a given channel by allocating a BF transmission mode, as long as the channel knowledge remains current, but switches to a space-frequency block coding (SFBC) transmission mode, when channel knowledge becomes outdated. To be applied in these methods, approximate BER expressions are also provided for BF and SFBC that are functions of SNR, modulation order and Doppler frequency. The initial channel knowledge provides decision metrics for mode allocation throughout the frame. These methods have been shown to perform as good as the better of BF and SFBC over all SNR values.
[0016] According to a second embodiment of the present invention, a method that exploits multiuser diversity adapts rate and transmission mode across symbols in a frame, based on a channel model of a monotonically decreasing average channel power as a function of time within a frame. Such a method provides even higher performance than the BF-SFBC method discussed above, due to more efficient use of channel conditions.
[0017] The present invention is better understood upon consideration of the detailed description below in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows allocation of a frame structure in an OFDMA system, in accordance with one embodiment of the present invention.
[0019] FIG. 2 is a flowchart which illustrates the first method for allocating MIMO transmission modes conditioned upon initial channel knowledge, in accordance with one embodiment of the present invention.
[0020] FIG. 3 shows applying a bit loading algorithm after transmission mode allocation, in the second method according to one embodiment of the present invention.
[0021] FIG. 4 shows allocation of multiple-input-single-output (MISO) transmission modes conditioned upon initial channel knowledge, in the second method accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] In one embodiment of the present invention, a downlink (DL) of an OFDMA wireless multi-user access network involves a transmitter having n t antennae, with each MS having n r receive antennas. The low-pass equivalent model of a received signal by user k on subchannel q at symbol time n is given by
[0000] y k ( n )= H q,n k x q k ( k )+ w q k ( n ) (1)
[0000] where x q k is the transmitted signal vector for user k on subchannel q, H q,n k is the n r ×n t matrix of channel coefficients for user k on subchannel q (“channel matrix”), and w q k (n) is the n r ×1 noise vector. In this model, both the channel coefficients and the noise are each modeled as a random variable having a zero-mean, unit-variance, circularly symmetric, complex Gaussian distribution. Also, the noise is assumed uncorrelated across antennas and the channels are assumed statistically independent and identically distributed (iid) between different users. Therefore, the average power of the transmitted signal, E[∥x q k (n)∥ 2 ]=η, is also the average SNR per receive antenna.
[0023] A fast-fading channel (i.e., a channel having operating conditions that vary during a frame, but remains highly correlated during an OFDM symbol time) has effects that can be observed for a high Doppler frequency or for a long frame duration. The channel matrix H q,n k for a fast-fading channel at symbol time n can be modeled by:
[0000] H q,n k =ρ n H q,0 k +√{square root over (1−ρ 2 n )} H e,q,n k , (2)
[0000] where H q,0 k represents the channel coefficients at the beginning of the frame, H e,q,n k is the perturbation term due to decorrelation in the channel over n symbol times, and ρ n is the correlation coefficient between the initial channel matrix H q,0 k and the channel matrix H q,n k at symbol time n. Although the channel varies within a frame, the receiver can estimate the channel by examining the pilot symbols that are spread over the frame in the time-frequency grid. Thus, this model provides the receiver channel knowledge over the entire frame.
[0024] Using adaptive channel assignment, an OFDMA system can harness frequency and multiuser diversity in the propagation environment. FIG. 1 shows allocation of a frame structure in an OFDMA system, in accordance with one embodiment of the present invention. As shown in FIG. 1 , the OFDMA spectrum may be divided into Q subchannels of consecutive subcarriers, and each MS may be assigned to a different subchannel depending on the channel condition it experiences. A base station (BS) can obtain channel information at the beginning of each frame to assign the channels and transmission mode selections for the MSs that are present. Assuming that the BS obtains channel information at the beginning of the frame without any time delay, a method of the present invention addresses responding to channel imperfections over the duration of the frame. Perfect channel information at the beginning of the frame is not required. For example, if channel information is known at time time μ—a negative number representing the number of symbol times preceding the beginning of the frame—one can use channel matrix H q,μ k in place of H q,0 k in Equation (2) with the corresponding change in the value of ρ n . Assuming a BS has channel knowledge H q,0 k for all users (i.e., for q=1, . . . , Q) at the beginning of the frame, the BS may assign channels to the users without delay. Under the channel model of equation (2) above, the channel decorrelates (with respect to the initial channel knowledge) at symbol time n, according to the parameter ρ n , which is an arbitrary correlation coefficient determined by the time-selectivity of the channel The benefits of adaptive channel assignment diminish with time as the initial channel knowledge H q,0 k becomes outdated. Thus, frequency and multiuser diversity can be utilized for a fraction of the frame in the beginning of the frame, and the fraction depends on Doppler frequency.
[0025] In a practical system, a channel may be assigned based on, for example, the quality-of-service requirements and fairness constraints imposed by media-access-control (MAC) and scheduling protocols. Other assignment criteria can also be used, even without optimizing MAC layer protocol. In the description below, a MS is assumed always assigned to its best channel. When the context is clear that the analysis is made from the point of view of a single user, the user index k and its channel index q may be omitted. However, the single-user analysis below can be readily generalized for multiple users.
[0026] At the beginning of each frame, a BS allocates the best channel to a user and assigns a MEMO transmission mode. For single-mode BF, since the channel with the largest eigenvalue provides the best performance, the transmitter selects the channel that has the largest maximum eigenvalue. In other words, in such a system, the selected channel index q* is given by:
[0000] q* bf =arg max q λ max,q,0 , (3)
[0000] where λ max,q,0 is the largest eigenvalue of the matrix H q,0 k H q,0 . For a SFBC transmission mode, however, the SNR-maximizing channel has the largest Frobenius norm. Therefore, the channel assignment criterion for a SFBC transmission scheme is
[0000] q* sfbc =arg max q ∥H q,0 ∥ F 2 , (4)
[0000] where ∥•∥ F denotes Frobenius norm operator. In this description, the notations g 0,bf and g 0,sfbc denotes the largest eigenvalue λ max,q* bf ,0 under BF, and the Frobenius norm ∥H q* sfbc ,0 ∥ F 2 under SFBC, respectively. For a single receive antenna system (e.g., in a multiple-input-single-output (MISO) system), however, the channel selection criteria is the same for both BF and SFBC. Specifically, the best channel is the one with largest Frobenius norm.
[0027] According to a first method in one embodiment of the present invention, MIMO transmission modes are allocated throughout the frame based on channel knowledge at the beginning of the frame, channel degradation coefficient, average SNR, Doppler frequency of each mobile user, and data rate. In this embodiment, for illustrative purpose, single-mode BF and orthogonal SFBC are provided as alternative transmission methods. Using its channel knowledge of all subchannels at the beginning of the frame, the BS chooses the best subchannel and determines the MIMO transmission mode for each symbol. Using channel knowledge of the selected subchannel and the correlation coefficient at each symbol, the BS computes an average BER for every symbol in the frame and allocates transmission modes at each symbol based on a minimum average BER criterion.
[0028] The following method derives, based on initial channel knowledge, an average BER for each symbol in the frame, for each of the BF and SFBC transmission modes. These BER expressions are used to select between the two transmission modes at each symbol. In this analysis, only M-ary quadrature amplitude modulated (M-QAM) signals are considered, although the method is applicable also to other modulation schemes. The BER expression for an order M modulation scheme is approximated as follows:
[0000]
P
b
≈
0.2
3
2
(
M
-
1
)
γ
,
(
5
)
[0000] where γ is the per-symbol SNR. After obtaining initial channel knowledge, the average BER performances under the BF and SFBC transmission modes are calculated for a given SNR, and the appropriate MIMO transmission mode for a fixed rate transmission is selected for each symbol, based on a minimum BER requirement. The transmission modes are communicated to the MS over a control channel or message from the BS or derived by the MS using the same selection criteria.
[0029] Channel knowledge at the transmitter can be used to provide array gain such as, for example, by transmitting in the direction of the dominant eigenvector of the channel matrix. With imperfect channel knowledge, performance may degrade due to a mismatch of eigenvectors between the initial channel matrix H 0 and the actual channel matrix H n . In single-mode BF, the transmitter selects BF in the direction of the largest eigenvalue of the matrix H n H H n in order to maximize the received SNR using the dominant eigenvector. In the current system, the transmitter has channel knowledge at the beginning of the frame (i.e., at n=0 or some delay n=μ with the corresponding ρ n ). For BF, the average BER at symbol n, based on the current channel realization H 0 , can be shown to be given by:
[0000]
P
b
bf
(
n
,
M
n
,
γ
0
)
≈
0.2
(
3
(
1
-
ρ
n
2
)
η
2
(
M
n
-
1
)
+
1
)
-
n
r
exp
(
-
3
ρ
n
2
γ
0
3
(
1
-
ρ
n
2
)
η
+
2
(
M
n
-
1
)
)
,
(
6
)
[0000] and therefore, the average BER over the entire frame, based on the current channel realization H 0 is given by
[0000]
P
b
bf
(
γ
0
)
≈
1
N
∑
n
=
0
N
-
1
P
b
bf
(
n
,
M
n
,
γ
0
)
,
(
7
)
[0000] where N is the number of OFDM symbols in a frame, M n is the M-QAM alphabet size used for the n-th symbol, and γ 0 is the SNR at symbol time n=0. γ 0 is given by γ 0 =ηg 0,bf , where η is the average power of the transmitted signal.
[0030] As mentioned above, the SFBC transmission mode exploits spatial diversity of the channel when channel knowledge is not available at the transmitter. In SFBC, a block of m modulated symbols are coded across n f subcarriers and the coded vectors are simultaneously transmitted from n t antennas. The effective transmission rate of such a SFBC is R=m/n f .
[0000] In this embodiment, the transmission mode is optimized for a fixed transmission rate and a fixed power. If the transmission rate of the SFBC transmission mode is less than 1 (i.e., R<1), then the modulation order of the SFBC transmission mode should be increased to maintain the constant transmission rate. In this embodiment, the orthogonal SFBC transmission mode achieves very low decoding complexity. Assuming that, within the duration of a symbol, the channel is highly correlated across consecutive subcarriers, a receiver can decode the received symbols with linear complexity. Symbols from each antenna are normalized by 1/√{square root over (n)} t ), to maintain constant power (i.e., E[∥x n ∥ 2 ]=η). Thus, the received SNR at symbol n is given by
[0000]
γ
n
=
η
n
t
H
n
F
2
,
[0000] where η is average per-symbol SNR. Thus, the received SNR during the first symbol time is given by
[0000]
γ
0
=
η
n
t
g
0
,
sfbc
.
[0000] The average BER performance of the SFBC transmission mode at symbol n for an M-QAM scheme is then given by:
[0000]
P
b
bf
(
n
,
M
n
,
γ
0
)
≈
0.2
(
3
(
1
-
ρ
n
2
)
η
2
(
M
n
-
1
)
n
t
+
1
)
-
n
t
n
r
exp
(
-
3
ρ
n
2
n
t
γ
0
3
(
1
-
ρ
n
2
)
η
+
2
(
M
n
-
1
)
n
t
)
,
(
8
)
[0000] and the average BER over a frame at a given SNR η is given by:
[0000]
P
b
sfbc
(
γ
0
)
≈
1
N
∑
n
=
0
N
-
1
P
b
sfbc
(
n
,
M
n
,
γ
0
)
.
(
9
)
[0031] In a fast fading channel for which quasi-static assumption does not hold, the BS station may obtain channel information in several ways. For example, in non-reciprocal channels (e.g., in a FDD system) feedback from receivers may be used. Similarly, in reciprocal channels (e.g., in a TDD system) an uplink measurement may be used. The receiver, however, has ready access to channel information at all times. Therefore, at the beginning of a frame, the BS and each MS have channel information (i.e., can determine channel matrix H 0 ). In addition, the average mobile speed based on the environment can also be used in the design. Consequently, the average BER for both the BF and the SFBC transmission modes can be calculated at both the BS and the MS using equations (6) and (8). Therefore, MIMO transmission modes may be assigned at symbol n based on:
[0000] m*(n)=argmin mε{bf,sfbc} P b m (n, M n , γ 0 ), (10)
[0000] where m*(n) is the transmission mode index at symbol n. Alternatively, the BS can inform an MS (e.g., through control information included in a packet header) the initial transmission mode and the criteria for switching modes subsequently. In this manner, both the complexity of implementing the present invention and the probability of error (i.e., the possibility of a mismatch between the BS and MS about a switching point) can be significantly reduced on the MS side.
[0032] FIG. 2 is a flow chart which illustrates the method described above, in accordance with one embodiment of the present invention. As shown in FIG. 2 , at the beginning of each frame (i.e., step 201 ), a BS obtains CSI, temporal correlation in the channel, average SNR and a modulation order. At step 202 , each MS is assigned its best channel (e.g., according to the largest eigenvalue of the channel matrix, or according to the Frobenius norm of the channel matrix). Then, at step 203 , for each symbol of the frame, the average BERs for that symbol under both the BF and the SFBC transmission modes are calculated according the equations (6) and (8) above. If the average BER for the BF transmission mode is less than the average BER for the SFBC transmission mode, then the BF transmission mode is selected (step 204 ). Otherwise, at step 205 , the SFBC transmission mode is selected. Due to the performance characteristics of BF and SFBC and the increased degradation of CSI knowledge with time within the transmission frame, the above calculations at each of the symbols can be stopped when the transmission mode switching point (from BF to SFBC) occurs. The transmission modes after the switching point will all be SFBC. The possible choices of transmission modes within a frame are (i) BF for all symbols, if the CSI knowledge is reliable throughout the frame, (ii) SFBC for all symbols, if the CSI knowledge is not reliable enough throughout the frame, or (iii) BF for earlier symbols, with reliable CSI knowledge and SFBC for the remaining symbols, if substantial CSI knowledge degradation occurs within the frame. Then, at step 206 , the allocated transmission modes are communicated to the receivers (i.e., the MSs) using a predetermined method, such as over a DL control channel. Under this method, the modulation order M n is fixed throughout the whole frame.
[0033] A second method according to one embodiment of the present invention provides an optimization that minimizes average BER. Under this second method, transmission modes are first allocated for the frame based on average BER, similar to the method described above. However, under this second method, CSI knowledge is used only in channel selection, but not in transmission mode allocation. The second method provides modulation order selection for each symbol to allow even higher performance. After allocation of transmission modes, a statistical bit loading algorithm is then carried out to assign modulation orders to each symbol in the frame. Note that channel knowledge is still exploited by BF and channel selection (multiuser and frequency diversity) at the beginning of the frame. Throughout the frame, as the channel decorrelates, channel state information (CSI) becomes outdated and the average received power decreases. Adaptive bit loading may be used to improve performance when channel quality varies. The bit loading algorithm takes advantage of better channel conditions at the beginning of each frame by transmitting at a higher data rate at the beginning of the frame. The optimization problem can be summarized by:
[0000]
(
M
1
*
,
M
2
*
,
…
,
M
N
*
)
=
arg
min
(
M
1
,
M
2
,
…
,
M
N
)
∑
n
=
1
N
P
b
m
*
(
n
)
(
n
,
M
n
)
2
R
=
∑
n
=
1
N
M
n
M
n
≤
2
r
max
for
n
∈
{
1
,
2
,
…
,
N
}
,
(
11
)
[0000] where M n is the modulation order at the n-th symbol and R is the transmission rate constraint (in number of bits per frame) and r max is the instantaneous rate constraint (in number of bits). A solution to this optimization problem can be found iteratively. An iterative algorithm adds a predetermined number of bits to the frame in each step, such that bits are loaded to the symbol in a manner that causes a minimum increase in BER at each step. The number of bits to be loaded in each step depends on the range of M n . In other words, r bits are loaded in each step, if log 2 (M n ) increases in steps of r bits. This algorithm requires the BER expressions to be averaged over the initial channel statistics.
[0034] For a MISO system with two or four transmit antennas (i.e., n t =2,4, which are of practical importance), this second method may be illustrated by closed-form BER expressions. For n t =2, the average BER for a BF transmission mode can be shown to be:
[0000]
P
b
bf
(
n
,
M
n
)
≈
0.2
d
f
(
3
(
1
-
ρ
n
2
)
η
2
(
M
n
-
1
)
+
1
)
-
1
∑
k
=
0
d
f
-
1
∑
l
=
0
k
(
d
f
-
1
k
)
(
k
l
)
(
-
1
)
k
Γ
(
l
+
2
)
×
(
3
ρ
n
2
η
3
(
1
-
ρ
n
2
)
η
+
2
(
M
n
-
1
)
n
t
+
k
+
1
)
-
(
l
+
2
)
,
(
12
)
[0000] where δ(•) is the Gamma function and d f is the diversity order due to exploiting frequency and multiuser diversities. The diversity order can be approximated by d f ≈N tap with N tap being the number of time domain channel taps. Following similar steps, the corresponding average BER for a SFBC transmission mode is given by:
[0000]
P
b
sfbc
(
n
,
M
n
)
≈
0.2
d
f
(
3
(
1
-
ρ
n
2
)
η
2
(
M
n
-
1
)
n
t
+
1
)
-
n
t
∑
k
=
0
d
f
-
1
∑
l
=
0
k
(
d
f
-
1
k
)
(
k
l
)
(
-
1
)
k
Γ
(
l
+
2
)
×
(
-
3
ρ
n
2
η
3
(
1
-
ρ
n
2
)
η
+
2
(
M
n
-
1
)
n
t
+
k
+
1
)
-
(
l
+
2
)
.
(
13
)
[0000] Similarly, for the MISO case with n t =4, the average BER for the BF transmission mode is given by:
[0000]
P
b
sfbc
(
n
,
M
n
)
≈
0.2
d
f
(
3
(
1
-
ρ
n
2
)
η
2
(
M
n
-
1
)
+
1
)
-
1
∑
k
=
0
d
f
-
1
∑
l
=
0
k
∑
m
=
0
k
-
l
∑
t
=
0
t
(
d
f
-
1
k
)
(
k
l
)
(
k
-
l
m
)
(
l
t
)
(
-
1
)
k
×
(
1
2
)
l
+
1
(
1
3
)
t
+
1
(
2
l
+
m
+
t
+
3
)
!
(
-
3
ρ
n
2
η
3
(
1
-
ρ
n
2
)
η
+
2
(
M
n
-
1
)
n
t
+
k
+
1
)
-
(
2
l
+
m
+
t
+
4
)
,
(
14
)
[0000] while the average BER for the SFBC transmission mode is given by:
[0000]
P
b
sfbc
(
n
,
M
n
)
≈
0.2
d
f
(
3
(
1
-
ρ
n
2
)
η
2
(
M
n
-
1
)
n
t
+
1
)
-
n
t
∑
k
=
0
d
f
-
1
∑
l
=
0
k
∑
m
=
0
k
-
l
∑
t
=
0
t
(
d
f
-
1
k
)
(
k
l
)
(
k
-
l
m
)
(
l
t
)
(
-
1
)
k
×
(
1
2
)
l
+
1
(
1
3
)
t
+
1
(
2
l
+
m
+
t
+
3
)
!
(
-
3
ρ
n
2
η
3
(
1
-
ρ
n
2
)
η
+
2
(
M
n
-
1
)
n
t
+
k
+
1
)
-
(
2
l
+
m
+
t
+
4
)
.
(
15
)
[0035] FIGS. 3 and 4 are flowcharts illustrating this second method according to one embodiment of the present invention. Specifically, FIG. 4 shows allocation of MISO transmission modes conditioned upon initial channel knowledge, in the second method in accordance with one embodiment of the present invention. FIG. 3 shows applying a bit loading algorithm after transmission mode allocation, in the second method according to one embodiment of the present invention.
[0036] As shown in FIG. 4 , at the beginning of each frame (i.e., step 401 ), a BS obtains CSI, temporal correlation in the channel, average SNR and an initial fixed modulation order. At step 402 , each MS is assigned its best channel (e.g., according to the Frobenius norm of the channel matrix). Then, at step 403 , for each symbol of the frame, the average BERs for that symbol under both the BF and the SFBC transmission modes are calculated according to the antenna configuration, using the equations (12) or (13) and (14) or (15) above, as appropriate. If the average BER for the BF transmission mode is less than the average BER for the SFBC transmission mode, then the BF transmission mode is selected (step 404 ). Otherwise, at step 405 , the SFBC transmission mode is selected. Selection of transmission modes continues until transmission modes for all N symbols in the frame have been assigned. Then, at step 406 , if bit-loading optimization is not required, the allocated transmission modes are communicated to the receivers (i.e., the MSs) using a predetermined method, such as over a DL control channel.
[0037] As shown in FIG. 3 , at step 301 , after allocation of transmission modes of FIG. 4 is completed, transmission data rate information is ascertained. At step 302 , the bit-loading optimization (summarized in equation set (11) above) is carried out using, for example, an iterative algorithm. At step 303 , the number of bits for each symbol in the frame and the allocated transmission modes are communicated to the receivers (i.e., the MSs) using a predetermined method, such as over a DL control channel.
[0038] Given channel temporal correlation, average SNR and diversity order, the transmission modes and modulation orders can be pre-computed offline and provided in a codebook, which can be stored at both the BS and each MS. Alternatively without using a codebook, the BS can communicate the mode and modulation order information to MS via a control channel within the same transmission frame.
[0039] Unlike the system disclosed in the Ylitalo patent application mentioned above, the methods of the present invention exploit both multiuser and frequency diversity. Consequently, the methods of the present invention can take advantage of, for example, statistical bit loading across OFDM symbols within the frame. Furthermore, Ylitalo assumes no delay in channel knowledge. In practice, however, some delay is inevitable due to feedback delay, signal processing delay or both, thus causing a performance degradation in Ylitalo's system. Channel knowledge delay can be incorporated in the methods of the present invention. Further, Ylitalo's adaptation criterion is based on SNR, while the adaptation criterion in the methods of the present invention is based on BER.
[0040] As discussed above, the present invention adapts even when channel conditions change from symbol-to-symbol. Adaptation without initial channel knowledge may require prohibitively complex optimization techniques, which are impractical for real-time delay sensitive applications. The MIMO switching methods of the present invention, however, allow the transmitter to simply chooses between space-frequency block coding (SFBC) and BF transmission modes based on a calculated average BER for each transmission mode. In high mobility applications, in which channel quality may degrade in the course of a frame, different transmission modes allowed in a single frame achieve the lowest average BERs. Besides multiple antenna transmission modes, the present invention allows data rate to be varied across symbols in a given frame.
[0041] The above detailed description is provided to illustrate the specific embodiments of the present invention and is not intended to be limiting. Numerous variations and modifications within the scope of the present invention are possible. The present invention is set forth in the accompanying claims.
|
In a wireless communication system including a base station and multiple mobile stations, a method transmits an orthogonal frequency division multiple access (OFDMA) data frame to the mobile stations. The method includes the steps of (a) at the beginning of the data frame, collecting metrics representing channel conditions for each of the channels; (b) assigning each mobile station to one or more communication channels based on the metrics collected; (c) for each symbol in the frame, calculating an average bit-error-rate for each of a number of transmission modes, and assigning to that symbol the transmission mode corresponding to the lowest calculated average bit-error-rate for that symbol; and (d) transmitting the symbols in the frame according to their respective assigned transmission mode. In addition, a bit-loading optimization step may be carried out in conjunction with the method to determine a modulation order for each symbol to be transmitted.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of International Application No. PCT/GB05/01679, filed on May 3, 2005, which claims priority to and benefit of United Kingdom Patent Application No. 0409677, filed Apr. 30, 2004, and United Kingdom Patent Application No. 0411248, filed May 20, 2004. The entire contents of these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a method of mass spectrometry and a mass spectrometer. The preferred embodiment relates to a method which allows relative quantitation of analyte compounds especially where incomplete and noisy measurements are made. The preferred embodiment is particularly applicable to the measurement and quantitation of peptide digest products or daughter compound abundances. The preferred embodiment relates to relative Bayesian quantitation of analyte/daughter groups.
As will be discussed in more detail below, the preferred embodiment relates to a probabilistic or Bayesian approach to determining the relative quantitation of a component, molecule or analyte present in two or more samples. By way of background, Bayesian probability theory handles probabilities of statements. Probabilities tell how certain those statements are true. For example, a probability of 1 means that there is absolute certainty. A probability of 0 also means that there is absolute certainty, but absolute certainty that the statement is false. A probability of 0.5 means that there is maximum uncertainty whether the statement is true or false.
Changing probabilities when getting new information is an important aspect of Bayesian reasoning. So called Bayes rule defines how a rational agent changes its beliefs when it gets new information (evidence).
Bayesian probabilities or certainties are always conditional. This means that probabilities are estimated in the context of some background assumptions. Conditional probabilities are usually written using the notation P(Thing|Assumption). The probabilities are numbers between zero and one that tell how certain it is that Thing is true when it is believed that the Assumption is true. Conditional probabilities are often written in the form P(D|M) or P(M|D), where M is dependency model and D is data. Accordingly, P(D|M) means the probability of obtaining data D if it is believed that model M is the true model. Likewise, P(M|D) means the probability that the model M is the true model given the data D. Sometimes probabilities are presented just as P(M) or P(D) but these are generally considered to be imprecise Bayesian notations, since all the probabilities are actually conditional. However, sometimes, when all the terms have the same background assumptions then it may not be necessary to repeat them. In theory, probabilities should be written in the form P(D|M,U) and P(M|D,U) and P(M|U) and P(D|U), where U is a set of background assumptions.
Expert systems often calculate the probabilities of inter-dependent events by giving each parent event a weighting. Bayesian Belief Networks are considered to provide a mathematically correct and therefore more accurate method of measuring the effects of events on each other. The mathematics involved enables calculations to be made in both directions. So it is possible, for example, to find out which event was the most likely cause of another.
The following Product Rule of probability for independent events is well known:
p ( AB )= p ( A )* p ( B )
where p(AB) means the probability of A and B happening.
This is a special case of the following Product Rule for dependent events, where p(A|B) means the probability of A given that B has already occurred:
p ( AB )= p ( A )* p ( B|A )
p ( AB )= p ( B )* p ( A|B )
So because:
p ( A ) p ( B|A )= p ( B ) p ( A|B )
Then:
p ( A|B )=( p ( A )* p ( B|A ))/ p ( B )
The above equation is a simpler version of Bayes' Theorem. This equation gives the probability of A happening given that B has happened, calculated in terms of other probabilities which are known.
Bayes' theorem can be summarised as:
P
(
H
0
❘
E
)
=
P
(
E
❘
H
0
)
P
(
H
0
)
P
(
E
)
H 0 can be taken to be a hypothesis which may have been developed ab initio or induced from some preceding set of observations, but before the new observation or evidence E. The term P(H 0 ) is called the prior probability of H 0 . The term P(E|H 0 ) is the conditional probability of seeing the observation E given that the hypothesis H 0 is true—as a function of H 0 given E, it is called the likelihood function. The term P(E) is called the marginal probability of E and it is a normalizing constant and can be calculated as the sum of all mutually exclusive hypotheses:
ΣP(E|H i )P(H i )
The term P(H 0 |E) is called the posterior probability of H 0 given E. The scaling factor P(E|H 0 )/P(E) gives a measure of the impact that the observation has on belief in the hypothesis. If it is unlikely that the observation will be made unless the particular hypothesis being considered is true, then this scaling factor will be large. Multiplying this scaling factor by the prior probability of the hypothesis being correct gives a measure of the posterior probability of the hypothesis being correct given the observation.
The keys to making the inference work is the assigning of the prior probabilities given to the hypothesis and possible alternatives, and the calculation of the conditional probabilities of the observation under different hypotheses.
In the analysis of multiple biological samples or a complex mixture of biological samples it may be desired to compare the relative concentrations of component compounds. For example, it may be desired to see whether or not a protein or peptide is expressed differently in two or more different samples. One sample may, for example, comprise a sample taken from a healthy organism, whilst the other sample may comprise a sample taken from a patient. If a particular protein or peptide is expressed to a significantly greater or lesser extent in the patient sample relative to the sample taken from a healthy organism (i.e. control sample) then this may be indicative of a disease state.
Complex mixtures of biological samples can be analysed using a mass spectrometer preferably in combination with a liquid chromatograph.
It is known to use the ion intensity or ion count rate recorded by a mass spectrometer as a measure of the concentration of each peptide. The data relating to each sample is, however, subject to various systematic errors such as injection volume errors as well as various non-systematic effects such as counting statistics.
Due to the complexity of the samples and the sometimes low concentrations of various components, molecules or analytes in the samples, the data can sometimes or often be incomplete. The data may also include interferences. As a result the assignment of data to components, molecules or analytes or the identification of components, molecules or analytes may be uncertain.
According to conventional approaches these factors can cause results that may appear to be anomalous and hence are thus discarded. As a result, it may not always be possible to quantify some components, molecules or analytes present in two or more samples and/or some data may be rejected out of hand when in fact it may not be anomalous.
It is therefore desired to provide an improved way of being able to quantify components, molecules or analytes present in two or more separate samples when noisy and incomplete measurements of the samples are made.
SUMMARY OF THE INVENTION
According to an aspect of the present invention there is provided a method of mass spectrometry comprising:
providing a first sample comprising a first mixture of components, molecules or analytes;
providing a second different sample comprising a second mixture of components, molecules or analytes; and
probabilistically determining or quantifying the relative intensity, concentration or expression level of a component, molecule or analyte in the first sample relative to the intensity, concentration or expression level of a component, molecule or analyte in the second sample.
Although the preferred embodiment may just relate to two separate samples, according to a particularly preferred embodiment a plurality of further samples each comprising a mixture of components, molecules or analytes may be provided. The components, molecules or analytes preferably comprise proteins, protein digest products, peptides or fragments of peptides.
The components, molecules or analytes in the first mixture are preferably the same species as the components, molecules or analytes in the second mixture and/or components, molecules or analytes in further mixtures. However, alternatively, the components, molecules or analytes in the first mixture may be different species to the components, molecules or analytes in the second mixture and/or to components, molecules or analytes in further mixtures.
The method preferably further comprises: digesting the first mixture of components, molecules or analytes; and/or digesting the second mixture of components, molecules or analytes; and/or digesting further mixtures of components, molecules or analytes. Preferably, the first mixture of components, molecules or analytes is digested to form a first complex mixture; and/or the second mixture of components, molecules or analytes is digested to form a second complex mixture; and/or further mixtures of components, molecules or analytes are digested to form further complex mixtures.
The complex mixtures preferably comprise complex mixtures of peptides or protein digest products.
According to the preferred embodiment the method further comprises: dividing the first sample into one or more first replicate samples; and/or dividing the second sample into one or more second replicate samples; and/or dividing further samples into one or more further replicate samples; and/or dividing the first complex mixture into one or more first replicate samples; and/or dividing the second complex mixture into one or more second replicate samples; and/or dividing the further complex mixtures into one or more further replicate samples.
According to an embodiment the method further comprises: separating components, analytes or molecules in the first sample by means of a separation process; and/or separating components, analytes or molecules in the second sample by means of a separation process; and/or separating components, analytes or molecules in further samples by means of a separation process; and/or separating components, analytes or molecules in the first replicate samples by means of a separation process; and/or separating components, analytes or molecules in the second replicate samples by means of a separation process; and/or separating components, analytes or molecules in further replicate samples by means of a separation process.
The separation process preferably comprises liquid chromatography. According to an embodiment the separation process may comprise: (i) High Performance Liquid Chromatography (“HPLC”); (ii) anion exchange; (iii) anion exchange chromatography; (iv) cation exchange; (v) cation exchange chromatography; (vi) ion pair reversed-phase chromatography; (vii) chromatography; (viii) single dimensional electrophoresis; (ix) multi-dimensional electrophoresis; (x) size exclusion; (xi) affinity; (xii) revere phase chromatography; (xiii) Capillary Electrophoresis Chromatography (“CEC”); (xiv) electrophoresis; (xv) ion mobility separation; (xvi) Field Asymmetric Ion Mobility Separation or Spectrometry (“FAIMS”); or (xvi) capillary electrophoresis.
The method preferably further comprises: ionising components, analytes or molecules in the first sample; and/or ionising components, analytes or molecules in the second sample; and/or ionising components, analytes or molecules in further samples; and/or ionising components, analytes or molecules in the first replicate samples; and/or ionising components, analytes or molecules in the second replicate samples; and/or ionising components, analytes or molecules in further replicate samples.
The method preferably further comprises: mass analysing components, analytes or molecules in the first sample; and/or mass analysing components, analytes or molecules in the second sample; and/or mass analysing components, analytes or molecules in further samples; and/or mass analysing components, analytes or molecules in the first replicate samples; and/or mass analysing components, analytes or molecules in the second replicate samples; and/or mass analysing components, analytes or molecules in further replicate samples.
The step of mass analysing components, analytes or molecules preferably further comprises producing mass spectral data comprising a plurality of mass peaks. Preferably, the method further comprises determining the mass or mass to charge ratio of one or more of the mass peaks. Preferably, the method further comprises determining the signal intensity, or the integrated signal, for one or more of the mass peaks.
According to the preferred embodiment the method further comprises determining the retention time for one or more of the mass peaks.
Preferably, the method further comprises clustering mass peaks from the first sample and/or the second sample and/or further samples. Preferably, the method comprises clustering mass peaks from the first replicate sample and/or the second replicate sample and/or further replicate samples.
According to an embodiment the method further comprises: recognising or identifying components, analytes or molecules in the first sample; and/or recognising or identifying components, analytes or molecules in the second sample; and/or recognising or identifying components, analytes or molecules in further samples; and/or recognising or identifying components, analytes or molecules in the first replicate samples; and/or recognising or identifying components, analytes or molecules in the second replicate samples; and/or recognising or identifying components, analytes or molecules in further replicate samples.
The components, analytes or molecules are preferably recognised or identified on the basis of mass or mass to charge ratio or accurate mass or accurate mass to charge ratio. The accurate mass or mass to charge ratio of the components, analytes or molecules is preferably determined to within 20 ppm, 19 ppm, 18 ppm, 17 ppm, 16 ppm, 15 ppm, 14 ppm, 13 ppm, 12 ppm, 11 ppm, 10 ppm, 9 ppm, 8 ppm, 7 ppm, 6 ppm, 5 ppm, 4 ppm, 3 ppm, 2 ppm, 1 ppm or <1 ppm.
The mass or mass to charge ratio of the components, analytes or molecules is preferably determined to within 0.01 mass units, 0.009 mass units, 0.008 mass units, 0.007 mass units, 0.006 mass units, 0.005 mass units, 0.004 mass units, 0.003 mass units, 0.002 mass units, 0.001 mass units or <0.001 mass units.
Components, analytes or molecules are preferably recognised or identified on the basis of chromatographic retention time or another physico-chemical property.
According to an embodiment, the method further comprises fragmenting components, molecules or analytes in a collision or fragmentation cell to form, create or generate a plurality of fragment, daughter or product ions. Preferably, the fragment, daughter or product ions are mass analysed.
According to an embodiment the method further comprises: identifying or recognising components, molecules or analytes in the first sample on the basis of fragment, daughter or product ions; and/or identifying or recognising components, molecules or analytes in the second sample on the basis of fragment, daughter or product ions; and/or identifying or recognising components, molecules or analytes in further samples on the basis of fragment, daughter or product ions.
According to an embodiment the method further comprises obtaining or assigning probabilities for the correct identification of mass peaks. Preferably, the method further comprises determining or deriving the probabilities from a protein search procedure.
The method preferably further comprises assigning a constant probability of correct identification where no probability is determined or derived from a protein search procedure. Preferably, the method further comprises assigning the probability of correct identification as a value x% wherein preferably x is selected from the group consisting of: (i)<5%; (ii) 5-10%; (iii) 10-15%; (iv) 15-20%; (v) 20-25%; (vi) 25-30%; (vii) 30-35%; (viii) 35-40%; (ix) 40-45%; (x) 45-50%; (xi) 50-55%; (xii) 55-60%; (xiii) 60-65%; (xiv) 65-70%; (xv) 70-75%; (xvi) 75-80%; (xvii) 80-85%; (xviii) 85-90%; (xix) 90-95%; and (xx)>95%.
According to an embodiment the method further comprises assigning a constant probability of correct identification in the event that no protein search procedure is performed. Preferably, the method further comprises assigning the probability of correct identification as a value x%.
Preferably, x is selected from the group consisting of: (i)<5%; (ii) 5-10%; (iii) 10-15%; (iv) 15-20%; (v) 20-25%; (vi) 25-30%; (vii) 30-35%; (viii) 35-40%; (ix) 40-45%; (x) 45-50%; (xi) 50-55%; (xii) 55-60%; (xiii) 60-65%; (xiv) 65-70%; (xv) 70-75%; (xvi) 75-80%; (xvii) 80-85%; (xviii) 85-90%; (xix) 90-95%; and (xx)>95%.
According to an embodiment the method further comprises determining, formulating or assigning a prior probability distribution function Pr(L) for the relative amount or concentration L of components, molecules or analytes present in each sample. Preferably, the prior probability distribution function Pr(L) is proportional to exp(−L/A) wherein A corresponds with a maximum signal intensity recorded for a mass peak. Preferably, A corresponds with a mean or average signal intensity recorded for mass peaks.
According to an embodiment the prior probability distribution function Pr(L) has a gamma, Poisson, Gaussian, exponential, normal or lognormal distribution. Preferably, the prior probability distribution function Pr(L) has a distribution with an integral equal to one.
According to an embodiment the method further comprises determining, formulating or assigning a prior probability distribution function Pr(k) for the overall response factor k of each component, molecule or analyte in the sample. Preferably, k includes one or more of the following: (i) digestion efficiency; (ii) relative product yield; (iii) losses in delivery; (iv) ionisation efficiency; (v) transmission efficiency; and (vi) detection efficiency. According to an embodiment the prior probability distribution function Pr(k) is proportional to exp(−k/k 0 ), where k 0 is a constant. Preferably, k 0 =1.
According to an embodiment the prior probability distribution function Pr(k) has a gamma, Poisson, Gaussian, exponential, normal or lognormal distribution. Preferably, the prior probability distribution function Pr(k) has a distribution with an integral equal to one.
According to an embodiment the method further comprises determining, formulating or assigning a prior probability distribution function Pr(h) for the relative amount of sample h of each component, molecule or analyte in each sample used in an analysis. Preferably, h includes one or more of the following: (i) amount of solvent added; and (ii) amount of material injected.
Preferably, the prior probability distribution function Pr(h) is proportional to exp(−h/h 0 ), where h 0 is a constant. Preferably, h 0 =1.
According to an embodiment the prior probability distribution function Pr(h) has a gamma, Poisson, Gaussian, exponential, normal or lognormal distribution. Preferably, the prior probability distribution function Pr(h) has a distribution with an integral equal to one.
According to an embodiment the method further comprises determining, formulating or assigning a prior probability distribution function Pr(G) for the noise contribution factor G assumed for observed signal intensities and/or applied to predicted signal intensities. Preferably, G includes one or more of the following: (i) ion statistical shot noise; and (ii) Electrospray ionisation droplet statistical shot noise.
The prior probability distribution function Pr(G) is preferably proportional to exp(−G/G 0 ), where G 0 is a constant. Preferably, G 0 =1.
According to an embodiment the prior probability distribution function Pr(G) has a gamma, Poisson, Gaussian, exponential, normal or lognormal distribution. Preferably, the prior probability distribution function Pr(G) has a distribution with an integral equal to one.
According to an embodiment the method further comprises locating, determining, identifying or choosing one or more internal standards or references. Preferably, the one or more internal standards or references comprise one or more components, molecules or analytes which have substantially the same intensity, concentration or expression level in all of the samples.
The one or more internal standards or references may comprise one or more components, molecules or analytes added to each sample. The one or more internal standards or references may be endogenous or exogenous to the first sample and/or the second sample and/or further samples.
The method preferably further comprises applying or using a Markov Chain Monte Carlo predictive procedure or investigating iteratively using a Markov Chain Monte Carlo algorithm to determine likely values for the relative concentrations L of each component, molecule or analyte in each of the samples. Preferably, the Markov Chain Monte Carlo predictive procedure or algorithm is selected from the group consisting of: (i) Metropolis Hastings algorithm; (ii) Gibbs Sampling algorithm; (iii) Hamiltonian Monte Carlo algorithm; and (iv) Slice Sampling algorithm.
According to an embodiment the Markov Chain Monte Carlo predictive procedure or algorithm is used in conjunction with simulated annealing and/or nested sampling.
According to an embodiment the method further comprises predicting what would be observed for each mass peak intensity given probability distribution functions Pr(L) and/or Pr(k) and/or Pr(h) and/or Pr(G) and/or given the probability p of correct identification.
According to an embodiment the method further comprises comparing peak intensities that are predicted with those that are observed.
According to an embodiment the method further comprises adjusting the value of L or the probability distribution function Pr(L).
According to an embodiment the method further comprises adjusting the value of k or the probability distribution function Pr(k).
According to an embodiment the method further comprises adjusting the value of h or the probability distribution function Pr(h).
According to an embodiment the method further comprises adjusting the value of G or the probability distribution function Pr(G).
According to an embodiment the method further comprises predicting what would be observed for each mass peak intensity given the adjusted probability distribution functions Pr(L) and/or Pr(k) and/or Pr(h) and/or Pr(G) and/or given the probability p of correct identification.
The method preferably further comprises comparing peak intensities that are predicted with those that are observed.
According to an embodiment the method further comprises accepting or rejecting adjusted probability distribution functions. Preferably, the method further comprises repeating or terminating the cycle of adjusting probability distribution functions and/or predicting intensities and/or comparing predicted intensities with observed intensities.
Preferably, the method further comprises determining the ratios L ij of relative concentrations L of each component, molecule or analyte in each of the samples for every pair i,j of samples.
According to an embodiment the method further comprises continuing the Markov Chain Monte Carlo predictive procedure to determine more likely values for the relative concentrations L of each component, molecule or analyte in each of the samples and the ratios L ij of the relative concentrations L.
The number of determinations of the ratios L ij of the relative concentrations L is preferably pre-defined according to required accuracy of mean values.
The method preferably further comprises calculating mean values for the ratios L ij of the relative concentrations L of each component, molecule or analyte in each of the samples for every pair i,j of the samples.
According to an embodiment the method further comprises calculating standard deviations and/or relative standard deviations for the ratios L ij of the relative concentrations L of each component, molecule or analyte in each of the samples for every pair i,j of the samples.
According to an embodiment the first sample and/or the second sample and/or further samples comprise a plurality of different biopolymers, proteins, peptides, polypeptides, oligionucleotides, oligionucleosides, amino acids, carbohydrates, sugars, lipids, fatty acids, vitamins, hormones, portions or fragments of DNA, portions or fragments of CDNA, portions or fragments of RNA, portions or fragments of mRNA, portions or fragments of tRNA, polyclonal antibodies, monoclonal antibodies, ribonucleases, enzymes, metabolites, polysaccharides, phosphorolated peptides, phosphorolated proteins, glycopeptides, glycoproteins or steroids.
The first sample and/or the second sample and/or further samples may comprise at least 2, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000, 2500, 3000, 3500, 4000, 4500, or 5000 components, molecules or analytes having different identities or comprising different species.
The first sample and/or the second sample and/or further samples may comprise non-equimolar heterogeneous complex mixtures. Preferably, either: (i) the first sample is taken from a diseased organism and the second sample is taken from a non-diseased organism; (ii) the first sample is taken from a treated organism and the second sample is taken from a non-treated organism; or (iii) the first sample is taken from a mutant organism and the second sample is taken from a wild type organism.
According to an embodiment the method further comprises identifying components, molecules or analytes in the first sample and/or the second sample and/or further samples
The components, molecules or analytes in the first sample and/or the second sample and/or further samples are preferably only identified if the intensity of the components, molecules or analytes in the first sample differs from the intensity of the components, molecules or analytes in the second sample and/or further samples by more than a predetermined amount.
The components, molecules or analytes in the first sample and/or the second sample and/or further samples may only identified if the average intensity of a plurality of different components, molecules or analytes in the first sample differs from the average intensity of a plurality of different components, molecules or analytes in the second sample and/or further samples by more than a predetermined amount.
The predetermined amount is preferably selected from the group consisting of: (i) 1%; (ii) 2%; (iii) 5%; (iv) 10%; (v) 20%; (vi) 50%; (vii) 100%; (viii) 150%; (ix) 200%; (x) 250%; (xi) 300%; (xii) 350%; (xiii) 400%; (xiv) 450%; (xv) 500%; (xvi) 1000%; (xvii) 5000%; and (xviii) 10000%.
The mass or mass to charge ratio of molecules, components or analytes and/or peptide digest products and/or fragment, daughter or product ions are preferably mass analysed by either: (i) a Fourier Transform (“FT”) mass spectrometer; (ii) a Fourier Transform Ion Cyclotron Resonance (“FTICR”) mass spectrometer; (iii) a Time of Flight (“TOF”) mass spectrometer; (iv) an orthogonal acceleration Time of Flight (“oaTOF”) mass spectrometer; (v) a magnetic sector mass spectrometer; (vi) a quadrupole mass analyser; (vii) an ion trap mass analyser; and (viii) a Fourier Transform orbitrap, an electrostatic Ion Cyclotron Resonance mass spectrometer or an electrostatic Fourier Transform mass spectrometer.
The first sample and/or the second sample and/or further samples are preferably ionised by an ion source selected from the group consisting of: (i) an Electrospray ionisation (“ESI”) ion source; (ii) an Atmospheric Pressure Photo Ionisation (“APPI”) ion source; (iii) an Atmospheric Pressure Chemical Ionisation (“APCI”) ion source; (iv) a Matrix Assisted Laser Desorption Ionisation (“MALDI”) ion source; (v) a Laser Desorption Ionisation (“LDI”) ion source; (vi) an Atmospheric Pressure Ionisation (“API”) ion source; (vii) a Desorption Ionisation on Silicon (“DIOS”) ion source; (viii) an Electron Impact (“EI”) ion source; (ix) a Chemical Ionisation (“CI”) ion source; (x) a Field Ionisation (“FI”) ion source; (xi) a Field Desorption (“FD”) ion source; (xii) an Inductively Coupled Plasma (“ICP”) ion source; (xiii) a Fast Atom Bombardment (“FAB”) ion source; (xiv) a Liquid Secondary Ion Mass Spectrometry (“LSIMS”) ion source; (xv) a Desorption Electrospray Ionisation (“DESI”) ion source; and (xvi) a Nickel-63 radioactive ion source.
According to an aspect of the present invention there is provided a mass spectrometer comprising means arranged to probabilistically determine or quantify the relative intensity, concentration or expression level of a component, molecule or analyte in a first sample relative to the intensity, concentration or expression level of a component, molecule or analyte in a second sample.
The mass spectrometer preferably further comprises a liquid chromatograph.
According to an embodiment the mass spectrometer further comprises one or mass filters and/or one or more mass analysers. The one or more mass filters and the one or more mass analysers are preferably selected from the group consisting of: (i) an orthogonal acceleration Time of Flight mass analyser; (ii) an axial acceleration Time of Flight mass analyser; (iii) a Paul 3D quadrupole ion trap mass analyser; (iv) a 2D or linear quadrupole ion trap mass analyser; (v) a Fourier Transform Ion Cyclotron Resonance mass analyser; (vi) a magnetic sector mass analyser; (vii) a quadrupole mass analyser; and (viii) a Penning trap mass analyser.
The mass spectrometer preferably further comprises an ion source. The ion source may comprise a pulsed ion source or a continuous ion source. The ion source may be selected from the group consisting of: (i) an Electrospray ionisation (“ESI”) ion source; (ii) an Atmospheric Pressure Photo Ionisation (“APPI”) ion source; (iii) an Atmospheric Pressure Chemical Ionisation (“APCI”) ion source; (iv) a Matrix Assisted Laser Desorption Ionisation (“MALDI”) ion source; (v) a Laser Desorption lonisation (“LDI”) ion source; (vi) an Atmospheric Pressure Ionisation (“API”) ion source; (vii) a Desorption Ionisation on Silicon (“DIOS”) ion source; (viii) an Electron Impact (“EI”) ion source; (ix) a Chemical Ionisation (“CI”) ion source; (x) a Field Ionisation (“FI”) ion source; (xi) a Field Desorption (“FD”) ion source; (xii) an Inductively Coupled Plasma (“ICP”) ion source; (xiii) a Fast Atom Bombardment (“FAB”) ion source; (xiv) a Liquid Secondary Ion Mass Spectrometry (“LSIMS”) ion source; (xv) a Desorption Electrospray Ionisation (“DESI”) ion source; and (xvi) a Nickel-63 radioactive ion source.
According to an aspect of the present invention there is provided a method of relatively quantifying one or more molecular species among several samples, the method comprising:
dividing each sample into multiple replicate samples;
for each of the replicate samples obtaining a signal for each of several tentatively identified digestion products of the molecular species in question, wherein the signal is proportional to the concentration of the parent species subject to random noise;
obtaining or assigning probabilities that each tentative identification is correct;
assigning a prior probability distribution function for the relative amount L of each molecular species in each sample;
assigning a prior probability distribution function for the relative amount k of digestion product produced from each molecular species;
assigning a prior probability distribution function for the relative amount h of sample for each replicate sample;
assigning a prior probability distribution function for the noise level G in each sample;
choosing an internal standard wherein the concentration of the internal standard is known to be the same in all of the replicate samples;
updating the probability distribution for the relative amount L of each molecular species in each sample;
obtaining samples according to the probability distribution for the relative amount L of each molecular species in each sample of a monotonic function of the ratios L_i to L_j for every distinct pair i,j of the replicate samples; and
calculating a mean value and standard deviation of the function for each of the pairs.
According to an aspect of the present invention there is provided a method of mass spectrometry comprising:
providing a first sample comprising a first mixture of components, molecules or analytes;
providing a second different sample comprising a second mixture of components, molecules or analytes; and
determining or quantifying the relative intensity, concentration or expression level of a component, molecule or analyte in said first sample relative to the intensity, concentration or expression level of a component, molecule or analyte in said second sample.
According to an aspect of the present invention there is provided a mass spectrometer comprising means arranged to determine or quantify the relative intensity, concentration or expression level of a component, molecule or analyte in a first sample relative to the intensity, concentration or expression level of a component, molecule or analyte in a second sample.
The preferred embodiment preferably uses a forward modelling algorithm to average over the contribution of unknown ionisation and digestion efficiencies to the measured ion count. The measured ion count of a peptide can be expressed as being proportional to the product of its concentration in the original sample and a factor relating to its ionisation and digestion efficiencies. Values of concentration and digestion/ionisation efficiency are preferably explored for each peptide and likelihoods are preferably calculated for each result using supplied probabilities of the compounds present in the samples. The likelihood calculation preferably does not advantageously require missing data to be interpolated or otherwise filled in. This is in contrast to conventional approaches.
A further feature of the exploration according to the preferred embodiment is that assignments to data can be switched on or off such that the presence of outliers or outlying data may be investigated. Relative concentrations of proteins or peptides in each sample can then be calculated and a percentage confidence interval given using the results of the probabilistic exploration.
Mass spectral data and microarray data present different challenges. The preferred embodiment is particularly concerned with data which exhibits underlying Poisson noise (counting statistics). This is particularly appropriate when an analytical instrument determines the abundance of daughter compounds (e.g. peptides or peptide digest products) and reports a number of events (e.g. intensity). The events may, for example, relate to the number of ion arrivals in a quadrupole Time of Flight mass spectrometer. However, this is not appropriate to continuous quantities such as the colour/brightness of a microarray spot.
In its simplest form, the preferred algorithm as implemented in the method and apparatus according to the preferred embodiment may be considered as being directed to solving a problem where there are two unknown numbers A and B and it is desired to determine the ratio of B/A. Samples of A (A 1 , A 2 . . . A N ) and B (B 1 , B 2 . . . B M ) are provided. In general, N and M are not equal although the cases N=1 and M=1 are permitted. The samples of A and B can either be considered as “Good” or “Bad” and each sample may be considered as coming with a probability e.g. Pr(A 3 is Good). A “Good” sample of A will be close to A in some mathematically well defined sense. “Bad” samples of A could be almost anything. The same applies to B.
According to the preferred embodiment it is desired to infer the ratio B/A given only this information, and also to provide an uncertainty estimate for the ratio. In the preferred embodiment, the numbers A and B are proportional to concentrations of peptides in solution as measured by a mass spectrometer. The following example may be considered:
Measurement
Prob
Sample A
100
0.91
96
0.89
107
0.92
111
0.98
98
0.91
104
0.97
111
0.83
104
0.88
246
0.89
Sample B
510
0.87
487
0.96
97
0.63
530
0.78
From the above data it may be considered that A equals 100 and that B equals 500 is plausible if the last sample of A and the third sample of B are considered as being “bad” and hence are rejected as being outliers. The preferred embodiment does not however immediately reject data which may initially appear to be spurious.
The ratio B/A as determined by the preferred embodiment and a corresponding uncertainty estimate is determined to be 5.1±0.1.
The preferred embodiment can be considered from a different perspective and can be considered as addressing a second related question. This problem can be considered to be that there are 2+K unknown numbers A, B, k 1 , k 2 . . . k K and that some of the 2*K possible products are provided or known:
A * k 1
A * k 2
. . .
A * k K
B * k 1
B * k 2
. . .
B * k K
It can be considered that any number of samples of any of these products are provided. Samples can either be considered to be “Good” or “Bad” in the same sense as above, and each sample again comes with an associated probability. The problem is again to estimate B/A and provide an uncertainty estimate.
According to the preferred embodiment the numbers A and B are proportional to concentrations of intact proteins in solution prior to digestion, and the other unknowns k i are related to the digestion and ionisation characteristics of the proteins tryptic peptides. The coefficients k i are not of particular interest and it is not necessary actually to calculate them.
The preferred embodiment relates to a method and apparatus which incorporates an algorithm designed to quantify changes in abundance of an analyte compound across several physical samples containing the analyte or its products and at least one internal standard compound. Any number of replicate measurements may be available from each sample, and the data may be noisy and generally also incomplete. It is known from the outset that there is a probability of incorrect assignment of data and that some assignments are more likely to be correct than others.
The preferred embodiment relates to the application of a novel mathematical model of the data and to using Markov chain Monte Carlo techniques to explore the space of model parameters in such a way that changes in abundance along with associated uncertainties can be measured and determined.
Standard statistical techniques such as pairwise t-tests and ANOVA cannot be applied in situations where the number of measurements in each sample is different, when measurements are missing, where assignments of data are ambiguous, where measurements are experimentally correlated or where the number of measurements is very small.
As will be appreciated by those skilled in the art, in the real world experimental data is often noisy and incomplete and hence it is apparent that conventional known techniques are of limited use in being able to process and analyse noisy and incomplete experimental data.
A particular advantageous aspect of the preferred embodiment is that a normalisation step does not need to be performed as a separate step in order to determine the relative concentration of a particular analyte present in two or more separate samples.
Multiple experiments are preferably performed and an analyte for which the concentration is the same in all experiments is preferably used as an internal standard. The preferred embodiment allows for daughter compounds (e.g. peptides) which are associated probabilistically with parents (e.g. proteins). This is particularly useful when daughters are enzymatic digest products of proteins and wherein peptide identification information comes from tandem mass spectrometry.
The preferred embodiment also deals transparently with missing data. Conventional approaches, by contrast, are particularly problematic and prone to error when data is missing.
The preferred embodiment relates to a probabilistic or Bayesian method of measuring differences in the relative concentration of a particular analyte present in multiple different samples.
The preferred embodiment is particularly advantageous in being able accurately to quantify analytes present in samples even though the experimental data may be less than perfect. The data may, for example, suffer from an unknown gain and/or there may be other global or poorly understood sources of noise. The concentration of each analyte in the original samples may be represented in the data by one or more compounds. These compounds preferably comprise digestion product/fragments which shall be referred to hereinafter as daughters.
For each sample several replicate experiments are preferably performed i.e. the sample is divided up into a number of sub-samples and each sub-sample may be separately analysed. As will be appreciated, running the preferred procedures on multiple replicate samples helps to improve the accuracy of the quantification steps according to the preferred embodiment. However, it is not essential that samples be divided into a number of replicate samples and that each replicate sample be analysed separately.
It is contemplated that different (and unknown) quantities of a sample may be used in each replicate experiment so that there may be significant variations in the data among the replicate experiments.
The identity of each peptide may be in question, but according to the preferred embodiment a probability P ij =Pr (Protein is analyte j given data associated with peptide i) is either available or is set to some uniform value. This information may, for example, come from the analysis of fragments of peptides by tandem mass spectrometry (MSMS) wherein peptide digest products are fragmented in a collision or fragmentation cell and the resulting fragment, daughter or product ions are mass analysed.
Some peptides may not have complete coverage across all experiments for reasons other than low concentration. Such reasons may be practical considerations. For example, a number of peptides with a similar mass to charge ratio may elute from the liquid chromatograph at a similar time making identification difficult.
The preferred embodiment enables an output to be generated which may comprise ratios of concentration for each analyte between pairs of conditions with associated uncertainties, the probability that each ratio exceeds one, a full posterior probability distribution for each ratio, or other desired statistics.
The preferred method assumes that the ideal measured intensity of each peptide in the mass spectral data is proportional to the concentration of the corresponding parent protein, that the measured intensities are inherently subject to at least Poisson noise (counting statistics), and that there exists at least one measured peptide which can be assumed to be at the same concentration in each experiment for each sample (this will be referred to hereinafter as an “internal standard”).
The preferred method depends on constructing a model of the data taking into account the problems and requirements described above.
The underlying data D U for each peptide (before noise and gain) is assumed to be given by:
D U =Lhk (1)
where L is the concentration of protein present in a sample, h expresses how much sample (or what fraction of the sample) was used in a particular replicate experiment and k is a coefficient which expresses the efficiency with which a peptide is produced from the corresponding protein ion and also how efficiently the mass spectrometer observes the peptide ion.
The actual observed data D o is assumed to be subject to Poisson noise and an unknown gain G to allow for global scaling of the noise level. For a particular peptide ion, the probability of observing D 0 given a particular set of model parameters L, k and h is:
Pr ( D O |L,k,h )= Pr ( D O |D U ) p+Pr ( D O |B )(1 −p ) (2)
where:
Pr ( D 0 ❘ D U ) = 1 G exp ( - D U / G ) ( D U D O / G ) Γ ( D O / G + 1 ) ( 3 )
and is a modified Poisson distribution which captures the degree of agreement of the predicted theoretical data with the actual experimentally observed data.
The quantity in Equation 2 will be referred to hereinafter as the likelihood. With reference to Equations 2 and 3 above, the Gamma function Γ(x) is a commonly used special function, p is the probability that the parent analyte is correctly assigned and Pr(D 0 |B) is the background probability of observing a particular datum D 0 given an incorrect parent assignment. According to the preferred embodiment:
Pr
(
D
O
❘
B
)
=
1
Λ
exp
(
-
D
O
Λ
)
(
4
)
Equation 4 reflects the fact that data attached to an incorrect assignment could be almost anything roughly consistent with the overall scale of the data Λ. In a preferred embodiment, Λ is taken to be the size of the largest datum. In a less preferred embodiment, Λ is taken to be a probability weighted average over all data. Should the result of the probability function as detailed in Equation 4 be larger and thus more significant in calculating the likelihood (Equation 2) than the result of Equation 3, then the assignment can be considered incorrect.
In order to complete the probabilistic formulation of the problem, it is necessary to specify prior probability distributions for each of the parameters L, h, k and G. The prior probability distributions are denoted Pr(L), Pr(h) etc. The prior probability distributions encapsulate what is known about the parameters before the data is examined, ensuring that unrealistic values are not investigated. In the preferred embodiment an exponential form for the prior probability distributions for parameters L, h, k and G is preferably used. For example:
Pr
(
L
❘
D
)
=
1
L
0
exp
(
-
L
/
L
0
)
(
5
)
There are various different possible prescriptions for choosing L 0 in Equation 5. According to the preferred embodiment L 0 is set as being Λ, k 0 is set as being 1, h 0 is set as being 1 and G 0 is also set as being 1.
With these parameters defined, particular choices of prior probability distributions can be linked with the calculated likelihood for given values of L, h and k to give the joint probability distribution, which can be expressed as:
Pr ( L , h , k , G , Data ) = Pr ( L ) Pr ( h ) Pr ( k ) Pr ( G ) ∏ Data Pr ( D O ❘ L , h , k ) ( 6 )
where L, h and k are vectors on the LHS of the above expression. The dimension of the vector L is the number of samples multiplied by the number of analytes. The dimension of the vector h is the number of experiments. The dimension of the vector k is the number of daughters (e.g. peptides). According, the total number of model parameters (including the gain and ignoring the internal standard) equals (the number of samples times the number of analytes) plus (the number of experiments) plus (the number of daughters) plus 1.
The joint probability distribution as given in Equation 6 is therefore a high dimensional function. The quantity of interest, however, is preferably the set of ratios of elements of the vector L and the corresponding set of uncertainties, relating to a single protein or peptide in multiple samples. It is preferred not to locate the single vector L which maximises the joint probability, but to obtain probability distributions for ratios of elements of L. An example would be Pr(L2/L1, Data). Such probability distributions are often asymmetrical, making the associated uncertainties difficult to express. Thus it is preferred to express the probability distributions for monotonic functions of ratios of elements of L, for instance natural logarithms of ratios of elements of L. These distributions allow estimates of the ratios to be quoted with associated uncertainties or any other desired statistics.
Appropriate methods to perform this exploration are known to those skilled in the art. General tools exist, for example, for solving this kind of problem including, for example, the publicly available inference engine BayeSys®.
An approximation may preferably be made to the full joint probability as detailed in Equation 6 above to bring about an increase in the speed of exploration. For each peptide, there is (at most) one contribution to the product in the joint probability (Equation 6) from each experiment.
These contributions have two terms each. The approximation preferably keeps only four terms per protein in the fully expanded joint probability. These four terms correspond to: (i) peptides assigned correctly in all experiments; (ii) peptides assigned correctly in all but least probable experiment (lowest value of p); (iii) peptides assigned incorrectly in all but strongest experiment (highest value of p); and (iv) peptides assigned incorrectly in all experiments.
In practice, however, even using powerful techniques such as applying Markov Chain Monte Carlo algorithms and simulated annealing, the solution to these problems can still become very slow when a large numbers of analytes is involved.
The preferred embodiment enables the exploration to proceed more efficiently by preferably analytically reducing the dimensionality of the posterior probability distribution (Equation 6) by removing all components of the vector k thus leaving one less parameter to explore and thus saving computational power, in a procedure known as marginalisation. This is possible as it is unnecessary to record the magnitude of the vector k.
Marginalisation is a process wherein both sides of the joint probability function (Equation 6) are integrated with respect to one of the vectors. In a preferred embodiment, marginalisation proceeds by the integration of the joint probability function with respect to k. In a less preferred embodiment, marginalisation may proceed by the integration of the joint probability function with respect to h.
In a less preferred embodiment, a further integration may be performed, such that k and h may both be removed from the joint probability function. The second integration in such a method is, however, often difficult (and sometimes impossible), as the first integral may not be a true function.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:
FIG. 1 shows some simulated noisy data where measurements for some analytes are not available; and
FIG. 2 shows the actual relationship between sample quality and analyte expression and the relationship as determined according to the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will now be described. FIG. 1 shows simulated data with numbers produced using a random number generator. Four samples were considered and two replicate experiments were modelled for each sample. Accordingly, a total of eight experiments were performed. The actual, underlying or true relationships or ratios between the sample quantities h 1 -h 8 and between the analyte expressions L1-L4 are shown in FIG. 2 . FIG. 2 also shows the experimentally determined relationships or ratios as reconstructed according to the preferred embodiment from the noisy and incomplete data as shown in FIG. 1 .
It is apparent from FIG. 1 that in the sixth experiment no data was modelled as being present or obtained for the internal standard or invariant ions. However, nonetheless as can be see from FIG. 2 the ratio h 6 /h 1 has still been recovered successfully despite the lack of any internal standard in this experiment by the method of the preferred embodiment.
It is to be noted that all of the sample ratios were successfully recovered and are shown in FIG. 2 consistent within the reported uncertainties. This would not be possible using conventional techniques.
A number of further modifications to the preferred embodiment are contemplated. According to a modification the Poisson distribution given in Equation 3 above may be replaced by a Gaussian approximation to a Poisson distribution.
According to another embodiment the exponential prior probability distribution function as presented in Equation 4 above may be replaced by a gamma distribution for any of the parameters G,L,h or k. For example, according to an embodiment:
Pr
(
L
❘
D
)
=
L
a
-
1
exp
(
-
L
/
t
)
Gamma
(
a
)
t
a
(
7
)
According to a further embodiment, the exponential prior probability distribution function as given in Equation 3 above may be replaced by a normal distribution for any of the parameters G, L, h or k. For example:
Pr
(
L
❘
D
)
=
1
σ
2
π
exp
(
-
(
L
-
μ
)
2
2
σ
2
)
(
8
)
The exponential prior probability distribution function as given in Equation 3 may according to another embodiment be replaced by a lognormal distribution for any of the parameters G, L, h or k. For example:
Pr
(
L
❘
D
)
=
1
SL
2
π
exp
(
-
(
ln
L
-
M
)
2
2
S
2
)
(
9
)
According to an embodiment the value L 0 in Equation 3 above is set to the average datum size.
It is contemplated that a dimension could be removed from the model. According to such an embodiment, L may be multiplied by a constant and k could be divided by the same constant without changing the likelihood (Equation 2). A constraint could be added such as:
∏ i h i = 1
and the dependence on h could be recast in hyperbolic coordinates. This describes an alternative method of simplifying the probability distribution to marginalisation. Rather than integrating a value out of the equation in the case of marginalisation, a limit could instead be imposed on its possible values, such that there is less “space” for the algorithm to explore. To understand the concept of “space” a graph of h 2 axis over h 1 axis can be considered. If there is no limit imposed on values of h, then the algorithm must explore all positive values—zero to infinity—for h 1 and likewise for h 2 , i.e. the entire positive region of the graph. By declaring the product of h 1 h 2 =1, the space that the algorithm needs to explore is limited to a single hyperbolic line on this graph (h2=1/h1, y=1/x). This leaves the values of h with some flexibility, so is a better approximation than simply assigning h1=1. This imposition can be made since the likelihood will remain the same if the value of k is altered accordingly.
According to another embodiment marginalisation may proceed by integrating over h instead of k.
As discussed above, since according to the preferred embodiment the values of L and Data are the only ones of particular interest, then all other values (i.e. G, h, k) in the joint probability function (See Equation 6 above) can be considered as being nuisance parameters i.e. parameter required for the calculation but otherwise unnecessary for the output. One of these values can be removed from the joint probability function by integrating both sides with respect to this value. For instance, to remove k, it is necessary to integrate with respect to k, giving:
Pr ( L , h , G , Data ) = ∫ ( Pr ( L ) Pr ( h ) Pr ( k ) Pr ( G ) ∏ Data Pr ( D O ❘ L , h , k ) ) ⅆ k ( 10 )
thus leaving the algorithm one less parameter to explore, and saving computational time. The result of such an integral is unlikely to be a function, so further integration is unlikely to be possible. It is not usually possible to integrate the function with respect to G, the program usually doing so with respect to h or k.
The analytes could according to an embodiment be processed one at a time along with the internal standard rather than modelling the whole data set at once.
According to an embodiment the preferred embodiment may tackle the problem in two parts. Firstly, h may be inferred and then L may be inferred given the inference about h.
According to an embodiment there may not be any daughters (e.g. peptides) i.e. it may be possible to quantify directly on the analytes, or it may not be possible to make the associations described above and treat each daughter as a separate analyte.
A further embodiment is contemplated wherein different approximations may be made to the joint probability distribution given in Equation 6 above. For example, up to six terms or eight terms may be kept, or all terms may be retained. It is also contemplated that the joint probability distribution could be explored without marginalisation.
Although the present invention has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the scope of the invention as set forth in the accompanying claims.
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A mass spectrometer and method of mass spectrometry are disclosed wherein two separate samples are mass analysed and then the relative intensity, concentration or expression level of one or more components, molecules or analytes in a first sample is quantitated relative to the intensity, concentration or expression level of one or more components, molecules or analytes in a second sample. The relative quantitation is performed probabilistically without the need to resort to using internal calibrants.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of producing mold parts in accordance with the cold box process, as well as to a mold part and a molding tool.
Mold parts of synthetic resin bound silica hereinbelow referred to as casting molds, include the mold parts having cores inserted therein and are an important basis for the mass production of high quality castings. Various manufacturing processes differ from one another in the type of synthetic resin used and their catalytic curing. The catalysis is performed either by heating or at room temperature by adding a catalyst. Heat curing manufacturing processes are known under the names of hot box, warm box and thermoshock processes. These processes, however, have been increasingly replaced by cold curing processes since they provide for the advantage in energy saving and improved working conditions. In addition, the manufacture of mold parts can be carried out in plastic mold tools.
It is known that the molded parts produced in accordance with various processes and also in accordance with the cold box process are provided after the formation of the mold parts with a layer on their sides which forms a mold cavity. The application and drying a layer require additional working operations and also a waiting time till casting of the casting mold and thereby sufficient time for drying the layer.
In the area of cold curing, the so-called cold box method has achieved a high degree of importance worldwide. Very high production outputs are obtained on automatic production lines. This method uses polyurethane as a binder. The starting components for use now are isocyanate and a phenolic resin, however, other binder combinations are also possible. They are mixed with silica sand in ratio of approximately 1-2 parts by weight. The thus produced molding material is introduced into the mold tool in automatic production of casting molds and immediately after this is cured in a cold tool by passing a catalyst gas, usually dimethylethylamine.
From technical and economical reasons and especially for reducing the environmental impact, the use of lowest possible binder content in the casting practice is desirable, which, however, leads to serious weaknesses of the cold box method.
Cold box binders contain approximately 30-40% of various solvents which are required for low viscosity, high reactivity of the binder, good blowing property of the mold material mixture and adequate strength. These high solvent quantities lead to considerable environmental impacts during processing and pouring off. Lower contents than those mentioned above impair however the strength of the mold parts, especially the mold part surfaces. The edge strength is affected and the mold parts become in their entirety sandy and brittle. Thereby the cold box method loses its usability. Polyurethane-bound mold parts with sufficient solvent and binder contents have good strength immediately after their manufacture. They are however very moisture sensitive and lose their strength within a short time in condition of high air moisture. High air moisture is however, unavoidable in casting. In addition, cold box cores are often treated with water slurry and introduced into wet casting molds thereby are subject to severe moisture damage. This especially impairs the mold part quality since this damage progresses from outside inwardly and thereby affects the especially important mold part surfaces. A highly undesirable strength gradient is produced with low outer strength and high inner strength.
This strength gradient is a disadvantage for a further reason since it makes difficult core destruction after pouring off. Poor core destruction of cold box mold parts is especially dreaded in light metal alloys casting. Remnants of cores are often very difficult to remove from the cold casting and require high fettling costs and extreme working conditions in the fettling shop.
The casting practice made an attempt to counteract the difficulties caused by low surface strength, by increasing binder contents and introduction of coating materials. High binder contents however additionally impair the core destruction since the strength in the interior of the core is increased very high. In addition, moisture damage takes place in the interior of the core to a smaller degree than in the surface layers. Cold box mold parts thus have the serious disadvantage of an undesirable strength distribution. Also their strength increases within 24 hours after the fabrication.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method of manufacturing of mold parts, a mold pat and a molding tool which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to improve in mold parts manufactured in accordance with the cold box method the strength properties and core destruction at a reduced binder content.
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 manufacturing of polyurethane bound mold parts in accordance with cold box process with mold part curing by impact-like passage of a gaseous catalyst, in which for improving application properties, prior to and/or during curing a property gradient is provided inside the cold box mold part such that the resistance in the surface layer of the mold part is increased relative to that of the interior of the mold part.
When the method is performed in accordance with the present invention, the mold part surface is improved to the depth of several millimeters, but the moisture sensitivity in the interior of the core is retained or even increased and thereby the strength in the course of the core storage in these areas is reduced. As a result of this, the strength and resistance to moisture is increased in the surface layer but reduced in the interior of the core so as to improve simultaneously the core destruction. Because of the surface improvement, lowering of the binder content is possible. This measure lowers the costs, reduces the environmental impact and improves the core destruction.
The inventive method is based on the consideration that the above described disadvantages of the cold box process are based on a cross-linking weakness of the polyurethane molecules caused by the blowing and a very fast cold curing taking place immediately after this. The only weak bonds between the molecule chains can be easily destroyed by water and the mold part strength will be reduced irreparably. The method in accordance with the present invention provides for converting of the polyurethane in the mold part surface into a highly cross-linked form and thereby increases the strength and especially the moisture resistance in the surface layer, but leaves the deeper layers of sand in a weakly cross-linked form.
It is another feature of the present invention to provide a mold part in which the resistance of its surface layer is increased to the resistance of its interior.
It is also an object of the present invention to provide a molding tool which has means for forming a mold part so that the resistance of its surface layer is increased relative to the resistance of its interior.
The novel features which are considered as characteristic for the 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 DRAWING
FIG. 1 is a view showing a molding tool of the present invention for performing the inventive method and producing the inventive mold part in a vertical section; and
FIG. 2 is a view showing a casting mold in a vertical section.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In accordance with the inventive method of manufacturing of polyurethane-bound mold parts with use of a cold box process and mold part curing by impact-like passage of a gaseous catalyst, a property gradient is obtained prior to and/or during curing inside the cold box mold part such that the resistance in the upper layer of the mold part is increased relative to the resistance in the interior of the mold part.
This can be obtained in accordance with the present invention either by a mild heat impulse or by a surface increase in the solvent contents, or by both measures, to form simultaneously or close after one another. Both measures improve the surface quality of the cold box mold parts in a surprising degree.
It has been found that the inventive method can be performed with high efficiency after the blow or shot and shortly before gas curing, since the mold part has already been shaped at this point, but the molecular mobility in still soft molding material is quite high. The inventive method therefore deals with a manufacturing step of the cold box process which has hitherto been passed over carelessly and as rapidly as possible. Improvement measures carried out only after curing of the finished mold component are considerably less effective because of the fixation of the binder structure and in particular cannot be achieved at the low temperatures which characterize the method in accordance with the present invention.
The invention method operates with heated molding tools. Relatively low temperatures of between 30° C. and 150° C., preferably below 100° C. (60°-80° C.) can be used. The uniformity of heating is also of secondary importance. Thus the same molding tool can be hot for example to 50° C. at one point to 80° C. at another point without significant quality differences becoming apparent.
Heating of metallic molding tools can be performed in a known manner by electrical or gas heating. Further possibilities include supplying hot air or guiding the necessary blowing, aerating and purging air through a preheater.
The inventive method is not exchangeable with the conventional hot box and warm box methods and differ from them basically. The conventional methods use the heat for curing and thus require through-heating of the entire mold part cross-section. They operate with significantly higher temperatures between approximately 150° C. and 250° C. and require high temperature uniformity with thermostatic control.
To the contrary, the heat of the invention method does not lead to curing in the heating surface layer. The molding material remains soft and cannot be handled. The inventive method remains a cold method in which the mold part curing is attained unchanged by a gaseous catalyst. The method serves solely to improve extraordinary the efficiency of the gas curing.
The inventive method requires pause between blowing and gas curing of approximately 20-90 seconds, preferably 15-30 seconds. Therefore it is necessary to somewhat lengthen the method course. This pause can be considerably reduced when needed in accordance with a further feature of the present invention, when as mentioned above the solvent contents are increased in the mold part surface. For achieving this, the molding tool in accordance with a further feature of this invention is provided before the blowing with a thin film of a solvent by spraying. The blown molding material absorbs the solvent and provides the desired surface improvement in a shorter time.
The rigid and moisture-resistant mold part surfaces obtained in accordance with the invention method and arrangement makes it possible, in a further embodiment of the invention to use low-solvent binders which now can be proposed for the cold box manufacture. They are recommended particularly for light metal alloys casting.
Low solvent cold box binders tend to loose strength during mold part storage and in addition are especially sensitive to moisture. For these reasons they could not be used up to now. These previous disadvantages remain in the inventive method limited to the interior of the mold parts and act in advantageous manner since the core destruction and also the reusability of the old sand are facilitated. These advantages and the considerable advantages already offered by the possibility of lowering the binder contents are contrasted by an insignificantly lengthened cold box process and the necessity of heating the molding tools.
The relatively low temperature of the inventive method make it possible to use plastic molding tools. Hot water is suitable for tool tempering, whereby the method can be simplified extraordinarily.
In accordance with a further embodiment of the invention, it is proposed to arrange during producing of the molding tool water pipes in a form corresponding to the shape of the pattern in the synthetic resin, through which water pipes hot water continuously flows during the production. It is further proposed to improve the heat transfer between the hot water conduit and the molten tool surface by providing high heat-conductive fillers of metal powder or metal granulate.
The invention is illustrated by the table shown on the following page.
Referring now to the drawing and particularly to FIG. 1 it can be seen that an upper half of the molding tool or corebox is identified with reference numeral 1 and lower part of the molding tool is identified with reference numeral 2. The upper and lower parts are arranged so that a separation plane 3 is formed therebetween. The molding tool is provided with an inlet 4. A mold cavity is identified with reference numeral 5, and the reference numeral 6 identifies a plastic layer with a precise contour. The molding tool has a plurality of pipes 7 for hot water, a water input 8, and a water output 9.
__________________________________________________________________________ Test Conditions Exposure Molding Tool Results Binder Level Time to Sprayed Moisture Sensitivity in Molding Solvent Level Molding Tool Molding Tool With Surface Interior Material (%) in Binder (%) Temp. (°C.) Temp. (sec) Solvent of Mold Part Collapse__________________________________________________________________________Conventional 1.6 33 18 None no high high fairCold BoxProcessExample 1 1.4 33 60 30 no low high improved(Only Heat)Example 2 1.3 30 60 20 yes eliminated very good(Heat and highSolvent)__________________________________________________________________________
A flexible hose 10 extends between two halves of the molding tool. It is filled with an aluminum granulate 11 which is available in a compact form in resin-bound sand. A heat-insulating outer jacket 12 is composed, for example, of silica sand bound with synthetic resin. The molding tool has a tool frame identified with reference numeral 13. A core 14 is provided with the molding tool of FIG. 1 and, as illustrated in FIG. 2, suggested in an upper box part 15 and a lower box part 16 in a molding sand 17 and 18 located therein. Reference numeral 19 identifies a gate. Also, a riser can be provided, through which the casting melt can exit upwardly after filling of a mold cavity 21.
FIG. 2 shows that not only a surface 23 of the core 14 has been improved with the molding tool in accordance with FIG. 1. This improvement over a certain layer thickness is identified with a shading 24. This figure also shows that the mold parts 17 and 18 of the upper mold part and lower mold part are each provided with a surface improvement identified with shading 25 and 26.
It should be noted that the improvement obtained in accordance with the invention only needs to be present on the surface of the mold part which limits the mold cavity 21.
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 constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a method of producing mold parts, a mold part and a molding tool, 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.
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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Mold parts are produced in accordance with a cold box procedure with passing a gaseous catalyst during curing, wherein for improvement of the application characteristics before/during curing, a gradient of properties within the mold part is caused such that the resistance of the surface layer of the mold part is increased relative to the resistance of the interior of the mold part.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of pending International patent application PCT/FR2006/002477 filed on Nov. 7, 2006 which designates the United States and claims priority from French patent application 0553432 filed on Nov. 10, 2005, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a two-component pump liable to equip a dispenser mainly intended for liquid or pasty cosmetics or pharmaceutical products and specifically applies to samples of such products.
BACKGROUND OF THE INVENTION
[0003] Conventional dispensers are generally equipped with a reservoir and a pump which interacts with a manually actuatable element of the push-button type provided with an ejection orifice.
[0004] However, the production cost of such dispensers is very high, because of the complexity of their structure and in particular, of the pump.
[0005] Such disadvantage is particularly penalising for applications in the field of samples because the manufacturing costs of a miniature pump are often out of proportion to the marketing requirements of such type of product.
[0006] Besides, as regards the packaging of products in an air-intake free (so-called “airless”) dispenser, the mechanisms of the conventional atmospheric pumps are inappropriate and do not make it possible to obtain a satisfactory sealing level.
[0007] In addition, the end of the ejection orifice is difficult to close in a satisfactory way and the product remains partially in contact with the air, which causes risks of drying and/or deterioration.
[0008] In addition, such pumps have a defect in that they include a metallic spring, the contact with the product of which is detrimental or even prohibited.
[0009] One object of the present invention is to solve the technical problems resulting from the prior art.
SUMMARY OF THE INVENTION
[0010] This aim is reached, according to the invention, with a dispenser characterized in that the pump consists of a body embodied in the form of a single piece comprising on the one hand, a seat which covers said reservoir and is provided with an intake orifice and on the other hand, a flap which is mounted on said seat by means of a joint associated with an elastic return means which enables said flap to be reversibly titled towards the seat by pressing on the actuating element in such a way that the ejection orifice is opened and the intake orifice is simultaneously closed.
[0011] According to an advantageous characteristic, said flap carries two sealing plugs for the intake orifice and the ejection orifice, respectively.
[0012] According to a first alternative embodiment of the invention, said plugs are made of bosses, the dimensions of which allow a sealing cooperation with the ejection and intake orifices, respectively,
[0013] Preferably, said plugs are mounted on either side of a triangular link.
[0014] Advantageously, said joint is made of a hinge connected to the angle of said link.
[0015] According to a specific alternative solution, said hinge is made of a connection nip having a spring effect.
[0016] According to another advantageous characteristic, said flap includes a control lever, which the actuating element is liable to come in bearing contact with for causing the tilting thereof.
[0017] Preferably, the actuating element is provided with elastic bellows, which form elastic return means for the flap.
[0018] According to an advantageous characteristic, such actuating element is made in a single piece with the upper part of the reservoir.
[0019] According to another alternative solution, the inner wall of the actuating element carries at least one draw lug for said flap.
[0020] In addition, said body includes two side bearings surrounding and/or supporting said flap.
[0021] According to still another alternative solution, at least one of said bearings has a longitudinal groove arranged in its inner wall for the passage of said draw lug.
[0022] According to another advantageous characteristic still, said seat includes a side sealing skirt, which is radially tightened against the inner wall of the actuating element or of the reservoir.
[0023] Preferably, the upper part of the flap has an inclined face facilitating the bearing contact of the actuating element.
[0024] The pump of the invention is a reliable and economic technical solutions to the problems met with the packagings of the prior art.
[0025] As a matter of fact, such pump can include only two simple structured parts likely to be moulded and assembled in a very easy and quick way which can thus be automated.
[0026] In addition, such pump includes only plastic material parts, the compatibility with cosmetic and pharmaceutical products of which is guaranteed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Other objects and advantages of the invention will appear upon reading the following description, which is made while referring to the appended drawings, in which:
[0028] FIG. 1 shows an outside perspective view of a dispenser equipped with an embodied pump according to the invention;
[0029] FIGS. 2A and 2B show partial views respectively in perspective and front views of an alternative embodiment of the body of the pump of the invention prior to the mounting thereof;
[0030] FIGS. 3A and 3B show partial perspective and front views respectively of the alternative solution of the body of the pump of FIGS. 2A and 2B in assembling position;
[0031] FIGS. 4A to 4D show sectional views of the embodiment of FIG. 1 and various rest and utilisation positions.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The pump, according to the invention, is intended for packaging and delivering liquid or gel cosmetic or pharmaceutical products and more particularly, samples or small doses of such products.
[0033] Generally speaking, dispensers for liquid cosmetic or pharmaceutical products include a reservoir R and a pump, at least partially mounted inside the reservoir and cooperating with a manually actuatable element 2 provided with an ejection orifice 20 , as shown in the outside view of FIG. 1 .
[0034] The embodiment of the dispenser according to the invention, such as shown in the Figures, is intended for an airless utilisation.
[0035] Consequently, the reservoir R is tightly closed in its lower part by a bottom F which forms a piston, which goes up inside the reservoir when and as the product is delivered while remaining in contact with the product, as shown in FIGS. 4A to 4D .
[0036] The pump, according to the invention, consists of a body 1 which is formed in a single piece and which is made for example, by means of an injection moulding method.
[0037] As shown in FIGS. 2A and 2B , when leaving the mould, the body 1 has on the one hand, a seat 11 which covers said reservoir R and provided with an intake orifice 10 and, on the other hand, a single flap 12 connected to said seat by means of a joint, here in the form of a hinge 13 .
[0038] The body 1 is configured, in a subsequent step, in operational position by closing the flap 12 over the seat 11 while maintaining the hinge 13 slightly under a stress, as shown in FIGS. 3A and 3B .
[0039] The body 1 is then captured in this configuration under the actuating element 2 , in the upper part of the reservoir R.
[0040] The seat 11 includes a side sealing skirt 17 , which is radially tightened against the inner wall of the actuating element 2 or the reservoir R.
[0041] The upper part of the flap 12 includes a control lever 14 which the actuating element 2 is liable to come in contact with for causing its forced tilting downwards, from a sealing closure position of the ejection orifice 20 .
[0042] Such tilting, which is reversible, causes the opening of the ejection orifice 20 and the simultaneously closing of the intake orifice 10 .
[0043] The lever 14 has an inclined face 14 a which facilitates the bearing contact of the actuating element 2 . The face 14 a is possibly provided with a central cavity 14 b , as shown, more particularly in FIGS. 3A and 3B , with a view to limiting the effects resulting from the shrinkage of the plastic material while it cools after the moulding operation.
[0044] The hinge 13 is made of a transversal nip or a thin web.
[0045] The single flap 12 carries two sealing plugs of the intake orifice 10 and the ejection orifice 20 , respectively.
[0046] Such plugs are made of bosses 12 a , 12 b , here in the form of spherical caps, the dimensions of which and more particularly, the diameters of which enable a sealing cooperation with the ejection orifice and intake orifice, respectively and which are mounted on either side of a triangular link 15 .
[0047] The link 15 is connected at its angle (here an angle of approximately 90°) to the connection nip forming said hinge 13 .
[0048] The body 1 includes two bearings 16 surrounding said flap 12 and providing the side wedging thereof.
[0049] According to an alternative solution not shown, the joint of the flap is provided in the form of pivots supported by the side bearings.
[0050] As shown in FIGS. 1 and 4A to 4 B, the actuating element 2 has an upper face 22 for the manual pressing, and is provided with an elastic return means for the flap, here in the form of elastic bellows 21 having a spring effect, which is made on the side wall and provides the connection to the reservoir R.
[0051] In the embodiment shown, the actuating element 2 is made in a single piece with the upper part of the reservoir R.
[0052] FIGS. 4A to 4D show a section view of a dispenser provided with a pump according to the invention during the various phases of operation.
[0053] In the rest position in FIG. 4A , the draw lugs 24 connected to the inner wall of the upper face 22 of the actuating element 2 are resting under the control lever 14 and pull it upwards by means of the action of the bellows 21 , having a spring effect, and the link 15 of the flap 12 is returned towards the hinge 13 on the right, in the direction of the arrow.
[0054] According to an optional alternative embodiment, the hinge 13 can facilitate or provide the elastic return of the flap 12 in the position of a sealing closure of the ejection orifice 20 like a spring having a shape memory or in addition to or instead of the bellows 21 .
[0055] The plug 12 b is then sealingly engaged into the ejection orifice 20 like a plug on a bottle, whereas the intake orifice 10 is opened.
[0056] In this position, when the priming is completed (for example in the factory), the compartment C located between the seat 11 and the inner face of the actuating element is filled with a liquid product and becomes a dosing chamber.
[0057] The actuating element 2 has, in this example, at least one and preferably, two symmetrical draw lugs 24 for pulling the control lever 14 of the flap 12 upwards through the action of the bellows 21 and thus make it possible to provide the sealing closure of the ejection orifice 20 in the rest position of the dispenser (the arrow in FIG. 4A ) and then to facilitate the return of the flap 12 in this same rest position, when the manual pressing stops (arrow in FIG. 4C ).
[0058] For this purpose, at least one and, here, both bearings 16 of the seat 11 has/have a longitudinal groove 16 a provided on the inner wall for the passage of the draw lugs 24 .
[0059] In the position shown in FIG. 4B , the user manually presses in the direction of the arrow on the upper part of the actuating element 2 .
[0060] Upon completion of an ineffective stroke resulting from the discrepancy between the pressing face of the draw lugs 24 and the inner wall of the upper face 22 , such pressing brings the wall of the element 2 in contact with the control lever 14 of the flap 12 which causes the forced tilting of the link 15 downwards towards the seat 11 in the direction of the arrow.
[0061] Such movement releases the ejection orifice 20 whereas the plug 12 a closes the intake orifice 10 .
[0062] At the same time, such pressing also causes the compression of the bellows 21 and the reduction in the volume of chamber C, which leads to the release of a dose of a pressurised product towards the outside through the ejection orifice 20 (grey arrow).
[0063] Such dose substantially corresponds to the volume of the product delivered during the tilting stroke of the flap 12 until the plug 12 a abuts against the orifice 10 .
[0064] In the position shown in FIG. 4C , the user releases the pressing which causes the release of the bellows 21 and the return of the link 15 rightwards in the direction of the arrow because of the shape memory of the bellows 21 .
[0065] The reverse tilting of the flap 12 is carried out by the lugs 24 , which are also pulled upwards by the bellows 21 .
[0066] Such motion of the flap 12 leads to the closing of the ejection orifice 20 , the simultaneous opening of the intake orifice 10 and because of the absence of air intake, the simultaneous up motion of the piston bottom F in the reservoir R when in contact with the product.
[0067] The intake orifice 10 being opened, the chamber C is refilled by means of a suction effect until an equilibrium is obtained in the new rest position as shown in FIG. 4D .
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The invention relates to a pump for a liquid product dispenser, which includes a reservoir and interacts with a manually actuatable element provided with an injection orifice. The pump includes a body embodied in the form of a single piece and including a seat which covers the reservoir and is provided with an intake orifice and a flap, which is mounted on the seat by means of a joint associated with an elastic return means which enables the flap to be reversibly tilted towards the seat, by pressing on the actuating element, in such way that the injection orifice is opened and the intake orifice is simultaneously closed.
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[0001] This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/709,174, filed Aug. 17, 2005, the contents of which are hereby incorporated by reference into the subject application.
FIELD OF THE INVENTION
[0002] The present invention relates to novel 2,3-dihydroindole compounds having affinity for the dopamine D 4 receptor and for the 5-HT 2A receptor. The compounds are therefore useful in the treatment of certain psychiatric and neurologic disorders, in particular psychoses.
BACKGROUND OF THE INVENTION
[0003] Dopamine D 4 receptors belong to the dopamine D 2 subfamily of receptors, which is considered to be responsible for the antipsychotic effects of neuroleptics. The characteristic extrapyramidal side effects of neuroleptic drugs, which primarily exert their effect via antagonism of D 2 receptors, are known to be due to D 2 receptor antagonism in the striatal regions of the brain. However, dopamine D 4 receptors are primarily located in areas of the brain other than striatum, suggesting that antagonists of the dopamine D 4 receptor will be devoid of extrapyramidal side effects. This is illustrated by the antipsychotic clozapine, which exerts higher affinity for D 4 than D 2 receptors and is lacking extrapyramidal side effects (Van Tol et al. Nature 1991, 350, 610; Hadley Medicinal Research Reviews 1996, 16, 507-526, and Sanner Exp. Opin. Ther. Patents 1998, 8, 383-393).
[0004] A number of D 4 ligands, which are postulated to be selective D 4 receptor antagonists, (L-745,879 and U-101958), have been shown to posses antipsychotic potential (Mansbach et al. Psychopharmacology 1998, 135, 194-200). However, recently it has been reported that these compounds are partial D 4 receptor agonists in various in vitro efficacy assays (Gazi et al. Br. J. Pharmacol. 1998, 124, 889-896 and Gazi et al. Br. J. Pharmacol. 1999, 128, 613-620). Furthermore, it was shown that clozapine, which is an effective antipsychotic, is a silent antagonist (Gazi et al. Br. J. Pharmacol. 1999, 128, 613-620).
[0005] Consequently, D 4 ligands, which are partial D 4 receptor agonists or antagonists, may have beneficial effects against psychoses.
[0006] Dopamine D 4 antagonists may also be useful for the treatment of cognitive deficits (Jentsch et al. Psychopharmacology 1999, 142, 78-84).
[0007] Furthermore, evidence for a genetic association between the “primarily inattentive” subtype of attention deficit hyperactivity disorder and a tandem duplication polymorphism in the gene encoding the dopamine D 4 receptor has been published (McCracken et al. Mol. Psychiat. 2000, 5, 531-536). A link between the D 4 receptor and attention deficit hyperactivity disorder is further strengthen by published data showing that D 4 receptor antagonists counteract the hyperactivity in rats induced by neonatal 6-hydroxydopamine lesions, a preclinical model for this disease (Zhang et al. Psychopharmacology 2002, 161, 100-106). This clearly indicates a link between the dopamine D 4 receptor and attention deficit hyperactivity disorder, and ligands affecting this receptor may be useful for the treatment of this particular disorder.
[0008] Various effects are known with respect to compounds, which are ligands at the different serotonin receptor subtypes. As regards the 5-HT 2A receptor, which was previously referred to as the 5-HT 2 receptor, the following effects have been reported e.g.:
[0009] Antidepressive effect and improvement of the sleep quality (Meert et al. Drug. Dev. Res. 1989, 18, 119.), reduction of the negative symptoms of schizophrenia and of extrapyramidal side-effects caused by treatment with classical neuroleptics in schizophrenic patients (Gelders British J. Psychiatry 1989, 155 (suppl. 5), 33). Furthermore, selective 5-HT 2A antagonists could be effective in the prophylaxis and treatment of migraine (Scrip Report; “Migraine—Current trends in research and treatment” ; PJB Publications Ltd.; May 1991) and in the treatment of anxiety (Colpart et al. Psychopharmacology 1985, 86, 303-305 and Perregaard et al. Current Opinion in Therapeutic Patents 1993, 1, 101-128).
[0010] Some clinical studies implicate the 5-HT 2 receptor subtype in aggressive behaviour. Furthermore, a typical serotonin-dopamine antagonist neuroleptics have 5-HT 2 receptor antagonistic effect in addition to their dopamine blocking properties, and they have been reported to possess anti-aggressive behaviour (Connor et al. Exp. Opin. Ther. Patents. 1998, 8(4), 350-351).
[0011] Recently, evidence has also accumulated which support the rational for selective 5-HT 2A antagonists as drugs capable of treating positive symptoms of psychosis (Leysen et al. Current Pharmaceutical Design 1997, 3, 367-390 and Carlsson Current Opinion in CPNS Investigational Drugs 2000, 2(1), 22-24).
[0012] Accordingly, dopamine D 4 receptor ligands are potential drugs for the treatment of schizophrenia and other psychoses, and compounds with combined effects at dopamine D 4 and 5-HT 2A receptors may have the further benefit of improved effect on positive and negative symptoms in schizophrenia, including depressive and anxiety symptoms.
[0013] Dopamine D 4 ligands related to the compounds of the invention are known from WO 98/28293. The indane and dihydroindole derivatives disclosed herein have the general formula
wherein A is an indole and Y is a group completing an indane or a dihydroindole and the other substituents are as defined in the application.
[0014] Other dopamine D 4 ligands, wherein the indane or dihydroindole is replaced by a pyrrolo[2,3-b]pyridine, a benzimidazole or a furo[2,3-b]pyridine, are described in WO 94/20497, WO 94/22839 and U.S. Pat. No. 5,700,802.
[0015] Most lipophilic drugs are mainly eliminated from the body through oxidative metabolism in the liver catalyzed by various cytochrome P450 isoenzymes.
[0016] The in vivo hepatic blood-clearance (CL b ), considered to be the single most important pharmacokinetic parameter for the drugability of a drug (Bennet, L. The role of pharmacokinetics in the drug development process. Integration of pharmacokinetics, pharmacodynamics, and toxicology in rational drug development, Ed. A. Yacobi et al, Plenum Press, New York, 1993. P. 115-123), may in theory be estimated by calculation from the intrinsic clearance CL int , the hepatic blood flow (Q) and the free unbound fraction (f u ) of the drug in the blood as CL b =(Q*f u *CL int )/(Q+f u *CL int ). From this follows that drug substances with high measured values for CL int CL b will in vivo approximate to the hepatic blood flow (Q) resulting in low oral bioavailability and short half-lives.
[0017] The intrinsic clearance (CL int ) is a theoretic measure for the metabolic capacity of a liver when there is no restrictions in blood supply of nutrients, co-factors etc. An in vitro approach for determining values for intrinsic clearance (CL int ) in humans and animals using in vitro human and animal liver preparations, as described in detail by e.g. Obach, S. et al., The Prediction of Human Pharmacokinetic Parameters from Preclinical and In Vitro Metabolism Data. JPET. Vol. 283, Issue 1, 46-58, 1997, is widely implemented in the pharmaceutical industry and used for evaluating and optimizing drugability of potential drug candidates.
[0018] The oral bioavailability and systemic half-life of a compound in vivo are closely related to the blood-clearance, and compounds with higher oral bioavailability and longer half-lives in humans may be sought in a discovery program by optimization on intrinsic clearance (CL int ), using human liver preparations, for values well below the average human liver blood flow of approximately 1.4 L/min.
[0019] One problem associated with some of the above-described compounds is that they possess poor oral bioavailability and that they are too rapidly cleared from the blood resulting in a very short half-live.
SUMMARY OF THE INVENTION
[0020] The object of the present invention is to provide compounds that are partial agonists or antagonists at the dopamine D 4 receptor, in particular such compounds with combined effects at the dopamine D 4 receptors and the 5-HT 2A receptor.
[0021] Another object is to provide such compounds with an improved pharmacokinetic profile, e.g. higher bioavailability and/or longer half-lives.
[0022] Accordingly, the present invention relates to novel compounds of formula I
wherein X-Y is selected from N—CH 2 , C═CH and CH—CH 2 ;
Z is CR 10 or N;
R 1 is A, A′ or A″
wherein * indicates the atom attached to N via a bond;
R 2 and R 3 are independently selected from hydrogen and C 1-6 -alkyl;
R 4 -R 7 are independently selected from hydrogen, C 1-6 -alkyl, C 1-6 -alkoxy and halogen;
R 8 and R 9 are independently selected from hydrogen and halogen;
R 10 is hydrogen or halogen;
R 11 and R 12 are independently selected from hydrogen and C 1-6 -alkyl; or enantiomers or salts thereof.
[0023] In a second aspect the present invention relates to the use of a compound of formula I as defined above for the manufacture of a medicament useful in the treatment of positive, negative and cognitive symptoms of schizophrenia, other psychoses, anxiety disorders, such as generalised anxiety disorder, panic disorder, and obsessive compulsive disorder, depression, aggression, cognitive disorders, side effects induced by conventional antipsychotic agents, migraine, attention deficit hyperactivity disorder and in the improvement of sleep.
[0024] In a third aspect the present invention relates to a pharmaceutical composition comprising a compound of formula I as defined above in a therapeutically effective amount together with one or more pharmaceutically acceptable carriers or diluents.
[0025] In a fourth aspect the present invention relates to a method of treating a disease where a D 4 receptor and/or a 5-HT 2A receptor is implicated comprising administration of a therapeutically effective amount of a compound of formula I as defined above.
[0026] In a fifth aspect the present invention relates to a method of treating the positive, negative and cognitive symptoms of schizophrenia, other psychoses, anxiety disorders, such as generalised anxiety disorder, panic disorder, and obsessive compulsive disorder, depression, aggression, cognitive disorders, side effects induced by conventional antipsychotic agents, migraine, attention deficit hyperactivity disorder and in the improvement of sleep comprising administration of a therapeutically effective amount of a compound of formula I as defined above.
[0027] In a sixth aspect the present invention relates to the use of compounds of the present invention in therapy.
DETAILED DESCRIPTION OF THE INVENTION
[0028] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein X-Y is N—CH 2 .
[0029] In another particular embodiment the present invention relates to compounds of formula I as defined above wherein X-Y is C═CH.
[0030] In another particular embodiment the present invention relates to compounds of formula I as defined above wherein X-Y is CH—CH 2 .
[0031] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein Z is CR 10 .
[0032] In another particular embodiment the present invention relates to compounds of formula I as defined above wherein Z is N.
[0033] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein R 1 is A
wherein * indicates the atom attached to N via a bond.
[0034] In another particular embodiment the present invention relates to compounds of formula I as defined above wherein R 1 is A′
wherein * indicates the atom attached to N via a bond.
[0035] In another particular embodiment the present invention relates to compounds of formula I as defined above wherein R 1 is A″
wherein * indicates the atom attached to N via a bond.
[0036] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein R 2 and R 3 are independently selected from hydrogen and C 1-6 -alkyl, preferably methyl.
[0037] In another particular embodiment the present invention relates to compounds of formula I as defined above wherein both R 2 and R 3 are hydrogen.
[0038] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein R 4 -R 7 are independently selected from hydrogen, C 1-6 -alkyl, preferably methyl or ethyl, C 1-6 -alkoxy, preferably methoxy and halogen, preferably fluoro.
[0039] In another particular embodiment the present invention relates to compounds of formula I as defined above wherein R 4 -R 7 are independently selected from hydrogen and fluoro.
[0040] In a more particular embodiment the present invention relates to compounds of formula I as defined above wherein only one of R 4 -R 7 , selected from R 4 , R 5 and R 7 , is different from hydrogen.
[0041] In a yet more particular embodiment the present invention relates to compounds of formula I as defined above wherein R 4 -R 7 are all hydrogen.
[0042] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein R 8 and R 9 are independently selected from hydrogen and halogen, preferably fluoro.
[0043] In a more particular embodiment the present invention relates to compounds of formula I as defined above wherein both R 8 and R 9 are hydrogen.
[0044] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein R 10 is hydrogen or halogen, preferably fluoro.
[0045] In a more particular embodiment the present invention relates to compounds of formula I as defined above wherein R 10 is hydrogen.
[0046] In a particular embodiment the present invention relates to compounds of formula I as defined above wherein R 11 and R 12 are independently selected from hydrogen and C 1-6 -alkyl, preferably methyl or ethyl.
[0047] In a more particular embodiment the present invention relates to compounds of formula I as defined above wherein both R 11 and R 12 are hydrogen.
[0048] In a particular embodiment the present invention relates to compounds of formula I, wherein R 2 and R 3 are both hydrogen; R 4 , R 5 , R 6 and R 7 are independently selected from hydrogen, methyl, fluor and methoxy; and R 8 , R 9 , R 10 , R 11 and R 12 are all hydrogen. Within this embodiment, particular mentioning is made of X-Y representing N—CH 2 and of Z representing CR 10 .
[0049] Particular compounds of the invention are compounds selected from:
(+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide; (+)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-5-fluoro-1H-indole-1-carboxylic acid amide; (+)-(S)-3-{2-[4-(1H-Pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide; (+)-3-{2-[4-(1H-Pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-5-fluoro-1H-indole-1-carboxylic acid amide; (RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide; 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; 2-((+)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-5-fluoro-1H-indol-1-yl)-acetamide; 2-((+)-(S)-3-{2-[4-(1H-Pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; 2-((−)-(R)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; 2-((RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; 2-((+)-(S)-3-{2-[4-(7-Fluoro-1H-indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol -1-yl)-acetamide; 2-((RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-4-methyl-2,3-dihydro-1H-indol -1-yl)-acetamide; 2-((RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-7-methoxy-2,3-dihydro-1H-indol -1-yl)-acetamide; 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-N-methyl-acetamide; N-Methyl-2-((+)-(S)-3-{2-[4-(1H-pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; (RS)-2-((S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-propionamide; 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-N,N-dimethyl-acetamide; 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-2-oxo-acetamide; 2-Oxo-2-((+)-(S)-3-{2-[4-(1H-pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide; 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-2-oxoacetamide; 2-((RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-7-methoxy-2,3-dihydro-1H-indol-1-yl)-2-oxo-acetamide; (+)-(S)-3-{2-[4-(1H-Indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide; and (+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide;
or salts thereof.
[0075] The term C 1-6 -alkyl refers to a branched or unbranched alkyl group having from one to six carbon atoms inclusive, such as methyl, ethyl, 1-propyl, 2-propyl, 1-butyl, 2-butyl, 2-methyl-2-propyl, and 2-methyl-1-propyl.
[0076] The term C 1-6 -alkoxy designates such groups in which the alkyl group is C 1-6 -alkyl as defined above.
[0077] Halogen means fluoro, chloro, bromo or iodo.
[0078] The present invention also comprises salts of the compounds of the invention, typically, pharmaceutically acceptable salts. The salts of the invention include acid addition salts, metal salts, ammonium and alkylated ammonium salts.
[0079] A “therapeutically effective amount” of a compound as used herein means an amount sufficient to cure, alleviate or partially arrest the clinical manifestations of a given disease and its complications. An amount adequate to accomplish this is defined as “therapeutically effective amount”. Effective amounts for each purpose will depend on the severity of the disease or injury as well as the weight and general state of the subject. It will be understood that determining an appropriate dosage may be achieved using routine experimentation, by constructing a matrix of values and testing different points in the matrix, which is all within the ordinary skills of a trained physician.
[0080] The term “treatment” and “treating” as used herein means the management and care of a patient for the purpose of combating a condition, such as a disease or a disorder. The term is intended to include the full spectrum of treatments for a given condition from which the patient is suffering, such as administration of the active compound to alleviate the symptoms or complications, to delay the progression of the disease, disorder or condition, to alleviate or relief the symptoms and complications, and/or to cure or eliminate the disease, disorder or condition as well as to prevent the condition, wherein prevention is to be understood as the management and care of a patient for the purpose of combating the disease, condition, or disorder and includes the administration of the active compounds to prevent the onset of the symptoms or complications. Nonetheless, prophylactic (preventive) and therapeutic (curative) treatment are two separate aspect of the invention. The patient to be treated, i.e. the patient in need thereof, is preferably a mammal, in particular a human being.
[0081] The salts of the invention are preferably acid addition salts. The acid addition salts of the invention are preferably pharmaceutically acceptable salts of the compounds of the invention formed with non-toxic acids. Acid addition salts include salts of inorganic acids as well as organic acids. Examples of suitable inorganic acids include hydrochloric, hydrobromic, hydroiodic, phosphoric, sulfuric, sulfamic, nitric acids and the like. Examples of suitable organic acids include formic, acetic, trichloroacetic, trifluoroacetic, propionic, benzoic, cinnamic, citric, fumaric, glycolic, itaconic, lactic, methanesulfonic, maleic, malic, malonic, mandelic, oxalic, picric, pyruvic, salicylic, succinic, methane sulfonic, ethanesulfonic, tartaric, ascorbic, pamoic, bismethylene salicylic, ethanedisulfonic, gluconic, citraconic, aspartic, stearic, palmitic, EDTA, glycolic, p-aminobenzoic, glutamic, benzenesulfonic, p-toluenesulfonic acids, theophylline acetic acids, as well as the 8-halotheophyllines, for example 8-bromotheophylline and the like. Further examples of pharmaceutical acceptable inorganic or organic acid addition salts include the pharmaceutically acceptable salts listed in J. Pharm. Sci. 1977, 66, 2, which is incorporated herein by reference.
[0082] Examples of metal salts include lithium, sodium, potassium, magnesium salts and the like.
[0083] Examples of ammonium and alkylated ammonium salts include ammonium, methyl-, dimethyl-, trimethyl-, ethyl-, hydroxyethyl-, diethyl-, n-butyl-, sec-butyl-, tert-butyl-, tetramethylammonium salts and the like.
[0084] Further, the compounds of this invention may exist in unsolvated as well as in solvated forms with pharmaceutically acceptable solvents such as water, ethanol and the like. In general, the solvated forms are considered equivalent to the unsolvated forms for the purposes of this invention.
[0085] The compounds of the present invention may have one or more asymmetric centres and it is intended that any isomers (i.e. enantiomers or diastereomers), as separated, pure or partially purified and any mixtures thereof including racemic and diastereomeric mixtures, i.e. a mixture of stereoisomers, are included within the scope of the invention.
[0086] Racemic forms can be resolved into the optical antipodes by known methods, for example, by fractional separation of diastereomeric salts thereof with an optically active acid, and liberating the optically active amine compound by treatment with a base. Another method for resolving racemates into the optical antipodes is based upon chromatography on an optically active matrix. The compounds of the present invention may also be resolved by the formation of diastereomeric derivatives. Additional methods for the resolution of optical isomers, known to those skilled in the art, may be used. Such methods include those discussed by J. Jaques, A. Collet and S. Wilen in “Enantiomers, Racemates, and Resolutions”, John Wiley and Sons, New York (1981). Optically active compounds can also be prepared from optically active starting materials, by stereoselective synthesis or by enzymatic resolution.
[0087] The pharmaceutical compositions of this invention, or those which are manufactured in accordance with this invention, may be administered by any suitable route, for example orally in the form of tablets, capsules, powders, syrups, etc., or parenterally in the form of solutions for injection. For preparing such compositions, methods well known in the art may be used, and any pharmaceutically acceptable carriers, diluents, excipients or other additives normally used in the art may be used. Tablets may be prepared by mixing the active ingredient with ordinary adjuvants and/or diluents and subsequently compressing the mixture in a conventional tabletting machine. Examples of adjuvants or diluents comprise: corn starch, potato starch, talcum, magnesium stearate, gelatine, lactose, gums, and the like. Any other adjuvants or additives usually used for such purposes such as colourings, flavourings, preservatives etc. may be used provided that they are compatible with the active ingredients.
[0088] Solutions for injections may be prepared by dissolving the active ingredient and possible additives in a part of the solvent for injection, preferably sterile water, adjusting the solution to desired volume, sterilizing the solution and filling it in suitable ampules or vials. Any suitable additive conventionally used in the art may be added, such as tonicity agents, preservatives, antioxidants, etc.
[0089] Conveniently, the compounds of the invention are preferably formulated in a unit dosage form, each dosage containing from about 0.01 to about 8000 mg, preferably from about 0.05 to about 5000 and more preferred from about 0.1 to about 1000 mg, the actual dosage may however vary e.g. according to the specific compound. The term “unit dosage form” refers to physically discrete units suitable as unitary dosages for human subjects and other mammals, each unit containing a predetermined quantity of active material calculated to produce the desired therapeutic effect, in association with one or more pharmaceutically acceptable carriers, diluents, excipients or other additives normally used in the art.
[0090] The compounds of the invention are effective over a wide dosage range. For example, dosages per day normally fall within the range of about 0.01 to about 100 mg/kg of body weight, preferably within the range of about 0.1 to about 75 mg/kg. However, it will be understood that the amount of the compound actually administered will be determined by a physician, according to the relevant circumstances, including the condition to be treated, the chosen route of administration, the actual compound administered, the age, weight, and response of the individual patient, and the severity of the patient's symptoms, and therefore the above dosage ranges are not intended to limit the scope of the invention in any way. In some instances dosage levels below the lower limit of the aforesaid range may be more than adequate, while in other cases still larger doses may be employed without causing any harmful side effect, provided that such larger doses are first divided into several smaller doses for administration throughout the day.
[0091] The compounds of the invention are prepared by the following general methods:
1) Alkylating a piperazine, piperidine or tetrahydropyridine of formula II with an alkylating derivative of formula III:
wherein R 1 , R 4 -R 9 , X-Y and Z are as previously defined, and L is a leaving group such as e.g. halogen, mesylate or tosylate
2) Introduction of R 1 at the indoline nitrogen atom of formula IV by e.g. alkylation, acylation or carbamoylation:
wherein R 4 -R 9 , X-Y and Z are as previously defined, by the use of an alkylating agent, an activated ester, an acid chloride, a carboxylic acid and a coupling reagent
3) Reduction of the pyridinium halide of formula V:
wherein R 1 , R 4 -R 9 and Z are as previously defined and A − is a negatively charged counter ion such as e.g. a halide, by the use of a reducing agent such as e.g. sodium borohydride
4) Reduction of the tetrahydropyridine of formula VI:
wherein R 1 , R 4 -R 9 and Z are as previously defined under reducing conditions such as e.g. hydrogenation in the presence of e.g. palladium; whereupon the compound of formula I is isolated as the free base or a pharmaceutical acceptable acid addition salt thereof.
[0096] Alkylation according to method 1) and 2) is conveniently performed in an inert organic solvent such as a suitably boiling alcohol or ketone, preferably in the presence of an organic or inorganic base (potassium carbonate, diisopropylethylamine or triethylamine) at reflux temperature. Alternatively, the alkylation can be performed at a fixed temperature, which is different from the boiling point, in one of the above-mentioned solvents or in dimethyl formamide (DMF), dimethylsulfoxide (DMSO) or N-methylpyrrolidin-2-one (NMP), preferably in the presence of a base. In some cases it is an advantage to add e.g. potassium iodide to the reaction mixture.
[0097] Piperazines of formula II are e.g. prepared from nitroindoles or substituted nitroindoles by reduction of the nitro group to the corresponding aniline. The aniline is then converted into a piperazine by methods obvious to a chemist skilled in the art (see e.g. Kruse et al. Red. Trav. Chim. Pays. Bas. 1988 107, 303-309 and WO 98/28293). Furthermore, piperazines of formula II are prepared from properly substituted nitro- or amino-2,3-dihydro-1H-indoles, which subsequently are oxidized to their corresponding indoles and subjected to piperazine synthesis as described above, or alternatively, which subsequently are subjected to piperazine synthesis as described above and oxidized to their corresponding indoles. The tetrahydropyridines are prepared by the method described in WO 94/20459, whereas the corresponding piperidines are prepared from the corresponding tetrahydropyridines by reduction of the double bond by e.g. hydrogenation.
[0098] The alkylating derivatives of formula III are described in the literature (see e.g. WO 98/28293) or by analogous methods.
[0099] Compounds of formula IV are prepared by method 1), where R 1 is a protecting group. R 1 is e.g. an acetyl or a boc group, which can be removed under acidic and/or alkaline condition.
[0100] Compounds of formula V are prepared by alkylation of 5-(pyridin-4-yl)-1H-indoles with alkylating derivatives of formula III, e.g. in 1,4-dioxane or in a ketone. The 5-(pyridin-4-yl)-1H-indoles are prepared by e.g. palladium catalyst cross coupling of an N-protected 5-halo-1H-indole with e.g. pyridine-4-boronic acid in an appropriate solvent.
[0101] Compounds of formula VI are prepared as described in method 3).
[0000] Experimental Section
[0000] LC-MS
[0102] General: Solvent system: A=water/TFA (100:0.05) and B=water/acetonitrile/TFA (5:95:0.035) (TFA=trifluoroacetic acid). Retention times (RT) are expressed in minutes. MS instruments are from PESciex (API), equipped with APPI-source and operated in positive ion mode.
[0103] Method A: API 150EX and Shimadzu LC8/SLC-10A LC system. Column: 30×4.6 mm Waters Symmetry C18 with 3.5 μM particles operated at room temperature. Linear Gradient elution with 90% A to 100% B in 4 min and a flow rate of 2 ml/min.
[0104] Method B: API 150EX and Shimadzu LC10AD/SLC-10A LC system. Column: 30×4.6 mm Waters Atlantis dC18 with 3 μM particles operated at 60° C. Linear Gradient elution with 98% A to 100% B in 2.4 min and a flow rate of 3.3 ml/min.
[0105] Method C: API 300 and Shimadzu LC10ADvp/SLC-10Avp LC system. Column: 30×4.6 mm Waters Atlantis dC18 with 3 μM particles operated at 60° C. Linear Gradient elution with 98% A to 100% B in 1.6 min and a flow rate of 5.2 ml/min.
[0000] Optical Rotation
[0106] Optical rotation was as standard performed as a single determination at a concentration of 1% of compound on a Perkin Elmer Polarimeter model 241 apparatus, using the Na 589 nm Spectral Line for the measurements. As standard, the experiment was done at ambient temperature and in dimethyl sulfoxide.
[0107] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference in their entirety and to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein (to the maximum extent permitted by law), regardless of any separately provided incorporation of particular documents made elsewhere herein. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. For example, the phrase “the compound” is to be understood as referring to various compounds of the invention or particular described aspect, unless otherwise indicated.
[0108] Unless otherwise indicated, all exact values provided herein are representative of corresponding approximate values (e.g., all exact exemplary values provided with respect to a particular factor or measurement can be considered to also provide a corresponding approximate measurement, modified by “about,” where appropriate).
[0109] The description herein of any aspect or aspect of the invention using terms such as “comprising”, “having,” “including,” or “containing” with reference to an element or elements is intended to provide support for a similar aspect or aspect of the invention that “consists of”, “consists essentially of”, or “substantially comprises” that particular element or elements, unless otherwise stated or clearly contradicted by context (e.g., a composition described herein as comprising a particular element should be understood as also describing a composition consisting of that element, unless otherwise stated or clearly contradicted by context).
EXAMPLES
[0000] Preparation of Intermediates
[0000] A. Amines and pyridines
5-(Piperazin-1-yl)-1H-indole
[0110] A mixture of 5-nitro-1H-indole (34 g), palladium (5 wt %, dry basis) on activated carbon (2.5 g) and ethyl acetate was shaken at room temperature for 1.5 h under 3 atmospheres of hydrogen. The mixture was filtered, and the solvent was removed in vacuo to yield a solid (28 g), which was dissolved in tetrahydrofuran (400 mL). This solution was added to a boiling mixture of N-benzyliminodiacetic acid (54.4 g) and 1,1′-carbonyldiimidazole (82.4 g) in tetrahydrofuran (1100 mL), and the resulting mixture was boiled under reflux for 3 h. The mixture was filtered and concentrated in vacuo. The residue was purified by flash chromatography on silicagel (eluent: ethyl acetate/triethylamine 100:4) to give a solid (57.5 g), which subsequently was suspended in tetrahydrofuran (300 mL) and added to alane in tetrahydrofuran (500 mL) at 5-16° C. The alane was prepared from lithium aluminium hydride (25 g) and 96% sulphuric acid (32.3 g). The mixture was stirred at 5° C. for 45 min and subsequently quenched by addition of water (50 mL), 15% aqueous sodium hydroxide solution (25 mL) and water (125 mL). The mixture was dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was purified by flash chromatography on silicagel (eluent: ethyl acetate) to give a brown oily compound (44.9 g), which subsequently was dissolved in methanol (1000 mL). Ammonium formate (150 g) and palladium (5 wt %, dry basis) on activated carbon (12 g) was added, and the mixture was boiled under reflux for 45 min, cooled, filtered and concentrated in vacuo. The residue was dissolved in tetrahydrofuran/ethyl acetate and poured onto brine. Concentrated aqueous ammonia solution was added to the mixture under cooling to give an alkaline reaction mixture. The two phases were separated, and the aqueous phase was extracted twice with tetrahydrofuran/ethyl acetate. The combined organic phases were washed with brine, dried (MgSO 4 ) and concentrated in vacuo. The residue was precipitated from tetrahydrofuran/heptane to give the title compound (17.3 g).
5-(3,6-Dihydro-2H-pyridin-4-yl)-1H-indole
[0111] 5-(3,6-Dihydro-2H-pyridin-4-yl)-1H-indole was prepared as described in WO 94/20459.
5-(Piperidin-4-yl)-1H-indole
[0112] A mixture of 5-(3,6-dihydro-2H-pyridin-4-yl)-1H-indole (3.4 g), platinum oxide (0.2 g) and acetic acid (50 mL) was shaken at room temperature for 24 h and under 3 atmospheres of hydrogen. The mixture was filtered, and the solvent was removed in vacuo. The residue was purified by flash chromatography on silicagel (eluent: 4 M ammonia in methanol) to give the title compound (1.3 g).
5-(piperazin-1-yl)-1H-pyrrolo[2,3-c]pyridine
[0113] To a solution of ethyl piperazine-1-carboxylate (80.7 g, 0.51 mol) in ethanol (500 mL) was added a solution of 2-chloro-4-methyl-5-nitropyridine (22 g, 0.13 mol) in ethanol (500 mL). The resulting mixture was stirred at room temperature for 3 days and filtered. The filter cake was washed with diisopropyl ether to give a yellow powder (38.2 g). This compound was mixed with N,N-dimethyl formamide dimethylacetal (86 mL, 0.65 mol) and dimethyl formamide (450 mL), and the resulting mixture was heated at 90° C. for 3 days. The mixture was poured onto brine and extracted with tetrahydrofuran. The combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was precipitated from a mixture of tetrahydrofuran/ethyl acetate/heptane (38.9 g). This compound (27.1 g, 0.78 mol) was dissolved in tetrahydrofuran (600 mL) and ethanol (50 mL), and acetic acid (10 mL) and palladium (5 wt %, dry basis) on activated carbon (4.0 g) was added. The mixture was hydrogenated at 3 bar for 4 h and filtered. Triethylamine (25 mL) was added to the filtrate, and the resulting mixture was concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate) to give a syrup (19.8 g). The syrup (18.3 g) was dissolved in ethanol (240 mL), and a solution of potassium hydroxide (22.5 g, 0.4 mol) in water (60 mL) was added to this solution. The resulting mixture was boiled under reflux for 48 h, reduced in vacuo (100 mL) and brine was added. The aqueous mixture was extracted with tetrahydrofuran. The combined organic phase was washed with brine, treated with activated carbon, dried (MgSO 4 ), filtered and concentrated in vacuo (11.6 g). The residue was precipitated from tetrahydrofuran/methanol to give the title compound (8.0 g).
5-(Pyridin-4-yl)-1H-indole
[0114] A mixture of pyridine-4-boronic acid (5.0 g, 0.041 mol), tert-butyl 5-bromo-indole-1-carboxylate (11.8 g, 0.04 mol), 2 M aqueous sodium carbonate (80 mL, 0.16 mol), tetrakis(triphenylphosphine)palladium(0) (0.92 g, 0.0008 mol), ethanol (19 mL) and toluene (175 mL) was boiled under reflux for 12 h. The experiment was repeated with the double amount of starting materials, e.g. 10 g of pyridine-4-boronic acid. The combined reaction mixture from the two experiments was poured onto a saturated sodium chloride solution (brine), and the aqueous phase was extracted with ethyl acetate. The combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate followed by ethyl acetate/triethylamine 95:5) to give tert-butyl 5-pyridin-4-yl-indole-1-carboxylate (25.5 g, 61%), which was dissolved in a mixture of methanol (500 mL), tetrahydrofuran (200 mL) and 15% aqueous sodium hydroxide (25 mL). The mixture was boiled under reflux for 1 h, concentrate in vacuo to 200 mL and poured onto brine. The aqueous phase was extracted with a mixture of ethyl acetate and tetrahydrofuran, and the combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was precipitated from a cold mixture of methanol and tetrahydrofuran to give the title compound as a creamy solid (9.5 g, 54%). A second crop of the title compound was obtained from the mother liquor (1.7 g, 9%).
7-Fluoro-5-(piperazin-1-yl)-1H-indole
[0115] To a mixture of 7-fluoro-1H-indole (18.5 g, 0.14 mol), borane trimethylamine complex (80 g, 1.1 mol) and 1,4-dioxane (700 mL) was, over a periode of 15 min, added a 37% aqueous HCl (80 mL) solution. The resulting solution reached a maximum temperature of 40° C., and the solution was subsequent stirred at room temperature for another 16 h. The mixture was boiled under reflux for 1 h, 6 M aqueous HCl (500 mL) was added, and the resuting mixture was boiled under reflux for another 15 min. The solution was concentrated at atmospheric pressure and poured onto a mixture of ice and brine. The aqueous phase was made alkaline by the use of 25% aqueous ammonia and extracted with ethyl acetate. The combined organic phase was dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was dissolved in a mixture of triethylamine (38 mL, 0.27 mol) and tetrahydrofuran (350 mL) and cooled to 10° C. Acetyl Chloride (11.2 g, 0.14 mol) was added to the mixture, which thereafter was filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/heptane 50:50) to give 1-(7-fluoro-2,3-dihydro-1H-indol-1-yl-ethanone (16.7 g, 0.09 mol), which was dissolved in acetic acid (250 mL). To this mixture was added 100% nitric acid (5.8 ml, 0.14 mol) over a period of 5 min, and the resulting mixture was stirred at room temperature for 2 h. The reaction was not run to completion, and an additional amount of 6 mL of 100% nitric acid was added. Another 6 mL of 100% nitric acid was added and the mixture was stirred at room temperature for 16 h. The mixture was poured onto a mixture of ice and brine. The aqueous phase was made alkaline by the use of 25% aqueous ammonia and extracted with ethyl acetate. The combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was crystallised from a mixture of ethyl acetate and 2-propanol to give 1-(7-fluoro-5-nitro-2,3-dihydro-1H-indol-1-yl)-ethanone (15.9 g), which was dissolved in methanol (500 mL). To this solution was added ammonium formate (44.4 g, 0.7 mol) and palladium (5 wt %, dry basis) on activated carbon (4.0 g), and the mixture was boiled under reflux for 30 min. The mixture was cooled in an ice bath, filtered and concentrated in vacuo. The residue was dissolved in methanol (100 mL) and ethyl acetate (500 mL), and ammonium formate precipitated out of solution and was removed by filtration. The mother liquor was concentrated in vacuo, and the residue was purified by flash chromatography (ethyl acetate/heptane 65:35) to give 1-(5-amino-7-fluoro-2,3-dihydro-1H-indol-1-yl)-ethanone (13.1 g, >91%). The compound was dissolved in methanol (350 mL), 28% aqueous sodium hydroxide (100 mL) and water (100 mL), and the resulting mixture was boiled under reflux for 4 h. The reaction mixture was concentrated to a volume of about 200 mL, and brine (1 L) was added. The aqueous phase was extracted with a mixture of ethyl acetate and tetrahydrofuran. The combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo to give 7-fluoro-2,3-dihydro-1H-indol-5-ylamine (11.0 g, 96%). This compound was dissolved in p-xylene (500 mL), and palladium (5 wt %, dry basis) on activated carbon (7.5 g) was added. The resulting mixture was boiled under reflux by the use of a Dean/Stark trap for 1.5 h, cooled and filtered. The filter cake was washed with ethyl acetate and tetrahydrofuran, and the organic phases were combined and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/heptane 50:50) to give 7-fluoro-1H-indol-5-ylamine (3.3 g, 29%). A further batch of 7-fluoro-1H-indol-5-ylamine was prepared (0.2 g), and the combined batch was used in the following. A mixture of N-benzyliminodiacetic (5.9 g, 0.027 mol), 1,1′-carbonyldiimidazole (9.0 g, 0.056 mol) and tetrahydrofuran (175 mL) was boiled under reflux for 30 min. To this solution was added a solution of 7-fluoro-1H-indol-5-ylamine (3.47 g, 0.023 mol) in tetrahydrofuran (75 mL) over a period of 1 h. The resulting mixture was boiled under reflux for 3 h and concentrated in vacuo to 50 mL. This solution was purified by flash chromatography (ethyl acetate/heptane 80:20) to give 4-benzyl-1-(7-fluoro-1H-indol-5-yl)piperazine-2,6-dione (7.8 g, 95%), which was dissolved in tetrahydrofuran (75 mL) and subsequently added drop wise to a solution of alane in tetrahydrofuran over 60 min at 5-10° C. The resulting mixture was stirred at 7° C. for 30 min and then quenched by addition of water (6.5 mL), 15% aqueous sodium hydroxide (3.25 mL) and water (16 mL). MgSO 4 was added to the mixture, which was filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/heptane 50:50) to give 5-(4-benzylpiperazin-1-yl)-7-fluoro-1H-indole (4.9 g, 63%). The alane was prepared as described in the following: Lithium aluminium hydride (3.23 g, 0.085 mol) was suspended in tetrahydrofuran (100 mL), and the mixture was cooled to 6° C. To this suspension was added a mixture of 96% sulphuric acid in tetrahydrofuran (75 mL) over 30 min at 5-11° C. The resulting mixture was stirred for 1 h at 5-7° C. to give alane in tetrahydrofuran.
[0116] A mixture of 5-(4-benzylpiperazin-1-yl)-7-fluoro-1H-indole (4.9 g, 0.016 mol), ammonium formate (16.0 g, 0.25 mol), palladium (5 wt %, dry basis) on activated carbon (2.0 g) and methanol (100 mL) was boiled under reflux for 2 h. The mixture was cooled, filtered and concentrated in vacuo. The residue was dissolved in 25% aqueous ammonia (50 mL) and brine, and the aqueous phase was extracted with a mixture of ethyl acetate and tetrahydrofuran. The combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was crystallized from a mixture of tetrahydrofuran, ethyl acetate and diisopropyl ether to give the title compound (1.6 g, 42%).
[0000] B. Alkylating Reagents
Methyl (RS)-(2,3-Dihydro-1H-indol-3-yl)acetate
[0117] A mixture of commercially available (1H-indol-3-yl)acetic acid (200 g, 1.14 mol), methanol (2700 mL) and a saturated solution of HCl in diethyl ether (750 mL) was stirred at room temperature for 16 h. The solvent was removed in vacuo, and the residue was subjected to aqueous work-up under alkaline conditions by the use of aqueous ammonia to yield methyl (1H-indol-3-yl)acetate as an oil (202.5 g, 94%). The crude oil was dissolved in acetic acid (2 L), and sodium cyanoborohydride (60 g, 0.95 mol) was added in portions of 1 g over a period of 8 h. The resulting mixture was stirred at room temperature for 16 h and then poured onto an ice/water mixture. Aqueous work-up under alkaline conditions gave the crude product that was purified by flash chromatography (ethyl acetate/heptane 1:1) to give the title compound (97.3 g, 48%).
Ethyl (RS)-(2,3-Dihydro-5-fluoro-1H-indol-3-yl)acetate
[0118] A mixture of ethyl (5-fluoro-1H-indol-3-yl)acetate (Bullock et al. J. Am. Chem. Soc. 1951, 73, 5155-5157) (72.5 g, 0.33 mol), 70% methane sulfonic acid (aq) (50 mL) and palladium (5 wt %, dry basis) on activated carbon (20 g) in ethanol (700 mL) was treated with hydrogen at 3 bar and 50° C. for 48 h. The mixture was filtered and concentrated in vacuo. The residue was dissolved in ethyl acetate, and aqueous ammonia was added. The phases were separated, and the aqueous phase was extracted twice with ethyl acetate. The combined organic phase was washed with brine, dried (MgSO 4 ) and concentrated in vacuo (55 g, 75%).
Methyl (RS)-(1-tert-Butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid
[0119] Methyl (RS)-(2,3-Dihydro-1H-indol-3-yl)acetate (97.2 g, 0.51 mol) was dissolved in tetrahydrofuran (1000 mL), and a solution of di-tert-butyl dicarbonate (118.2 g, 0.54 mol) in tetrahydrofuran (500 mL) was added. The resulting mixture was stirred at room temperature for 16 h and poured into water. The aqueous phase was extracted with diethyl ether, and the combined organic phase was washed with brine and dried (MgSO 4 ). The organic solvent was removed in vacuo, and the oily residue was purified by flash chromatography (heptane/ethyl acetate 2:1) to give crude title compound (148 g, 100%).
[0120] Ethyl (RS)-(1-tert-Butoxycarbonyl-2,3-dihydro-5-fluoro-1H-indol-3-yl)acetic acid was prepared in a similar manner starting from ethyl (RS)-(2,3-dihydro-5-fluoro-1H-indol-3-yl)acetate.
(+)-(1-tert-Butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid
[0121] Methyl (RS)-(1-tert-Butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid (50 g, 0.17 mol) was mixed with Candida Antarctica Lipase (CAL, SP-435, Novo Nordisk, Denmark) (2.5 g) and subsequently added 0.1 M phosphate buffer (pH=7.0) (3 L) under vigorous stirring. The resulting mixture was stirred vigorously at 25° C. for 120 h, and the pH was maintained at 7 by the addition of 0.5 N NaOH. After addition of about 0.45 equivalent of base, filtering off the enzyme stopped the reaction. The enzyme was washed with diethyl ether (1 L), and the pH of the aqueous phase was adjusted to 8. The aqueous phase was extracted with diethyl ether (2×1 L), and the combined organic extracts were dried (MgSO 4 ) and concentrated in vacuo to give crude methyl (R)-(1-tert-butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid, which was used for the synthesis of (−)-(R)-(1-tert-butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid (see below). The aqueous phase was cooled by addition of ice, and the pH adjusted to 1.5 with 37% HCl (aq). The aqueous phase was extracted with diethyl ether (3×1 L), and the combined organic extracts were dried (MgSO 4 ) and concentrated in vacuo to give crude title compound (enantiomeric excess was about 80-85%). A number of precipitations from diisopropyl ether gave the title compound: mp 137-138° C.; enantiomeric excess 96.5%; [α] D =+12.8° (c=0.45, methanol). The chiral analysis was performed on a Ultron ES OVM 150×4.6 mm, flow 1.0 ml/min, eluent 25 mM phosphate buffer (pH≅4.6)/methanol/2-propanol/tetrahydrofuran 90/5/5/0.5, T=30° C. Enantiomeric purities expressed as enantiomeric excess (ee) were calculated from peak areas.
[0122] (+)-(1-tert-Butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid was assigned as the (S)-enantiomer, as the dihydrogen phosphate salt of 2-(2,3-dihydro-1H-indol-3-yl)ethanol (obtained as described below from (+)-(1-tert-butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid) was measured as the (+)-enantiomer (Frydenvang et al. Chirality 2004, 16, 126-130).
[0123] The following compound was prepared in a similar manner:
(+)-(1-tert-Butoxycarbonyl-2,3-dihydro-5-fluoro-1H-indol-3-yl)acetic acid
[0124] from ethyl (RS)-(1-tert-butoxycarbonyl-2,3-dihydro-5-fluoro-1H-indol-3-yl)acetic acid. Assignment of the optical rotation was done in methanol.
(−)-(1-tert-Butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid
[0125] Crude methyl (R)-(1-tert-butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid (33.7 g, 0.116 mol) was treated with CAL enzyme and subsequently subjected to work-up as described above for the synthesis of the (+)-(S)-enantiomer. The residue, which was further enriched in the (R)-enantiomer, was purified by flash chromatography and dissolved in a mixture of ethanol (500 ml) and 1 N NaOH (500 ml). The resulting mixture was stirred at room temperature for 30 min, and the ethanol was removed in vacuo. The aqueous phase was washed with diethyl ether, cooled by the addition of ice, and the pH was adjusted to 1. The aqueous phase was extracted with diethyl ether (3×400 mL), and the combined organic extracts were washed with brine, dried (MgSO 4 ), and the solvent was removed in vacuo (31 g, enantiomeric excess: 94.6%). The residue was precipitated from diisopropyl ether (50 ml) to give the title compound (26 g): mp 136-137° C.; enantiomeric excess 97.7%; [α] D =−12.6° (c=0.47, methanol). The chiral analysis was performed on a Ultron ES OVM 150×4.6 mm, flow 1.0 mL/min, eluent 25 mM phosphate buffer (pH≅4.6)/methanol/2-propanol/tetrahydrofuran 90/5/5/0.5, T=30° C. Enantiomeric purities expressed as enantiomeric excess (ee) were calculated from peak areas.
Methyl (S)-(2,3-Dihydro-1H-indol-3-yl)acetate
[0126] (+)-(S)-(1-tert-Butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid (14.2 g, 0.05 mol) was dissolved in methanol (600 mL), cooled (5° C.) and a saturated solution of HCl in diethyl ether (150 mL) was added. The resulting mixture was stirred at room temperature for 16 h, concentrated in vacuo to about 50 mL and poured onto an ice/water mixture. The aqueous phase was extracted with ethyl acetate and diethyl ether, and the combined organic phases were washed with aqueous ammonia and brine. The organic phase was dried and concentrated in vacuo to give the title compound (9.8 g, 100%).
[0127] The following compounds were prepared in a similar manner:
Methyl (R)-(2,3-Dihydro-1H-indol-3-yl)acetate
[0128] from (−)-(R)-(1-tert-butoxycarbonyl-2,3-dihydro-1H-indol-3-yl)acetic acid.
Methyl (R) or (S)-(2,3-Dihydro-5-fluoro-1H-indol-3-yl)acetate (enantiomer A)
[0129] from (+)-(1-tert-butoxycarbonyl-2,3-dihydro-5-fluoro-1H-indol-3-yl)acetic acid.
(RS)-2-(2,3-Dihydro-1H-indol-3-yl)ethanol
[0130] Methyl (RS)-(2,3-Dihydro-1H-indol-3-yl)acetate (30.0 g, 0.16 mol) was dissolved in tetrahydrofuran (500 mL) and subsequently added to a suspension of lithium aluminium hydride (10.6 g, 0.28 mol) in tetrahydrofuran (500 mL) over a period of 75 min at 33-39° C. The reaction was quenched by sequential addition of water (20 mL), 15% NaOH (10 mL) and water (50 mL), and then MgSO 4 . The mixture was stirred at room temperature for 1 h, filtered and concentrated in vacuo to give the title compound (24.2 g, 95%).
[0131] The following compounds were prepared in a similar manner:
(S)-2-(2,3-Dihydro-1H-indol-3-yl)ethanol
[0132] from methyl (S)-(2,3-dihydro-1H-indol-3-yl)acetate
(R)-2-(2,3-Dihydro-1H-indol-3-yl)ethanol
[0133] from methyl (R)-(2,3-dihydro-1H-indol-3-yl)acetate
(R) or (S)-2-(2,3-Dihydro-5-fluoro-1H-indol-3-yl)ethanol
[0134] from methyl (R) or (S)-(2,3-dihydro-5-fluoro-1H-indol-3-yl)acetate (enantiomer A)
(RS)-2-(4-Methyl-2,3-dihydro-1H-indol-3-yl)ethanol
[0135] A mixture of 4-methyl-1H-indole (15.7 g, 0.12 mol), diethyl ether (300 mL) and tetrahydrofuran (300 mL) was stirred at room temperature. To this solution was added oxalyl chloride (22.8 g, 0.18 mol) drop wise. The resulting solution was stirred at room temperature for 16 h. Ethanol (100 mL) was added, and the mixture was stirred for 5 min. Triethylamine (100 mL) was added under cooling (20-30° C.) and then ice (200 mL) and brine (1 L). The aqueous phase was extracted with ethyl acetate, and the combined organic phase was washed with brine, dried (MgSO 4 ) and concentrated in vacuo. The solid compound formed was stirred with diethyl ether, collected by filtration and dried in vacuo to give ethyl (4-methyl-1H-indol-3-yl)-oxo-acetate (22.5 g). This compound was dissolved in tetrahydrofuran (250 mL) and subsequently added to lithium aluminium hydride (13 g, 0.35 mol) in tetrahydrofuran (500 mL). The resulting mixture was boiled under reflux for 1 h and then quenched with water (50 mL). The mixture was filtered, and the mother liquor was concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/heptane 50:50) and subsequently crystallised from ethyl acetate to give 2-(4-methyl-1H-indol-3-yl)ethanol (14.4 g, 85%). To a mixture of 2-(4-methyl-1H-indol-3-yl)ethanol (14.4 g, 0.08 mol), borane trimethylamine complex (64 g, 0.88 mol) and 1,4-dioxane (500 mL) was added 37% aqueous HCl (55 mL), and the resulting mixture was stirred at room temperature for 16 h. The mixture was boiled under reflux for 1.5 h. 6 M aqueous HCl (260 mL) was added, and 300 mL of 1,4-dioxane/water was removed by distillation. The aqueous phase was cooled to 20° C. and then made alkaline by the use of 28% aqueous sodium hydroxide. The aqueous phase was added brine (500 mL) and extracted with ethyl acetate. The combined organic phase was washed with brine, dried (MgSO 4 ) and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate) to give the title compound (12.5 g, 86%).
[0136] The following compound was prepared in a similar manner:
(RS)-2-(7-Methoxy-2,3-dihydro-1H-indol-3-yl)ethanol
[0137] from 7-methoxy-1H-indole.
(S)-3-(2-Bromoethyl)-2,3-dihydro-1H-indole-1-carboxylic acid amide
[0138] To a solution of (S)-2-(2,3-dihydro-1H-indol-3-yl)ethanol (23.4 g, 0.14 mol), 37% HCl (aq) (15 mL) and water (15 mL) was added a solution of potassium cyanate (12.6 g, 0.15 mol) in water (85 mL) over a period of 10 min. The resulting mixture was added water (60 mL) and then poured onto a mixture of ice and brine. The aqueous phase was made alkaline by the use of 25% NH 3 (aq) and subsequently extracted with ethyl acetate. The combined organic phase was washed with brine and dried (MgSO 4 ). The organic phase was filtered and concentrated in vacuo (19.9 g). The residue was dissolved in tetrahydrofuran (400 mL) and triethylamine (20 mL), which subsequently was cooled to 3° C. To this mixture was added a solution of methanesulfonyl chloride (8.6 mL, 0.11 mol) in tetrahydrofuran (100 mL). The mixture was stirred at room temperature for 30 min, filtered and concentrated in vacuo. The crude product was dissolved in acetone (1400 mL) and lithium bromide (83.8 g, 0.96 mol) was added. The resulting mixture was boiled under reflux for 1 h, filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate) and precipitated from ethyl acetate and heptane to give the title compound (8.8 g).
[0139] The following compounds were prepared in a similar manner:
(R)-3-(2-Bromoethyl)-2,3-dihydro-1H-indole-1-carboxylic acid amide
[0140] from (R)-2-(2,3-dihydro-1H-indol-3-yl)ethanol.
(R) or (S)-3-(2-Bromoethyl)-2,3-dihydro-5-fluoro-1H-indole-1-carboxylic acid amide
[0141] from methyl (R) or (S)-(2,3-dihydro-5-fluoro-1H-indol-3-yl)acetate (enantiomer A) via (R) or (S)-2-(2,3-dihydro-5-fluoro-1H-indol-3-yl)ethanol.
(RS)-3-(2-Bromoethyl)-2,3-dihydro-1H-indole-1-carboxylic acid amide
[0142] from (RS)-2-(2,3-dihydro-1H-indol-3-yl)ethanol.
1-[(S)-3-(2-Bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone
[0143] To a cooled (−28° C.) solution of (S)-2-(2,3-dihydro-1H-indol-3-yl)ethanol (8.5 g, 0.052 mol) in tetrahydrofuran (500 mL) and triethylamine (5.6 g, 0.055 mol) was added a solution of acetyl chloride (4.0 g, 0.051 mol) in tetrahydrofuran (200 mL) over a period of 35 min at −35 to −30° C. The mixture was stirred at −25 to −18° C. for 20 min, and an additional amount of triethylamine (6.3 g, 0.062 mol) was added followed by a solution of methanesulfonyl chloride (6 g, 0.052 mol) in tetrahydrofuran (200 mL) over a period of 25 min at −12 to −3° C. The resulting mixture was filtered and concentrated in vacuo. The residue was dissolved in acetone (600 mL) and lithium bromide (21.7 g, 0.25 mol) was added. The mixture was boiled under reflux for 1 h, filtered and concentrated in vacuo. The residue was purified by flash chromatography (heptane/ethyl acetate 1:1) to give the title compound (10.6 g, 76%).
[0144] The following compounds were prepared in a similar manner:
1-[(R)-3-(2-Bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone
[0145] from (R)-2-(2,3-Dihydro-1H-indol-3-yl)ethanol.
1-[(R) or (S)-3-(2-Bromoethyl)-2,3-dihydro-5-fluoro-1H-indol-1-yl]-ethanone
[0146] from methyl (R) or (S)-(2,3-dihydro-5-fluoro-1H-indol-3-yl)acetate (enantiomer A) via (R) or (S)-2-(2,3-dihydro-5-fluoro-1H-indol-3-yl)ethanol.
1-[(RS)-3-(2-Bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone
[0147] from (RS)-2-(2,3-Dihydro-1H-indol-3-yl)ethanol.
1-[(RS)-3-(2-Bromoethyl)-4-methyl-2,3-dihydro-1H-indol-1-yl]-ethanone
[0148] from (RS)-2-(4-Methyl-2,3-dihydro-1H-indol-3-yl)ethanol
1-[(RS)-3-(2-Bromoethyl)-7-methoxy-2,3-dihydro-1H-indol-1-yl]-ethanone
[0149] from (RS)-2-(7-Methoxy-2,3-dihydro-1H-indol-3-yl)ethanol
[0000] C. Indolines
5-{4-[(S)-2-(2,3-Dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole
[0150] A mixture of 5-(piperazin-1-yl)-1H-indole (38.0 g, 0.19 mol), 1-[(S)-3-(2-bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone (49.6 g, 0.19 mol) and potassium carbonate (32 g, 0.23 mol) in a mixture of N,N-dimethyl formamide (400 mL) and butanone (800 mL) was boiled under reflux for 8 h. The mixture was filtered and concentrated in vacuo. The reaction was performed once more with the same amounts of starting material, and the combined residues were purified by flash chromatography (ethyl acetate/ethanol/triethylamine 90:5:5). The purified residue was precipitated from a mixture of methanol/ethyl acetate/heptane to give a solid (77.4 g). This compound (77.2 g, 0.20 mol) was suspended in methanol (1000 mL), and to this suspension was added a mixture of 37% HCl (aq) (125 mL) and water (125 mL). The resulting mixture was boiled under reflux for 4.5 h. The mixture was poured onto ice and brine, and the aqueous phase was made alkaline by the use of 25% NH 3 (aq). The aqueous phase was extracted with ethyl acetate, and the combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo (75.1 g). The residue was purified by flash chromatography (ethyl acetate/ethanol/triethylamine 90:5:5) to give the title compound as a solid (58.8 g).
[0151] The following compounds were prepared in a similar manner:
5-{4-[(R)-2-(2,3-Dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole
[0152] from 5-(piperazin-1-yl)-1H-indole and 1-[(R)-3-(2-bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone.
5-{4-[(R) or (S)-2-(2,3-Dihydro-5-fluoro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}1-1H-indole
[0153] from 5-(piperazin-1-yl)-1H-indole and 1-[(R) or (S)-3-(2-bromoethyl)-2,3-dihydro-5-fluoro-1H-indol-1-yl]-ethanone (obtained from enantiomer A).
5-{4-[(S)-2-(2,3-Dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-pyrrolo[2,3-c]pyridine
[0154] from 5-(piperazin-1-yl)-1H-pyrrolo[2,3-c]pyridine and 1-[(S)-3-(2-bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone.
5-{4-[(RS)-2-(2,3-Dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole
[0155] from 5-(piperazin-1-yl)-1H-indole and 1-[(RS)-3-(2-bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone.
5-{-4-[(S)-2-(2,3-Dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-7-fluoro-1H-indole
[0156] from 7-Fluoro-5-(piperazin-1-yl)-1H-indole and 1-[(S)-3-(2-bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone
5-{4-[2-((RS)-4-Methyl-2,3-dihydro-1H-indol-3-yl}-ethyl]-piperazin-1-yl)-1H-indole
[0157] from 5-(piperazin-1-yl)-1H-indole and 1-[(RS)-3-(2-bromoethyl)-4-methyl-2,3-dihydro-1H-indol-1-yl]-ethanone
5-{4-[2-((RS)-7-Methoxy-2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}1H-indole
[0158] from 5-(piperazin-1-yl)-1H-indole and 1-[(RS)-3-(2-bromoethyl)-7-methoxy-2,3-dihydro-1H-indol-1-yl]-ethanone.
5-{1-[(S)-2-(2,3-Dihydro-1H-indol-3-yl)-ethyl]-1,2,3,6-tetrahydropyridin-4-yl}1H-indole
[0159] A mixture of 5-(pyridin-4-yl)-1H-indole (17.2 g, 0.089 mol), 1-[(S)-3-(2-bromoethyl)-2,3-dihydro-1H-indol-1-yl]-ethanone (28.5 g, 0.11 mol), 1,4-dioxane (900 mL), tetrahydrofuran (150 mL) and methanol (100 mL) was heated under reflux at approximately 80° C. for 68 h. The mixture was cooled, and the solid formed was collected by filtration and washed with tetrahydrofuran. The compound was dried in vacuo to give 1-[2-((S)-1-acetyl-2,3-dihydro-1H-indol-3-yl)ethyl]-4-(1H-indol-5-yl)pyridinium bromide (27.5 g, 64%), which was suspended in methanol (900 mL) and cooled (5° C.). To this mixture was added sodium borohydride (6.75 g, 0.18 mol) over a period of 20 min. The resulting mixture was stirred at 10° C. for 1 h and concentrated to about 200 mL. The mixture was poured onto a mixture of brine (750 mL) and 28% aqueous sodium hydroxide (20 mL), and the aqueous phase was extracted with a mixture of ethyl acetate and tetrahydrofuran. The combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/tetrahydrofuran/triethylamine 70:25:5) to give 1-((S)-3-{2-[4-(1H-indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]ethyl}-2,3-dihydro-1H-indol-1-yl)-ethanone (20.5 g, 85%). This compound (8.0 g, 0.02 mol) was dissolved in 1-propanol (220 mL) and heated to 60° C. To this mixture was added 28% aqueous sodium hydroxide, and the resulting mixture was boiled under reflux for 7 h. The mixture was cooled and poured onto brine. The aqueous phase was extracted with a mixture of ethyl acetate and tetrahydrofuran, and the combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was combined with a residue coming from another experiment starting from 1 g of 1-((S)-3-{2-[4-(1H-indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]ethyl}-2,3-dihydro-1H-indol-1-yl)-ethanone. The combined residue was purified by flash chromatography (ethyl acetate/triethylamine 95:5) to give the title compound (4.95 g).
5-{1-[(S)-2-(2,3-Dihydro-1H-indol-3-yl)-ethyl]-piperidin-4-yl}-1H-indole
[0160] A mixture of 1-((S)-3-{2-[4-(1H-indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]ethyl}-2,3-dihydro-1H-indol-1-yl)-ethanone (15.3 g, 0.040 mol), palladium (10 wt %, dry basis) on activated carbon (4.0 g), ammonium formate (50 g, 0.80 mol) and methanol (600 mL) was boiled under reflux for 3 h. The mixture was cooled and filtered, and the filter cake was washed with tetrahydrofuran. The organic phase was reduced in vacuo to 200 mL and poured onto a mixture of brine (1 L) and 28% aqueous sodium hydroxide (20 mL). The aqueous phase was extracted with ethyl acetate, and the combined organic phase was washed with brine, dried (MgSO 4 ) and concentrated in vacuo (13.2 g, 82%). This compound was dissolved in 1-propanol at 80° C., and 28% aqueous sodium hydroxide (100 mL) was added. The resulting mixture was boiled under reflux for 20 h. The mixture was poured onto brine, and the aqueous phase was extracted with ethyl acetate. The combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/triethylamine 95:5) to give the title compound (9.8 g, 80%).
[0000] Preparation of the Compounds of the Invention
EXAMPLES
1a, (+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide
[0161]
[0162] A mixture of 5-(piperazin-1-yl)-1H-indole (3.37 g, 0.017 mol), (S)-3-(2-bromoethyl)-2,3-dihydro-1H-indole-1-carboxylic acid amide (3.0 g, 0.11 mol), potassium carbonate (2.31 g, 0.017 mol) in butanone (450 mL) was boiled under reflux for 12 h. The mixture was filtered, concentrated in vacuo, and the residue was purified by flash chromatography (ethyl acetate/ethanol/triethylamine 70:25:5). The purified residue was precipitated from ethyl acetate to give the title compound as a white solid (3.0 g). Assignment of the optical rotation was done in dimethyl sulfoxide.
[0163] LC/MS (m/z) 390 (MH + ); RT=1.55 (Method A).
[0164] The following compounds were prepared in a similar manner from:
1b, (+)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-5-fluoro-1H-indole-1-carboxylic acid amide oxalate
[0165]
from 5-(piperazin-1-yl)-1H-indole and (R) or (S)-3-(2-bromoethyl)-2,3-dihydro-5-fluoro -1H-indole-1-carboxylic acid amide (obtained from enantiomer A). Assignment of the optical rotation was done in dimethyl sulfoxide. LC/MS (m/z) 408 (MH + ); RT=1.65 (Method A).
1c, (+)-(S)-3-{2-[4-(1H-Pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro -1H-indole-1-carboxylic acid amide
[0166]
from 5-piperazin-1-yl-1H-pyrrolo[2,3-c]pyridine and (S)-3-(2-bromoethyl)-2,3-dihydro -1H-indole-1-carboxylic acid amide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0167] LC/MS (m/z) 391 (MH + ); RT=1.05 (Method A).
1d (+)-3-{2-[4-(1H-Pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-5-fluoro-1H-indole-1-carboxylic acid amide
[0168]
from 5-piperazin-1-yl-1H-pyrrolo[2,3-c]pyridine and (R) or (S)-3-(2-bromoethyl)-2,3-dihydro-5-fluoro-1H-indole-1-carboxylic acid amide (obtained from enantiomer A). Assignment of the optical rotation was done in dimethyl sulfoxide.
[0169] LC/MS (m/z) 409 (MH + ); RT=1.23 (Method A).
1e, (RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide hydrochloride
[0170]
from 5-(piperazin-1-yl)-1H-indole and (RS)-3-(2-bromoethyl)-2,3-dihydro-1H-indole-1-carboxylic acid amide.
[0171] LC/MS (m/z) 390 (MH + ); RT=1.56 (Method A).
2a, 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide dihydrochloride
[0172]
[0173] To a clear solution of 2-chloroacetamide (17.7 g, 0.19 mol) in N-methylpyrrolidin-2-one (500 mL) was slowly added a solution of 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole (52.6 g, 0.15 mol) in butanone (600 mL). Potassium iodide (29.0 g, 0.17 mol) and potassium carbonate (31.4 g, 0.15 mol) was added and the resulting mixture was boiled under reflux for 1 h, filtered and poured onto a mixture of ice and brine. The aqueous phase was extracted with ethyl acetate, and the combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/ethanol/triethylamine 70:5:5) to give crude title compound (30.6 g). This was precipitated from methanol by addition of hydrochloric acid in diethyl ether until pH was approximately 3. The compound was collected by filtration as a powder (7.7 g). Assignment of the optical rotation was done in dimethyl sulfoxide.
[0174] LC/MS (m/z) 404 (MH + ); RT=1.48 (Method A).
[0175] The following compounds were prepared in a similar manner.
2b, 2-((+)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-5-fluoro-1H-indol-1-yl)-acetamide dihydrochloride
[0176]
from 5-{4-[(R) or (S)-2-(2,3-dihydro-5-fluoro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole (obtained from enantiomer A) and 2-chloroacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0177] LC/MS (m/z) 422 (MH + ); RT=1.67 (Method A).
2c, 2-((+)-(S)-3-{2-[4-(1H-Pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide dihydrochloride
[0178]
from 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-pyrrolo[2,3-c]pyridine and 2-chloroacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0179] LC/MS (m/z) 405 (MH + ); RT=1.16 (Method A).
2d, 2-((−)-(R)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide dihydrochloride
[0180]
from 5-{4-[(R)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and 2-chloroacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0181] LC/MS (m/z) 404 (MH + ); RT=1.51 (Method A).
2e, 2-((RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide oxalate
[0182]
from 5-{4-[(RS)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and 2-chloroacetamide.
[0183] LC/MS (m/z) 404 (MH + ); RT=1.0 (Method B).
[0184] 2f, 2-((+)-(S)-3-{2-[4-(7-Fluoro-1H-indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide oxalate.
from 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-7-fluoro-1H-indole and 2-chloroacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0185] LC/MS (m/z) 422 (MH + ); RT=1.1 (Method B).
2g, 2-((RS)-3-(2-[4-(1H-Indol-5-vi)-piperazin-1-yl]-ethyl-4-methyl-2,3-dihydro-1H-indol -1-yl)-acetamide oxalate
[0186]
from 5-{4-[2-((RS)-4-methyl-2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and 2-chloroacetamide.
[0187] LC/MS (m/z) 418 (MH + ); RT=0.40 (Method C).
2h, 2-((RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-7-methoxy-2,3-dihydro-1H-indol -1-yl)-acetamide oxalate
[0188]
from 5-{4-[2-((RS)-7-methoxy-2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and 2-chloroacetamide.
[0189] LC/MS (m/z) 434 (MH + ); RT=0.37 (Method C).
2i, 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-N-methyl-acetamide oxalate
[0190]
from 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and 2-chloro-N-methylacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0191] LC/MS (m/z) 418 (MH + ); RT=1.07 (Method B).
2j, N-Methyl-2-((+)-(S)-3-{2-[4-(1H-pyrrolo[2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide oxalate
[0192]
from 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-pyrrolo[2,3-c]pyridine and 2-chloro-N-methyl-acetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0193] LC/MS (m/z) 419 (MH + ); RT=0.78 (Method B).
2k, (RS)-2-((S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-propionamide oxalate
[0194]
from 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and 2-chloropropionamide. The compound is approximately a 1.1 mixture of diastereomers according to NMR.
[0195] LC/MS (m/z) 418 (MH + ); RT=1.03 (Method B).
2l, 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-N,N-dimethyl-acetamide oxalate
[0196]
from 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and 2-chloro-N,N-dimethylacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0197] LC/MS (m/z) 432 (MH + ); RT=0.41 (Method C).
2m, 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide oxalate
[0198]
from 5-{1-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-1,2,3,6-tetrahydropyridin-4-yl}-1H-indole and 2-chloroacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0199] LC/MS (m/z) 401 (MH + ); RT=1.12 (Method B).
2n, 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide oxalate
[0200]
from 5-{1-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperidin-4-yl}-1H-indole and 2-chloroacetamide. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0201] LC/MS (m/z) 403 (MH + ); RT=0.4 (Method C).
3a, 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}2,3-dihydro-1H-indol-1-yl)-2-oxo-acetamide
[0202]
[0203] To a solution of oxalamic acid (2.35 g, 0.026 mol) and 1,1′-carbonyldiimidazole (4.66 g, 0.029 mol) in dry N,N-dimethyl formamide (50 mL) was slowly added a solution of 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole (8.3 g, 0.024 mol) in N,N-dimethyl formamide (75 mL). The resulting mixture was stirred at room temperature for 1 h, filtered and poured onto brine. The aqueous phase was extracted with ethyl acetate, and the combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/heptane/triethylamine 70:25:5) to give the title compound as an oil (6.5 g). The oil was precipitated from ethyl acetate to give a powder (4.1 g). Assignment of the optical rotation was done in dimethyl sulfoxide.
[0204] LC/MS (m/z) 418 (MH + ); RT=1.62 (Method A).
[0205] The following compound was prepared in a similar manner:
3b, 2-Oxo-2-((+)-(S)-3-{2-[4-(1H-pyrrolo [2,3-c]pyridin-5-yl)-piperazin-1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-acetamide
[0206]
from 5-{4-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-pyrrolo[2,3-c]pyridine. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0207] LC/MS (m/z) 419 (MH + ); RT=1.16 (Method A).
3e, 2-((+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperidin 1-yl]-ethyl}-2,3-dihydro-1H-indol-1-yl)-2-oxoacetamide oxalate
[0208]
from 5-{1-[(S)-2-(2,3-dihydro-1H-indol-3-yl)-ethyl]-piperidin-4-yl}-1H-indole and oxalamic acid. Assignment of the optical rotation was done in dimethyl sulfoxide.
[0209] LC/MS (m/z) 417 (MH + ); RT=0.39 (Method C).
3d, 2-((RS)-3-{2-[4-(1H-Indol-5-yl)-piperazin-1-yl]-ethyl}-7-methoxy-2,3-dihydro-1H-indol-1-yl)-2-oxo-acetamide oxalate
[0210]
from 5-{4-[2-((RS)-7-methoxy-2,3-dihydro-1H-indol-3-yl)-ethyl]-piperazin-1-yl}-1H-indole and oxalamic acid.
[0211] LC/MS (m/z) 448 (MH + ); RT=0.3 (Method C).
4a, (+)-(S)-3-{2-[4-(1H-Indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide hydrochloride
[0212]
[0213] A mixture of 5-(pyridin-4-yl)-1H-indole (2.6 g, 0.13 mol), 1,4-dioxane (250 mL), tetrahydrofuran (20 mL) and methanol (10 mL) was heated to reflux temperature, and (S) -3-(2-bromoethyl)-2,3-dihydro-1H-indole-1-carboxylic acid amide (3.9 g, 0.015 mol) was added. The resulting mixture was boiled under reflux for 96 h. The mixture was cooled, and the liquid decanted off. The residue was washed with ethyl acetate and then dissolved in methanol (500 mL) under heating. The organic phase was concentrated in vacuo to give 1-[2-((S)-1-carbamoyl-2,3-dihydro-1H-indol-3-yl)ethyl]-4-(1H-indol-5-yl)pyridinium bromide (5.7 g, 75%). This compound was suspended in methanol (130 mL), and sodium borohydride (1.48 g, 0.039 mol) was added over a period of 10 min at 12-20° C. The resulting mixture is stirred at 10° C. for 30 min and then poured onto a mixture of brine (500 mL) and 28% aqueous sodium hydroxide (50 mL). The aqueous phase was extracted with ethyl acetate, and the combined organic phase was washed with brine, dried (MgSO 4 ), filtered and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/ethanol/triethylamine 85:10:5) to give crude title compound (3.5 g). Starting from 0.7 g of crude compound, the hydrochloric acid salt was prepared (0.63 g). Assignment of the optical rotation was done in dimethyl sulfoxide.
[0214] LC/MS (m/z) 387 (MH + ); RT=1.11 (Method B).
5a. (+)-(S)-3-{2-[4-(1H-Indol-5-yl)-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide oxalate
[0215]
[0216] A mixture of (S)-3-{2-[4-(1H-indol-5-yl)-3,6-dihydro-2H-piperidin-1-yl]-ethyl}-2,3-dihydro-1H-indole-1-carboxylic acid amide (2.6 g, 0.007 mol), palladium (10 wt %, dry basis) on activated carbon (1.0 g), ammonium formate (8.5 g, 0.13 mol) and methanol (130 mL) was boiled under reflux for 6 h. The mixture was cooled and filtered, and the filter cake was washed with ethanol. The organic phase was poured onto a mixture of brine (500 mL) and 28% aqueous sodium hydroxide (10 mL). The aqueous phase was extracted with ethyl acetate, and the combined organic phase was washed with brine, dried (MgSO 4 ) and concentrated in vacuo. The residue was purified by flash chromatography (ethyl acetate/ethanol/triethylamine 85:10:5) to give the title compound, which was precipitated as the oxalate salt (2.3 g). Assignment of the optical rotation was done in dimethyl sulfoxide.
[0217] LC/MS (m/z) 389 (MH + ); RT=1.09 (Method B).
List of reagents Name Supplier CAS No. Cat.No. Acetyl Chloride FLUKA 75-36-5 01000 Lithium Bromide ALDRICH 7550-35-8 21,322-5 Methanesulfonyl Chloride ALDRICH 124-63-0 47,125-9 Lithium Aluminium Hydride ALDRICH 16853-85-3 19,987-7 Sodium Cyanoborohydride ALDRICH 25895-60-7 15,615-9 5-Nitro-1H-indole ALDRICH 6146-52-7 N1,760-2 (1H-Indole-3-yl)acetic Acid AVOCADO 87-51-4 10556 Ammonium Formate ALDRICH 540-69-2 15,626-4 Triethylamine RIEDEL- 121-44-8 16304 DEHAËN Potassium Iodide ALDRICH 7681-11-0 22,194-5 1,1′-Carbonyldiimidazole ALDRICH 530-62-1 11,553-3 Ethyl Piperazine-1-carboxylate ACROS 120-43-4 11887- ORGANICS 1000 N,N-Dimethylformamide Dimethyl LANCASTER 4637-24-5 0621 Acetal Oxalamic Acid ALDRICH 471-47-6 0-920-4 Di-tert-Butyl Dicarbonate FLUKA 24424-99-5 34660 Potassium Cyanate MERCK 590-28-3 804957 SCHUCHARDT N,N-Dimethyl Formamide FLUKA 68-12-2 40255 Methanol FLUKA 67-56-1 65550 2-Butanone ACROS 78-93-3 149670010 ORGANICS Tetrahydrofuran RIEDEL- 109-99-9 16212 DEHAËN 2-Propanol RIEDEL- 67-63-0 24137 DEHAËN Sodium Hydrogencarbonate ALDRICH 144-55-8 34,094-4 Potassium Hydroxide ALDRICH 1310-58-3 22,147-3 Phosphoric Acid (85% in water) RIEDEL- 7664-38-2 04107 DEHAËN Methanesulfonic Acid (70% in ALDRICH 75-75-2 47,134-8 water) Sodium DihydrogenPhosphate ALDRICH 10049-21-5 22,352-2 Monohydrate Sodium Hydroxide ACROS 1310-73-2 134070025 ORGANICS Sodium Chloride ACROS 7647-14-5 20779- ORGANICS 0050 Potassium Carbonate AVOCADO 584-08-7 16625 Diethyl Ether RIEDEL- 60-29-7 24004 DEHAËN 1,4-Dioxane SIGMA- 123-91-1 360481-2L ALDRICH Di-isopropyl Ether RIEDEL- 108-20-3 33159 DEHAËN 2-Chloro-5-nitro-4-picoline ACROS 23056-33-9 361030000 ORGANICS Ammonia (25% in water) MERCK 7664-41-7 5432 Hydrochloric Acid (37% in water) ALDRICH 7647-01-0 32,033-1 Sulfuric Acid (95-98% in water) ALDRICH 7664-93-9 43,558-9 Acetic Acid ALDRICH 64-19-7 24,285-3 Ethyl Acetate ALDRICH 141-78-6 31,990-2 Heptane ALDRICH 142-82-5 H219-8 Ethanol ALDRICH 64-17-5 45,984-4 Acetone ALDRICH 67-64-1 17,912-4 Dichloromethane ALDRICH 75-09-2 D6,510-0 Hydrogen Chloride (2.0 M in ALDRICH 7647-01-0 45,518-0 diethylether) Oxalic Acid ALDRICH 144-62-7 24,117-2 N-Methylpyrrolidin-2-one RIEDEL- 872-50-4 15780 DEHAËN Hydrogen ALDRICH 1333-74-0 29,539-6 Novozyme 435 ALDRICH — 53,732-2 Magnesium Sulfate ALDRICH 7487-88-9 20,809-4 Palladium, 5 wt % (dry basis) ALDRICH — 33,011-6 on activated carbon Palladium, 10 wt % (dry basis) ALDRICH 7440-05-3 20,569-9 on activated carbon Silica gel, Merck grade 9385 ALDRICH 112926-00-8 22,719-6 Molecular sieves 3A ALDRICH — 20,858-2 Filter agent, Celite 521 ALDRICH 61790-53-2 22,179-1 Activated carbon ALDRICH 7440-44-0 16,155-1 Di-sodium Hydrogen Phosphate, ACROS 10039-32-4 27106- Dodecahydrate ORGANICS 0025 N-Benzyliminodiacetic acid ALDRICH 3987-53-9 B2,475-8 Platinum Oxide ALDRICH 1314-15-4 52,061-6 Borane Trimethylamine Complex ALDRICH 75-22-9 17,898-5 1-Propanol RIEDEL- 71-23-8 24135 DEHAËN 2-Chloroacetamide ALDRICH 79-07-2 10,802-2 2-Chloro-N,N-dimethylacetamide FLUKA 2675-89-0 24350 2-Chloro-N-methylacetamide ABCR 96-30-0 FR-1355 2-Chloropropionamide ALDRICH 27816-36-0 19,239-2 Pyridin-4-boronic acid ALDRICH 1692-15-5 63,449-2 tert-Butyl 5-Bromoindole-1- ALDRICH 182344-70-3 55,7749 carboxylate Sodium Carbonate ALDRICH 497-19-8 22,353-0 Tetrakis(triphenylphosphine)palladium ALDRICH 14221-01-3 21,666-6 (0) Toluene RIEDEL- 108-88-3 24526 DEHAËN 7-Fluoro-1H-indole APOLLO 387-44-0 PC9454 7-Methoxy-1H-indole ALDRICH 3189-22-8 11,398-0 Oxalyl Chloride ALDRICH 79-37-8 22,101-5 4-Methyl-1H-indole ALDRICH 16096-32-5 24,630-1 Sodium borohydride ALDRICH 16940-66-2 48,088-6 p-Xylene ALDRICH 106-42-3 31,719-5 100% Nitric acid MERCK 7697-37-2 1.00450.1000
Pharmacological Testing
[0218] The compounds of the invention were characterised in vitro in dopamine D 4 , serotonin 5-HT 2A and microsomal stability assays according to the following methods:
[0000] 3 [H]-YM-09151-2 binding to dopamine D 4 receptors
[0219] CHO cells expressing human recombinant D 4.2 receptors were generated at Lundbeck using standard stable transfection techniques. Membranes were harvested using standard protocols and affinities were measured by the addition of a serial dilution of compound to a membrane preparation in a mixture of 50 mM Tris-HCl, 5 mM Na 2 -EDTA Titriplex III, 5 mM MgCl 2 , 5 mM KCl and 1.5 mM CaCl 2 0.06 nM 3 [H]-YM-09151-2 was used as the radioligand assessing the affinity for the human D 4.2 receptor. Total binding was determined in the presence of buffer and non-specific binding was determined in the presence of 10 μM Clozapine. The mixture was incubated for 30 minutes at 37° C., cooled briefly on ice. Bound and free radioactivity was separated by vacuum filtration on GF/C filters pretreated with 0,1% Polyetyleneimine (PEI) and filters were counted in a scintillation counter.
[0000] Dopamine D 4 Efficacy as Determined by a cAMP Assay
[0220] The ability of the compounds to inhibit the D 4.2 receptor mediated inhibition of cAMP formation in CHO cells stably expressing the human recombinant D 4.2 receptor was measure as follows.
[0221] Cells were seeded in 96 well plates with 400 cells/well 4 days prior to the experiment. On the day of the experiment the cells were washed once in preheated G buffer (1 mM MgCl 2 , 0.9 mM CaCl 2 , 1 mM IBMX in PBS) and the assay was initiated by addition of 100 μl of a mixture of 1 μM quinpirole, 10 μM forskolin and test compound in G buffer. The cells were incubated 20 minutes at 37° C. and the reaction was stopped by the addition of 100 μl S buffer (0.1 M HCl and 0.1 mM CaCl 2 ) and the plates were placed at 4° C. for 1 h. 68 μl N buffer (0.15 M NaOH and 60 mM NaAc) were added and the plates were shaken for 10 minutes. 60 μl of the reaction were transferred to cAMP FlashPlates (DuPont NEN) containing 40 μl 60 mM NaAc pH 6.2 and 100 μl IC mix (50 mM NaAc pH 6.2, 0.1% NaAzid, 12 mM CaCl 2 , 1% BSA and 0.15 μCi/ml 125 I-cAMP) were added. Following an 18-h incubation at 4° C. the plates were washed once and counted in a Wallac TriLux counter.
[0000] Serotonin 5-HT 2A efficacy as determined by a Ca 2+ -release assay
[0222] 2 or 3 days before the experiment, CHO cells expressing 250 fmol/mg 5-HT 2A receptors are plated at a density sufficient to yield a mono-confluent layer on the day of the experiment. The cells are dye loaded (Ca 2+ -kit from Molecular Devices and using Hank's balanced salt w/o phenol red, added 20 mM HEPES and pH adjusted to 7.4 with 2M NaOH as assaybuffer) for 60 minutes at 37° C. in a 5% CO 2 incubator at 95% humidity. Lacer intensity is set to a suitable level to obtain basal values of approximately 8000-10000 fluorescence units. The variation in basal fluorescence should be less than 10%. EC 50 values are assessed using increasing concentrations of test compound covering at least 3 decades. IC 50 values are assessed challenging the same range of concentrations of test substances with EC 85 of 5-HT. Test substances are added to the cells 5 minutes before the 5-HT. K i values were calculated using Cheng-Prusoff equation. % Stimulation of a concentration of the test compound is measured with respect to a maximal concentration of 5-HT (100%). % Inhibition of a concentration of the test compound is measured as the percentage with which the response of EC 85 of 5-HT is lowered. Maximum inhibition is the level of inhibition the curve reaches.
[0000] In Vitro Stability in Human and Rat Liver Microsomes.
[0223] The stability of compounds in liver microsomes is determined by the T½ method, i.e. the disappearance of 1 μM drug is measured over time by LCMS. 0.5 mg/ml of microsomal protein (liver microsomes from several donors pooled to obtain an average enzyme content) is used in a NADPH (Nicotinamide-Adenine Dinucleotide Phosphate, reduced form) generating system (1.3 mM NADP (oxidized form), 3.3 mM glucose 6-phosphate and 0.4 U/ml glucose 6-phosphate dehydrogenase), 3.3 mM MgCl2 (magnesium Chloride), 0.1 M Potassium phosphate buffer (pH 7.4), in a total volume of 100 μl, and stopping the incubations at time points 0, 5, 15, 30 and 60 min with 1:1 v/v acetonitrile. The half live is subsequently scaled to the metabolic competence of a whole liver using 45 mg microsome/g liver, 45 g and 20 g liver/kg and Std. weight 70 kg and 0.25 kg, human and rats respectively.
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The invention relates to compounds of the formula I
wherein the variables are as defined in the claims. The compounds are useful in the treatment of a disease where a D4 receptor and/or a 5-HT 2A receptor is implicated.
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BACKGROUND AND PRIOR ART
The field of this invention relates to measurement of the concentration of the hormone pregnanediol in women's urine. In urine, this hormone occurs in the form of pregnanediol glucuronide (PG) and is detected in that form. The amount of PG in a woman's urine rises rapidly at the time of ovulation, and declines rapidly at the time of menstruation. However, if conception has occurred, the PG level remains high. Therefore, measurement of pregnanediol levels in urine is a potential usable procedure for either preventing or diagnosing pregnancy.
Although ovulation may be detected by characteristic in basal body temperature or in physical properties of cervical mucus, these methods are subject to variability from body functions unrelated to ovarian function and therefore not sufficiently reliable for detecting ovulation in many women.
Although pregnanediol is the major urinary product of progesterone, pregnanediol assays have not been widely utilized for assessment of luteal function. There are basically two reasons for this. First, earlier methods have required the collection of 24-hour urine specimens, an unreasonable request for even highly motivated patients when, to be most useful, collections should be made daily for at least 10 days during the middle of the menstrual cycle. Second, the assay procedure has been laborious, requiring usually two days for completion, and is subject to errors from several sources; the necessity for enzymatic or acid hydrolysis of the glucuronide moiety for colorimetry or gas chromatography is the most difficult and variable aspect of the assay.
It has been demonstrated that measurements of PG levels in overnight urine specimens correspond closely with 24-hour specimens. See Judge, et al, Steroids 31: 175-187 (1978). The reported tests were conducted on a laboratory basis by a gas chromatographic method.
Samarajeewa, et al have published a method for preparing antiserum specific for PG. J. Steroid Biochem. 11: 1165-1171 (1979). Pregnanediol in its free acid form was joined covalently to bovine serum albumin, and the antisera was prepared in rabbits. A calibration curve was prepared with radio-labelled PG, as part of the development of direct radioimmunoassay procedure for PG in women's urine. Specificity was established by showing that other steroids present in urine did not cross-react.
The antiserum prepared as described by Samarajeewa, et al, was used by Collins et al in radioimmunoassay procedure for measuring PG in overnight and 24-hour urine samples. Acta Endocrinologica 90: 336-348 (1979). The results confirmed the correlation previously observed by Judge et al. In the reported assay procedure, radio-labelled PG was employed as the test reagent for competing with the urine PG in binding to the antibodies of the immune serum. Thus, an expensive and relatively unstable reagent, pregnanediol glucuronide was required both for preparing the antiserum and as a radio-labelled test reagent, and the radioimmunoassay was carried out on a laboratory basis requiring special equipment. Heretofore, no one has provided the ovulation detection art with a simple, inexpensive and accurate procedure for determining levels of PG in urine which can be employed by women on a home-use basis.
SUMMARY OF INVENTION
This invention is based in part on the discovery that a commercially available relatively inexpensive steroid can be substituted for pregnanediol glucuronide in assay procedures using PG-antiserum. This steroid is 20α-hydroxy-4-pregnen-3-one (referred to herein as the 20-α reagent). Further, if desired, the antibodies binding to PG can be produced by using the 20-α reagent as the antigen. Even more importantly, however, the 20-α reagent can be used as the basis of a test kit for homeuse by women to determine PG in overnight urine samples, the level of PG in the urine being indicated by a visual color comparison. In one preferred embodiment, the 20-α reagent is immobilized on a solid adsorbent in the form of a fibrous strip, such as glass fiber paper, which can be dipped into the urine for reaction with the antibodies therein which have not bound to the PG of the urine. The amount of antibodies adsorbed on the strip can be indicated by having the antibodies labelled with a substance capable of providing a color reaction, such as a color compound like rhodamine, or an enzyme such as peroxidase which will react to produce a color. Alternatively, the amount of antibody protein bound to the test strip can be indicated by applying a protein staining dye such as Coomassie blue. Women are therefore provided with a simple, inexpensive and effective method for defining the time of ovulation. The woman may then use this information either to promote or prevent conception, or as a method for early self-diagnosis of pregnancy.
DETAILED DESCRIPTION
The method and indicator strip of the present invention utilize a 20-α reagent which comprises 20α-hydroxy-4-pregnen-3-one as the base reagent. The 20-α reagent as used in this invention is preferably in the form of a conjugated derivative which reacts readily with antibodies binding to pregnanediol glucuronide (PG). For example, the 20-α reagent can be conjugated through the C-3 of the steroid to a solid support material or to an antigenic protein. For example, a suitable coupling group is introduced at the C-3 position of the 20-α reagent. This does not modify the antigenic properties of the reagent, while adapting it for attachment to a glass fiber strip or other solid support, or to a suitable antigenic protein.
The other required reagent is the antiserum containing the antibodies binding to PG. This can be prepared by hyperimmunizing animals, such as rabbits, to a conjugate of PG and an antigenic protein, such as bovine thyroglobulin. For example, the procedure described by Samarajeewa, et al, J. Steroid Biochem. 11: 1165-1171 (1979), can be used. The 20-α reagent is conjugated to a suitable antigenic protein and used to prepare the antiserum. The antiserum obtained provides anti-PG antibodies that bind to the 20-α reagent either as the free steroid or as its C-3 derivatives.
In general, the method of this invention for determining the concentration of PG in a woman's urine is characterized by the steps of reacting a predetermined amount of anti-PG antibodies with a measured amount of the urine to leave a definite amount of unreacted antibodies for reaction with the 20-α reagent on the strip, or the antibodies are reacted with a measured amount of the urine which contains a quantity of a colored derivative of the 20-α reagent so that the reagent and the PG in the urine competitively react with anti-PG antibodies on the strip. In either case, after the reaction, either the amount of the reacted antibodies or the amount of unreacted 20-α reagent is determined. For example, this can be done by radiolabelling of the antibodies or the 20-α reagent. The radioimmunoassay may be conducted, in general, as described by Collins, et al, Acta Endocrinologica 90: 336-348 (1979), except that the radiolabelled 20-α reagent would be employed instead of radio-labelled PG. However, to achieve the full benefits of the present invention, it is preferred to employ a visual immunoassay procedure employing a color indicator.
In practicing the present invention, either a predetermined quantity of the antibodies or a predetermined quantity of the 20-α reagent can be immobilized on a color indicator support. For example, the support may comprise an adsorbent fibrous strip, such as that composed of porous glass beads or glass fiber paper. The antibodies may be attached to a solid surface without interfering with their binding capacity using the method described by Robbins and Schneerson, Methods in Enzymology 34: 703-731 (1974). Similarly, 20-α reagent may be bound to the glass without interfering with its reactivity with the antibodies by the method of Parikh et al, Methods in Enzymology 34: 670-688 (1974). General methods of conjugation to glass surfaces are described by Weetall and Filbert, Methods in Enzymology 34: 59-71 (1974).
In one preferred embodiment, a precise quantity of the 20-α reagent, provided with a coupling group at its C-3, is bound to a small test strip, such as a piece of glass fiber filter paper, and means are provided for dipping the entire strip in the urine. Such means may comprise tweezers, or the test strip may be attached to the end of a rod, the assembly providing a dipstick. Preferably, the antibodies to be added to the urine are labelled with a substance capable of providing a visual color indication. For example, the antibodies may be conjugated to a dye such as rhodamine. A suitable procedure for such conjugation is described in J. Immunol. Methods, 13: 305 (1976). After the reaction of the antibodies with the PG in the urine sample, the remaining unreacted antibodies are adsorbed by the 20-α reagent on the test strip. The intensity of the color will depend on the amount of the antibodies adsorbed. Further, additionally or alternatively, the antibodies after adsorption can be stained with a protein-staining dye such as Coomassie blue, bromophenol blue or tetrabromophenolphthalein ethyl ester.
One especially desirable procedure providing a high degree of color sensitivity is to conjugate the antibody to an enzyme which will produce a color reaction in a specific developing solution. For example, in one preferred procedure, the antibodies are conjugated to the enzyme peroxidase. This can be done by the method of Avrameas, Methods in Enzymology 44: 709-717 (1976). The unreacted portion of the antibodies are then adsorbed from the urine sample by the 20-α reagent on the test strip. The color is then developed by immersing the test strip in 0.05% of 3,3'-diaminobenzidine in pH 7.6 buffer. Hydrogen peroxide (2 drops of 3% solution) is added for color development. This procedure is also described in the article by Avrameas cited above.
In other procedures which could be employed, the 20-α reagent is conjugated to a color indicator dye such as rhodamine, and is used in the urine sample. A suitable procedure for such conjugation is described in J. Steroid Biochem., 13: 489-493 (1979). However, the sample of urine containing the color-indicator conjugated 20-α reagent is then contacted with the test strip for competitive adsorption of the PG and 20-α reagent. This procedure can provide a color indication of the amount of PG in the urine, it does not give as great a sensitivity or as clear a color discrimination as the procedures described above.
The technical basis for this invention and various embodiments thereof are further illustrated by the following examples.
EXAMPLE I
Antisera was produced in rabbits that were immunized by 3 intradermal injections 3 weeks apart with pregnanediol glucuronide that had been conjugated to bovine thyroglobulin via the mixed anhydride reaction. See Erlanger, et al, The Preparation of Steroid-Protein Conjugates to Elicit Antihormonal Antibodies, in Williams and Chase, Methods in Immunology and Immunochemistry, Vol. 1: Preparation of Antigens and Antibodies, New York,Academic Press, 1967; and, Kellie, et al, Steroid Glucuronide-BSA Complexesas Antigens, The Radioimmunoassay of Steroid Conjugates, J. Steroid Biochem. 3: 275-288 (1972). The conjugate had been purified by dialysis and by precipitation from acetone. A 5 mg sample of the product was analyzed after it was hydrolyzed by heating in 0.75 N HCl in 66% (v/v) acetic acid at 100° C. for 15 minutes. The liberated steroid was extracted from the cooled, neutralized reaction mixture with ethyl acetateand was analyzed by gas chromatography. A molar ratio of steroid to proteinof 157/1 was found. For each injection the conjugate was suspended in 1.0 ml of 0.9% NaCl and emulsified with an equal volume of Freund's incompleteadjuvant (the first injection in each animal was made with Freund's complete adjuvant). Rabbits received 2.5 mg of conjugate on each of the first 3 injections. Booster injections, also intradermal, were 0.25 mg. The titer of antisera was assessed by determination of the percent bindingof 3 H-pregnanediol in doubling dilutions of sera. The antiserum (0.2 ml) bound 50% of 15,000 dpm of 3 H-pregnanediol at a serum dilution of approximately 1/5000.
EXAMPLE II
In order to test the specificity of pregnanediol glucuronide antiserum prepared as described in Example I, competition of several unlabelled steroids for 3 H-pregnanediol was measured. Table A summarizes the activity of these steroids in terms of the inverse of the concentration ofcompetitor divided by the inverse of the concentration of pregnanediol thatis required for 50% decreases in binding of the labelled ligand. The antiserum was found to be highly specific for the 20-α reagent of this invention as well as for pregnanediol and its glucuronide, the reactivity of the 20-α reagent being of the same order as shown by the tabulated results.
TABLE A______________________________________Specificity of Anti-pregnanediolGlucuronide AntiserumSteroid % Competition______________________________________5β-Pregnane-3α,20α-diol 100(pregnanediol)Pregnanediol glucuronide 13320α-hydroxy-4-pregnen-3-one 126(20-α reagent)5β-Pregnane-3α,20α-diol 05β-Pregnane-3α,17α,20α-triol 05β-Pregnane-3α,20α-diol diacetate 0Progesterone 0Estradiol 0Estriol 0Androsterone 0Cortisol 0Corticosterone 0______________________________________
EXAMPLE III
The 20-α reagent can be bound to glass fiber paper after reacting thecleaned paper with 10% (v/v) 3-aminopropyltriethoxysilane in toluene. The free amino groups in this product can be cross-linked in 2.5% glutaraldehyde to polylysine (mol. wt. about 50,000). This provides a suitable support for covalently binding C-3 coupling derivatives of 20-α. For this purpose the 3-(0-carboxymethyl) oxime can be preparedin high yield by treatment of the 20-α steroid with aminooxyacetate in pyridine. This product can be conjugated directly, via the carbodiimideproduct promoted condensation, with the solid support (see Erlanger et al, cited in Example I), or a "bridge" such as p-aminobenzoic acid can be inserted between the steroid oxime and polylysine to decrease steric hindrance in the binding of antibody to the 20-α. See Weetall and Filbert, Methods In Enzymology, 34: 59-71 (1974). Using the carbodiimide procedure, 0.02 μmoles of steroid can be conjugated to 1 cm 2 of the solid support. This is more than 20 times the amount necessary to bindall of the antipregnanediol antibody (APD) that is required for the visual assay. An excess of binding capacity is needed to separate the APD that has not already bound pregnanediol glucuronide from the solution.
The glass fiber filter paper (or other solid surface) with the 20-α attached can be fastened to the inside surface of a tube in which the competition reaction takes place, or to a "dipstick" with an epoxy cement.
EXAMPLE IV
A preferred form the visual assay system employs 20-α bound to a solid support within a test tube. Sufficient lyophillized APD (purified IgG fraction) is added to the test tube to bind the amount of pregnanediolglucuronide typically found in 0.1 ml of urine from women six days after ovulation (0.0007 μmoles with an antibody valence of 2).
The person using the assay adds 0.1 ml of urine and an ampule containing 0.9 ml of buffer to the test tube that is already prepared as described above, and mixes the solution in the tube briefly. After 15 minutes, the solution is poured out, rinsed with water, and the indicator dye (Coomassie blue) is added. The color that develops within a few minutes isstable for several days, and can be compared with a color chart to determine the approximate level of pregnanediol glucuronide in urine.
The composition of the dye is that described by Bradford (Anal. Biochem. 72: 248, 1976). The darkest blue color develops when no pregnanediol glucuronide is present in the urine specimen, i.e., all of the APD is bound by the 20-α on the solid support. When the highest concentrations of pregnanediol glucuronide occur, e.g., after conception, the color will be light brown since very little APD will be available to bind to 20-α on the solid support and will be rinsed out of the tube. Intermediate concentrations of pregnanediol glucuronide in urine will give intermediate intensities of blue in the dye solution.
EXAMPLE V
In a procedure providing even greater reading sensitivity than that of Example IV, the antibodies are conjugated to peroxidase (Avrameas, MethodsIn Enzymology, 44: 709-717, 1976), and added to the urine in that form. Theamount of antibody picked up and bound to a 20-α on the solid supportin this case is measured by the color that develops on the surface of the solid support when the peroxidase enzyme that is conjugated to APD reacts with a substrate for a definite period of time. One preferred procedure isto add 0.5 mg of 3,3'-diaminobenzidine tetrahydrochloride in 1.0 ml of 0.1 M Tris-HCl buffer, pH 7.6. After adding a drop of 3% H 2 O 2 , the mixture is incubated for 5 min. at room temperature. The solution is poured out and the tube rinsed with water. Staining of the antibody on thesolid support surface is proportional to the amount of antibody present. Quantification is done by the use of a color chart as with the procedure employing Coomassie blue.
EXAMPLE VI
The procedure for using the 20-α reagent in a radioimmunoassay requires that the tritiated form, [1,2- 3 H(N)] 20α-hydroxy-4-pregnen-3-one, which is available from New England Nuclear Corp., 549 Albany Street, Boston, Mass, be substituted for the compound (pregnanediol glucuronide) to be measured. Antiserum (APD) prepared as described earlier is diluted until a concentration that binds approximately 70% of 20,000 dpm of tritiated 20-α (specific activityapproximately 50 Ci/mmole) is obtained. This dilution of APD with the [ 3 H] 20-α is used to set up a standard curve in which either 20-α or pregnanediol glucuronide can be used as the steroid that is the competitor for [ 3 H] 20-α. If unlabeled 20-α is used as the competitor, a mathematical correction may have to be made for the difference in binding affinity of 20-α and pregnanediol glucuronide.Otherwise the procedures for radioimmunoassay are the standard methods.
Urine to be assayed is diluted 1/50, 1/100, and 1/500 with Buffer A (0.1 M sodium phosphate, 0.15 M sodium chloride, 0.015 M sodium azide, pH 7.0, containing 0.1% gelatin), and 0.1 ml aliquots of each dilution are added to assay tubes. Then 0.1 ml of the diluted antiserum (APD) containing 20,000 dpm of [ 3 H] 20-α is added to each sample. After incubation of the samples and standards for 2 hrs. at room temperature, the tubes are placed in a 4° C. cold room for 1/2 hour. Then, 0.2 ml of a suspension of dextran-coated charcoal (250 mg activated charcoal and 25 mg of dextran in 100 ml of Buffer A) is added to each tube. The samples are centrifuged to sediment the charcoal, and aliquots of the [ 3 H] 20-α bound to the diluted APD in solution are counted in a liquid scintillation counter.
The counting method and calculation of results by comparison of displacement of [ 3 H] 20-α from APD by samples and standards follow usual procedures.
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A method is provided for determining the concentration of pregnanediol glucuronide (PG) in a woman's urine which is characterized by utilization of the reagent 20α-hydroxy-4-pregnen-3-one (20-α reagent) in a form in which it reacts with antibodies binding to PG. The method is adaptable to a visual color indication test which can be performed by the woman herself as well as by laboratory analysis. The method can be used to define the period in which conception can occur, to define a post-ovulation safe period in which conception is prevented, and as an early pregnancy indicator.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to corrosion inhibitor compositions which are useful in inhibiting corrosion in aerosol products.
2. Description of the Prior Art
Many products designed for household, personal, automotive and other types of use are available as aerosol products. Typical examples of such products include personal products such as hair care products (sprays, coloring agents and styling/conditioning mousses), deodorants, antiperspirants, first aid sprays, and colognes; household products such as waxes, polishes, pan sprays, insecticides and room fresheners; automotive products such as cleaners and polishes; industrial products such as cleaners, lubricants and mold release agents; and animal care products such as tick and flea repellents.
Although some aerosol products are packaged in glass bottles or aluminum cans or lined steel cans, most formulations are loaded into unlined cans made of tin-plated steel. While the tin affords protection against corrosion, the thinness of the coating, imperfections in the surface, wear and tear, and chemical action may ultimately expose the steel to the contents of the can and corrosion can result. When aerosol formulations contain less than about 80 ppm (parts per million) water, corrosion of tin-plate cans is not generally a serious problem. However, if the water content of an aerosol formulation is more than 80 ppm, problems due to corrosion are more likely to occur.
The introduction of dimethyl ether (DME) as an aerosol propellant has opened the way to the use of more water-based aerosol formulations and made possible the manufacture of products of lesser flammability and lower ingredient cost. However, the use of water in such aerosol formulations also increases the problem of corrosion on the interior of the tin-plated steel cans which are so widely used, thus leading to contamination of the aerosol product and ultimately to leaking of the can if corrosion is severe enough. For this reason, corrosion inhibitors are used with aerosol propellants containing DME, when this propellant is to be used in tin-plated steel cans containing a water-based formulation.
The matter of inhibiting corrosion in an aerosol can presents the dual problem of achieving corrosion inhibition in a system where there is both liquid and vapor phase contact with the metal. In a system that contains DME and water, corrosion of the can in areas in contact with the vapor phase is aggravated by the fact that relatively large amounts of water vapor are present along with the DME propellant in the vapor space above the liquid contents of the container. For example, the vapor phase of a 95/5 wt % dimethyl ether/water system contains 7,750 ppm water vapor of 70° F. (21.1° C.). Moreover, the addition of ethanol to a DME/water system will often exacerbate the problem of vapor phase corrosion. A 90/5/5 (wt %) DME/ethanol/water system will contain 9,100 ppm water vapor at 70° F.
SUMMARY OF THE INVENTION
Many commercially available corrosion inhibitors are either ineffective for aerosol systems containing DME or they fail to provide adequate protection against both liquid phase and vapor phase corrosion. It often happens that a corrosion inhibitor gives good protection where the liquid phase is in contact with the can but fails to provide protection in areas where the interior surfaces of the can are in contact with vapor during storage. The reverse can also occur where the inhibitor gives good protection on the interior where there is contact with vapor, but poor protection where liquid normally contacts the container. The present invention provides an improvement in aerosol compositions containing an aqueous aerosol-dispersible media and a propellant gas in which the improvement comprises the presence of a corrosion inhibitor in the aerosol composition in a minor amount sufficient to provide corrosion inhibition to the composition. The corrosion inhibitor which constitutes the improvement in the aerosol composition is effective against both vapor phase and liquid phase corrosion, and it is comprised of about 15 to 85 wt % of an amine neutralized phosphate ester selected from the group consisting of 2-ethylhexylamine salt of mixed mono- and di-isooctyl acid phosphate, tertiary C 12-14 alkyl primary amine salt of mixed mono- and di-isooctyl acid phosphate, diethylamine salt of mixed mono- and di-butoxyethyl acid phosphate and 2-ethylhexylamine salt of mixed mono- and di-tridecyl acid phosphate and 85 to 15 wt % of a volatile amine selected from the group consisting of cyclohexylamine, isopropylamine and morpholine. Such corrosion inhibitors are useful in a wide variety of aerosol compositions where there is a need to protect the container from corrosive attack. As a general rule, this includes aerosol compositions in which the formulation is water-based. Because of the compatibility of DME with water, it is common in the aerosol industry to use DME as the propellant gas either alone or in combination with other well known aerosol propellants. Propellants such as, 1,1-difluoroethane (FC-152a), hydrocarbons such as butane, isobutane and propane and compressed gases such as CO 2 and nitrogen and mixtures of these propellants can be used in water-based aerosol formulations with or without DME. The corrosion inhibitor compositions of this invention can be used in aerosols containing any of these propellants or combinations thereof. The introduction of the inhibitor into the propellant prior to loading into the aerosol can is a convenient way to incorporate the inhibitor into the final aerosol formulation, and therefore, one of the objects of the invention to provide aerosol propellant compositions containing one or more propellants, such as those described above, in combination with the corrosion inhibitor in an amount sufficient to provide corrosion inhibition in water-based aerosols.
The effectiveness of the two components of the corrosion inhibitor compositions of the invention is not additive or supplementary but is greater than expected or predicted from the performance of the individual ingredients. Thus, neither the amine neutralized phosphate esters nor the volatile amines performed entirely satisfactorily as corrosion inhibitors in the liquid or the vapor phase of the aerosol formulations evaluated. Hence, it is clear that the effectiveness of the corrosion inhibitor compositions of the invention is not simply the result of blending liquid phase and vapor phase inhibitors.
DETAILED DESCRIPTION
All of the components of the corrosion inhibitor composition of the invention are commercially available materials. On the other hand, if one wishes to prepare the amine neutralized phosphate esters, this can be achieved by the addition of P 2 O 5 to an alcohol, such as isooctyl alcohol, at a rate which will allow the temperature to be maintained in the range of about 50° to 55° C. Reaction occurs in the ratio of three mols of alcohol to one mol of P 2 O 5 thus producing a mixture of mono- and di-esters in a mol ratio of 1:1. The ester mixture thus obtained is then neutralized by contacting the mixture with an amine, such as 2-ethylhexyl amine or diethyl amine, in an amount that will provide one mol of amine for each equivalent of phosphate ester, assuming the equivalent weight of the ester to be the average of the molecular weights of the mono- and di-esters. The chemical reactions for the preparation are as follows: ##STR1## where R' is either C 2 H 5 , C 8 H 17 or tertiary C 12-14 alkyl and
R" is H or C 2 H 5 .
One of the preferred amines for neutralization of the acid phosphates is a mixture comprising principally tertiary C 12-14 branched alkyl primary amines in the molecular weight range of 185-213 with a neutralization equivalent of 191. Such a mixture is available commercially as "Primene 81-R".
The proportion of the two constituents that form the inhibitor composition can be in the range of 15 to 85 wt % amine neutralized phosphate ester and 85 to 15 wt % volatile amine. A preferred range is 40 to 60 wt % phosphate ester and 60 to 40 wt % of the amine. A 50/50 mixture by weight is a preferred composition. The optimum concentration of inhibitor composition needed to obtain effective corrosion inhibition will, of course, vary with the formulation in which it is to be used, and it can be determined by storage tests, such as those described in the Examples. Generally, the effective concentration range is 0.15 to 2 wt % based on the total weight of the aerosol formulation including the weight of a propellant as well as the weight of the other ingredients. A preferred weight range is 0.15 to 0.5 wt % of the aerosol formulation. The inhibitors can be added directly to the aerosol can either alone or mixed with other non-pressurized ingredients, or if preferred, they can be introduced as solutions in the propellant in an amount which when incorporated with the other ingredients will provide the desired 0.15 to 2 wt % of corrosion inhibitor in the final composition.
The composition of the aqueous aerosol-dispersible media which is, in essence, the formulation containing the active ingredients, will, quite naturally, depend upon the use for which the aerosol is designed. Such formulations are well known to persons skilled in the art, and the choice of formulation is not critical to the use of the invention so long as the medium is compatible with the components of the inhibitor composition, particularly the volatile amines. The use of the corrosion inhibitors in tin-plated cans with dry-type antiperspirants containing aluminum chlorohydrate is not recommended. Lined cans should be used in these instances.
EXAMPLES
Sixty-day corrosion tests at 120° F. (48.9° C.) were run on the corrosion inhibitors in three aerosol formulations. These formulations were selected as being representative of commercial products, in their chemical compositions. Distilled water was used in each of the five formulations because it was readily available in the laboratory. However, similar results would be expected with deionized water which is often used in commercial aerosols.
______________________________________Component Wt. %______________________________________Formulation No. 1Room Freshener (pH = 6)Rose fragrance 1.40Ethanol (SDA 40-1) 19.60Water (distilled) 49.00Dimethyl ether 30.00Formulation No. 2Insecticide (pH = 6)Natural pyrethrins 1.50Piperonyl butoxide 0.65Polyglyceryl fatty acid 0.97ester surfactant ("Witconol 14"Witco Chemical Corp.)Ethanol (SDA 40-1) 10.01Water (distilled) 51.87Dimethyl ether 35.00Formulation No. 3Insecticide (pH = 5)Phosphorothioic acid O, 0.98O--diethyl O--(3,5,6-trichloro-2-pyridyl) esterNatural pyrethrins 0.06Piperonyl butoxide 0.13Polyglyceryl fatty acid ester 0.20surfactantWater (distilled) 63.63Dimethyl ether 35.00______________________________________
Procedure
All of the examples were prepared using the following procedure. The active ingredients were weighed individually into an eight-ounce three-piece aerosol can 21/8" in diameter and 5-9/16 " long, except when the corrosion inhibitors were added to the aerosol can as a solution in the propellant (noted in tables). The can was purged with dichlorodifluoromethane (FC-12) vapor to displace the air in the container. The aerosol can valve was then placed into the can and crimped. The propellants were introduced into the can as liquids through the aerosol valve. Volume amounts corresponding to the weights of the propellants were calculated prior to loading, and a glass, calibrated, pressure buret was used to measure and transfer the liquids from storage cylinders to the can. A nitrogen gas pressure of 100 psig was applied to the buret to aid in transferring the liquids from the buret to the can. After the propellant was loaded, the can was weighed, and the weight of propellant recorded.
The aerosol cans used in the corrosion tests were commercially available containers and are described in trade literature as: one inch round dome top unlined aerosol containers, size 202×509 (21/8" diameter, 5-9/16" can wall height), 0.25 lb. electrolytic tin-plated (ETP), full concave bottom with welded side seam.
A corrosion test rating system was used which provides a complete visual description of the appearance of the interior surface of the tin-plated steel aerosol cans after 60 days storage at 120° F.
______________________________________CAN CORROSION - RATING SYSTEMRating* Description______________________________________0 No Corrosion1 Trace Corrosion2 Light Corrosion3 Moderate Corrosion4 Heavy Corrosion5 Severe Corrosion______________________________________ *This numerical rating is an overall assessment of the total can (tinplate, joints and side seams) and represents the primary rating of a test. A rating of 0-2 is considered effective and 3 or greater is a faile rating.
TABLE NO. 1__________________________________________________________________________CORROSION TEST DATA Corrosion Corrosion Test Test Test Description ofCorrosion Inhibitor Wt. % Procedure Medium Rating Test Can Corrosion__________________________________________________________________________NONE -- 60 days Formulation 5 Severe detinning in at 120° F. No. 2 liquid and vapor phase; consider- able vapor phase corrosion2-Ethylhexylamine 0.50 60 days Formulation 2 Light vapor phasesalt of mixed mono- at 120° F. No. 2 corrosionand di-isooctylacid phosphate2-Ethylhexylamine " 60 days Formulation 2 Light vapor phasesalt of mixed mono- at 120° F. No. 2 corrosionand di-tridecylacid phosphateTertiary C.sub.12-14 " 60 days Formulation 3 Moderate vaporalkyl primary amine at 120° F. No. 2 phase corrosionsalt of mixed mono-and di-isooctyl acidphosphateCyclohexylamine 0.50 60 Days Formulation 3 Detinning at at 120° F. No. 2 bottom joint; some vapor phase rustingIsopropylamine " 60 Days Formulation 4 Moderate to severe at 120° F. No. 2 vapor phase corro- sion; liquid phase detinningMorpholine " 60 Days Formulation 3 Detinning in liquid at 120° F. No. 2 phase; vapor phase corrosion2-Ethylhexylamine 0.25 60 Days Formulation 0 No corrosionsalt of mixed mono-and di-isooctylacid phosphateCyclohexylamine 0.252-Ethylhexylamine 0.25 60 Days Formulation 0 No corrosionsalt of mixed mono- at 120° F. No. 2and di-isooctylacid phosphateMorpholine 0.252-Ethylhexylamine 0.25 60 Days Formulation 0 No corrosionsalt of mixed mono- at 120° F. No. 2and di-tridecylacid phosphateIsopropylamine 0.25Tertiary C.sub.12-14 0.10 60 Days Formulation 0 No Corrosionalkyl primary amine at 120° F. No. 2salt of mixed mono-and di-isooctyl acidphosphateMorpholine 0.10Tertiary C.sub.12-14 0.25 60 Days Formulation 0 No Corrosionalkyl primary amine at 120° F. No. 2salt of mixed mono-and di-isooctyl acidphosphateMorpholine 0.25Tertiary C.sub.12- 14 0.50 60 Days Formulation 0 No Corrosionalkyl primary amine at 120° F. No. 2salt of mixed mono-and di-isooctyl acidphosphateMorpholine 0.50Tertiary C.sub.12-14 1.00 60 Days Formulation 1 Trace of Vaporalkyl primary amine at 120° F. No. 2 Phase Corrosionsalt of mixed mono-and di-isooctylacid phosphateMorpholine 1.00Tertiary C.sub.12-14 0.10 60 days Formulation 1 Trace of Vaporalkyl primary amine at 120° F. No. 2 Phase Corrosionsalt of mixed mono-and di-isooctyl acidphosphateMorpholine 0.50Tertiary C.sub.12-14 0.25 60 days Formulation 1 Trace of Vaporalkyl primary amine at 120° F. No. 2 Phase Corrosionsalt of mixed mono-and di-isooctylacid phosphateMorpholine 0.50Tertiary C.sub.12-14 0.50 60 days Formulation 0 No Corrosionalkyl primary amine at 120° F. No. 2salt of mixed mono-and di-isooctylacid phosphateMorpholine 0.10Tertiary C.sub.12-14 0.50.sup.a 60 Days Formulation 0 No Corrosionalkyl primary amine at 120° F. No. 2salt of mixed mono-and di-isooctylacid phosphateMorpholine 0.10Tertiary C.sub.12-14 0.50 60 Days Formulation 0 No Corrosionalkyl primary amine at 120° F. No. 2salt of mixed mono-and di-isooctylacid phosphateMorpholine 0.25Tertiary C.sub.12-14 0.50.sup. a 60 Days Formulation 0 No Corrosionalkyl primary amine at 120° F. No. 2salt of mixed mono-and di-isooctylacid phosphateMorpholine 0.25__________________________________________________________________________ .sup.a Corrosion inhibitors were dissolved in propellant and added to aerosol can as propellant solution. In all other examples, corrosion inhibitors and propellants were added individually to aerosol can.
TABLE NO. 2__________________________________________________________________________CORROSION TEST DATA Corrosion Corrosion Test Test Test Description ofCorrosion Inhibitor Wt. % Procedure Medium Rating Test Can Corrosion__________________________________________________________________________NONE -- 60 days at Formulation 5 Severe corrosion in 120° F. No. 3 liquid and vapor phase2-Ethylhexylamine 0.50 60 days at Formulation 2 Light vapor phasesalt of mixed mono- 120° F. No. 3 corrosionand di-isooctylacid phosphate2-Ethylhexylamine 0.50 60 days at Formulation 2 Light vapor phasesalt of mixed mono- 120° F. No. 3 corrosionand di-tridecylacid phosphateCyclohexylamine 0.50 60 days at Formulation 4 Moderate to severe 120° F. No. 3 vapor phase corro- sion; liquid phase detinningIsopropylamine 0.50 60 days at Formulation 4 Moderate to severe 120° F. No. 3 vapor phase corro- sion; liquid phase detinningMorpholine 0.50 60 days at Formulation 4 Moderate to severe 120° F. No. 3 vapor phase corro- sion; liquid phase detinning2-Ethylhexylamine 0.25 60 Days at Formulation 0 No corrosionsalt of mixed mono- 120° F. No. 3and di-isooctyl acidphosphateCyclohexylamine 0.252-Ethylhexylamine 0.25 60 Days at Formulation 0 No corrosionsalt of mixed mono- 120° F. No. 3and di-tridecyl acidphosphateIsopropylamine 0.252-Ethylhexylamine 0.25 60 Days at Formulation 0 No corrosionsalt of mixed mono- 120° F. No. 3and di-isooctyl acidphosphateMorpholine 0.25__________________________________________________________________________
TABLE NO. 3__________________________________________________________________________CORROSION TEST DATA Corrosion Corrosion Test Test Test Description ofCorrosion Inhibitor Wt. % Procedure Medium Rating Test Can Corrosion__________________________________________________________________________NONE -- 60 days at Formulation 5 Brown/red residue on walls; 120° F. No. 1 pitting on valve cup; de- tinning in vapor phase and on can bottomTertiary C.sub.12-14 0.50 60 days at Formulation 3 Moderate vaporalkyl primary amine 120° F. No. 1 phase corrosionsalt of mixed mono-and di-isooctylacid phosphateCyclohexylamine 0.50 60 days at Formulation 4 Detinning in both phases; 120° F. No. 1 some vapor phase corrosionTertiary C.sub.12-14 0.25 60 days at Formulation 2 Light vapor phase corrosionalkyl primary amine 120° F. No. 1salt of mixed mono-and di-isooctylacid phosphateCyclohexylamine 0.25Tertiary C.sub.12-14 0.50 60 days at Formulation 1 Slight vapor phase corrosionalkyl primary amine 120° F. No. 1salt of mixed mono-and di-isooctylacid phosphateCyclohexylamine 0.50__________________________________________________________________________
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Corrosion inhibitor compositions comprising a mixture of an amine neutralized phosphate ester and a volatile amine selected from the group consisting of cyclohexylamine, morpholine and isopropylamine. Such compositions are useful in inhibiting corrosion on the interior surfaces of tin-plated aerosol cans containing water-based aerosol formulations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit, under 35 U.S.C. 119(e), of U.S. Provisional Patent Application No. 60/475,561, filed on Jun. 3, 2003, entitled F8 Bus Specification, which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present application relates to systems and methods for exchanging electrical signals, and in particular to the communication of digital information between two or more electronic components over a communication bus.
BACKGROUND
[0003] Electrical and electronic circuits and systems, and elements thereof, exchange electrical signals. The signals can be in analog form, generally signified by a magnitude of some characteristic of the signal, e.g. voltage. Alternately, the signals can be in digital form, signified by discrete values of the signal, e.g. binary signals (0/1, +1/−1, high/low, etc.).
[0004] Modern electronic systems commonly exchange digital information over conducting lines or wires, often arranged in groups, called buses. A bus can contain any number of conducting lines, and can be formed by grouping the conducting lines physically or logically. Buses can be produced in bundles, braids, or flat ribbons, and can have endpoint connectors or terminators suitable for making contact between the components coupled by the buses. Buses can also be produced by laying out solder lines on an electronic circuit board, or by etching conductive traces into a semiconducting substrate. When packaged in a chip, buses can be manufactured along with the chip in the package.
[0005] One communication bus provided by the Common Switch Interface Consortium is known as the CSIX bus, used in network processors. The CSIX bus provides lines for data communication, including header information, a Ready bit, and vertical parity checking bits. Another available communication bus is the proprietary Focus bus from Vitesse Semiconductor Corporation. The Focus bus provides data lines, header information, but no Ready bit or vertical parity information. Both the CSIX and Focus buses require flow control data to be exchanged outside the buses, on separate lines, which consume valuable bus and pin locations. The CSIX bus requires start-of-frame (SOF) and parity (PAR) lines in addition to clock and data lines. The Focus bus requires flow control lines in addition to clock and data lines.
[0006] As features, functions, and communication bandwidths multiply, it becomes helpful or necessary to optimize or efficiently make use of the communication buses in electronic systems and devices. Accordingly, data is usually packaged and delivered in a way that leaves as much bandwidth over the buses available as possible while still achieving the desired function.
[0007] One way to address the problem of limited bus connections might be to increase the number of communication data lines (lines) in the buses. However, this would require a corresponding increase in the number of connecting pins coupling the devices to the buses, and would also require a corresponding modification to the communication protocols, memory array sizes, communication software, clock regulation, and other design factors. Furthermore, increasing the size of communication buses results in buses and devices that are significantly larger in physical area (footprint) and cost. Therefore, it is useful to develop new systems and techniques that reduce the need for added buswork and connections, and efficiently utilize the lines and pin connections of existing systems.
SUMMARY
[0008] Recognizing at least the points mentioned above, and appreciating solutions to the challenges presented by modem digital bus communications, new systems and methods for communicating over buses are described. In some aspects, the buses provide improved bus availability, bandwidth, and performance by utilizing common clock signals instead of conventional clock sourcing. In other aspects, the buses use useful and new cell formats that enable devices to exchange information and payloads in a streamlined fashion within existing hardware limitations that are less prone to error. In some specific embodiments, a bus and method for using the same is provided to satisfy the “F8” bus used in the ST-16 intelligent mobile gateway device from Starent Networks of Tewksbury, Mass., or similar devices. More generically, the present buses and methods may be used with any compatible or adaptable components, the digital communication and signal processing types being only one example thereof.
[0009] One embodiment of the present disclosure is directed to a method for exchanging digital data between devices over a bus, including providing at least one bit of data to indicate the type of digital data being exchanged; providing at least one bit of data to indicate whether a device coupled to the bus is ready to communicate with other devices over the bus; and providing at least one vertical parity bit for checking for error conditions in corresponding bits of the digital data.
[0010] Another embodiment of the present disclosure is directed to a system for transferring digital data between at least two devices, including a communication bus having a plurality of communication lines, the communication bus coupled at a first end thereof to a first device and coupled at a second end thereof to a second device; at least one of the plurality of communication lines carrying a bit of data to indicate the type of digital data being exchanged; at least one of the plurality of communication lines carrying a bit of data to indicate whether a device coupled to the communication bus is ready to communicate with other devices over the communication bus; and the plurality of communication lines carrying vertical parity bits for checking for error conditions in corresponding bits of the digital data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a fuller understanding of the nature and objects of the present disclosure, reference should be made to the following detailed description, in connection with the accompanying drawings, in which the same reference numerals are used to indicate the same or similar parts, wherein:
[0012] FIG. 1 illustrates an exemplary grouping of FPGA circuits arranged on a motherboard and interconnected by communication buses;
[0013] FIG. 2 illustrates an 8-bit byte of a data cell, with notation for numbering the bits;
[0014] FIG. 3 illustrates an exemplary F8 cell format, showing the information contained in each byte and bit of the cell;
[0015] FIG. 4 illustrates the operation of vertical parity in a data cell;
[0016] FIG. 5 illustrates data blocks within an exemplary F8 data cell, including payload cells; and
[0017] FIG. 6 illustrates a null cell.
DETAILED DESCRIPTION
[0018] FIG. 1 illustrates an exemplary motherboard 100 having various logic chips, circuits, and communication elements coupled thereto. Motherboard 100 is typically provided with connection pins (not shown) that deliver power, ground connections, data, and control signals between the motherboard and a computer system in which the motherboard is installed. The computer system may be local and has motherboard 100 installed into a hardware slot designed for such cards. The computer system may be also be remote or distributed such that motherboard 100 and the computer system are not in physical proximity to one another.
[0019] The motherboard 100 of FIG. 1 includes a voice data transport (VDT) field programmable gate array (FPGA) chip 110 that manages aspects of delivery and processing of information from voice communication sessions. Two other FPGAs are disposed on motherboard 100 : a general purpose digital signal processing (GP DSP) chip 130 and a voice over internet protocol digital signal processing (VoIP DSP) chip 140 . The chips in this example are constructed as packaged integrated circuits (ICs) and are generally mounted on cards or daughter boards, e.g. 131 , 132 , which themselves are electrically and/or mechanically coupled to motherboard 100 , but the FPGAs may also be placed directly onto appropriate mating connections on motherboard 100 .
[0020] Each of the FPGAs 130 and 140 are connected to FPGA 110 by “F8” communication bus lines 150 . An F8 bus has 16 total lines, consisting of 8 lines for receiving data, and another 8 lines for transmitting data. This is indicated by the slash symbols accompanying the numerals “8” in the figures, as well as the directionality of the arrows and the letters “R” (receive) and “T” (transmit). F8 bus 150 A connects VDT 110 and GP DSP 130 , while F8 bus 150 B connects VDT 110 and VoIP DSP 140 . Of course, not all buses connecting the various components need to be of the same design or of the F8 type, but rather, it is possible to have a variety of bus types represented on a single board or system if appropriate.
[0021] This system of integrated circuits and associated computing components provides the ability to receive, process, store, and retransmit digital data from a variety of sources and in one or more formats. For example, the circuits may be used to handle voice and data communication in internet protocol (IP), asynchronous transfer mode (ATM), or time division multiplexing (TDM) applications.
[0022] One feature, of one aspect of the invention, shown in FIG. 1 is a shared clock feature. A clock source, usually a solid state resonator crystal 120 is powered from some source of power on a daughter board or a motherboard 110 . The clock 120 generates a cyclical (CLK) signal suitable for actuating and synchronizing other parts of the system. In the exemplary embodiment shown, the clock signal is delivered to the FPGAs 110 , 130 , and 140 through clock lines 121 , 122 , and 123 , respectively. The clock signals to all of the FPGAs are thus shared from their source 120 and will be substantially synchronized (having contemporaneous rising and falling edges).
[0023] In some instances, the present system of sharing a common clock signal is preferable to conventional clock sourcing. In conventional clock sourcing, a clock signal is generated at a clock and then passed to a first circuit. The first circuit in turn passes on a clock signal to a second circuit, which may pass a clock signal to a third, and so on. Clock sourcing works by a two-way (back and forth) communication between the circuits. Therefore, clock sourcing requires two lines dedicated to the exchange of clock signal information. By contrast, and as can be seen in FIG. 1 , a shared clock signal method only requires a single clock line per clocked device ( 121 , 122 , 123 ), and provides a savings of one communication line at each of the circuits. Therefore, in shared or common clocked embodiments, an extra communication line is freed up to be used for other communication functions or data transfer.
[0024] We now turn to the use of the communication buses 150 according to some embodiments of the invention. As mentioned earlier, a double-eight communication bus, such as the F8 bus, can be used to communicate digital information bits between two circuits or components. The communication is performed according to a pre-determined format so that the two communicating components may properly parse the significance of the information. As a preliminary step, a convention for illustrating and describing the information content is shown in FIG. 2 . An exemplary byte 200 is shown having 8 bits 210 . The bits are designated sequentially from 0 to 7. Each bit (binary digit) carries a “0” or a “1” (or their equivalent) information. In the example, bit number 0 carries a “1” datum of information, bit number 1 carries a “0” datum of information, bit number 2 carries a “1” datum of information, etc. The entire 8-bit byte 200 carries the data “10001101.” The bus 150 is usually “unconcerned” with the actual data it carries, and the communicating circuits are the elements that will parse and process the information sent and received over the bus. In the present description, a short hand notation 220 is used to indicate a group of bits carrying information of some significance. Figure 2 provides an example of a group of bits “100” carried in bit 7 through bit 5 of byte 200 . This group of bits is indicated by the notation “7:5” or seven-through-five. This notation will be used below to describe the use of the bytes and what information is delivered in an exemplary F8 format.
[0025] FIG. 3 illustrates an exemplary format of a cell of information comprising several 8-bit bytes. Data strings, structures, and words of other size and other orderings of the information within the cell are possible and can be implemented by those skilled in the art. In the F8 example cell format, the first byte (byte 0 ) carries three pieces of information:
[0026] First, in bits 7:5, the type of cell. The figure shows several types of cell types that can be indicated by the 7:5 bits of byte 0 . The are:
000 Idle - the bus is not carrying information (is in an idle state) 001 Middle of packet - portions of a data packet precede and follow 010 End of packet, aborted packet 011 End of packet, good packet 100 Null - no payload present, for flow control uses 101 Start of packet 110 Reserved 111 Start and end of packet, good packet having only one cell
[0027] Second, in bit number 4 of byte number 0 , a “Ready” bit is carried. If the value of the Ready bit is “0” then the device is not ready to receive data from the bus. If the value of the Ready bit is “1” then the device is ready to receive data.
[0028] Third, bits 3:0 are reserved, and not used by the devices.
[0029] The next byte (byte 1 ) carries the Byte Count (BC), or number of bytes of payload data in the cell, in bits 6:0, with bit 7 being reserved. The byte count is an integer number, represented in a 7-bit binary format in the present example.
[0030] It should be appreciated that more than one byte may be used to signify the number of payload bytes in the cell. This could be used if the number of payload bytes is too large to be represents by the bits in a single Byte Count byte or portion thereof.
[0031] The final byte (number BC+2) is for vertical parity (VP). Parity bits are used for error checking. Errors arise in digital communication from a variety of sources. For example, electrical interference can cause a “0” bit to arrive at its destination as a “1” bit, or vice versa. A parity sense is adopted to check for flipped bits. Even vertical parity means that an even number of “1”s were packaged in a column of cells at its origin, and odd vertical parity means that an odd number of “1”s were packaged in a column of cells at its origin.
[0032] FIG. 4 illustrates an exemplary F8 cell similar to that described above, having odd parity error checking. Data content of the first two columns 310 , 320 are shown for illustrative purposes, while the rest of the cell's data values are not shown for simplicity. The last row 350 of cell 300 contains the VP bits. Bits 330 and 340 contain the VP bits for columns 310 and 320 , respectively. Each VP bit is made to produce an odd total number of “1”s in its column. Hence, bit 330 is a “1” because its column contains two other “1”s, and a “1” is needed in VP bit location 330 to make the number of “1”s for column 310 equal 3, an odd number. Likewise, in column 320 , VP bit 340 is made to be a “0” because the column 320 otherwise contains one “1” value, which is an odd number of “1”s. The VP bits in the other six positions of row 350 would similarly be made to be “0” or “1” as necessary to keep the total number of “1”s per column of the cell odd. If the figure was for an even parity configuration, the “1”s and “0”s of the VP row 350 would be interchanged.
[0033] FIG. 5 illustrates another F8 cell 400 according to the present exemplary format, showing blocks of bits in each byte of the cell signifying various content. The shaded blocks of bits are reserved or unused. The cell illustrated in FIG. 5 includes 64 8-bit data (payload) bytes, D 0 . . . D 63 . In some embodiments, this number of payload bytes facilitates communication with components using the TDM format or IP packet format. Other embodiments could have less, more, or no payload cells.
[0034] FIG. 6 illustrates a “null” cell 500 . Byte 0 includes the Type of cell in bits 7:5 as described previously. This type according to the example used is defined by bit values “100” in the 5:7 bits 510 . The Ready bit 520 follows in bit 4 of byte 0 . Byte 1 of null cell 500 is used for vertical parity. No payload data is carried in a null cell, but it does carry the Ready bit to indicate the availability of the device.
[0035] As described in the present disclosure and figures, new communication buses and methods for carrying data over the buses have been presented. In some aspects, shared clocking of interconnected devices provides a savings in lines used for clock signals to the devices. In other aspects, data cell formats including flow control functionality and being indicative of the type of data cell, including whether the data cell is a null cell are provided. In yet other aspects, the disclosure teaches a way to populate a data cell with binary information suitable for use with the F8 bus and compatible systems. The systems and methods include provisions for error checking using vertical parity, and improve the overall performance and pin/line availability to devices communicating over the bus lines. Therefore, increased functionality and lower cost can be achieved in digital communication systems using such buses.
[0036] Upon review of the present description, figures, and specific exemplary embodiments, it will be understood that modifications and equivalent substitutions may be performed in carrying out the invention without departing from the essence of the invention. Thus, the invention is not meant to be limited by the embodiments described explicitly above, rather it should be construed by the scope of the claims that follow.
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Systems and methods for communicating data over a communication bus are disclosed. In some aspects, the data is digital information communicated over a multiple-line bus connecting two or more electronic devices such as integrated circuits. The disclosure presents useful formats for arranging data into data cells communicated over the bus, and include some exemplary features as shared clock signals, Ready bit information, and vertical parity checking.
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BACKGROUND OF THE INVENTION
The present invention relates to a solar cell having a thin film of, for example, amorphous silicon formed on a flexible substrate.
Amorphous silicon (hereunder a-Si) solar cells using amorphous silicon formed by the glow discharge decomposition of silane gas are considered most promising as low-cost solar cells, and many researchers are engaged in active efforts to improve the conversion efficiency of such cells. The a-Si cells, produced by vapor phase growth techniques, provide a large area for receiving sunlight. Since these cells can be fabricated at temperatures as low as 200° to 300° C., they allow a great latitude in the selection of substrate materials. As a further advantage, an a-Si film has good adhesion to the substrate material so that a flexible substrate can be used without any reduction in the performance characteristics of the cell due to flexing of the substrate.
A typical example of a conventional thin-film a-Si solar cell is depicted in FIG. 1. The cell has a substrate 1 which is an insulating film of a thickness of 50 to 100 microns and which is made of a polymeric material such as polyamide. The substrate is successively overlaid with a metal electrode 2, a p-type a-Si film 3, an undoped a-Si film 4, and an n-type a-Si film 5. The metal electrode 2 is formed by sputtering or electron-beam vapor depositing a high-melting point metal such as stainless steel, chromium, titanium, or molybdenum. The p-type a-Si 3 is deposited on the metal electrode, heated to 200° to 300° C., by decomposing a reactive gas (silane+1% diborane) at 1 to 10 Torr in a glow-discharge plasma produced by a radio frequency field. The undoped a-Si film 4 is formed to a thickness of about 0.5 microns on the p-type a-Si film 3 by the glow discharge decomposition of silane gas. The n-type a-Si film 5 is formed on the undoped a-Si film by the decomposition of a reactive gas (silane+1% phosphine). The p-i-n type a-Si layer composed of the films 3, 4, and 5 is overlaid with a transparent electrode 7 made of ITO (indium tin oxide) or SnO 2 (tin oxide) and is formed to a thickness of 700 to 2,000 Å by a suitable technique such as sputtering, electron-beam vapor deposition, or thermal CVD.
FIGS. 2A and 2B show a solar cell array wherein a plurality of cell elements having the configuration shown in FIG. 1 are connected in series, of which FIG. 2A is a plan view thereof and FIG. 2B is a cross section taken along a line A--A in FIG. 2A. In the embodiment shown, a flexible insulating substrate 1 is overlaid with three strips of metal electrode 2 as well as a terminal electrode 21. These electrodes may be formed by vapor deposition using a metal mask. The metal electrodes 2 are respectively overlaid with three discrete strips of an a-Si layer 6 having a p-i-n junction. The regions of the a-Si layer 6 may be formed of an a-Si layer which is deposited on the entire surface of the substrate and then divided into three separate areas by photoetching. The three a-Si layers are respectively overlaid with a transparent electrode 7 formed with the aid of a metal mask. Three solar cell elements 11, 12, and 13, each composed of a metal electrode 2, a-Si layer 6 and transparent electrode 7, are connected in series, and their output is taken at the end portion 20 of the metal electrode of the leftmost element 11 and the terminal electrode 21.
The solar cell array shown in FIG. 2 is excited when sunlight falls on the transparent electrodes 7. Since the terminals 20 and 21 are on the side of the insulating substrate on which the sunlight falls, the output characteristics of the array must be measured with a lead inserted to connect the terminals 20 and 21 on the incident side of the substrate. In this case, the leads or the terminals should not interfere with the incoming light. When two solar cell arrays of the configuration shown in FIGS. 2A and 2B are connected in series, an electrode 21 on one substrate must be connected to an electrode 20 on the other substrate by a metal foil or lead wire in such a manner that the latter does not interfere with the path of the incoming light. The same precautions must be taken in parallel connecting the two arrays, and this puts a considerable limit on the type of electrical components that can be used in establishing connection and involves much difficulty in attaining the desired connection.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a solar cell having terminals that permit easy electrical connection without experiencing the difficulties conventionally encountered in connecting solar cells provided on an opaque flexible substrate.
According to the present invention, the stated and other objects are achieved by a thin-film solar cell comprising a plurality of cell elements each having a first electrode, a thin semiconductor film and a transparent second electrode formed successively on the obverse surface of a flexible insulating substrate, these elements being connected in series by the second electrode which overlaps the first electrode of an adjacent element or a separate terminal electrode formed on the obverse surface of the substrate, characterized in that the opposite surface of the substrate as at least two terminal electrodes made of a metal layer and which are respectively connected to the first electrode of a cell element at the extreme end of the obverse surface of the substrate and to the terminal electrode on the same obverse surface. To accomplish this, the flexible substrate may be bent at both ends at an angle of 180° in such a manner that the first electrode of the cell element at the extreme end of the obverse surface of the substrate and the terminal electrode of the same obverse surface extend to its back side to provide respective terminal electrodes on the opposite surface of the substrate. Otherwise, the terminal electrodes on the opposite surface of the substrate may be connected to the first electrode and terminal electrode on the obverse surface of the substrate by a conductive material that fills holes formed in the substrate and which are positioned at the back of each of the first electrode and terminal electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section of an a-Si solar cell;
FIGS. 2A and 2B show an embodiment of a solar cell wherein a plurality of cell elements are connected in series, of which FIG. 2A is a plan view and FIG. 2B is a cross section taken along a line A--A in FIG. 2A;
FIG. 3 is a cross-sectional view of a first preferred embodiment of a solar cell of the present invention;
FIG. 4 is a cross-sectional view showing a second embodiment of a solar cell of the present invention;
FIGS. 5A and 5C show an a-Si solar cell according to the present invention which is formed on a flexible substrate of a large area, of which FIG. 5A is a plan view and FIGS. 5B and 5C are cross sections of 5A taken along lines X--X and Y--Y, respectively;
FIG. 6 is a cross section showing interconnections of solar cell units separated from the substrate shown in FIG. 5A;
FIGS. 7A to 7C show an a-Si solar cell according to another embodiment of the present invention formed on a flexible substrate of a large area, of which FIG. 7A is a plan view and FIGS. 7B and 7C are cross sections of FIG. 7A taken along lines X--X and Y--Y, respectively;
FIG. 8 is a cross section showing interconnected solar cell units separated from the substrate shown in FIG. 7A;
FIG. 9 is a cross section showing essential parts of a solar cell module composed of cell units having the configuration shown in FIG. 4; and
FIG. 10 is a cross section showing a solar cell module composed of cell units having the configuration shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 shows a solar cell array according to a preferred embodiment of the present invention which, as in FIG. 2, is composed of three cell elements 11, 12, and 13. However, in the solar cell array of the invention, the electrode 20 of the leftmost element 11 and the terminal electrode 21 extend past the edges of a flexible substrate and are bent downwardly at an angle of 180° at end portions 31 of the substrate 1, and sealed to the bottom of the substrate 11 by an adhesive 32. For ease of fabrication, the use of a quick drying adhesive such as "Aron Alpha" (tradename of a product of Toagosei Chemical Co., Ltd., of Japan) is recommended. According to the embodiment of FIG. 3, metal electrodes 22 are formed on the side of the flexible substrate 1 which is opposite to the side where sunlight falls.
FIG. 4 shows another embodiment of the present invention in which electrodes 22 made of a vapor-deposited metal layer are formed on the opposite surface of the flexible substrate 1 in areas which correspond to the electrodes 20 and 21 formed at both ends of the obverse surface of the substrate. A hole 33 penetrating the substrate 1 is formed in each electrode 22. This hole 33 is made by punching or the like either before or after the fabrication of the electrodes 22. The hole 33 has a diameter of about 200 microns to 1 mm, which is greater than the thickness of the substrate 1. When a conductive adhesive such as silver paste 34 is forced into the hole 33, the paste spreads and wets both the metal electrode 20 or terminal electrode 21 and the electrode 22 on the reverse surface of the substrate so as to establish an electrical connection between the electrodes on the obverse and reverse surfaces of the substrate. As a result of this procedure, either of the electrodes 22 on the reverse surface of the substrate shown in FIG. 3 or 4 can be connected to an external lead wire without the possibility of interfering with the path of the incident sunlight.
In the embodiment of FIGS. 5A to 5C, a plurality of a-Si solar cells according to the present invention are formed on a flexible substrate of a large area. FIG. 5A is a plan view, and FIGS. 5B and 5C are cross sections taken on lines X--X and Y--Y, respectively. In the embodiment shown, three series-connected cell elements 10 are arranged in three rows. As can be seen from FIG. 5C, the metal electrode 2 is continuous in the direction of the line Y--Y. The a-Si layer 6 is also continuous in the direction of the line Y--Y, but is provided with large holes 35 between adjacent rows of series-connected cell elements 10. The holes 35 are formed simultaneously with the patterning of the a-Si layer 6. The metal electrode 2 and substrate 1 are provided with through-holes 36 which are smaller than the holes 35 and positioned both between adjacent rows of series-connected cell elements and between each array of series-connected cell elements. The holes 36 between cell elements in the direction of the line X--X are preferably concentric with the holes 35. As in the case of FIG. 4, electrodes 22 are formed around the holes 36 on the side of the substrate opposite the side where the holes 35 are formed.
The solar cell array shown in FIG. 5A is cut along a perforated line 41 or 42 with a cutter or scissors. The perforated line 41 is used to separate otherwise parallel-connected cell elements arranged in the direction of the line Y--Y and to leave a sequence of series-connected cell elements, while the perforated line 42 is used to separate different sequences of otherwise series-connected cell elements arranged in the direction of the line X--X and to leave a small sequence of series-connected and parallel-connected cell elements. If a solar cell module providing a large current but low voltage is required, the perforated line 42 is used, and if a module for high voltage operation is necessary, the perforated line 41 is used. By connecting these two kinds of modules, a system capable of producing desired levels of voltage and current can be provided. In the embodiment of FIGS. 5A to 5C, the smallest unit of thin-film solar cells that can be used independently is three series-connected elements, but it should be understood that the number of cell elements that are connected in series to make the smallest unit may be varied depending on the application.
FIG. 6 shows an embodiment wherein solar cell units separated at the perforated line 42 shown in FIG. 5 are subsequently interconnected. The concept shown in connection with FIG. 6 also applies to the case where solar cell units are separated at the perforated line 41. Two units 61 and 62, each composed of three series-connected cell elements, are placed in a partially overlapping relation so that the holes 36 in one unit, which now have a semi-circular cross section as a result of the separation at the perforated line 42, are in alignment with the holes 36 in the other unit, which also have a semi-circular cross section. A conductive adhesive 34 is applied to the joining edges of the units so as to establish an electrical connection between the metal electrode 20 at the end portion of the obverse surface of the unit 61 and the terminal electrode 22 formed at the end portion of the reverse surface of the unit 62. As a result, the two units 61 and 62, each having three series-connected cell elements, are connected in series. The thicknesses of each unit shown in FIG. 6 are exaggerated; in actuality, the substrate 1 has a thickness of about 100 microns and each hole 36 a diameter of about 0.5 mm. Therefore, the two units 61 and 62 can be connected by simply injecting the conductive adhesive 34 from the side of only one unit.
FIGS. 7A to 7C show an embodiment somewhat different from that of FIGS. 5A to 5C, of which FIG. 7A is a plan view and FIGS. 7B and 7C are cross sections taken along lines X--X and Y--Y, respectively, in FIG. 7A. In this embodiment, each of the holes 36 is replaced by two adjacent holes 37 and 38 between which the perforated lines 41 and 42 are provided. In the embodiment shown, the a-Si layer 6 is not continuous in the direction of the line Y--Y, but if desired, the a-Si layer 6 may be rendered continuous as in the case of FIGS. 5A to 5C with the diameters of holes 37 and 38 being made slightly larger than in the case of FIGS. 5A to 5C. A common factor to both the embodiment of FIGS. 5A to 5C and that of FIGS. 7A to 7C is that the transparent electrode 7 is discontinuous in the direction of the line Y--Y and no part of it is provided with holes 36 or pairs of holes 37 and 38. This arrangement is necessary for permitting two units of solar cell elements to be separated without causing a short circuit between the transparent electrode 7 and the metal electrode 2.
FIG. 8 shows an embodiment wherein solar cell units separated at the perforated line 42 shown in FIG. 7 are subsequently interconnected. The holes 37 and 38 remain circular even after separation at the line 42. Thus, the embodiment of FIG. 8 permits easier alignment and has a smaller chance of leakage of the adhesive than in the case of the embodiment of FIG. 6.
FIG. 9 shows an illustrative module fabricated by interconnecting thin-film solar cell units provided by the procedure described above. In the embodiment of FIG. 9, four units 61 to 64 of a suitable size are interconnected. First, the unit 61 is bonded to a glass plate 8 on the side of the thin semiconductor film 6 by an adhesive such as an epoxy compound. Then, the adjacent unit 62 is placed on the unit 61 in a partially overlapping relation so that the centers of holes 36 (in the case of the FIGS. 5A to 5C embodiment) or those of holes 37 and 38 (in the case of the FIGS. 7A to 7C embodiment) are in alignment. Again, the thin semiconductor film 6 on the unit 62 is bonded to the glass plate 8 by an adhesive. Subsequently, a conductive material is forced into the holes 36 or the holes 37 and 38, thereby establishing electrical connection between two overlapping electrodes. After bonding the two other units 63 and 64 to the glass plate 8 in the same manner, the resulting combination of the four units is covered with a protective film 9 on the side opposite the glass plate. The protective film may be made of an epoxy resin. The thus-fabricated module may be installed on glass windows of a building or used as a substitute for wall paper. In this case, in order to let in a maximum amount of light, the flexible substrate 1 and the protective film 9 should have the highest degree of transparency. Another effective way to attain the same result is by replacing the metal electrode 2 with a transparent electrode. The shape of the metal electrode 2 as well as the size and layout of holes 36, 37 and 38 may be modified to suit a specific decorative purpose.
FIG. 10 shows an embodiment using solar cell units of the type shown in FIG. 3. Four units 65 to 68 are arranged side by side and bonded to a glass substrate 8 on the side of a thin semiconductor film 6. As in the case of FIG. 9, a conductive adhesive 34 is subsequently applied to connect the units either in series or in parallel. One particular advantage with the embodiment of FIG. 10 is that the units fixed to the glass plate 8 can be interconnected by applying the conductive adhesive to the side opposite that where sunlight falls, and therefore the solar cell system of FIG. 10 can be easily fabricated by an automated process.
In the embodiment shown above, a conductive adhesive is used for interconnection of the electrodes, but it should be understood that they may be connected by soldering if the flexible substrate is sufficiently heat resistant.
According to the thin-film solar cell of the present invention which is formed on the obverse surface of a flexible substrate, output electrodes are provided on the opposite surface of the substrate by either bending the substrate downwardly by an angle of 180° together with an extension of each output electrode, or by connecting each output electrode to a corresponding electrode on the obverse surface of the substrate by means of a conductive material such as a conductive adhesive applied into through-holes in the substrate. Due to this arrangement, the output electrodes can be connected to either themselves or external lead wires on the back side of the substrate by any suitable means without interfering with the incident light. As a further advantage, a plurality of solar cells having the configuration shown above may be formed on a flexible substrate of a large area and subsequently cut into units of a desired size and then interconnected by, for example, application of an adhesive with the aid of the electrodes formed on the reverse surface of each cell unit. By this procedure, a solar cell module producing a voltage and current required by the user can be readily obtained. Since the solar cell of the present invention may be installed on windows, an array of cells may be combined to present various patterns with the aid of the metal electrodes or interconnection through-holes if decorative purposes are of primary concern. A greater freedom in design can be provided by replacing the metal electrodes with transparent ones.
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A thin-film solar cell device in which multiple series-connected cell elements are formed in units which can then be readily joined together in either a series or parallel connection. At least two terminal electrodes are provided on the opposite side of the insulating substrate of each unit, connected to the respective end electrodes of the elements at the extreme ends on the obverse surface of the substrate. This may be done either by bending the flexible substrate around at opposite ends at angles of 180°, or by forming through-holes in the substrate at opposite ends and filling the through-holes with a conductive material. Units can then be joined merely by overlapping their edge portions and connecting them with a conductive adhesive.
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BACKGROUND
[0001] The present disclosure relates to a gas turbine engine and, more particularly, to a geared architecture therefor.
[0002] Epicyclic gear systems with planetary or star gearboxes may be used in gas turbine engines for their compact designs and efficient high gear reduction capabilities. Planetary and star gearboxes generally include three gear train elements: a central sun gear, an outer ring gear with internal gear teeth, and a plurality of planet gears supported by a planet carrier between and in meshed engagement with both the sun gear and the ring gear. The gear train elements share a common longitudinal central axis, about which at least two rotate.
[0003] In gas turbine engine architectures where speed reduction transmission is required, the central sun gear generally receives rotary input from the powerplant, the outer ring gear is stationary and the planet gear carrier rotates in the same direction as the sun gear to provide torque output at a reduced rotational speed. In star gear trains, the planet carrier is held stationary and the output shaft is driven by the ring gear in a direction opposite that of the sun gear.
[0004] During flight, lightweight structural engine case assemblies may deflect upon aero and maneuver loads that may cause transverse deflection commonly known as backbone bending. This deflection may cause the individual sun or planet gear's axis of rotation to lose parallelism with the central axis and may result in some misalignment at gear train journal bearings and at the gear teeth mesh. This misalignment may lead to efficiency losses and the potential for reduced life.
SUMMARY
[0005] A gas turbine engine according to one disclosed non-limiting embodiment of the present disclosure includes a geared architecture with a multiple of intermediate gears, and a structural oil baffle housing that at least partially supports said set of intermediate gears.
[0006] In a further embodiment of the foregoing embodiment, each of said multiple of intermediate gears is mounted to a respective flexible carrier post. In the alternative or additionally thereto, the foregoing embodiment includes a spherical joint mounted to each flexible carrier post. In the alternative or additionally thereto, in the foregoing embodiment structural oil baffle housing is mounted to a spherical joint mounted to each flexible carrier post.
[0007] In a further embodiment of any of the foregoing embodiments, the gas turbine engine includes a rotationally fixed carrier, each of said multiple of intermediate gears mounted to a respective flexible carrier post which extends from said carrier. In the alternative or additionally thereto, the foregoing embodiment includes an oil manifold defined by said carrier. In the alternative or additionally thereto, in the foregoing embodiment the oil manifold includes a first oil circuit and a second oil circuit. In the alternative or additionally thereto, in the foregoing embodiment the first oil circuit communicates with each respective flexible carrier post. In the alternative or additionally thereto, in the foregoing embodiment the second oil circuit communicates with a multiple of oil nozzles.
[0008] In a further embodiment of any of the foregoing embodiments, the gas turbine engine includes a rolling element bearing mounted between said structural oil baffle housing and each of said multiple of intermediate gears. In the alternative or additionally thereto, in the foregoing embodiment the structural oil baffle housing directs oil to said multiple of intermediate gears. In the alternative or additionally thereto, in the foregoing embodiment the multiple of oil nozzles are external to said structural oil baffle housing.
[0009] In a further embodiment of any of the foregoing embodiments, the geared architecture includes a planetary gear system.
[0010] In a further embodiment of any of the foregoing embodiments, the geared architecture includes a star gear system.
[0011] A gas turbine engine according to another disclosed non-limiting embodiment of the present disclosure includes a carrier which defines an oil manifold with a first oil circuit and a second oil circuit, a multiple of flexible carrier post which extends from said carrier to support a respective intermediate gear, said first oil circuit communicates with each respective flexible carrier post, a structural oil baffle housing which at least partially supports said set of intermediate gears, and a multiple of oil nozzles in communication with said second oil circuit.
[0012] In a further embodiment of the foregoing embodiment, the multiple of oil nozzles are each adjacent to a sun gear and one of said multiple of intermediate gears. In the alternative or additionally thereto, the foregoing embodiment includes a rolling element bearing mounted between said structural oil baffle housing and each of said multiple of intermediate gears. In the alternative or additionally thereto, in the foregoing embodiment the rolling element bearing is a ball bearing. In the alternative or additionally thereto, in the foregoing embodiment the rolling element bearing is a roller bearing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiment. The drawings that accompany the detailed description can be briefly described as follows:
[0014] FIG. 1 is a schematic cross-sectional view of a geared architecture gas turbine engine;
[0015] FIG. 2 is an expanded schematic view of the geared architecture;
[0016] FIG. 3 is an schematic front view of a planetary gear system type epicyclic gear system of the geared architecture according to one disclosed non-limiting embodiment;
[0017] FIG. 4 is an schematic front view of a star gear type epicyclic gear system of the geared architecture according to another disclosed non-limiting embodiment;
[0018] FIG. 5 is an sectional view of the epicyclic gear system along line 5 - 5 in FIG. 7 ;
[0019] FIG. 6 is a sectional view of the epicyclic gear system along line 6 - 6 in FIG. 7 ; and
[0020] FIG. 7 is a schematic front view of an epicyclic gear system with a structural oil baffle housing according to one disclosed non-limiting embodiment.
DETAILED DESCRIPTION
[0021] FIG. 1 schematically illustrates a gas turbine engine 20 . The gas turbine engine 20 is disclosed herein as a two-spool turbofan that generally incorporates a fan section 22 , a compressor section 24 , a combustor section 26 and a turbine section 28 . Alternative engines architectures such as a low-bypass turbofan may include an augmentor section (not shown) among other systems or features. Although schematically illustrated as a turbofan in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines to include but not limited to a three-spool (plus fan) engine wherein an intermediate spool includes an intermediate pressure compressor (IPC) between a low pressure compressor and a high pressure compressor with an intermediate pressure turbine (IPT) between a high pressure turbine and a low pressure turbine as well as other engine architectures such as turbojets, turboshafts, open rotors and industrial gas turbines.
[0022] The fan section 22 drives air along a bypass flowpath and a core flowpath while the compressor section 24 drives air along the core flowpath for compression and communication into the combustor section 26 then expansion through the turbine section 28 . The engine 20 generally includes a low spool 30 and a high spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine case assembly 36 via several bearing compartments 38 - 1 , 38 - 2 , 38 - 3 , 38 - 4 .
[0023] The low spool 30 generally includes an inner shaft 40 that interconnects a fan 42 , a low-pressure compressor 44 (“LPC”) and a low-pressure turbine 46 (“LPT”). The inner shaft 40 drives the fan 42 through a geared architecture 48 to drive the fan 42 at a lower speed than the low spool 30 . The high spool 32 includes an outer shaft 50 that interconnects a high-pressure compressor 52 (“HPC”) and high-pressure turbine 54 (“HPT”). A combustor 56 is arranged between the HPC 52 and the HPT 54 . The inner shaft 40 and the outer shaft 50 are concentric and rotate about the engine central longitudinal axis A that is collinear with their longitudinal axes.
[0024] Core airflow is compressed by the LPC 44 then the HPC 52 , mixed with the fuel and burned in the combustor 56 , then expanded over the HPT 54 and the LPT 46 . The HPT 54 and the LPT 46 drive the respective low spool 30 and high spool 32 in response to the expansion.
[0025] In one example, the gas turbine engine 20 is a high-bypass geared architecture engine in which the bypass ratio is greater than about six (6:1). The geared architecture 48 can include an epicyclic gear system 58 , such as a planetary gear system ( FIG. 2 ), star gear system ( FIG. 3 ) or other system. The example epicyclic gear train has a gear reduction ratio of greater than about 2.3, and in another example is greater than about 2.5 with a gear system efficiency greater than approximately 98%. The geared turbofan enables operation of the low spool 30 at higher speeds which can increase the operational efficiency of the LPC 44 and LPT 46 and render increased pressure in a fewer number of stages.
[0026] A pressure ratio associated with the LPT 46 is pressure measured prior to the inlet of the LPT 46 as related to the pressure at the outlet of the LPT 46 prior to an exhaust nozzle of the gas turbine engine 20 . In one non-limiting embodiment, the bypass ratio of the gas turbine engine 20 is greater than about ten (10:1), the fan diameter is significantly larger than that of the LPC 44 , and the LPT 46 has a pressure ratio that is greater than about five (5:1). It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present disclosure is applicable to other gas turbine engines including direct drive turbofans.
[0027] In one non-limiting embodiment, a significant amount of thrust is provided by the bypass flow due to the high bypass ratio. The fan section 22 of the gas turbine engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. This flight condition, with the gas turbine engine 20 at its best fuel consumption, is also known as bucket cruise Thrust Specific Fuel Consumption (TSFC). TSFC is an industry standard parameter of fuel consumption per unit of thrust.
[0028] Fan Pressure Ratio is the pressure ratio across a blade of the fan section 22 without a Fan Exit Guide Vane system. The low Fan Pressure Ratio according to one non-limiting embodiment of the example gas turbine engine 20 is less than 1.45. Low Corrected Fan Tip Speed is the actual fan tip speed divided by an industry standard temperature correction of (“T”/518.7) 0.5 in which “T” represents the ambient temperature in degrees Rankine. The Low Corrected Fan Tip Speed according to one non-limiting embodiment of the example gas turbine engine 20 is less than about 1150 fps (351 m/s).
[0029] With reference to FIG. 4 , the epicyclic gear system 58 generally includes a sun gear 60 driven by a flexible input shaft 62 driven by the low spool 30 , a ring gear 64 connected to a ring gear output shaft 66 which connects the geared architecture 48 with the fan 42 , and a set of intermediate gears 68 in meshing engagement with the sun gear 60 and ring gear 64 . The flexible input shaft 62 transfers torque as well as facilitates the segregation of vibrations and other transients.
[0030] With reference to FIG. 5 , each intermediate gear 68 is rotationally mounted about a non-rotating flexible carrier post 70 that is respectively supported by a carrier 74 rotationally fixed to the engine case assembly 36 . In another, disclosed, non-limiting embodiment, the carrier may rotate while the ring gear is fixed ( FIG. 2 ). Each of the intermediate gears 68 is rotationally mounted on a respective spherical joint 76 mounted to each of the non-rotating flexible carrier posts 70 . The spherical joint 76 and non-rotating flexible carrier posts 70 allow the system to flex or “squirm” to reduce misalignment and minimize loads upon the intermediate gears 68 as well as permit the use of relatively large rolling element bearings 78 such as cylindrical roller or ball bearings. That is, the spherical joints 76 permit angular movement of the non-rotating flexible carrier posts 70 with minimal, if any, effect upon the intermediate gears 68 .
[0031] The carrier 74 includes an oil manifold 80 that communicates oil through a first oil circuit 82 into each flexible carrier post 70 and a second oil circuit 84 through a multiple of oil nozzles 86 mounted to the carrier 74 . That is, the first oil circuit 82 communicates oil into each flexible carrier post 70 and thereby into the spherical joints 76 , then a structural oil baffle housing 88 and onto the rolling element bearings 78 . The second oil circuit 84 communicates oil as, for example, a spray directly onto the mesh between the sun gear 60 and the intermediate gears 68 .
[0032] With reference to FIG. 6 , the rolling element bearings 78 are mounted within the structural oil baffle housing 88 . The structural oil baffle housing 88 operates to support the intermediate gears 68 as well as an oil baffle to direct oil to the rolling element bearings 78 . The structural oil baffle housing 88 may include a first baffle portion 90 and a second baffle portion 92 which may be attached together, for example, with fasteners 94 and a tight overlap interface 96 . Various interfaces and baffle assembly methods may alternatively be provided.
[0033] The structural oil baffle housing 88 is circumferentially segmented arcuate shape ( FIG. 7 ) about each intermediate gear 68 to permit gear mesh with the ring gear 64 and the sun gear 60 as well as entry and exit of oil. The structural oil baffle housing 88 is thereby shaped to direct oil without separate pressurization.
[0034] Once communicated through the epicyclic gear system 58 the oil is radially expelled into an engine case 36 - 1 often referred to as a front center body of the engine case assembly 36 . To scavenge the oil rejected from the epicyclic gear system 58 , the engine case 36 - 1 includes an oil scavenge scoop 98 to capture oil.
[0035] The structural oil baffle housing 88 reduces misalignment in the rolling element bearings 78 , which facilities usage of relatively higher capacity rolling element bearings 78 as compared to other bearing types. The structural oil baffle housing 88 also facilities direction of scavenge oil out to the ring gear 64 which facilitates an increase in efficiency from 98% to 99.5% efficiency. The difference in heat loss of 0.5% versus 2.0% drives a large amount of weight out of the oil cooling system which facilitates a size reduction of air-oil and fuel-oil coolers for engine thermal management to thereby facilitate a reduction in cost, weight and complexity of the engine 20 .
[0036] It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. The foregoing description is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be understood that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For that reason the appended claims should be studied to determine true scope and content.
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A gas turbine engine includes a structural oil baffle housing which at least partially supports a set of intermediate gears.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Provisional Application Ser. No. 60/322,617 filed on Sep. 17, 2001 in the name of William Roberts as inventor.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a slip mechanism in anchors or packers used in the oil and gas industry, and more particularly to a mechanically set retrievable packer with a torsional resistant slip mechanism. The disclosure of U.S. patent application Ser. Nos. 09/302,738, now U.S. Pat. No. 6,164,377 issued Dec. 26, 2000, and 09/302,982, now U.S. Pat. No. 6,305,474, are incorporated herein by reference.
2. Background of the Invention
It is often desirable to sidetrack or deviate from an existing well borehole for various reasons. For instance, when a well bore becomes unusable, a new bore hole may be drilled in the vicinity of the existing cased bore hole or alternatively, a new bore hole may be sidetracked from the serviceable portion of the cased well bore. Such sidetracking from a cased borehole may also be useful for developing multiple production zones. This drilling procedure can be accomplished by milling through the side of the casing with a mill that is guided by a wedge or whipstock component. It is well known in the industry that whipstocks are used to sidetrack drill bits or mills at an angle from a borehole. The borehole may be lined with pipe casing or uncased. More often than not, the previous borehole is cased.
To complete a sidetracking operation, a typical down hole assembly consists of a whipstock attached to some form of packer or anchor mechanism that holds the whipstock in place once the whipstock has been set at the desired location and angle orientation. The upper end of a whipstock comprises an inclined face. Once the whipstock is properly set and aligned, as a mill is lowered, the inclined face guides the mill laterally with respect to the casing axis. The mill travels along the face of the whipstock to mill a window and/or to create the deviated borehole.
Mechanically set anchors typically utilized to support whipstocks have one or more slips which engage the casing or borehole. Often, the holding capabilities of these conventional devices are not enough to prevent slippage or movement during sidetracking operations. It has been found that conventional whipstock supports may be susceptible to small, but not insignificant amounts of rotational movement. If a misalignment were to occur during a window milling operation, the mill could become stuck in the hole resulting in a difficult and expensive fishing operation. Another unintended result could be that a lateral well bore is drilled in the wrong direction.
Typical slip mechanisms provide minimal upward loading capability and very little torque resistant capacity. These traditional slip mechanisms use wickers or grooves machined into the outer surface of the slip to grip the well bore and resist torsional and longitudinal (axial) forces. These gripping mechanisms allowed for very limited penetration into the casing or borehole, and therefor were prone to unwanted movement. These known problems with tools in the prior art demand that drillers limit the amounts of force applied during such milling and drilling operations. This results in lower rates of penetration, and ultimately, a more costly well.
Hence, it is desired to provide an anchor and whipstock setting apparatus that effectively resists torsional forces and prevents a whipstock from rotating. It is a further desire to provide an effective whipstock support that can be run into a borehole and set using conventional wireline methods.
Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a wellbore anchoring tool with a torsional resistant slip mechanism that effectively resists both axial and rotational forces. According to the preferred embodiment, the present tool includes a mandrel, a plurality of slips disposed about the circumference of the mandrel. The slips include a first set of inserts oriented to resist axial forces and a second set of inserts oriented to resist rotational forces. The present invention further provides a setting means adjacent each slip for radially expanding and setting said slips, so as to resist rotation about the tool axis when the slips engage the casing.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which: The present invention will be more fully understood by reference to the following figures illustrating the preferred embodiment of the present invention:
FIG. 1 is a quarter section view of the preferred embodiment of a packer with the torsional resistant slip mechanism of the present invention.
FIG. 2 is a circumferential plane view of the torsional resistant slip mechanisms of the present invention.
FIG. 3 is a top cross section view of the tool wherein one slip is shown in an engaged position.
FIG. 4 is a top cross section view of an embodiment of the invention comprising eight slips.
NOTATION AND NOMENCLATURE
Certain terms are used throughout the following description and claims to refer to particular system components. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . .”.
The present invention is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein.
In particular, various embodiments of the present invention provide a number of different constructions and methods of operation. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Reference to up or down will be made for purposes of description with “up” or “upper” meaning toward the surface of the well and “down” or “lower” meaning toward the bottom of the primary wellbore or lateral borehole.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 a – 1 g there is shown a side view of a wireline set retrievable whipstock seal bore packer with the torsional resistant slips mechanism of the present invention. Tool 100 has an upper cone 101 and a lower cone 102 . Each slip 10 includes an upper and lower slip camming surface 11 , 12 . A packer assembly 40 is disposed above the slip and cone mechanisms.
The upper cone 101 preferably includes an upper camming surface 111 to engage lower slip camming surface 11 . The lower cone 102 is disposed below the slip 10 and has a camming surface 112 to engage lower slip camming surface 12 . In the preferred embodiment, the camming surfaces of the cones and slips are flat surfaces, resulting in uniform forces applied between these members. Slips known in the prior art had conical shaped back surfaces; thus, contact between those cones and slips resulted in an undesirable bending moment. No bending moments result from the contact between the flat camming surfaces of the cones and slips of the present invention. The above description of setting the slips is the preferred method of this invention; however, other methods of radially extending and setting the slips are well known by those skilled in the arts. Any such method may be practiced without departing from the spirit and scope of this invention.
Referring to FIG. 2 , the slips 10 in the preferred embodiment of the wellbore tool comprise a first and second set of carbide inserts 20 , 21 on the outer surface 18 of the slips. A first set of inserts 20 is oriented so that they most effectively resist axial forces. Inserts 20 preferably comprise generally cylindrical disks that are mounted with their axes inclined with respect to the tool axis and their faces oriented upward or downward and radially outward to resist axial forces.
As best shown in FIGS. 1 d and 2 , the inserts are inclined with respect to the tool axis and their faces oriented upward or downward and radially outward. The smaller surface area of the insert when so oriented allows for greater penetration into the casing inner wall and thereby improves the resistance to any movement once the slips 10 are set. Wickers milled on slips, as is common in the prior art, are known to penetrate the casing by approximately 0.030″. In contrast, inserts configured as in the present invention can penetrate the casing by more that 0.096″. Increased penetration allows the inserts to better resist axial and torsional loads.
A second set of inserts 21 is also likewise oriented and then rotated 90 degrees in a transverse plane. Thus, the second set of inserts 21 is configured to most effectively resist torsional forces. As will be readily recognized by one skilled in the art, degrees of rotation between the first set of inserts 20 and the second set of inserts 21 need not be 90 degrees and may vary without departing from the spirit of the inventions. However, in the preferred embodiment of this invention, the first and second set of inserts 20 , 21 are rotated by at least 45 degrees in a transverse plane. In the most preferred embodiment, the inserts are rotated about 90 degrees in a transverse plane.
In the embodiment illustrated in FIG. 2 , the first set of inserts 20 are configured to resist both upward and downward axial forces. Inserts 20 a are inclined with respect to the tool axis and their faces oriented upward and radially outward such that they are most resistant to upward axial forces. The faces of inserts 20 b are oriented downward such that they are most resistant to downward axial forces.
Similarly, the second set of inserts 21 is configured to resist both clockwise and counterclockwise torsional forces. Inserts 21 a are oriented such that they best resist clockwise rotational forces. Inserts 21 b are oriented such that they best resist counterclockwise torsional forces.
In the preferred embodiment, the inserts are carbide discs; however, one skilled in the art will recognize that the inserts may be constructed from a variety of materials, including tungsten carbide, diamond, or carbonized steel. In the preferred embodiment, the inserts may be constructed of any material that is harder than the material used in common casing so that the inserts can easily bite into the casing wall.
As is also shown in FIG. 2 , the inserts 20 are inserts that are generally cylindrical in shape. While a preferred configuration for the inserts is shown, it will be understood that any insert shape can be used. One skilled in the art will recognize that inserts of other geometric shapes, such are cubes, triangular or rectangular shapes may also be used as the insert of the rotational resistant slip mechanism.
As shown in FIG. 3 , one preferred embodiment of a tool utilizing the rotational resistant slip mechanism comprises six slip mechanisms arranged at 60 degree intervals on the tool so as to create a “full circle” of slip members 10 . The under faces of the slips are keyed to the remaining parts of the tool. Alternative embodiments may include various numbers of slips. For example, FIG. 4 a shows an embodiment of the present invention where eight slips are utilized. However, it is preferred that regardless the number of slips, the slips are configured or otherwise sized to create a “full circle” around the tool mandrel.
The foregoing detailed description has been given for understanding only and no unnecessary limitations should be understood there from as some modifications will be obvious to those skilled in the art without departing from the scope and spirit of the apparatus.
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A well bore tool with a torsional resistant slip mechanism for resisting axial and torsional forces comprising a mandrel, a plurality of slips disposed about the circumference of the mandrel. The slips include a plurality of inserts oriented to resist axial forces and torsional forces. The tool also comprises a setting means adjacent each to slip for radially expanding and setting said slips.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application 60/376,095, filed on Apr. 26, 2002, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to novel 2-(quinolonyl)-fused heterocyclyl derivatives, pharmaceutical compositions containing said derivatives and their use in the treatment of disorders and conditions modulated by the androgen receptor. More particularly, the compounds of the present invention are useful in the treatment of prostate carcinoma, benign prostatic hyperplasia (BPH), hisiutism, alopecia, anorexia nervosa, breast cancer, acne, AIDS, cachexia, as a male contraceptive, and as a male performance enhancer.
BACKGROUND OF THE INVENTION
[0003] Androgens are the anabolic steroid hormones of animals, controlling muscle and skeletal mass, the maturation of the reproductive system, the development of secondary sexual characteristics and the maintenance of fertility in the male. In women, testosterone is converted to estrogen in most target tissues, but androgens themselves may play a role in normal female physiology, for example, in the brain. The chief androgen found in serum is testosterone, and this is the effective compound in tissues such as the testes and pituitary. In prostate and skin, testosterone is converted to dihydrotestosterone (DHT) by the action of 5α-reductase. DHT is a more potent androgen than testosterone because it binds more strongly to the androgen receptor.
[0004] Like all steroid hormones, androgens bind to a specific receptor inside the cells of target tissues, in this case the androgen receptor. This is a member of the nuclear receptor transcription factor family. Binding of androgen to the receptor activates it and causes it to bind to DNA binding sites adjacent to target genes. From there it interacts with coactivator proteins and basic transcription factors to regulate the expression of the gene. Thus, via its receptor, androgens cause changes in gene expression in cells. These changes ultimately have consequences on the metabolic output, differentiation or proliferation of the celll that are visible in the physiology of the target tissue.
[0005] Although modulators of androgen receptor function have been employed clinically for some time, both the steroidal (Basaria, S., Wahlstrom, J. T., Dobs, A. S., J. Clin Endocrinol Metab (2001), 86, pp5108-5117; Shahidi, N. T., Clin Therapeutics, (2001), 23, pp1355-1390), and non-steroidal (Newling, D. W., Br. J. Urol., 1996, 77 (6), pp 776-784) compounds have significant liabilities related to their pharmacological parameters, including gynecomastia, breast tenderness and hepatoxicity. In addition, drug-drug interactions have been observed in patients receiving anticoagulation therapy using coumarins. Finally, patients with aniline sensitivities could be compromised by the metabolites of non-steroidal antiandrogens.
[0006] Non-steroidal agonists and antagonists of the androgen receptor are useful in the treatment of a variety of disorders and diseases. More particularly, agonists of the androgen receptor could be employed in the treatment of prostate cancer, benign prostatic hyperplasia, hirsutism in women, alopecia, anorexia nervosa, breast cancer and acne. Antagonists of the androgen receptor could be employed in male contraception, male performance enhancement, as well as in the treatment of cancer, AIDS, cachexia, and other disorders.
[0007] Edwards, et.al., in WIPO publication WO97/49709 and U.S. Pat. No. 6,017,924 disclose non-steroidal compounds that are high affinity, high selectivity modulators for androgen receptors.
[0008] Jones, et.al., in U.S. Pat. No. 5,696,130 disclose tricyclic, non-steroidal compounds that are high affinity, high selectivity modulators for androgen receptors.
[0009] Jones et. al., in WIPO publication WO95/11215 and U.S. Pat. No. 5,677,336 disclose non-steroid androgen receptor antagonists.
[0010] Friebe et. al., in WIPO publication WO95/02588 and U.S. Pat. No. 5,716,983 disclose coumarins and carbostyrils as PLA 2 inhibitors.
[0011] Gaster et. al., in WIPO publication WO99/31086 disclose quinolinepiperazine and quinolinepiperidine derivatives and their use as combined 5-HT1A, 5-HT1b and 5-HT1D receptor antagonists, useful in the treatment of CNS disorders.
[0012] More recently, Higuchi et al., in WIPO publication WO01/16139 disclose non-steroidal compounds that are modulators of androgen receptors.
[0013] Nonetheless, there exists a need for small molecule, non-steroidal antagonists of the androgen receptor. We now describe a novel series of (2-quinolonyl)-fused heterocyclic derivatives as androgen receptor modulators.
SUMMARY OF THE INVENTION
[0014] The present invention is directed to a compound of formula (Ia)
[0015] wherein
[0016] R 1 is selected from the group consisting of hydrogen, alkyl, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl and alkoxycarbonyl;
[0017] R 2 is selected from the group consisting of hydrogen, halogen and alkyl;
[0018] R 3 is selected from the group consisting of hydrogen and fluorinated alkyl;
[0019] R 3a is absent or hydroxy;
[0020] [0020] represents an optional double bond; (such that when R 3a is absent, the double bond extends from the carbon atom of the ring bound to R 2 to the carbon atom of the ring bound to R 3 );
[0021] R 4 and R 5 are taken together with the carbon atoms to which they are bound to form a five to eight membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group;
[0022] R 6 and R 7 are each independently selected from the group consisting of hydrogen, halogen, hydroxy, carboxy, alkyl, halogenated alkyl, alkoxy, alkoxycarbonyl, alkyl-C(O)—O—, alkyl-C(O)—, alkyl-C(O)—NH—, carboxamide, formyl, cyano, mercapto, thioalkyl, nitro, amino, alkylamino and dialkylamino;
[0023] provided that when R 1 is hydrogen, R 2 is hydrogen, R 3 is hydrogen, R 3a is absent, represents a double bond, R 6 is hydrogen, R 7 is hydrogen and R 4 and R 5 are taken together with the carbon atoms to which they are bound to form a heterocyclyl group, said heterocyclyl group is not 3,5-dioxin-1-yl, wherein the 3,5-dioxin-1-yl is optionally substituted with one to two alkyl groups;
[0024] provided further that when R 1 is hydrogen, R 2 is hydrogen, R 3 is hydrogen, R 3a is absent, represents a double bond, R 6 is hydrogen, R 7 is hydrogen and R 4 and R 5 are taken together with the carbon atoms to which they are bound to form a heterocyclyl group, said heterocyclyl group is not 4H-imidazolyl, wherein the 4H-imidazolyl is optionally substituted with one to two alkyl groups;
[0025] or a pharmaceutically acceptable salt, ester or prodrug thereof.
[0026] The present invention is further directed to a compound of formula (Ib)
[0027] wherein
[0028] R 1 is selected from the group consisting of hydrogen, alkyl, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl and alkoxycarbonyl;
[0029] R 2 is selected from the group consisting of hydrogen, halogen and alkyl;
[0030] R 3 is selected from the group consisting of hydrogen and fluorinated alkyl;
[0031] R 3a is absent or hydroxy;
[0032] [0032] represents an optional double bond; (such that when R 3a is absent, the double bond extends from the carbon atom of the ring bound to R 2 to the carbon atom of the ring bound to R 3 );
[0033] R 4 and R 5 are each independently selected from the group consisting of hydrogen, halogen, hydroxy, carboxy, alkyl, halogenated alkyl, alkoxy, alkoxycarbonyl, alkyl-C(O)—O—, alkyl-C(O)—, alkyl-C(O)—NH—, carboxamide, formyl, cyano, mercapto, thioalkyl, nitro, amino, alkylamino and dialkylamino;
[0034] R 6 and R 7 are taken together with the carbon atoms to which they are bound to form a five to eight membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group;
[0035] provided that when R 1 is hydrogen, R 2 is hydrogen, R 3 is tifluoromethyl, R 3 a is absent, represents a double bond, R 4 is hydrogen, R 5 is alkoxy, and R 6 and R 7 are taken together with the carbon atoms to which they are bound to form a heterocyclyl group, said heterocyclyl group is not 2,4-dioxol-1-yl;
[0036] or a pharmaceutically acceptable salt, ester or prodrug thereof.
[0037] The present invention is further directed to a compound of formula (Ic)
[0038] wherein
[0039] R 2 is selected from the group consisting of hydrogen, halogen and alkyl;
[0040] R 3 is selected from the group consisting of hydrogen and fluorinated alkyl;
[0041] R 3a is absent or hydroxy;
[0042] [0042] represents an optional double bond; (such that when R 3a is absent, the double bond extends from the carbon atom of the ring bound to R 2 to the carbon atom of the ring bound to R 3 );
[0043] R 4 , R 5 and R 6 are each independently selected from the group consisting of hydrogen, halogen, hydroxy, carboxy, alkyl, halogenated alkyl, alkoxy, alkoxycarbonyl, alkyl-C(O)—O—, alkyl-C(O)—, alkyl-C(O)—NH—, carboxamide, formyl, cyano, mercapto, thioalkyl, nitro, amino, alkylamino and dialkylamino;
[0044] R 7 and R 1 are taken together with the carbon atoms to which they are bound to form a five to eight membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group;
[0045] or a pharmaceutically acceptable salt, ester or prodrug thereof.
[0046] 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.
[0047] Exemplifying the invention are methods of treating disorders and conditions modulated by the androgen receptor 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.
[0048] An example of the invention is a method for treating an androgen receptor modulated disorder selected from the group consisting of prostate carcinoma, benign prostatic hyperplasia, hirsutism, or for male contraception, in a subject in need thereof comprising administering to the subject an effective amount of any of the compounds or pharmaceutical compositions described above.
[0049] Another example of the invention is the use of any of the compounds described herein in the preparation of a medicament for treating: (a) prostate carcinoma, (b) benign prostatic hyperplasia, (c) hirsutism, (d) alopecia, (e) anorexia nervosa, (f) breast cancer, (g) acne, (h) AIDS, (i) cachexia, for (j) male contraception, or for (k) male performance enhancement, in a subject in need thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0050] The present invention is directed to compounds of formula (I)
[0051] wherein R 1 , R 2 , R 3 , R 3a R 4 , R 5 , R 6 and R 7 are as herein defined, useful for the treatment of disorders and conditions modulated by the androgen receptor.
[0052] More particularly, the present invention is directed to compounds of formula (I) wherein one of (R 4 and R 5 ) or (R 6 and R 7 ) or (R 7 and R 1 ) are taken together with the carbon atoms to which they are bound to form a five to eight membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group.
[0053] More particularly, The present invention is a compound of the formula (Ia)
[0054] wherein R 1 , R 2 , R 3 , R 3a R 6 and R 7 are as previously defined and wherein R 4 and R 5 are taken together with the atoms to which they are bound to form a a five to eight membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group.
[0055] In an embodiment of the present invention is a compound of formula (Iaa)
[0056] wherein
[0057] taken together with the atoms to which it is bound represents a five to six membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group; wherein X and Y are each independently selected from the group consisting of O, N and S; and wherein R 1 , R 2 , R 3 , R 3a R 6 and R 7 are as previously defined.
[0058] The present invention is further directed to a compound of the formula (Ib)
[0059] wherein R 1 , R 2 , R 3 , R 3a R 4 and R 5 are as previously defined and wherein R 6 and R 7 are taken together with the atoms to which they are bound to form a five to eight membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group.
[0060] In an embodiment of the present invention is a compound of formula (Iba)
[0061] wherein
[0062] taken together with the atoms to which it is bound represents a five to six membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group; wherein X and Y are each independently selected from the group consisting of O, N and S; and wherein R 1 , R 2 , R 3 , R 3a R 4 and R 5 are as previously defined.
[0063] The present invention is further directed to a compound of the formula (Ic)
[0064] wherein R 2 , R 3 , R 3a R 4 , R 5 and R 6 are as previously defined and wherein R 7 and R 1 are taken together with the atoms to which they are bound to form a five to eight membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group.
[0065] In an embodiment of the present invention is a compound of formula (Ica)
[0066] wherein
[0067] taken together with the atoms to which it is bound represents a five to six membered, heterocyclyl group containing at least two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen, alkyl, halogenated alkyl, alkoxy, cyano, alkylcarbonyl, alkylsulfonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkoxycarbonyl or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group; wherein X is selected from the group consisting of O, N and S; and wherein R 2 , R 3 , R 3a R 4 , R 5 and R 6 are as previously defined.
[0068] In an embodiment of the present invention R 1 is hydrogen. In another embodiment of the present invention R 2 is hydrogen. In yet another embodiment of the present invention R 5 is hydrogen. In yet another embodiment of the present invention R 6 is hydrogen.
[0069] In an embodiment of the present invention R 3 is halogenated lower alkyl, preferably, R 3 is trifluoromethyl. In an embodiment of the present invention R 3a is absent. In another embodiment R 3a is hydroxy. In an embodiment of the present invention R 3a is absent and represents a double bond which extends from the carbon atom of the ring bound to R 2 to the carbon atom of the ring bound to R 3 . In another embodiment of the present invention R 3a is hydroxy and represents a single double bond which extends from the carbon atom of the ring bound to R 2 to the carbon atom of the ring bound to R 3 .
[0070] In an embodiment of the present invention R 4 is selected from the group consisting of hydrogen, amino, lower alkyl amino or di(lower alkyl)amino. Preferably, R 4 is amino. In another embodiment of the present invention R 7 is selected form the group consisting of hydrogen and lower alkyl. Preferably, R 7 is selected from the group consisting of hydrogen and methyl.
[0071] In an embodiment of the present invention R 4 and R 5 are taken together with the atoms to which they are bound to form a six membered heterocyclyl group containing two heteroatoms selected from the group consisting of O, N and S; wherein the heterocyclyl group is optionally substituted with one to four substituents independently selected from halogen or oxo; provided that when the substituent is oxo, then the substituent is bound to a S atom of the heterocyclyl group. Preferably, R 4 and R 5 are taken together with the atoms to which they are bound to a heterocyclyl group selected from [1,4]-dioxanyl, 2,2,3,3,-tetrafluoro-[1,4]-dioxanyl, thiomorpholinyl, thiomorpholinyl-1,1-dioxide, thiomorpholinyl-1-oxide and morpholinyl.
[0072] In an embodiment of the present invention R 7 and R 1 are taken together with the atoms to which they are bound to form a six membered, heterocyclyl group containing two heteroatoms selected from the group consisting of O, N and S. Preferably, R 1 and R 7 are taken together with the atoms to which they are bound to form thiomorpholinyl or morpholinyl.
[0073] In an embodiment of the present invention R 6 and R 7 are taken together with the carbon atoms to which they are bound to form a heterocyclyl group, wherein said heterocyclyl group is not 2,4-dioxol-1-yl.
[0074] In another embodiment of the present invention R 4 and R 5 are taken together with the carbon atoms to which they are bound to form a heterocyclyl group, wherein said heterocyclyl group is not 3,5-dioxin-1-yl, optionally substituted with one to two alkyl groups.
[0075] In yet another embodiment of the present invention R 4 and R 5 are taken together with the carbon atoms to which they are bound to form a heterocyclyl group, wherein said heterocyclyl group is not 4H-imidazolyl, optionally substituted with one to two alkyl groups.
[0076] Representative compounds of the present invention are compounds of formula (Ia) and (Ic) as listed in Tables 1 and 2. The notation “-” indicates the absence of the R 3a group and the presence of a double bond extending from the carbon atom bound to the R 2 group to the carbon atom bound to the R 3 group, as indicated by the “ ” notation.
TABLE 1 ID # RWJ # R 1 R 3 R 3a R 4 + R 5 R 7 Meas. MW 1 388786 H CF 3 — H 271.2 2 389316 H CF 3 — H 343.2 3 389840 H CF 3 — CH 3 4 393654 H CF 3 OH H 5 394022 H CF 3 — H 286.3 6 394135 H CF 3 — H 318.3 7 394175 H CF 3 — H 8 400494 H CF 3 — H 270.2 13 400215 H CF 3 OH H 288.2
[0077] [0077] TABLE 2 ID # RWJ # R 3 R 3a R 1 + R 7 MW MH + 304.29 10 398196 CF 3 — 286.28 14 402195 CF 3 —
[0078] As used herein, “halogen” shall mean chlorine, bromine, fluorine and iodine.
[0079] As used herein, the term “alkyl” whether used alone or as part of a substituent group, include straight and branched chains comprising one to six 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.
[0080] 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.
[0081] As used herein, unless otherwise noted, “aryl” shall refer to unsubstituted carbocylic aromatic groups such as phenyl, naphthyl, and the like.
[0082] 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. For example, benzyl, phenylethyl, phenylpropyl, naphthylmethyl, and the like.
[0083] 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.
[0084] 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.
[0085] 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.
[0086] As used herein, the term “heterocycloalkyl” shall denote any five to seven membered monocyclic, saturated, partially unsaturated or partially 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 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.
[0087] Examples of suitable heterocycloalkyl 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, [1,4-dioxanyl], and the like. Preferred heterocycloalkyl groups include [1,4]-dioxanyl, morpholinyl, thiomorpholinyl and piperadinyl.
[0088] As used herein, unless otherwise noted, the term “heterocycle” or “heterocyclyl” shall mean any heteroaryl or heterocycloalkyl ring as herein defined.
[0089] As used herein, particularly in the schemes below, the symbol
[0090] shall represent a five to eight membered ring structure wherein X and Y are independently selected from the group consisting of O, N and S. Suitable examples include imidazolidine, oxazolidine, thiazolidine, 1,3-thiolane, 1,3-oxathiolane, 1,3-dioxalane, piperazine, morpholine, thiomorpholine, 1,4-dioxane, 1,4-dithiane, 1,4-oxathiane, [1,4]dioxepane, [1,4]oxazepane, [1,4]oxathiepane, [1,4]diazepane, [1,4]thiazepane, [1,4]dithiepane, [1,4]dioxocane, [1,4]oxazocane, [1,4]oxathiocane, [1,4]diazocane, [1,4]thiazocane, [1,4]dithiocane, and the like.
[0091] As used herein, the notation “*” shall denote the presence of a stereogenic center.
[0092] When a particular group is “substituted” (e.g., 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.
[0093] 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.
[0094] 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
[0095] “phenylalkylaminocarbonylalkyl” substituent refers to a group of the formula
[0096] Unless otherwise noted, wherein R 4 and R 5 or R 6 and R 7 or R 7 and R 1 are taken together with the atoms to which they are bound to form- a ring structure, the ring structure shall be named such that the point of attachment for R 4 , R 5 , R 6 or R 7 , respectively, is numbered as position 1, with the remainder of the ring structure numbered in a clockwise manner. For example, for the compound
[0097] R 6 and R 7 are taken together with the atoms to which they are bound to form 2-thiomorpholinyl, where the numbering is as indicated.
[0098] Abbreviations used in the specification, particularly the Schemes and Examples, are as follows:
DBU = 1,8-Diazabicyclo[5.4.0]undec-7ene DDT = Dithiothreitol DIEA = Diisopropyl ethyl amine DMF = Dimethyl formamide DMSO = Dimethylsulfoxide EDTA = Ethylene Diamine Tetraacetic Acid PEG = Polyethylene glycol TED Buffer = Tris-EDTA-DTT THF = Tetrahydrofuran Tris HCl = Tris[hydroxymethyl]aminomethyl hydrochloride
[0099] 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.
[0100] 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.
[0101] 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.
[0102] The compounds of the present invention may be prepared from known compounds or compounds prepared by known methods. For example, the compounds of formula (I) of the present invention wherein two adjacent R groups (i.e. R 4 and R 5 ; R 6 and R 7 ; or R 7 and R 1 ) are taken together to form a six membered heterocyclyl ring may be prepared from the starting materials labeled (S1) through (S9).
[0103] Compounds of formula (S1), (S2) and (S3) are known compounds.
[0104] Compounds of formula (S4), (S5) and (S6) may be prepared from known compounds by known methods. For example, compounds (S4) and (S6) may be prepared by known methods from 7-amino-4H-benzo[1,4]oxazine-3-one and 6-amino-4H-benzo[1,4]thiazin-3-one, respectively. The compound of formula (S5) may be prepared by known methods from 7-amino-2-methyl-4H-benzo[1,4]thiazin-3-one.
[0105] Compounds of formula (S7), (S8) and (S9) may be prepared from known compounds. For example, the compounds of formula (S7), (S8) and (S9) may be prepared from the corresponding 2,3-dihydro-benzo[1,4]dithiine and 2,3-dihydro-benzo[1,4]oxazthiine, respectively, by nitrating and then reducing the nitro group to the corresponding amine.
[0106] One skilled in the art will recognize that substitution of the heterocyclyl ring portion of any of the compounds of formula (Ia), (Ib) and/or (Ic) may optionally be introduced prior to cyclization of the heterocyclyl protion by known methods.
[0107] Compounds of formula (Ia) and (Ic) may be prepared according to the process outlined in Scheme 1.
[0108] More particularly, a suitably substituted compound of formula (II), a known compound or compound prepared by known methods, is reacted with 1,1,1-trifluoro-heptane-2,4-dione, in an organic solvent such as toluene, xylene, decalin, and the like, in the presence of an organic base such as pyridine, DBU, DIEA, K 2 CO 3 , and the like, to yield a mixture of compounds of formula (III), (IV) and (V), and when Y is N, compound of formula (VI). (Wherein the compound of formula (V) is an intermediate in the preparation of the compound of formula (Ia), a compound of formula (I) wherein R 4 and R 5 are taken together to form a heterocyclyl ring; and wherein Y is N, the compound of formula (VI) is an intermediate in the preparation of the compound of formula (Ic), a compound of formula (I) wherein R 7 and R 1 are taken together to forma heterocyclyl ring.)
[0109] Preferably, the mixture of compounds of formula (III), (IV), (V) and (VI) are separated to yield the desired component.
[0110] One skilled in the art will recognize that compounds of formula (Ia) and (Ic) wherein R 3a is absent may be prepared from the corresponding compound of formula of (Ia) or (Ic) wherein R 3a is hydroxy, by reacting with an acid such as sulfuric acid, hydrochloric acid, and the like. Alternatively, when R 3a is hydroxy group, the hydroxy group may be removed by known dehydration methods.
[0111] One skilled in the art will further recognize that compounds of formula (Ia) and (Ic) wherein R 3 is a halogenated alkyl other than trifluoromethyl may be similarly prepared according to the process outlined above with substitution of an suitably substituted reagent for the 1,1,1-trifluoro-heptane-2,4-dione.
[0112] One skilled in the art will further recognize that compounds of formula (Ia) wherein R 1 , R 6 and/or R 7 are other than hydrogen, and/or compounds of formula (Ic) wherein R 4 , R 5 and/or R 6 are other than hydrogen, may be prepared by known methods, for example by employing a suitably substituted starting material or reagent. Additionally, R 1 groups other than hydrogen may be incorporated into the compound of formula (I) by known methods after formation of the corresponding compound of formula (I) wherein R 1 is hydrogen.
[0113] Compounds of formula (Ib) wherein R 6 and R 7 are taken together to form a six membered heterocyclyl ring, may be prepared according to the process outline in Scheme 2.
[0114] Accordingly, 2-fluoro-1,3-dinitro-5-trifluoromethyl-benzene, a known compound, is reacted with a suitably substituted compound of formula (VII), a known compound or compound prepared by known methods, in the presence of a base such as NaH, K 2 CO 3 , and the like, in an organic solvent such as DMF, DMSO, and the like, to yield the corresponding compound of formula (VIII).
[0115] The compound of formula (VIII) is reduced by known methods, for example, by hydrogenation in the presence of a catalyst such as Pd on Carbon, in an organic solvent such as methanol, ethanol, ethyl acetate, and the like, to yield the corresponding compound of formula (IX).
[0116] The compound of formula (IX) is selectively reduced with a suitable reducing agent such as borane, LiAH, and the like, in an organic solvent such as THF, diethyl ether, and the like, to yield the corresponding compound of formula (X).
[0117] The compound of formula (X) is reacted with 1,1,1-trifluoro-heptane-2,4-dione, in an organic solvent such as toluene, xylene, decalin, and the like, in the presence of an organic base such as pyridine, DBU, DIEA, K 2 CO 3 , and the like, to yield a mixture of the corresponding compound of formula (XI) and the corresponding compound of formula (XII). (Wherein the compound of formula (XII) is a compound of formula (Ib) or an intermediate in the formation of a compound of formula (Ib).)
[0118] Preferably, the compound of formula (XI) and the compound of formula (XII) are separated by known methods.
[0119] One skilled in the art will recognize that compounds of formula (Ib) wherein R 6 and R 7 are taken together to form a six membered heterocyclic ring, other than those described above, may be similarly prepared by known methods, by substitution of suitably substituted reagents of the formula (XIII)
[0120] wherein X and Y are independently selected from O, N and S, for the compound of formula (X) in Scheme 2.
[0121] Compounds of formula (Ib) wherein R 3a is absent may be prepared from the corresponding compound of formula of (Ib) wherein R 3a is hydroxy, by known methods, for example by reacting with an acid such as sulfuric acid, hydrochloric acid, and the like. Alternatively, when R 3a is hydroxy group, the hydroxy group may be removed by known dehydration methods.
[0122] One skilled in the art will further recognize that compounds of formula (Ib) wherein R 3 is a halogentaed alkyl other than trifluoromethyl may be similarly prepared according to the process outlined above with substitution of an suitably substituted reagent for the 1,1,1-trifluoro-heptane-2,4-dione.
[0123] One skilled in the art will further recognize that compounds of formula (Ib) wherein R 1 , R 4 and/or R 5 are other than hydrogen, may be prepared by known methods, for example by employing a suitably substituted starting material or reagent. Additionally, R 1 groups other than hydrogen may be incorporated into the compound of formula (I) by known methods after formation of the corresponding compound of formula (I) wherein R 1 is hydrogen.
[0124] One skilled in the art will recognize that compounds of formula (Ia), (Ib) and/or (Ic) wherein two adjacent R groups (i.e. R 4 and R 5 ; R 6 and R 7 ; or R 7 and R 1 ) are taken together to form a five, seven or eight membered heterocyclyl ring may be prepared according to the process outlined in Scheme(s) 1 and 2, with suitable selected and substitution of compounds of formula (II) and the compound of formula (VII), respectively. For example, the compound of formula (II) may be selected such that the
[0125] portion of the compound of formula (II) is a chain of 4 to 6 atoms. Similarly, the compound of formula (VII) may be chosen such that the —CH 2 — portion of the compound of formula (VII) found between the X and CO 2 portions is replaced with a —CH 2 CH 2 — portion or a —CH 2 CH 2 CH 2 — portion to yield the 7 membered or eight membered group respectively.
[0126] One skilled in the art will further recognize that compounds of formula (Ia), (Ib) and/or (Ic) wherein R 4 and R 5 or R 6 and R 7 or R 7 and R 1 are taken together to form a five membered heterocyclyl group may be similarly prepared from suitably substituted known starting materials, for example, amine substituted benziimidazolyl, benzthiazolyl, and the like.
[0127] The following Examples are set forth to aid in the understanding of the invention, and are not intended and should not be construed to limit in any way the invention set forth in the claims which follow thereafter.
EXAMPLE 1
[0128] 6-Nitro-4H-benzo[1,4]oxazin-3-one
[0129] A suspension of 2-amino-4-nitrophenol (7.7 g, 50 mmol) was prepared in 125 mL chloroform. To this suspension was added benzyltriethylammonium chloride (11.4 g, 50 mmol) and sodium bicarbonate (16.80 g, 200 mmol) and the suspension cooled in an ice bath. A solution of chloroacetyl chloride (4.8 mL, 60 mmol) in chloroform (10 mL) was added. The solution was stirred overnight at room temperature, then refluxed for 3 hours and again let sit overnight at room temperature. The solvent was removed under vacuum and water was added to the residue. The solid was filtered, washed with water, and recrystallized from ethanol. The recrystallized solid was filtered and washed with cold ethanol and then dried, to yield 6-nitro-4-H-benzo[1,4]oxazin-3-one as a solid product. Some additional product precipitated from the ethanol filtrate as a second crop and was recovered by filtration.
[0130] Yield: 5.5 g, 57%
EXAMPLE 2
[0131] 6-Nitro-3,4-dihydro-2H-benzo[1,4]oxazine
[0132] To a suspension of 6-nitro-4-H-benzo[1,4]oxazin-3-one (7.84 g, 40.38 mmol) in tetrahydrofuran (100 mL) was added a solution of 2.0M borane-methyl sulfide complex in tetrahydrofuran (91 mL, 181 mmol). The mixture was heated to reflux for 4.5 hours then allowed to stir overnight at room temperature. Methanol was added slowly to react with unreacted borane-methyl sulfide complex, which resulted a violent evolution of gas. When this subsided, excess methanol was added and the solution heated to reflux. After 2 hours the solution was cooled, the solvent evaporated under vacuum, and the residue triturated with ethyl acetate/hexane. An orange solid was filtered off which was rinsed with hexane, to yield 6-nitro-3,4-dihydro-2H-benzo[1,4]oxazine as a solid product. More of the solid was recovered as a second crop from the filtrate.
[0133] Yield: 5.6 g, 77%
EXAMPLE 3
[0134] 3,4-Dihydro-2H-benzo[1,4]oxazin-6-ylamine
[0135] A solution of 6-nitro-3,4-dihydro-2H-benzo[1,4]oxazine (1.8 g, 10.0 mmol) in methanol (150 mL) was hydrogenated on a Parr hydrogenator for 6 hours with 10% palladium on carbon (1.06 g) as a catalyst. The reaction mixture was filtered through Celite to remove the catalyst and the Celite rinsed with methanol. The filtrate was evaporated under vacuum to yield 3,4-dihydro-2H-benzo[1,4]oxazin-6-yl amine as a solid product.
[0136] Yield: 1.48 g, 99%
EXAMPLE 4
[0137] 5-Hydroxy-5-trifluoromethyl-3,4,5,8-tetrahydro-2H,6H-1-oxa-4,8-diaza-phenanthren-7-one
[0138] 7-amino-6-hydroxy-6-trifluoromethyl-2,3,5,6-tetrahydro-1-oxa-3a-aza-phenalen-4-one
[0139] 6-ethoxy-8-trifluoromethyl-3,4-dihydro-2H-1-oxa-4,5-diaza-anthracene
[0140] To a solution of 3,4-dihydro-2H-benzo[1,4]oxazin-6-yl amine (0.56 g, 3.73 mmol) in toluene (20 mL) was added ethyl 4,4,4-trifluoroacetoacetate (0.55 mL, 3.73 mmol) and 4 drops of pyridine. The solution was heated to reflux for 6 hours, then allowed to stir overnight at room temperature. The solvent was removed under vacuum and the residue triturated with diethyl ether. The solid was filtered off and washed with diethyl ether to yield a gray solid which was determined by 1 HNMR to contain crude N-(3,4-dihydro-2H-benzo[1,4]oxazin-6-yl)-4,4,4-trifluoro-3-oxo-butyramide. The rest of the material in the filtrate was also determined by 1 HNMR to be crude N-(3,4-dihydro-2H-benzo[1,4]oxazin-6-yl )-4,4,4-trifluoro-3-oxo-butyramide, but much less pure than the gray solid filtered off. The mixture was recovered by evaporating the ether. This mixture (0.8 g) was stirred in of concentrated sulfuric acid (8 mL) overnight at room temperature. The reaction mixture was then poured onto ice and neutralized by adding 1N sodium carbonate. The resulting solution was extracted three times with ethyl acetate, the extracts dried over magnesium sulfate, filtered and evaporated under vacuum to yield a brown oil. The brown oil (crude material) was purified by column chromatography on a Biotage system eluting with 4% methanol/ethyl acetate to yield 8-trifluoromethyl-3,4-dihydro-2H,5H-1-oxa-4,5-diaza-anthracen-6-one as the main product.
[0141] Yield: 67 mg, 9% (RWJ-392715)
[0142] linear, MH + =289
[0143] Some early, impure fractions were purified again by chromatography eluting with 20% ethyl acetate/hexane to yield:
[0144] (a) 6-ethoxy-8-trifluoromethyl-3,4-dihydro-2H-1-oxa-4,5-diaza-anthracene
[0145] Yield: 24.3 mg, 3%, MH + =299
[0146] (b) 5-hydroxy-5-trifluoromethyl-3,4,5,8-tetrahydro-2H,6H-1-oxa-4,8-diaza-phenanthren-7-one
[0147] Yield: 230 mg, 29%
[0148] (c) mixture of 7-amino-6-hydroxy-6-trifluoromethyl-2,3,5,6-tetrahydro-1-oxa-3a-aza-phenalen-4-one and 5-hydroxy-5-trifluoromethyl-3,4,5,8-tetrahydro-2H,6H-1-oxa-4,8-diaza-phenanthren-7-one
[0149] Yield: 0.2 g, 25%
EXAMPLE 5
[0150] 5-Trifluoromethyl-3,4-dihydro-2H,8H-1-oxa-4,8-diaza-phenanthrene-7-one
[0151] A solution of 5-hydroxy-5-trifluoromethyl-3,4,5,8-tetrahydro-2H,6H-1-oxa-4,8-diaza-phenanthren-7-one compound in concentrated sulfuric acid (3 mL) was prepared and allowed to stir overnight, then heated to 140° C. for 2 hours. The solution was added to ice, neutralized with 1M sodium carbonate, and extracted 3 times with ethyl acetate. The organic extracts were dried over magnesium sulfate, filtered, and the filtrate evaporated under vacuum to yield 5-trifluoromethyl-3,4-dihydro-2H,8H-1-oxa-4,8-diaza-phenanthren-7-one as a yellow solid.
[0152] Yield: 0.16 g, 84%
[0153] MH + =271
EXAMPLE 6
[0154] 7-Amino-6-trifluoromethyl-2,3-dihydro-1-oxa-3a-aza-phenalen-4-one
[0155] 5-Trifluoromethyl-3,4-dihydro-2H,8H-1-oxa-4,8-diaza-phenanthren-7-one
[0156] Impure 7-amino-6-hydroxy-6-trifluoromethyl-2,3,5,6-tetrahydro-1-oxa-3a-aza-phenalen-4-one (0.2 g) was heated to 140° C. for 1.5 hours then stirred at room temperature overnight. The reaction mixture was poured onto ice, made basic with 1M sodium carbonate, extracted three times with ethyl acetate, dried the organic extracts over magnesium sulfate, filtered, evaporated to a yellow solid. The yellow solid (crude material) was purified using the Biotage 40S system eluting with 30% ethyl acetate/hexane to yield 7-amino-6-trifluoromethyl-2,3-dihydro-1-oxa-3a-aza-phenalen-4-one
[0157] Yield: 37.2 mg, 20%
[0158] MH + =271
[0159] and when eluted with 50% ethyl acetate/hexane to yield 5-trifluoromethyl-3,4-dihydro-2H,8H-1-oxa-4,8-diaza-phenanthren-7-one
[0160] Yield: 80 mg, 42%
EXAMPLE 7
[0161] (2,4-Dinitro-phenylsulfanyl)-acetic acid ethyl ester
[0162] A solution of 2,4-dinitrofluorobenzene (15.7 mL, 124.8 mmol) in tetrahydrofuran (32 mL) was prepared. To this solution, triethylamine (17.4 mL, 124.8 mmol) was added and the solution cooled in an ice bath. To the solution was then added a solution of ethyl 2-mercaptoacetate (15 g, 124.8 mmol) in tetrahydrofuran (10 mL) slowly, dropwise. The reaction mixture was allowed to warm to room temperature overnight under nitrogen atmosphere. The solution was then poured onto 200 mL of ice and stirred until the ice melted. The resulting solution was extracted twice with ethyl acetate and the organic layers were washed with water, brine, and dried over magnesium sulfate. The magnesium sulfate was filtered off and the filtrate evaporated under vacuum to yield a brown oil. The oil was triturated with hexane and a small amount of diethyl ether. A sticky solid was filtered off and then washed with hexane to yield (2,4-dinitro-phenylsulfanyl)-acetic acid ethyl ester.
[0163] Yield: 37.2 g
EXAMPLE 8
[0164] 6-Amino-4H-benzo[1,4]thiazin-3-one
[0165] A mixture of iron (30.2 g, 540 mmol), glacial acetic acid (2 mL), and water (40 mL) was prepared in a 500 mL 3-necked round bottom flask equipped with a dropping funnel and an overhead stirrer. A solution of (2,4-dinitro-phenylsulfanyl)-acetic acid ethyl ester (11.79 g, 41.2 mmol) in glacial acetic acid (40 mL) and ethyl acetate (40 mL) was added dropwise. After addition the dropping funnel was replaced with a condenser and the solution heated at 80° C. for 3.5 hrs, then allowed to stir overnight at room temperature. The mixture was filtered through Celite and the Celite washed with ethyl acetate and water. The layers were separated in a separatory funnel and the aqueous layer extracted twice with ethyl acetate. The organic layers were washed with water, twice with saturated sodium bicarbonate, then dried over magnesium sulfate, filtered, and evaporated under vacuum to yield a 6-amino-4H-benzo[1,4]thiazin-3-one as a brown solid.
[0166] Yield: 3.9 g, 52%
EXAMPLE 9
[0167] 3,4-Dihydro-2H-benzo[1,4]thiazin-6-ylamine
[0168] A solution of 6-amino-4H-benzo[1,4]thiazin-3-one (1.95 g, 10.82 mmol) in 50 mL tetrahydrofuran (50 mL) was prepared. To this solution was added 2M borane-dimethyl sulfide complex (24 mL) in tetrahydrofuran (24 mL, 48.69 mmol). The solution was heated at reflux under a nitrogen atmosphere for 5 hours, then cooled to room temperature overnight. Methanol was added in portions to quench unreacted borane-dimethyl sulfide complex. The solution was then refluxed for 0.5 hrs. The solvent was removed under vacuum and the residue purified by column chromatography eluting with 20, 40, and 60% ethyl acetate/hexane. The cleanest fractions containing product were collected to yield 3,4-dihydro-2H-benzo[1,4]thiazin-6-ylamine as a green oil.
[0169] Yield: 1.0 g, 58%
EXAMPLE 10
[0170] 5-Hydroxy-5-trifluoromethyl-3,4,5,8-tetrahydro-2H,6H-1-thia-4,8-diaza-phenanthren-7-one
[0171] 8-hydroxy-8-trifluoromethyl-3,4,7,8-tetrahydro-2H,5H-1-thia-4,5-diaza-anthracen-6-one
[0172] A solution of 3,4-dihydro-2H-benzo[1,4]thiazin-6-ylamine (0.95 g, 5.72 mmol), ethyl 4,4,4-trifluoroacetoacetate (0.84 mL, 5.72 mmol), and 4 drops of pyridine in 20 mL of toluene was prepared and then heated to reflux. Some solid was observed to precipitate out of solution. After 5 hours, the reaction mixture was cooled and the solvent evaporated under vacuum. The material was purified using the Biotage system eluting with 50% and 75% ethyl acetate/hexane to yield two products: 5-hydroxy-5-trifluoromethyl-3,4,5,8-tetrahydro-2H,6H-1-thia-4,8-diaza-phenanthren-7-one
[0173] Yield: 0.72 g
[0174] MH + =305
[0175] and 8-hydroxy-8-trifluoromethyl-3,4,7,8-tetrahydro-2H,5H-1-thia-4,5-diaza-anthracen-6-one
[0176] Yield: 80 mg
[0177] MH + =305
EXAMPLE 11
[0178] 5-Trifluoromethyl-3,4-dihydro-2H,8H-1-thia-4,8-diaza-phenanthren-7-one
[0179] The dehydration of 5-hydroxy-5-trifluoromethyl-3,4,5,8-tetrahydro-2H,6H-1-thia-4,8-diaza-phenanthren-7-one (69 mg, 0.23 mmol) was carried out in concentrated sulfuric acid at 150° C. The solution was cooled to about rrom temperature, added to ice water, made basic with 1M sodium carbonate, extract with ethyl acetate three times, the organic layers washed with brine, dried over sodium sulfate, filtered and the filtrate evaporated to yield 5-trifluoromethyl-3,4-dihydro-2H,8H-1-thia-4,8-diaza-phenanthren-7-one as a green solid.
[0180] Yield: quantitative yield
[0181] MNa + =309
EXAMPLE 12
[0182] 5-Hydroxy-1,1-dioxo-5-trifluoromethyl-1,3,4,5,6,8-hexahydro-2H-1λ 6 -thia-4,8-diaza-phenanthren-7-one
[0183] A solution of 5-trifluoromethyl-3,4-dihydro-2H,8H-1-thia-4,8-diaza-phenanthren-7-one (0.16 g, 0.559 mmol) was prepared by dissolving it in methanol (20 mL) and dichloromethane (2 mL). To this solution was added oxone (1.03 g, 1.677 mmol) dissolved in a minimal amount of water. The solution became cloudy so a small amount of THF was added and the mixture was allowed to stir overnight at room temperature. The solution was evaporated under reduced pressure. Ethyl acetate was then added to the residue. The solution was washed twice with water, dried over magnesium sulfate, filtered, and concentrated under reduced pressure. The material was purified using the Biotage 40S system eluting with 60% and 70% ethyl acetate/hexane to yield 5-hydroxy-1,1-dioxo-5-trifluoromethyl-1,3,4,5,6,8-hexahydro-2H-1λ 6 -thia-4,8-diaza-phenanthren-7-one as a yellow solid.
[0184] Yield: 0.11 g, 61%
[0185] MH + =319.
EXAMPLE 13
[0186] In Vitro Assay—Androgen Receptor Filtration Binding Assay
[0187] The assay was run on a 96 well plate with each well filled with total reaction volume 150 μL, of a solution containing 5 pmol androgen receptor LBD (Panvera) or 30L of freshly prepared rat cytosol, 0.5 nM [ 3 H] R1881 tracer (NEN), 1.5 μL (10 μM) test compound or vehicle (diluted in 30% DMSO, final concentration of DMSO 0.75%) and 150 μL of TED buffer. (TED buffer contains 10 mM Tris.HCl pH 7.4, 1 mM sodium molybdate (60 mg/250 mL), 1.5 mM EDTA, 1 mM DTT and 10% (v/v) glycerol.)
[0188] On day one, the solution containing receptor, tracer and TED buffer was distributed onto a 96 well plate. Diluted test compound or control vehicle was then added to individual wells and the plate incubated ay 4° C. overnight.
[0189] On day two, to each well was then added 20 μL human γ-globulin (ICN 823102), prepared at 25 mg/ml in TE pH 8.0 and 55 μL 40% polyethylene glycol 8000 (JT Baker U222-08), prepared in TE pH 8.0. The plate was incubated at 4° C. for 60 minutes. During incubation, the harvester was rinsed with 10% PEG 8000, prepared in TE pH 8.0 and the GF/C Unifilter-96 prewet with 10% PEG. The binding reaction was filtered, the retentate was washed three times with 10% PEG and dried under vacuum for about four minutes, then dried at 50° C. for 5 min and then bottom sealed. 25 μL of Microscint-20 (Packard) was added to the filter wells and top sealed. The plate wells were then counted on a TopCount (Packard).
[0190] Representative compounds of the present invention were tested for binding to the androgen receptor according to the procedure described above with results as listed in Table 3. % Inhibition values less that 0% indicate no binding at the 1 μM level. The negative number(s) are a result of experimental error from the low number of counts detected.
TABLE 3 Androgen Receptor Binding Results Binding % Inhibition ID # (μM)* @ 1 μM** 1 5.2 2 4.8 3 0.5% 4 14% 5 7.2 6 63 7 17% 8 12 9 83 10 24 13 −19% 14 −18%
[0191] 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 2-(quinolonyl)-fused heterocyclyl derivatives of the general formula (I)
wherein R 1 , R 2 , R 3 , R 3a , R 4 , R 5 , R 6 and R 7 are as herein defined, pharmaceutical compositions containing them and their use in the treatment of disorders and conditions modulated by the androgen receptor.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to cryptography and, more particularly, to the secure transmission of messages between parties using non-secure communication channels.
[0003] 2. Description of the Prior Art
[0004] Cryptographic systems are widely used to ensure the privacy of messages communicated over insecure channels. Such systems prevent the extraction of information by unauthorized parties from messages transmitted over insecure channels, thus assuring the sender that a transmitted message is being read only by the intended recipient.
[0005] Two distinct classes of cryptographic methods and protocols are widely used, symmetric-key cryptography and public-key cryptography. In symmetric-key techniques, the same key and cryptographic method are used by both the encoding party for sending the message and by the receiving party for decoding the message. The security of symmetric-key protocols is based on the secrecy of the required key and the strength of the cryptographic method. The message can be properly decoded by the receiving party only if the transmitting party and the receiving party possess the identical key used for encoding the message.
[0006] For conventional public-key key techniques such as those pioneered by Diffie and Hellman, there are two keys, a public key to which anyone can gain access and with which a plaintext message is encrypted, and a private key that only the recipient possesses and with which the encrypted message is decrypted. The security of public key protocols relies on the considerable difficulty of determining the private key by analyzing the public key. Such computational difficulty is essentially inherent in most public key processes making them considerably slower than symmetric-key protocols even for the recipient who possesses the private key. Chang has devised protocols for the exchange (or simultaneous creation) of cryptographic keys similar to the broadcast-and-response processes of public-key techniques. These key exchange techniques appear to be fully secure but simply create cryptographic keys for subsequent use by other cryptographic systems; they do not allow for the direct transmission of agent-created messages.
[0007] Mechanical systems exist which are analogous to symmetric-key and public-key systems. For the symmetrical-key process, the mechanical analogy is a locked box carried between the two parties where each party has previously obtained a copy of the key that opens the box. The first, transmitting party unlocks and opens the box, places the message inside, relocks the box and sends it to the second, receiving party who then unlocks the box and removes the message. The public-key process resembles an unlocked box and open lock with a special locking-only key left in a public place. The locking-only key is available for public inspection and analysis. Any interested, transmitting party may place a message in the box, close the lock, and secure the lock with the locking-only key; only the box's recipient owner will be able to unlock the lock with a different unlocking-only key, open the box, and remove the message.
[0008] A third mechanical analogy demonstrates the processes of the claimed invention. In it, a first party places a message in a box, locks it, and sends it to the intended recipient. The recipient places a second lock on the box and returns it to the original sender. The first party then removes the first lock from the doubly locked box and sends the still singly locked box to the intended recipient a final time. The recipient then removes the second lock, opens the box, and retrieves the message. This is the essence of the so-called three-pass protocol. Neither party shares a key to the box, differentiating this process from the symmetric-key process, and the keys to the box are never available for public inspection and analysis, differentiating this process from the public-key processes. This three-pass protocol as utilized in the claimed invention represents a third distinct class of encryption techniques that could best be described as independent-key processes, since neither party possesses nor shares a key with the other party.
[0009] In the context of modern cryptography, Schneier describes the three-pass process as a public-key system and attributes the protocol to Shamir. A primary limitation of the three-pass protocol has been the ability of an eavesdropping third party to use the three transmitted encrypted messages to “crack the code” and derive the original plaintext message. Schneier demonstrates that even otherwise secure symmetric key protocols such as one-time pads are not secure in a three-pass process. Shamir (concurrently with Omura) devised an encryption algorithm for the three-pass protocol using an RSA-like factoring algorithm as the key mechanism. Others have used the three-pass protocol as well; for example, Massey devised a key mechanism based on GF(2 m ) finite fields. Both implementations use key processes that are computationally difficult—like conventional public-key methods—but not fully secure.
[0010] The claimed invention uses the three-pass protocol and creates cryptographic processes that are fully secure while requiring no cryptographic key exchange. The processes of the invention are differentiated from the previous, public-key-like, three-pass protocols. The technique of the invention is designated as an independent-key process.
SUMMARY AND OBJECTS OF THE INVENTION
[0011] One object of the invention is to provide a fully secure cryptographic technique for maintaining privacy of messages conveyed or transmitted over non-secure channels while requiring no exchange of any cryptographic keys, either public or private.
[0012] Accordingly, it is another object of this invention to allow two parties to the communication of a message to exchange the message privately even though another party (an eavesdropper) intercepts all of their communications.
[0013] Another object of this invention is to provide for the fully secure exchange of messages—including cryptographic keys—between two parties even when the communication is transmitted over non-secure channels.
[0014] Another object of this invention is to provide for a message exchange protocol that is fully secure against all but a brute force cryptanalysis attack.
[0015] Another object of this invention is to provide for a fully secure message exchange protocol that is faster than most, if not all, present protocols that do not require each party to share identical encryption/decryption keys.
[0016] Briefly, for two parties desiring the private communication of a plaintext message (P)—the first, transmitting party (T) and the second, receiving party (R)—three encrypted messages (C 1 , C 2 , and C 3 ) are created and communicated between the parties to generate the fully secure transmission of the initial message P.
[0017] The first party T chooses two distinct transformation processes (α and β) and key elements for those processes with characteristics such that the plaintext message P may be embodied in the output of the transformation process α, the transformation process β can be readily reversed, and the composite transformation of the operation of the transformation process β on the output of the process α embodying message P cannot be reversed. The first encrypted message C, is created as the output of the operation of the transformation process β on the output of the process α embodying P and is transmitted by the first party T over a non-secure channel to the second party R. The steps taken by the first party T in creating the first encrypted message C 1 are represented as follows:
α(P) The result of the transformation α embodies P β′ exists The transformation β can be reversed where β′ represents the reverse transformation of β β(α(P))′ does not exist The composite process of the transformation β acted on the transformation α can not be reversed C 1 β(α(P)) The encrypted message C 1 is assigned the composite result of the transformation β acted on the transformation α
[0018] Reversal of a transformation is taken to mean that given the specific characteristics of the transformation and a specific output of that transformation, the corresponding inputs to the transformation can be derived. Transformations that cannot be reversed are those for which even when given the specific characteristics of the transformation and a specific output of that transformation, the corresponding inputs to the transformation cannot be derived. For the purpose of the invention, transformations may include but are not limited to mathematical functions and their equivalents. For transformations consisting of mathematical functions, the process of reversing the transformations is known as inverting the functions. In general, the transformations referenced herein may exhibit a more limited or more expansive set of properties than those distinctly attributed to mathematical functions.
[0019] Upon receipt of the first encrypted message C 1 , the second party R chooses a distinct transformation processes (γ) and key elements for that process with characteristics such that the transformation process γ can be readily reversed and the composite transformation of the operation of the transformation process γ on the received encrypted message C 1 cannot be reversed. The second encrypted message C 2 is created as the output of the operation of the transformation process γ on the received encrypted message C 1 and is transmitted by the second party R over a non-secure channel back to the first party T. The steps taken by the second party R in creating the second encrypted message C 2 are represented as follows:
γ′ exists The transformation γ can be reversed where γ′ represents the reverse transformation of γ γ (C 1 )′ does not exist The composite result of the transformation γ acted on the first encrypted message C 1 cannot be reversed C 2 γ (C 1 ) The encrypted message C 2 is assigned the composite result of the transformation γ acted on the first encrypted message C 1
[0020] Upon receipt of the second encrypted message C 2 , the first party T reverses the second of the first two transformation processes β using the reversal process that is known to exist according to the initial choice of that transformation. The third and final encrypted message C 3 is created as the output of the operation of the reverse transformation process β′ on the received encrypted message C 2 and is transmitted by the first party T over a non-secure channel back to the second party R. The steps taken by the first party T in creating the third encrypted message C 3 are represented as follows:
C 3 β′ (C 2 ) The encrypted message C 3 is assigned the composite result of the reverse transformation β′ acted on the second encrypted message C 2
[0021] Following the reversal transformation β′, the third encrypted message C 3 represents the composite output of the operation of the transformation process γ on the output of the process α embodying message P.
[0022] A key characteristic of the transformation processes β and γ for the protocol is the requirement of viable reverse transformations that are independent of the order of the reversal operations. That is, the composite result of the second encrypted message C 2 is the culmination of all three transformation processes α, β, and γ, and it must be the case that the transformations β and γ can be reversed and applied to C 2 —in any order—to yield the sole result of the first transformation α alone. For mathematical functions, this condition is essentially equivalent to the commutative property. This key characteristic allows the operation of β on α in creating C 1 to be reversed as β′ in the creation of C 3 even though the intervening transformation of γ has been applied. The invention identifies and applies transformations that make such order-independent reversal possible.
[0023] Another constraint of the choice of the transformation process γ is that the composite transformation that is the result of the operation of the transformation process γ remaining in the output C 3 after the reversal of β has been applied to C 2 cannot be reversed.
[0024] Upon receipt of the third encrypted message C 3 , the second party R reverses the transformation processes γ using the reversal process that is known to exist according to the initial choice of that transformation. Following that reverse transformation, the result is simply the output of the process α embodying message P. That is,
[heading-0025] α(P) γ′ (C 3 ),
[0026] except that this copy of α (P) is now in the possession of the second party R rather than in that of the initial party T. The second party R removes the plaintext message P from its embodiment in the output of the transformation process α to yield possession of the original message created by T. The invention identifies and applies means of embodying the message P in the output of transformation process α in a manner such that the second party R can remove the message P from that embodiment.
[0027] The processes of the invention are distinctly different from previous implementations of three-pass protocols that used complex, public-key-like computational methods to implement the encryption components of each pass. The processes of the invention are straightforward transformation methods that are fully secure and yet computationally efficient. Because the invention doesn't require either party to possess or gain any information about the other's primary encryption process, the technique of the invention is designated as an independent-key process.
[0028] An advantage of the present invention is that it is technically impossible for an eavesdropper, even knowing the transmitted quantities C 1 , C 2 , and C 3 and the general properties and processes of the transformations α, β, and γ, to directly determine the plaintext message P because no reverse transformations can be applied to the transmitted quantities to make that determination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a block diagram depicting a cryptographic system that may be employed for fully secure transmission of a message over non-secure channels without the prior exchange of cryptographic keys, according to the invention claimed herein.
[0030] FIG. 2 is a block diagram depicting a general example of a possible embodiment of such a cryptographic system that may be employed for fully secure transmission of a message over non-secure channels without the prior exchange of cryptographic keys, according to the invention claimed herein.
[0031] FIG. 3 is a block diagram depicting a specific example of a possible embodiment of such a cryptographic system that may be employed for fully secure transmission of a message over non-secure channels without the prior exchange of cryptographic keys, according to the invention claimed herein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Referring to FIG. 1 , a cryptographic system is shown in which all communication takes place over a non-secure channel 21 . The non-secure channel 21 may include a telephone line, a radio connection, a cellular telephone connection, a fiber optic line, a microwave connection, a coaxial line, an infrared optical link, or any other communication technology that permits the transmission of information from a first location to a second location. Two-way communication is exchanged on the non-secure channel 21 between the initial converser 11 referred to as the transmitting party T and the second converser 31 referred to as the receiving party R using transceivers 22 and 23 , for example digital cellular telephones, modems, or any other mechanism for converting information into the structure necessary for transmission by the non-secure channel 21 . The transmitting party 11 possesses a plaintext message P 10 to be communicated to the receiving party 31 .
[0033] Both the transmitting party T 11 and the receiving party R 31 use cryptographic devices 12 and 32 respectively, for encrypting and decrypting information under the action of the processes of this invention. Each cryptographic device 12 and 32 receives the output of transformation generators 13 and 33 respectively. The first transformation generator 13 creates the transformations α 14 , β 15 and β′ 16 which are provided to the cryptographic device 12 . The transformation β′ 16 is the reverse transformation or inversion of process β 15 . The second transformation generator 33 creates the transformations γ 34 and γ′ 35 which are provided to the cryptographic device 32 . The transformation γ′ 35 is the reverse transformation of γ 34 .
[0034] The transmitting party T's 11 cryptographic device 12 encrypts the plaintext message P 10 into the first cryptographic message C 1 24 by transforming message P 10 through the transformations α 14 and β 15 so that no reverse transformation is possible for the resulting output C 1 24 . The first cryptographic message C 1 24 is then transmitted through the first transceiver 22 , over the non-secure channel 21 , and through the second transceiver 23 to the receiving party R 31 .
[0035] The receiving party R's 31 cryptographic device 32 further encrypts the received first cryptographic message C 1 24 into the second cryptographic message C 2 25 by transforming C 1 24 through the transformation γ 34 so that no reverse transformation is possible for the resulting output C 2 25 . The second cryptographic message C 2 25 is then transmitted through the second transceiver 23 , back over the non-secure channel 21 , and through the first transceiver 22 to the transmitting party T 11 .
[0036] The transmitting party T's 11 cryptographic device 12 partially decrypts the received second cryptographic message C 2 25 into the third cryptographic message C 3 26 by transforming C 2 25 through the reverse transformation β′ 16 so that no reverse transformation is possible for the resulting output C 3 26 . The third cryptographic message C 3 26 is then transmitted through the first transceiver 22 , over the non-secure channel 21 , and through the second transceiver 23 to the receiving party R 31 .
[0037] The receiving party R's 31 cryptographic device 32 device further decrypts the received third cryptographic message C 3 26 by transforming C 3 26 through the reverse transformation γ′ 35 . The result now in the possession of the receiving party R 31 is the output of the process α 14 embodying P 10 . The receiving party R 31 removes the plaintext message P 10 from its embodiment in the output of the transformation process α 14 to yield possession of the original message created by T 11 . The receiving party R 31 does not know nor need to know the transmitting party T's 11 transformation process β 15 nor does the transmitting party T 11 know nor need to know the receiving party R's 31 transformation process γ 34 . Both T 11 and R 31 know and utilize the transformation process α 14 , but α 14 can be publicly known or transmitted from T 11 to R 31 without fear of interception, since the message P 10 cannot be decoded by an eavesdropper 41 who knows only transformation process α 14 . Because the invention doesn't require either party to possess or gain any information about the other's primary encryption processes, the technique of the invention is designated as an independent-key process.
[0038] The cryptographic system of the invention includes a non-secure communications channel 21 , making it possible for an eavesdropper 41 that is not included in the cryptographic system to receive all of the communications between the transmitting party T 11 and the receiving party R 31 . The eavesdropper 41 may possess a cryptographic device 42 that includes the same processing capabilities and knowledge of the transformation processes as the cryptographic devices 12 and 32 available to the transmitting party T 11 and the receiving party R 31 , and a transformation generator 43 that includes the same capabilities and available transformation processes as the transformation generators 13 and 33 available to the transmitting party T 11 and the receiving party R 31 . However, even given the full content of the encrypted messages C 1 24 , C 2 25 , and C 3 26 , the eavesdropper 41 cannot directly determine or otherwise deduce the transformations α 14 , β 15 , or γ 34 to determine the original plaintext message P 10 . The best that the eavesdropper 41 can do with the information from the messages C 1 24 , C 2 25 , and C 3 26 is to establish some limited relationships between some of the components of the messages. However, knowledge of those relationships alone is not very informative or substantially useful to the eavesdropper 41 since the eavesdropper 41 would still have to guess the values of many specific components of the transformations. Refining that relationship information would require an amount of effort by the eavesdropper 41 no less than that required for a brute-force break of the cryptographic system. Therefore, the cryptographic system is fully secure, being no more susceptible to cryptanalytic attack than to a brute-force attack.
[0039] As merely a general example of a possible embodiment of the processes of this invention, the basic techniques of matrix algebra may be applied to create transformations that satisfy the requirements of the invention. This example is demonstrated in FIG. 2 . As shown in FIG. 2 , the transmitting party T 11 has a plaintext message P 10 to be transmitted over a non-secure channel 21 to the receiving party R 31 . The transmitting party T 11 uses a transformation generator 13 to generate two transformations α 14 and β 15 such that β 15 can be reversed, but the combined transformation (α 14 ) (β 15 ) cannot be reversed. The transformation α 14 for this example is the creation of a singular (i.e., non-invertible) matrix [A] 14 where the plaintext message P 10 is embodied in the upper left block of the matrix and the remaining three blocks of the matrix are established by the transformation process to be random or quasi-random elements which exhibit characteristics such that the matrix [A] 14 cannot be inverted. The second transformation β 15 is taken to be that of post-multiplying the matrix [A] 14 by an invertible matrix [B] 15 composed of random or quasi-random elements to create the first encrypted message [AB] 24 . The first encrypted message [AB] 24 which is created by the cryptographic device 12 is singular or non-invertible because one of its key components—[A] 14 (which embodies P 10 )—is singular. The transmitting party T 11 transmits the matrix of elements in [AB] 24 to the receiving party R 31 over a non-secure channel 21 . Upon receipt of [AB] 24 , the receiving party R 31 uses the transformation generator 33 to generate the transformation γ 34 such that γ 34 can be reversed. For this example, the transformation γ 34 is taken to be the process of pre-multiplying the matrix [AB] 24 by an invertible matrix [C] 34 composed of random or quasi-random elements. Once the cryptographic device 32 is used to apply the transformation γ 34 to matrix [AB] 24 , the resulting second encrypted message [CAB] 25 is also singular or non-invertible because [A] 14 , a key component of that result, is singular. The receiving party R 31 transmits the matrix of elements in [CAB] 25 to the transmitting party T 11 over a non-secure channel 21 . Upon receipt of [CAB] 25 , the transmitting party T further transforms [CAB] 25 by post-multiplying the matrix [CAB] 25 by the inverse of the matrix [B] 15 , which is [B] −1 16 . That post-multiplication effectively reverses the transformation β that was the process of post-multiplying [A] 14 by [B] 15 . The resulting third encrypted message [CA] 26 is also singular or non-invertible because [A] 14 is still a component of the result and is singular. The transmitting party T 11 transmits the matrix of elements in [CA] 26 to the receiving party R 31 over a non-secure channel 21 . Upon receipt of [CA] 26 , the receiving party R 31 further transforms [CA] 26 by pre-multiplying the matrix [CA] 26 by the inverse of the matrix [C] 34 , which is [C] −1 35 . That pre-multiplication effectively reverses the transformation γ 34 that was the process of pre-multiplying [AB] 24 by [C] 34 . The final result of these combined transformations (implemented in this example as matrix multiplications) is the matrix [A] 14 , which embodies the plaintext message P 10 in its upper left block. That result is now in the possession of the receiving party R 31 . The receiving party R 31 does not know nor need to know the transmitting party T's 11 transformation matrix [B] 15 nor does the transmitting party T 11 know nor need to know the receiving party R's 31 transformation matrix [C] 34 . Because the invention doesn't require either party to possess or gain any information about the other's primary encryption processes, the technique of the invention is designated as an independent-key process.
[0040] A specific example of an embodiment of the processes of this invention using the basic techniques of matrix algebra is shown in FIG. 3 . As shown in FIG. 3 , the transmitting party T 11 has a plaintext message P 10 of the phrase “HI” to be transmitted over a non-secure channel 21 to the receiving party R 31 . The phrase “HI” is converted to a numeric equivalent of “8, 9” using the conversion of “A” to “1”, “B” to “2”, etc. Other numeric conversions of characters, such as for the standard ASCII character set, could be used. The transmitting party T 11 generates two transformations α 14 and β 15 such that β 15 can be reversed, but the combined transformation (α 14 ) (β 15 ) cannot be reversed. The transformation α 14 for this example is taken to be the creation of a singular (i.e., non-invertible) matrix [A] 14 where the plaintext message P 10 is embodied in the upper left area of the matrix and the remaining elements of the matrix are established by the transformation process to be random or quasi-random elements which exhibit characteristics such that the matrix [A] 14 cannot be inverted. The numeric equivalent “8, 9” of the message “HI” is loaded in the upper left block of [A] 14 and the remaining elements are chosen for this example to be “7, 5, 6, 3, 1, 0, 5” so that [A] 14 is non-invertible. Thus, the transformation α 14 in this example converts the message “HI” to the non-invertible matrix [A] 14 . The second transformation β 15 is taken to be that of post-multiplying the matrix [A] 14 by an invertible matrix [B] 15 composed of random or quasi-random elements to create the first encrypted message [AB] 24 . The matrix [B] 15 is chosen for this example to contain the elements “3, 4, 6, 2, 1, 1, 5, 8, 4” so the transformation β 15 yields the resulting elements of [AB] 24 as “77, 97, 85, 42, 50, 48, 28, 44, 26”. This first encrypted message [AB] 24 is singular or non-invertible. The transmitting party T 11 transmits the matrix of elements in [AB] 24 to the receiving party R 31 over a non-secure channel 21 . Upon receipt of [AB] 24 , the receiving party R 31 generates the transformation γ 34 such that γ 34 can be reversed. For this example, the transformation γ 34 is taken to be the process of pre-multiplying the matrix [AB] 24 by an invertible matrix [C] 34 composed of random or quasi-random elements. The matrix [C] 34 is chosen for this example to contain the elements “5, 7, 1, 2, 3, 6, 4, 9, 0” so the transformation γ 34 yields the resulting elements of [CAB] 25 as “707, 879, 787, 448, 608, 470, 686, 838, 772”. The resulting second encrypted message [CAB] 25 also is singular. The receiving party R 31 transmits the matrix of elements in [CAB] 25 to the transmitting party T 11 over a non-secure channel 21 . Upon receipt of [CAB] 25 , the transmitting party T further transforms [CAB] 25 by post-multiplying the matrix [CAB] 25 by the inverse of the matrix [B] 15 , which is [B] −1 16 . That post-multiplication effectively reverses the transformation β that was the process of post-multiplying [A] 14 by [B] 15 . The resulting third encrypted message [CA] 26 contains the elements “76, 87, 61, 37, 36, 53, 77, 90, 55” and also is singular or non-invertible because [A] 14 is still a component of the result and is singular. The transmitting party T 11 transmits the matrix of elements in [CA] 26 to the receiving party R 31 over a non-secure channel 21 . Upon receipt of [CA] 26 , the receiving party R 31 further transforms [CA] 26 by pre-multiplying the matrix [CA] 26 by the inverse of the matrix [C] 34 , which is [C] −1 35 . That pre-multiplication effectively reverses the transformation γ 34 that was the process of pre-multiplying [AB] 24 by [C] 34 . The final result of these combined transformations (implemented in this example as matrix multiplication) is the original matrix [A] 14 with the elements “8, 9, 7, 5, 6, 3, 1, 0, 5”, which embodies the plaintext message P 10 entered as “8, 9” in its upper left block. That result is now in the possession of the receiving party R 31 . The receiving party R 31 does not know nor need to know the transmitting party T's 11 transformation matrix [B] 15 nor does the transmitting party T 11 know nor need to know the receiving party R's 31 transformation matrix [C] 34 in order for the plaintext message P 10 to be securely transmitted between the two.
[0041] The elements of the transformation matrices [B] 15 and [C] 34 and the non-message elements of the matrix [A] 14 can be considered “key” elements and in conjunction with the transformation processes could be labeled the “keys” to the cryptographic system of this invention.
[0042] Because the cryptographic system of the invention includes a non-secure communications channel 21 , an eavesdropper 41 that is not included in the cryptographic system may receive all of the communications between the transmitting party T 11 and the receiving party R 31 . The eavesdropper 41 may possess a cryptographic device 42 that includes the same processing capabilities (matrix multiplication in the case of this example) and knowledge of the transformation processes (matrix operations in the case of this example) as the cryptographic devices 12 and 32 available to the transmitting party T 11 and the receiving party R 31 , and a transformation generator 43 that includes the same capabilities and available transformation processes (matrix operations in the case of this example) as the transformation generators 13 and 33 available to the transmitting party T 11 and the receiving party R 31 . However, even given the full content of the encrypted messages [AB] 24 , [CAB] 25 , and [CA] 26 , the eavesdropper 41 cannot directly determine or otherwise deduce the matrices [A] 14 , [B] 15 , or [C] 34 to determine the original plaintext message P 10 because the observed matrices [AB] 24 , [CAB] 25 , and [CA] 26 are not invertible. The best that the eavesdropper 41 can do with the information from the messages [AB] 24 , [CAB] 25 , and [CA] 26 is to establish some limited linear relationships between some of the elements of the message matrices. However, knowledge of those linear relationships alone is not very informative or substantially useful to the eavesdropper 41 since the eavesdropper 41 would still have to guess the values of many specific elements in the matrices. Refining that linear relationship information would require an amount of effort by the eavesdropper 41 no less than that required for a brute-force break of the cryptographic system. Therefore, the cryptographic system is fully secure, being no more susceptible to cryptanalytic attack than to a brute-force attack.
[0043] The precise encrypted messages transmitted 24 , 25 , 26 between transmitting party T 11 and the receiving party R 31 depend on the plaintext message P 10 and the transformation processes 14 , 15 , 34 . The options for choices of the transformation processes 14 , 15 , 34 make possible nearly any observable combination of encrypted messages 24 , 25 , 26 regardless of the initial plaintext message P 10 . The magnitude of the alternatives for observable combinations of encrypted messages is so large as to frustrate any attempt by an eavesdropper 41 to develop cryptanalytic approaches to attack the cryptographic system.
[0044] Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is purely illustrative and is not to be interpreted as limiting. Consequently, without departing from the spirit and scope of the invention, various alterations, modifications, and/or alternative applications of the invention will, no doubt, be suggested to those skilled in the art after having read the preceding disclosure. Accordingly, it is intended that the following claims be interpreted as encompassing all alterations, modifications, or alternative applications as fall within the true spirit and scope of the invention.
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A cryptographic system transmits a fully secure cryptographic message over a non-secure communication channel without prior exchange of cryptographic keys using a three-pass protocol. The transmitting agent initiating the communication embodies the message for the designated receiving agent in the composite output of two distinct transformations such that a generalized reversal of the combined transformations cannot be determined from that output. That output is transmitted as a first-pass over a non-secure channel to the receiving agent. The receiving agent generates a second composite output by transforming the received message such that a generalized reversal of this second combined transformation cannot be determined from that resulting output. That second output is transmitted as a second-pass over a non-secure channel to the initial transmitting agent. The initial agent generates a third composite output from the returned message by reversing one of the two initial transformations such that a generalized reversal of this third composite transformation cannot be determined from that resulting output. The third output is transmitted as a third-pass over a non-secure channel to the receiving agent. The receiving agent uses a reversal of the second transformation applied to the final message to extract the initial message. The transformations (or keys) used by either party need not be known by the other, making this an independent-key cryptographic process. It is technically impossible for any eavesdropping agent, even one who captures all transmissions between the transmitting and receiving agents, to directly recreate the initial message from the observed transmissions.
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BACKGROUND OF THE INVENTION
The increased use of microwaves for cooking has given rise to a large market in microwavable foods. While the advantage of microwave cooking over convection oven cooking is the time savings, the disadvantage heretofore has been that flavored baked goods do not develop the surface flavoring (in addition to browning or crust formation) or internal flavoring expected with convection oven cooking.
Our objective has been to create that internal and/or surface flavor retention and, optionally, browning which enhances the products' appearance, taste and mouth feel properties making it look as if it were cooked in a convection oven and making it taste as if it were cooked in a convection oven; particularly applied to chocolate flavored foodstuffs.
Heretofore, when using the microwave oven for cooking foodstuffs containing flavoring and browning formation additives, the food to be cooked taken in combination with additives therefor did not have the proper time-temperature-heat transfer variable (e.g., heat capacity, thermal conductivity, viscosity and density) combination for the (i) added materials useful for surface and/or internal flavoring to be effective or (ii) added chemicals responsible for browning and/or crust formation to react. Therefore, for a microwave (i) internal or surface flavoring system to work and (ii) browning and/or crust system to work, firstly, it must excellerate the rate of the browning reactions or locally increase the surface temperature and, secondly, the physical heat and mass transfer conditions must be such that the added flavor values; internal and/or surface must not be driven off or destroyed.
Ultimately, the reactions responsible for browning and/or flavor formation, particularly chocolate flavor formation have to be accomplished in the relatively short time frame dictated by the foods' preparation conditions. The times needed for preparing microwave foods vary depending upon the power output of the microwave unit and the mass of the food to be cooked. A typical 750 watt microwave will cook baked goods in 40 seconds to 4 minutes.
Several additional requirements for a successful microwave flavor retention system are as follows:
1. formation of a flavor (e.g., chocolate flavor) having authentic aroma and taste nuances;
2. retention of authentic flavor (e.g., chocolate) aroma and taste nuances.
Furthermore, when appropriate, several additional requirements for a successful microwave browning system are as follows:
1. in addition to the desired browning effect, it must generate either no aroma or one which is compatible with the target food (e.g., a chocolate flavored food such as a "brownie");
2. the browning reaction must not take place before cooking the food; and
3. after cooking, the browning must stop, and not cause the food to be darkened substantially so that it becomes aesthetically displeasing.
The reaction responsible for chocolate flavor formation during convection oven cooking is the reaction between sugar, leucine and phenyl alanine which results in the creation of various reaction products including aldol condensation products such as COCAL® (a Registered Trademark of International Flavors & Fragrances Inc.) having the structure: ##STR1##
Furthermore, the reactions responsible for browning during convection oven cooking are the carmelization of sugars and the Maillard reaction between naturally occurring reducing sugars, amino acids, amines, peptides and proteins which results in the formation of colored melanoidins. Until recently (1984) there were numerous patent and literature references to such reactions for the production of flavors, where the generation of color was inconsequential or objectionable. In the past few years several patents have appeared wherein microwave browning created by Maillard reactions have been the topic.
Although the prior art does take advantage of the reaction between reducing sugars and amino acids, it has not made any correlation of reaction rates needed for browning reactions with reaction variables such as pH, solvent, amino acid reactivity or sugar reactivity.
Furthermore, although the prior art takes advantage of the reaction between amino acids and sugars to form flavors, e.g., chocolate flavors again it has not made any correlation of reaction rates needed for flavor retention with reaction variables such as pH, solvent, amino acid reactivity or sugar reactivity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut-away side elevation view of a coated food article prior to carrying out the microwave flavor formation (and, optionally, browning) step of the process of our invention.
FIG. 2 is a cut-away side elevation view (in schematic form) of a microwave oven containing a coated food article prior to and during the carrying out of the process of our invention.
FIG. 3 is a block flow diagram showing the steps, in schematic form, for carrying out the process for forming drum chilled flavor precursor powder and spray chilled flavor precursor powder useful in the practice of the process of our invention.
FIG. 4 is a schematic diagram setting forth apparatus and process steps useful in forming spray chilled flavor precursor powder useful in the practice of the process of our invention.
FIG. 5 is a flow diagram setting forth in schematic form the apparatus and process steps required in producing drum chilled flavor precursor powder useful in the practice of the process of our invention.
FIG. 6 is a block flow diagram showing the steps, in schematic form, for carrying out the process of our invention and indicating the multiple means (apparatus elements) useful in carrying out the process of our invention whereby an uncooked food article is coated with flavor (and optionally browning) precursor powder or liquid prior to microwave heating.
FIG. 7 is a block flow diagram showing the steps, in schematic form for carrying out another aspect of the process of our invention; and indicating the multiple means (apparatus elements) useful in carrying out that aspect of the process of our invention wherein flavor precursor powder is admixed into the matrix of an uncooked food article prior to microwave heating.
SUMMARY OF THE INVENTION
Our invention is directed to a process for providing a microwave-cooked baked goods foodstuff having flavor retention (preferably a chocolate flavored foodstuff) and, optionally, being given a natural "browning effect" and being given a natural "cresting" effect, comprising the steps of:
(a) providing a composition of matter consisting essentially of precursors of a reaction flavor (preferably a chocolate reaction flavor; e.g., a sugar, leucine and phenyl alanine) and a solvent capable of raising the dielectric constant of the surface and/or the internal matrix of an uncooked foodstuff to be cooked whereby the cooking time will be less than 120 seconds (such as propylene glycol or glycerine or a mixture of glycerine and propylene glycol; or a mixture of glycerine and ethanol; or a mixture of propylene glycol and ethanol) and water;
(a') optionally, also providing a Maillard reaction product flavor in admixture with composition (a), supra, or separately with a solvent capable of raising the dielectric constant of the surface and/or internal matrix of the foodstuff to be cooked whereby the cooking time will be less than 120 seconds (such as propylene glycol or glycerine) and water;
(b) providing an uncooked baked goods foodstuff, e.g., dough;
(c) coating the composition of (a) and, optionally, (a') onto the surface of the uncooked foodstuff and/or incorporating the composition of (a) and optionally, (a') first into a controlled release system (such as a drum chilled or spray chilled product) and then incorporating the controlled release system into the internal matrix of the foodstuff; and
(d) exposing the thus-treated uncooked foodstuff to microwave radiation for a period of under 120 seconds whereby the resulting product is caused to be edible as a cooked foodstuff having, flavored nuances, preferably chocolate flavor nuances and optionally having a naturally "browned" and/or "crusty" surface.
Our invention is also directed to the products produced according to such process.
In carrying out a preferred aspect of our invention, a chocolate flavor would be produced either (a) in the coating of the foodstuff during the microwave cooking and/or (b) in the internal matrix of the foodstuff being cooked via the microwave cooking. Such chocolate flavor necessarily contains the compound "COCAL"® a Registered Trademark of International Flavors & Fragrances Inc. having the structure: ##STR2## The precursors for producing such a chocolate flavor are phenyl alanine having the structure: ##STR3## leucine having the structure: ##STR4## and a sugar shown by the letter:
S
The reaction for forming the chocolate flavor either in the surface coating or in the internal matrix of the foodstuff being subjected to microwave cooking is as follows: ##STR5## wherein the symbol:
R
is indicative of other reaction products being formed in the formation of the chocolate flavor. In causing the process of our invention to be operable, the proper solvent-reactant makeup must be employed. Necessarily, the reaction solvent (when carrying out that aspect of the process of our invention employing coating of the flavor precursor composition onto uncooked foodstuff) physical properties are interrelated.
Thus, a mathematical model found to be useful in relating each of the variables involved in the development of our invention is set forth thusly: ##EQU1##
In an approximate version an equation for calculating the time of heating as a function of viscosity of the coating (prior to cooking) and further, as a function of the temperature differential between the center of the food article to be cooked and the outer surface of the coating during the microwave browning operation is set forth thusly: ##EQU2## wherein the terms
ΔQ
is the total microwave energy input during the process of our invention; ##EQU3## is the rate of heat input equivalent to the rate of energy use by the microwave oven;
R
is the effective radius of the food article being cooked;
K
is the heat transfer coefficient of the food article being cooked (the solid material);
μ
is the viscosity of the coating immediately prior to cooking;
λ1
is a proportionality constant which is a function of the coating thickness immediately prior to cooking and the geometry of the article being cooked as well as the geometry of the microwave oven;
Cp
is the heat capacity of the coating immediately prior to cooking;
ρ
is the density of the liquid coating immediately prior to cooking;
T1
the temperature at the center of the food article being cooked;
T2
is the temperature at the outer surface of the food article being cooked;
h.sub.a
is the convection heat transfer coefficient for the air layer surrounding the food article being cooked;
λ2
proportionality constant for radiation term for concentric spheres (the coating surrounding the uncooked food);
ε
electric field strength;
ν
frequency;
ε'
relative dielectric constant of coating material;
Δθ
time of microwave cooking.
The foregoing equations were derived from equations set forth in:
"Heat Transfer And Food Products", Hallstrom, et al, Elsevier Applied Science Publishing Company, 1988;
"Principals of Chemical Engineering", Walker, et al, Third Edition, McGraw Hill Book Company, 1937; and
"Chemical Engineer's Handbook", Fifth Edition, Perry and Chilton, McGraw Hill Book Company, pages 10-10, 10-11 and 10-12.
In another aspect of our invention, the flavor precursors (and, optionally, the browning precursors compatible therewith) are first incorporated into a controlled release system prior to incorporation into the matrix of the foodstuff to be cooked via microwave cooking. Thus, for example, the amino acid precursors (leucine and phenyl alanine) taken together with a sugar are admixed with a fat in a weight ratio of from about 1 part precursor composition to 2 parts fat composition down to 1 fat composition to 2 parts precursor composition. The resulting mixture is drum chilled as more specifically set forth in the examples, infra. The drum chilled product is then incorporated into an uncooked foodstuff, for example, uncooked cookie dough. The resulting product is then placed in a microwave oven yielding a chocolate flavored cake product having substantially entire flavor retention.
Rather than using actual fat, or spray chilled or drum chilled product, the flavor precursor mixture together with solvent (e.g., ethanol and glycerine) can be intimately admixed with melted bakers chocolate. The resulting mixture is then further admixed with cooking ingredients such as corn oil, vegetable shortening, egg, water, salt, baking soda and flour. The resulting product is cooked in a microwave oven yielding a product having a superior taste and room aroma as further exemplified, infra.
DETAILED DESCRIPTION OF THE INVENTION
In copending application for U.S. Pat. Ser. No. 356,503 filed on May 25, 1989 (IFF-4815J) which is a continuation-in-part of application for U.S. Pat. Ser. No. 295,450 filed on Jan. 10, 1989 and in application for U.S. Pat. Ser. No. 295,450 filed on Jan. 10, 1989, it was shown that the order of sugar reactivities observed for the typical thermally induced Amadori and Maillard reactions holds true in microwave cooking. It was further shown that pentoses were more reactive than hexoses and 6-deoxyhexoses were more reactive than hexoses.
Our invention herein has shown that there is a strong relationship between the sugar reactivity and the particular amino acid utilized for production of chocolate flavor whether in a coating formulation during the microwave cooking or whether it is introduced into the matrix of foodstuff to be cooked by means of incorporation of the flavor precursors in a controlled release system as by spray chilling, drum chilling or merely by incorporation into cocoa butter.
We have also found that chocolate flavor precursors, that is, phenyl alanine, leucine and a sugar such as ribose, rhamnose or cerelose may be used in conjunction with a compatible browning reaction system.
In application for U.S. Pat. Ser. No. 295,450 filed on Jan. 10, 1989, incorporated herein by reference it was shown that there is a strong relationship between pH and reactivity. At pH's in the range of 9-13, a browning reaction was accelerated at acid pH's. Such a rate enhancement was attributed to the removal of a proton from the amino acid leaving the amino acid group unprotonated and therefore, more nucleophilic. It was indicated therein that the consequence of the latter is to accelerate the nucleophilic substitution of the amino group on the carbonyl of the reducing sugar. Since this reaction is the first step in the formation of color, it was concluded that this is the rate determining step to melanoidins.
The instant invention, also carried out at pH's in the range of 9-13 involves amino acid degradation followed by aldol condensation, interalia. Thus, phenyl alanine and leucine are reacted in the presence of a sugar such as ribose, rhamnose and cerelose at a pH in the range of 9-13. The reaction for the purposes of carrying out same in a coating on an uncooked foodstuff during microwave cooking is carried out using a specific solvent. An unexpected finding in the instant invention is that the solvent in which the flavor is formed dramatically affects the rate of reaction. Aprotic solvents, such as triacetin and vegetable oil, are useless in such a reaction system since the reactants are not soluble in the solvent. Polar protic solvents are amongst the solvents in which the reactants are soluble; however, not all members of this solvent class are useful for carrying out the reaction, to wit: ##STR6## wherein the symbol:
S
represents a sugar and the symbol:
R
represents other reaction products necessary to create a chocolate flavor.
Both water and ethanol are unacceptable, per se as solvents since the rate of the reaction: ##STR7## in these solvents is on the order of hours.
In propylene glycol and glycerine the rate of the reaction: ##STR8## is rapid, achieving the desired chocolate flavor formation in 40 seconds to 2 minutes (120 seconds).
In application for U.S. Pat. Ser. No. 295,450 filed on Jan. 10, 1989 it was shown that the solvent in which the Maillard browning is run dramatically affects the rate of browning. It was also shown there that aprotic solvents, such as triacetin and vegetable oil, were useless in the browning reaction systems since the reactants in the Maillard reaction were not soluble in the solvent. Polar protic solvents were set forth to be amongst the solvents in which the Maillard reactants are soluble; and it was further indicated that not all members of this solvent class are useful for microwave browning. It was further indicated that both water and ethanol, per se, are unacceptable as solvents since the rate of the browning reaction in these solvents is on the order of hours. It was further indicated that in propylene glycol and glycerine the rate of browning is rapid, achieving the desired coloration in 40 seconds to 2 minutes (120 seconds).
The mechanism of solvent action is believed to be twofold. First, the ability of the solvent to solubilize the reactants is essential; however, that in itself is insufficient to qualify a solvent without the second property. The successful solvent has the ability to absorb microwave radiation (2450 MHz) and retain this absorbed energy as heat. Solvents with high heat capacities, high viscosities and low thermal conductivities are desirable (that is high Prandtl numbers), to wit: ##EQU4## as they facilitate heat retention. With the above properties, the solvent effectively focuses part of the microwave radiation on the food's surface, locally raising the temperature and accelerating the reaction: ##STR9## and, optionally, the browning reaction (if desired). Propylene glycol and glycerine are two materials which meet the necessary requirements as solvents for the reaction: ##STR10## and, optionally, as solvents for the microwave browning reaction.
When desired to carry out a browning reaction simultaneously with the carrying out of the reaction: ##STR11## examples of Maillard reaction products useful in the practice of our invention are as follows:
(a) reaction products of amino acids and sugars as described in U.S. Pat. No. 4,735,812 issued on Apr. 5, 1988, the specification of which is incorporated herein by reference;
(b) reaction product of a monosaccharide and/or a disaccharide and an amino acid as described in U.S. Pat. No. 4,547,377 issued on Oct. 15, 1985, the specification of which is incorporated by reference herein;
(c) Amadori products as described in Chem. Abstracts, Volume 109:169074 g as set forth below:
109:169074 g Studies of the Maillard reaction. Part 15. Derivatographic studies of the systems D-glucose/glycine, alanine, phenylalanine and the corresponding Amadori products. Westphal, G.; Oersi, F.; Kroh, L. (Sekt. Nahrungsguterwirtsch. Lebensmitteltechnol., Humboldt-Univ., Berlin, Ger. Dem. Rep.). Nahrung 1988, 32(2), 109-16 (Ger). From results of investigations of the D-glucose/DL-phenylalanine (1:1) model it was possible to classify under the chosen conditions the reaction into an earlier phase with a temp. of 130°, a developed phase at 130°-150° and the beginning of the final phase of the Maillard reaction at >150° whereby insol. polymers were formed. The loss of carbohydrates and amino acids caused by thermal changes can be detd. by HPLC. A comparative study of the derivatograms of the 3 model systems (D-glucose with glycine, DL-alanine, and DL-phenylalanine) with their corresponding Amadori products shows the thermal instability of the Amadori compds. depended on the aglycon. The extremely small endothermal enthalpy values (DTA curves) of the reaction products supports this assumption.
and
(d) flavor compounds which are Amadori rearrangement compounds of 6-deoxy-aldohexoses such as rhamnose and alpha amino acids such as proline as described in detail in U.S. Pat. No. 4,022,920 issued on May 10, 1977, the specification of which is incorporated herein by reference.
With respect to the sugar components of the reactants in the coating, whereby the reaction: ##STR12## is carried out indicated by reference numeral 10 in FIG. 1, the preferred sugars are:
(i) ribose;
(ii) rhamnose; and
(iii) cerelose.
With respect to the sugar components of the reactants in the coating when desired to also carry out a browning reaction, with the coating being indicated by reference numeral 10 in FIG. 1, the preferred order of use is as follows (in descending order):
(i) ribose; and
(ii) rhamnose.
In the browning reaction when it is desired to be carried out simultaneously with the reaction: ##STR13## with respect to the amino acid component of the reaction material, lysine and proline are prefered; but glycine and alanine are not recommended. Dimethylanthranilate having the structure: ##STR14## and secondary amino acids and diamino acids in general are preferred. Thus, lysine having the structure: ##STR15## is a preferred structure and proline having the structure: ##STR16## is a preferred material. Also useful are dipeptides.
Referring now to the drawings, FIG. 1 is a cut-away side elevation view of the coated food article prior to cooking. The overall article is indicated by reference numeral 20. The uncooked baked goods material is indicated by reference numeral 12 having an effective radius "R". The coating containing the mixture of precursors, the phenyl alanine having the structure: ##STR17## the leucine having the structure: ##STR18## and the sugar, that is, ribose, rhamnose or cerelose, for example, for the reaction: in a solvent which is capable of raising the dielectric constant of the surface of the foodstuff 12 to be cooked whereby the foodstuff to be cooked is completely cooked in a period of time under 120 seconds is indicated by reference numeral 10. The coating is located on the surface of the food article 12 and reference numeral 14 indicates the surface of the uncooked baked goods composition. The term "ΔX" is the thickness of the coating prior to microwave cooking.
FIG. 2 is a schematic diagram of the coated food article in a microwave oven during the carrying out of the process of our invention. The food article 20 having the coating 10 on the uncooked baked goods (solid) 12 is contained in microwave oven 138, more specifically in box 40 wherein microwave source 42 emits energy substantially perpendicular to the upper surface of the food article 20. The microwave energy passes through the coating surface and causes the reaction in coating 10 to take place, to wit: ##STR19## whereby a chocolate flavor is produced which includes the compound having the structure: ##STR20## In addition a reaction may also take place whereby Maillard or Amadori reaction products are produced. The syrup 10 heats up and activates the molecules of the reactants. Simultaneously, the solid material 12 (the uncooked baked goods) is heated and the coating 10 is adsorbed through the surface 14 into the outer interstices of the baked goods article 12. Prior to 120 seconds the entire baked goods article 12 is cooked and the surface coating now containing the chocolate flavor and, optionally, the Amadori or Maillard reaction product is substantially adsorbed into the outer interstices of the baked goods article.
The food article 20 rests at point 39 in box 40.
FIG. 3 sets forth a schematic block flow diagram of the process for producing spray chilled flavor precursor powder or drum chilled flavor precusor powder useful in forming material for incorporation into the interstices of the uncooked baked goods product prior to microwave cooking (rather than as a "coating").
The flavor precursor materials which would include the leucine, phenyl alanine and sugar at 501 are admixed with molten fat and emulsifier from source 503 which is heated to its molten state at 505 and mixed with the flavor precursor materials at 507. Into the mixing operation is also placed texturizer from source 509. Drum chilling at 513 results in a product which is ground at 517 and sent to location 519 for further use. Spray chilling at location 511 of the resulting mixed texturized product causes the spray chilled flavor precursor product to be available for the microwave cooking step at location 515.
Examples of fatty materials useful in this process are set forth, supra and their respective melting points are as follows:
TABLE I______________________________________Fatty Material Melting Point Range______________________________________Partially hydrogenated 141-147° F.cotton seed oilPartially hydrogenated 152-158° F.soybean oilPartially hydrogenated 136-144° F.palm oilMono and diglycerides 136-156° F.Glycerol monstearate 158° F.Glycerol monopalmitate 132° F.Propylene glycol monostearate 136° F.Polyglycerol stearate 127-135° F.Polyoxyethylene sorbitol beeswax 145-154° F.derivativesPolyoxyethylene sorbitan 140-144° F.esters of fatty acidsSorbitan monostearate 121-127° F.Polyglycerol esters of 135-138° F.fatty acidsBeeswax 143-150° F.Carnauba wax 180-186° F.______________________________________
Texturizers include precipitated silicon dioxide, for example, SIPERNAT®50S (bulked density 6.2pounds per cubic foot; particle size 8 microns; surface area 450 square meters per gram manufactured by the Degussa Corporation of Teterboro, New Jersey. Other silicon dioxide texturizers are as follows:
SIPERNAT®22S manufactured by Degussa Corparation;
ZEOTHIX®265 manufactured by J. M. Huber Corporation of Havre de Grace, Maryland;
CAB-SIL® EH-5 manufactured by the Cabot Corporation, of Tuscola, Illinois.
FIG 4. is a diagram of the process and apparatus (in schematic form) for producing spray chilled flavor precursor powder useful in the process of our invention. Flavor precursor materials, fat emulsifier in molten state and texturizer are admixed in mixing kettle 601. The resulting mixture is sprayed chilled in spray chiller 603 and the resulting spray chilled articles containing flavor precursor are classified. The classification is carried out in cyclone separator 605 with the larger size particles which are useful in the practice of our invention going through sieve 607 into receiver 609.
More specifically, the molten mixture maintained in the fluid state is pumped to the "spray chiller" which is actually a spray-drier and atomized into fine droplets using an atomizer. A nozzle may be specifically engineered to exclude chilled air or chilled air may be utilized to solidify the resulting fat particles. Atmospheric unheated air may be used to blow through the spray-drier. The final product collected is in fine powder form with particles about 50-120 microns in size.
FIG. 5 is a schematic diagram setting forth a process and apparatus useful in preparing drum chilled flavor precursor powder useful in carrrying out the process of our invention wherein the resulting powder contains flavor precursor, e.g., phenyl alanine, leucine and a sugar such as cerelose.
The flavor precursor materials, that is the phenyl alanine, leucine and sugar is admixed with molten fat and emulsifier and texturizer in mixing kettle 701. The molten material is then pumped through feed line 703 into drum chiller 709. The resulting drum chilled product collected at location 705 is passed into grinder/sifter 711 and then collected at location 713.
An example of a grinder/sifter useable in the instant invention is the KEMUTEC BETAGRIND®. Another example of workable apparatus is the KEK-Gardner Centrifugal Sifter.
The controlled release systems useful in the practice of our invention may also be prepared according to the process and using the apparatus set forth in U.S. Pat. No. 3,949,094 issued on Apr. 6, 1976, the specification for which is incorparated herein by reference.
FIG. 6 sets forth a schematic block flow diagram of the process of our invention whereby fluid, e.g., glycerine heated at 302 and reactants, leucine, phenyl alanine and sugar at location 301 are mixed in mixing means 304. The resulting coating is utilized at coating means 306. Dough is mixed at mixing means 309 and shaped into pre-cooked uncoated food articles at shaping means 307. The shaped dough is then transported to coating means 306 where the fluid from 304 is coated onto the shaped pre-cooked food articles. The now coated shaped pre-cooked food articles are cooked in microwave means 138 using microwave source 42. The resulting cooked articles are then transported for marketing to location 310.
FIG. 7 sets forth a schematic block flow diagram of another aspect of the process of our invention whereby flavor precursor powder, for example, drum chilled flavor precursor power from location 519 in FIG. 3 or spray chilled flavor precursor powder from location 515 in FIG. 3 is transported from location 401 mixing means 405 where the flavor precursor powder is mixed with dough composition from location 403. The resulting product, dough composition containing flavor precursor powder is shaped at location 407 and then placed into microwave heating means 138. The now coated shaped uncooked food articles are cooked in microwave means 138 using microwave source 42 (shown in FIG. 2). The resulting cooked articles are then transported for marketing to location 410.
In summary, the solvents useful in carrying out our invention have dielectric constants which cause the cooking via microwave radiation to take place in under 120 seconds (in the range of from about 40 seconds up to about 120 seconds) whereby flavored microwaved cooked products are produced.
It should be noted an additional advantage achieved in practicing our invention wherein the flavor precursor liquid composition is coated onto uncooked baked goods foodstuffs is that water evaporation is retarded when the resulting coated product is cooked in a microwave oven. This advantage, too is unexpected, unobvious and advantageous.
The principles given above are illustrated in the following examples.
EXAMPLE I
Into 100 ml beakers were placed exactly 40.1 g of solvent. Each beaker was irradiation with 245 OMHz microwave radiation for 20 seconds, afterwhich the solvents temperature was measured. Experiments were run in triplicate. The results for several solvents are set forth in the following Table II.
TABLE II______________________________________SOLVENT TEMPERATURE (C.)______________________________________Propylene glycol 91Glycerine 88Ethanol 78Water 61Triacetin 80______________________________________
EXAMPLE II
Blotters weighing 0.61 g were dosed with 0.10 g of test solutions. The test solutions are each placed on the center of each of the blotters. Blotters spotted in this manner were irradiated with 2450 MHz microwave (750 watts) radiation for various periods of time, starting at 20 seconds. The results of testing variables are summarized in Table III.
The microwave radiation source is a 750 watt Amana RADARANGE® Microwave Oven (trademark of the Amana Corporation).
TABLE III AMINO pH pH MICRO- AMINO ACID SUGAR SOLVENT ADJUSTMENT ADJUSTMENT WAVE COLOR ENTRY ACIDS WEIGHT SUGAR WEIGHT SOLVENT WEIGHT pH AGENT AGENT WEIGHT TIME APPEARANCE AROMA II-1 PHENYL RIBOSE 4.5 g ETHANOL 16 g 7-8 NaHCO.sub.3 2.7 g 20 sec. TAN MALTY ALANINE 5.0 g GLYCER- 25 g (MW84) BURNT COCOA (MW 131.2) INE LEUCINE 4.0 g (MW 165.2) II-2 PHENYL RHAMNOSE 5.5 g ETHANOL 16 g 7-8 NaHCO.sub.3 2.7 g 20 sec. YELLOW FAINT CHOCOLATE ALANINE 5.0 g GLYCER- 75 g 40 sec. LIGHT BROWN FAINT CHOCOLATE LEUCINE 4.0 g INE II-3 PHENYL RHAMNOSE 5.5 g ETHANOL 16 g 7-8 NaHCO.sub.3 5.4 g 20 sec. LIGHT BROWN CHOCOLATE ALANINE 5.0 g GLYCER- 25 g 40 sec. BROWN CHOCOLATE LEUCINE 4.0 g INE II-4 PHENYL RHAMNOSE 5.5 g ETHANOL 16 g 7-8 NaHCO.sub.3 4.5 g 20 sec. BROWN CHOCOLATE ALANINE 5.0 g GLYCER- 75 g 40 sec. DARK BROWN DARK COCOA LEUCINE 4.0 g INE II-5 PHENYL CERELOSE 5.5 g ETHANOL 16 g 7-8 NaHCO.sub.3 5.4 g 20 sec. LIGHT YELLOW NONE ALANINE 5.0 g GLYCER- 25 g 40 sec. LIGHT BROWN FAINT CHOCOLATE LEUCINE 4.0 g INE 60 sec. NO CHANGE II-6 PHENYL CERELOSE 5.5 g ETHANOL 16 g 7-8 NaHCO.sub.3 5.4 g 20 sec. BROWN YELLOW NONE ALANINE 5.0 g GLYCER- 75 g 40 sec. BROWN CHOCOLATE LEUCINE 4.0 g INE 60 sec. DARK BROWN DARK CHOCOLATE II-7 PHENYL CERELOSE 11.0 g ETHANOL 16 g 7-8 NaHCO.sub.3 5.4 g 20 sec. NONE NONE ALANINE 5.0 g GLYCER- 75 g 40 sec. TAN FAINT CHOCOLATE LEUCINE 4.0 g INE 60 sec. LIGHT BROWN MILK CHOCOLATE
EXAMPLE III
Formation of Drum Chilled Chocolate Flavor Precursor Power
The following mixture is prepared:
______________________________________Ingredients Parts by Weight______________________________________Sugar-amino acid composition 30 gramsof Example II-6 (10.0 gramsphenyl alanine, 8.0 gramsleucine and 11 grams cerelose)20% MYVEROL ® 1806 in 24 gramsDURKEE ® 17 (MYVEROL ® isa fatty acid mono glycerideand DURKEE ® 17 is a stearicacid ester manufactured by theGlidden-Durkee Corporation ofSt. Louis, Missouri)SIPERNAT ® 50S (a precipitated 6 gramssilicon dioxide compositionhaving a bulk density of 6.2 poundsper cubic foot; and average particlesize of 8 microns; and a surfacearea of 450 square meters pergram manufactured by theDegussa Corporation of Teterboro,New Jersey)______________________________________
The flavor precursor composition is intimately admixed with the SIPERNATE®50S a Hobart mixer (No. 1 speed for 5 minutes). The mix becomes a mass of paste and the resulting mass is intimately admixed with the fat mixture (30% MYVEROL®1806 and 70% STEARINE®17).
The resulting product is drum chilled at a speed of 5 in a small unit drum-drier producing 0.5 pounds per minite. The temperature of the feed is 170° F. The drum-drier is:
Blaw-Knox Model 639.
The drum chilled films were crushed and sifted through a Baker's screen basket and then sieved through a No. 10 sieve.
EXAMPLE IV
Production of Chocolate Cake
The following materials are utilized in various combinations as set forth in Examples IV(A), IV(B) and IV(C), infra.
______________________________________Ingredients Parts by Weight______________________________________Egg 100 gWater 300 gCorn Oil 100 gFlavor Precursor (of 255 gExample II)Sodium chloride 2 gBaking powder 3 gCRISCO ® (a trademark of 40 gthe Proctor & Gamble Companyof Cincinnati, Ohio)Sugar 200 gBaker's chocolate 4.5 gProduct of Example III 0.5 g______________________________________
EXAMPLE IV(A)
The egg, water, corn oil, flavor precursor mixture, salt, baking soda, CRISCO® shortening, sugar and melted baker's chocolate are intimately admixed.
EXAMPLE IV(B)
The egg, water, corn oil, flavor precursor composition of Example II-6, salt, baking soda, CRISCO® shortening, sugar, melted baker's chocolate and the product of Example III are initmately admixed.
EXAMPLE IV(C)
The melted baker's chocolate and product of Example III are intimately admixed. The mixture is added to corn oil, CRISCO® and shortening. Then egg, water, sodium chloride, baking soda and flour is added and the resulting product is intimately admixed.
Doughs's from Examples IV(A), IV(B) and IV(C) were baked separately in a 1050 watt microwave oven for 12 minutes turning 90 degrees after six minutes.
In a blind panel test:
(i) cakes (A) and (B) were judged to be equal to each other by taste and room aroma; and
(ii) cake (C) was unanimously judged to be superior in taste and room aroma with reference to cakes (A) and (B).
On organoleptic scale of 1-10 (with 1 being the least preferred and 10 being the most preferred) cake (A) was given a value of 7; cake (B) was given a value of 7 and cake (C) was given a value of 9.
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Described is a process for carrying out microwave production of baked goods having a chocolate flavoring thereon and/or therein and products produced thereby.
The process comprises the steps of:
(a) providing a composition of matter consisting essentially of precursors of a chocolate flavor (e.g., sugar, leucine and phenyl alanine) and a solvent capable of raising the dielectric constant of the surface and/or the internal matrix of a foodstuff to be cooked whereby the cooking time will be less than 120 seconds (such as propylene glycol or glycerin) and water;
(a') optionally, also providing a composition of matter consisting essentially of precursors of a Maillard reaction product flavor in admixture with the composition (a), supra, or separately with a solvent capable of raising the dielectric constant of the surface and/or internal matrix of the foodstuff to be cooked whereby the cooking time will be less than 120 seconds (such as propylene glycol or glycerine) and water;
(b) providing an uncooked baked goods foodstuff, e.g., dough;
(c) coating the composition of (a) and, optionally (a') onto the surface of the uncooked foodstuff and/or incorporating the composition of (a) and, optionally, (a') firstly into a controlled release system and then incorporating the controlled release system into the internal matrix of the foodstuff; and
(d) exposing the thus-treated uncooked foodstuff to microwave radiation for a period of under 120 seconds whereby the resulting product is caused to be edible as a cooked foodstuff having chocolate flavor nuances.
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BACKGROUND OF THE INVENTION
This invention relates to a pressure sensitive adhesive system for use in moldable automotive trim panels. Automotive trim panels are used to cover the hard surfaces of car interiors. Parts such as instrument panels, armrests, center consoles, seating, head rests, door skins and body pillar trim are some of the components provided with interior trim panels. These components typically comprise a structural substrate of aluminum, ABS or polypropylene. The surfaces are covered by a trim panel which typically has a vinyl or textile outer surface cushioned by a layer of foam padding underneath. The outer surface exposed to the vehicle passenger is referred to as an A-side layer. Typical materials for the A-side layer are leather, vinyl or textile materials such as cloth or carpet.
A desirable characteristic of a trim panel is that it have a padded or cushioned feel, for both styling and safety purposes. Also, for ease of installation, it is preferred that the trim panel be pre-formed to a contour that matches that of the underlying substrate to which the panel is applied. While the typical A-side materials have suitable qualities in terms of durability and appearance, none of them by themselves provide a padded or cushioned feel, nor can they be formed into a permanently contoured shape. Accordingly, a layer that provides padding and structure must be attached to the A-side material, such that it will lie between the substrate and the A-side layer. A suitable trim panel that is padded and formable to retain the contour of the substrate is described and claimed in U.S. patent application Ser. No. 08/797,643, now U.S. Pat. No. 5,962,089 invented by Vincent H-H. Jones and David L. Simon and in U.S. patent application Ser. No. 08/797,646, now U.S. Pat. No. 5,847,961 invented by Vincent H -H. Jones, David L. Simon and Scott M. Kloock, both filed on Jan. 31, 1997. The disclosures of these two applications are incorporated herein by reference.
The two patent applications describe a technique for thermoforming an automotive trim part formed of an A-side material laminated to a thermoformable foam layer. The material of the applications provides a self-supporting, padded trim panel, contoured to match a non-flat substrate and ready for attachment thereto. The present invention is directed to a construction for attachment of the trim panel to a substrate and is particularly concerned with a pressure sensitive adhesive which can be applied prior to the thermoforming of the part.
Pressure sensitive adhesive (PSA) systems comprise an adhesive layer covered by a removable release liner. These systems are also referred to as peel and stick adhesive systems. In general, PSA systems are not new. Bumper stickers, window decals, two-way tape and new postal stamps are all examples of PSA technology. The idea of using PSA for flat automotive trim panels is also known. There are many examples of substantially flat items of carpet, cloth, insulation and other trim pieces being applied to cars and trucks. While the performance requirements for automotive applications are more stringent than for a window decal (for example, the automotive component must withstand heat and cold cycles ranging from −30° F. to +212° F.), the general concept and methods of making the parts are essentially the same. In each case, a substantially flat adhesive layer and a release liner are applied to a substantially flat item. The end user or an assembly plant worker then removes the release liner and applies the item to its intended position, manipulates the part in place until it is properly located, and then applies pressure to wet-out the adhesive and adhere the part.
PSA represents a tremendous advantage to the automotive industry, particularly over hot-melt adhesives, for a number of reasons:
1. A PSA system eliminates “open time” as a factor in bond performance. Open time is the maximum amount of time an operator has available to complete the assembly of two or more components once the adhesive is ready for assembly;
2. No external heat source is required. A PSA system uses only normal ambient room temperature to secure components. This eliminates the potential for injuries resulting from the use of heat-activated processes like hot-melt adhesives;
3. PSA eliminates the need for adhesive dispensing equipment and the traditional application of adhesive at assembly. This also eliminates equipment such as robots, glue guns, etc., as well as environmental and safety issues sometimes associated with gluing operations;
4. PSA eliminates applying adhesive promoters to the back of a trim panel intended for use with a low surface energy substrate such as polypropylene. Such promoters are necessary to make traditional gluing systems work;
5. PSA technology allows for more consistent application of the adhesive layer, improving quality and allowing for the use of adhesives targeted at tough applications such as bonding to polypropylene. All of the above represent cost savings.
With all of the clear advantages, there is a strong desire for a PSA system for non-flat, contoured automotive trim panels which has heretofore not been satisfied. The reasons for this are as follows:
1. Lack of a PSA system which lends itself to being molded into a contoured shape;
2. Lack of a PSA system which will withstand the temperatures typically used in molding automotive trim components such as door bolsters. Such temperatures typically range from 300° F. to 700° F.;
3. Lack of a method for making dimensionally repeatable contoured automotive trim panels which has the tooling and process controls required for handling a PSA system; and
4. Lack of a method to manufacture a PSA system which can withstand items 1, 2 and 3 above.
The above difficulties have led to failures with PSA systems in contoured trim panels. These failures include the release liner wadding up, the part material getting stuck in the tooling, the release liner tearing during the molding process, and the PSA system being burned away during the molding process.
SUMMARY OF THE INVENTION
The present invention is directed to a pressure sensitive adhesive for moldable automotive trim materials and to a non-flat automotive trim part having the PSA system applied thereto.
The trim panel has an A-side layer laminated to a thermoformable layer. A pressure sensitive adhesive is applied to the thermoformable layer and covered by a release liner that can withstand the high heat of thermoforming. The part is then thermoformed at a temperature of at least about 300° F. or at least about 350° F. The release liner is preferably a polyester film with a differential release silicone treatment. That is, the polyester film has a silicone coating or layer on both sides, but one of the silicone layers has an inhibitor added so that the pressure sensitive adhesive sticks more tightly to that side than the other side. The silicone treated polyester film is said to have a “tight” side and a “loose” side. The pressure sensitive adhesive is applied to the tight side; the film can then be rolled up on itself and when it is unrolled, the adhesive will preferentially adhere to the tight side and release from the loose side. The pressure sensitive adhesive system can be applied to the thermoformable layer at the time the thermoformable layer is laminated to the A-side layer. Or, the PSA system could be applied separately from the lamination of the A-side and thermoformable layers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of an automotive trim part with a corner fanned apart to illustrate the layers making up the part.
FIG. 2 is an exploded section taken along line 2 — 2 of FIG. 1 .
FIG. 3 is a section similar to FIG. 2, showing an alternate embodiment.
DETAILED DESCRIPTION OF THE INVENTION
An automotive trim panel made in accordance with the present invention is shown generally at 10 in FIG. 1 . This particular example is for a door. The present invention may also be used for other automotive trim panels or components, including trim bolsters, console panels, glove box doors, sail panels, door bolsters, door trim, quarter trim, and less preferably package tray panels, instrument panels and headliners. The panel 10 defines a contour which includes an arm rest 12 , a door latch opening 14 and curved upper and lower edges 16 and 18 . In particular, the arm rest 12 causes the panel to have a non-flat, contoured shape. The non-flat, contoured shape of the panel is imparted by a thermoforming process as described in the patent applications referred to above. The panel has an A-side material on its outer surface, a thermoformable layer laminated to the A-side material by an adhesive layer, and a pressure sensitive adhesive (PSA) system on the inner surface of the thermoformable layer. The PSA system allows installation of the panel by removing a release liner, positioning the panel in the correct location on a substrate (which in this case would be the interior structural member of a door), and pressing the panel in place to fully activate the adhesive and set the bond between the panel and substrate.
The panel material is shown in FIG. 2 . It includes an A-side layer 20 , such as vinyl, leather, cloth or carpet. An adhesive layer 22 laminates A-side layer 20 to a thermoformable layer 24 , such as urethane foam, polypropylene foam, felt or polyethylene foam. The thermoformable layer can be any material that will be self-supporting after thermoforming, i.e., the formed material has sufficient stiffness or rigidity to retain a contoured shape and will not crumple under its own weight. Further details of the A-side layer and thermoformable layer and methods of laminating them together are disclosed in the patent applications referred to above. Taken together the A-side layer, adhesive layer and thermoformable layer may be considered a structural layer.
The PSA system comprises a release liner 26 and a pressure sensitive adhesive layer 28 . The release liner 26 is a moldable film that can retain its shape after thermoforming and withstand the high heat (300° F. to 700° F., more preferably 350° F. to 400° F.) required to thermoform the materials used for automotive trim panels. Polyester film has been found to be a suitable release liner material. A differential silicone treatment is applied to the surfaces of the polyester film. The adhesive is applied to the “tight” side of the liner, i.e., the side with the inhibitor. A preferred polyester film release liner is Product No. 2-2PESTR(P2)-6200&4320C, available from Daubert Coated Products of Westchester, Ill., which is a 2 mil polyester film with differential release silicone treatment. A less preferred release liner from Daubert is Product No. 2-PESTR(P2)-4000&4320C. The polyester film release liner is preferably 1-6, more preferably 2-6, more preferably 2-4, and optimally about 2, mils thick.
The adhesive layer is preferably a styrene isoprene styrene block copolymer pressure sensitive adhesive. A suitable example of this type of adhesive is PL915M available from SIA Adhesives, Inc. of Akron, Ohio. This adhesive has the desirable characteristic of being repositionable. That is, a part can be lightly placed in position and if the position is not correct, the part can be lifted off the substrate and repositioned to the correct location. The adhesive will not produce a full bond until heat or pressure are applied (or after an appreciable passage of time). The adhesive is 100% solids as there is no solvent or the like to keep it in a dispersed state. Less preferably the adhesive may be a styrene-butadiene-styrene pressure sensitive adhesive, such as Products 8706, 8707, 8709 and 1191 from Avery Dennison, Fasson Films Div., Painesville, Ohio. Further less preferable alternate pressure sensitive adhesive systems include acrylic, butadiene-acrylonitrile, butyl rubber, natural rubber, silicone, polychloroprene, polyvinyl acetate, polyvinyl ether, polyurethanes or other synthetic rubber or resin systems. Other useful PSAs are shown in U.S. Pat. No. 4,820,746, the disclosure of which is incorporated herein by reference.
Preferably the pressure sensitive adhesive meets the heat resistance requirements of General Motors Specification No. 3608 Type 1 Grade A and Chrysler Specification No. MS-CC925 Type A. SIA Adhesives' Product No. PL915M meets both of these specifications. For automotive trim panels in some higher heat areas of the car, such as the instrument panel and rear package tray and other areas at or above the “belt line” (the lower edge of the glass in the doors and windshields), it is preferred that the pressure sensitive adhesive meet Grade B of the GM specification mentioned above.
When preparing the PSA system, the adhesive is heated to a liquid state and cast or coated onto a moving release liner in a coating machine, e.g., a slot die coater. The adhesive layer preferably has a thickness of 4-16 mils, more preferably 6-12 mils, more preferably about 8 to about 12 mils, which has been found to produce effective bond strengths. Once the adhesive solidifies on the release liner, the liner and adhesive may be immediately attached to the structural layer, such as by a nip roller. Or the liner and adhesive may be rolled up for transportation and/or storage followed by subsequent unrolling and lamination to the structural layer. When the adhesive is applied to a foam structural layer, unprimed foam has produced acceptable results.
Less preferably, the pressure sensitive adhesive can be applied to the thermoformable layer 24 by spray coating, roll coating, slot die coating, or other coating technique known in the art, and then the protective release liner is applied on top of the adhesive layer. The part is then subsequently thermoformed. Another alternate application method is laminating the adhesive to the thermoformable layer, as described below. If the adhesive is first applied to the thermoformable layer, it is possible to use a release liner having a silicone treatment only on the side of the liner facing the adhesive. Thus, the outer face of the release liner would not necessarily have to have the silicone treatment, leading to cost reduction.
Another alternative method of applying the pressure sensitive adhesive to a structural layer is to first apply the adhesive to a carrier sheet, laminate this sheet to the structural layer and then replace the carrier sheet with a polyester release liner The carrier sheet has a differential release silicone treatment so the carrier sheet acts like a release liner. The carrier sheet could be made of an inexpensive material that is not necessarily thermoformable, such as paper. The adhesive and carrier sheet is laminated to the structural layer on the side opposite the A-side material. Thereafter, the carrier sheet is removed, leaving the adhesive on the structural layer. Finally the adhesive is covered by a moldable release liner, such as polyester, making the panel ready for thermoforming. This method has the advantage of permitting preparation of the adhesive layer and the structural layer at different times or locations, which may afford cost advantages. And the release liner could have the single-sided silicone treatment referred to above.
An alternate form of the panel material of the present invention is illustrated in FIG. 3 at 30 . This panel material includes only a thermoformable structural layer 32 , such as felt, with no A-side layer. A pressure sensitive adhesive layer 34 and release liner 36 are applied as in the above embodiment. The point here is that the PSA system of the present invention can be used on parts that do not require a cosmetic outer surface. Examples of this are insulation parts that are not exposed to an automotive interior.
While a preferred form of the invention has been shown and described, it will be realized that alterations and modifications may be made thereto without departing from the scope of the following claims.
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An automotive trim panel has a thermoformable structural layer shaped into a non-flat contour with a pressure sensitive adhesive system applied to one side of the panel. The pressure sensitive adhesive is coated onto a release liner which is then attached to the structural layer. Both the adhesive and release liner are capable of withstanding the high heat of thermoforming. The trim panel can be applied to a substrate by peeling away the release liner and sticking the panel to the substrate.
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This is a continuation of application Ser. No. 07/558,431, filed Jul. 27, 1990 which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
The present invention relates to an optical recording and/or reproducing apparatus such as optical disc apparatus, and in particular, relates to an optical system for such optical recording and reproducing apparatus.
Optical disc apparatus such as opto-magnetic disc apparatus has come to be widely used for text data file for the recording of computer data.
Generally, since the optical system for the opto-magnetical disc apparatus is complicated, the weight of the system increases. This fact results in a major problem in realizing a high speed access. As the means for solving this drawback, there is known a separation-type system such that only an objective lens of the optical system, an actuator unit for driving the lens and relay prism for directing a laser beam to the lens are mounted on a feed/or tracking mechanism, to thus construct a movable unit transferred in a radial direction of the disc, and that other portion of the optical system are fixed to the base of the recording and reproducing apparatus to thereby reduce the weight of the movable unit to much degree, thus performing a high-speed access.
In case of recording or reproducing, the disc is driven to rotate at a high speed (such as 3,600 rpm) and irradiating the light spot of the laser beam to the disc and performing the optical recording and reproducing requires that the light spot be moved in the direction of the diameter of the disc and with the range from the outer diameter to the inner diameter of the disc. In addition, when there is the vibration of the surface of the disc, the point of focus of the light spot must automatically track on the disc.
the movement of the light spot in the direction of the radius (feed operation) uses a tracking servo actuator and is performed by moving the relay prism and the objective lens. In addition, the operation so that the point of focus tracks the disc uses a focus servo actuator and is performed by moving the objective lens up and down.
These tracking servo and focus servo actions should desirably be performed at a high access speed with respect to the disc, and have improved controllability of the objective lens without causing vibration and the like. In addition, it is also desirable that the servo actuator be small and lightweight.
SUMMARY OF THE INVENTION
The present invention relates to an optical recording and reproducing apparatus such as optical disc apparatus, and in particular, relates to optical system drive apparatus for such optical recording and reproducing apparatus.
This object of the present invention can be achieved by an optical system having a first moving portion that holds an objective lens, a second moving portion that holds an relay prism, a connection means connecting the first moving portion and second moving portion, a focus moving means to move the first moving portion in the direction of focus, and a tracking feed moving means to move the first and second moving portions in the direction of tracking feed.
In addition, the optical system of the present invention has as the connection means, a first connection means that can be displaced in the direction of focus, and a second connection means that can be displaced in the direction of tracking feed.
In addition, the optical system of the present invention has as the focus moving means and the tracking feed means, a coil for both focus servo and tracking servo feed fixed to the first moving means, and a magnet fixed around the coil.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will now be described in greater detail with reference to the accompanying drawings wherein:
FIG. 1 is schematic view of a first embodiment of an optical recording and reproducing apparatus in accordance with the present invention;
FIG. 2 is a perspective view of the optical system of FIG. 1;
FIG. 3 is a cross-sectional view of the optical system of FIG. 2;
FIG. 4 is a bottom view of the optical system of FIG. 2;
FIG. 5 is a view similar to FIG. 1 showing a second embodiment of the present invention;
FIG. 6 is a perspective of the optical system of FIG. 5;
FIG. 7 is a cross-sectional view of the optical system of FIG. 6;
FIG. 8 is a bottom view of the optical system of FIG. 6;
FIG. 9 is a view similar to FIG. 1 showing a third embodiment of the present invention;
FIG. 10 is a perspective view of the optical system of FIG. 9;
FIG. 11 is a cross-sectional view of the optical system of FIG. 9;
FIG. 12 is a bottom view of the optical system of FIG. 9;
FIG. 13 is a view similar to FIG. 1 of a forth embodiment of the invention;
FIG. 14 is a perspective of the optical system of FIG. 14;
FIG. 15 is a bottom view of the optical system of FIG. 14; and
FIG. 16 is a cross-sectional view of the optical system of FIG. 14.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 through FIG. 4 are views indicating a first embodiment of the present invention. FIG. 1 is an outline view indicating the configuration of a compact opto-magnetic disc apparatus, and an opto-magnetic disc apparatus 1 is configured from a compact opto-magnetic disc 2, an electromagnet 6, an optical unit including a focus and tracking servo actuator 20, and a base 5.
The disc 2 consisting of a transparent substrate 2a, an opto-magnetic film 26 and a protective film 2c, is rotatably driven at a speed CAV 3,600 rpm by a spindle motor (not indicated in the figure) which is fixed to the base 5. Then, an electromagnet 6 disposed via a gap, on the side of the protective film 2c, impresses a bias magnetic field in the direction vertical with respect to the opto-magnetic film 2b. In addition, laser light 16B from an optical unit 7 comprising a fixed unit 7A and movable unit 7B performs the recording and reproducing of information with respect to the opto-magnetic film 2b and from the side of substrate 2a.
The optical unit 7 is configured from a laser diode 8, a collimator lens 9, a beam splitter 10, a relay prism 11, an objective lens 12, a polarizing beam splitter 13, converging lenses 14A and 14B, and photodiodes 15A and 15B, etc.
The laser light that is emitted from this laser diode 8 is collimated into parallel beams by the collimator lens 9 and then the sectional shape of the beam is shaped into a predetermined shape by a beam shaping prism not indicated in the figures. The light beams 16A that pass the beam splitter 10 are irradiated to the relay prism 11. The laser light 16B that is reflected by this relay prism 11 is irradiated by the objective lens 12, as a minute spot 17 onto the surface of the opto-magnetic film 2b on a recording track of a recording area 3 of the disc 2.
In the status where the optical unit 7 is operating in the recording mode, this minute spot 17 that is irradiated onto the surface of this opto-magnetic film 2b, has a light intensity that is suitable for recording. Also, in the status where the optical recording and reproducing apparatus 7 is operating in the reproducing mode, the laser diode 8 is controlled by an output control apparatus (not indicated in the figure) so that it has a light intensity which is suitable for reproduction.
When there is this recording mode, the direction of vertical magnetization of the opto-magnetic film 2b on the recording track at those places scanned by the light spot 17 modulated by the recording data, is reversed by the bias magnetic field of the electromagnet 6, and the recording of data signals is therefore performed.
When there is the reproduction mode, because of the previously described opto-magnetic effect and the vertical magnetization direction of the photo-magnetic film 2b, the laser light reflected by the surface of the photo-magnetic film 2b varies in its plane of polarization, and is reflected by the beam splitter 10 and via the objective lens 12 and relay prism 11, and is irradiated via a 1/2-wavelength plate (not indicated in the figure) to the polarizing beam splitter 13. The laser light that passes this polarizing beam splitter 13 is converged by the convergence lens 14A and is converted into electrical signals by the photodiode 15A, and is outputted as detection signals. On the other hand, the laser light that is reflected by this polarizing beam splitter 13 is converged by the converging lens, 14B, converted into electrical signals by the photodiode 15B, and outputted as detection signals.
These electrical signals respectively vary in their amplitude in response to the variation of the plane of polarization, to the opposite direction because of the action of the polarizing beam splitter 13 and so reproduction of the data recorded on the disc is performed from the difference between both of them.
The focus and tracking servo actuator 20 is comprised of a focus servo actuator 21 and a tracking servo actuator 27, and is incorporated into the movable unit 7B.
This focus and tracking servo actuator 20 has a coil holder 24 supporting the objective lens 12, a movable base portion 27b supporting the relay prism 11, and supported so as to be slidably movable in the direction of the linear ball bearing 27a fixed to the base 5, and in addition, the coil holder 24 and the movable base portion 27b are connected by a focus servo leaf spring 25 and a tracking servo leaf spring 36. The focus servo coil 23 and the coil for tracking servo/feed coil 34 are provided with a fixed portion 28 which is a magnetic field portion fixed to the base 5 for both the tracking servo/feed, and the focus servo that form closed magnetic fields in the tracking servo/feed coil 34 and the focus servo coil 23, respectively. This tracking servo actuator 27 is such that tracking is performed by the displacement of the tracking servo spring, and so that feed operation is mainly performed by the sliding of the linear ball bearing. In this manner, the light spot 17 is movable within the range from the outer diameter to the inner diameter of the recording area 3 of the disc 2.
FIG. 2 through FIG. 4 are diagrams indicating a specific embodiment of the focus and tracking servo actuator 20.
As has been described, this focus and tracking servo actuator 20 is monolithically configured of a focus servo actuator 21 and a tracking servo actuator 27. The moving portions 22 and 33 of each move in conjunction with the fixed portion 28 common to both, and perform the focus servo operation and the tracking servo/feed operation described above.
This tracking servo actuator 27 is configured from rectangularly-shaped plate magnets 29A and 29B which are magnetized in the direction of their thickness, steel plate back yokes 30A and 30B, prism-shaped steel yokes 31A and 31B, steel spacers 32A, 32B, 32C and 32D, and the like.
The outer surfaces of the magnets 29A and 29B are respectively fixed to the inner surfaces of the back yokes 30A and 30B respectively fixed to the lower surface of the base 5, so that they are respectively parallel with respect to the light beams 16A, and on the left and right of the light beams 16A of the laser light from the fixed unit 7A of the optical unit 7 described above. The yokes 31A and 31B are respectively disposed so that there are gaps of a predetermined size between the ends of their outer surfaces, so as to be parallel to and maintain gaps of a predetermined size with respect to the inner surfaces of the magnets 29A and 29B, and are fixed to the inner end surface of the spacers 32A, 32B, 32C and 32D.
The spacers 32A, 32B, 32C and 32D have their outer end surfaces respectively fixed to both of the ends of the inner surfaces of the back yokes 30A and 30B.
The moving portion 33 is configured from two coils 34A and 34B that have prism-shaped hollow cores, an intermediate moving resin body 35 that is the shape of a rectangular plate, two leaf springs 36A and 36B, a moving resin spacer 37, and a linear ball bearing 38, and the like.
These coils 34A and 34B have gaps of a predetermined inner diameter at their centers, and these gaps have the yokes 31A and 31B passing through them respectively. Both of the end surfaces of the coils 34A and 34B, and their outer surfaces that face the inside are fixed to a coil holder 24 to be described later. The intermediate moving resin body 35 is disposed so that both of the end surfaces on the right side with respect to the light beams 16A from the fixed unit 7A are fixed to the movable ends of the leaf springs 36A and 36B. In addition, the round through hole 35a formed in the center portion is disposed so that the light beams 16A pass through it. This intermediate moving resin body 35 is linked to the leaf springs 25A, 25B, 25C and 25D by the coil holder 24 to be described later. In addition, the leaf springs 36A and 36B are disposed so as to be vertical and parallel at a predetermined distance to each other, and perpendicular to the direction of the light beams 16A.
The linear ball bearing 38 has its fixed portion fixed to the lower surface of the base 5 at a position on the outer side of the back yoke 30B and so that its movable portion 38b can slidably move parallel to the direction of the light beams 16A.
The moving portion base 37 is configured from a base portion 37a, an relay prism support portion 37b, and a leaf spring support portion 37c. The upper surface of this base portion 37a is fixed to the lower surface of the movable portion 38b of the linear ball bearing 38. In addition, the side of the fixed unit 7A extends for a predetermined length from the end surface of the fixed portion 38a of the linear ball bearing 38. Then, the leaf spring support portion 37c is formed perpendicular to the upper surface of this end portion that extends. The leaf springs 36A and 36B are respectively fixed to the surface on the inner side of this leaf spring support portion 37c. These leaf springs 36A and 36B, and the linear ball bearing 38 enable the intermediate moving resin body 35 and hence the coil holder 24 to move only in the direction of the light beams 16A and without contacting the fixed portion 28. In addition, the relay prism support portion 37b is disposed beneath the magnet 29B, the back yoke 30B and the coil 34B, and one end of it is formed as a single unit with a portion that overlaps the movable portion 38b of the linear ball bearing 38 on the surface of the inner side of the base portion 37a. To this distal end portion and corresponding to the light beams 16A is fixed the relay prism 11 that converts the optical axis of the light beams 16A into the perpendicular direction. This relay prism 11 is inserted at a predetermined distance into the cavity formed between the coil 34A and the coil 34B of the coil holder 24 described above.
The focus servo actuator 21 is configured from a moving portion 22 and a fixed portion 28. This moving portion 22 is configured from four L-shaped hollow coils 23A, 23B, 23C and 23D, a resin coil holder 24, and four leaf springs 25A, 25B, 25C and 25D.
These coils 23A, 23B, 23C and 23D are formed into an L-shape by bending them at right angles around the corners of the coils that have been wound around square-shaped hollow centers. These two coils 23A and 23B overlap and are fixed to the outer peripheries of the coil 34A of the tracking servo actuator 27 and the other two coils 23C and 23D overlap and are fixed to the outer periphery of the previously described coil 34B. This is to say that these coils 23A and 23B are disposed so that one side of each of the coils is respectively fixed to an upper surface and a lower surface of the side of the coil 34A, so that the other sides of each of the coils are respectively disposed so that there is a gap of predetermined size between the inner surface of the magnet 29A inside the cavity formed between the magnet 29A and the yoke 31A. These coils 23C and 23D are disposed so that one side of each of the coils is respectively fixed to the upper surface and the lower surface of the side of the coil 34B, and so that the other sides of each of the coils are respectively disposed so that there is a gap of predetermined size between the inner surface of the magnet 29B inside the cavity formed between the magnet 29B and the yoke 31B. Also, the distal ends of the outer peripheries that are other than the contact end surfaces of these coils 23A and 23B, and 23C and 23D are respectively fixed to the coil holder 24.
This coil holder 24 is formed as a single unit with the coil holder portion and a lens holder portion. This coil holder portion has the coils 23A, 23B, and 34A, and coils 23C, 23D and 34B fixed to it in the manner that has already been described, and its top surface is formed so that it is flush with the side surfaces of coils 23a and 23C, its bottom surface is flush with the bottom surfaces of coils 23B and 23D, its left side surface is flush with the left side surfaces of coils 23A and 23B, and its right side surface is flush with the right side surfaces of coils 23C and 23D. This lens holder portion protrudes in a cylindrical shape into the central portion of the coil holder portion, and to its inner periphery is fixed the objective lens 12 with its center positioned on the optical axis of the light beams that are converted into the perpendicular direction by the relay prism 11.
The movable ends of the leaf springs 25A, 25B, 25C and 25D are respectively fixed perpendicular to the end portions of the upper left and right and lower left and right corners f the end surface forming a side of the fixed unit 7A of the coil holder portion of the coil holder 24, with each of the fixed ends being fixed so that they are perpendicular to the upper and lower left and right portions of the surface of the side of the coil holder 24 of the intermediate moving resin body 35. These leaf springs 25A, 25B, 25C and 25D are disposed so as to be horizontal and mutually parallel with respect to the light beams 16A. By this, the coil holder 24 can be moved only in the direction of the optical path of the light beams converted to the perpendicular direction by the relay prism 11. Moreover, these leaf springs 25A, 25B, 25C and 25D, and the leaf springs 36A and 36B are for the damping of parasitic vibrations and so to each of them are respectively adhered the rubber damping members 26A, 26B, 26C and 26D (not indicated in the figure), and 39A and 39B.
Focus servo signals flow through the coils 23A and 23B, and coils 23C and 23D of the focus servo actuator 21 previously described. By this, each of the sides of the coils 23A and 23B, and the coils 23C and 23D that are respectively disposed within the magnetic field in the cavities between the magnet 29A and the yoke 31A, and the magnet 29B and the yoke 31B, receive a magnetic force and these coils 23A, 23B, and coils 23C and 23D move in the upwards and downwards direction because of the displacement of the leaf springs 25A, 25B, 25C and 25D. Accordingly, the objective lens 12 moves on the optical axis of the light beams that have been converted into the perpendicular direction by the relay prism 11, and the point of focus of the light spot 17 produced by the objective lens 12 is kept on the disc 2 and focus servo operation performed.
Tracking servo signals flow through the coils 34A and 34B of the tracking servo actuator 27. By this, the sides of the coils 34A and 34B respectively disposed in a magnetic field in the cavity between the magnet 29A and the yoke 31A, and the magnet 29B and the yoke 31B receive a magnetic force so that the coils 34A and 34B move in the longitudinal direction of the magnets 29A and 29B and the yokes 31A and 31B because of the displacement of the leaf springs 36A and 36B. Accordingly, the objective lens 12 moves in the direction of the light beams 16A, and the light spot moving in the direction of the diameter of the disc 2 performs the tracking servo operations. In the same manner, feed signals flow through these coils 34A and 34B so that the sliding of the movable portion 38b of the linear ball bearing 38 causes the relay prism 11 and the objective lens 12 to move in the direction of the light beams 16A, and the movement of the light spot 17 within the range from the inner diameter to the outer diameter of the recording area 3 of the disc 2 performs the feed operation.
Moreover, in order to improve the response of this feed operation and tracking operation, the spring characteristics of the leaf springs 36A and 36B and the internal load characteristics of the linear ball bearing 38 are adjusted to predetermined values.
In addition, in the description of one embodiment of the present invention, these leaf springs 36A and 36B were described as being disposed on the side of the fixed unit 7A in the direction of the tracking feed but it is also possible for them to be disposed on both sides of the coil holder 24. It is a matter of course that the present invention not be limited to this, and that the leaf springs for focus servo, the leaf springs for tracking servo, and the bearing apparatus for feed be capable of various types of design modification within the scope of the present invention.
The focus and tracking servo actuator 20 of one embodiment of the present invention and having the configuration described above directly drives the objective lens 12 without the coils 34A and 34B for tracking servo feed acting via the leaf springs for focus servo. In addition, the longitudinal direction of the leaf springs 25A, 25B, 25C and 25D for focus servo is disposed in alignment in the direction of the tracking servo feed. By this, it is possible to have superior response and control characteristics for the tracking servo operation and the feed operation without there being any secondary vibration. In addition, the tracking servo operation and the feed operation have an improved access speed because they are both performed by the tracking servo actuator 27 described above.
In addition, the tracking servo operation is performed by the displacement of the leaf springs 36A and 36B for tracking servo and the feed operation is also performed in the same manner for the range of displacement of these leaf springs 36A and 36B. Accordingly, the frequency of operation of the linear ball bearing 38 is reduced, the friction is also reduced, and the reliability improved.
Also, the linear motors 49a and 69a for the dedicated feed apparatus 49 and 69 for feed operation are no longer required, and the moving portion 33 which is the field magnet portion is used for both the focus servo actuator 21 and the tracking servo actuator 27 and so the magnetic disc apparatus 1 can be made more compact and the costs reduced.
In addition, when the leaf springs 36A and 36B for the tracking servo are disposed on the side of the fixed unit 7A of the coil holder 24, the distance from the center of rotation of the disc 2 to the focus and tracking servo actuator 20 can be made larger and so it is possible to use a flat, thin type of motor of large diameter for the spindle motor and this also makes it possible for the disc apparatus 1 to be made thinner and be manufactured at lower cost.
FIG. 5 through FIG. 8 indicate a second embodiment of the present invention. In a disc apparatus 10 according to this second embodiment, two parallel arms 35c are fixed to the inner surface of a leaf spring holder portion 35b, in the direction perpendicular to that surface. The other ends of these parallel arms 35c are fixed to both of the end portions of the relay prism 11.
In this manner, the relay prism 11 is held by the two parallel arms 35c so that it is not necessary to provide the relay prism support portion 37b that extends to the lower portion of the relay prism 11 as there was in the first embodiment. Because of this, the movable base 371 is configured from the base portion 371a and a leaf spring holder portion 371b. The base portion 371a has its upper surface fixed to the lower surface of the movable portion 38b of the linear ball bearing 38, in the same manner as for the first embodiment. In addition, the leaf spring holder portion 371b that supports the leaf springs 36A and 36B is provided so as to cross the end portion of the base portion 371a at right angels.
The other portions of the configuration are the same as those for the first embodiment, are indicated with the same numerals, and the corresponding description of them is omitted.
In this embodiment, the relay prism 11 is supported by the two parallel arms 35c and so it is possible for the center of the objective lens 12 to always be in agreement with the optical axis of the light beams 16A that have been converted to the perpendicular direction by the relay prism 11. By this, it is possible for the recording and reproducing operation of the optical recording and reproducing apparatus to be performed accurately.
FIG. 9 through FIG. 12 indicate a third embodiment of the present invention. In the disc apparatus 100 according to this embodiment, the tracking operation is performed by the displacement of the shaft and bearings for the tracking servo.
The moving portion 331 is configured from a coil 341 that has a prism-shaped hollow core, a resin lens holder 351, a shaft 361, ring-shaped rubber plate dampers 371A and 371B, square rubber dampers 371C, 371D, 371E and 371F, a resin movable base 381, and a linear ball bearing 38, and the like.
This coil 341 has a gap of a predetermined inner diameter at its center, and this gap has the steel-bar 311 passing through it. The outer surfaces of the coil 341 that face the inside are fixed to an outer-facing surface of a coil holder 351b of a lens holder 351.
This lens holder 351 is comprised as a single unit, with a coil holder portion 341b disposed to the left side of light beams 16A of laser light from the fixed unit 7A, a shaft holder portion 351c that is C-shaped in section across its center portion and disposed on the right side of these light beams 16A, and a cylindrical-shaped lens holder 351a that protrudes into the center portion of the upper surface of a portion linking the upper surfaces of the coil holder portion 351b and the shaft holder portion 351c. To an upper end of an inner periphery of this lens holder portion 351a is disposed an objective lens 12 so that its center is positioned on the optical path of the light beams that are converted to the perpendicular direction by the relay prism 11. In addition, to the center portions of the lower side portion and the upper side portion of the shaft holder portion 351c are fixed the upper and lower end portions of the shaft 361. This shaft 361 is supported so as to be freely rotatable by the bearings 241a of the bearing means 241 to be described later, and which is inserted in the cavity portion of the C-shaped bearing holder portion 351c.
The movable base 381, the base portion 381a, the leaf spring holder portion 381b and the relay prism holder portion 381c are configured as a single unit, and the upper surface of this base portion 381a is fixed to the lower surface of the movable portion 38b of the linear ball bearing 38. The leaf spring holder portion 381b is a plate that is disposed parallel to, and so as to maintain a predetermined gap with respect to an inner surface and an outer surface of the fixed portion 38, and so as to be perpendicular to the upper surface of the base portion 381a. To its inner surface is vertically fixed the fixed end of the leaf springs 251A and 251B for focus servo (to be described later) and which support both the previously described bearing means 241.
In addition, the relay prism holder 381c is disposed beneath the bearing body 241, the leaf spring 251B and the previously described base portion 381a. At the end of the relay prism holder 381c, the relay prism 11 is fixed so as to correspond to the light beams 16A of laser light from the fixed unit 7A.
On the other hand, the focus and tracking servo actuator 210 is configured from a moving portion 220 and a fixed portion 28. This moving portion 220 is configured from two coils 23A and 23B having L-shaped cores, a resin bearing means 241 and two leaf springs 251A and 251B, and the like.
The previously described bearing means 241 is formed as a single unit from the leaf spring holder portion 381b of the moving base 381 and a leaf spring holder portion 241b and a bearing portion 241a which protrudes vertically in the upper and lower directions of the central portion of the inner surface of this leaf spring holder portion 241b. To the upper and lower end portions of the end surface of this leaf spring holder portion 241b are perpendicularly fixed the moving ends of these leaf springs 251A and 251B. In the central portion of the bearing portion 241a are formed bearing holes that pierce in the upper and lower directions and these bearing holes engage with the shaft 361.
The leaf springs 251A and 251B are respectively disposed parallel to each other and the bearing means 241, and therefore the lens holder 351 are movable only in the direction of the optical axis of the light beams that have been converted to the vertical direction by the relay prism 11. Moreover, these leaf springs 25A and 25B are for the damping of parasitic vibrations and so to each of them are respectively adhered the rubber damping members 26A and 26B.
In addition, between the upper side portion and the lower side portion of the shaft holder portion 351c of the lens holder 351 and the bearing portion 241a are respectively inserted dampers 371A and 371B so as to stop the play in the up and down direction of the shaft holder portion 351c of the lens holder 351 and the bearing portion 241a. Also, between the four corners of the inner surface of the leaf spring holder portion 241b and both ends of the surfaces of the outer ends of the lower and upper sides of the C-shaped shaft holder portion 351c are respectively fixed dampers 371C, 371D, 371E and 371F. Accordingly, the rotational movement of the shaft 361 with respect to the bearing holes of the bearing portion 241a is small with respect to the amount of the damping of these dampers 371C, 371D, 371E and 371F. Then, in accordance with this fine rotational movement, the direction of movement of the objective lens 12 is regarded as the direction of the optical axis of the light beams 16A and hence there is no problem. The range of movement of the objective lens 12 in accordance with this rotational movement can be adjusted by the material, hardness and shape of the dampers 371C, 371E, 371E and 371F so that it corresponds to the tracking servo movement described above.
The other portions of the configuration are the same as those described for the disc apparatus 1 and the disc apparatus 10 of the fist and second embodiment, the corresponding portions are indicated with the same numerals, and the corresponding descriptions of them are omitted. These coils 23A and 23B move slightly in the up and down direction. Accordingly, the objective lens 12 moves on the optical axis of the light beams that have been converted into the perpendicular direction by the relay prism 11, and perform focus servo operation.
Also, the flow of tracking servo signals through the coil 341 of the tracking servo actuator 270 causes the coil 341 to move slightly in the longitudinal direction of the magnet 29 and the yoke 31 in accordance with the rotational movement of the shaft 36. Accordingly, the objective lens 12 moves int he direction of the optical axis of the light beams 16A and performs tracking servo operation. In the same manner, the flow of feed signals through this coil 341 moves the relay prism 11 and the objective lens 12 in the direction of the optical axis of the light beams 16A and performs the previously described feed operation.
According to the present embodiment, the leaf springs for tracking servo are not used and so the displacement of the objective lens 12 in the direction of tracking feed is performed by only the shaft 361 and the bearings 241 and so there is good controllability of the tracking servo operation. In addition, by this, the frequency of operation of the linear ball bearing 38 is reduced, and the amount of wear of the bearing is also reduced. Furthermore, the leaf springs 251A and 251B for focus servo have a wide width and so secondary vibration does not generate and the tracking servo operation and the feed operation have a good response and controllability.
FIG. 13 through FIG. 16 are diagrams indicating a fourth embodiment of the present invention. In the apparatus 110 according to the present embodiment, the coil for focus servo is divided into two parts left and right, and disposing a relay prism between these two coils enables the focus servo actuator to be made thinner. In addition, the relay prism holder portion has a cantilevered structure and the compactness and light weight of the moving portion is emphasized.
As indicated in FIG. 14 through FIG. 16, the focus and tracking servo actuator 40 according to the present embodiment is configured as a single unit from the focus servo actuator 41 and the tracking servo actuator 52.
This tracking servo actuator 52 is configured from a fixed portion 53 and a moving portion 58. This fixed portion 53 is configured from a rectangular plate-shaped magnet 54 which is magnetized in the direction of its thickness, a steel back-yoke 55, a prism-shaped steel yoke 56, and spacers 57 and 58, etc.
This prism-shaped steel yoke 56 is fitted at both ends via the spaces 57A and 57B so that one surface of it is parallel to and held at a predetermined distance from the magnetized surface of the plate-shaped magnet 54. The side opposing the yoke 56 and this magnet 54, and the side opposing this are fixed to the inner surface of the back-yoke 55. To the upper end surface of this back-yoke 55 is fixed the lower surface of the base 5 so that the long direction of the plate-shaped magnet 54 and the prism-shaped steel yoke 56 are parallel to the direction of the optical axis of the light beams from the fixed unit 7A of the optical unit 7.
This moving portion 58 is configured from a oil 59 that has a prism shaped core, a resin movable base 60, and left and right leaf springs 61A and 62B, etc.
This coil 59 is inserted into the yoke 56 so as to maintain a predetermined gap with the inner surface of the hollow portion. Then, the surface of the side of the coil that is on the opposite side to the coil side that opposes the magnetized surface of the plate-shaped magnet 54 is fixed to the central portion of the outer surface of the base 60a of the moving base 60 that is parallel to this magnetized surface. To a lower end of an inner surface of the base portion 60a of this moving base 60 is formed a prism holding portion 60b which is perpendicular to the base portion 60a and which forms a single unit with it. The lower side of this relay prism holding portion 60b has the same dimension as the width of the base portion 60a and the upper surface is flat, has the same depth as the relay prism 11, and has a constant plate thickness. To the distal end of this relay prism holding portion 60b is fixed an relay prism 11 that converts the optical path into the perpendicular direction, and so as to correspond to the optical path of the light beams from the fixed unit 7A. also, to the upper distal ends of both ends of the inner surface of the base portion 60a are perpendicularly fixed one end of the leaf springs 61A and 61B. The other ends of these leaf springs 61A and 61B are respectively perpendicularly fixed to each of the ends of the inner surface of the back yoke 44A to be described later. In the status where these left and right leaf springs 61A and 61B control the focus servo actuator 41, the moving portion 46 of the focus servo actuator 41 and the moving portion 58 are movable only in the direction of the optical axis of the light beams from the fixed unit 7A. Then, when there is such movement, the leaf springs 61A and 61B are disposed parallel to and at a predetermined distance from each other so that they do not contact the focus servo actuator 41.
The focus servo actuator 41 is configured from a fixed portion 42 and a moving portion 46. This moving portion 46 is configured from two coils 47A and 47B with hollow prism-shaped centers that are rectangular in section, a resin objective lens holder 48, a resin coil holder 49 and upper and lower leaf springs 50A and 50B, etc.
On the inner surface of the cylinder-shaped lens holder portion that protrudes into the center portion of this objective lens holder 48 is fixed the objective lens 12 with its center positioned on the optical path of the light beams that are converted into the perpendicular direction by the relay prism 11. To the right and left of the relay prism 11 that opposes the direction of the optical axis of the light beams from the fixed unit 7A are disposed coils 47A and 47B with the direction of the windings on the coil sides on their long sides wound so as to be parallel to the direction of the optical axis. The surfaces of the upper ends of these coils 47A and 47B are fixed to the lower surface of the right and left of the lens holder portion of the objective lens holder 48. Also, the surfaces of the lower ends of these coils 47A and 47B are fixed to the upper surfaces of the left and right of the coil holder 49 for reinforcing. The portions of the coil 47A and 47B of the coil holder 49 and the objective lens holder 48 that are fixed are respectively formed with holes in the longitudinal direction and having the same shape as the hollow center portions of the coils 47A and 47B. To the end surface of the side of the base portion 60a of the objective lens holder 48 and coil holder 49 are respectively and perpendicularly fixed one end of the leaf spring 50A and 50B. The other ends of these leaf springs 50A and 50B are respectively and perpendicularly fixed to the inner surface of this base 60a. In the status where these upper and lower leaf springs 50A and 50B control the back yoke 44B and the magnet 43 that is to be described later, and which are between them, the moving portion 46 is movable only in the direction of the optical axis of the light beams that have been converted into the perpendicular direction by the relay prism 11. When there is this movement, the leaf springs 50a and 50B are disposed so as to be parallel to, and so as to maintain a predetermined distance to each other so as not to contact the magnet 53B and the back yoke 54B.
The fixed portion 42 is configured from a prism shaped magnets 43A and 43B and which are magnetized in the direction of the plate thickness, steel back yokes 44A and 44B, and rectangular, plate-shaped steel yokes 45A and 45B.
These yokes 45A and 45B are inserted into the center portions of the hollow portions of the hollow coils 47A and 47B, so that a gap of a predetermined size is maintained between the inner surfaces of the coil sides, and to the upper surfaces are respectively fixed the lower surface of the base 5. The magnetized surfaces of the magnets 43A and 43B are respectively disposed so as to oppose at a predetermined distance the surfaces of the coil side on the side opposite the relay prism 11. Also, the surfaces of the sides opposite the sides opposing these coils sides are respectively fixed to an inner surface of the back yokes 44A and 44B that have their upper surfaces respectively fixed to the lower surface of the base 5.
The other portions of the configuration are the same as those for the first embodiment, are indicated with the same numerals, and the corresponding description of them is omitted.
Also, the flow of tracking servo signals through the coil 59 of the tracking servo actuator 52 causes the coil 59 to move slightly in the longitudinal direction of the magnet 54 and the yoke 56 and perform tracking servo operation. In addition, the feed operation is also performed in the same manner by the tracking servo actuator 52.
Also, the flow of focus servo signals to the coils 47A and 47B of the focus servo actuator 41 moves these coils 47A and 47B in th downwards direction. Accordingly, the objective lens 12 moves in the direction of the optical axis of the light beams 16A that have been converted into the perpendicular direction by the relay prism 11, and the movement of the spot by the objective lens 12, in the direction of the plate thickness of the disc 2 performs the focus servo operation.
In order to dampen harmful vibration during the focus servo operation and the tracking servo operation, this leaf springs 50A, 50B and 61A and 61B of this focus servo actuator 41 and tracking servo actuator 52 have rubber damping members 51A, 51B, and 62A and 62B respectively adhered to them.
Moreover, in the focus and tracking servo actuator 40 of one embodiment according to the present invention, the tracking servo actuator 52 is used to perform both tracking servo operation and feed operation as has been described before but, it is also possible for it to perform only tracking servo operation and for the feed operation to be performed by a separately disposed feed apparatus.
Furthermore, the relay prism holding portion 60b of the moving base 60 was described using the example where there was a constant plate thickness but it is also possible to have plate thicknesses of various sizes in order to lighten the weight or improve the strength.
According to the present embodiment, it is possible to have the relay prism 11 disposed between the left and right coils 47A and 47B, and realize a compact optical recording and reproducing apparatus. In addition, the relay prism holding portion 60b has a cantilevered structure that enables the moving base portion 60 to be compact and lightweight.
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An optical system for an optical recording and/or reproducing apparatus that irradiates laser light emitted from a light emitting diode (8) to an opto-magnetic disk (2) via a relay prism (11) and an objective lens (12) and irradiates light reflected by said opto-magnetic disk to a light-receiving diode (15 A,B), and which has a first moving portion (22) that holds the objective lens, a second moving portion (33) that holds the relay prism, a connection mechanism connecting the first moving portion and the second moving portion, a focus moving device (21) to move said first moving portion in the direction of focus, and a tracking feed moving device (27) to move the first and second moving portions in the direction of tracking feed.
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CROSS REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY
[0001] This patent application claims benefit under 35 U.S.C. 119(e), 120, 121, or 365(c), and is a National Stage entry from International Application No. PCT/KR2011/006645, filed Sep. 8, 2011, which claims priority to Korean Patent Application numbers 10-2010-0088656 filed Sep. 10, 2010, and 10-2010-0099563 filed Oct. 13, 2010, entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to an endoscopy instrument guide port.
[0004] 2. Description of the Related Art
[0005] In general, since a size of an operation hole (incision window) of a laparoscopic endoscopic operation (that is also called ‘minimally invasive surgery’) is small as compared with that of a traditional laparotomy operation, the laparoscopic endoscopic operation has merits that scars left from surgery are not bad-looking, pain due to the wound is more reduced, and the hospital treatment period is shorten due to a short recovery time so that the patient returns more quickly to daily life. Thus, in recent years, the laparoscopic endoscopic operation has been widely conducted for most diseases except for several cancers.
[0006] According to the endoscopic operation, a small hole is perforated in the belly of a patient by using an intubation surgical device called a trocar, in which at least one trocar is inserted into the belly and various surgical devices such as a forceps, a cutting device, an internal organ extraction device, and an endoscopic camera are introduced to an operated portion in the belly through the trocar to perform various operations such as cholecystectomy, biliary stone removal, appendectomy, and a general surgical operation.
[0007] Meanwhile, in recent years, endoscopic operations are being performed through a portion of a navel by using a plurality of trocars described above without incising the belly to reduce the scar left in the belly of the patient and allow the patient to recover promptly.
[0008] In general, if a hole for an operation is perforated in the navel of a human body, the scar is not easily exposed to the outside even after the wound is healed up and is not visually recognized as the scar, so an endoscopic operation through a navel is currently preferred.
[0009] In order to perform such a surgical operation, an operation hole of 10 mm to 12 mm is perforated in the navel according to the type of the operations, and a surgical tool guide for introducing various surgical tools into the belly is installed in the operation hole to be used.
[0010] However, the surgical tool guide according to the related art delays an operation because the surgical tool guide is easily separated from its installation position such as a belly or nitrogen gas introduced to ensure the operation space is often leaked during the operation. In this regard, the present applicant has developed a surgical tool guide for preventing separation of the guide to ensure a smooth operation, which was filed on Mar. 27, 2009 and registered as Korean Patent No. 10-915882.
[0011] The patented surgical tool guide of Korean Patent No. 10-915882 is shown in FIG. 13 . In the surgical tool guide 1 , a plurality of tool entrances 3 for entry of various surgical tools are provided at an upper portion of a body 2 , an attaching ring 4 having a resiliency to be attached to and supported by an upper portion of an operation hole is installed at an end of an opened bottom surface of the body 2 , and a support ring 5 is located at an outer portion of the body 2 in the longitudinal direction of the body 2 in an interior, which is defined as the attachment ring 4 overlaps an outer wall of the body 2 , in order to support the body 2 in correspondence with the attachment ring 4 according to a thickness of an abdominal wall when it is introduced into an abdominal cavity through an operation hole.
[0012] According to the surgical tool guide 1 as shown in FIG. 14 , the attaching ring 4 located at an upper portion of the operation hole is folded upward in a state that the support ring 5 is suspended in the abdominal cavity such that the attachment ring 4 can be positioned at an upper side of the belly according to a thickness of the belly wall to tightly tension the body 2 . Thus, the surgical tool guide 1 is not easily separated from the operation hole during the operation and the body 2 can be tightly maintained between the support ring 5 and the attaching ring 4 .
[0013] However, in spite of the merits described above, there are several problems in the above surgical tool guide. First, since the attaching ring 4 is provided at an end portion of the body 2 after the body 2 has surrounded the support ring 5 , even if the attaching ring 4 is wrapped in the state that the support ring 5 is suspended in the abdominal cavity, only a portion of the body 2 between the support ring 5 and the attachment ring 4 is tightly tensioned and a portion of the body 2 extending toward the surgical instrument entrance parts 3 from the support ring 5 may not be sufficiently tensioned.
[0014] Thus, it is difficult to properly adjust the length of the body 2 in the state that the support ring 5 is introduced in the abdominal cavity through the operation hole. Therefore, when the installed body 2 is too long (that is, the length from the operation hole to the surgical instrument entrance part is too long), there is a problem to reintroduce the support ring 5 into the abdominal cavity after adjusting the length of the body 2 by taking the introduced support ring 5 out of the abdominal cavity. Further, since the traction force for expanding the operation hole is insufficient, it is limited to ensure the space and the visual field for entry of a surgical instrument so that the operation may not be smoothly performed.
[0015] Further, since the surgical instrument entrance parts 3 are integrally and fixedly formed with the body 2 , the positions of surgical instruments may not be changed after the surgical instruments are introduced into the abdominal cavity, so that the positions of the surgical instruments may not be properly adjusted according situations during the operation. Thus, when it is necessary to control the positions of the surgical instruments, after the surgical instruments are inevitably taken out of abdominal cavity to change the positions of the surgical instruments, the surgical instruments must be again introduced inconveniently in the abdominal cavity through the surgical instrument entrance part.
[0016] In addition, when an organic extraction of a large size is resected during the operation after installation of the surgical tool guide, it is impossible to take the organic extraction out of the belly if the installed surgical tool guide is not dismantled. Further, since the distance between the surgical instrument entrance parts 3 , through which the surgical instrument is introduced, and the belly is too long, the operation is difficult and the distance control is not easy.
SUMMARY
[0017] The present invention has been made in an effort to solve one or more of the above-described problems, and an aspect of the present invention is to provide an endoscopy instrument guide port which can easily and simply control a length of a protective tube in an installed state thereof and can ensure the traction force for expanding an operation hole.
[0018] An embodiment of the present invention also provides an endoscopy instrument guide port in which a surgical instrument entrance part is constructed to be rotated in a horizontal direction and to be separated as necessary such that the surgical instrument entrance part can be properly modified according to the operation situation.
[0019] An embodiment of the present invention also provides an endoscopy instrument guide port in which an upper tube is connected to or separated from a lower tube through a tube connection unit such that the upper tube can be separated if necessary, such as for organic extraction, and the length of the guide can be easily adjusted according to the conditions of the patient and the operation environment so that an operation can be smoothly performed.
[0020] In order to solve the above problems, according to an aspect of the present invention, there is provided an endoscopy instrument guide port including a main body member having a top end at which at least one surgical instrument entrance part is formed; a protective tube extending downward from the main body member by a predetermined length; a support ring member provided at a lower end portion of the protective tube, the support ring member being freely deformed and restored; and an adjustment ring member fixedly provided at a predetermined position lengthwise along the protective tube to coil the protective tube through a folding motion in order to adjust a length of the protective tube.
[0021] The main body member includes an upper cap having a top end at which at least one surgical instrument entrance part is formed; and a rail ring member connected to the protective tube to support the upper cap such that the upper cap is able to horizontally rotate.
[0022] Further, there is provided an endoscopy instrument guide port including an upper cap having a top end at which at least one surgical instrument entrance part is formed; a rail ring member supporting the upper cap such that the upper cap is able to rotate in a horizontal direction; a protective tube connected to the rail ring member and extending downward by a predetermined length; and a support ring member provided at a lower end portion of the protective tube, the support ring member being freely deformed and restored.
[0023] The coupling ring member is formed at an upper end portion of the protective tube, a coupling member coupled to the coupling ring member is formed at a lower end portion of the rail ring member, and the rail ring member and the protective tube are detachably connected to each other.
[0024] The rail space portion is formed inside the rail ring member, and a shaft end protrudes from a lower end of the upper cap and is received in the rail space portion such that the shaft end is slidably rotated in a horizontal direction.
[0025] In addition, the endoscopy instrument guide port further includes a packing ring member received in the rail space portion and disposed above and below the shaft end in the rail space portion.
[0026] In addition, there is provided an endoscopy instrument guide port including an upper tube having a top end portion at which at least one surgical instrument entrance part is formed; a lower tube having a lower end portion at which a support ring freely deformed and restored is provided; and a tube connection unit for detachably coupling the upper tube and the lower tube.
[0027] The tube connection unit includes an upper ring member fixed to a lower end portion of the upper tube; and a lower ring member fixed to an upper end portion of the lower tube, and, in a state that the upper ring member is fitted around the lower ring member, the lower ring member is folded outward to coil the upper and lower tubes together such that the upper and lower tubes are connected to each other.
[0028] The lower ring member has a longitudinal length longer than a longitudinal length of the upper ring member.
[0029] The endoscopy instrument guide port according to the present invention can easily and simply control the length of the protective tube in an installed state thereof through a folding operation of the adjustment ring member included in the protective tube and tightly tension the protective tube through the length adjustment, so that a sufficient traction force can be ensured.
[0030] Further, since the surgical instrument entrance part can be rotated in a horizontal direction, a suitable treatment can be performed by rotating the upper cap without taking a surgical instrument out of the belly when necessary to adjust a position of the surgical instrument during an operation.
[0031] In addition, an organic extraction can be taken out of a belly by separating only the upper tube without a need to disassemble the entire endoscopy instrument guide port when it is necessary to take the organic extraction out of the belly. Specifically, after separating the upper tube, if the lower ring member is continuously coiled, the operation hole is expanded so that an organic extraction having a large size can be very easily extracted.
[0032] Further, in the state that the upper tube and the lower tube are connected to each other, the length of the guide can be easily adjusted through the coiling operation of the lower ring member and in addition, the extension of the operation hole can be smoothly controlled so that the operation can be more easily performed.
[0033] In addition, if the lower tube is used after separating the upper tube from the lower tube, the lower tube can be utilized as a wound protector to protect an incised surface of an operation hole.
[0034] Furthermore, besides the above effects, the unique effects, which can be easily induced and expected from the feature and configurations of the present invention, are also included in the effects of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a perspective view showing an endoscopic instrument guide port according to a first embodiment of the present invention;
[0036] FIG. 2 is an exploded perspective view showing a main body member and a protective tube according to the first embodiment of the present invention;
[0037] FIG. 3 is a sectional view showing an endoscopic instrument guide port according to the first embodiment of the present invention;
[0038] FIG. 4 is a sectional view illustrating an operation of an adjustment ring member according to the first embodiment of the present invention;
[0039] FIGS. 5 to 7 are exploded perspective views illustrating an operation of endoscopic instrument guide port according to the first embodiment of the present invention;
[0040] FIG. 8 is a perspective view showing an endoscopic instrument guide port according to the second embodiment of the present invention;
[0041] FIG. 9 is a sectional view of FIG. 8 ;
[0042] FIG. 10 is a view illustrating an operation of a tube connection unit according to the second embodiment of the present invention;
[0043] FIG. 11 is a view illustrating an installation state of an endoscopic instrument guide port according to the second embodiment of the present invention;
[0044] FIG. 12 is a view illustrating a separated state of an upper tube of an endoscopic instrument guide port according to the second embodiment of the present invention; and
[0045] FIGS. 13 and 14 are views illustrating a configuration and an operation of an endoscopic instrument guide port according to the related art.
DETAILED DESCRIPTION
[0046] Hereinafter, an exemplary embodiment of an endoscopy instrument guide port according to the present invention will be described in detail with reference to the accompanying drawings.
[0047] The embodiment is provided to more fully describe the present invention to those skilled in the art to which the present invention pertains, and it is noted that the shapes and sizes of elements in the drawings may be exaggerated to emphasize a more clear description.
[0048] Further, in the description of the embodiment, a detailed description of known functions and configurations which are apparent to those skilled in the art to which the present invention pertains will be omitted when they may make the technical feature of the present invention unnecessarily unclear.
[0049] FIGS. 1 to 4 are drawings showing an endoscopic instrument guide port 100 according to the first embodiment of the present invention. Referring to the drawings, an endoscopic instrument guide port (hereinafter, referred also to as ‘surgical instrument guide port’) 100 according to the first embodiment of the present invention includes a main body member 110 , a protective tube 120 , and a support ring member 130 .
[0050] First, the main body member 110 has a top end at which at least one surgical instrument entrance part 110 a is formed. Here, the surgical instrument entrance part 110 a is provided for the purpose of introducing various surgical instruments such as forceps or an endoscope into the surgical instrument guide port 100 for a laparoscopic operation. A valve unit 110 b may be provided at an upper end portion of the surgical instrument entrance part 110 a for the purpose of easily introducing the surgical instrument with preventing gas leakage as possible.
[0051] Since various configurations of the surgical instrument entrance part 110 a are well known in the art, the detailed description thereof will be omitted. In addition, it is possible to construct the surgical instrument entrance part 110 a according to an embodiment of the present invention in various configurations, so configurations of the surgical instrument entrance part 110 a are not limited to those shown in the drawings.
[0052] Further, in addition to the surgical instrument entrance part 110 a, a gas adjusting valve 110 c may be provided at an upper portion of the main body member 110 for the purpose of controlling entry and exit of the gas for expanding a belly.
[0053] The protective tube 120 has a hollow shape and extends downward from the main body member 110 by a predetermined length. The protective tube 120 may be formed of a urethane sheet having an excellent resiliency and durability.
[0054] The support ring member 130 which is a ring having an annular shape is fixed to a lower end portion of the protective tube 120 .
[0055] When the surgical instrument guide port 100 is installed, the support ring member 130 is suspended to an abdominal wall in an abdominal cavity after passing through an operation hole of a patient so that the support ring member 130 performs a function of supporting the surgical instrument guide port 100 . Thus, the support ring member 130 is formed of a resilient material which can be freely deformed, that is, can be folded or shrunk to be easily suspended during and after passing through the operation hole, and can be directly restored into an original state if an external force is removed.
[0056] The surgical instrument guide port 100 according to the first embodiment of the present invention having the configuration described above may further include an adjustment ring member 140 .
[0057] The adjustment ring member 140 , which is used for controlling a length of the protective tube 120 , may be fixed at a predetermined position lengthwise along the protective tube 120 . Preferably, the adjustment ring member 140 is substantially provided at a middle portion between the main body member 110 and the support ring member 130 .
[0058] Further, the adjustment ring member 140 , which has a ring shape, may be attached and fixed to an inner side surface or an outer side surface of the protective tube 120 . A sectional surface of the adjustment ring member 140 may substantially have a rectangular shape.
[0059] The adjustment ring member 140 coils the protective tube 120 through a folding operation so that the length of the protective tube 120 can be adjusted. As shown in FIG. 4 , if the adjustment ring member 140 fixed to the protective tube 120 is folded, the protective tube 120 is coiled around the adjustment ring member 140 while the protective tube 120 is being folded, so that the length of the protective tube 120 is reduced by the extent that the protective tube 120 is folded. Thus, the length of the protective tube 120 may be easily controlled and traction force may be obtained by controlling the number of folding times of the adjustment ring member 140 .
[0060] That is, if the protective tube 120 is continuously coiled around the adjustment ring member 140 , the length of the protective tube 120 is reduced more and more. Thus, the distance between the surgical instrument entrance part 110 of the main body member 110 and the belly may be reduced and in addition, the protective tube 120 is tightly strained, so that great traction force, by which an operation hole is expanded, may be generated.
[0061] Further, the surgical instrument guide port 100 according to the first embodiment of the present invention may be implemented such that the main body member 110 is able to be rotated horizontally.
[0062] To this end, the main body member 110 may include an upper cap 111 and a rail ring member 112 for supporting the upper cap 111 such that the upper cap 111 can horizontally rotate.
[0063] At least one surgical instrument entrance part 110 a may be formed at the top surface of the upper cap 111 and a shaft end 113 may protrude at the lower end of the upper cap 111 .
[0064] A rail space portion 114 may be formed inside the rail ring member 112 such that the rail space portion 114 may receive the shaft end 113 of the upper cap 111 therein to allow the shaft end 113 to be slidably rotated in a horizontal direction.
[0065] Thus, in the state that the shaft end 113 of the upper cap 111 is received in the rail space portion 114 of the rail ring member 112 , while the shaft end 113 is sliding, the shaft end 113 may be rotated in the horizontal direction, so that the upper cap 111 is rotatably supported by the rail ring member 112 . Thus, the upper cap 111 may be freely rotated in the horizontal direction as necessary. Therefore, it may be understood that a position of the surgical instrument entrance part 110 a which is formed in the upper cap 111 can be changed.
[0066] Meanwhile, a packing ring member 115 may be received in the mil space portion 114 , such that the packing ring member 115 may be installed on and below the shaft end 113 received in the mil space portion 114 .
[0067] The packing ring member 115 enhances a sealing function between the shaft end 113 and the mil space portion 114 , so that efficiency to prevent the gas leakage can be improved. A silicon material packing ring may be employed as the packing ring member 115 .
[0068] Further, the surgical instrument guide port 100 according to the first embodiment of the present invention may be implemented such that the main body member 110 can be separated from the protective tube 120 .
[0069] To this end, a coupling ring 121 may be provided at an upper end portion of the protective tube 120 , and a coupling member 116 , which is detachably connected to the coupling ring 121 , may be formed at a lower end portion of the rail ring member 112 .
[0070] The detachable coupling scheme between the coupling ring 121 and the coupling member 116 may be variously implemented. As shown in the drawings as one example, a female screw portion 121 a is formed on an inner surface of the coupling ring 121 and a male screw 116 a is formed on an outer surface of the coupling member 116 , so that the coupling ring 121 and the coupling member 116 may be detachably coupled to each other in a screw coupling scheme.
[0071] FIGS. 5 to 7 are views illustrating an installation and an operation of the surgical instrument guide port 100 according to the first embodiment of the present invention. The operation of the surgical instrument guide port 100 according to the first embodiment of the present invention will be described with reference to FIGS. 5 to 7 as follows.
[0072] First, as shown in FIG. 5 , after an operation hole for a laparoscopic operation is perforated at the navel of a patient, a portion of the surgical instrument guide port 100 is introduced through the operation hole.
[0073] In more detail, after folding or shrinking the support ring member 130 fixed to a lower end portion of the protective tube 120 in a narrow size, the support ring member 130 is introduced into the abdominal cavity through the operation hole.
[0074] Then, after completely passing through the operation hole, the introduced support ring member 130 is restored to the original state (that is, the annular state) due to the resilient force thereof, and accordingly, the support ring member 130 is expanded in the belly with the restoring force and is naturally suspended to the abdominal wall.
[0075] After the surgical instrument guide port 100 is installed at the operation hole through the support ring member 130 and the gas for expanding the belly is introduced (formation of gas belly), various surgical instruments (not shown) such as an endoscopy are introduced into the belly through the surgical instrument entrance part 110 a, such that an entropic operation is performed.
[0076] According to the surgical instrument guide port 100 of the present invention, before the gas for expanding the belly is introduced or while the entropic operation is being performed, as shown in FIG. 6 , the length of the protective tube 120 is reduced through the folding operation of the adjustment ring member 140 so that the distance between the surgical instrument entrance part 110 a and the operation hole may be reduced and the protective tube 120 is more tensioned. Thus, the space where the surgical instrument is moved may be expanded and a vision may be broadened, thereby facilitating the smooth operation.
[0077] While the entropic operation is proceeding by using the surgical instruments, if there is a need to change the positions of the surgical instruments, the positions of the surgical instruments may be changed by rotating the upper cap 111 without taking the surgical instruments out of the surgical instrument guide port 100 .
[0078] In addition, when an organic extraction having a large size is removed while performing an entropic operation, the organic extraction must be taken out of the belly. In this case, as shown in FIG. 7 , after the coupling member 116 of the rail ring member 112 coupled to the coupling ring 121 of the protective tube 120 is rotated in a screw releasing direction to allow the main body member 100 to be separated upward from the protective tube 120 , the organic extraction may be taken out of the belly through the opened upper end portion of the protective tube 120 .
[0079] As described above, according to the endoscopic instrument guide port 100 of the first embodiment of the present invention, the length adjustment of the protective tube and the traction force may be easily achieved through the adjustment ring member and the main body member may be rotated and separated, so that a suitable treatment may be performed according to an operation situation, so a delay of operation time may be prevented and endoscopic operation may be more smoothly performed.
[0080] FIGS. 8 and 9 are perspective and sectional drawings showing an endoscopic instrument guide 200 according to the second embodiment of the present invention. Referring to the drawings, an endoscopic instrument guide port (hereinafter, referred to as ‘surgical instrument guide port’) 200 according to the second embodiment of the present invention includes an upper tube 210 , a lower tube 220 , a support ring 230 and a tube connection unit 240 .
[0081] First, At least one surgical instrument entrance part 211 is formed at an upper end portion of the upper tube 210 .
[0082] The surgical instrument entrance part 211 is adapted to introduce various surgical instruments for an operation into the surgical instrument guide 200 , and a valve unit 212 may be provided at an upper end of the surgical instrument entrance part 211 for easily introducing the surgical instruments while preventing leakage of gas as possible. Various structures for the surgical instrument entrance part 211 are well known in the art, to which the present invention pertains, and the surgical instrument entrance part 211 may have various known structures, and the surgical instrument entrance part 211 may not be limited to those shown in the drawings.
[0083] A gas adjusting valve 213 may be provided at an upper end portion of the upper tube 210 in addition to the surgical instrument entrance part 211 , and the gas adjusting valve 213 is adapted to control entry and exit of the gas for expanding a belly during an operation.
[0084] The lower tube 220 is implemented separately from the upper tube 210 and has a structure in which an upper end portion and a lower end portion are all opened. The upper tube 210 and the lower tube 220 may be formed of a urethane sheet having an excellent resiliency and durability.
[0085] The support ring 230 which is a ring having an annular shape is provided to a lower end portion of the lower tube 220 . When the surgical instrument guide 200 is installed, the support ring 230 is suspended to an abdominal wall in an abdominal cavity after passing through an operation hole of a patient. Thus, the support ring 230 is formed of a resilient material which can be freely deformed, that is, can be folded or shrunk to be easily suspended during and after passing through the operation hole, and can be directly restored into an original state if an external force is removed.
[0086] The tube connection unit 240 connects the upper and lower tubes 210 and 220 , which are separately formed from each other. The tube connection unit 240 may include an upper ring member 241 and a lower ring member 242 .
[0087] The upper ring member 241 is fixed to a lower end portion of the upper tube 210 , and the lower ring member 242 is fixed to an upper end portion of the lower tube 220 corresponding to the upper ring member 241 . Similar to the support ring 230 , the upper and lower ring members 241 and 242 may be formed of a resilient material.
[0088] Further, sections of the upper and lower ring members 241 and 242 may have a rectangular shape. Specifically, the section of the lower ring member 242 preferably has a rectangular shape such that the lower tube 220 is easily coiled around the lower ring member 242 while the section of the lower ring member 242 is being folded outward. In addition, as shown in the drawings, a longitudinal length of the section of the lower ring member 242 is preferably longer than that of the upper ring member 241 .
[0089] According to the tube connection unit 240 , in the state of fitting the upper ring member 241 around the lower ring member 242 as shown in (a) of FIG. 10 , the lower ring member 242 is folded outward as shown in (b) of FIG. 10 , so that the folded upper and lower ring members 241 and 242 are coiled together as shown in (c) of FIG. 10 . Thus, the separated upper and lower tubes 210 and 220 are connected to each other in a tight and sealed state. The connected upper and lower tubes 210 and 220 may be simply separated from each other by releasing the folded lower ring member 242 in an opposite direction.
[0090] Further, if the coiling number of the lower ring member 242 is adjusted, the entire length of the surgical instrument guide port 200 may be controlled. That is, in the state shown in (c) of FIG. 10 , if the lower ring member 242 is continuously coiled, the lengths of the upper and lower tubes 210 and 220 are reduced while the lengths of the upper and lower tubes 210 and 220 are being reduced, so that the distance between the surgical instrument entrance part 211 and the belly may be shorten, so the operation hole may be more expanded while the tube is being more tightly strained.
[0091] FIGS. 11 and 12 are views illustrating an installation and an operation of the surgical instrument guide port 200 according to the second embodiment of the present invention. The operation of the surgical instrument guide port 200 according to the second embodiment of the present invention will be described with reference to FIGS. 11 and 12 as follows.
[0092] First, as shown in FIG. 11 , after an operation hole for a laparoscopic operation is perforated at the navel of a patient, a portion of the surgical instrument guide port 200 is introduced through the operation hole. In more detail, after the support ring 230 has been shrunk or folded to a narrow size in the state that the upper and lower tubes 210 and 220 are connected to each other through the tube connection unit 240 , the support ring 230 fixed to a lower end portion of the lower tube 220 is introduced into the abdominal cavity through the operation hole.
[0093] Then, after completely passing through the operation hole, the introduced support ring 230 is restored to the original state by the resilient force thereof, and accordingly, the support ring 230 is expanded in the belly by the restoring force thereof and is naturally suspended to the abdominal wall.
[0094] As described above, if the support ring 230 is introduced and suspended to an abdominal wall, the lower ring member 242 further performs the coiling operation, so that the length of the surgical instrument guide port 200 may be properly adjusted.
[0095] In addition, after adjusting the length of the surgical instrument guide port 200 , the gas for expanding the belly is introduced through the gas adjusting valve 213 provided to the upper tube 210 .
[0096] Then, as the belly is expanded by the introduced gas, the upper and lower tubes 210 and 220 , which are sealed and connected to each other, are expanded so that the tubes are tightly strained, so that the surgical instrument guide port 200 are stably installed in the operation hole.
[0097] As described above, if the installation of the surgical instrument guide port 200 is completed, after closing the gas adjusting valve 213 , various surgical instruments (not shown) are introduced into the belly through the surgical instrument entrance part 211 , such that an entropic operation is performed.
[0098] When an organic extraction is removed while a laparoscopic operation is being performed by using surgical instruments, the organic extraction must be taken out of the belly. Thus, the organic extraction may be taken out of the belly through the upper end portion of the lower tube 220 which is opened after the upper tube 210 is separated from the lower tube 220 by releasing the lower ring member 242 in an opposition direction.
[0099] Further, when the size of the organic extraction is too large to be easy to pass through the operation hole, as shown in FIG. 12 , the incision portion of the operation hole is expanded by coiling only the lower tube 220 by continuously folding the lower ring member 242 in the state that the upper tube 210 is separated, so that the organic extraction may be more easily taken out.
[0100] In addition, according to the surgical instrument guide port 200 of the second embodiment of the present invention, if the upper tube 210 is separated from the surgical instrument guide port 200 and the lower tube 220 is only used as shown in FIG. 12 , the lower tube 220 may be utilized as a wound protector which is used for protecting an incision portion from bacterial infection by expanding a surgical hole and preventing an incision portion from being exposed.
[0101] As described above, according to the endoscopic surgical instrument guide port 200 of the second embodiment of the present invention, a large size of an organic extraction can be easily taken out of the belly and the length of the guide port can be easily adjusted, so that an operation can be smoothly performed. In addition, besides the surgical instrument guide, the present invention can provide a wound protector by separately utilizing the lower tube.
[0102] Although exemplary embodiments of the present invention have been described until now, the scope of the present invention is not limited to the embodiments and the contents of the drawings, but the equivalent configurations corrected or modified by those skilled in the art to which the present invention pertains fall within the scope of the present invention.
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An endoscopy instrument guider port includes a main body member where at least one surgical instrument entrance part is disposed at an upper surface, a protective tube extending downwards from the main body member, a retaining ring body fixed to a lower end portion of the protective tube, the retaining ring body being freely deformed and restored, and a control ring body disposed at a predetermined position along a length direction of the protective tube to be coiled around the protective tube through a folding motion and control a length of the protective tube. According to the present invention, the control ring body disposed at the protective tube facilitates length adjustment and traction generation of the protective tube, appropriate handling of surgical situations is possible because an upper body may be turned and separated, and surgical delays may be prevented while endoscopy operations may be made easier.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a theft control device for an automotive vehicle and more specifically to a portable device attachable to the steering column of such a vehicle to render inaccessible both the ignition switch and the skin of the steering column, the two most vulnerable locations for automotive thievery.
2. Description of the Prior Art
The ordinary way that most persons employ to lock their automobiles against thieves is to lock the ignition switch and the doors of the automobile. However, is is well-known that such precautions, although somewhat successful against amateur thieves, are virtually no deterrent at all to professional car thieves. Unfortunately, the number of thefts and the number of professional thieves appears to be ever on the increase. Hence, the number of persons that are capable of stealing an automobile in spite of the doors and ignition switches being locked is also on the increase.
It is also true that there are more very expensive automobiles being driven than ever before. Hence, the loss of an automobile by virtue of a car theft is a more expensive loss to the owner, on average, than ever before. It is well-known, for example, that some expensive models are "in demand" by car thieves and, therefore, are more subject to being stolen than other models of automobiles. Car thieves roam the streets and parking lots looking for certain models of automobiles to steal.
Because of this, certain prior art devices have been made to protect against thievery at the ignition switch. However, the vast majority of such devices are very vulnerable to attack. For example, there are ignition switch covers that are bolted merely by a padlock. A padlock, of course, can be quickly cut off by a bolt cutter.
Some of the devices that have been employed are designed to be permanently installed. Hence, when the automobile is to be operated, even by its owner, the device remains attached to the steering wheel and either remains in place, as is, or hangs down in place, making an unsightly appendage to what is otherwise usually a very stylish interior appearance.
The two main weaknesses, from an anit-theft point of view, against starting an automobile without a proper ignition key are the design of the ignition switch and the vulnerability to access of the control rod inside the steering column. The ignition switch is usually held in place by a side set screw in its housing opening. Hence, it is easily punched or pulled out by a tool inserted in the keyed cylinder. Once the cylinder is removed, then the control rod can be manually operated to start the car.
If a thief wishes, or if for some reason the locking cylinder cannot be removed in the above fashion, he can also gain access to the control rod by penetrating the skin of the steering column alongside the control rod. Once access to the rod has been made, then it can be cut or unhooked from its switch connection so that it can be manipulated to start the car without having to have the proper key.
To be a deterrent to most thieves it is necessary to protect against both the thief who attacks the ignition lock cylinder as well as the thief who attacks the skin of the steering column. Further, the lock of the anti-theft device has to be highly impregnable to attack. It is further desirable that the device be portable so that it can be removed during use of the automobile by its rightful operator so that it does not detract from the appearance of the automobile. Finally, it is highly desirable that the device be recognized by potential thieves so that they will not even break into the automobile door or window to try to steal the automobile, thereby preventing any damage from occurring even in an unsuccessful theft attempt.
Therefore, it is a feature of the present invention to provide an improved locking apparatus for an automobile steering column that renders inaccessible through common means both the ignition switch and the skin of the steering column adjacent the ignition control rod.
It is another feature of the present invention to provide an improved locking apparatus for an automobile steering column that is so formidable and recognizable that potential thieves will be deterred without forcing entry into a locked vehicle protected by such a device.
It is still another feature of the present invention to provide an improved locking apparatus for an automobile steering column that employs a virtually unassaultable locking mechanism.
It is yet another feature of the present invention to provide an improved locking apparatus for an automobile steering column that protects both the ignition switch and the skin of the steering column from theft attack, while nevertheless being removable or portable and yet substantial in appearance and therefore relatively invulnerable to attack.
SUMMARY OF THE INVENTION
The apparatus described and illustrated herein is a portable steering column locking apparatus for an automotive vehicle steering column that includes an ignition switch thereon, which, in turn, operates an ignition control rod that is aligned next to the inside wall or skin of the column. The apparatus is generally defined by a two-piece housing, hinged together, that wraps around the steering column. Part of one piece covers the ignition switch entirely. The other has openings for the control levers, but otherwise provides a thick, steel cover for the column that is not readily penetrable by conventional tools. The locking cylinder of the apparatus operates within bores located within wings of the housing that align when the apparatus is in its locked condition. The bolt wing includes a bore slotted to receive a cylinder having a hardened, preferably carbon steel deadbolt crosspiece. The other wing, the striker wing, includes a recessed bore that leaves a substantial amount of metal to prevent the cylinder from reverse end attack. The hinges of the two pieces include interengaged knuckle parts and a hinge pin, the pin being sealed from external access.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above-recited features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in detail, more particular description of the invention summarized above may be had by reference to the embodiment thereof that is illustrated in the appended drawings, which drawings form a part of the specification. It is to be noted, however, that the appended drawings illustrate only a preferred embodiment of the invention and are therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
IN THE DRAWINGS
FIG. 1 is a top view of a preferred embodiment of the present invention.
FIG. 2 is an end view of the embodiment shown in FIG. 1 taken at line 2--2 of FIG. 1.
FIG. 3 is a left side view of the embodiment shown in FIG. 1 taken at line 3--3 of FIG. 2.
FIG. 4 is a right side view of the embodiment shown in FIG. 1 taken at line 4--4 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now referring to the drawings, and first to FIG. 1, a top view of a preferred embodiment of the present invention is illustrated. Steering column locking apparatus 10 is shown in its locked condition after surrounding steering column 12 shown in dash lines. The steering column, which is illustrated, is common for instance to late model General Motors automobiles and includes a keyed ignition switch hidden from view in FIG. 1 but located on the right side of the steering column. Control levers, such as turn indicators, tilt control for the steering wheel, and the like are also shown in dotted section at 14 and 16. These controls are attached to the left side of steering column 12. Although these features are found on late model General Motors automobiles, they are common to many, many vehicles makes and models and the invention is not limited to use only with late model General Motors automobiles.
Also located inside of the steering column is a control rod that moves longitudinally to start the car. The end of the rod near the ignition switch is connected to a short switch rod and the distant end is connected to the electrical solenoid switch. When the ignition switch is operated by the turning of the key, the switch rod moves the control rod, which, in turn, actuates the solenoid switch.
Locking apparatus 10 generally comprises a two-piece housing hinged together at hinge 18, best shown in FIGS. 2 and 4. The left hand piece of locking apparatus 10, identified by reference numeral 20, is generally semi-circular and is designed to enclose roughly the left hand portion of steering column 12 between the portion of the steering column adjacent the steering wheel and a portion the steering column adjacent the front bulkhead of the vehicle.
It is apparent that this distance varies between models of automobiles and, therefore, locking apparatus 10 is not universally sized for all cars. However, many models are closely similar in their sizing and the same locking apparatus will fit more than one model of car. For example, practically all General Motor automobiles of the same year will fit with the same sized locking apparatus 10.
As best shown in FIG. 3, a control lever cover portion 21 of piece 20 is shaped to fit around protruding base or bases 22 of control levers 14 and 16. Also, as shown in Fi. 3, openings are included in this portion of piece 20 to permit the control levers to project therethrough without exposing very much of the adjacent steering column to outward access.
Also as shown in FIG. 1, left hand piece 20 includes an extension 24 for covering more of steering column 12 than right hand piece 26 of locking apparatus 10. The reason for this is best shown in FIG. 3. Extension 24 covers the skin of steering column 12 underneath which ignition control rod 28 is located. It is this extension 24 that is the most critically sized to fit with the length of the steering column of a particular automobile.
Right hand piece 26 includes a housing portion 30 that covers the entire ignition switch located on the side of steering column 12. It will be seen that housing cover portion 30 includes a front end 32 and a rear end 34 so as to make access to the ignition switch virtually impossible from any direction. There is an opening 36 in right hand piece 26 to allow hazard switch 38 to project therethrough. This feature is best shown in FIG. 4. Wear pads of felt or other suitable material are glued to the inside of the housing to protect the steering column paint from being scraped off.
Now referring to FIG. 4 for a description of hinge 18, it will be seen that left hand piece 20 includes two knuckle parts 40 and 42 interengaged with similar knuckle parts 44 and 46 of right hand piece 26. A hinge pin is accommodated through the center opening of the four knuckle parts to provide the hinge action and knuckle parts 42 and 44 are welded shut on their ends so as to prevent access to the hinge pin. Furthermore, each of the knuckle parts is welded on its side to the body of the piece of which they are a part so that these knuckle parts cannot be forceably unrolled.
Now referring to the locking arrangement for the locking apparatus, it will be seen that there are two wing housing parts, namely, striker wing 48 and bolt wing 50, in which lock cylinder 52 operates in a manner hereafter described. Striker wing housing part 48 is generally circular in cross-section and is welded on its side by weld 54 to the housing of left hand piece 20. Externally the periphery of wing housing part 48 is slightly reduced or recessed on the right side so as to permit engagement of projection 56 attached to right hand piece 26.
In similar fashion, bolt wing housing part 50 is also generally circular in cross-section and is attached to right hand piece 26 by weld 58. Its periphery is also slightly reduced on the left side to accommodate projection 60 attached by welding to left hand piece 20. It will be seen that when pieces 20 and 26 are closed around steering column 12, wing parts 48 and 50 are axially aligned and are prevented from being pried apart by the interplay between projections 56 and 60 within the side reduced peripheries of parts 48 and 50, respectively.
Internally, wing part 50 is bored all the way through to accommodate locking cylinder 52. However, wing part 48 is bored or recessed only partly to accommodate only the end of extended locking cylinder 52, which cylinder is long enough to extend only about half way into part 48 when it is extended to its locking condition. The actual longitudinal dimension of each part 48 and 50 is approximately two inches. Therefore, there is approximately one inch of solid metal which is not bored through in wing part 48 that closes off the bore or recess therein and makes access to locking cylinder 52 impossible from the end opposite its bore opening.
Wing part 50 internally includes an "F" groove in the inside wall for receiving a deadbolt crosspiece which is part of locking cylinder 52. Preferably, this crosspiece is made of carbon steel or other extremely hard material. When the housing parts are open the locking cylinder can only be removed from the inside end of part 50 because of the interplay of the crosspiece and the "F" slot. That is, the locking cylinder is removable only from the bore end adjacent part 48 when the two parts are brought together as shown in FIG. 1. That is because the "F" slot opens only to that end of the bore. The crosspiece is of substantial diameter and therefore cannot be punched out or removed from the key end of the cylinder, as ignition switches are capable of being removed, as described above.
It is also noted that the top of the "F" slot being connected with the crosspiece when the locking cylinder is in its retracted or unlocked position, prevents the cylinder from moving forward.
There is a slight elongated recess on the side of the locking cylinder for accepting a side-advancing set screw to hold the locking cylinder housing in place, but this locking screw is not the piece that prevents the removal of the locking cylinder by force.
Although a general description has been given above of the operation of the cylinder, a detailed description of the operation is disclosed in U.S. Pat. No. 3,827,266, Walters, issued Aug. 6, 1974, which patent is incorporated by reference herein for all purposes. The Walters patent describes a lock which is marketed under the trademark TUFLOC, a registered trademark of Electroline. The TUFLOC lock incorporates a locking cylinder marketed under the trademark MEDECO, a cylinder which has proved to be virtually pick proof and utilizes special key blanks which insures stringent key control.
It will be seen from the above description, that locking apparatus 10 is virtually unassailable at the locking cylinder, at the housing parts in which the cylinder operates, at the portion covering the ignition switch, and at the portion covering the skin of the steering column opposite the ignition control rods.
The preferred material for the locking apparatus housing is hardened steel and the preferred color for the housing is red.
It should be noted that red is a universal color signifying "stop". Since the entire locking apparatus is virtually invulnerable to being broken into by car thieves, potential car thieves will most likely not attempt to break into the automobile door or window in order to try to steal an automobile protected by the apparatus which has been described herein. The red color will be eye catchiing and itself will be a deterrent to car thieves.
It should be noted that the lawful operator of the vehicle will remove locking apparatus 10 at the time of operating the car, putting the apparatus either in the glove compartment, under the seat or in the trunk so that it will be out of the way and will not detract from the internal aesthetics or appearance of the interior design of the vehicle.
Although the locking apparatus has been described with respect to General Motors automobiles, it should be again noted that any vehicle can be protected using the locking apparatus that is designed to fit therewith. This includes any vehicle that has an ignition switch on the side of the steering column and an ignition control rod operating internally to the steering column and adjacent the skin on the left hand side to the column as the column appears from the top. As has been previously mentioned, the skin of the column is protected to prevent access to the control rod. Once accessed, the rod can be cut or disconnected from the switch and the car started by manipulating the rod. Moreover, not only automobiles, by also jeeps, pickups, station wagons, trucks and the like can be similarly protected.
While a preferred embodiment of the invention is generally been described and specific variations have been discussed, it will be understood that the invention is not limited thereto.
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A portable steering column locking apparatus in two pieces for surrounding the steering column of an automotive vehicle and specifically enclosing the ignition switch and the skin of the steering column beneath which the ignition control rod is located. The cylinder operates in a bolt wing and a striker wing part that cannot be pried apart because of housing projections fitting respectively within side recesses in the wings. The locking cylinder has a carbon steel crosspiece deadbolt operating within an internal "F" groove in the bolt wing and therefore cannot be defeated by common tools used to extract cylinder tools. The hinge of the housing pieces is sealed by welding against access.
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FIELD OF INVENTION
[0001] The present application generally relates to systems and methods for optimizing the system settings of an electronic device, such as a laser scanner control system. Specifically, the exemplary system and methods may maximize laser power while adapting system parameters such as motor amplitude, receiver bandwidth, etc., in order to best match the operation of the control system with the needs of the target symbol.
BACKGROUND
[0002] Barcodes are machine-readable (e.g., computer readable) representations of information on a surface. Optical scanning devices such as laser-based barcode scanners and image-based scanners are used in a multitude of situations for both personal and business purposes. A variety of barcode readers and laser scanning devices have been developed to decode these bar symbols into a multiple-digit representation of information such as inventory checks, delivery tracking, product sales, etc.
[0003] Certain portable barcode scanners incorporate laser diodes that allow the user to scan the target barcode symbols at various distances from the surface on which the barcode resides. Typical barcodes are formatted as two-dimensional matrices and include vertical bar symbols such as, dark and light bars of varying widths. When light is projected onto these symbols, the light is mostly absorbed by the dark bars of the symbol and mostly scattered by the light bars of the symbol. Accordingly, the pattern of symbols may be read by photo-detectors within the scanner or imager devices. In addition, normal usage may require different operating positions in which a target symbol may be at varying distances and/or angles from the barcode scanner. However, a conventional barcode laser scanner only uses one laser power setting and one motor amplitude setting, regardless of the distance to the target symbol.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a scanning device having a laser source emitting a laser scanning beam, a movable scanning mirror reflecting the laser scanning beam towards an on object to be scanned, a mirror moving element moving the movable scanning mirror and a controller receiving an input corresponding to a range estimate from the scanning device to the object and adjusting a setting of the scanning device based on the range estimate.
[0005] The present application also relates to a method for determining a range estimate from a scanning device to an object to be scanned and adjusting a setting of the scanning device based on the determined range estimate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows an exemplary system for dynamically adjusting one or more system parameters of an electronic device, such as a laser scanner, according to the exemplary embodiments of the present invention.
[0007] FIG. 2A represents an exemplary method for optimizing the performance of the scanning device according to the exemplary embodiments of the present invention.
[0008] FIG. 2B illustrates an exemplary method for selecting a predetermined range setting via the receiver gain measurements detected by the AGC.
[0009] FIG. 3 shows an exemplary schematic of an additional AGC according to the exemplary embodiments of the present invention.
DETAILED DESCRIPTION
[0010] The exemplary embodiments of the present invention may be further understood with reference to the following description of exemplary embodiments and the related appended drawings, wherein like elements are provided with the same reference numerals. The present invention is related to systems and methods used for optimizing the system settings of an electronic device, such as a laser scanner control system. Specifically, the system and methods for automatically adjusting system parameters of the electronic device based on one or more properties of a target symbol. The adjustment made to the system parameters may include adjusting motor amplitude and adjusting receiver bandwidth in order to dynamically adapt the device for reading a target symbol based on observable conditions, such as a scanning range of the symbol. It should be noted that throughout this description, the term “motor amplitude” may be used interchangeably with the term “scan amplitude” to refer to the amplitude of oscillation for a scanning motor within a laser scanning device. Furthermore, the terms “motor angle” and “scan angle” may both be used to describe a measurement of the motor amplitude in degrees from a normal position.
[0011] The exemplary systems and methods of the present invention allow for an increase in laser power from a scanning device without exceeding class limits, thereby optimizing the performance of the scanning device on a per-session basis. Furthermore, the exemplary embodiments of the present invention allow for a reduced bandwidth of the receiver, thereby improving the signal to noise ratio (“SNR”) of the received signals. Other exemplary embodiments of the present invention to improve the SNR will also be discussed. Thus, the laser scanners may benefit from a significant performance advantage, and may easily switch from a normal barcode-reading range to a longer barcode-reading range, thereby improving the overall versatility of the device.
[0012] Throughout this description, the exemplary embodiments will be described with reference to scanning a barcode symbol or target symbol. Those skilled in the art will understand that this includes any type of laser scannable symbol, e.g., 1-D barcode symbol (or “linear barcodes”), 2-D barcode, etc. In addition, the present invention is not limited in application to laser scanners used for scanning symbols, but may also be applied to any type of laser scanner.
[0013] FIG. 1 shows an exemplary system 100 for dynamically adjusting one or more system parameters of an electronic device, such as a laser scanning device 101 , according to the exemplary embodiments of the present invention. According to the exemplary embodiment, FIG. 1 shows a block diagram view of the scanning device 101 according to the present invention, wherein the scanning device 101 includes a scan engine 105 . The scan engine 105 may control the scanning functions, the detection of optical barcode signals, and the conversion (i.e., digitization) of the optical barcode signals into a digital electrical signal (e.g., a digital bar pattern (“DBP”)). Specifically, the scan engine 105 include various electrical components such as a controller 110 , a digitizer circuit 120 , a laser source 130 , an oscillating mirror 140 , a scanning motor 150 , an automatic gain control (“AGC”) 160 , and a decoder 170 . Furthermore, the scan engine 105 may include additional components for filtering out noise (e.g., ambient light), for enhancing edges between bars and spaces of optical barcode signals, for rejecting “false edges” from noisy signals, and providing signals within a suitable range for the digitizer circuit 120 . Accordingly the laser scanner device 101 may optimize scanning performance over a wide variety of scanning ranges, barcode densities, signal depth of modulation, etc.
[0014] The functions of the controller 110 may include managing the laser output power from the laser source 130 , adjusting the motor amplitude of the scanning motor 150 , and maintaining electronic beam clipping points of the laser in order to best meet the scanning requirements of a particular scanning session. Specifically, the controller 110 may regulate the operation of the scan engine 105 within the scanning device 101 by facilitating communications between the various components. For example, the controller 110 may include a microprocessor, an embedded controller, a further application-specific integrated circuit, a programmable logic array, etc. The controller 110 may perform data processing, execute instructions and direct a flow of data between devices coupled to the controller 110 (e.g., the digitizer circuit 120 , the laser source 130 , the oscillating mirror 140 , the scanning motor 150 , and the AGC 160 , etc.). As will be explained below, the controller 110 , according to the exemplary embodiments of the present invention, may be used to program and configure various parameters of the scanning device.
[0015] When a user of the scanning device 101 activates the scan engine 105 (e.g., via a triggering mechanism, etc.), the light source 130 generates a beam that traverses through one or more lens towards the oscillating mirror 140 . The scanning motor 150 may control the oscillation of the mirror 140 and thereby direct the beam as it strikes the mirror 140 . The beam may be directed by the mirror 140 in various patterns and scanning angles, or scanning amplitudes. Specifically, as the motor 150 oscillates the mirror 140 , the laser beam (e.g., a laser spot of the beam) may be swept across a target. The displacement of the laser spot may be sinusoidal (e.g., around 50 Hz). The mirror 150 may be used to send the laser beam out from the scanning device 101 and to receive a reflected signal from the target barcode. According to the exemplary embodiments of the present invention, a unique laser output power may be used for each scanning angle setting. Due to laser safety issues, the laser output power for each of the scanning angle setting may be reduced as the scanning amplitude is reduced. Conversely, the laser power output power may be increased for larger scanning amplitudes.
[0016] FIG. 2A represents an exemplary method 200 for optimizing the performance of the scanning device 101 according to the exemplary embodiments of the present invention. The exemplary method 200 will be described with reference to the exemplary system 100 of FIG. 1 . In step 210 of the method 200 , the AGC 160 may provide a distance measurement (e.g., range information) between the scanning device 101 and a targeted barcode. Specifically, the receiver gain measurement from the AGC 160 may be digitized and transmitted to the controller 110 for processing. According to one embodiment of the exemplary method 200 , the AGC 160 may provide a best estimate of the range information to the controller 110 . According to an alternative embodiment, the gain measurement from the AGC 160 may be determined to lie in one of a plurality of coarse range categories in order to estimate the range to the targeted barcode (e.g., near-range, mid-range, far-range, etc.).
[0017] For example, FIG. 2B illustrates an exemplary method 211 for selecting a predetermined range setting via the receiver gain measurements detected by the AGC 160 . At the beginning of the method 211 , the AGC 160 may have a default range setting, such as a near-range setting. Furthermore, the AGC 160 may have threshold receiver gain values for additional settings, such as a receiver gain threshold value of X for a mid-range setting, and a receiver gain threshold value of Y for a far-range setting. Furthermore, according to an alternative, or additional embodiment of the present invention, the scan engine 105 may also include an AGC feedback signal that may be used to estimate the distance to the target barcode.
[0018] In step 212 , the scanning device 101 may start a scan session. A scan session may be defined as the period of time between a user activating the scanning device 101 and the decoder 170 decoding the digitized barcode signal (e.g., when the scanning device 101 translates the optical barcode signal). In step 213 , a determination may be made as to whether or not the decoder 170 was able to decode the barcode signal. Specifically, a maximum time limit may be placed, such as, for example, 1 second, for allowing the decoder 170 to decode the signal. Accordingly, if the decoder 170 decodes the signal within the time limit, the method 211 may advance to step 214 wherein the scan session may be terminated. However, if the decoder 170 fails to decode the signal within the time limit, the method 211 may advance to step 215 .
[0019] In step 215 , the method 211 may examine the receiver gain measured by the AGC 160 . Furthermore, the method 211 may determine whether the receiver gain is below a first threshold (e.g., the threshold value of X for the mid-range setting). If the receiver gain is below the first threshold, the method 211 may advance to step 216 , wherein the controller 110 may set the scanning device 101 to use the near-range settings. As will be described in more detail below, exemplary near-range settings may include a bigger scanning amplitude, a higher receiver bandwidth, a higher laser power and less clipping of the image. The terms “bigger,” “higher” and “less” are relative terms referring to the settings of the device in relation to, for example, mid-range and far range settings (discussed in more detail below). The actual settings for each of these parameters and any other adjustable parameters based on the range of the targeted barcode may depend on the specifics of the individual scanning device.
[0020] Returning to the method 211 , if the receiver gain is above the first threshold, the method 211 may advance to step 217 . In step 217 , the method 211 may determine whether the receiver gain is below a second threshold (e.g., the threshold value of Y for the far-range setting). If the receiver gain is below the second threshold, the method 211 may advance to step 218 , wherein the controller 110 may set the scanning device 101 to use the mid-range settings. Again, exemplary mid-range settings may include reducing the scanning amplitude from the near-range setting, reducing the receiver bandwidth from the near-range setting, reducing the laser power from the near-range setting and increasing the clipping of the image from the near-range setting. However, if the receiver gain is above the second threshold, the method 211 may advance to step 218 , wherein the controller 110 may set the scanning device 101 to use the far-range settings. Exemplary far-range settings may include a further reduction of the scanning amplitude from the mid-range setting, a further reduction of the receiver bandwidth from the mid-range setting, a further reduction of the laser power from the mid-range setting and a further increase of image clipping from the mid-range setting. Thus, the method 211 may use the receiver gain measured at the AGC 160 to determine a distance between the scanning device 101 and the target barcode. It should be noted that while method 211 utilizes three varying range settings based on the receiver gain measurement, the exemplary systems and methods of the present invention may utilize any number of range settings, wherein each range setting may have a distinct threshold value for the receiver gain. It should also be noted that the above settings are only exemplary and that each setting does not need to be adjusted for each differing range. For example, it may be that in the mid-range, the laser power is set to a maximum allowable value. Thus, when the scanning device determines that it should switch to near-range settings, the laser power will remain the same as in the mid-range because the laser power should not be set above the maximum allowable value.
[0021] Returning to method 200 , in step 220 , the controller 110 may adjust the scan amplitude of the scanning motor 150 based on the distance, or distance range, determined in step 210 . As opposed to conventional scanning devices that only utilize a single scan amplitude, the exemplary embodiments of the present invention allow the controller 110 of the scanning device 101 to dynamically adjust the scan amplitude based on a determined distance or range. For example, a conventional scanning device may have a fixed scan amplitude of 50 degrees. However, this scan amplitude may be too wide for a targeted barcode that is far away from the scanning device. Accordingly, the large receiver bandwidth associated with the wide scan amplitude may result in a DBP signal that the decoder 170 cannot accurately decode. Therefore, according to this example, in step 220 the controller 110 may adjust the scan amplitude to a narrower scan angle, such as 25 degrees, thereby narrowing the projected spread of the sweeping laser spot as the motor 150 oscillates the mirror 140 . Having a lower scan angle may result in a decrease in the frequency content of the received bar code signal, while the noise frequency remains mostly unchanged. Therefore a low-pass filter may be used to separate the noise from the signal more efficiently. Thus, in this case, the low-pass filter may improve the SNR. It should be noted that the spot speed (i.e., speed of the laser as it sweeps) may be a function of the scan amplitude and the distance to the target barcode. Therefore, the conventional scanning device may use a spot speed that is fixed at too high of rate, wherein the frequency content of the information signal received from the target has too wide of a frequency spread. Thus, adjustments made to the scan amplitude may allow for a reduction to the frequency content of the received signal and a corresponding decrease in the receiver bandwidth, thereby improving the SNR. For example, decreasing the scan amplitude from 50 degrees to 25 degrees may result in reducing the spot speed in half, thereby, in turn, reducing the frequency content of the information signal.
[0022] In step 230 , the controller 110 may adjust the receiver bandwidth of the scan engine 105 . The receiver bandwidth may be defined as the range of frequencies accepted by the scan engine 105 to receive the barcode signal. According to one exemplary embodiment of the present invention, the scan engine may include a receiver (not shown) having a programmable receiver bandwidth, wherein the receiver bandwidth may be modified by the controller 110 in order to best match the scan amplitude selected in step 220 . The receiver bandwidth may be adjusted and may have a direct relationship to the SNR, wherein a smaller bandwidth improves the SNR but may, however, cause spatial distortions in the signal. A larger receiver bandwidth reduces the SNR (e.g., there is more noise from the extremes of the spectrum), however a larger receiver bandwidth allows for a higher spot speed and larger scan angles. It should be noted that any adjustments made by the microprocessor 110 to the scan amplitude in conjunction with adjustments made to the receiver bandwidth may result in an improved SNR, and may also reduce the spot speed of the laser beam.
[0023] According to an alternative, or additional, exemplary embodiment of the present invention, the scanning device 101 may include an information signal frequency estimator (not shown), wherein the receiver bandwidth is modified by the controller 110 in order to best match the targeted barcode. The estimator may estimate the frequency content of the received information signal by measuring the DBP transition timing. For example, if the estimator measures an average value of narrow elements within the DBP pattern is only 20 KHz, the controller 110 may adjust the receiver bandwidth from a default setting (e.g., 170 KHz) to a setting of 20 KHz. The adjusted receiver bandwidth may result in a significant SNR benefit.
[0024] According to a further alternative, or additional, exemplary embodiment of the present invention, the digitizer circuit 120 of the scanning device 101 may include a margin timeout circuit, wherein the margin timeout is adjusted in proportion to any adjustments made to the receiver bandwidth. The margin timeout circuit may be a noise gate in the scanning device 101 . The timeout circuit may remain closed until a signal crosses a threshold setting for valid information. While opening the timeout circuit may be easily achieved, the closing of the circuit may be delayed, thereby allowing unwanted noise in the signal to be digitized with the valid information. A receiver bandwidth signal of a lower frequency may have a slower laser spot speed, thereby limiting the noise received in the signal. Thus, the setting for the threshold may be adjusted in response to adjustments made to the receiver bandwidth, wherein the noise gate may have a more lenient threshold hold when the receiver bandwidth is low, and vice versa. In addition, the digitizer circuit 120 may further include a received signal noise estimator, wherein the sensitivity, settings of the digitizer 120 is adjusted to best match the targeted barcode. While conventional digitizers may cycle through a number of settings, the exemplary digitizer 120 may efficiently determine a suitable sensitivity setting based on the received signal noise estimator.
[0025] In step 240 , the controller 110 may adjust the laser output power of the laser source 130 in order to optimize the performance of the scan engine 105 while ensuring that the scanning device 101 remains compliant with any laser emission regulations. According to laser emission regulations, the laser output power may be directly related to the scan amplitude. In other words, a scanning device having a larger scan amplitude may be allowed a greater laser output power than a device having a smaller scan amplitude. In addition, it should be noted that the scan engine 105 may include a further receiver (not shown) having an adjustable gain that supports on-the-fly gain changes in order to compensate for any changes made to the laser output power. According to an alternative, or additional, exemplary embodiment of the present invention, the controller 110 may instruct the laser source 130 to selectively turn off the laser beam on alternate scans, thereby reducing the average laser power in half. At the expense of a more effective scan rate, this decrease in average laser power may allow the laser source 130 to increase the laser output power while remaining within safety limits. In other words, an increase in instantaneous laser power on any one scan may improve the SNR, and turning off the laser on alternate scans will reduce the average power, thereby allowing for the increased laser power.
[0026] According to a further alternative, or additional, exemplary embodiment of the present invention, the controller 110 may measure the angular speed of the oscillating mirror 140 . Accordingly, the angular velocity of the mirror 140 may be used to modulate the laser output power, such that the laser power is proportional to the angular speed.
[0027] In step 250 , the controller 110 may establish and adjust settings for electronic beam clipping points on the spread of the projected laser. As an exemplary laser beam oscillates between two endpoints of the scanning spread, the laser spot must decrease in velocity as it approaches either one of the endpoints. The oscillating laser beam may safely oscillate from one endpoint to the other. As the laser spot reaches the endpoints of the scan, the velocity of the laser spot will decrease. However, the laser spot must meet regulatory requirements at both the higher velocity in the central portion of the scan and at the lower velocity at the edges of the scan. Therefore, according to the exemplary embodiments of the present invention, the controller 110 may implement electronic beam clipping to “clip” or turn off the laser beam as the laser spot approaches either one of the endpoints (e.g., as the speed of the laser spot approaches, and reaches, a zero velocity). Specifically, a predetermined threshold velocity may be established by the controller 110 that may trigger the deactivation of the laser beam at the laser source 130 .
[0028] By clipping the beam, and eliminating any instances where the laser spot is at a low or zero velocity, the controller 110 may be allowed to increase the laser output power while maintaining compliance with laser emission regulations. Furthermore, the controller 110 may dynamically adjust the electronic beam clipping locations in order to maximize the laser output power based on the distance determined for the target barcode in step 210 . In other words, more of the laser beam may be clipped when the targeted barcode is far away, thereby permitting an increase in the laser output power. Conversely, when the targeted barcode is within a closer range, the controller 110 may clip less of the beam (while decreasing laser output power) in order to achieve greater barcode coverage near contact.
[0029] The dynamic adjustments of the electronic beam clipping points may not proportionately impact the SNR. The controller 110 may determine a fraction of the scan session that is being used to detect barcode information. The controller 110 determines a portion of time the scan sweep that contains relevant barcode data packets, wherein the remaining portion may be considered noise. When the barcode is determined to be too far away in step 210 , then less time may be used to receive barcode data packet. Accordingly, the controller 110 may reduce the scan amplitude in step 220 , reduce the receiver bandwidth in step 230 , increase the laser output power in step 240 , and clip a greater portion of the laser beam sweep in step 250 .
[0030] As described above, an alternative exemplary embodiment of the present invention may support a few preset scan angles (e.g., near-range, mid-range, and far-range). According to this alternative embodiment, each of the scan angles may be associated with a setting having a unique receiver bandwidth, laser output power, corresponding electronic beam clipping points, etc. These associated settings may be stored in a memory (not shown) of the scanning device 101 and may be calibrated (e.g., automatically, manually, etc.) based on the operating procedures of the scanning device 101 . The controller 110 may start scanning operations at the smallest scan angle setting. Based on the range information provided by the AGC 160 , the controller 110 may then choose the next scan angle setting (and associated laser power, beam clipping points, etc.). Accordingly, the controller 110 may use simple algorithms to adjust the scan angle, wherein the closer the target barcode is determined, the larger the scan angle, the larger the receiver bandwidth, the greater the laser output power, and the wider the electronic beam clipping points may be set.
[0031] While the AGC 160 described in the above embodiments may be used to determine a distance from the scanning device 101 to a barcode target (e.g., the gain may be correlated to a distance), the AGC 160 may also be used to dynamically adjust overall receiver gain of the scan engine 105 . Alternatively, it should be noted that the AGC 160 may be used primarily for distance calculations and an additional AGC (not shown) may be implemented within the scanning device 101 to adjust the receiver gain. The additional AGC may adjust faster than the AGC 160 . The receiver gain may be defined as the ratio of an output barcode signal from the scanning device 101 to an input barcode signal. Specifically, the additional AGC may monitor and regulate peak averages of the output signal of the scan engine 105 . The scan engine 105 may include a plurality of amplifier stages to deliver a large overall gain from the input to the output. The additional AGC may detect and filter the output signal, resulting in a direct current voltage that is proportional to the average peak value of the received input signal. The additional AGC may then compare the average peak value of the output signal to a fixed direct current reference voltage, and dynamically adjust the receiver gain in order to reduce any difference between the two voltages.
[0032] As illustrated in FIG. 3 , an AGC circuit 10 is utilized to control the gain in a laser scanning system receiver. The block diagram represents a single feedback path control circuit with an input signal 12 (VIN) and output signal 14 (VOUT). The receiver comprises an amplifier section having at least three amplifiers 16 , 18 , and 20 . It should be noted that the action of the AGC is not limited by the number of amplifier stages used in the receiver. The total number of amplifier stages used, depends on the gain limitation of each stage and the maximum receiver gain required by the application. The voltage gains of amplifiers 18 and 20 are fixed at K 1 and K 2 , respectively, while the voltage gain K(Vg), of amplifier 16 is variable and controlled by error voltage signal 22 (Vg). The output signal 14 is sensed in a feedback path comprising high pass filter 24 , rectifier 26 , peak-detector 28 , and error amplifier 30 having a gain K 3 . The output of the receiver 14 is high pass filtered to prevent any low frequency components of the signal, such as those signals that are received due to ambient light in the scanner's environment, from interfering with proper gain adjustment of the receiver. The output of the high pass filter 24 contains the alternating current (a.c.) component of the received signal 14 resulting from the bar code being scanned. This signal is rectified using a half wave rectifier 26 . The output of the rectifier 26 is used to charge AGC capacitor 34 which includes a peak detector 28 . The AGC capacitor 34 , at steady state, will be charged to a d.c. voltage (VOUT(PEAK)) 32 which will be proportional to the average peak amplitude of the received signal. The charge rate of the AGC capacitor 34 , which determines the attack time of the AGC, is determined by the output impedance and the cutoff frequency of the high pass filter 24 . The attack time of this AGC can be reduced, at the expense of accuracy, by maximizing the amount of signal that will pass through the filter 24 . This can be achieved by reducing the cutoff frequency of filter 24 , and by reducing its output impedance. The automatic gain control action occurs dynamically as amplifier 30 compares the voltage difference between the average peak voltage signal 32 present on AGC capacitor 34 , and a fixed reference voltage 36 (Vr), that for example, may be 1.2 volts dc. Essentially, the gain of amplifier 16 and hence overall receiver gain, is adjusted as amplifier 30 minimizes the voltage difference between voltage signals 36 and 32 . The error voltage signal 22 is indicative of this voltage difference, is generated from amplifier 30 and is used to control the resistance in the feedback 38 of amplifier 16 . To adjust the gain, error voltage signal 22 is input to the gate of transistor 40 , and due to the characteristics of transistor 40 , dynamically controls the resistance between its drain and source terminals 42 and 44 . This controllable resistance is connected in parallel with resistor 46 in the feedback path 38 and can therefore vary the gain (Vg) of amplifier 16 . It should be noted that any means for automatically adjusting the gain of amplifier 16 using error voltage signal 22 is acceptable. For instance, in the present embodiment a JFET operating as a voltage controlled resistor is used. Other types of transistors or integrated circuits can be used to accomplish the same gain adjustment. As a result of minimizing the voltage difference present at the inputs of amplifier 30 , the output signal 14 is regulated at a constant amplitude. Note that in this configuration, the output signal 14 will be unaffected by fluctuations in input signal 12 .
[0033] In the exemplary embodiment of FIG. 3 , an identical JFET 40 ′ is also connected in parallel to the output of amplifier 30 . The receiver's gain may be estimated by measuring the feedback voltage. With the voltage signal, the “on resistance” of the JFET 40 ′ may be calculated. With this resistance, receiver gain may be calculated based on the fact that resistance and receiver gain are proportional.
[0034] It will be apparent to those skilled in the art that various modifications may be made in the present invention, without departing from the spirit or the scope of the invention. Thus, it is intended that the present invention cover modifications and variations of this invention provided they come within the scope of the appended claimed and their equivalents.
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A scanning device includes a laser source emitting a laser scanning beam, a movable scanning mirror reflecting the laser scanning beam towards an on object to be scanned, a mirror moving element moving the movable scanning mirror and a controller receiving an input corresponding to a range estimate from the scanning device to the object and adjusting a setting of the scanning device based on the range estimate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Divisional application of co-pending U.S. patent application Ser. No. 11/102,952, filed Apr. 11, 2005, hereby incorporated by reference in its entirety.
BACKGROUND OF INVENTION
[0002] In the process of rotary drilling a well, drilling fluid, or mud, is circulated down the rotating drill pipe, through the bit, and up the annular space between the pipe and the formation or steel casing, to the surface. The drilling fluid performs different functions such as removal of cuttings from the bottom of the hole to the surface, to suspend cuttings and weighting material when the circulation is interrupted, control subsurface pressure, isolate the fluids from the formation by providing sufficient hydrostatic pressure to prevent the ingress of formation fluids into the wellbore, cool and lubricate the drill string and bit, maximize penetration rate, etc.
[0003] The required functions can be achieved by a wide range of fluids composed of various combinations of solids, liquids and gases and classified according to the constitution of the continuous phase mainly in two groupings: aqueous drilling fluids, and oil-based drilling fluids. In drilling water-sensitive zones such as reactive shales, production formations, or where bottom hole temperature conditions are severe or where corrosion is a major problem, oil-based drilling fluids are preferred.
[0004] Oil-based drilling fluids typically contain oil-soluble surfactants that facilitate the incorporation of water-wet clay or non-clay formation minerals, and hence enable such minerals to be transported to surface equipment for removal from circulation before the fluid returns to the drill pipe and the drill bit. The largest formation particles are rock cuttings, the size typically larger than 0.1 to 0.2 mm, removed by shale-shaker screens at the surface. Smaller particles, typically larger than about 5 μm, will pass through the screens, and must be removed by centrifuge or other means.
[0005] Oil-based drilling fluids have been used for many years, and their application is expected to increase, partly owing to their several advantages over water based drilling fluids, but also owing to their ability to be re-used and recycled, so minimizing their loss and their environmental impact.
[0006] As mentioned above, during drilling, formation particles become incorporated into the drilling fluid. Unless these are removed, they eventually alter the fluid's properties, particularly the rheological parameters, out of the acceptable range. However, formation particles that are less than about 5 to 7 μm in size are more difficult to remove than larger particles. These low gravity solids can build up in a mud system, causing inefficient drilling problems such as drill pipe sticking, increased pipe torque, and other high viscosity issues.
[0007] While low gravity solids may be removed from drilling fluids using mechanical means such as a centrifuge, it has been found that longer run-times are required to remove the colloidal particles, if the low gravity solids can be removed at all. Thus, there is a need for an apparatus that can be used with traditional solids separation equipment to reduce the run-time required to remove low gravity solids. Further, it would be an improvement in the art to have an apparatus that can be utilized both on active drilling projects to facilitate solids control equipment efficiency as well as by mud plants in reclaiming and/or reconditioning mud returned from field operations.
SUMMARY
[0008] In one aspect, the claimed subject matter is generally directed to an apparatus for preparing an oil-based drilling fluid for recovery. The apparatus includes a first static mixer in which the oil-based drilling fluid and a surfactant are mixed. In a second static mixer a flocculant and a base fluid may be mixed. The flocculant mixture is added to the drilling fluid mixture and further mixing occurs through a series of additional mixers. Upon exiting the final mixer, the drilling fluid mixture is prepared to have solids separated therefrom so that the oil-based drilling fluid may be further processed for recovery. A centrifuge may be used to separate solids from the remaining effluent.
[0009] In another illustrated aspect, the claimed subject matter is directed to an apparatus for reclaiming oil-based drilling fluid and recovering valuable weighting agent. The apparatus includes an additional centrifuge to remove the weighting agent prior to the injection of polymer to the oil-based drilling fluid.
[0010] In another illustrated aspect, a method for preparing an oil-based drilling fluid for recovery is claimed. The method includes demulsifying the drilling fluid with a surfactant and preparing a flocculant mixture. The flocculant mixture is then mixed with the drilling fluid mixture. The next step includes separating solids from the drilling fluid mixture and collecting them. Effluent from the separating solids step may be collected for further processing.
[0011] Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic of an apparatus for preparing an oil-based drilling fluid for recovery.
[0013] FIG. 2 is a schematic of an alternative embodiment of an apparatus for preparing an oil-based drilling fluid for recovery.
[0014] FIG. 3 is a layout of the apparatus mounted on a skid.
DETAILED DESCRIPTION
[0015] The claimed subject matter relates to an apparatus and method for preparing an oil-based drilling fluid for recovery. The oil-based drilling fluid includes oil, water, and solids in relative proportions consistent with used drilling fluid that has been subjected to preliminary processes to remove large solids from the fluid. The solids remaining in the drilling fluid typically include a percentage of high gravity solids and a percentage of low gravity solids. High gravity solids are those solids that are dense, as in barite or hematite, while low gravity solids are those solids that have a lower density than barite. The oil and water in the used drilling fluid are present in proportionate amounts, the relationship between them often being expressed as an oil-to-water ratio.
[0016] In a first embodiment, shown in FIG. 1 , the apparatus 10 includes a plurality of mixers 12 - 20 that may be mounted to a common skid 22 . Oil-based drilling fluid 24 is pumped from a mud plant 26 to the first mixer 12 . A pump 28 may be used to introduce the drilling fluid 24 to the first mixer 12 with a predetermined pressure and flow rate. A surfactant 32 is pumped into the first mixer 12 from a surfactant tank 34 . The surfactant 32 may be diluted with water 30 from water tank 38 prior to its introduction to the first mixer 12 . A dose pump 36 may be used to introduce the surfactant 32 to the mixer with a predetermined pressure and flow rate. The surfactant 32 acts on the mud solids, improving their hydrophilicity so that the polymer, which is very hydrophilic and added downstream, can flocculate the solids.
[0017] The first mixer 12 preferably is a static shear mixer including an insert (not shown) that provides shear to the fluid passing through the first mixer 12 sufficient to mix the surfactant 32 and the drilling fluid 24 . The surfactant 32 and the drilling fluid 24 are introduced to the first mixer 12 upstream from the insert and exit the mixer 12 as a surfactant treated mud 40 .
[0018] A flocculant polymer 42 is stored in a flocculant storage tank 44 and may be mixed with a base fluid 46 from base fluid storage tank 47 , when necessary, to form a flocculant mixture 48 . The dilution of the flocculant polymer 42 with the base fluid 46 can improve the dispersal of the polymeric droplets into the mud.
[0019] The decision to do this or not is based on the type of dosing equipment, the viscosities of the mud 24 and the flocculant polymer 42 , and the strength to the mixing employed.
[0020] Dosing pumps 50 , 52 may be used to introduce the flocculant 42 and the base fluid 46 , respectively, to the second mixer 14 in predetermined relative quantities. The second mixer 14 preferably is a static shear mixer including an elongated insert to enhance the dispersion of flocculant 42 within the base fluid 46 and to provide turbulence to the flow. The turbulence created by the insert causes the flocculant 42 and the base fluid 46 to form the flocculant mixture 48 .
[0021] The flocculant mixture 48 is mixed with the surfactant treated mud 40 in a third mixer 16 . Like the first mixer 12 , the third mixer 16 preferably is a static mixer including an insert to provide shear to the passing fluids sufficient to mix the fluids together. The addition of flocculant 48 to the surfactant treated mud 40 causes solid material in the surfactant treated mud 40 to coagulate around the flocs. Creating larger solid masses aids in their later removal from the drilling fluid.
[0022] The treated mud 54 is mixed further in additional downstream mixers 18 , 20 . Preferably, a fourth mixer 18 is a dynamic mixer. In the dynamic mixer 18 , the treated mud 54 is subjected to agitation providing additional shearing to facilitate the coagulation of solids and floc. Additional mixers 20 , 21 may be included. The additional mixers 20 , 21 preferably are in-line mixers, providing additional mixing by subjecting the drilling fluid and polymer mixture 54 to shear as in the second mixer 14 discussed earlier. By including a plurality of mixers downstream from the injection of flocculent polymer 48 , the exposure of solids to the flocculant is enhanced prior to directing the treated mud 54 to a separation process.
[0023] Upon exiting the final mixer 21 , the treated mud 54 is a prepared mud mixture 56 ready for further processing to remove the solids from the fluid. The prepared mud mixture 56 may be directed to equipment outside of the skid 22 for additional processing. Such equipment may include a centrifuge 58 to which the prepared mud mixture 56 is directed. The centrifuge 58 includes a bowl that is rotated at a speed sufficient to separate the solids 60 in the prepared mud mixture 56 from the fluid, or effluent 62 . As the solids 60 are discharged from the centrifuge 58 , they may be collected in a cuttings box 64 . Effluent 62 may be released to a fluid storage area 66 , or directed to additional equipment (not shown) for further processing.
[0024] As previously stated, the equipment required to process the drilling fluid 24 prior to its being directed to the centrifuge 58 may be housed on a skid 22 . To consolidate the equipment onto a single skid 22 , attention must be given to the layout of the equipment. In a preferred embodiment, shown in FIG. 3 , water and base oil tanks 38 , 47 are positioned directly above the surfactant and polymer tanks 34 , 44 . The water and base fluid tanks 38 , 47 may be placed on rails so that they are movable to an outward position, away from the polymer and surfactant tanks 34 , 44 for refilling.
[0025] Dosing pumps 36 , 39 , 50 , 52 may be positioned on the skid 22 such that the polymer and base oil pumps are directly beside their respective tanks with one pump placed atop another to conserve space. Likewise, the surfactant and water pumps may be stacked to conserve space.
[0026] The flocculant polymer 42 or flocculant mixture 48 added to the drilling fluid enhances removal of the solids 60 by the centrifuge 58 by forming larger solid particles. The polymer droplets have to be well dispersed into the mud to be flocculated, without dissolving the polymer. The droplets remain intact and adhere the solids in the mud together, thus greatly improving the solid-liquid separation efficiency upon centrifugation. In order to derive the most benefit from the polymeric droplets as a flocculant, it is necessary that they be well mixed into the mud, and at an efficacious dose. The amount of flocculant polymer 48 added to the surfactant treated mud 40 should be that sufficient to leave the polymeric droplets homogeneously dispersed throughout the mud 24 to be flocculated.
[0027] A second embodiment of the apparatus 10 ′ is shown in FIG. 2 . In this embodiment, the drilling fluid 24 is pumped from the mud plant 26 into a first centrifuge 70 . The first centrifuge 70 is optimized to recover the weighting agent 72 , such as barite, from the drilling fluid 24 . The weighting agent 72 is discharged from the first centrifuge 70 to a cuttings box 74 or a storage tank 66 ′ to be reintroduced to the recovered drilling fluid 62 ′ discharged from the apparatus 10 ′. Effluent 76 from the first centrifuge 70 is pumped into the first mixer 12 . As previously described, surfactant 32 is injected into the first mixer 12 and the effluent 76 and surfactant 32 are subjected to static shear sufficient to distribute the surfactant through the drilling fluid to form a surfactant treated effluent 40 ′.
[0028] Continuing to refer to FIG. 2 , the surfactant 32 may be diluted with water 30 from water tank 38 prior to its introduction to the first mixer 12 as previously described with respect to FIG. 1 . A dose pump 36 may be used to introduce the surfactant 32 to the mixer with a predetermined pressure and flow rate. Likewise, a dose pump 39 may be used to introduce water 30 to the surfactant 32 with a predetermined pressure and flow rate. A polymer mixture 48 is made by mixing a flocculant 42 and a base fluid 46 , from base fluid storage tank 47 , in a mixer 14 , if a base fluid is needed. The polymer mixture 48 is directed to mixer 16 where it is mixed with the surfactant treated effluent 40 ′, as previously described.
[0029] If a base fluid is not needed, flocculant 42 may be directed to the mixer 16 , in which it is mixed directly with the surfactant treated effluent 40 ′ to form a treated mud 54 ′.
[0030] The treated mud 54 ′ from the mixer 16 is directed through a series of additional mixers 18 , 20 , 21 to ensure there is sufficient mixing to prepare the treated mud 54 ′ for separation and further processing. As previously described, a dynamic mixer 18 and one or more inline mixers 20 , 21 are preferred to ensure sufficient mixing of the flocculant 42 within the surfactant treated effluent 40 ′.
[0031] A centrifuge 58 may be used to separate solids 60 ′ and effluent 62 ′. The recovered weighting agent 72 from the first centrifuge 70 may be added to the effluent 62 ′ as needed to reproduce drilling fluid to be used in drilling operations.
[0032] While the claimed subject matter has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the claimed subject matter as disclosed herein.
[0033] Accordingly, the scope of the claimed subject matter should be limited only by the attached claims.
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Oil-based drilling fluid is prepared for further processing to recover the drilling fluid by pumping the drilling fluid through a flow meter. Surfactant may be added to the drilling fluid by using a dose pump and a flow meter. The drilling fluid and surfactant are then blended by passing them through a static mixer. A flocculating polymer is transferred via dose pumps to another static mixer where it is blended with the surfactant and drilling fluid mixture. To ensure adequate mixing and reaction, additional mixers are included through which the mixture passes. A centrifuge is used to separate solid particles from the fluid.
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FIELD OF INVENTION
[0001] The present invention concerns a front derailleur for a bicycle.
BACKGROUND
[0002] Front derailleurs are used to move a bicycle chain during travel from one toothed wheel of the bottom bracket to another one having a different diameter. This process functions to carry out gearshifting, varying the transmission ratio.
[0003] Known derailleurs typically comprise a chain guide positioned above the bicycle chain and a chain guide positioning mechanism, normally an articulated parallelogram mechanism, which is fixed to the bicycle frame along the tube that connects the bottom bracket to the saddle (seat-tube).
[0004] The chain guide is formed from an inner plate and an outer plate that face one another and are substantially parallel. The inner plate acts by pushing upon the chain to make it pass from a wheel having a small diameter to one having a larger diameter (upward gearshifting), and the outer plate acts by pushing upon the chain to make it pass from a wheel having a larger diameter to one having a smaller diameter (downward gearshifting).
SUMMARY
[0005] The present invention concerns, a front bicycle derailleur having a fixed member and a mobile member provided with a bicycle chain-guide. A connecting rod is hinged to the fixed member about a first articulation axis and to the mobile member about a second articulation axis. An actuation arm for controlling the derailleur is provided with a driving area, and the connecting rod transfers force exerted on the driving area to the mobile member, causing it to move. At the first articulation axis, the fixed member comprises a forked structure that embraces the first connecting rod.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a derailleur according to a first embodiment of the invention;
[0007] FIG. 2 is a view of the derailleur of FIG. 1 , taken from direction II;
[0008] FIG. 3 is an enlarged perspective view of the fixed member of the derailleur of FIG. 1 ;
[0009] FIG. 4 is a view of the fixed or stationary member of FIG. 3 , taken from direction IV;
[0010] FIG. 5 is a partially exploded top view of a derailleur according to a second embodiment of the invention;
[0011] FIG. 6 is an enlarged view of the fixed member of the derailleur of FIG. 5 ;
[0012] FIG. 7 is a view of a variant of a fixed member of the derailleur of FIG. 5 ;
[0013] FIG. 8 is a perspective view of a derailleur according to a third embodiment of the invention;
[0014] FIG. 9 is an enlarged perspective view of the fixed member of the derailleur of FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS INTRODUCTION TO THE EMBODIMENTS
[0015] The present invention concerns a front derailleur for a bicycle. The claimed front derailleur includes a mobile member provided with a chain-guide suitable for sliding engagement with a transmission chain of the bicycle. The mobile member is mobile between a first position and at least one second position. Also included is a fixed member, suitable for being fixed to a part of the bicycle frame. A first connecting rod, and a second connecting rod are hinged to the fixed member and to the mobile member, about four substantially parallel articulation axes so as to form an articulated quadrilateral, able to be deformed so as to move the chain-guide between the first and at least one second position. An actuation arm of the first connecting rod is provided with a driving area for controlling the derailleur through application of a thrust to the actuation arm so as to deform the deformable quadrilateral. At a first of the four articulation axes between the fixed member and the first connecting rod the fixed member includes a first forked structure that embraces the first connecting rod. The first forked structure is defined by opposite flanges.
[0016] It has been found that providing the fixed member of a bicycle front derailleur with a forked structure that surrounds the first connecting rod creates a more favorable distribution of the stresses caused by the traction of a derailleur control cable. In the derailleur of the present invention, the stress exerted on the actuation arm of the first connecting rod during the actuation of the control cable is distributed in a central area of the pin, because the ends of the pin are supported by the fixed member. This configuration simplifies the process of sizing the actuation arm, which can be made narrower or longer without jeopardizing its strength. The weight of the arm can also be reduced without this jeopardizing its mechanical strength. Moreover, the improved distribution of stresses also reduces the deformability of the biased parts, allowing for better rotational coupling and a consequent lower wear on the pins.
[0017] Preferably, the driving area on the actuation arm of the first connecting rod comprises a hook for receiving a derailleur control cable, and more preferably the derailleur comprises an elastic return member, acting on the articulated quadrilateral in a direction to push the chain-guide towards said first position, in which the thrust applied by the cable to the hook acts in the opposite direction to the return of the elastic return member. Alternatively, in a motorized derailleur (also known as an automatic or electric derailleur) the driving area can be a toothed sector engaged with a driving screw.
[0018] Preferably, the flanges of the first forked structure are provided with respective holes aligned along the first articulation axis and the first connecting rod comprises a hole aligned with the first articulation axis. A pin is inserted through the two holes of the first forked structure and further through the hole of the first connecting rod. Alternatively, it is possible for the pin to be formed as one piece with the connecting rod and for the flanges to consequently be in two pieces, so as to permit mounting on the pin. Alternatively, the pin may be formed in two parts and be formed as a single piece with the flanges and the connecting rod may consequently be formed as two pieces, so as to permit mounting on the pin.
[0019] Preferably, the first connecting rod comprises a main arm extending between the first and second of said four articulation axes, between the first connecting rod and the mobile member, and the main arm and the actuation arm substantially extend in the same plane perpendicular to the four articulation axes. The first connecting rod therefore has a very regular and uniform configuration, such as to regularly and uniformly transmit the stresses induced by the control cable to the pin.
[0020] Preferably, at a third of said four articulation axes between the fixed member and the second connecting rod, the fixed member comprises a second forked structure that embraces the second connecting rod, and the second forked structure comprises two opposite flanges. More preferably, the flanges of the second forked structure are provided with respective holes aligned along the third articulation axis, the second connecting rod comprises a hole aligned with the third articulation axis, and a pin is inserted through the two holes of the second forked structure and further through the hole of the second connecting rod. Alternatively, it is possible for the pin to be formed as a single piece with the connecting rod and for the flanges to consequently be formed as separate pieces, so as to permit mounting on the pin. Alternatively, it is possible for the pin to be formed in two parts and be formed as a single piece with the flanges and for the connecting rod to consequently be formed as two pieces, so as to permit mounting on the pin.
[0021] Alternatively, at a third of said four articulation axes between the fixed member and the second connecting rod, the fixed member comprises a cantilevered pin, and the second connecting rod comprises a hole aligned with the third articulation axis, inserted on the cantilevered pin of the fixed member.
[0022] Preferably, at a fourth of said four articulation axes between the second connecting rod and the mobile member, the mobile member comprises two opposite flanges perforated along the fourth articulation axis, in which the second connecting rod comprises a hole aligned with the fourth articulation axis, and in which a pin is inserted into the flanges and into the hole of the second connecting rod. More preferably, the elastic return member is a helical spring, mounted on the pin and provided with two ends, one engaged with an abutment tooth formed on the second connecting rod, the other engaged with an abutment portion formed on the mobile member.
[0023] Preferably, the fixed member comprises a cylindrical portion for a braze-on attachment to the bicycle frame. Alternatively, the fixed member comprises two semi-circular portions articulated together and a locking element for locking such semi-circular portions about the part of bicycle frame. According to this embodiment, the fixed member preferably is formed as a single piece with one of the two articulated semi-circular portions.
[0024] Preferably, the second connecting rod is substantially S-shaped and extends between the third and a fourth of said four articulation axes, between a first plane at the third articulation axis and a second plane at the fourth articulation axis. The first and the second planes are perpendicular to the four articulation axes and spaced apart by a predetermined distance.
[0025] Further characteristics and advantages of a derailleur according to the invention shall become clearer from the following description of some preferred embodiments thereof, made with reference to the attached drawings.
DETAILED DESCRIPTION
[0026] FIGS. 1 to 4 show a derailleur 10 suitable for being mounted on a bicycle according to one preferred embodiment of the invention. The derailleur 10 comprises a chain guide 11 , which is suitable for sliding engagement with a transmission chain of the bicycle, to move the chain between a first position and at least one second position, corresponding to distinct transmission ratios.
[0027] As shown in FIGS. 3 and 4 , the chain guide 11 forms part of a mobile member 12 , or cage, of an actuation mechanism that also includes a fixed member 13 , a first connecting rod 14 (or outer connecting rod), and a second connecting rod 15 (or inner connecting rod). The terms “inner” and “outer,” just like “lower” and “upper” as used hereafter, refer to the position taken up with respect to the mounting position of the derailleur in the bicycle.
[0028] The fixed or stationary member 13 , the mobile member 12 , and the two connecting rods 14 and 15 are articulated together along four parallel articulation axes A, B, C, D, such that they form an articulated parallelogram. More precisely, the fixed member 13 and the first connecting rod 14 are articulated about the first axis A; the first connecting rod 14 and the mobile member 12 are articulated about the second axis B; the fixed member 13 and the second connecting rod 15 are articulated about the third axis C; and the second connecting rod 15 and the mobile member 12 are articulated about the fourth axis D.
[0029] The mobile member 12 comprises an inner plate 17 facing an outer plate 18 , which form the chain guide 11 . The mobile member 12 is provided with lower flanges 19 , 20 perforated along the axis D for connection to the second connecting rod 15 , and with upper flanges 21 , 22 for connection to the first connecting rod 14 .
[0030] The first connecting rod 14 comprises a main arm 24 , extending between the axes A and B, and an actuation arm 25 , at the end of which a driving area is provided, in particular a hook 27 for receiving a derailleur control cable (not shown). The first connecting rod 14 is configured so that the main arm 24 and the actuation arm 25 substantially extend in a plane perpendicular to the four articulation axes A, B, C, D. The main arm 24 and the actuation arm 25 are substantially collinear with each other are substantially the same length.
[0031] At the axis B, a pin 29 rotatably connects the flanges 21 and 22 to a hole 28 made in the connecting rod 14 (see FIG. 2 ).
[0032] The second connecting rod 15 is substantially S-shaped and has an upper portion 34 articulated to the fixed member 13 about the third articulation axis C, an intermediate portion 35 and a lower portion 36 articulated to the mobile member 12 about the fourth articulation axis D. With respect to the common direction of the axes A, B, C, D, the upper and lower portions 34 and 36 of the connecting rod 15 extend in distinct planes M and N, spaced apart by a distance k.
[0033] At the axis D, a pin 39 rotatably connects the flanges 19 and 20 to a hole made in the lower portion 36 of the connecting rod 15 . About the axis D, an elastic return member, preferably a preloaded helical spring 40 , is arranged. The spring 40 is provided with an end 41 abutting a tooth 42 of the lower portion 36 of the second connecting rod 15 and with an end 43 abutting a portion 44 of the mobile member 12 . The spring 40 keeps the articulated parallelogram mechanism pushing towards a rest position, which is normally the position in which the chain guide 11 is closest to the bicycle, and the axis A is at its farthest possible position from the axis D.
[0034] A pair of screws 50 and 51 are adjustably mounted in respective threaded holes on the fixed member 13 and cooperate with the upper portion 34 of the second connecting rod 15 to define the extreme rotational positions of the connecting rod 15 itself and therefore the extreme deformation positions of the articulated parallelogram and of its parts, including in particular the position of the chain guide 11 . These extreme positions are adjustable through screwing and unscrewing of the screws 50 and 51 .
[0035] The fixed member 13 (which can be seen separate from the rest of the derailleur in FIGS. 3 and 4 ) comprises a cylindrical surface 61 for attachment to a portion of the seat-tube of the bicycle frame of a shape matching the cylindrical surface 61 (braze-on attachment). The cylindrical surface 61 extends around a central axis Y.
[0036] The fixed member 13 further comprises, at the first axis A, a first forked structure 62 that embraces the first connecting rod 14 . The first forked structure 62 is formed from a first flange 63 facing a second flange 64 , each provided with respective holes 65 and 66 aligned along the axis A. A pin 68 is inserted through the holes 65 and 66 and further through a hole 69 aligned with them formed in the first connecting rod 14 , so as to provide the articulated coupling between the fixed member 13 and the connecting rod 14 .
[0037] The fixed member 13 also comprises, at the third axis C, a second forked structure 72 that embraces the second connecting rod 15 . The second forked structure 72 formed from a first flange 73 facing a second flange 74 . The flanges are provided with respective holes 75 and 76 aligned along the axis C. A pin 78 is inserted through the holes 75 and 76 and further through a hole aligned with them formed in the upper portion 34 of the second connecting rod 15 to provide the articulated coupling between the fixed member 13 and the connecting rod 14 .
[0038] A through hole 60 facing into the cylindrical surface 61 is formed in the fixed member 13 , to receive an attachment screw (not shown) for connecting to the seat of the seat-tube.
[0039] As can be seen more clearly in FIG. 2 , the first forked structure 62 with its flanges 63 and 64 laterally embraces the first connecting rod 14 and supports the articulation pin 68 at the ends thereof. When a traction force is applied to the hook 27 of the actuation arm 25 by the derailleur control cable, the stress is transmitted from the actuation arm 25 into the articulation area at the pin 68 . The stress is distributed through the central area of the pin 68 , located between the two flanges 63 and 64 , instead of being concentrated at one end, as in derailleurs of the prior art.
[0040] FIGS. 5 and 6 show a view from above of an alternative embodiment of a derailleur 110 according to the present invention, which differs from the derailleur 10 described above in that it connects to the seat-tube, through a clamp attachment instead of in a seat with cylindrical surface.
[0041] The derailleur 110 is similar to that which is described above and shall only be described with respect to those features that differ from the first described embodiment. In FIGS. 5 and 6 , the parts of the derailleur 110 that correspond to the derailleur 10 of FIG. 1 are indicated with the same reference numerals increased by 100.
[0042] In the derailleur 110 , a clamp adapter element 181 is attached, preferably screwed, to the fixed member 113 , to connect the derailleur 110 to the seat-tube of the bicycle. For this purpose, the clamp adapter element 181 comprises two semi-circular portions 182 , 183 , articulated together, to allow them to open out, with respective circular surfaces 184 , 185 that are clamped on the frame by a bolt 186 when the derailleur 110 is in mounted configuration.
[0043] FIG. 7 shows a variant 213 of the fixed member of the derailleur that differs from the fixed member 113 of FIGS. 5 and 6 in that it comprises two semi-circular portions 282 , 283 , articulated together, and having respective circular surfaces 284 , 285 that are clamped on the frame by a bolt 286 when the derailleur is in its mounted configuration. The fixed member 213 is formed as a single piece with the semi-circular portion 283 .
[0044] FIG. 8 shows a perspective view of another embodiment of the derailleur 310 , which comprises a fixed member 313 ′ that differs from the fixed member 13 of the derailleur 10 . The fixed member 313 ′ is shown in greater detail in FIG. 9 .
[0045] Aside from the fixed member 313 ′, the derailleur 310 is similar to the derailleur 10 . In FIGS. 8 and 9 , the parts of the derailleur 310 that correspond to the derailleur 10 are indicated with the same reference numerals increased by 300.
[0046] The fixed member 313 ′ shown in FIGS. 8 and 9 differs from the fixed member 13 of FIG. 1 only in the area of the articulation axis C. In this area, the fixed member 313 ′ comprises a flange 373 ′ provided with a hole 375 ′ for receiving a pin 378 ′ arranged cantilevered with respect to the flange 373 ′. The fixed member 313 ′ does not have an additional flange facing the flange 373 ′, as in the embodiment of FIG. 1 . The second connecting rod 315 is connected to the fixed member 313 ′ such that it is cantilevered on the pin 378 ′, as can be seen in FIG. 8 .
[0047] Other variations are possible, while still remaining covered by the present invention as defined by the following claims. For example, it is possible to make a derailleur similar to the derailleur 310 of FIG. 8 , but suitable for connection to the bicycle like the derailleur 110 of FIG. 1 , possibly with a fixed group like the group 213 of FIG. 7 .
[0048] Furthermore, in the couplings between any of the described forked structures and connecting rods, it is possible for the pin to be formed as a single piece with the connecting rod and for the flanges of the forked structure to consequently be formed as two pieces, to permit mounting on the pin. Alternatively, the pin may be formed in two pieces and as part of a continuous structure with the flanges. The connecting rod is consequently formed in two pieces to permit mounting on the pin.
[0049] Furthermore, in the case of a motorized derailleur (also known as an automatic or electric derailleur) the driving area of the actuation arm of the first connecting rod can consist of a toothed sector engaged with a driving screw.
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A derailleur including an articulated quadrilateral mechanism, having four parallel articulation axes is provided. At a first articulation axis, between a fixed member and a first connecting rod, the fixed member includes a first forked structure embracing the first connecting rod. The first forked structure includes two opposite flanges having respective holes aligned along the first articulation axis, and the first connecting rod includes a hole aligned with the first articulation axis. A pin is inserted through the two holes of the first forked structure and the first connecting rod. The use of the fixed member creates a more favorable distribution of the stresses induced in the first connecting rod and the pin by the traction of the derailleur control cable.
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DESCRIPTION OF THE INVENTION
This invention relates to a method of combustion and to fuel burners. It is particularly concerned with the combustion of a particulate fuel, particularly pulverised coal, in an aqueous carrier medium.
It is known to burn pulverised coal in an aqueous carrier medium using air to support combustion of the coal. Even if large volumes of excess air are used it is found necessary to employ around 75% by weight of coal in the combined pulverised coal-aqueous carrier mixture in order to obtain adequate combustion of the coal unless the air is preheated to a substantial extent. At such high concentrations of coal, difficulties arise in transporting the coal-aqueous carrier mixture to the burner and one or both of special high pressure pumping equipment or special grinding equipment is typically required. Alternatively, in order to facilitate transport of the coal in suspension in an aqueous carrier various additives such as emulsifiers and stabilisers may be incorporated in the aqueous carrier medium. Whichever of these expedients is resorted to, considerable additional costs are entailed. For example, it if is decided to preheat the air, a large heat exchanger is typically required to heat exchange the gaseous products of combustion with the air.
We have performed experiments using commercially pure oxygen rather than air to support combustion of pulverised coal in suspension in water. We have obtained two surprising results.
First, we have managed to burn a composition comprising pulverised coal of normal commercially available particle size in suspension in water, said composition including only 60% by weight of coal. We have therefore found it unnecessary to add emulsifiers to the composition to facilitate pumping of the composition or to use special high pressure pumping equipment.
Second, by atomising the water we have been able to obtain a flame that resembles a typical fuel oil-oxygen flame, i.e. one that is relatively short and hence has a relatively intense flame.
Both these results may be achieved without preheating the oxygen or oxygen-enriched air.
According to a first aspect of the present invention, there is provided a method of burning a particulate fuel, which comprises supplying to a combustion zone and atomising a composition which comprises 50 to 70% by weight of particulate fuel and 30 to 50% by weight of an aqueous carrier and which is able to be pumped without the presence in the composition of an emulsifying agent or lubricant to facilitate such pumping, and also supplying to the combustion zone substantially pure oxygen or oxygen-enriched air whereby to support combustion of the particulate fuel.
We prefer to atomise the composition, at least until a chosen temperature has been attained in an enclosure being heated by burning the particulate fuel and preferably continuously, whereby to obtain a flame having a temperature profile similar to an oxygen-oil flame. The atomisation is preferably carried out upstream of the combustion zone.
The particulate fuel is preferably pulverised coal. In this connection the term coal includes within its scope mineral coal, anthracite coal, sub-bituminous coal and lignite.
We prefer not to preheat the oxygen or oxygen-enriched air to any substantial extent, i.e. we find it unneccesary to employ a heat exchanger to raise the temperature of the oxygen or oxygen-enriched air by heat exchange with the gaseous combustion products. Typically, the oxygen or oxygen-enriched air is supplied to the combustion zone at ambient temperature; and so is the said composition.
The proportion of coal in the composition is selected such that the composition is readily able to be pumped without the presence of an emulsifying or other chemical agent or lubricant to facilitate such pumping. Generally a composition including from 55 to 65% by weight of coal and particularly one containing about 60% by weight of coal and a balance of water will meet this criterion.
The coal is typically present in the composition in a range of particle sizes. One suitable bituminous coal composition had 73.6% by weight of its particles passing through a sieve of 106 microns in mesh size; 57.8% passing through a sieve of 75 microns (200 mesh) in mesh size and 40.7% passing through a sieve of 40 microns in mesh size. Spiers Technical Data on Fuel, Sixth Edition, 1961, published by the The British National Committe, World Power Conference, 201 Grand Building, Trafalgar Square, London, WC2, 1961 quotes (at Page 300) a proportion of 70% of bituminous coal particles passing through a sieve of 75 microns mesh size (200 mesh) as being typical of a pulverised bituminous coal composition, i.e. the typical composition is considerably finer than the one which is described above as being suitable for use in accordance with the invention and which contains less than 60% by weight of particles passing through a 75 micron mesh size. This is a relatively coarsely ground composition. Such a range of particle sizes as described above can be produced in simple wet grinding equipment of conventional design that can be employed on site with a burner or burners used to perform the method according to the invention.
The composition is preferably atomised by introducing an atomising agent into it. The atomising agent is preferably a pressurised non-condensible fluid. Compressed air may for example be used as the atomising agent and may be introduced into the said composition upstream of a burner employed to burn the composition. Alternatively, substantially pure oxygen or oxygen-enriched air may be used as the atomising agent, a part of the oxygen or oxygen-enriched air supplied to the combustion zone being used for this purpose.
A burner for use in the present invention may be of relatively simple construction. The burner typically has an outer shell (which may have a cooling jacket) and a head or nozzle located within the shell at or near its outlet end. The head or nozzle preferably defines an inner passage or passages for the said composition and may define separate passage(s) for oxygen or oxygen-enriched air, or alternatively may define with the shell one or more passages for this purpose. The tip of the head or nozzle may be coplanar with the tip of the shell or may be set inside the shell.
If desired the burner may be provided with a passage for an auxiliary fluid fuel which may be burnt at start-up of the burner in order to facilitate the creation of a stable flame. Propane may be employed as the said auxiliary fuel. The passage for the auxiliary fuel may be formed through the head or nozzle of the burner.
In a preferred burner the head or nozzle has a passage communicating at one end with the passage for oxygen or oxygen-enriched air (or with one such passage if more than one oxygen or oxygen-enriched air passage is provided) and at its other end with the passage for the sald composition, whereby a proportion of the oxygen or oxygen-enriched air is able to be diverted into the passage for the said composition so as to atomise its water. Typically, from 5%-10% by volume of the oxygen or oxygen-enriched air is so diverted.
The present invention also provides a particulate fuel burner for burning a composition comprising water and particulate fuel, said burner including a head or nozzle, at least one passage through the head or nozzle for said composition, at least one passage for substantially pure oxygen or oxygen-enriched air, and an auxiliary passage affording communication between a (or the) oxygen passage and a (or the) composition passage whereby in operation of the burner oxygen or oxygen-enriched air is able to be conducted into the said composition passage so as to atomise the said composition.
The methods and burner according to the invention will now be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a schematic side elevation, partly in section, of a burner according to the invention for burning a composition comprising pulverised coal and water; and
FIG. 2 is an end view of the burner shown in FIG. 1.
FIG. 3 is a schematic diagram illustrating plant for forming a coal-water composition for use in the present invention.
FIG. 4 is a graph illustrating the profile of a coal-water composition flame produced by the method according to the invention.
The drawings are not to scale.
Referring to the accompanying drawings, a burner 2 has an outer shell 4 and an inner head or nozzle 6. The head or nozzle 6 is coaxial with the shell 4 and is in the form of a monolithic body having a frusto-conical innermost portion 8 diverging in the direction of the burner tip 14, a central right cylindrical portion 10, and an outermost frusto-conical portion 12 converging in the direction of the burner tip 14.
The head of nozzle 6 and the shell 4 define therebetween a generally annular passage 16 for substantially pure oxygen or oxygen-enriched air. The head or nozzle 6 has a central relatively unrestricted axial passage 18 therethrough for a composition of water and pulverised coal. A conduit 20 is received in the passage 18 and extends between the head or nozzle 6 and a backplate 22 of the burner 2. The backplate 22 is provided with connecting means 24 whereby a supply of coal-water slurry or composition can be pumped by means not shown to the conduit 20 and thence the passage 18 of the head or nozzle 6. The shell 4 is similarly provided with connecting means 26 whereby oxygen or oxygen-enriched air may be passed from outside the burner into the interior of the shell 4 and thence to the passage 16.
The head of nozzle 6 has a relatively narrow passage 28 therethrough extending parallel to the central passage 18 and receiving a conduit 30 for the supply of propane or other combustible fluid. The conduit 30 is received in the backplate 22 which is provided with a connecting means 32 whereby the conduit 30 can be connected to a source of propane (not shown).
The head or nozzle 6 also has an auxiliary passage 34 extending and affording communication between the passage 16 and the passage 18 thereby enabling oxygen to flow from the passage 16 into the passage 18 so as to atomise the water supplied to the passage 18 with the pulverised coal.
The head or nozzle 6 is typically formed of copper and is in good heat-conductive relationship with the shell 4. The head or nozzle 6 has integral therewith three equally spaced lugs 36 about the circumference of its right cylindrical portion 10 which engage the inner surface of the shell 4. The shell 4 is typically provided with a jacket (not shown) through which a coolant such as air or water may be circulated so as to prevent the burner 2 from becoming excessively hot during its use.
The exposed end of the head or nozzle 6 may be coplanar with that of the shell 4, or the head or nozzle 6 may be inset with respect to the shell 4.
The burner 2 is typically provided with means (not shown) for igniting the fule at start-up of the burner 2. Such means are well known in the combustion art and will accordingly not be further described herein.
In operation, a composition comprising pulverised coal suspended in water without the presence of emulsifying agents and the like is pumped through the conduit 20 to the passage 18, is atomised and passes from the passage 18 into the burner flame (not shown). Oxygen, of commercial purity, and at or neat to ambient temperature is passed under pressure into the shell 4 and flows through the passage 16 and issues therefrom typically but not necessarily at supersonic velocity and passes into the burner flame where it supports combustion of the pulverised coal. From 5%-25% by volume of the oxygen supplied to the shell 4 flows through the passage 34 into the stream of water-pulverised coal suspension flowing through the passage 18. The kinetic energy of the oxygen passing through the passage 34 is sufficient to atomise the water as mentioned above.
It is not essential in performing the methods according to the invention to employ the oxygen as the atomising medium. One alternative is to supply compressed air typically at ambient temperature to the suspension of pulverised coal in water as it is being pumped to the burner 2. Other pressurised fluids that do not condense in the water can alternatively be substituted for the air.
The suspension of pulverised coal in water may typically include 60% by weight of pulverised coal and 40% by weight of water.
As the particles of pulverised coal leave the burner 2 and enter the flame they experience the following sequence of events. First, the heat of the flame causes surrounding water to be converted to steam. Second, volatile substances are emitted from the coal as the temperature rises and these volatile substances burn in the presence of oxygen molecules supplies from the passage 16 to the flame. It is believed that supplying some of the oxygen through the passage 34 helps to bring the oxygen into intimate contact with the particles of coal and thereby facilitate the combustion of the volatile substances. Third, the carbon content of the coal burns. In conventional combustion of suspensions of pulverised coal in water using air and not oxygen or oxygen-enriched air to support combustion, the combustion proceeds from the second phase of the combustion process (combustion of volatile vapours evolving from the coal) to the third phase (combustion of carbon). However, when oxygen instead of air is used to support combustion, we hypothesise that the said second and third phases proceed more or less simultaneously rather than consecutively but do not wish to limit the scope of the invention in any way by this hypothesis.
As the partices of pulverised coal progress through the flame their temperature reaches a maximum and then falls again before they exit from the flame in the form of ash having a relatively small carbon content. Indeed, we have found it possible to produce an ash with a lower carbon content than has been achieved when using air to support the combustion of a suspension of pulverised coal in water. Moreover, we have produced a relatively short flame comparable with that formed by an oxygen-heavy fuel oil burner. These results have been obtained when burning a suspension containing only 60% by weight of pulverised coal.
Typically, substantially all the oxygen molecules that take part in the combustion of the pulverised coal are supplied from the burner 2. The oxygen or oxygen-enriched air may typically be supplied at a rate of from 90%-110% of that required for complete stiochiometric combustion of the coal.
It is preferred to use substantially pure oxygen rather than oxygen-enriched air to burn the pulverised coal as the nitrogen content of oxygen-enriched air tends to militate against complete combustion of the coal.
In order to facilitate the obtaining of a stable flame at start-up of the burner, propane may be supplied to the passage 28 via the conduit 30. This supply may, if desired, be stopped once a flame temperature typically in the order of 700° C. is achieved. This may take from say 5-500 seconds.
It is an advantage of the method according to the invention that a burner of relatively simple design, for example as illustrated in the accompanying drawings, may be used. In particular, the passage 18 can be of relatively wide diameter such that blockages caused by the particulate fuel are avoided.
The burner 2 may, if desired, fire into a cowl having a refractory inner wall or into a quorl forming part of a furnace.
It is not essential to provide the passage 28 and associated conduit 30 and connecting means 32 for propane in the burner 2. If desired, a separate supply of propane may be used to obtain a stable flame at start-up and event this provision is not essential.
Referring now to FIG. 3 of the accompanying drawings, there is illustrated schematically a plant for making a composition comprising pulverised coal and water.
A stock 40 of run of mine coal is screened by means of a screening device 42. The particles that pass through the screen are passed directly into a wet grinder 44. Those retained on the screen are passed into a jaw crusher 46 and the resulting comminuted coal fed into the wet grinder 44. A pump 48 takes a suspension of coal dust in water from the stock 40 and pumps it to the wet grinder. If desired, colliery tailings or other colliery waste may be added to this suspension.
Sufficient water is fed into the grinder 44 to form a slurry or composition of the desired composition. The resulting slurry is pumped by a pump 50 to a burner system 52 for burning the slurry in accordance with the invention.
If desired a chosen proportion of the slurry may be recycled to the suction side of the pump 50 for the purposes of monitoring flow rate and another proportion recycled to the stock 40 for the purpose of entraining particles of coal dust.
If desired, suitable fluxes to change the chemical composition of the ash produced by burning the coal may be added to the slurry upstream or downstream of the wet grinder. Such additions are described in our U.K. patent application No. 2 099 132 A.
The method according to the invention will now be further described with reference to the following example.
EXAMPLE
A composition comprising 40% by weight of water and 60% by weight of a coarse fraction of bituminous coal particles was formed. The coarse fraction had a range of particle sizes such that 73.6% by weight passed through a sieve of sieve size 106, 57.8% passed through a sieve of sieve size 75 and 40.7% passed through a sieve of sieve size 40. The fine fraction had a range of particle sizes such that 88.7% by weight passed through a sieve of sieve size 106, 76.8% by weight passed through a sieve of sieve size 75, and 50.7% by weight passed through a sieve of sieve size 40. The coal employed was classified as bituminous 701 coal, had a calorific value of 32 540 KJ/kg, a volatile content of 35.4% by weight, an ash content of 4.6% by weight and a moisture (DAF) content of 0.8% by weight.
The composition was burned using a burner generally similar to that shown in FIGS. 1 and 2 save that no internal passage for forming a pilot flame such as the passage 30 was employed and that no passage equivalent to the passage 34 was used. Instead, an external propane pilot flame and air atomisation (instead of oxygen atomisation) were PG,11 employed. The burner was fired into a flame tunnel 0.91 m in diameter and 3.66 m long. The burner was tilted downwards at an angle of 30° to the horizontal. A flame profile was obtained with a maximum tunnel wall temperature of 1480° C. and is shown in FIG. 4. From the shape of the profile, we deduce that flame temperatures in excess of 2000° C. can be produced with a coal-water mixture containing 60% by weight of coal of a relatively coarse grinding. It is to be appreciated that the flame produced was short, intense and highly luminous in comparison with air-oil flames and air-pulverised coal flames that are characterised by being long, lazy and less luminous.
In order to produce the profile in FIG. 4, at steady state operation, the 40% by weight water, 60% by weight coal composition was supplied to the burner at a rate of 2.0 kg per minute and temperature of 15° C. commercially pure oxygen was supplied at a rate of 2.16 cubic meters per minute, and atomising air at a rate of 0.36 cubic meters per minute. In order to obtain ignition and a stable flame a propane pilot flame was employed. Initially, the propane was supplied at a rate such that the propane supplied 30 of the total thermal energy. When the mean wall temperature had reached 530° C. after 4 minutes, the rate at which the propane was supplied was halved and when the mean wall temperature had reached 730° C. (after about 7 minutes) the supply of propane was stopped and hence the pilot flame was extinguished.
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A composition comprising a particulate fuel, typically pulverized coal, carried in water is formed such that it is readily able to be pumped without adding emulsifiers or lubricants to the composition. The composition typically includes at least 25% water and preferably 30 to 50% water. The composition is pumped to a burner 2 and is atomized therein, typically by means of a stream of oxygen supplied through a passage 6 in the nozzle 6 of the burner. This oxygen is taken from that supplied to a further passage for supporting combustion of the particulate fuel. A relatively short and intense flame can be produced at relatively low coal concentrations in the composition such that the need to use expensive emulsifiers etc. is avoided.
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[0001] The invention relates to a method and apparatus for transfer of particulate products between zones of different pressure.
[0002] The invention is especially suitable for transfer of low density biomass such as straw but not limited to that.
[0003] The method invented is based on a sluice system according to which the product is first conveyed through a portioning device, which produces a sequence of uniform product portions divided by uniform particle free spaces, and subsequently the product portions are conveyed individually through a sluice device, which comprises at least one sluice chamber and two pressure locks of which at least one at any time secures a pressure tight barrier between the two pressure zones, and the product portions are force loaded from the first zone into a sluice chamber by means of a piston screw, the axis of which is practically in line with the axis of the sluice chamber, and the product portions are force unloaded from the sluice chamber and into the second pressure zone by means of said piston screw or a piston or by means of gas, steam or liquid supplied at a pressure higher than that of the second pressure zone.
[0004] A piston screw in this context means a screw conveyor to which a reciprocating axial movement can be added independent of the rotation. An example of a piston screw is described in SE Patent 469.536.
[0005] A sluice system in this context means a portioning device combined with a sluice device. A sluice device means a sluicechamber combined with pressure locks.
[0006] A sluice chamber in the sense of the invention is a chamber which alternately can be connected to one of two pressure zones, while it at the same time is pressure tight separated from the other pressure zone. The devices which in closed condition secures pressure tight separation will in the following be called pressure locks.
[0007] Force loaded/unloaded means loaded/unloaded by positive product conveying which imply, that other conveying forces than gravity are applied.
BACKGROUND
[0008] There is an increasing interest in producing energy, cellulosis, ethanol and other products from biomass. This includes, that the biomass undergoes pressurized processes, such as steam treatment, hydrolyzation, solvent extraction, pulping, explosion pulping, gasification, drying with superheated steam. The biomass can comprise of dry or wet particles or particles suspended in a liquid.
[0009] To achieve lowest possible production costs, it is crucial to establish reliable continuous processes and produce round the clock throughout the year.
[0010] Straw is a large biomass resource, which have not yet been intensively exploited, because its properties makes it very difficult to transport into, through and out of pressurized equipment. The main obstacles are:
[0011] Straw has a low density (loose shredded straw app. 50 kg/m 3 ).
[0012] Straw is a non flowing product and has very strong bridging properties.
[0013] Straw has a high content of abrasive silicon.
[0014] These obstacles means that a method and apparatus able to handle straw in relation to pressurized equipment will be able to handle almost everything else such as woodchips, coal, residential garbage, by-products from slaughterhouses etc.
[0015] To be reliable the apparatus must meet the following requirements:
[0016] machine parts should only to a very limited extend “cut through” the product, in order to avoid wear and jamming.
[0017] the risk of bridging should be eliminated by forcing the product through the critical zones. This means that forced loading and unloading of sluice chambers are abselutely nescessary.
[0018] it should be possible to compress low density products to a higher density in order to obtain a suitable capacity within reasonable dimensions.
[0019] None of the known methods and apparatus based on sluice devices are meeting these requirements.
[0020] SE Patent 469 536 describes a chamber into which product is conveyed by a piston screw. At the inlet a cylinderknife slides forward and cuts through the product to close the inlet, but its function is to close for product and not to provide a pressure lock. At the outlet there is a pressure lock, but since there is only one, It is not a sluice device as previously defined. The apparatus is a plug flow feeder based on the ability of the higly compressed plug of product to reduce escape of gas when the pressure lock is open.
[0021] Rotary locks e.g. U.S. Pat. No. 5,114,053, where a rotor, comprising several pockets, rotates continously in a cylindrical housing, demands a product with good flow properties. Machine parts have to “cut through” the product, which is problematic especially at the inlet. The product cannot be compressed and forced loading/unloading is not possible.
[0022] By DT Patent 24 26 035 a rotor with one sluice chamber turns intermittently, allowing the opening alternately to be connected to the high and the low pressure zones. A piston in the sluice chamber secures forced unloading of the sluice chamber and prevents emission from the high pressure zone. The product is not force loaded into the sluice chamber, therefore it can not be compressed, and machine parts have to “cut through” the product.
[0023] U.S. Pat. No. 5,095,825 describes a method where a rotor has two sluice chambers, which are force unloaded by pistons placed in the sluice chambers. The openings of the sluice chambers are placed in one end of the rotor, so that each of them will be connected to one of the two pressure zones when the rotor stops. The method seeks to reduce the risk of bridging during loading of the sluice chamber by creating a vacuum with the piston. This means, that the risk of bridging is only partly reduced if the product is penetrable for air. Machine parts would have to “cut through” the product and it is not possible to compress the product by this method.
[0024] By U.S. Pat. No. 5,819,992 a rotor with several parallel sluice chambers is used. The sluice chambers have inlet in one end and outlet in the other end. When the rotor stops for loading of one sluice chamber and unloading of another, tightness is established by expansion of dynamic sealing rings. When the loading/unloading operation is finalized, the dynamic sealing rings are contracted, thereafter the rotor can move to the next postion with less friction but incomplete tightness. The method does not include portioning, so machine parts have to “cut through” the product. Furthermore the method does not include forced loading, option for compression or forced unloading.
[0025] SE Utläggningsskrift 456 645 describes a T-shaped sluice chamber, which forces the product to make a perpendicular movement from horizontal to vertical direction. The product is conveyed past the inlet pressure lock and into the sluice chamber by means of a piston or a piston screw, and thereafter the product has to fall by gravity only through the vertikal branch, until it lands on the outlet pressure lock. A separate piston secures forced unloading of the sluice chamber. The fact that the product during the loading of the sluice chamber has to make a 90° turn by means of gravity only increases the risk of bridging, and makes capacity increasing compression of the product in the sluice chamber impossible.
[0026] By U.S. Pat. No. 5,192,188 the product is loaded into the sluice chamber by means of gravity only, wich gives a very poor filling. The discharge piston has to “cut through” the product at the inlet opening, and capacity increasing compression is not possible.
[0027] The advantage by the method according to the invention is, that it meets all the requirements for for transfer of particulate, abrasive, low density, non flowing products between zones with different pressures.
[0028] To avoid “cutting through” the product the method according to the invention comprises a portioning device before the sluice device. The portioning device produces one or several sequenses of uniform product portions divided by uniform particle free spaces. The particle free spaces secures, that no product particles occur in the working space of the pressure locks when they are closing.
[0029] To achieve force loading, the product portions are conveyed into the sluice device by means of a piston screw. The rotation and axial movement of the screw piston can be controlled independently wich makes it possible to provide any degree of compression from light packing to transformation of the product portions into solid plugs.
[0030] Force loading and the possibility to achieve an ajustable compression of the product are very important features of the invention, because of the improved reliability and increased capacity that the apparatus according to the invention will achieve compared to the known apparatus. The known apparatus is designed to transfer particles of coal and wood with densities from 0.4-0.8 compared to 0.05 for shredded straw. This means, that the capacity on straw would drop to app. 10% if the volume of the sluice chamber was unchanged.
[0031] To achieve forced unloading of the sluice chamber according to the invention, different embodiments of the invention can be selected depending on whether emission from the high pressure zone during transfer of product from the sluice chamber to the high pressure zone is acceptable or not.
[0032] If emission is acceptable, as for example when the emission consists of steam, from which energy can be recovered by condensation, the piston screw which performs the forced loading can also perform the forced unloading of the sluice chamber. This implies that for each product portion transferred into the high pressure zone, a volume of steam will be transferred to the sluice chamber and further on to the place of condensation. For this situation pressure lock devices can be selected among well known valves such as slid valves, ball valves or piston valves. The inner diameter of the valves should at least be of the same size as that of the sluice chamber. Before opening the pressure locks, the pressure of the sluice chamber must be adjusted to establish substantially the same pressure at both sides of the pressure lock in order to reduce the power needed to open the pressure lock.
[0033] In special situations such as explosion pulping, where the product has to be discharged at high speed from the high pressure of the digester, the pressure of the sluice chamber should be maintained or even increased to accelerate the product to a very high velocity when the pressure lock is opened. For this special situation the diameter of the valve can be much smaller than the diameter of the sluice chamber, because of the high velocity of the product during discharge. A ball valve is a good choise because it can be opened completely in a very short time.
[0034] If emission is unacceptable for example when poisonous, explosive or malodorous gases are involved, the preferred embodiment of the invention comprises a rotor with two sluice chambers placed practically parallel to the axis of the piston screw, and either perpendicular or parallel to the axis of the rotor and equipped with pistons for forced unloading.
[0035] In this preferred embodiment of the invention the sealing system preventing gases vapours or liquid to leak out when product is transferred from the sluice chamber into the high pressure zone have to be resistant to the impact of the chemicals and the temperatures prevailing in the high pressure zone. By gasification for example the temperatures can be in the range of 700-1100° C. and process gases can contain considerable amounts of tare, wich can condense at the much lower temperature of the sluice chamber. To avoid hot process gas to enter into the sluice chamber during unloading, it is known for example from U.S. Pat. No. 5,095,825 and DT 24 26 035 A1 to raise the pressure of the sluice chamber before unloading by means of pressurized inert gas. The supply of inert gas is however a substantial extra cost, and therefore a special sealing system has been developed to the invention, which practically eliminates leaking of process gas without utilization of pressurized inert gas at all.
[0036] The special sealing system comprises three sealing devices, which will be active at three different places.
[0037] The first sealing device comprises two sealing rings which will be active between the open ends of the sluice chambers and the outlet of the low pressure zone and the inlet of the high pressure zone during loading and unloading. This first sealing device is a known type of seal which can be extended to establish tightness during loading respectively unloading and contracted during movement of the rotor in order to avoid friction.
[0038] The second sealing device shall prevent escape of gas, vapour or liquid from the high pressure zone into the part of the sluice chamber behind the piston. Emission can occur when the sealing edges of the piston become worm, which is inevitable especially when silicia is present in the product. The second sealing device uses gas, vapour or liquid behind the piston, pressurized to substantially the same pressure as that of the low pressure zone during loading, and pressurized to the same or a higher pressure than that of the high pressure zone during unloading. The pressurized gas, vapour or liquid can also be used to move the piston during unloading.
[0039] The third sealing device comprises a vessel housing the rotor and is providing a sealed connection between the two pressure zones. This third sealing device will take care of any emissin from the high pressure zone caused by wear or failures of the two other sealing devices. Any emission to the vessel will be detected and directed to a place where it will do no harm. The detection can release the action nescessary to stop further emission.
DETAILED DESCRIPTION
[0040] The method of the invention is based on a sluise system comprising a portioning device and a sluice device. In the following the invention is described in details by means of two examples of embodiments of the portioning device and three examples of embodiments of the sluice device.
[0041] Example 1 describes a portioning device appropriate for atmospheric conditions and with good buffering capacity for the product to be transferred. FIGS. 1 a and 1 b are illustrating example 1.
[0042] The feed conveyer 1 . 2 moves the product under a levelling rotary drum 1 . 3 creating a product flow with uniform cross section. The thickness of the product layer 1 . 4 can be adjusted by changing the distance between 1 . 3 and 1 . 2 . At the upper end of 1 . 2 the product drops into the hopper 1 . 5 with bottom trap doors 1 . 6 . When the correct amount of product has been transferred into the hopper 1 . 5 , the trap doors 1 . 6 will open up and the product portion will drop into the belt conveyer 1 . 7 , wich will move the portion into the sluice device (not shown). When the hopper 1 . 5 has been unloaded, the trap doors 1 . 6 will be dosed and the accumulation of a new product portion will begin.
[0043] Example 2 describes a portioning device appropriate for pressurized conditions and with the possibility to serve two sluice devices. FIGS. 2 a and 2 b illustrates example 2.
[0044] [0044]FIG. 2 a
[0045] The product is conveyed out from the high pressure zone by a screw conveyer 2 . 1 in the house 2 . 2 . A traversing screw conveyer in the house 2 . 4 can rotate in both directions and thereby convey the product alternately through the pressure locks 2 . 5 . 1 and 2 . 5 . 2 and into the sluice chambers 2 . 6 . 1 and 2 . 6 . 2 . When the traversing screw conveyer is loading for example the sluice chamber 2 . 6 . 1 a space free of product particles is created around the pressure lock 2 . 5 . 2 . When sluice chamber 2 . 6 . 2 is loaded a space free of product partides is created around the pressure lock 2 . 5 . 1
[0046] Example 3 describes a sluice device appropriate when a controlled emission is acceptable during transfer of product from the low to the high pressure zone. FIG. 3 a - 3 i illustrates example 3.
[0047] [0047]FIG. 3 a
[0048] The conveyer 3 . 1 moves the product portion into the intake hopper 3 . 3 equipped with 2 belt conveyers 3 . 2 providing combined compression- and transport. The product portion under the pressure P1 is forced into the sluice chamber 3 . 6 . through an open pressure lock 3 . 4 . A screw piston 3 . 5 . in its position under the intake hopper 3 . 3 conveys the product portion towards the closed outlet pressure lock 3 . 8 by its rotating movement only, until the whole product portion has passed the inlet pressure lock 3 . 4 .
[0049] [0049]FIG. 3 b
[0050] The inlet pressure lock is closed.
[0051] [0051]FIG. 3 c
[0052] The pressure in the sluice chamber is changed to the new pressure P2 by means of the equalization valve 3 . 9
[0053] [0053]FIG. 3 d
[0054] The outlet pressure lock is opened, and an axial movement of the piston screw 3 . 5 is added to the rotation with an axial movement, wich forcing the product portion out of the sluice chamber 3 . 6 past the outlet pressure lock and Into the new pressure zone 3 . 10 .
[0055] [0055]FIG. 3 e
[0056] The outlet pressure lock 3 . 8 is closed when the piston screw 3 . 5 has been pulled back in the sluice chamber 3 . 6 by its axial movement.
[0057] [0057]FIG. 3 f
[0058] The pressure is changed to the pressure P1 of the first pressure zone by means of the equalization valve 3 . 9 , after which the inlet pressure lock 3 . 4 is opened and the next product portion can be loaded into the sluice chamber.
[0059] Example 4 describes an embodiment of the sluice device appropriate when emission during transfer of product from the low to the high pressure zone is unacceptable. The flow of the product turns 180° by passing through the sluice device. FIG. 4 a - 4 e illustrates example 4.
[0060] [0060]FIG. 4 a
[0061] A product portion is conveyed into the intake hopper 4 . 1 equipped with two belt conveyers 4 . 2 . At the same time the pressure lock 4 . 8 is opened. A piston screw 4 . 5 positioned at the inlet 4 . 3 forces the product portion into the sluice chamber 4 . 6 . 1 by its rotating movement only. The sluice chamber 4 . 6 . 1 is loaded and unloaded through the same opening, and can be turned around an axis 4 . 12 parallel to that of the piston screw and it is equipped with a piston 4 . 11 . 1 By this embodiment a second sluice chamber 4 . 6 . 2 is placed symmetrically in relation to the axis 4 . 12 and is equipped with the piston 4 . 11 . 2 . The two sluice chambers with their pistons and means to move the pistons constitute a rotor 4 . 13 , which can turn around the axis 4 . 12 and be moved by axial displacement
[0062] [0062]FIG. 4 b
[0063] The sluice chamber piston 4 . 11 . 1 is during the forced loading moved from the starting position at the sluice chamber opening towards the back of the sluice chamber 4 . 6 . 1 . The other sluice chamber piston 4 . 11 . 2 will at the same time move from the start position in the back of the sluice chamber towards and past the opening, forcing the product portion out of the sluice chamber into the second pressure zone 4 . 10 . The piston screw 4 . 5 forces the product portion past the opening of the sluice chamber 4 . 6 . 1 by an axial movement added to the rotation.
[0064] [0064]FIG. 4 c
[0065] The piston 4 . 11 . 2 is pulled so far back, that it aligns with the opening of the sluice chamber 4 . 6 . 2 , and the pressure lock 4 . 8 is closed by moving it to the inlet 4 . 7 of the high pressure zone and the piston screw 4 . 5 is pulled back to its position at the inlet 4 . 3 of the sluice chamber.
[0066] [0066]FIG. 4 d
[0067] The pressure locks 4 . 4 . 1 and 4 . 4 . 2 are opened by axial displacement of the rotor away from the inlet hopper 4 . 1 and the inlet 4 . 7 to the high pressure zone. Thereafter the rotor is turned 180° whereby the sluice chamber 4 . 6 . 1 will change positions with the sluice chamber 4 . 6 . 2 .
[0068] [0068]FIG. 4 e
[0069] The pressure locks 4 . 4 . 1 and 4 . 4 . 2 are closed by retraction of the rotor 4 . 13 , and the sluice chamber 4 . 6 . 2 is ready to be force loaded with the next product portion, and the pressure in the sluice chamber 4 . 6 . 1 is changed to the high pressure P2 by the equalization valve 4 . 9 . Thereafter the pressure lock 4 . 8 is opened and the sluice chamber 4 . 6 . 1 is ready to be emptied.
[0070] Example 5 describes like example 4 an embodiment of the sluice device appropriate when emission is unacceptable during transfer of product from the low pressure zone to the high pressure zone. Contrary to example 4, the axis of the sluice chamber rotor of example 5 is perpendicular to the axis of the sluice chambers and the piston screw. This means, that the flow of product will maintain the direction imposed by the piston screw by passing through the sluice device. Furthermore the pistons unloading the sluice chambers of example 5 are driven by a pressurized liquid, which at the same time serve as a very effective sealing device against leaking from the high pressure zone into the sluice chamber during forced unloading. This sealing method is of special importance when the temperature of the high pressure zone is higher than traditional sealing materials can tolerate as for example the 700-1100° C. in a gasifier.
[0071] [0071]FIG. 5 a
[0072] A product portion is conveyed into the intake hopper 5 . 1 equipped with two belt conveyers 5 . 2 . At the same time the pressure lock 5 . 8 is opened. A piston screw 5 . 5 positioned at the inlet 5 . 3 forces the product portion into the sluice chamber 5 . 6 . 1 by its rotating movement only. The sluice chamber 5 . 6 . 1 is loaded and unloaded through the same opening, and can be turned around an axis 5 . 12 perpendicular to that of the piston screw and equipped with a piston 5 . 11 . 1 By this embodiment a second sluice chamber 5 . 6 . 2 is placed symmetrically in relation to the axis 5 . 12 and is equipped with the piston 5 . 11 . 2 . The two sluice chambers with their pistons constitute a rotor 5 . 13 , which can turn around the axis 5 . 12 in the rotorhouse 5 . 15 . The two pistons 5 . 11 . 1 and 5 . 11 . 2 are connected by a piston rod 5 . 14 . The rotorhouse is pressure tight connected to the intake hopper 5 . 1 and the high pressure zone 5 . 10 .
[0073] The combined driving and sealing device for the double piston 5 . 11 . 1 / 5 . 11 . 2 consist of a container 5 . 16 with a reservoir of a liquid, which can be pumped by the pump 5 . 17 to a container 5 . 18 partly filled with the said liquid, thereby maintaining a pressure P1+ somewhat higher than P1. The said liquid can be pumped by the pump 5 . 20 from the container 5 . 18 into a similar container 5 . 19 , thereby maintaining a pressure P2++ somewhat higher than P2. Furthermore the combined driving and sealing device consist of pipes and ducts in the axis 5 . 12 and 4 valves 5 . 21 - 5 . 24 by which the two sluice chambers 5 . 6 . 1 and 5 . 6 . 2 can be connected to the two containers 5 . 18 and 5 . 19 . When the sluice chamber 5 . 6 . 1 is loaded the liquid behind the piston 5 . 11 . 1 will be conducted through 5 . 21 into 5 . 18 and simultaneously an equivalent amount of liquid will be conducted from 5 . 19 through 5 . 23 into the part of the sluice chamber 5 . 6 . 2 behind the piston 5 . 11 . 2 . In order to maintain correct pressures an equivalent amount of liquid will be pumped from 5 . 18 to 5 . 19 simultaneously.
[0074] [0074]FIG. 5 b
[0075] The sluice chamber piston 5 . 11 . 1 is during the forced loading moved from the opening towards the back of the sluice chamber 5 . 6 . 1 . Thereby the piston 5 . 11 . 2 will at the same time move from the back of the sluice chamber 5 . 6 . 2 towards and past the opening, forcing the product portion out of the sluice chamber into the second pressure zone 5 . 10 . The piston screw 5 . 5 forces the product portion past the opening of the sluice chamber 5 . 6 . 1 by an axial movement added to the rotation.
[0076] [0076]FIG. 5 c
[0077] The pressure lock 5 . 8 is closed by moving it to the inlet 5 . 7 and thereby it forces the piston 5 . 11 . 2 so far back, that it aligns with the opening of the sluice chamber 5 . 6 . 2 . The piston screw 5 . 5 is pulled back to its position at the inlet 5 . 3 .
[0078] [0078]FIG. 5 d
[0079] The pressure locks 5 . 4 . 1 and 5 . 4 . 2 are opened by contraction of the sealing rings, and the ball valves 5 . 21 and 5 . 23 are closed. Thereafter the rotor 5 . 13 is turned 180° whereby the sluice chamber 5 . 6 . 1 will change positions with the sluice chamber 5 . 6 . 2 .
[0080] [0080]FIG. 5 e
[0081] The pressure locks 5 . 4 . 1 and 5 . 4 . 2 are closed by expansion of the sealing rings, and the pressure in the sluice chamber 5 . 6 . 1 is changed to the high pressure P2 by the equalization valve 5 . 9 . Thereafter the pressure lock 5 . 8 and the ball valves 5 . 22 and 5 . 24 are opened and the sluice chamber 5 . 6 . 2 is ready to be force loaded with the next product portion, and the sluice chamber 5 . 6 . 1 is ready to be force unloaded.
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The method invented is based on sluice system according to which the product is first conveyed through a portioning device, which produces a sequence of uniform product portions divided by uniform particle free spaces, and subsequently the product portions are conveyed individually through a sluice device, which comprises at least one sluice chamber and two pressure locks of which at least one at any time secures a pressure tight barrier between the two pressure zones, and the product portions are force loaded from the first zone into a sluice chamber by means of a piston screw, the axis of which is practically in line with the axis of the sluice chamber, and the product portions are force unloaded from the sluice chamber and into the second pressure zone by means of said piston screw or a piston or by means of gas, steam or liquid supplied at a pressure higher than that of the second pressure zone.
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This application is a continuation of application Ser. No. 07/459,295 filed on Dec. 29, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electron gun for a color picture cathode-ray tube (hereinafter "CRT") for reducing deterioration of focusing property, minimizing deflection aberration from deflection yoke, and improving focusing property.
2. Description of the Prior Art
Generally, conventional electron guns are utilized in an electrostatic focusing system. An electrostatic focusing lens of the electrostatic focusing system placed between a first accelerating and focusing electrode and a second accelerating and focusing electrode closely focuses the beams from the electron beam forming region consisting of cathodes and a number of electrodes in front of the cathodes. The performance of such electrostatic lens depends on the difference of focusing force between the near-axis region and the maximum outer angle region, causing the spherical aberration of the lens. The larger the lens diameter is, the lesser the spherical aberration becomes.
In order to obtain a good electron beam focusing property for an electron gun for the color picture CRT, the electron beam through-holes of the first and second accelerating and focusing electrodes are preferred to be as large as possible.
FIGS. 1, 2(A), 2(B), and 3 show a conventional electron gun for a color picture cathode-ray tube. Such conventional electrode gun includes a first accelerating and focusing electrode 8 and a second accelerating and focusing electrodes.
The first accelerating and focusing electrode 8 and the second accelerating and focusing electrodes 9 form an electrostatic lens. Each of the electrodes 8 and 9 has an open end on one side and a oblong-shaped closed end and the two closed ends face each other. The closed end 13 of the electrode 8 and the closed end 14 of the electrode 9 connected to respective end walls 11 and 12, respectively are provided with three through-holes 11a and 12a, 11b and 12b, and 11c and 12c for passing electron beams. The through-holes have a rimmed lip extending from the closed end faces, respectively.
In the focusing electrodes 8 and 9, the upper walls 11 and 12 have 6 mm in height (hereinafter "H"), the lips 15 and 16 have 1.2-3.5 mm h, the electron beam holes have 5.5-5.9 mm in diameter (hereinafter "D"), and the distance between the adjacent holes is 6.6-6.9 mm. However, the above measurements are subject to the limitation of the optimum diameter 29.1 mm of the tube neck in a conventional color picture CRT.
The first and second focusing electrodes 8 and 9 are also arranged, as shown in FIG. 1, for the first focusing electrode 8 to be connected with its open end to a third grid electrode 7. The electron gun for the color CRT basically includes a cathode 4 fixed to a cathode support 2, first, second and third grid electrodes 5, 6, and 7, and the first and second accelerating and focusing electrodes 8 and 9 wherein they are arranged in a pile in the above mentioned order and fixed to a pair of bead glass 10.
In a conventional color picture CRT shown in FIG. 1, a heater 3 welded to a support 1 and inserted into the cathode 4, heats the cathode 4 and make it emit heated electrons. The third grid electrode 7 having an elongated cylindrical configuration and positioned in front of the first and second grid electrodes 5 and 6 connects to the first accelerating and focusing electrode. The first and second accelerating and focusing electrodes 8 and 9 constitute an electrostatic focusing lens, that is a bi-potential focus (hereinafter "BPF").
The first and second accelerating and focusing electrodes 8 and 9 may be utilized in an electron gun including a plurality of additional electrodes disposed in the third grid electrode 7.
According to the conventional electron gun for the CRT, the electrons emitted from the cathode 4 by the heating of the heater 3 form an electron beam. The electron beam passes through the first grid electrode 5, the second grid electrode 6 and the third grid electrode 7 and enters the electrostatic focusing lens formed between the first and the second focusing electrodes 8 and 9. The received electron beams are closely focused to reach the fluorescent screen of the CRT and form a beam spot. The beam spot formed on the screen should have a high density in a round form in the least possible area.
However, in the first and second accelerating and focusing electrodes 8 and 9 for forming an electrostatic focusing lens of the electron gun shown in FIG. 2, the beam spot is distorted into a laterally oblong shape under the influence of the electrostatic focusing lens diameter. The diameter is restricted by the limited holes 11a-11c and 12a-12c for passing electron beams. Furthermore, the beam spot is distorted the deflection aberration caused by a deflection yoke. Therefore, the beam spot has a low density which deteriorates the resolution of the color picture CRT as a disadvantage.
For example, as shown in FIG. 3, the electrodes 8 and 9 for constituting an electrostatic focusing lens are housed in a tube neck 17 having an optimum diameter of 29 mm for the CRT. The thickness (b) of the rims respectively surrounding three beam through-holes in the closed end face of the first focusing electrode 8 has to be 1 mm in actual structure. Therefore, their relation is expressed by the following formula (I):
D≦S-1 (I)
Furthermore, the distance (a) between the inner wall of the tube neck 17 and the outer end walls 11 and 12 of the focusing electrodes requires to be 1 mm, their relationship being expressed by the following formula (II):
D≦R-(2a)-2(S+b) (II)
wherein R is the inner diameter of the tube neck, approximately 24 mm.
Therefore, the diameter is represented by the following formula (III):
D≦20-2S (III), and
Dmax=6 mm and Smax=7 mm result from the formulas (I) and (III).
The conventional first and second focusing electrodes 8 and 9 form merely an electrostatic focusing lens of 6 mm at the maximum in diameter. Therefore, the small diameter of the focusing lens increases the spherical aberration, that is, the difference in focusing force between the near-axis region and the maximum outer angle region in the lens forms beam spots with a low density on the screen.
Also, because of the round shape of the electrostatic focusing lens, the beam spot with a low beam density distorts into a laterally oblong shape by the deflection aberration of deflection yoke to and further deteriorates the resolution of the color picture CRT. The known art concerning the lateral distortion of electron beams by the deflection aberration of deflection yoke will be omitted.
Besides, in order to obtain a better concentration of three electron beams for focusing three beam spots to gather a small converging area on the image screen, the distance S between adjacent beam holes is required to be smaller, but the conventional art gives 7 mm of S at the maximum under the limitation of the maximum lens diameter of 6 mm from the formulas (I) and (III). Accordingly, it is an disadvantage that the large distance S between the holes brings deterioration of the concentrating property of the CRT.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved electron gun for a color picture CRT, which can be shortened the distance among electron beams and yet effectively enlarge the lens diameter without changing the distance among the beams even when the first and second focusing electrodes for the electrostatic focusing lens are housed in a restricted tube neck so as to eliminate the disadvantages of the conventional art.
Another object of the present invention is to provide an electron gun construction which includes a slanted enlarging electrode provided with a laterally oblong hole having openings through which three beams jointly pass together. The openings are formed at the opposite faces of the first and second focusing electrodes and surrounded by respective rims extending from the end walls. A longitudinally oblong hole through which three beams pass, has a distance from the end rim so that the laterally oblong hole and the longitudinally oblong hole form a perpendicularly oblong hole.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
Briefly described, the present invention relates to an electron gun for a color picture cathode-ray tube, which includes a main focusing lens having a large diameter for reducing deterioration of the focusing property, short distances among three electron beams for minimizing the deflection aberration from deflection yoke and a feasible design for effective enlargement of the lens diameter disposed in the color picture cathode-ray tube so as to achieve a better focusing property of the three beams.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is an elevational view of the conventional electron gun for the color picture CRT containing cut away portions in order to illustrate the construction of basic components thereof;
FIG. 2(A) is an sectional view of FIG. 1 showing the main electrostatic focusing lens including a first accelerating and focusing electrode and a second accelerating and focusing electrode;
FIG. 2(B) is a top plan view of the first accelerating and focusing electrode of FIG. 1;
FIG. 3 is a sectional view of the electrode of FIG. 2(B) showing the electrode placed within the tube neck of the color picture CRT;
FIG. 4(A) is a front elevational view of the electron gun for the color picture CRT according to the present invention containing cut away portions in order to illustrate the construction of basic components of the present invention;
FIG. 4(B) is a sectional view of FIG. 4(A), taken along line A--A;
FIG. 5(A) is a top plan view of the first accelerating and focusing electrode for the electrostatic lens according to the present invention;
FIG. 5(B) is a sectional view of FIG. 5(A), taken along line B--B;
FIG. 5(C) is a sectional view of FIG. 5(A), taken along line C--C;
FIG. 6(A) is a top plan view of the slanted enlarging electrode disposed on the side of the first accelerating and focusing electrode according to the present invention; and
FIG. 6(B) is a sectional view of FIG. 6(A), taken along line B--B.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings for the purpose of illustrating preferred embodiments of the present invention, the electron gun for the color picture cathode-ray tube as shown in FIGS. 4(A) and 4(B), includes a cathode 4 fixed to a support 2, a first grid electrode 5a, a second grid electrode 6a, a third grid electrode 7a, a first accelerating and focusing electrode 18 and a second accelerating and focusing electrode 19 wherein they are arranged in a pile in the above-mentioned order and fixed to a pair of bead glasses 10.
The first and second accelerating and focusing electrodes 18 and 19 are shown in FIG. 5(A). That is, the first accelerating and focusing electrode 18 is fully open at one side thereof and is provided at the other side thereof, with a slanted enlarging electrode 20 disposed on the interior of an oblong cylindrical electrode 24 which has an opening surrounded by an upper rim 23 extending from an outer end wall 22.
Also, as shown in FIGS. 6(A) and 6(B), the slanted enlarging electrode 20 is provided with connecting parts 26 formed at both ends thereof with same angle. The connection parts 26 extend to a head 27 and bend inward and form slopes 29 connected to a bottom portion 28. Three oblong holes 30a, 30b, and 30c are disposed from the bottom to the slopes 29 for passing beams through the holes.
The slanted enlarging electrode 20 as shown in FIG. 5(A) has the electron beam holes 30a, 30b, and 30c wherein the distance S between the hole centers of the beam holes is in the range of 5.1 mm-6.6 mm. The angle θ of inclination from the head 27 to the bottom portion 28 is in the range of 100-140 degree as shown in FIG. 6(B). The electrode 20 is disposed on the inner end wall 22 of the oblong shaped electrode 24 wherein the distance from the rim 23 of the electrode 24 to the bottom of the electrode 20 is in the range of 1.5-3 mm as shown in FIG. 5(C).
Also, referring to the oblong electron beam holes 30a, 30b, and 30c as shown in FIG. 5(A), the central hole 30b has a ratio 2:1 for the longitudinal length to the lateral width, and the holes 30a and 30c respectively having an approximate ratio 4:3 for the same directional measurements.
Furthermore, due to optimum limitation of the tube neck of 29.1 mm, for the lateral width of the open end surrounded by the upper rims 23 of the focusing electrodes 18 and 19 determines approximately 8 mm and the longitudinal diameters of the oblong holes 30a, 30b, and 30c of the electrode 20 also is set approximately at 8 mm.
In the arrangement of the focusing electrodes 18 and 19, the open end of the electrode 18 connects to the third grid electrode 7a, and the space disposed at the opposite rim 23 plays the function of an electrostatic focusing lens. Although the above description was made concerning solely an electron gun having a BPF lens, the present invention may be employed for an electron gun having multistaged connections with addition of a plurality of electrodes disposed at the position of the third grid electrode 7a.
According to the present invention, the electron gun operates as follows:
The oblong opening surrounded by the upper rim 23 extending from the outer end wall 22 of the oblong cylindrical electrode 24 of the first and second acceleration and focusing electrodes 18 and 19 forms a common beam hole for passing three electron beams therethrough as a common electrostatic focusing lens.
The above arrangement means that even through the shortest width of the oblong opening is about 8 mm due to the limitation of the tube neck, the size thereof shows an expansion of 1.45 times based on the diameter of 5.5 m of the conventional electron beam hole. It is to indicate the reduction of the spherical aberration by an approximate factor of 0.33 and the reduction of the lens force by an approximate factor of 0.69.
If the dimension of the electrostatic lens enlarges by a ratio of M, the derivative of the second order to the dislocation potential in the electrostatic lens reduces by 1/M 2 , because results are the lens force A=1/M . . . (4) and the lens spherical aberration C=1/M 3 . . . (5).
Consequently, the electrostatic focusing lens formed by the first and second focusing electrodes 18 and 19 according to the present invention not only greatly reduces the spherical aberration of the lens but also reduces the magnification of the lens by its weak function such that small beam spots of high density beams form on the fluorescent screen of the color CRT.
Thus, according to the common electrostatic focusing lens formed by the common oblong opening surrounded by the upper rim 23, the lens has a short length in the longitudinal direction and a long length in the lateral direction such that the lens action in the longitudinal direction is strong. On the other hand, the lens action in the lateral direction is weak such that the beam after passing the lens comes to have a different ratio of lengths between longitudinal and lateral directions and have a more laterally elongated shape. The electron beam further distorts into a most laterally elongated shape due the deflection aberration of deflection yoke. Thus, the arrangement of slanted enlarging electrodes 20 and 21 to the first and second accelerating and focusing electrodes 18 and 19 brings the function of a supplementary electrostatic lens for compensating the lateral elongation of the electron beam.
As shown in FIGS. 5(A) and 6(A), the three oblong electron beam holes of the slanted enlarging electrode 20 have a ratio of the longitudinal length and the lateral width of 2:1 about the central hole 30b and 4:3 about the outer holes 30a and 30c, so that the electron beams passing the longitudinally oblong holes of the electrode 20 are subject to a weak focusing action in the longitudinal direction and a strong focusing action in the lateral direction to form a longitudinally oblong form of beams.
Thus, the laterally elongating action of the common electrostatic focusing lens formed by the common oblong opening surrounded by the upper rim 23 and the laterally elongating action from the deflection aberration are compensated to form screen small round beam spots of high density electron beams on the CRT and improves the resolution of the color picture CRT.
Besides, according to the electron gun of the present invention, the longitudinally oblong holes 30a, 30b, and 30c of the slanted electrode 20 perform solely the function of the supplementary electrostatic lens at the focusing electrodes 18 and 19 such that the shortening of the distance S among the three beams still gives enough action as the supplementary lens without influencing the function of the three electron beams from the action of the common electrostatic focusing lens regardless of the variation of the distance S.
The present invention therefore obtains a better concentration for three electron beams due to deflection by shortening the distance S among the beams and also greatly improves the focusing property of the electron gun by the electrostatic focusing lens enlarged to the bottom portion 28 of the slanted electrode 20 regardless of any variation of the distance S among the beams.
Furthermore, the supplementary electrostatic lens formed by the longitudinally oblong holes 30a, 30b, and 30c which are perforated across the bottom 28 to the slant portion 29 of the slanted electrode 20 are controlled for their accurate function by a longitudinal and lateral ratio and the difference in electrostatic lens action between the openings in the slant portion 29 and the bottom portion 28. For the electron gun of the present, the distance S among the electron beams of the slanted enlarging electrode 20 disposes at the first focusing electrode 18 and the second focusing electrode 19, and the dimension of the electron beam holes are determined from the action of the common electrostatic focusing lens of three beams enlarged from the rim 23 to the bottom 28.
For example, if an electron gun is placed in a tube neck of 29 mm diameter with the longitudinal opening of the upper rim 23 determined to have 8 mm in diameter, the distance S is set at 5 mm, the longitudinal direction diameter of the oblong hole of the electrode 20 is set at 8 mm, and the lateral direction diameters and set 4 mm for the central hole and 6 mm for the outer holes, respectively.
According to the present invention, the first and second accelerating and focusing electrodes 18 and 19 with the electrostatic focusing lens include an improved supplementary electrostatic lens construction such that the focusing of electron beams improves and the housing of the first and second focusing electrodes 18 and 19 within the restricted tube neck rather shortens the distance among the electron beams and effectively enlarges the diameter of the lens. Thus, the present invention provides a high quality electron gun.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included in the scope of the following claims.
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An electron gun for a color picture cathode-ray tube which includes a main focusing lens of a large diameter for reducing deterioration of the focusing property caused by the spherical aberration of the main focusing lens, shortening the distances among three electron beams to minimize the deflection aberration from deflection yoke and making feasible a design for effective enlargement of the lens diameter even with the shortening of the distances among the three electron beams in the color picture cathode-ray tube requiring a good focusing property of the three beams.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S. provisional application serial No. 60/290,474, filed May 11, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to a method and apparatus for viewing internet on a television, and more specifically a method and apparatus for selecting links in internet content displayed on a television.
BACKGROUND OF INVENTION
[0003] Use of the internet is becoming ever more widespread, and increasingly important in our daily lives. The internet allows users unparalleled access to information around the world via its huge network of connected computers. Most internet users use the World Wide Web WWW to access information whether it be text, sound, images, etc. Currently the majority of internet users use personal computers consisting of high speed microprocessors, accompanying peripherals, high definition computer monitors, and modems connected to telephone lines or other communications means. However there still exists a large segment of the population (more so in less developed countries) that do not have access to personal computers or to the internet. Many of these households however do have a television and an ability to connect to the internet (e.g. phone line). Even for people who do have a personal computer, exploring the internet in the same way they view television can be very appealing due to factors such as greater comfort. Therefore a need exists for an internet device that can display information on a normal television screen. Many problems exist with the implementation of this idea however. In a typical computer environment, computer users choose to explore the internet using a mouse wherein a representative object such as a cursor can have its movement on a graphical interface controlled by hand movement. The representative object can be placed over specialized areas on the screen called links and though the clicking of a button on the mouse an object can be chosen. A keyboard is also used for typing website addresses, search keywords, tabbing between links and so forth. Television users view their television for entertainment purposes and typically do not find it convenient to use a computer mouse or keyboard. Some current systems for selecting links displayed on a television include tabbing between links, or using modified pointing devices to move a cursor on the television screen. These methods however are cumbersome to use, or require a dedicated effort that many television viewers find undesirable. Therefore a need exists for a simple convenient method for selecting internet links on a television-internet system.
SUMMARY OF THE INVENTION
[0004] A primary goal of the invention is to provide a method and apparatus for selecting links on a television-internet system.
[0005] The basic system consists of a television connected to a web appliance. The web appliance is connected to the internet and can display internet content on the television. The web appliance has a remote control. In a preferred embodiment of the invention as internet content passes through the web appliance, links are located and identifiers added, each link given a corresponding identifier. The identifier can appear beside a link, or in another embodiment can be superimposed over the link. The modified internet content is then displayed for viewing. A user can input an identifier and the corresponding link will be chosen by the web appliance.
BRIEF DESCRIPTION OF DRAWINGS
[0006] [0006]FIG. 1 shows an example of an internet-television system;
[0007] [0007]FIG. 2 shows a flowchart exemplifying a preferred embodiment of the invention;
[0008] [0008]FIG. 3 shows an example web page with identifiers appearing beside the links; and
[0009] [0009]FIG. 4 shows an example web page with identifiers appearing superimposed over the links.
DETAILED DESCRIPTION
[0010] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the invention may be practiced. The preferred embodiments are described in sufficient detail to enable these skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
[0011] The present invention deals with a method of displaying information on a standard television screen commonly known as “Web television” or “Internet television”. FIG. 1 shows one configuration for the system. A television 20 is connected to a web appliance 10 typically through an audio-video cable. Someone skilled in the art will recognize that the web appliance signal can also be provided to the television through a television signal input. The web appliance 10 is connected to an internet connection. The internet connection can be though phone lines, coaxial cable, RF and so forth. With the web appliance 10 a viewer can watch television as normal, or can activate the web appliance 10 and view the internet through the television. In addition, a viewer can also have the capability to combine television viewing with the internet through interactive programming guides and the linking of web content to television content. The web appliance 10 has an accompanying remote control 30 . Typically remote controls are small battery powered devices with a plurality of buttons having different functions. The remote control of the invention can transmit signals using infrared, or alternatively RF signals.
[0012] The World Wide Web is the dominant multimedia information retrieval system on the internet. The internet includes a massive collective of documents that are linked together. Most information (e.g. text, graphics, images, sound, video etc.) are transferred using a Hypertext Transfer Protocol (HTTP). HTTP further uses a standard page description language known as Hypertext Markup Language (HTML). HTML is used for marking documents to indicate how a document should be displayed, and how multiple documents should be linked together. For linking the World Wide Web utilizes an addressing scheme known as URLs, or Uniform Resource Locators to find the location of files and documents from computers on the internet. URLs typically consist of an identifier for the type of internet server, an internet address, and a file path to a particular item of interest whether it be text, graphics, video etc. Links usually appear as highlighted text known as the anchor of the link or as pictures, icons, or graphics which can be selected.
[0013] The following is an example of HTML code with the links highlighted:
<div id=“Layer2” style=“position:absolute; left:570px; top:200px; width:88px; height:61px; z-index:2”><α href=“ http://www.leadtek.com ”><img src=“ images/pro/proline/usa.jpg ” width=“48” height=“69” alt=“USA” border=“0”></a><b><font color=“#FFFF00”><a href=“ http://www.leadtek.com ” class=“all”><font size=“2” face=“Arial, Helvetica, sans- serif”>USA</font></a></font></b></div> <div id=“Layer3” style=“position:absolute; left:571px; top:283px; width:63px; height:58px; z-index:3” class=“all”><a href=“ http://www.leadtek.com.cn ”><img src=“ images/pro/proline/china.jpg ” width=“70” height=“41” alt=“China” border=“0”></a><b><font color=“#FFFF00” size=“3”><a href=“ http://www.leadtek.com.cn” class=“all”><font face=“Arial, Helvetica, sans-serif”>China</font></a></font></b></div> <div id=“Layer4” style=“position:absolute; left:493px; top:280px; width:64px; height:103px; z-index:4”> <p class=“all”><a href=“ http://www.leadtek.nl ”><b><font size=“3” color=“#FFFF00”></font></b><img src=“ images/pro/proline/europe.jpg ” width=“56” height=“63” alt=“Europe” border=“0”></a><br> <font size=“3”><b><font color=“#FFFF00”><a href=“ http://www.leadtek.nl” class=“all”><font face=“Arial, Helvetica, sans-serif”>Europe</font></a></font></b></font>
[0014] From the above HTML source code the number, type, and position of the links can be determined as highlighted above.
[0015] A preferred embodiment is shown in FIG. 2. The web appliance 10 requests an internet document in step 100 . After the document is received the web appliance 10 scans the document for links (step 130 ). The web appliance 10 then modifies the internet document by adding identifiers to each of the links in the document (step 140 ). In a preferred embodiment of the invention the identifiers are added by modifying the HTML code, although the invention is not limited to this method. Identifiers can be added to the final visual output in a variety of ways such as manipulating the visual signal output in an output buffer. The modified document is then displayed on a television screen (step 150 ). Once an internet document has been displayed on the television screen, a user can input an identifier (typically using a remote control) to choose a link. The web appliance 10 waits for an identifier or other command to be inputted by a user (step 160 ). If an identifier is entered the web appliance 10 goes to the identified link returning to step 100 . The identifier can appear in a variety of colors, fonts, and locations around the displayed link. The identifier can further be superimposed over the link. FIG. 3 shows fictitious web page 200 , with the identifiers indicated as reference numerals 1 - 7 appearing beside each of the links including texts of “ABOUT COMPANY”, “United States Headquarters”, “VIEW PRODUCT”, “China Office”, and “CONTACT US”, and graphics of US flag and China flag in the web page. FIG. 4 shows fictitious web page 210 with the identifiers 1 - 7 appearing superimposed over each of the above-mentioned links.
[0016] Various additional modifications may be made to the illustrated embodiments without departing from the spirit and scope of the invention. Therefore, the invention lies in the claims hereinafter appended.
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An apparatus and method for selecting links on a television-internet system. A television is connected to a web appliance having an internet connection. Internet content is loaded by the web appliance which proceeds to analyze the internet content identifying links therein. The internet content is then modified with identifiers corresponding the links. The modified document is then displayed on the television. A user can input an identifier and select a corresponding link.
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BACKGROUND OF THE INVENTION
This invention relates to hydrocarbon cracking catalyst. In another aspect, this invention relates to a method of at least partially restoring the activity of contaminated cracking catalyst. In still another aspect, the invention relates to decreasing the susceptibility of cracking catalysts to the effect of contamination. Also provided is an improved cracking process utilizing said improved catalyst.
In most conventional catalytic cracking processes in which hydrocarbon feedstocks are cracked to produce light distillates a gradual deterioration in the cracking ability of the catalyst occurs. Some of this deterioration is attributable to the deposition on the catalyst of contaminants contained within the feedstock. The deposition of these contaminants, which include nickel, vanadium and iron, tends to adversely affect the cracking process by decreasing production of gasoline and increasing the yields of hydrogen and coke.
OBJECTS OF THE INVENTION
It is thus an object of the present invention to provide a method for restoring the activity of a cracking catalyst which has been at least partially deactivated by metals contamination.
It is a further object of this invention to at least partially prevent deleterious effects caused by metals such as nickel, vanadium and iron on a cracking catalyst.
It is another object of this invention to provide a cracking catayst composition which is less susceptible to the adverse effects caused by metals contamination.
It is yet another object of this invention to provide a cracking process which is particularly useful in cracking hydrocarbon feedstocks containing contaminating metals.
These and other objects of the present invention will be more fully explained in the following detailed description of the invention and the appended claims.
SUMMARY OF THE INVENTION
According to this invention, there is provided a method of reducing the adverse effects caused by deposits of contaminating metals on the cracking catalyst by contacting the cracking catalyst with barium or a compound thereof.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, a cracking catalyst is contacted with a treating agent comprised of at least one of barium and compounds of barium. It is presently believed that most forms of barium are effective. The barium compounds suitable for use in the present invention can be organic or inorganic. Oil- or water-soluble barium compounds are preferred. Suitable inorganic barium compounds include the barium salts of mineral acids and basic barium compounds. Examples of suitable barium salts are barium nitrate, barium sulfate, barium halides such as barium chloride, and barium oxyhalides, such as Ba(ClO 3 ) 2 . The halogen-containing inorganic compounds are less preferred because of their corrosive effect on process equipment. Representative basic barium compounds suitable for use are barium hydroxide, barium hydrosulfide and barium carbonate. Suitable organic barium compounds include the barium salts of carboxylic acids and barium-chelating agent complexes. The barium carboxylic acid salts can contain from one to about 40 carbon atoms per molecule and the acid moiety can be aliphatic or can be aromatic in nature. Representative compounds are barium acetate, barium butyrate, barium citrate, barium formate, and barium stearate. Suitable barium complexes include complexes in which barium has been incorporated by chelating agents such as 1,3-diketones, ethylene-diamine tetraacetic acid and nitrilotriacetic acid. Barium pentanedionate is the treating agent presently preferred.
Generally, the amount of treating agent which should be contacted with the cracking catalyst is at least a passivating amount. By passivating amount is meant an amount of treating agent which is sufficient to at least partially mitigate at least one of the deleterious effects to the cracking process of decreased catalyst selectivity to gasoline, increased hydrogen and increased coke caused by a deposition on the cracking catalyst of at least one contaminating metal selected from the group of nickel, vanadium and iron. Generally, the amount of treating agent employed will be an amount sufficient to impart to said cracking catalyst a barium concentration of from about 0.01 to about 8 weight percent, based on the weight of the treated cracking catalyst. Preferably, the amount of treating agent contacted with the cracking catalyst is an amount sufficient to impart to the cracking catalyst a barium concentration of from 0.02 to about 2 weight percent. For most equilibrium catalysts, a desirable ratio of barium to contaminants on the catalyst is from about 2:100 to about 200:100, expressed as the weight ratio of barium to the combined weights of vanadium and four times the weight of nickel on the catalyst, the combined weights of vanadium and four times the weight of nickel being referred to hereinafter as vanadium equivalents. More preferably, this ratio is from about 5:100 to about 100:100, and most preferably from about 10:100 to about 80:100. The narrower ranges of values seem to be more preferable from an economic viewpoint.
A variety of methods can be used to contact the treating agent of barium or barium compounds with the catalyst. It can be added to the catalyst as a finely divided solid and mixed by rolling, shaking, stirring, etc. Or, it can be dissolved in a suitable solvent, aqueous or organic, and the resulting solution sprayed on the catalyst or used to impregnate the cracking catalyst--followed by drying to remove the solvent. It can also be dissolved or suspended in the feedstock to the cracking process. A desirable concentration of barium in the feedstock is from about 0.1 to about 100 parts million, preferably from about 10 to about 200 parts per million, based on the elemental weight of barium in the total weight of the feedstock including the treating agent. The narrower range simplifies maintaining an equilibrium concentration of barium on the catalyst. The preferred method of contact is impregnation because it has been employed with good results.
The time required to effect a contact between the treating agent and cracking catalyst is not particularly important. Generally, such time period can range from 0 to about 30 minutes. Likewise, the temperatures at which the contact is effected can be selected from a wide range of values, depending, for example, on whether the treating agent is contacted with the cracking catalyst as a vapor or as in a solution with a relatively low boiling solvent.
It is inherent in this invention that the treated cracking catalyst will be subjected to elevated temperatures. When utilized in a continuous cracking process, the treated cracking catalyst is subjected to temperatures between 800° F. (427° C.) and 1200° F. (649° C.) in the cracking zone and temperatures between 1000° F. (538° C.) and 1500° F. (816° C.) in the regeneration zone. Free oxygen containing gas is also present in the regeneration zone. The contacting of the treating agent with the cracking catalyst can occur in the cracking zone, in the treating zone, or in a catalyst stream between the two zones.
The term "cracking catalyst" as used herein refers to either new or used cracking catalyst materials that are useful for cracking hydrocarbons in the absence of added hydrogen. The cracking catalyst referred to can be a conventional cracking catalyst. The term "unmodified cracking catalyst" as used herein means any cracking catalyst which has not been modified by contact with barium or barium compounds.
Suitable cracking catalysts can be any of those cracking catalysts employed in the catalytic cracking of hydrocarbons boiling above 400° F. (204° C.) for the production of gasoline, motor fuel blending components and light distillates. These cracking catalysts generally contain silica alumina which is frequently associated with zeolitic materials. These zeolitic materials can be naturally occurring or synthetic. Generally, they will have been at least partially ion exchanged with ammonium or rare earth cations. Zeolite modified silica alumina catalysts are particularly applicable to this invention and are preferred because of their stability, high activity, and desirable selectivity. Examples of cracking catalysts into or onto which barium or barium compounds can be incorporated include hydrocarbon cracking catalysts obtained by admixing an inorganic oxide gel with an aluminosilicate, and aluminosilicate compositions which are strongly acidic as the result of treatment with a fluid medium containing at least one rare earth metal cation and a hydrogen ion, or ion capable of conversion to a hydrogen ion. The catalytic cracking materials can vary in pore volume and surface area. Generally, however, the unused cracking catalyst will have a pore volume in the range of about 0.1 to about 1 ml/gram. The surface area of this unused catalytic cracking material generally will be in the range of 50 to about 500 m 2 /gram. The unused catalytic cracking material employed will generally be in particulate form having a particle size principally within the range of about 10 to about 200 micrometers.
The unused catalytic cracking material as employed in the present invention contains essentially no nickel, vanadium or iron. Particularly and preferably, the nickel, vanadium, and iron and metals content of the unused catalytic cracking material which constitutes the major portion of the unused cracking catalytic of this invention is defined by the following limits:
TABLE I______________________________________Nickel 0 to 0.2 weight percentVanadium 0 to 0.6 weight percentIron 0 to 0.8 weight percentCopper 0 to 0.02 weight percent______________________________________
The weight percentages in this table relate to the total weight of the unused catalytic cracking material including the metals nickel, vanadium and iron but excluding the added barium or compounds of barium. The contents of these metals on the cracking catalyst can be determined by standard methods well known in the art, for example, atomic absorption spectroscopy or by X-ray fluorescence spectroscopy.
Feedstocks amenable to treatment by the cracking catalyst of this invention are, generally, oils having an initial boiling point above 204° C. This includes gas oils, fuel oils, topped crude, shale oil, and oils from coal and/or tar sands. The feedstocks can contain a significant concentration of at least one metal from the group of vanadium, iron, and nickel. The presence of such metals normally affects adversely the catalyst's selectivity. Since these metals become concentrated in the least volatile fractions of oil suitable for use as feedstock, cracking the heavy oil fractions is probably the most important application for the passivated catalyst of this invention. The quantity of added barium required to passivate vanadium, iron and nickel is related directly to the concentration of contaminating metals in the feedstock. The following table relates the total concentration in the feedstock of effective metals, defined herein as the sum of the elemental weights of vanadium, iron and four times the weight of nickel, to a preferred concentration of barium on the cracking catalyst.
TABLE II______________________________________Total Effective Metals Barium Concentrationin Feedstock, ppm on Catalyst, wt. %.sup.1______________________________________ 40-100 0.05-0.8100-200 0.1-1200--300 0.15-1.5300-800 0.2-2______________________________________ .sup.1 Based on weight of treated catalyst. Quantities are expressed as the element.
The method of this invention can be applied to catalytic cracking operations using cracking catalysts to crack hydrocarbons for the production of blending components for motor fuels. The cracking process can utilize a fixed catalyst bed or a fluidized catalyst. A fluid catalyst is preferred. Fluid catalytic operations are generally carried out at temperatures between about 800° F. (427° C.) and about 1200° F. (649° C.) at pressures within the range of subatmospheric to several hundred atmospheres.
Specific conditions in the cracking zone and the regeneration zone of a fluid catalytic cracker depends on the feedstock used, the condition of the catalyst, and the products sought. In general, conditions in the cracking zone include:
TABLE III______________________________________Temperature: 427-649° C. (800-1200° F.)Contact time: 1-40 secondsPressure: 10 kiloPascals to 21 megaPascals (0.1 to 205 atm.)Catalyst: oil ratio: 3/1 to 30/1, by weightConditions in the regenerator include:Temperature: 538-816° C. (1000-1500° F.)Contact time: 2-40 minutesPressure: 10 kiloPascals to 21 megaPascals (0.1 to 205 atm.)Air rate (at 16° C., 100-250 ft.sup.3 /lb coke, or1 atm.): 6.2-15.6 m3/kg coke.______________________________________
The treating agent can be advantageously contacted with the cracking catalyst either before or after the cracking catalyst accumulates deposits of heavy metals from the group of nickel, vanadium and iron. Treatment of new cracking catalysts in the above-described manner decreases the susceptibility of the cracking catalyst to becoming partially deactivated when contaminating metals become deposited thereon. Treatment of used cracking catalysts which have become partially deactivated by deposits of contaminating metals with the above-described treating agent at least partially mitigates the detrimental effects caused by the heavy metals.
EXAMPLE 1
A commercial cracking catalyst that had been used in a commercial fluid catalytic cracker until it had attained equilibrium composition with respect to metals accumulation (catalyst was being removed from the process system at a constant rate) was used to demonstrate passivation with barium. The catalyst, being a synthetic zeolite combined with amorphous silica/alumina (clay), was predominantly silica and alumina. Concentrations of other elements together with pertinent physical properties are shown in Table IV.
TABLE IV______________________________________Surface area, m.sup.2 g.sup.-1 74.3Pore volume, ml g.sup.-1 0.29Composition, wt. %Nickel 0.38Vanadium 0.60Iron 0.90Cerium 0.40Sodium 0.39Carbon 0.06______________________________________
A portion of this used, metals-contaminated catalyst was treated with barium as follows. A solution, prepared by dissolving 0.700 g of barium acetylacetonate in 35 ml of water, was stirred into 35 g of the used catalyst. Solvent was removed by heating, with stirring, on a hot plate at about 260° C. This treatment added 0.82 wt. % barium to the catalyst. The treated catalyst was then prepared for testing by aging it. The catalyst, in a quartz reactor, was fluidized with nitrogen while being heated to 482° C., then it was fluidized with hydrogen while the temperature was raised from 482° to 649° C. Maintaining that temperature, fluidization continued for 5 minutes with nitrogen, then for 15 minutes with air. The catalyst was then cooled to about 482° C., still being fluidized with air. The catalyst was then aged through 10 cycles, each cycle being conducted in the following manner. The catalyst at about 482° C. was fluidized with nitrogen for one minute, then heated to 510° C. during two minutes while fluidized with hydrogen, then maintained at 510° C. for one minute while fluidized with nitrogen, then heated to about 649° C. for 10 minutes while fluidized with air, and then cooled to about 482° C. during 0.5 minutes while fluidized with air. After 10 such cycles it was cooled to room temperature while being fluidized with nitrogen.
The used catalyst and the barium-treated catalyst were evaluated in a fluidized bed reactor using topped West Texas crude oil as feedstock to the cracking step. The cracking reaction was carried out at 510° C. and atmospheric pressure for 0.5 minutes, and the regeneration step was conducted at about 649° C. and atmospheric pressure for about 30 minutes using fluidizing air, the reactor being purged with nitrogen before and after each cracking step.
Properties of the topped West Texas crude used in the cracking steps are summarized in Table V.
TABLE V______________________________________API gravity at 15.6° C. 21.4°Distillation (ASTM D 1160-61)IBP 291° C.10% 42820% 46830% 49840% 52850% 555Carbon residue, Ramsbottom 5.5 wt. %Analysis for some elementsSulfur 1.2 wt. %Vanadium 5.29 ppmIron 29 ppmNickel 5.24 ppmPour point (by ASTM D 97-66) 17° C.Kinematic viscosity (by ASTM D 445-65)at 82.2° C. 56.5 centistokesat 98.9° C. 32.1 centistokes______________________________________
Results of the tests using the two catalysts are summarized in Table VI.
TABLE VI__________________________________________________________________________ Yields Conversion SCF H.sub.2 /bbl Gasoline Material Catalyst: oil Vol. % Coke, wt. % feed Vol. % balanceCatalyst weight ratio of feed of feed converted of feed wt. %__________________________________________________________________________Used 7.7 74.9 17.6 895 54.6 100.7Used + 0.82% 7.5 76.9 15.7 682 62.1 98.6Ba__________________________________________________________________________
This comparison of the two catalysts shows that, at essentially identical conditions, the addition of 0.82 wt. % barium as barium acetylacetonate increased conversion of the feedstock by 2.6 percent, increased gasoline yield by 14 percent, decreased coke yield by 11 percent, and decreased the yield of hydrogen by 24 percent.
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A cracking catalyst is contacted with barium or a compound thereof to mitigate the adverse effects of catalyst contaminants.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional patent application Ser. No. 60/781,394 filed with the USPTO on Mar. 11, 2006, which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention generally relates to a method and apparatus for reinforcing a shingled roof to withstand the destructive forces of wind and/or rain; more specifically, the present invention relates to an adhesive and a reinforcing net disposed in an overlying relationship with the upper surface of a roof.
[0006] 2. Background Art
[0007] Property damage occurs on a daily basis due to extreme weather conditions such as wind gusts, gales, hurricanes and similar weather systems that produce high wind activity. Such events cause the loss of personal property when a roof covering is destroyed, exposing both the building interior and its contents to the same elements that caused the loss of the roof. Numerous attempts have been made to eliminate or limit the damage to roofs due to high winds and/or heavy rains, however, such attempts have largely proven to be unsuccessful or not commercially feasible.
[0008] For instance, some systems propose partial removal of existing roofs to allow installation of mechanical fastening systems to provide roof reinforcement. However, such methods are extremely labor intensive and, in view of the associated cost, have not met with a great deal of commercial success. Additionally, heavier gauge and/or reinforced shingles have been produced, but these are also costly due to the required removal of old shingles and reinstallation of the new reinforced shingles.
[0009] A problem with conventional shingles is that strong winds are capable of generating strong uplift forces in excess of 100 lbs./sq. ft., resulting in the tearing or shearing of shingles from their underlying support members. The use of mechanical fasteners, such as nails or screws, does not provide a surface area sufficient to withstand such forces without tearing the shingle around the fastener head. The heads of the fasteners tear through the shingle in a random fashion resulting in shingle loss and subsequent damage to the structure. Reinforcement with glues and various adhesives and the inclusion of additional standard mechanical fasteners have helped, but these fail to provide viable protection when exposed to high wind speeds including, but not limited to, hurricane-force winds. Use of adhesives on older roofs is again costly, and requires movement of the fragile shingles to dispose adhesive there below. Manipulating the shingles in such a manner can cause damage to the shingles in and of itself. During a storm, should one or more of the shingles become torn from the support members, the entire roof covering or a large portion thereof can easily be torn from the structure. The exposed interior of the building, along with its contents, are then subject to water and wind damage, resulting in extensive loss.
[0010] U.S. Pat. No. 6,247,289 issued to Karpinia discloses shingle straps composed of materials such as aluminum and steel that are positioned along each horizontal row of successive shingle layers to cause shingle tab detachment at a region demarcated by the reinforcing shingle strap. Such a device is fastened to the roof by nails, screws, or the like, and may involve manipulation of the pre-existing shingles in order to place the strap beneath the overlap of the immediately adjacent shingle row.
[0011] U.S. Pat. Appl. No. 2006/0075690 filed by Murray discloses a modular roof protector for periods of high winds. Mesh panels are placed over a roof and held down under tension by means of a fixed connection with anchor points along the home's foundation, the underside of mobile homes or pre-installed earth anchors. The disclosed device is fast and easy to deploy, and is only meant as a temporary reinforcement that is removed and then redeployed for later, successive high wind incidents.
[0012] While it is generally understood how to make a structure capable of surviving significant hurricane winds, the cost of retrofitting an already constructed home to the standards of a modern fully engineered building is generally prohibitive. The prior art does not define a fast, easy, and economically feasible means by which a typical home built with common construction materials and techniques can be reinforced against wind damage on a permanent basis by a homeowner, wherein the retrofit home will perform as a fully engineered building would in hurricane or near-hurricane conditions.
[0013] A need therefore exists for an economical method for retrofitting existing homes to withstand damage from high wind storms such as hurricanes. A further need exists for a roof reinforcing method that does not require the laborious removal or manipulation of pre-existing roofing materials. Yet another need exists for a roof reinforcing method that is durable, relatively permanent in nature, and would not require setup and removal, thereafter, during specific incidents of high wind activity.
BRIEF SUMMARY OF THE INVENTION
[0014] An inventive method for reinforcing a typical roofing system is disclosed, comprising the steps of applying an adhesive to the upper shingled surface of a roof, and disposing a net over the adhesive on the upper shingled surface of the roof, wherein the adhesive adheres the net to the upper shingled surface of the roof.
[0015] The present inventive method may further include the step of applying a compressive force to the net, wherein the net is compressed against both the adhesive and the upper surface of the roof. Still further, the present inventive method may include the step of applying a top coat material onto the net, the adhesive and the roof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a conventionally shingled roof having an adhesive sprayed onto the roof shingles.
[0017] FIG. 2 is a perspective view of the conventionally shingled roof coated with adhesive of FIG. 1 , having a net disposed on top of the adhesive and over the upper surface of the roof.
[0018] FIG. 3 is a perspective view of the roof, adhesive, and net of FIG. 2 , further having an additional top coat of material applied over the net and upper surface of the roof.
[0019] FIG. 4 is a perspective view of the roof, adhesive, net, and top coat of FIG. 3 , wherein the adhesive and top coat have dried, thus both protecting and adhering the net to the upper surface of the roof.
[0020] FIG. 5 is a top view of one embodiment of the net, wherein the vertical portions of the net are aligned to bisect the shingle flaps of every other horizontal row of shingles.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention is for use with majority of shingle types currently available in the marketplace. Such shingles are exemplified by, but not limited to, tile shingles and shingles made with a substrate of either organic fiber saturated with asphalt or chopped glass fiber with a urea-formaldehyde binder. For example, a typical shingle consists of a substrate first coated with a mixture of asphalt and fillers such as limestone, sand or stone dust. The coated substrate then is covered with colored granules to give aesthetic appeal to the front of the shingles. In some instances, a parting agent may be applied to the back of the substrate so that the packaged shingles do not stick together. Additionally, an asphalt sealant may be placed on the granulated side of the shingles to enhance adhesion to the back of covering shingles in the final applied configuration. Although shingles manufactured in this manner are affordable and generally perform well in a wide variety of applications, such shingles will not withstand extreme weather conditions, including but not limited to high winds, and are characteristic of one of the weakest types of shingles. The present invention operates independently of the particular shingle, despite its own structural strength, providing universal applicability to a wide range of roofing situations and materials. Because the net of the present invention is not a part of the shingle, the present inventive method adhesively disposes the applied net onto rooftop shingles to aid in prevention of shearing of the free ends of the shingles.
[0022] Referring now to FIGS. 1-5 , a method of reinforcing a typical shingle roofing system in accordance with the present invention will be described. Typical shingle roofs 10 have overlapping offset standard shingles 11 . As further depicted in FIG. 1 , the present inventive method may be initiated by applying 12 an adhesive 14 to the upper surface of any pre-existing roof 10 . The application 12 of the adhesive 14 can be accomplished by any means known within the art, including but not limited to, spraying, brushing or rolling application methods. FIG. 1 depicts the spray application of adhesive 14 onto the shingles 11 of the roof 10 . Preferably, the adhesive 14 may be clear in appearance and allow casual observers to view the underlying shingle 11 coloring in an unobstructed manner.
[0023] The applied adhesive 14 may be any adhesive or glue known within the art capable of adhering the net 15 to the shingled 11 upper surface of the roof 10 . Examples of such adhesives include, but are not limited to, liquid nylon, shingle adhesives, shingle cements, roof patch materials, roof coating materials, polyurethane adhesives, and any other suitable materials known within the art.
[0024] FIG. 2 depicts the net 15 disposed on the adhesive-coated upper surface of the roof 10 . The placement of the net 15 onto the shingles 11 of the roof 10 may be accomplished and facilitated by any means known within the art, including but not limited to rolling out bundles of the netting 15 across the adhesive-coated roof 10 surface. The net 15 may be composed of material selected from the group consisting of, but not limited to, nylon, polyester, polypropylene, polyethylene, combinations thereof, and any other materials known within the art. The elements of the net 15 may also be constructed in a variety of forms including, but not limited to, monofilament or multifilament varieties. Preferably, the net 15 may be clear in appearance and allow casual observers to view the underlying shingle 11 coloring in an unobstructed manner.
[0025] With the net 15 in position on the roof 10 , a compressive force may then be applied to the net 15 to more closely conform the net 15 to the profile of the shingles 11 on the roof 10 . Such a compressive force may be generated by a great number of means, including but not limited to, any tool or object capable of being pressed down upon the net 15 after the net 15 is disposed on the upper surface of the roof 10 . Unique task specific tools may also be used, wherein the bottom surface of the tool closely matches the roof 10 profile to enhance the task of conforming the net 15 to the exact contour of the roof 10 surface.
[0026] As depicted in FIG. 3 , once the net 15 is in place a top coat material 22 may be applied 20 over the upper surface of the roof 10 . The top coat 22 serves to cover the net 15 , the adhesive 14 , and roof 10 . Optimally, the characteristics and properties of the top coat 22 may help to provide a beneficial trait, including but not limited to, durability, thermal stress resistance, structural integrity, tensile strength, pliability, and resistance to ozone, ultraviolet, oxidation, humidity and/or corrosive environments. Examples of such top coat materials 22 include, but are not limited to, liquid nylon, polyurethane sealant or coating, known roof patch material, known roof coating material, known roof membranes, and any other materials known within the art. Additional top coat materials may be found in the soil stabilizer, dust control, and construction/soil sealer arts. As an example, Enviroseal Corp., a Florida corporation, markets water-based acrylic industrial sealers (e.g. Duraseal™, Roof-Guard 101™, and Roof-Guard 102™) and acrylic soil stabilizers (M10+50™, LDC™, and LBS™). Such top coat acrylic industrial sealers have proven effective in repelling water, ultraviolet rays, oil, mold and mildew, while such acrylic soil stabilizers improve adhesion, abrasion resistance, flexural strength, and exterior durability. Preferably, the top coat 22 may be clear in appearance and allow casual observers to view the underlying shingle 11 coloring in an unobstructed manner. The properties of many top coat materials listed above further allow their use as the adhesive 14 component in the method of the present invention.
[0027] FIG. 4 depicts a roof 10 after a method of the present invention has been completed. A top coat 22 is disposed over the net 15 , which is held to the shingles 11 of the roof 10 by the applied adhesive 14 .
[0028] The net 15 of the present invention may be provided in a wide variety of configurations. Such configurations include, but are not limited to, square grids, rectangular grids, diamond-shape grids, and any non-uniform randomized mesh pattern. FIG. 5 depicts an embodiment of the net 15 configuration where the net 15 comprises vertical portions 16 that are disposed perpendicular to the drip edge of the roof 10 , and horizontal portions 18 that are disposed parallel to the drip edge of the roof 10 . The drip edge of a roof is defined as a roof edge that is parallel to the ground, i.e. horizontal. In use, at least one vertical portion 16 will be disposed over each shingle flap 24 . In the configuration depicted in FIG. 5 , vertical portions 16 of the net 15 approximately bisect each shingle flap 24 of every other horizontal row of shingles 11 . Due to the standard offset pattern used in most shingle installations, the vertical portion 16 may approximately bisect a first shingle flap 24 . The vertical portion 16 may then fall within the groove between the shingle flaps 24 of the first overlain horizontal shingle 11 row (see FIG. 5 ), and thereafter the vertical portion 16 may bisect the shingle flap 24 of the second overlain horizontal shingle 11 row.
[0029] The present inventive method may also be applied to various roofing surfaces including, but not limited to, asphalt shingles, tile shingles, slate shingles, composite shingles (e.g. rock, clay, fiberglass, etc.), wood shingles, metal shingles and architectural shingles. The method steps described above can easily be adapted for use in any of the above roof applications. As an example, tile roofs may require the selection of an adhesive 14 known in the art to bond more effectively to tile shingles. Additionally, if the net 15 is to be compressed, a tool specifically configured to match the contours of the tile roof may be employed to facilitate the compression process. Thus, the method of reinforcing a typical roofing system of the present invention may be used to retrofit pre-existing structures that possess a great number of conventional roofing systems currently in the marketplace.
[0030] While the above descriptions contain much specificity, these should not be construed as limitations on the scope of any embodiment, but as exemplifications of the presently preferred embodiments thereof. Many other ramifications and variations are possible within the teachings of the various embodiments.
[0031] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not by the examples given.
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An adhesive coating and a net are applied to the upper surface of a preexisting roof in a manner effective for reinforcing and securing roof shingles when exposed to high wind conditions. A compressive force and a top coat may additionally be applied atop the net for added adhesion and durability. Appropriate application results in improved resistance to shingle damage, and subsequent building damage, during winds storms, gales, hurricanes, and any other high wind incidents. The method and apparatus may be used to retrofit existing buildings, without requiring partial or total removal of pre-existing roof shingles or other roof structures.
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RELATED APPLICATIONS
This application claims priority to commonly-owned and co-pending U.S. Provisional Patent Application 60/127,515 filed on Apr. 2, 1999, and which is incorporated in its entirety herein by specific reference thereto.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally pertains to mineral mining processes and, more particularly, but not by way of limitation, to a mining system particularly adapted for the recovery of coal from coal seams.
2. History of the Related Art
The recovery of coal, ore, or other material from mineral bearing strata or seams has been the subject of technological development for centuries. Among the more conventional mining techniques, drum-type mining systems have found industry acceptance. Drum-type mining machines typically utilize a cutting head having a rotating cylinder or drum with a plurality of mechanical bits on an exterior surface for cutting into the mineral bearing material. The dislodged material is permitted to fall to the floor of the mining area, gathered up, and transported to the mining surface via conveyors or other transportation means.
Although drum-type mining machines have proven effective, conventional drum-type cutting systems generally rely solely on a mechanical cutting action which subjects motors and bits to considerable wear and produces significant amounts of dust. Also, to increase the productivity of conventional mechanical cutting machines will normally require the installation of larger and heavier cutting motors on the miner to produce the additional power needed.
Thus, there is a need for a reliable mining system which addresses the limitations of the above-described conventional mining systems and which achieves higher rates of penetration and improved productivity.
SUMMARY OF THE INVENTION
The present invention overcomes the foregoing and other problems with a water jet assisted, drum-type mining system which positions a plurality of high pressure water jets to cut the mining face independently of mechanical bits. This unique combination of mechanical and hydraulic cutting results in higher rates of penetration and improved productivity. The high pressure water used in cutting may be pumped via a hose line or other conduit from a remote location. Alternatively, a high pressure water pump may be located on the chassis of the miner. Of course, this means that the cutting motors on the drum-type miner itself can be much smaller than the motors used to generate equivalent production by conventional means. Moreover, because the mining face is pre-scored by the water jets, the amount of wear on both the mechanical bits and the motors may be significantly reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and for further objects and advantages thereof, reference is made to the following Detailed Description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevational view of a drum-type cutting head contacting a mineral seam;
FIG. 2 is a simplified, top plan view of a drum-type mining system;
FIG. 3 a is a cutaway, side elevational view of a hard-head cutting head for drum-type mining systems;
FIG. 3 b is a cutaway, side elevational view of a ripper-chain cutting head for drum-type mining systems;
FIG. 4 is a side elevational view of a cutting drum with mechanical bits mounted on an exterior surface and showing an effective cutting diameter;
FIG. 5 is a front elevational view of a cutting drum showing a typical scrolling pattern to the bits;
FIG. 6 a is a side elevational view of a water jet assisted cutting head of the present invention showing a high pressure fluid conduit mounted tangentially above and below the drum;
FIG. 6 b is a side elevational view of a water jet assisted cutting head of the present invention showing a high pressure fluid conduit shaped to fit between the exterior surface of the drum and the effective cutting diameter as defined by the mechanical bits;
FIG. 7 is a top plan view of a hard-head embodiment of the water-jet assisted cutting head of the present invention.
FIG. 8 is a top plan view of a ripper-chain embodiment of the water jet assisted cutting head of the present invention.
DETAILED DESCRIPTION
The preferred embodiment of the present invention and its advantages are best understood by referring to FIGS. 1-8 of the drawings, like numerals being used for like and corresponding parts in each of the various drawings.
The mechanical cutting capabilities of drum-type continuous miners, used for mining coal and other minerals, can be supplemented by the inclusion of high-pressure water jets. Unlike borer-type miners where mechanical bits continuously contact the cutting face, the mechanical bits on a drum miner cut coal or contact the excavation point less than 50% of the circumference of the drum. As best seen in FIG. 1, less than half of the mechanical bits 105 on the drum-type cutting head 110 typically contact the cutting surface 25 at one time. For example, the bits denoted by reference number 30 are in contact with and cutting the mining face 25 while the other bits 35 will not contact the mineral seam until the drum is rotated almost 180°. This also complicates the addition of water jets to the rotating drum 110 itself, and substantially reduces their effectiveness because, if mounted this way, at least half of the nozzles would be directed away from the mining face 25 at any one time.
As best seen in FIG. 2, a simplified drum-type continuous miner 100 has a horizontal cylinder or drum 110 with its axis of rotation 111 perpendicular to the center line 55 of the opening or entry being developed 50 . As the miner 100 is advanced toward the mining face 25 , the drum is turned in a top-forward direction of rotation 112 to achieve a cutting action with the mechanical bits, not shown. Also, the drum 110 is generally moved up and down in a vertical plane, not shown, to increase the height of the opening 50 and overall production.
With reference now to FIGS. 3 a and 3 b together, the cylinder 110 is rotatably mounted to an arm or a boom 120 . The electric motors 130 to rotate the drum 110 may be mounted in the body of the miner, not shown, or the boom 120 , with the energy being transferred from the motors 130 to the drum 110 using either: ( 1 ) rotating drive shafts 140 housed within fixed supports 150 , as shown in FIG. 3A, or ( 2 ) gears 160 located behind and beneath a cutter or ripper chain 170 , seen in FIG. 3B, which wraps around the drum 110 , a central portion of which has gear-like teeth 175 for engaging the underside of the chain 170 , and an idler located on the support boom 120 . Either of these methods uses the rotating mechanical energy of an electric motor 130 to cause the drum 110 to rotate, top forward at a speed of approximately 60 revolutions per minute.
As best seen in FIG. 4, the effective cutting diameter 115 as defined by the cutting bits 105 is greater than the diameter 116 of the smooth exterior surface of the drum 110 . This provides an off-set or distance 117 within which water jet nozzles and high pressure conduits may be mounted as in FIGS. 6A and 6B. The distance 117 may be calculated by subtracting the drum radius from the effective cutting radius. This distance 117 will typically range from about 3 to about 8 inches, but it is understood that this distance 117 is dependent only on the size of the drum 110 and the length of the bits 105 and bit blocks 107 selected and is not limited only to this particular range.
As illustrated in FIG. 5, mechanical bits 105 are typically attached to the smooth exterior surface of the drum 110 in positions that create various patterns as it rotates. This is referred to as the scroll 106 of the bits 105 . The spacing of the track, made by the mechanical bits 105 on the cutting surface 25 , varies, depending on the longitudinal spacing of the mechanical bits 105 . Typically, the track spacing or bit lace spacing will be from about 1 . 5 to about 3 inches, or more. These mechanical bits 105 are removable. They are inserted in bit lugs or bit blocks 107 , which are in turn welded solidly to the exterior surface of the drum 110 . The mechanical bits 105 can be routinely removed from this bit lug 107 and replaced as they wear.
The plumbing necessary to provide high-pressure water at sufficient flows to water jets can take advantage of the bit spacing or lacing, and the distance 117 between the smooth exterior surface of the drum 110 and the actual cutting diameter of the bits 105 . Water jets can be preferably mounted in two different ways.
As shown in FIG. 6A, a first embodiment would involve the addition of a high pressure water hose, not shown, and metal piping 180 , which is run from the miner body or the boom 120 and mounted tangent to the upper and lower surfaces of the drum 110 . This piping 180 , positioned within the effective cutting diameter 115 of the cutting head 110 , can actually extend beyond the center line of the cylinder 110 , so that the water jet nozzles 185 , are only slightly back from the mechanical bits 105 in contact with the mineral seam, not shown.
As illustrated in FIG. 6B, a second embodiment would involve the addition of a high pressure water hose, not shown, and metal piping 180 , which is run from the miner body or the boom 120 and may be curved or shaped to fit about the circumference of and just beyond the smooth exterior surface of the drum 110 . The piping or conduits 180 are positioned within the effective cutting diameter 115 of the cutting head 110 , and can be tapped and fitted with nozzles 185 which are located between the surface of the drum 110 and the cutting face 25 of the material being mined. Thus, the distance between the coal face 25 and the nozzles 185 is effectively minimized.
Either of these two exemplary embodiments would provide rigidly mounted high-pressure conduits 180 having water jet nozzles 185 at a very close distance to the solid coal being cut. The jet nozzles 185 provide high-pressure water which assists mining by cutting and creating a vertical slot or groove in the coal face from roof to floor as the drum 110 is moved up and down in a conventional cutting motion. These vertical grooves effectively pre-score the coal face and make it far easier for the mechanical bits 105 to then fracture the coal.
As shown in FIG. 7, an alternative method of mounting water jets 185 would involve running high-pressure water lines 180 at least partially within the existing support struts 150 of a hard-head miner, introduced in FIG. 3 A. Various techniques are used to rotate the drum 110 . The support struts 150 are rigid, non-rotating members that may or may not contain drive shafts for rotating the cylinder 110 . The plumbing 180 can provide high-pressure water and sufficient flow to several water jets 185 mounted on the front, or core breaker edge 190 of these support struts 150 . These support struts 150 are non-rotating, while the actual segmented cylinder, or drum 110 , rotates on either side of the support strut 150 . Since these support struts 150 must be sufficiently wide to contain mechanical parts like a drive shaft, there is usually a zone of solid, uncut coal, referred to as a core, which forms between the two rotating drums 110 . The front edge 190 of the support strut 150 typically contains bits or sharp points 195 , see FIG. 3A, designed to break or cut the core, which remains between the two rotating cylinders. The high-pressure water jets 185 can be mounted in several positions on this core breaker 190 . This would also place the water jets 185 very close to the surface being cut mechanically by the bits 105 . In this and other mounting applications, either fixed or swivel mounted water jets can be used.
Turning now to FIG. 8, in conjunction with FIG. 3B, a ripper-chain embodiment miner of the present invention is illustrated. The drum 110 is segmented or formed of three sections which are linked together by a spline, axle or other means to turn as a single unit about a common axis of 15 rotation. The central section has gear-like teeth 175 , shown in FIG. 3B, which engage the underside of a ripper chain 170 . The chain 170 is looped around the drum 110 , and drive gears 160 . As the drive gears 160 turn, the chain 170 and the drum 110 are rotated top-forward to mine coal.
As shown in FIG. 8, the chain 170 and the outer sections of the drum 110 have mechanical bits on their exterior surfaces. As shown in FIGS. 6A and 6B, rigid conduits 180 which are tapped to supply water nozzles 185 may be located above or below the cutting portions of the drum 110 or may be curved to fit completely around the drum 110 . Although the depicted embodiment has four conduits or tubes 180 around the drum 110 , it is understood that these rigid tubes 180 may be provided in any number which does not hinder the cutting drum 110 . If necessary, mechanical bits 105 may even be removed from the drum 100 to provide the lateral spacing required for mounting the high pressure conduits or tubes 180 .
The application of high-pressure water jets 185 to the drum-type continuous miner 100 allows additional hydraulic cutting power to be provided for the excavation of coal or other materials, beyond the power provided by the mechanical cutting head motors. This additional power is provided by high-pressure water pumps, not shown, which are powered by additional motors which may be located remotely from the continuous miner 100 . Of course, if small enough, these high-pressure pumps, not shown, could also be located on the continuous miner itself.
The water jets 185 assist in the liberation of the coal from the working face. The high-pressure streams of water, which are produced by the water jets 185 , actually penetrate and cut into the coal surface independent of and beyond the reach of the mechanical bits 105 . These slots, or grooves, cut by the high-pressure water jets 185 reduce the amount of energy required for mechanical excavation by pre-fracturing the coal and providing additional free faces for the coal to break as it is impacted by the mechanical bits 105 .
The high-pressure water jets 185 and the water provided to the working area also have the significant benefit of greatly reducing the amount of coal dust liberated during the mining process. The amount and pressure of water provided to each of the water nozzles 185 may further be varied independently, depending on the specific application.
By way of example only, Table 1 is provided to better illustrate how the use water jet assisted cutting on a drum-type miner may result in significant improvements in both penetration rate and production. For comparison purposes, a conventional drum-type miner in a ripper-chain configuration was first tested using mechanical cutting alone. The miner was then fitted with a water jet system according to the present invention. The water jets were supplied at about 6,000 psi and about 150-170 gallons per minute. Data from repeated trials were then averaged to produce Table 1. It is notable that the production with water jet assistance was nearly double that of the conventional mechanical bit drum-type miner.
TABLE 1
Penetration
Production
Cutting Motor
Technique
(ft/min)
(tons/hour)
(amps)
Mechanical
1.00
227
125-130
Bits Only
Mechanical +
1.83
415
100
Water Jets
Repeated tests were also made to determine the best configuration and orientation of water jets 185 . It was found that the water jets 185 on a single metal conduit 180 should focus cutting to produce a vertical groove or slot rather than random erosion of the entire face.
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description of a preferred embodiment. While the device shown is described as being preferred, it will be obvious to a person of ordinary skill in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention, as defined in the following claims. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein.
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A drum-type miner having a plurality of water jet nozzles which cut independently of the mechanical bits is disclosed. The drum-type miner may configured in either a hard-head or a ripper-chain design. The unique combination of mechanical and hydraulic cutting results in higher rates of penetration and improved productivity. Moreover, because the mining face is pre-scored by the water jets, the amount of wear on both the mechanical bits and the motors may be significantly reduced.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of U.S. patent application Ser. No. 10/468,530, filed Aug. 19, 2003 in the name of Francisco Speich and entitled PATTERNED FABRIC AND A METHOD FOR THE PRODUCTION THEREOF, which is a 35 U.S.C. §371 National Stage of International Application No. PCT/CH02/00088, filed on Feb. 14, 2002. Priority is claimed on that application and on the following applications: Countries: Switzerland, Application No. 299/01, filed: Feb. 20, 2001 and Switzerland, Application No. 1027/01, filed: Jun. 6, 2001.
TECHNICAL FIELD
[0002] The invention relates to a patterned fabric, in particular a Jacquard fabric and to a method for producing it.
PRIOR ART
[0003] WO 00/60151 describes a patterned fabric and a method for producing it in the fabric technique with warp threads which form a shed and with weft threads. In this method, at least four weft threads of different basic colors, which form a thread group, are inserted in a defined constant sequence, in such a way that, together with a warp thread, a constant cell is formed. The weft threads are tied off by means of regular weaves with repeat repetition, in such a way that a color cell with a defined color impression is obtained. To produce a Jacquard fabric with an illustration, a weaving program is set up. For this purpose, the illustration present on a model is broken down into weavable image dots or color cells. In this case, the mixed colors in the fabric are produced on the basis of the low resolution of the human eye.
[0004] It has become clear, then, that the use of regular weaves has a greater influence on the illustration reproduced in the fabric. Although a large number of color shades can be generated, the nuances generated in the color breakdown used today are not always reproduced by means of the repeat repetition. Quality differences between the illustration to be woven and the woven illustration consequently occur, this being a disadvantage.
[0005] DE 44 38 535 discloses a method for the Jacquard weaving of colored cloth. In this method, an illustration to be woven is broken down by means of the screening method known from printing technology. In this method, a model is transferred into a computer by scanning and is indicated on the display unit, a very large number of color shades being present. The colors are subsequently reduced to an illustratable or desired number of colors. Finally, this number of colors is broken down into screen dots, that is to say into image dots having the colors red, yellow and blue and also black and white, the screen dot having the size of a weavable dot. After the color breakdown, the weaving program is set up by means of computer technology, each screen dot corresponding to a weaving dot. These weaving dots are tied off according to the classic Jacquard method, that is to say regular weaves with repeat repetitions are employed.
[0006] The known method has substantial disadvantages. An experienced person skilled in the art with weave experience is absolutely necessary in order to carry out the method. To be precise, it became clear that, in woven colored illustrations in the colors yellow, red and blue, the color mix is faulty, that is to say they do not have all the colored shades of the model. Normally, corrections are necessary in order to improve the woven illustration. However, such corrections can be carried out only by an experienced person skilled in the art with weave experience. In the color breakdown for reproduction graphics, it is to be assumed that a color mix occurs in the region between the print colors during the printing operation. In other words, the printed color dots are not delimited with high definition, but, instead, the print colors of the adjacent color dots flow partially one into the other in the edge region. In the known method, the illustration is broken down into screen dots which form a weaving dot with high-definition delimitation. The mixing effects are to be generated owing to the low resolution of the human eye.
SUMMARY OF THE INVENTION
[0007] The object of the invention is to improve the initially mentioned patterned fabric, in particular Jacquard fabric, and the initially mentioned method for producing it.
[0008] The fabric according to the invention consists of warp threads and weft threads which form a thread group and are tied off by means of a warp thread in a cell in such a way that the cell has a defined color impression. The cell is formed by at least two warp threads and two weft threads, without repeat repetition, by means of weaves which are irregular in the warp direction and the weft direction.
[0009] An improved reproduction of the illustration to be woven is advantageously achieved in the fabric by means of the irregular weave.
[0010] It is advantageous if the irregular weave is predetermined according to the [lacuna] during the image breakdown of the illustration, because the desired color impression is copied directly by the weave.
[0011] For this purpose, at least one weft thread of the thread group can cross at least one warp thread, above the latter, on the face side of the fabric, so that a dot is illustrated by a color. In order to illustrate nuances of the color, further weft threads of the thread group may be arranged above the warp thread. In this case, the weft threads may also float.
[0012] Advantageously, the fabric has weft threads of different basic color. In the case of a black/white illustration, the thread group may consist of weft threads in the colors black and white. In a colored illustration, the thread group advantageously comprises weft threads in the basic colors red, green, blue, yellow, black and white or magenta, cyan, yellow, black and white.
[0013] For larger single-colored regions, it is advantageous if a regular weave is provided.
[0014] It is advantageous if the weft threads on the face side of the fabric float over a maximum of forty-eight warp threads, because the face side of the fabric thereby leaves a better impression. Since the weft threads on the back side of the fabric float over a minimum of four warp threads, the overall impression of the fabric is advantageously improved.
[0015] Various methods for producing the patterned fabric from weft threads and warp threads are possible. In one embodiment of the inventive method, a file format is set up from a model of the illustration to be woven, and the illustration to be woven is broken down into pixels consisting of at least four selected basic colors. According to the invention, each basic color is broken down into pixels with a color depth of 8 bits. The pixels of the basic colors are in each case stored on a separate bitmap, and the color depth is subsequently reduced to 2 bits for each basic color. Thereafter, the bitmaps of the basic colors are each offset by the amount of one pixel and are subsequently assembled to form a further bitmap having the basic colors. By means of this bitmap, a weaving program for a Jacquard weaving machine is set up, which provides for the use of irregular weaves without weave repeat repetitions and according to which the fabric is produced on the Jacquard weaving machine.
[0016] By means of the electronic image processing according to the method, from a predetermined file format a file format is set up which has a high resolution and constitutes a true-to-original reproduction of the illustration in the fabric. The file format is transferred into a weaving program and converted into a weavable data format. The advantage of this is that the image dots can be generated according to the predetermined file format without manual corrections—by a person skilled in the art with weave experience. By the use of irregular weaves without repeat repetition, image dots in the basic colors in the fabric are generated which, by virtue of the high resolution, result in the true-to-original reproduction of the illustration of the model.
[0017] In the reduction of the color depth, with a threshold value being included, the color depth of the basic colors can be influenced in an advantageous way.
[0018] By the bitmaps being offset by the amount of one pixel in the warp direction or the weft direction, the fabric density can be improved in an advantageous way.
[0019] In addition to the colors known from image processing, other or up to sixteen colors may advantageously also be selected.
[0020] By means of a CAD system, in setting up the weaving program, the weaves are fixed by means of the data of the further bitmap and a predetermined warp/weft thread ratio is included. The advantage of this is that the setting up of a weaving program can be simplified and the outlay necessary for this purpose can be reduced.
[0021] With the weft threads being inserted in a constant sequence, the design of the insertion device can advantageously be simplified. Advantageously, the sequence of the basic color of the weft threads during insertion is freely selectable, so that the illustration to be woven can be adapted to the color impression of the model.
[0022] A weft thread of the thread group may be tied off in such a way that the weft thread crosses over a warp thread on the face side of the fabric. A color dot is thereby advantageously formed. Two or more weft threads may also be tied off in such a way that a color mix effect is achieved.
[0023] Other features and advantages of the present invention will become apparent from the following description of the invention that refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Exemplary embodiments of the invention are explained in more detail below by means of drawings in which:
[0025] FIG. 1 shows a block diagram of one embodiment of an operation for producing a Jacquard fabric with an illustration,
[0026] FIG. 2 shows a copy of a model of an illustration to be woven,
[0027] FIG. 3 shows an enlarged detail A of the model according to FIG. 2 on a larger scale after the color breakdown of the illustration in selected basic colors,
[0028] FIG. 4 shows an enlarged detail B in FIG. 3 ,
[0029] FIG. 5 shows a paper weave design for an irregular weave,
[0030] FIG. 6 shows a sectional illustration of a fabric with an irregular weave,
[0031] FIG. 7 shows a top view of the fabric according to FIG. 6 ,
[0032] FIG. 8 shows a paper weave design for a regular weave,
[0033] FIG. 9 shows a block diagram of a further embodiment of the method according to the invention for producing a fabric with a colored pattern,
[0034] FIG. 10 shows a paper weave design for an irregular weave;
[0035] FIG. 11 shows a sectional illustration of a fabric with an irregular weave; and
[0036] FIG. 12 shows a top view of the fabric according to FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0037] Reference is made to FIGS. 1 to 4 . FIG. 1 shows, in the form of a block diagram, the steps necessary for producing a Jacquard fabric with an illustration.
[0038] FIG. 2 shows a model with the illustration to be woven, which is converted into image dots by color breakdown and forms the basis for a weaving program ( FIGS. 2 and 3 ). A version of a fabric according to the invention, which is described below, is then produced by means of a Jacquard weaving machine.
[0039] FIG. 5 shows a paper weave design for the fabric to be produced, according to which weft threads in the basic colors red R, green G, blue B, yellow Y, black S and white W are inserted in a defined sequence. The insertion of the weft threads and the movement of the warp threads (upstroke and downstroke) are regulated by means of this paper weave design. The weave is obtained according to the image dots generated during the color breakdown of the illustration. As FIG. 5 shows, a red and a green image dot are to be generated in the fabric. On the basis of the instructions of the paper weave design, the warp thread K 1 is located in the bottom shed and the other warp threads are located in the top shed, so that, after the tie-off, the red weft thread crosses the warp thread K 1 above the latter and the green weft thread crosses the warp thread K 2 above the latter ( FIGS. 6 and 7 ). A plurality of weft threads with different colors may also be tied off in the same way, in order to obtain a color mix or color nuance.
[0040] As FIG. 6 shows, the weft threads 11 float on the back side of the fabric. It is likewise possible for the weft threads 11 to float on the face side of the fabric. In order to improve the fabric structure, the floating length of the weft threads is limited, specifically over a minimum of four warp threads 12 on the back side and over a maximum of forty-eight warp threads 12 on the face side.
[0041] If an illustration to be woven has a relatively large single-colored region, the weft threads in the fabric are tied off by means of a regular weave.
[0042] In a further exemplary embodiment according to FIG. 9 , the method comprises image preparation 1 , image breakdown 2 , weaving program set-up 3 and weaving 4 . In the image preparation, by means of scanning from a model, for example a photograph, image data in a TIFF file format are read into a program for image processing and are presented, as an image of the illustration to be woven, on a display unit. Depending on the resolution of the scanner and of the display unit, the image illustration which appears on the display unit has a few thousand colors or color shades.
[0043] Image breakdown is carried out on the basis of the illustration on the display unit. In the image breakdown, first the basic colors cyan C, magenta M, yellow Y and black S, which are used during weaving, are selected. Thereupon, the image colors are broken down into the basic colors and are stored in a separate bitmap 6 in pixels with a color depth of 8 bits for each basic color. Subsequently, the color depth is reduced in each case to 2 bits, with the result that a square pixel is formed. In this case, by means of a threshold value, the gray steps are broken down into the basic colors C, M, Y, S or white O and the basic color of the pixel is thus fixed. Finally, the bitmaps of the basic colors are offset by the amount of one pixel in the weft direction and are assembled on a further bitmap 7 . Owing to the offset by the amount of one pixel, the weft sequence of the weft threads in the basic colors cyan, magenta, yellow, black and white is fixed at the same time. These data are read in a TIFF file format into a CAD system 8 and presented on the display unit.
[0044] From this data, a weaving program for the Jacquard weaving machine is set up, which provides for the use of irregular weaves without weave repeat repetitions. With the aid of the illustration, the weaves are fixed by means of the read-in data and with a warp/weft thread ratio being included. In this case, the data are illustrated as square pixels and transferred into a pattern card 9 which, on the display unit, show the pixels as square image dots of the illustration to be woven. Subsequently, the weaving card 10 , by means of which the Jacquard weaving machine is controlled, is set up.
[0045] During weaving, five weft threads 11 are inserted, in the weft sequence of cyan, magenta, yellow, black and white, as a thread group in a weft line. The weft threads are tied off by means of warp threads 12 in a cell which is formed by two warp threads and at least two weft threads by means of a weave without weave repeat repetition.
[0046] FIG. 10 shows a paper weave design for the fabrics to be produced, which is derived from the weaving program. The insertion of the weft threads and the movement of the warp threads (upstroke and downstroke) are regulated by means of this paper weave design. The weave is obtained according to the image dots generated during the color breakdown of the illustration. According to FIG. 10 , an image dot with the basic color cyan and an image dot with the basic color magenta are to be generated in the fabric. On the basis of the instructions of the paper weave design, the warp thread K 1 is located in the bottom shed and the other warp threads are located in the top shed, so that, after the tie-off, the weft thread with the basic color magenta crosses the warp thread K 3 above the latter ( FIG. 11 and FIG. 12 ). A plurality of weft threads with different colors may also be tied off in the same way, in order to obtain a color mix or color nuance.
[0047] Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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A patterned fabric having warp threads and weft threads that form an illustration. The weft threads are arranged to form a threaded group and, together with at least one warp thread, form a cell. The weft threads are tied off in the cell by the warp thread so that the cell has a defined color impression. The cell has weaves formed irregularly in a warp direction and a weft direction by at least two of the warp threads and two of the weft threads without periodic repetition.
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This application is a continuation application of U.S. patent application Ser. No. 10/085,142, filed Mar. 1, 2002, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
The invention relates generally to the field of DNA genotypic analysis. More particularly, the invention relates to the allelic classification of DNA samples through cluster analysis of analyzed emission spectra observed from excited fluorophore-labeled nucleotide probes. Specifically, fluorophore-labeled nucleotide probes can be used verify DNA variations between individual samples and verify the expression of a region of DNA in different cell lines.
BACKGROUND OF THE INVENTION
Individual DNA sequence variations are known to directly cause specific diseases or conditions, or to predispose certain individuals to specific diseases or conditions. Such variations also modulate the severity or progression of many diseases. Additionally, DNA sequence variations exist between populations. Therefore, determining DNA sequence variations is useful for making accurate diagnoses, for finding suitable therapies, and for understanding the relationship between genome variations and environmental factors in the pathogenesis of diseases and prevalence of conditions.
There are several types of DNA sequence variations. These variations include insertions, deletions, restriction fragment length polymorphisms (“RFLPs”), short tandem repeat polymorphisms (“STRPs”), and single nucleotide polymorphisms (“SNPs”). Of these, SNPs are considered the most useful in studying the relationship between DNA sequence variations and diseases and conditions because they are more common, more stable, and more amenable to being employed in large-scale studies than other sorts of variations.
Currently, a set of over 3 million putative SNPs has been identified in the human genome. It is a current goal of researchers to verify these putative SNPs and associate them with phenotypes and diseases, eventually replacing currently-used RFLP and STRP linkage analysis screening sets. In order to successfully accomplish this goal, it will be necessary for researchers to generate and analyze large amounts of genotypic data.
A number of methods have been developed which can locate or identify SNPs. These methods include dideoxy fingerprinting (ddF), fluorescently labeled ddF, denaturation fingerprinting (DnF1R and DnF2R), single-stranded conformation polymorphism analysis, denaturing gradient gel electrophoresis, heteroduplex analysis, RNase cleavage, chemical cleavage, hybridization sequencing using arrays and direct DNA sequencing.
One method of particular relevance to the present invention employs a pair of fluorescent probes, each probe containing a different dye and specific for a different allele. In this method, the two probes are added to the DNA sample to be tested, and the mixture is amplified using PCR. If the DNA sample is homozygous for the first allele, the first probe's dye will exhibit a high degree of fluorescence and the fluorescence from the second probe's dye will be absent. Conversely, if the DNA sample is homozygous for the second allele, the second probe's dye will exhibit a high degree of fluorescence and the fluorescence from the first probe's dye will be absent. If the DNA sample is heterozygous for both alleles, then both probes should fluoresce equally. A commercial implementation of this method is APPLIED BIOSYSTEMS' TAQMAN platform, which employs APPLIED BIOSYSTEMS' PRISM 7700 and 7900HT SEQUENCE DETECTION SYSTEMS to record the fluorescence of each sample's PCR product.
A typical implementation generates amplification products from a set of a large number of samples at a time, and measures a pair of fluorescence values, one for each dye, from each amplified sample. To classify the samples, it is useful to first plot the fluorescence values of the entire set on a two dimensional graph, and observe that the plotted points tend to cluster into separate groups according to genotype, as illustrated in FIG. 1 . In this figure, a human observer can readily discern that the data falls into four groups. The first group, in the lower-left hand corner, represents samples that had no amplification or were a no template control (“NTC”) reaction. The second group, in the lower right hand corner, represents those samples homozygous for Allele 2. The third group, at the top, represents those samples homozygous for Allele 1. Finally, the fourth group, located between the second and third groups, represents the heterozygous samples. This classification is illustrated further in FIG. 2 . Although it is relatively easy for human observer to analyze this type of data, it is necessary to develop a fast, reliable, and unsupervised method of computational analysis to produce the level of throughput necessary to analyze the large amounts of genotypic data generated.
Previous methods of computational analysis have employed a family of in algorithms known as clustering algorithms. A typical clustering algorithm receives raw unstructured data and processes it to form groups of data elements that are similar to each other. Clustering algorithms are well known in the field of computer science, and are typically applied in data mining applications. In a data mining application, clustering is used to identify relationships in data collections not readily observable to an expert user due to the volume of information.
A typical clustering algorithm examines the distance between data elements to find a common centroid. The centroid is mean of the value of the data elements belonging to a cluster. Clusters are selected by the algorithm to minimize the distance between the elements contained within it relative to the elements contained in other clusters. Clustering algorithms belong to the greater class of unsupervised machine learning algorithms. Other supervised machine learning algorithms, including decision trees and neural networks, were considered for application to analyzing output from a fluorometric genotyping device. However, all machine learning algorithms considered were determined to be insufficient to analyze this type of data accurately. A thorough review of initial collection of 80 human reviewed outputs revealed characteristics of the data that would not allow standard machine learning algorithms to work with a high degree of accuracy.
It is an object of this invention to provide a fast, accurate, and unsupervised method of classifying genotypic samples based on fluorometric data generated from them.
SUMMARY OF THE INVENTION
In one aspect, the invention relates to a method for categorizing the members of a dataset into discrete categories. In this aspect the dataset has a plurality of datapoints, and each datapoint has at least two numerical values associated with it. In this aspect, the method has the following steps: Assign each datapoint an angular value based on that datapoint's numerical values; sort the dataset by angular value; calculate the differences between adjacent angular values in the sorted dataset; determining category-dividing values by identifying differences that are larger than a predetermined threshold; and classifying datapoints according to their angular values relative to the category-dividing values.
In a further aspect, each datapoint has exactly two numerical values, and the angular value is an arctangent of the datapoint's numerical values. In a further aspect the numerical values are normalized before the angular values are calculated.
In a further aspect, the numerical values represent fluorometric data, wherein the different numerical values for each datapoint represent the fluorescence of a different dye.
In a further aspect, the method identifies exactly two category-dividing values and three categories. In a further aspect, these three categories represent homozygosity for a first allele, homozygosity for a second allele, and heterozygosity for both alleles.
In a further aspect the fluorometric data is measured from the product of an amplification reaction, and the method includes a step for removing datapoints that represent either a control reaction or a failure to amplify. In this aspect, the datapoints whose Euclidean distance falls beneath a predetermined threshold are removed from any further classification.
In a further aspect, the results of the classification are examined to determine whether to bring them to the attention of a human user. In this aspect, the results are examined for conditions that indicate that the classification was unsuccessful. Such conditions include excess classification in one category; classification into more than three categories, absence or near absence of any classification in one or more categories, unclassified datapoints, inadequate separation from control or nonamplification reactions, clusters having angular values that are either too high or too low, clusters whose ranges of angular values are too wide, classification that is not compatible with a Hardy-Weinberg equilibrium, and control or nonamplification reactions that are too far from the origin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 provides a two dimensional scatterplot of fluorometric data.
FIG. 2 provides a two dimensional scatter plot of fluorometric data classified by allele.
FIG. 3 provides a two dimensional scatterplot of raw fluorometric data
FIG. 4 provides a two dimensional scatterplot of normalized fluorometric data.
FIG. 5 provides a two dimensional scatterplot of normalized fluorometric data classified by allele.
FIG. 6 provides a two dimensional scatterplot of normalized fluorometric data classified by allele, and undetermined datapoints identified.
FIG. 7 provides a bargraph of the differences in arctangent values between adjacent datapoints sorted by arctangent.
DETAILED DESCRIPTION OF INVENTION
Although the methods of the current invention can be used to classify any kind of bivariate or multivariate data, they are particularly useful for classifying genotypic data, especially allelic data generated by fluorescence.
In one embodiment, the fluorometric genotyping device generates for each sample a unique sample identifier, a value from one of the sample's fluorometric probes, and a value from the sample's other fluorometric probe. The paired fluorescence values can then be plotted as x and y values on a two-dimensional grid. Ideally, the data generated in this fashion should yield heterozygous datapoints in the upper-right quadrant, and homozygous datapoints for each allele in the upper-left and lower-right quadrants, respectively. If that were the case, then allele calling would be a simple matter of dividing the grid by quadrants. However, fluorometric genotypic has been observed to exhibit several characteristics and idiosyncrasies that must be addressed in order for an automated allele caller to function accurately, and have not been adequately addressed by previous methods of clustering and machine learning.
Traditional machine learning algorithms such as decision trees and neural networks generate solutions by training on a given collection of data where the outcome is known and then applying the trained system to predict data in unknown outcomes. Training these algorithms with fluorometric data produces a solution where a set of X and Y boundaries are defined that had the highest probability of being correct. However, the predictions of results that deviate from the trained form would have poor accuracy. Because fluorometric data tends to vary from instance to instance, a trained system is too rigid to be sufficiently accurate to operate unsupervised on a large number of samples.
Another imperfection of fluorometric data is that outputs from fluorometric genotyping devices can validly produce one to three clusters, in addition to clusters formed by samples that had no amplification or no template control reactions (“NTCs”). In general, fluorometric genotyping devices are expected to produce three clusters, but can validly produce only one or two. For example, if three clusters are expected but only two valid clusters are produced, then the datapoints could be invalidly categorized into three clusters. Clustering algorithms are generally given a fixed number of expected and any, deviation from the expected number of clusters greatly reduces their effectiveness.
Another imperfection of fluorometric data is that datapoints belonging to the same category can be spread out spatially. A widely-spread cluster is usually observed for the category of heterozygous genotypes, where both fluorometric probes are active. A widely-spread cluster greatly reduces the effectiveness of clustering algorithms, especially when the distance between the furthest datapoints of a cluster and its centroid is greater than their distance to other clusters. Furthermore, as noted above, the number of valid clusters produced by fluorometric data can vary from the expected three to one or two. For example if two valid clusters are produced and one of them is widely-spread, it is likely that a clustering algorithm will incorrectly divide that one valid cluster into two invalid clusters.
In one embodiment, the dataset has a plurality of datapoints, and each datapoint has two numerical values associated with it. In an alternate embodiment, each datapoint has more than two numerical values associated with it. In a further embodiment, the numerical values represent quantitative empirical data. In yet a further embodiment, the quantitative empirical data is measured fluorescence. In a further embodiment, the numerical values are normalized before being used in any subsequent calculations.
In this embodiment, an angular value is calculated for each datapoint in the dataset based upon the datapoint's numerical values. In a further embodiment, the angular value is an arctangent of the numerical values. The dataset is then sorted by to angular value. A difference value is then calculated for each datapoint by subtracting the angular value of the previous datapoint from that of the current datapoint. The difference value of the first datapoint is that point's angular value.
If the difference value is large enough to exceed a predetermined threshold, a new category-dividing value is designated between the two angle values from which that difference value was calculated. In one embodiment, the category-dividing value is the average of the two angle values from which the above-threshold difference value was calculated. FIG. 7 illustrates the difference values for an example dataset. In this example, the samples are lined along the X-axis according to the rank of their angular value, and each sample's difference value is plotted on the Y-axis. As illustrated in FIG. 7 , the results indicate the presence of two difference values which stand out dramatically from the rest of the data. Two dividing values are designated, one between sorted samples 131 and 132 and the other between sorted samples 222 and 223 , each at a angle value between the two angle values which generated the above-threshold difference value.
As their name suggests, the category-dividing values are subsequently used to separate datapoints into categories. In this example, sorted datapoints 1 - 131 are classified as homozygous for a first allele, sorted datapoints 132 - 222 are classified as heterozygous, and samples 223 - 239 are classified as homozygous for a second allele.
The data contained in the example illustrated in FIG. 7 and described above are relatively clean and well-adapted to machine analysis. In one embodiment, the data are examined for conditions which indicate that the data are less well-formed and may not yield correct results when subjected to unsupervised machine analysis. In a further embodiment, if such conditions are detected, the method adapts its analysis to the idiosyncrasies of the dataset in order to yield a more accurate analysis. In yet a further embodiment, if such conditions are detected the dataset is flagged to indicate that it should be examined by a human reviewer.
In one embodiment, the data are examined to determine if control samples are present in the dataset. In a further embodiment, identified control samples are removed from the dataset before any further classification is performed.
In one embodiment, the range between the maximum and minimum observed values for each fluorophore-labeled nucleotide probe is calculated. If the range falls below a predetermined threshold, it is determined that the results are only valid for the other probe. Those samples producing data with the valid probe are then distinguished from samples that had no amplification or were NTCs. In one embodiment, all datapoints within a predetermined distance from the minimum observed values of the dataset are determined to be NTCs and the remaining datapoints are classified as belonging to the observed probe.
If, on the other hand, the range between maximum and minimum observed values for each fluorophore-labeled nucleotide probe exceeds the predetermined threshold, it is determined that multiple clusters are probably present, and the following steps are taken: All of the numerical values are normalized. In a further embodiment, all of the numerical values are normalized on a scale ranging from 0.0 to 1.0. Then the Euclidean distance between minimum values and each sample is computed. Samples are predicted as NTC or non-amplification and removed from further consideration if their distance to minimum values fall below a predetermined distance threshold.
The average distance of all remaining datapoints is then computed and used to calculate a threshold. All remaining datapoints that fall below this threshold are predicted as undetermined and removed from further classification.
Once the above-described screening steps are performed, the method of this embodiment proceeds similarly to that of the previous example: Angular values are calculated for each datapoint; the dataset is sorted by angular value; difference values are calculated; category-dividing values are identified; and each datapoint is categorized according to its angular value.
In one embodiment, the classification results are then examined with a series of evaluations to determine if there are any characteristics to bring to the attention of a human reviewer. Examples of such conditions include excess classification in one category, classification into more than three categories, absence or near absence of any classification in one or more categories, unclassified datapoints, inadequate separation from control or nonamplification reactions, clusters having angular values that are either too high or too low, clusters whose ranges of angular values are too wide, classification that is not compatible with a Hardy-Weinberg equilibrium, and control or nonamplification reactions that are too far from the origin.
If the samples were identified as all homozygous, it not considered an error of the clustering algorithm, but needs to be noted to the investigator that the assay is not variable.
If only ene cluster was identified and it could not be determined to be all homozygous then the dataset is flagged to indicate that human review is recommended.
If more than three clusters were identified then the dataset is flagged so that a human user can review the calls.
If more than a preset number of datapoints are predicted as undetermined then the dataset is flagged indicating that human review is desired. In a further embodiment, this preset number is 4.
If the samples from a probe are not separated from the node template controls by a threshold distance determined by the probe technology used then the dataset is flagged to indicate that the probe is producing a weak signal.
If the heterozygosity of the predicted calls is greater than a given heterozygosity threshold then the dataset is flagged so that a human user can review the predicted results. Heterozygosity is the predicted number of heterozygous sample divided by the number of heterozygous and homozygous samples.
If the homozygous cluster for a first allele is below an arctangent of 1.0 then the dataset is flagged indicating that the cluster is in too low of a position and should be human reviewed.
If the homozygous cluster for a second allele is above an arctangent of 0.67 then the database is flagged indicating that the cluster is in too high of a position and should be human reviewed.
If the heterozygous cluster is above an arctangent of 1.35 then the database is flagged indicating that the cluster is in too high of a position and should be human reviewed. Similarly, if the heterozygous cluster is below an arctangent of 0.18 then the database is flagged indicating that the cluster is in too low of a position and should be human reviewed.
If there are three clusters and the cluster with the smallest number of samples, also known as the minor allele cluster, is greater then the heterozygous cluster then these results do not agree with population genetics Hardy-Weinberg principle and the database is flagged so that a human will review the results.
If any cluster is wider then 0.6 the start of the cluster's arctangent to its end then the cluster is unusually wide and the dataset is flagged to have the results human reviewed.
If the center of the predicted node template control cluster is greater then 0.3 on a probe axis in a 0.0 to 1.0 normalized coordinate system, this indicates a problem with the probe and the dataset is flagged so the results are human reviewed.
Equivalents
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative, rather than limiting, of the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all variants which fall within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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The present invention provides methods and systems for an automated method of identifying allele values from data files derived from processed fluorophore emissions detected during the observation of fluorophore labeled nucleotide probes used in analyzing polymorphic DNA are provided. These methods are used in the rapid and efficient distinguishing of targeted polymorphic DNA sites without control samples.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with United States government support awarded by the following agencies: NSF 0238633.
The United States has certain rights in this invention.
CROSS-REFERENCE TO RELATED APPLICATIONS
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BACKGROUND OF THE INVENTION
The present invention relates to instruments for the study of combustion gases and in particular to an improved sensor system for providing high-speed optical measurements of combustion gas temperature, water mole fraction and the like.
Knowledge about combustion, including combustion temperature and combustion gas composition, can be important in the study and control of internal combustion engines. For this purpose of measuring combustion gas temperature, it is generally known to use an optical pyrometer observing light emitted from the combustion gases and/or materials contacting combustion gases. For example, U.S. Pat. No. 6,370,486 describes a sensor that measures infrared energy emitted at several preselected wavelengths from hot gas to calculate gas temperature.
A more sophisticated system is described in U.S. Pat. No. 6,640,199, which analyzes the emission spectrum of the combustion gases to deduce temperature and relative concentration of some chemical species making up the combustion gas.
SUMMARY OF THE INVENTION
The present invention provides a measurement of combustion gas temperature and species concentration using absorption spectroscopy techniques. In contrast to the measurement of emission spectra, such absorption spectroscopy requires the introduction of a known light signal into the combustion space and the extraction of sufficient energy at multiple light frequencies to perform the spectroscopic measurement. The present invention meets these requirements while using a light guide that may be as small as a fiber optic, by employing a sensing systems that eliminates the standard optical slit required of, for example, grating spectrometers. The elimination of the optical slit or similar aperture reducing structure improves the use of light energy and allows high-resolution spectrographs to be created at an extremely high rate.
Specifically, the present invention provides a high-speed spectrographic sensor for internal combustion engines having a plug receivable into a combustion chamber of an operating internal combustion engine and a light source providing light at multiple frequencies between 2000 and 3000 nm. A light guide, for example one or more optical fibers held by the plug, receives the light source to communicate the light into the combustion chamber for interaction with combustion gases. The light guide also communicates the light out of the combustion chamber for sensing. A sensor system distinguishes the strength of the light after interaction with the combustion gases at no less than twenty multiple frequencies and at a rate of no less than 1000 times per second.
Thus it is an aspect of at least one embodiment of the invention to provide real-time multi-spectral absorption measurements of combustion gases.
The sensor system may be a spatial heterodyne spectroscope receiving the light from the light guide after the light has passed through the combustion chamber.
Thus it is another aspect of at least one embodiment of the invention to provide for a spectrographic decomposition that avoids the energy loss incident to a standard slit or similar-type spectrometer. The spatial heterodyne spectroscope may operate with an input aperture that is as much as two orders of magnitude larger than a slit spectroscope.
The sensor system may further include a computer deducing and outputting temperature within the combustion chamber from the strengths of the multiple frequencies.
It is thus another aspect of at least one embodiment of the invention to provide for automatic temperature measurements of combustion gases.
The computer may deduce and output water concentration within the combustion chamber from the strengths of the multiple frequencies.
It is thus another aspect of at least one embodiment of the invention to provide for automatic measurements of water mole fractions.
The computer may deduce a physical parameter of combustion gases by matching the strengths of the multiple frequencies to corresponding multiple frequencies of signatures representing known different physical parameters within the combustion chamber.
It is thus another aspect of at least one embodiment of the invention to allow complex analysis of absorption spectra on an automatic basis.
The light source may provide frequencies substantially within a range of 2400-2600 nm.
It is thus another aspect of at least one embodiment of the invention to provide for absorption measurements in a novel frequency band for combustion gases.
The sensor system may distinguish the strength of no less than 100 multiple frequencies.
It is thus another aspect of at least one embodiment of the invention to provide for the measurement of high-resolution absorption spectra of combustion gases.
The sensor system may distinguish the strength of the multiple frequencies at no less than 10,000 times a second.
It is thus another aspect of at least one embodiment of the invention to provide for measurements that accurately capture the real-time dynamic process of combustion.
In an alternative embodiment, the sensor system may include a Fourier spectroscope positioned between the light source and the combustion chamber on the light guide. The Fourier spectroscope may measure and time-modulate the multiple frequencies passing into the combustion chamber. A demodulating intensity detector may be positioned on the light guide after the combustion chamber providing a time signal measuring a combination of the multiple frequencies and demodulating the time signal to distinguish the strength of the multiple frequencies.
It is thus another aspect of at least one embodiment of the invention to provide for a system that easily compensates for variation in the spectra of the exciting light signal.
The Fourier spectroscope may employ a photoelastic modulator to vary its effective optical length.
It is thus another aspect of at least one embodiment of the invention to provide a novel high speed Fourier spectroscope that can provide sufficiently fast measurements for combustion gas analysis.
The plug may be a spark plug providing a spark for the internal combustion engine.
It is thus another aspect of at least one embodiment of the invention to provide for measurement in the vicinity of the spark in operating the internal combustion engine.
These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a modified spark plug holding a light guide for receiving light to interact with combustion gases and transmitting the light back to a spectroscope for high-speed analysis;
FIG. 2 is a block diagram of a spatial heterodyne spectrometer suitable for use as the spectroscope of FIG. 1 ;
FIG. 3 is a diagram of the process steps of converting an image from the spatial heterodyne spectrometer into a spectrum and in performing signature matching;
FIG. 4 is a block diagram of the alternative embodiment of the invention using the spark plug of FIG. 1 but employing a Fourier spectrometer upstream from the spark plug; and
FIG. 5 is a figure similar to that of FIG. 3 showing those steps of signal analysis in the embodiment of FIG. 4 that differ from the embodiment of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , a high-speed spectrographic sensor 10 of the present invention provides for a modified spark plug 12 that may be fit to a combustion chamber 18 . In the manner of conventional spark plugs, the spark plug 12 may provide a conductive threaded flange 14 fitting within a corresponding threaded bore in the wall 16 of the combustion chamber 18 , providing a seal therewith.
The spark plug 12 provides a center electrode 20 coaxially within a ceramic insulator 22 and passing from outside of the chamber 18 where it is accessible at a high-voltage terminal 24 to inside the chamber 18 where it extends out of the insulator 22 as an electrode tip 26 . A ground electrode 28 extends from the flange 14 into the combustion chamber 18 to a point opposite the electrode tip 26 across a spark gap 27 in a manner known in the art.
The insulator 22 or threaded flange 14 also holds a light guide 30 passing through the insulator 22 or threaded flange 14 from outside the combustion chamber 18 to a point within the combustion chamber 18 near the spark gap 27 . The light guide 30 may be, in a preferred embodiment, two adjacent optical fibers 32 and 34 , one for carrying light into the combustion chamber 18 and one for carrying light out of the combustion chamber 18 for sensing.
The fiber 32 carrying the light into the combustion chamber 18 may receive light from a broad spectrum light source, such as an incandescent bulb in the form of a quartz tungsten-halogen lamp, or a wideband LED or broadband laser, providing substantial energy in the range of 2000 nm to 3000 nm and preferably in a range of 2400 nm to 2600 nm and having a known spectrum.
A mirror 36 is positioned across a gap 37 from the point where the light guide 30 terminates in the combustion chamber 18 . The mirror 36 is positioned so that light passing through optical fiber 32 exits the light guide 30 and passes across the gap 37 to strike the mirror 36 , to be reflected back across the gap 37 and be received by fiber 34 . The optical path through the gap 37 may be as great as 10 mm to allow the light to interact with combustion gases in the region of the electrode tip 26 .
Light received from optical fiber 34 , after interacting with the combustion gases, passes through a filter 40 , for example, a band limiting filter of the desired frequency range (e.g. 2400-2600 nm). The filtered light is then received by a spectrometer 42 which in the preferred embodiment is a spatial heterodyne spectrometer.
The spectrometer 42 provides a digitized output 44 received by a computer 46 . The computer executes a program to display a high-resolution absorption spectrum 48 (based on known or measured spectrum of light source 38 ) extracted every 100 μs and no less than every 1000 μs and consisting of hundreds of resolved frequency points and no less then twenty resolved frequency points. The computer 46 , operating according to the stored program, may also identify a quantitative parameter value 49 , being for example a temperature of the combustion gases or a species mole fraction such as water concentration or other similar measurement, as will be described.
Referring now to FIG. 2 , the spatial heterodyne spectrometer 42 provides an open aperture and high-speed response made possible by its efficient use of minor energy obtained through fiber 34 . Spectrometers of this type are described in U.S. Pat. No. 5,059,027, issuing Oct. 22, 1991, assigned to the assignee of the present invention, and hereby incorporated by reference. Such a spectrometer receives a light signal 50 from the fiber 34 and collimates this light using an optical assembly 52 to provide for a beam 53 having generally an aligned wavefront 54 .
A dispersive optical system 56 tips the wavefronts 55 of each of multiple frequency component in the light signal 50 (only two shown) to an angle α dependent on the wavelength of that frequency component. The wavefront-modified beam 58 is then received by an imaging optical assembly 60 to project an image on a solid-state image detector 62 such as an extended InGaAs line scan camera commercially available from Xenics Leuven, Belgium. The signal from the solid-state image detector 62 may be digitized and sampled per block 63 to produce an image 64 at approximately 1000 times per second or as much as 10,000 times per second.
Referring now also to FIG. 3 , the image 64 from the solid-state image detector 62 will contain a series of bands of different intensities 66 caused by interference in the image produced by the constructive and destructive interference of the wavefronts 55 as tipped by dispersive optical system 56 . The information of this image 64 may be collapsed to a single dimension (x) to produce a spatially dependent signal 68 with improved signal-to-noise ratio that better utilizes all of light energy from the fiber 34 both improving the speed and the resolving power of the spectrum.
This signal 68 , when operated on by the Fourier transform 70 , as may be implemented in the computer 46 of FIG. 1 , produces a high-resolution spectrum 48 providing resolvable points for more than 100 different frequencies. The high-resolution spectrum 48 may be compared to spectrum 74 of a library 76 of different signature spectra 74 by a correlator 78 , where each signature spectra 74 is associated with a known physical parameter that is to be extracted. For example, the multiple spectra 74 may each represent measurements of combustion gases at a different temperature. Alternatively the multiple spectra 74 may each represent a measurement of a different water concentration or another species concentration.
The correlator 78 finds the best correlation between high-resolution spectrum 48 and each of spectra 74 to output a measured temperature or other quantitative parameter value 49 as shown in FIG. 1 , according to the parameter associated with the most highly correlated spectra 74 .
Referring now to FIG. 4 , in an alternative embodiment the light source 38 provides light to a filter 40 operating in a manner described above with respect to filter 40 in FIG. 1 . The filtered light is then provided to a Fourier spectrometer 71 . The Fourier spectrometer 71 operates in a manner similar to conventional Fourier spectrometers by separating the light beam into two paths one of which is changed in effective length to create interference between the light of the two paths. The interference effectively modulates by frequency each of the wavelengths of light from the light source 38 with that wavelength having highest frequency being modulated at the highest rate. A Fourier transform of this modulation reveals the spectrum of the light. Ideally the changing cavity length is a simple linear function, for example, following a triangle or sawtooth wave 75 .
The output of the Fourier spectrometer 71 is thus a modulated light beam which is sent to the fiber 32 and which may be sampled locally at a local sensor 73 to allow local characterization of the spectrum of the light before modification by combustion gases as will be described. The modulated light from the Fourier spectrometer 71 passes through the fiber 32 to the spark plug 12 , as described above with respect to FIGS. 1 and 2 , and is modified by combustion gases and received by fiber 34 ultimately to be provided to a sensor 72 . Sensor 72 is not frequency discriminating and thus may employ an open aperture to efficiently measure multi-spectral light intensity. A Fourier transform of the modulated intensity at sensor 72 yields a spectrum which when compared to the spectrum calculated from the sensor 73 provides an absorption spectrum.
Referring still to FIG. 4 , in order to provide the necessary speed and resolution for measuring combustion gases, the Fourier spectrometer 71 differs from those spectrometers of the prior art by eliminating a mechanically movable mirror or optical element that could not provide sufficiently responsive modulation. Instead the Fourier spectrometer 17 employs a non-mechanical cavity length control, for example, a photoelastic modulator 77 to provide for a sweeping of the cavity length at least 1000 times per second and as much as 10,000 times per second.
Referring to FIG. 5 , the sensor 73 used in conjunction with the high speed Fourier spectrometer 71 thus produces a time signal 80 that provides a high resolution spectrum of more than 100 points at a sampling rate as described above.
The system of the present invention may be employed while the internal combustion engine is operating to measure gas temperatures in the vicinity of the electrode at an extremely high rate and accuracy. For example, it is beleived that a temporal resolution of 100 μs (˜1 deg. crank angle) with a better than 4 cm −1 spectral resolution to provide a temperature resolution of ˜5 degrees C. or less than 0.1% to 1000K and 1% to 3000K.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
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A high-speed absorption spectrographic system employs a slit-less spectroscope to obtain high-resolution, high-speed spectrographic data of combustion gases in an internal combustion engine allowing precise measurement of gas parameters including temperature and species concentration.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present application relates to a carton for viewing the contents thereof without disturbing the integrity of the carton. More particularly, the present invention relates to a carton having a unitary body enclosed by a wall or walls having apertures for manipulating and viewing articles contained therein.
[0003] 2. State of the Art
[0004] The art is replete with references to cartons for the packaging, transportation and display of various articles of commerce including foodstuffs and beverages. U.S. Pat. No. 3,695,505 issued to D. G. Wolf on Oct. 3, 1972, describes a container for shipping asparagus, the container having windows spaced on its side walls for ventilation of the vegetables during transit. Similarly, U.S. Pat. No. 4,127,228 issued to R. A. Hall on Nov. 28, 1978, describes a carton primarily for the long distance shipping of asparagus, and also for displaying the foodstuff. The carton comprises two parts: the lower half, the box for packing the asparagus having vent holes for ventilating the carton, and the upper half, the cover for the box also having vent apertures for ventilating the food stuff. The carton has viewing apertures in the box and cover enabling a prospective buyer to inspect a portion of the asparagus contained in the box without disrupting the carton. U.S. Pat. No. 4,201,330 issued to E. F. Gilbert on May 6, 1980 also describes a shipping carton having container slots in the rear and front walls for ventilation and a slot on the cover, which is hinged to the container, for ventilation and partial viewing of the contents (not specified) of the container. U.S. Pat. No. 5,263,612 issued to T. L. Nederveld on Nov. 23, 1993 discloses a strong stackable container primarily for storing fresh produce such as asparagus spears, the container providing specific openings to partially view the asparagus spears within the container, as well as specific openings for ventilation and hydrocooling of the foodstuffs. U.S. Pat. No. 5,983,562 issued to W. C. Lai on Nov. 16, 1999, shows a multicomponent bean sprout culture carton having a water carrying plate, a transparent box with a plurality of vent and draining holes, a net plate, including a net sheet, and a transparent hood having a plurality of vent ports, the bean sprouts being only partially viewable from the sides and the top of the carton. U.S. Pat. No. 3,709,425 issued to W. C. Stapp on Jan. 9, 1973, describes a crush resistant shipping carton made of corrugated paper having end panels of paper faced wood veneer with apertures in the front and rear of the cartons, providing a partial view of the contents of the carton.
[0005] U.S. Pat. No. 4,214,660 issued to L. B. Hunt, Jr. on Jul. 29, 1980, discloses a carton for beverage cans having a matrix of inspection holes on the top and bottom of the carton for partially viewing the cans. U.S. Pat. No. 4,417,657 issued to D. T. Thibodeau on Nov. 29, 1983, describes an open top carton having chambers to hold beverage cans in the vertical position and a carrying strap across the open top. U.S. Pat. No. 5,398,869 issued to D. Dickson, et al., on Mar. 21, 1995, describes a display ready shipping carton formed of a corrugated material having an opening in the front panel and an extension of the opening into the top panel for viewing by the purchaser of the contents of the carton and being sufficiently large to remove the contents. U.S. Pat. No. 5,375,700 issued to M. Joss, et al., on Dec. 27, 1994, discloses a carton for displaying an item contained in the carton by means of a cut out window opening in the front panel of the carton to allow a customer to view the article without opening the container. U.S. Pat. No. 6,237,777 B1 issued to D. L. Bierly on May 29, 2001 shows a carton for displaying articles contained therein, the carton having cut outs for the partial visualization of the article, surrounded by a printer silhouette to simulate the article. U.S. Pat. No. 5,505,371 issued to J. S. O'Neill on Apr. 9, 1996, teaches a partitioned shipping and display carton having a cut out in the front wall for partially viewing the contents, generally household products. U.S. Pat. No. 3,631,970 issued to W. F. Trauschke on Jan. 4, 1972, describes a carton having a window on one of its sides containing an article having a label affixed thereto, the article label of the article being held in register with the windows by a rotation preventing insert.
[0006] U.S. Pat. No. 3,562,555 issued to R. Barbedienne on Feb. 16, 1971, depicts a carton for packing flexible tubes side by side having a base and side pieces with openings to visually inspect a portion of the tubes stacked on the base.
[0007] U.S. Pat. No. 5,462,220 issued to M. R. Bacchetti, et al. on Oct. 31, 1995, describes stackable shipping and display cartons having ventilation holes on the top panel, large holes in the front, rear and side panels, stacking holes in the bottom panel overlaid with a moisture pad. The contents of the carton, fresh produce, such as asparagus may be watered through the top holes and drained through the various drain holes and partially viewed through the holes.
[0008] U.S. Pat. No. 4,927,008 issued to R. G. Platt on May 22, 1990, depicts paperboard cartons for holding a cylindrical article having cut-out windows in the front, back and side walls, the cut-out windows having v-shaped bottom dimensions to partially view articles.
[0009] U.S. Pat. No. 3,204,759 issued to C. E. Palmer on Sep. 7, 1965 describes a carton for the packaging of a non-rotatable container having a window in the front panel extending to the side panels for the partial viewing of the label on the container.
SUMMARY OF THE INVENTION
[0010] As discussed in the section “State of the Art,” numerous cartons are described in the art for the packaging, shipping, inspecting and displaying of various articles of commerce such as foodstuffs, beverage containers, household products and utensils. Many of the cartons are designed to prevent damage to the contents, water and ventilate the foodstuffs contained in the carton during storage and transportation, inspecting the contents of the carton during shipping and displaying the contents at the point of final destination. None of the cartons are designed, however, to allow a person to view entirely an article contained in the carton, for example, the label attached to and completely surrounding an article, for example, a bottle, vial or the top and bottom of a blister pack or a blister, without comprising the integrity of the carton.
[0011] The present invention relates to a carton for the packaging, shipping, storage, inspecting and viewing of the contents of the carton at its destination, without disrupting the integrity of the carton, particularly for viewing an article in its entirety, for example, the labeling of the container for a medicinal for clinical evaluation in the carton. The total viewing of an article in the carton is accomplished by, if necessary, manipulating the article through an aperture, for example by rotating the vial or bottle contained in the carton to expose the whole label, or by flipping a blister pack or blister to expose the label on the front or back of the blister pack or blister, and viewing the article through an aperture, if necessary. The aperture through which the article is manipulated must be sufficiently large to accommodate an instrument such as a finger to rotate the bottle or vial, or flip the blister pack or blister, and view the article, and small enough to prevent the item from escaping. Any instrument small enough to be inserted through the aperture and long enough to be able to rotate or flip the contents of the carton may be used to manipulate the items. A pointer, stylus, needle, rod, or a finger, preferably, the index finger or the index finger and thumb of the human hand would suffice for the intended purpose of flipping or rotating the article within the container. The apertures may be any shape that would permit the insertion of the instrument into the carton to manipulate the articles so that the entire surface labeling of the article may be viewed. Circular, square, triangular or rectangular apertures would be suitable for inserting the instrument; a rectangular aperture would be particularly suitable for the thumb and index finger as the instrument for manipulating the articles of the carton.
[0012] The apertures may be arranged on any or all of the walls of the carton in various shapes and configurations, and combinations thereof. The apertures may be positioned symmetrically, staggered, randomly and independently on each wall. An arrangement where all of the walls of the carton have circular apertures positioned symmetrically on all walls of the carton except the end walls, the end walls having rectangular apertures, for manipulating and viewing of the articles in the box is preferred. The end side rectangular apertures provide a convenient means for manipulating the articles as preferred in the carton for complete viewing of the labeling attached to the surfaces thereof.
[0013] The carton may be fabricated from any rigid or flexible, transparent, translucent or opaque material commonly used for the construction of packaging and shipping containers. Wood, paper, including corrugated cardboard and plastic may be used. Corrugated cardboard and plastics such as polyvinyl chloride are particularly useful for constructing the carton. When transparent corrugated cardboard is used for constructing the carton, the apertures are used for both manipulating and viewing the contents of the carton. Similarly, when a translucent material such as ______ is used, the apertures are used for both manipulating and viewing labels of the bottles, vials and blister packs and blisters contained in the carton. The apertures suitably arranged on the walls of the carton may be employed to manipulate the contents of the carton, when a transparent plastic, for example, polystyrene, polyvinyl chloride, or poly(ethylene teraphthalate) is employed. The article within the container may also be viewed through the container when it is constructed from a transparent plastic. Typically, a carton for manipulating and viewing entirely the labels of bottles, vials, blisters, and blister packs containing medicaments for clinical evaluations is rectangular, having circular or symmetrically circular apertures in plural rows on four walls of the carton and rectangular slots (apertures) on two opposing walls, the carton being made of a flexible plastic such as poly(ethylene teraphthalate).
[0014] In accordance with the present invention related to a carton having provisions for manipulating and viewing the articles contained in the carton, without disturbing the integrity of the carton, and accessing the contents of the carton, a blank is provided to construct the carton. The blank is cut and scored to define the walls and tabs of the carton, having suitably arranged apertures, and a means of accessing the carton. The carton typically has top, bottom, back, front and end walls and is constructed from a flexible material. The construction of the carton generally involves folding a bottom panel along a scored line over the end panels resting the bottom panel on the tabs of the end panels, and securing the end panels, preferably by an adhesive. The carton is secured by tucking the fold over the flap of a bottom panel in back of the panel and installing a tamper evident seal.
[0015] While the carton may be fabricated from a plastic material, preferably a flexible plastic material such as, for example, a polyethylene, a polypropylene, a polyvinyl chloride, or a poly(ethylene terapthalate), it may be made from a fiber such as paper, for example, corrugated paper board, or wood, or a metal such as a sheet metal. In keeping with the present invention, the carton may be geometrical in shape such as spherical, cylindrical, cubic or rectangular; the apertures may be circular, square, triangular or rectangular. For packaging and shipping, a cubic or rectangular carton is preferred; for viewing an article, a transparent, flexible carton having round or rectangular apertures is also preferred.
DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a plan view of the blank from which the carton is constructed.
[0017] [0017]FIG. 2 is a perspective view of the carton constructed from the blank of FIG. 1 with the hinged access cover in the open position.
[0018] [0018]FIG. 3 is a perspective view of the carton constructed from a blank FIG. 1 with the hinged access cover in the closed position.
[0019] [0019]FIG. 4 is a perspective view of the carton constructed from the blank of FIG. 3 having a row of vials containing medicaments (not shown) for dispensing in clinical trials.
[0020] [0020]FIG. 5 is a perspective view of the carton constructed from the blank of FIG. 1 having a stack of blister packs containing medicaments for dispensing in clinical trials.
DETAILED DESCRIPTION
[0021] In accordance with the practice of the present invention, a carton illustrated in FIGS. 2 - 5 , generally designated by the reference numeral 10 is constructed from a flexible plastic material by utilizing the carton blank 11 shown in FIG. 1.
[0022] The carton blank 11 includes symmetrically situated a front panel 12 , a rear panel 13 , end panels 14 and 15 , top panel 16 and bottom panel 17 , each panel separated from the other by fold lines 18 , 19 , 20 , 21 and 22 . The panels 12 , 13 , 14 , 15 and 16 contain apertures 23 , 24 , 25 and 26 for manipulating and viewing the contents of the carton. The end panels 14 and 15 include support flaps 27 , 28 , 29 and 30 foldably attached to the top edge 31 and bottom edge 32 of the end panel 14 by fold lines 33 and 34 and to the top edge 35 and bottom edge 36 of end panel 15 by fold lines 37 and 38 . The rear panel 13 includes joining flap 39 foldably attached to the outer edge 40 of the rear panel 13 through fold line 41 . The top panel 16 and the bottom panel 17 incorporate closure flaps 42 and 43 foldably attached to the outer edges 44 and 45 of top wall 16 and bottom wall 17 by fold lines 46 and 47 , respectively. While the panels of the carton blank 11 are shown to be rectangular providing a rectangular carton by constructing the preferred embodiments of the present invention, carton blank 11 having related shapes providing cartons having related configurations are embraced by the instant invention.
[0023] The carton blank 11 of FIG. 1 is folded and assembled into carton 10 , shown in FIG. 2. The various panels and flaps of the blank 11 are arranged as walls and flaps of carton 10 , as follows: The rear panel 13 is folded upwardly and inwardly along fold line 21 of end panel 15 until it is perpendicularly aligned with inner edge 48 of end panel 14 to form wall 14 . Top panel 17 attached to the upper edge 14 of rear panel 13 along fold line 22 is then folded upwardly and inwardly and positioned on support panels 27 and 28 of end panel 14 to form wall 17 . Closure flap 39 attached to rear panel 13 along fold line 41 of edge 40 of rear panel 13 is now folded downwardly and inwardly along fold line 41 to complete wall 13 . Front panel 12 attached to end panel 14 along fold line 18 of edge 49 is then upwardly and inwardly folded along fold line 18 at the edge 49 until front panel 12 is perpendicularly aligned with end panel 14 to form front wall 12 . End panel 14 attached to front panel 12 is folded downwardly and inwardly along fold line 18 of edge 49 of front panel 12 until end panel 14 is perpendicularly aligned with edge 50 of front panel 12 and the inner surface 51 of end panel 14 is juxtaposed with the outer surface of the closure flap 39 of rear panel 13 to form end wall 14 and adhesively secured to joiner flap 39 to form wall 14 . The closure flap 43 attached to the outer edge 47 of bottom panel 17 is folded upwardly along fold line 47 . The bottom panel 16 is then folded upwardly and inwardly until it is perpendicularly aligned with front panel 12 and juxtaposed on support flaps 29 and 30 of end panel 15 and tucked into rear panel 13 to form cover 16 of carton 10 . Similarly, closure flap 42 attached to outer edge 44 of top panel 16 is folded downwardly along fold line 36 . Top panel 16 is then folded downwardly and inwardly until it is perpendicularly aligned with front panel 12 and juxtaposed with support flap 29 of end panel 15 and tucked inside of front panel 12 to form top cover 16 . The top and bottom covers 16 and 17 respectively, are secured to front and rear walls by a tamper evident lock (not shown).
[0024] The carton 10 may be assembled by simultaneously folding the opposing panels and flaps and tabs securing the end panels to the rear panel.
[0025] [0025]FIG. 2 shows carton 10 with the top cover 16 in the open position to accept and remove articles such as bottles 51 (FIG. 4), vials (not shown), blister packs 52 (FIG. 5) and blisters (not shown). Each of the containers, the bottles, vials, blister packs and blisters, which typically contain medicaments generally to be dispensed to patients in clinical investigations, are surrounded by labels 53 (FIGS. 4 and 5) as required by law. When the carton 10 is fully packed with the containers, at least part of the label 53 is restricted from view.
[0026] [0026]FIG. 3 shows carton 10 with top cover 16 in the closed position secured to front wall 12 by, for example, a tamper evident lock (not shown). The bottom panel 17 , which is hingedly attached to the edge 48 of rear wall 13 of blank 11 (FIG. 1), may be opened to gain access to the bottom panel 17 of carton 10 to remove the containers.
[0027] [0027]FIG. 4 shows carton 10 containing bottles 51 with the top cover 16 in the open position to remove the bottles contained in the carton after viewing the entire label attached to the bottle with the top cover 16 in the closed position. To view the entire label 53 bound to the bottle, the bottle is rotated until the entire label 53 is exposed to the viewer 54 . Rotation of the bottle within carton 10 is accomplished by inserting the index fingers into the carton through suitably placed apertures in the walls of the carton 10 and turning the bottle manually around its vertical axis through 360° or until the entire label is exposed to the viewer 54 . In the event the carton 10 is constructed from a transparent material, the viewer 54 will be able to see the entire label 53 through the walls of the carton 10 . The viewer 54 may also view the entire label 53 through the appropriate aperture 23 , 24 , 25 or 26 . When the carton 10 is constructed from a translucent or transparent material, the viewer 54 would by necessity view the entire label through the appropriate apertures 23 , 24 , 25 or 26 .
[0028] The bottles 51 of carton 10 may be rotated to expose the entire label 53 to the viewer 54 by suitable mechanical means through the appropriate apertures 23 , 24 , 25 or 26 .
[0029] Vials, not shown, in carton 10 may be rotated to expose the label attached to the vial, and the label viewed in its entirety by rotation and viewing as in the case of the bottles, above.
[0030] Labels 55 attached to the top 56 and bottom 57 of the blister pack 52 as shown in FIG. 5 are exposed to the viewer 54 by flipping the blister pack over, that is, turning it 180° over the axis parallel to the bottom panel 16 . Initially the top of the blister pack is exposed to the viewer 54 ; the bottom is exposed to the viewer by flipping the blister pack through 180° within the carton 10 . As in the case of the bottles 51 illustrated and discussed above, the labels 53 on the top 56 and bottom 57 of the blister pack 52 is viewed through the walls of the carton 10 , when the carton 10 is made of a transparent material, or through the appropriate apertures 23 , 24 , 25 and 26 when the blister pack is made of a translucent or opaque material. The blister packs are generally turned over, this is, rotated or flipped 180° over the axis parallel to the top or bottom of the carton 10 , by the viewer 54 inserting his index fingers, and if necessary, the thumb, into the appropriate aperture, 23 , 24 , 25 or 26 , preferably the rectangular apertures 25 and 26 of the end panels 14 and 15 of the carton 10 , by placing the fingers below the blister pack and moving the fingers upwardly and outwardly, or inwardly to view, initially the top, and then the bottom of the blister pack's label 55 . Any device similar in shape and size, for example, a stylus, dowel, or rod may be used in place of the fingers.
[0031] A preferred embodiment has been illustrated and described. The invention, it is understood, should not be limited by the illustration or description, since various modifications of the invention may be made within the scope thereof.
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A carton for viewing the contents thereof without disturbing the integrity of the carton comprising a unitary body enclosed by a wall or walls having apertures for manipulating and viewing the articles contained therein.
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RELATED APPLICATIONS
[0001] The present application is a non-provisional of U.S. Provisional Patent Application No. 61/220,041, entitled “Method of Transmitting, Receiving, Recording, Playing and Displaying Weather Radio,” filed Jun. 24, 2009, the contents of which are incorporated herein by reference in their entirety for all purposes. This application is a continuation-in-part of U.S. patent application Ser. No. 12/466,521, filed May 15, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 12/057,761, entitled “Display Station,” filed on Mar. 28, 2008, which claims priority to U.S. Provisional Patent Application No. 60/982,137, entitled “Method of Transmitting, Receiving and Forwarding Data in a Low Power Network System,” to Allan McCormick and Rolf Haupt, filed on Oct. 23, 2007, U.S. Provisional Patent Application No. 60/982,096, entitled “Method of Transmitting, Receiving and Displaying/Playing Data such as Internet Radio Time, and Music on a Network System,” to Allan McCormick and Rolf Haupt, filed on Oct. 23, 2007, U.S. Provisional Patent Application No. 60/981,862, entitled “Method and Apparatus of Transmitting, Receiving, Displaying and Playing Weather Data,” to Allan McCormick and Rolf Haupt, filed on Oct. 23, 2007, and U.S. Provisional Patent Application No. 61/019,299, entitled “Method and Apparatus of Transmitting, Receiving, Displaying and Playing Weather Data,” to Rolf Haupt and Allan McCormick, filed on Jan. 7, 2008, all of which are herein incorporated by reference in their entirety.
FIELD OF INVENTION
[0002] The present disclosure is generally related to electronic systems such as wide area network based weather communication systems including weather radio.
BACKGROUND
[0003] Weather radios are used by consumers to scan radio frequencies, such as 162.400-162.550 MHz, which are dedicated for broadcasting weather and other alerts. These dedicated frequencies are not in a range that most conventional radios can receive, and thus a consumer must have a weather radio or other similar device to monitor these broadcasts. Organizations such as the National Oceanic and Atmospheric Administration (NOAA) broadcast such alerts to be received by these devices. Current weather radio devices, however, are required to be always on and always listened to in order to be useful. This has reduced the applicability of these devices for the average consumer. Further, the interface for weather radios have made them less than ideal platforms for communicating information. For example, the voice messages are often not particularly useful for those users who are not intimately familiar with the geographic region.
BRIEF SUMMARY
[0004] The current disclosure relates to a method and apparatus for receiving radio-broadcasted alerts and presenting them in a useful format for an end user.
[0005] In accordance with one or more aspects of the disclosure, a device may receive data through any number of receivers, including a receiver and a wide area network receiver, and record the message for later playback. For example, in certain aspects of the disclosure, a tone may be played for 10, 20, or 30 or more seconds preceding a weather alert. This tone may be utilized in order to enable weather radios with useful battery life to be built. Currently, the weather radios must be constantly on and constantly listened to in order to avoid missing an alert. The use of the tone allows battery operated weather radios to turn on once every 10 to 30 seconds and “listen” for the tone. If the tone is not present, the weather radio shuts off to conserve battery power. If the tone is present, the weather radio turns on and receives the weather alert.
[0006] In further embodiments of the disclosure, the weather alert is recorded and stored in the weather radio. In this manner, the user does not have to be continually listening to the weather radio. Once the message is recorded, a visual and/or audible indication is provided to the user that there is a weather alert message waiting. The visual and/or audible indication may be different for different weather alerts. For example, there may be a tornado icon (flashing or stable), a severe thunderstorm warning icon (flashing or stable), flood warning icon (flashing or stable), etc. Additionally, there may be a user input device coupled to the icons enabling the user to play the alert associated with the icon. In embodiments of the disclosure where such icons are utilized, they may be liquid crystal display (LCD) icons and/or icons printed on the device's casing with illuminations next to the icon.
[0007] In still further embodiments of the disclosure, the weather radio displays a map or satellite image of the user's current location along with various points of interest such as nearby cities. Overlaid on this map and/or satellite image are various storm path Polygons provided by the weather alerts. This allows the user to determine visually whether or not the user is in the storm path. For example, the user may input a zip code or longitude and latitude coordinates (or have it determined through a built-in GPS module) and then have the device indicate whether or not the user is in the storm path as well as a time to arrival of the storm. Furthermore, the device may be configured to allow a user to see visually whether or not the weather radio's location (or another selectable location) is in the storm path. The weather radio may also be configured to provide the user with directions (detour directions) to exit the storm path. The user may zoom in on the current location to see specifics as to time to arrival or zoom out of the current location zoom level to see a global picture of the storm path.
[0008] Additional embodiments of the disclosure include a user interface which displays the various weather alerts that are potentially available and allows the user to select and deselect individual alerts. Further, the user can enter one or multiple zip codes for which alerts may be available. Additionally, the weather alerts may be recorded for each of the zip codes and scrolled through so the user may see which alerts are associated with which zip codes. In addition, the user may be able to individually select the alerts that are associated with each zip code. For example, a user may not be interested in flooding where his main home is located in the mountains, but may be keenly interested in flooding for his beach house.
[0009] In still further aspects of the disclosure, a stable or moving icon may be used as illustrative of various details of interest. For example, where the user's location map is shown on the screen, one or more tornado icons may appear on the screen and may move across the screen depending on the storm's track. In these embodiments, the user's location is fixed and the storm's location is shown as moving relative to the user's location. Alternately, both the user's location and the storm's track or other icon may be shown as moving.
[0010] In additional embodiments of the disclosure, the device may include other co-located devices for, for example, measuring local weather conditions and sending and receiving weather data to locally connected devices. For example, the weather radio may reside in the user's main home and be “always on” and plugged in to wall power. Display devices may be located throughout the home that receive data from the main weather radio and are battery powered. These devices display weather alerts every few 10s of seconds or minutes. They wake up, determine if a weather alert has been recorded in the main weather radio, and if so, then provide the alert in a remote location. In this manner, the main weather radio may be located in a den in the house and the satellite display devices may be located throughout the home, garage, barn, boat, and office.
[0011] In additional embodiments of the disclosure, the device may also be configured to plug into a cradle. The cradle will keep the device always charged. In this manner, the user may simply take the device, for example, to a soccer game, swimming match, or boating outing. Thus, the alerts will be available at the external location when needed. The device may also be configured to include other desirable features and data such as a radio, alarm clock, indoor and outdoor temperature and min/max temperatures. In one embodiment, the device could be configured with a similar form factor to a PDA or so called “blackberry” like device.
[0012] In still further embodiments of the disclosure, once the device is removed from the cradle, it may be configured to turn on or off certain function such as the receipt of outdoor temperature and/or the feeding of data to remote weather display devices.
[0013] In still further embodiments of the disclosure, the user may choose the particular weather radio tower that is closer and the display can be configured to display the name/location of the tower selected.
[0014] In additional aspects of the disclosure, a weather radio tower is selected using a combination of a signal strength indicator (e.g., RSSI Radio Signal Strength Indicator) taken in combination with a measurement of the signal to noise ratio of the signal. In this way, a weaker but low noise signal may be selected over a very strong, but very high noise signal. Hence the user can be provided the optimal signal. In still further embodiments, two or more signal icons will be displayed with the user able to select between the icons. As an example, the device may receive seven different signals from different weather radio towers, and may be configured to display one or more different icons for each of the different signals. For instance, two icons might be displayed for each signal: a first signal strength indicator icon, and a second signal-to-noise ratio icon. In other examples, one icon may be displayed without the other, or a combination icon may be displayed that combines measurements of signal strength and signal-to-noise ratio in a single indicator.
[0015] In further embodiments of the disclosure, the user is provided with various predetermined profiles. In this way, the user programming of the Specific Area Messaging Encoding (SAME) profiles are simplified to allow a user to select which counties and watches the user is interested in viewing/hearing. The user can simply scroll through the default profiles such as a travel profile, a home profile, a boating profile, a freeze profile, a tornado profile, a vacation home profile, and a hurricane profile. The user can simply select the profile and everything will be set.
[0016] According to additional embodiments of the disclosure, the user interface of the weather radio may provide one or more systems to allow the user to search for and enter current locations for receiving alerts. As discussed above, the user may enter a zip code for a current location to subscribe to weather alerts applicable to that location. Additionally, the device may use location codes, such as Federal Information Process Standards (FIPS) codes for the US, or another set of location codes corresponding to another country. For example, the user interface of the weather radio may display a selectable list of states for the user. After the user selects a state from the list, the user interface may be updated to allow the user to select a county from the selected state, and thereafter to select a portion of the county. Based on this information, the weather radio accesses an internal storage mapping to identify the proper FIPS code (or other location code) corresponding to the location, so that the location code can be associated with the weather radio and/or one of the user profiles on the radio (e.g., home, work, current, travel, vacation, grandmother's house, friend's house, etc.). In other embodiments, the user interface may first present a list of countries, followed a list of states/provinces, followed by a list of cities, and so on. In other embodiments, rather than hierarchical menus, the weather radio may present a flat list of the location names (e.g., city/state combinations, county/state combinations, etc.) and allow the user to scroll through and select the desired location from the list. In certain other examples, after the user has selected the location name, the weather radio will present the FIPS code (or other location code), and await for a user entry and/or confirmation of that code. In other examples, the location code (e.g., FIPS code) may be hidden from the user and the user will only see the associated location name (e.g., country, state, province, city, county, and/or county part, etc.). The weather radio may also alert the user when a location code associated with the device (e.g., the current location code for a profile) has changed in a national FIPS database. Alternatively, the weather radio might not alert the user, but may automatically update the location code in the internal storage of the weather radio. In other embodiments, the weather radio may periodically access an external FIPS database (e.g., via the Internet) to confirm that the internal list of location codes is up to date, and if not, the weather radio may automatically download the updated FIPS location code list, and replace any outdated codes associated with user profiles on the weather radio. In still other embodiments, the location codes might not be stored internally at the weather radio device. For example, the weather radio may transmit a location name to an external location code provider (e.g., FIPS database) which may determine the FIPS code corresponding to the location name and transmit the FIPS code back to the weather radio. In other examples, the weather radio might only use location names and not location codes. It may receive weather alerts from a third party capable of translating location codes into location names for the weather radio.
[0017] These and other embodiments will become more apparent from the below drawings and detailed description of the disclosure provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A more complete understanding of the features described herein and the advantages thereof may be acquired by referring to the following description by way of example in view of the accompanying drawings, in which like reference numbers indicate like features, and wherein:
[0019] FIG. 1 shows an illustrative computer system in accordance with one or more aspects of the present invention; and
[0020] FIG. 2 shows an illustrative embodiment of a mobile receiver device in accordance with one or more aspects of the present invention.
[0021] FIG. 3 shows an illustrative embodiment of a receiver device in accordance with one or more aspects of the present invention.
[0022] FIG. 4 shows an illustrative embodiment of a watch device in accordance with one or more aspects of the present invention.
DETAILED DESCRIPTION
[0023] In the following description of the various embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration various embodiments in which the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope and spirit of the present disclosure.
[0024] Aspects of the disclosure provide a method and apparatus for receiving radio-broadcasted alerts and presenting them in a useful format for the end user.
[0025] Referring to FIG. 1 , a block diagram of illustrative electronics is depicted for a receiver 400 . The illustrative electronics include one or more computer units 401 (e.g., microprocessor/microcontroller), a power supply 417 (e.g., a battery and power regulator unit), a timer 415 (e.g., a watchdog timer), a network connection 414 (e.g., Ethernet and/or 802.11 a-g, n), a screen interface 402 (e.g., touch screen display), a motion detector, light controller, door/window sensor, infrared detector, and/or appliance control/sensor 403 , a user interface control 404 (e.g. a handset or keypad), various indicators, displays, and keypads 405 , voice recognition circuits 406 , still and/or video camera(s) 407 , data interface circuitry 408 (e.g., wired and/or wireless circuitry), signal processing circuits 412 (e.g., image processor), appliance control interface 416 (e.g., heat, window controls, bathroom heater, cooling, water heater, lighting, alarm clocks), speech processor 410 and associated audio device 409 (e.g., speakers and/or headset), various antenna transmitters and/or receivers 413 and associated receiver/transmitter (e.g., transceiver) and/or GPS circuitry 411 .
[0026] The receiver 400 may be implemented in a standalone configuration and/or coupled to one or more other receivers 400 . The receiver 400 may alternatively be configured as low cost display station with the minimum components for receiving and displaying information to a user. Example embodiments of the receiver include, but are not limited to, mobile or stationary weather station appliances, wall clocks or wrist watches, personal digital assistants (PDAs), mobile phones, and other mobile devices, radios, CD players, MP3 players, bedside alarms, and/or temperature display devices. Each of these example embodiments may be implemented with or without localized information, such as, for example, weather and/or traffic information.
[0027] In illustrative embodiments, the receiver 400 is configured as illustrative form factors 200 , 201 , and 202 as shown in FIGS. 2-4 . In these examples, receiver 400 includes an outer casing 331 , various user inputs (e.g. a keypad 1403 , volume buttons 325 , etc.), and a display screen 332 which may be a touch screen. The receiver may be continuously powered or may be turned on by depression of a power button 322 . The receiver may include a LED power indicator 324 and/or simply use the screen backlighting as the power indicator. The receiver 400 may be variously configured to include weather button 301 , Fahrenheit and Celsius selection buttons 319 and 320 , respectively, one or more emergency light(s) 333 and/or icons 323 to provide customized alerts, speaker button 313 , microphone button 314 , video button 315 , reset button (not shown), volume button 325 , keypad 1403 , GPS locating buttons 310 , alert selection buttons 308 , and/or other suitable user interface buttons. In addition, the device may have recording functions to record alerts either manually and/or automatically and include various associated user interface buttons including play 801 , pause 801 a, fast forward 802 , and rewind 803 . The receiver 400 may also include a map button 307 for displaying a satellite image on the device and a weather button 301 for overlaying storm alerts on the display. The receiver may have additional buttons and devices to accommodate additional features desirable in such a receiver including, but not limited to, an antenna 328 , traffic button 302 , call button 1401 , menu button 306 , end button 1402 , wi-fi button 326 , mp3 button 804 , radio button 1001 , FM/AM frequency selector buttons 303 and 304 respectively, and time and date buttons 1501 and 1502 , respectively. Additionally, the various embodiments may include a band 1503 to accommodate a wrist-worn embodiment of the receiver.
[0028] In further embodiments of the disclosure, various ports may be included to include additional modules and/or other communication and/or sensor devices. For example, a GPS module 411 may be included in the receiver 400 . The GPS receiver may be permanently and/or detachably mounted to the receiver 400 . Where the receiver 400 including the GPS module is a weather station, the device may automatically extract weather data based on the coordinates of the GPS system. These coordinates may come from the GPS module or may be inputed by the user manually. When the coordinates are derived from the GPS module, the weather station receiver 400 may translate the GPS coordinates to zip codes and/or zip plus four codes. In either event, the receiver 400 extracts the relevant weather related data based on the location.
[0029] In an additional aspect of the disclosure, the receiver 400 may be configured to enable the user to select various options such as selecting and/or choosing an alert in which to record and/or a particular weather radio tower that is closer in which to receive radio broadcasts from.
[0030] Additionally, if there were particular NOAA weather alerts detected in the vicinity of the location of a user's home, present location, or a one or more programmable locations, these alerts may trigger an alert on the screen 332 . This device may record the actual weather radio alert or used synthesized voice to generate an alert to the user.
[0031] In additional aspects of the disclosure, a user is provided with a simplified user-interface such that the user may select a particular alert. In this embodiment, based on the particular tower of the user's geographic location, certain alerts are pre-selected. That is, users who are located proximate to a tower in certain geographical areas will receive alerts that are most relevant to that area's weather conditions. For example, if the user is located proximate a tower in the midwest, certain alerts such as tornado alerts or dust storm warnings are automatically enabled, while users located proximate to a tower in coastal areas will have coastal warning alerts automatically enabled. This automatic alert filtering function may provide potential advantages to users that do not want to receive many alerts not of interest to the user, and to user that may have limited abilities to reconfigure their devices, yet still wish to receive critical alerts.
[0032] Additionally, in certain embodiments, some users may be provided a whole range of alerts. For example, civil danger warnings in the United States have become of much more interest to the general public. In one example, if the water were to become contaminated, NOAA provides a water contamination alert. Similarly, there are alerts for chemical hazards, dam break warning, contagious disease warnings and other similar alerts which may require a user to take emergency action. These alerts may take priority over other settings (e.g., sound volume) and be immediately presented to the user.
[0033] In an additional embodiment of the disclosure filters, for the alert functions may be vicariously configured. For example, the alert could be selected on a geographic basis. In alternate embodiments, the device may contain different alerts for different counties, different states, and different regions.
[0034] In still another embodiment of the disclosure, the receiver 400 may be configured to monitor the radio broadcasts for a tone or other indication preceding a weather alert such as three beeps. The device may be configured through a screen 332 / 402 to record and store the alert in the internal memory of a microprocessor(s) 401 and/or in an external memory (not shown). For example, certain radio broadcasts may play a tone 10, 20, or 30 or more seconds preceding a weather alert. This tone may be utilized by receivers 413 to determine when a weather alert is about to be sent. The receiver/transmitter 411 will then generate an interrupt to microprocessor 401 to “wake up” the device in order to enable weather radios with useful battery life to be built. Currently, the weather radios must be constantly on and constantly listened to in order to avoid missing an alert, and hence the microprocessor 401 and associated support circuitry must be constantly powered. The use of the tone allows battery operated weather radios to turn on once every 10 to 30 seconds and “listen” for the tone. If the tone is not present, the weather radio shuts off to conserve battery power and the microprocessor 401 goes into a sleep mode. If the tone is present, the weather radio turns on and receives the weather alert.
[0035] In further embodiments of the disclosure, the weather alert is recorded by, for example, microprocessor 401 using an analog-to-digital (A/D) converter (not shown) and stored in a memory in the microprocessor 401 and/or an external memory (not shown). In this manner, the user does not have to be continually listening to the weather radio but rather the receiver 400 performs this function automatically. Once the message is recorded, a visual and/or audible indication is provided to the user via a screen 332 , speaker 313 , and/or any other suitable indicator that there is a weather alert message waiting. The audible/visual indication may be different for different weather alerts and may include an icon on the screen 332 and/or an icon printed on the face of receiver 400 along with a visual indicator such as an LED. Similarly, the visual indication may be different for different weather alerts and include different icons on the screen 332 or printed on the face of receiver 400 . For example, there may be a tornado icon (flashing or stable), a severe thunderstorm warning icon (flashing or stable), flood warning icon (flashing or stable), etc. on screen 332 . Additionally, there may be a user input device coupled to the icons enabling the user to play the alert associated with the icon. See, for example, the play button 801 in FIG. 3 .
[0036] In still further embodiments of the disclosure, the weather radio displays a map or satellite image of the user's current location along with various points of interest such as nearby cities on display 332 . Overlaid on this map and/or satellite image may be various storm path polygons provided by the weather alerts and which may be enabled by a selection option on the touch screen 332 and/or using a weather overlay button such as button 301 . This allows the user to determine visually whether or not the user is in the storm path. For example, the user may input a zip code or longitude and latitude coordinates (or have it determined through a built-in GPS module) and then may have the device indicate whether or not the user is in the storm path as well as a time to arrival of the storm. The device may input the zip code using a keypad 1403 and/or use the current location using button (not shown). The device may be configured to allow a user to see visually whether or not the satellite radio's location (or another selectable location) is in the storm path by, for example, using a satellite image and/or map on display 332 overlaid with a one or more storm path polygons. The weather radio may also be configured to provide the user with audio and/or graphic directions (detour directions) to exit the storm path. The user may manipulate the screen 332 , for example using buttons 321 , to zoom in on the current location in order to see specifics as to time of arrival of the storm, or zoom out of the current location zoom level in order to see a global picture of the storm path.
[0037] Presenting another aspect of the disclosure, the weather radio may also include a user interface on screen 332 which displays the various weather alerts that are potentially available and allows the user to select and deselect individual alerts either using the touch screen or selection buttons such as buttons 321 . Further, the user can enter one or multiple zip codes for which alerts may be available using, for example, keypad 1403 . Additionally, the weather alerts may be recorded for each of the zip codes and scrolled through, using, for example buttons 321 or the touch screen, so the user may see which alerts are associated with which zip codes. In addition, the user may be able to individually select the alerts that are associated with each zip code. For example, a user might not be interested in flooding where his main home is located in the mountains, but may be keenly interested in flooding for his beach house.
[0038] In still further aspects of the disclosure, an icon may be stable or moving on screen 332 . For example, where the user's location map is shown on the screen, one or more tornado icons may appear on the screen and/or move across the screen depending on the storm's track. In these embodiments, the user's location may be fixed on screen 332 and the storm's location may be shown as moving relative to the user's location. Alternately, both the user's location and the storm's track may be fixed on the screen 332 , or both may be shown as moving on the screen 332 .
[0039] In an additional embodiment of the disclosure, the receiver 400 may include other co-located receiver devices for measuring local weather conditions, sending and receiving weather data to locally connected devices via transmitter/receiver 411 , or any other task. The co-located devices may be any device that those with ordinary skill in the art will appreciate as appropriate, including, but not limited to, weather stations, clocks, alarm clocks, watches, temperature displays, telephones, personal computer computers, personal digital assistants (PDAs), and other suitable co-located devices. For example, the weather radio may reside in the user's main home and be “always on” and plugged in to wall power. In other examples, battery powered display devices may be located throughout a user's home, office, or other location, and/or on the user's person (e.g., watch device 202 in FIG. 4 ), and may receive data from the main weather radio. These devices may display weather alerts periodically, for example, every few seconds or minutes. In these examples, the plugged in or battery powered display devices, located remotely from a main weather radio, may periodically wake up, determine if a weather alert has been recorded in the main weather radio, and if so, then provide the alert in a remote location. In this manner, the main weather radio may be located, for example, in a den in the house and the remote display devices may be located throughout the home, for example, in a nearby garage, office, barn, boat, and/or on the user (e.g., the watch 202 in FIG. 4 ).
[0040] In an additional embodiment of the disclosure, the receiver 400 may also be configured to plug into a cradle. The cradle will keep the receiver 400 always charged such as is common for home phones. In this manner, the user may simply take the device to a soccer game, swimming match, or boating outing. Thus, the alerts may be available at different locations when needed. The receiver 400 may also be configured to provide a radio, alarm clock, indoor and outdoor temperature and min/max temperatures. In one embodiment, the receiver 400 may be configured with a similar form factor to a PDA or so called “blackberry” like device, see, e.g., FIG. 2 .
[0041] In still further embodiments of the disclosure, once the receiver 300 is removed from the cradle, it may be configured to turn on or off certain function such as the receipt of outdoor temperature and/or the feeding of data to remote weather display devices.
[0042] In still further embodiments of the disclosure, a user may choose a particular weather radio tower that is closest to a user's location or one that has the strongest signal and the display can be configured to display the name and location of the tower selected.
[0043] In additional aspects of the disclosure, the weather radio tower may be selected using a combination of the signal strength indicator (e.g., Radio Signal Strength Indicator (RSSI)) from the transmitter/receiver 411 and/or a measurement of the signal to noise ratio of the signal as calculated by, for example, microprocessor 401 . In this way, for example, a weaker but low noise signal may be selected over a very strong, but very high noise signal. Hence the user may be potentially provided with a preferred or optimal signal. In still further embodiments, two or more signal icons will be displayed on the display 332 / 402 with the user able to select between the icons.
[0044] In further embodiments, the user is provided with various predetermined profiles on screen 332 . In this way, the user programming of the NOAA-broadcasted Specific Area Messaging Encoding (SAME) profiles are simplified to allow a user to select which counties and alerts the user is interested in viewing/hearing by scrolling through the screen. The user can simply scroll through the default profiles such as a travel profile, a home profile, a boating profile, a freeze profile, a tornado profile, a vacation home profile, and a hurricane profile. In some examples, a user can simply select the profile and all criteria associated with the selected profile will be set automatically.
[0045] As will be appreciated by one of skill in the art upon reading the following disclosure, various aspects described herein may be embodied as methods, systems, apparatus, and/or computer program product. Accordingly, those aspects may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, such aspects may take the form of a computer program product stored by one or more computer-readable storage media having computer-readable program code, or instructions, embodied in or on the storage media. Computer executable instructions and data used by the processor(s) and other components of the computer system may be stored in a storage facility such as a memory. The memory may comprise any type or combination of read only memory (ROM) modules or random access memory (RAM) modules, including both volatile and nonvolatile memory such as disks. The software may be stored within the memory to provide instructions to the processor(s) such that when the instructions are executed, the processor(s), the receiver and/or other components are caused to perform various functions or methods such as those described herein. Computer executable instructions and data may further be stored on computer readable media including electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, CD-ROM, DVD or other optical disk storage, magnetic cassettes, magnetic tape, magnetic storage and the like, and/or any combination thereof
[0046] The present disclosure has been described in terms of preferred and illustrative embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure. For example, while a single microprocessor is shown in the accompanying drawings, one or more microprocessors may be utilized. Further, any type of microprocessor may be utilized and are interchangeable including computers, microcontrollers, Application-Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs), and other computing devices.
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A receiver may receive alerts from a radio-broadcast following a tone or other indication preceding each alert, for example, the National Oceanic and Atmospheric Administration's (NOAA) broadcasted weather alerts. Received alerts may be recorded and stored for future playback to an end user, and the receiver may indicate to the user that an alert has been stored, varying the type of indication according to the type of alert stored. The receiver may record alerts specific to one or more zip codes, geographic regions, Global Positioning System (GPS) coordinates, Federal Information Processes Standards (FIPS) codes, Specific Area Messaging Encoding (SAME) profiles, or other user location data. The user may then select locations and type of alerts to be replayed. Additionally, the receiver may be used in conjunction with other co-located devices to provide information to an end user through a variety of methods and devices.
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FIELD OF THE INVENTION
[0001] The present invention relates to an automatic pipe gridding method allowing implementation of codes for modelling fluids carried by these pipes.
[0002] The method according to the invention finds applications in many spheres. It can notably be used in the sphere of hydrocarbon production for implementation of codes allowing simulation of multiphase flows in oil pipes from production sites to destination sites.
[0003] The grid obtained by means of the method can notably be used for implementing the TACITE modelling code (registered trademark) intended to simulate steady or transient hydrocarbon flows in pipes. Various algorithms allowing to carry out flow simulation according to the TACITE code form the subject of patents U.S. Pat. No. 5,550,761, FR-2,756,044 and FR-2,756,045 (U.S. Pat. No. 5,960,187).
[0004] The modes of flow of multiphase fluids in pipes are extremely varied and complex. Two-phase flows, for example, can be stratified, the liquid phase flowing in the lower part of the pipe, or intermittent with a succession of liquid and gaseous plugs, or dispersed, the liquid being carried along as fine droplets. The flow modes vary notably with the inclination of the pipes in relation to the horizontal and it depends on the flow rate of the gas phase, on the temperature, etc. Slippage between the phases, which varies according to whether the ascending or the descending pipe sections are considered, leads to pressure variations without there being necessarily a compensation. The characteristics of the flow network (dimensions, pressure, gas flow rate, etc.) must be carefully determined.
[0005] The TACITE simulation code takes into account a certain number of parameters that directly influence the physics of the problem to be dealt with. Examples of these parameters are the properties of the fluids and of the flow modes, the topographic variations (length, inclination, diameter variations, etc.), the possible roughness of the pipes, their thermal properties (number of insulating layers and their nature), or the arrangement of equipments along the pipe (pumps, injectors, separators, etc.) that lead to physical flow changes.
BACKGROUND OF THE INVENTION
[0006] Gridding of a physical domain is an essential stage within the scope of numerical simulation. The validity of the results and the calculating times depend on the quality thereof. It is therefore fundamental to provide the code with a correct grid prior to starting simulation. The quality of a grid is generally judged from its capacity to properly describe physical phenomena without simulation taking up too much time, so that there always is an optimum grid for each problem studied. An unsuitable grid can lead, during implementation of the numerical pattern that governs the simulation, to errors that are difficult to detect, at least initially, and can even make calculation impossible and stop the execution of the code if it is excessively aberrant. Code users are not necessarily experienced enough in numerical analysis to produce a correct grid likely to really take into account the physical phenomena to be studied.
[0007] The topography of a cylindrical pipe can be compared to a succession of segments of lines connecting successive points. In cartesian coordinates, two successive points of the pipe on the vertical (ascending or descending) portions thereof can have the same abscissa (curve A in FIG. 1). It is therefore preferable to represent the elevation of each point as a function of its curvilinear abscissa along the pipe. With this mode of representation, successive points of the pipe of different elevations necessarily have two distinct curvilinear abscissas and the slope of the pipe sections is at most 45° to the horizontal (case of absolutely vertical ascending or descending sections, curve B in FIG. 1). One ordinate and only one always corresponds to an abscissa.
[0008] With some physical sense, certain gridding errors can be prevented. A finer grid pattern can be imposed in places of the pipe likely to undergo great physical parameter variations if they can be foreseen. Less calculations are thus carried out in each time interval while keeping the desired fineness in the important places. However, going from a fine cell to a coarser cell must be continuous with a view to obtaining a continuous solution.
[0009] [0009]FIG. 2 a shows for example a 2-km long W-shaped pipe section comprising four 500-m long sections. If such a pipe is discretized with cells having a constant 40-m interval from beginning to end, the important points of the route at 500 m and 1500 m are left out. The simulation will not allow to correctly show the accumulation of liquid at these lower points of the topography. More important yet, the calculation is distorted by the fact that the angles of the W are replaced by horizontal segments of lines (FIG. 2b). The physical phenomena observed are thus not the phenomena that are sought.
[0010] The method according to the invention allows to obtain automatically gridding or discretization of a pipe taking into account, in the best possible way, the topography and the physical parameters that affect the flow physics, subjected to the following constraints:
[0011] 1—Ensure calculation convergence;
[0012] 2—Best represent large accumulations of liquid at the lower points of the pipe;
[0013] 3—Place the equipments on a cell edge;
[0014] 4—Impose the same order of length on two consecutive cells;
[0015] 5—Respect the total length of the pipe;
[0016] 6—Limit the number of cells to the possible minimum by respecting the previous constraints so as not to penalize simulation with the calculating time.
[0017] Respecting the previous six constraints is not easy, but it is essential in order not to grid the pipe studied homogeneously, without having to care about the physics of the problem, like most automatic gridders do.
[0018] In order to limit the number of cells, one has to try to simplify, if possible, the topography in order to keep only the zones of the pipe where the significant profile variations likely to significantly influence the physical phenomena are present.
SUMMARY OF THE INVENTION
[0019] The method according to the invention allows automatic 1D gridding of a pipe exhibiting any topography or profile over the total length thereof, in order to facilitate implementation of flow modelling codes. The grid obtained with the method has a distribution of cells of variable dimensions, suitable to best take into account the flow physics.
[0020] The method is characterized in that, after defining a minimum and a maximum grid cell size, the pipe is subdivided into sections delimited by bends, a cell of minimum size is positioned on either side of each bend, large cells whose size is at most equal to the maximum size are positioned in the central portion of each section, and cells of increasing or decreasing sizes are distributed on the intermediate portions of each section between each minimum-size cell and the central portion.
[0021] The distribution of the cells of increasing or decreasing sizes on the portions of each intermediate section between each minimum-size cell and the central portion is for example obtained by determining the points of intersection, with each pipe section, of a pencil of lines concurrent at one point and forming a constant angle with one another.
[0022] The position of the vertex of the pencil of lines is for example determined on an axis passing through a bend of the pipe and perpendicular to each section, at a distance therefrom that depends on the size of the extreme cells of each intermediate portion and on the distance between them.
[0023] Automatic positioning of the cells with smaller cells in the neighbourhood of the ends of each section allows to exercise great care in modelling of the phenomena in the pipe portions exhibiting changes of direction (inflection or bend).
[0024] The method according to the invention preferably comprises previous simplification of the pipe topography so that the total number of cells of the pipe grid allows realistic modelling of the phenomena physics within a fixed time interval.
[0025] According to a first implementation mode, the method comprises representing the pipe in form of a graph connecting the curvilinear abscissa and the level variation, and simplifying the number of sections a) by assigning to each point between two successive sections a weight taking into account the length of the sections and the respective slopes thereof, b) by selecting, from among the points arranged in increasing or decreasing order of weight, those whose weight is the greatest, the simplified topography being that of the graph passing through the points selected.
[0026] Selection of the points of the pipe whose weight is the greatest is obtained for example by locating, in the arrangement of points, a weight discontinuity that is above a certain fixed threshold.
[0027] According to another implementation mode, the method comprises representing the pipe in form of a graph connecting the curvilinear abscissa and the level variation, and simplifying the number of sections a) by forming the frequency spectrum of the curve representative of the pipe topography, b) by attenuating the highest frequencies of the spectrum showing the slightest topography variations, and c) by reconstructing a simplified topography corresponding to the rectified frequency spectrum.
[0028] Selection is made for example a) by sampling the curve representative of the pipe topography with a sampling interval that is so selected that the smallest section of the pipe contains at least two sampling intervals, b) by determining the frequency spectrum of the curve sampled by application, c) by correcting the spectrum by low-pass filtering whose cutoff frequency is selected according to a fixed maximum number of cells for subdividing the pipe, and d) by determining the topography corresponding to the rectified frequency spectrum.
[0029] The two automatic simplification modes described above can be applied independently of one another or successively, the second mode being preferably applied when the first mode does not allow to obtain a notable simplification of the topography.
BRIEF DESCRIPTION OF THE FIGURES
[0030] Other features and advantages of the method according to the invention will be clear from reading the description hereafter of non limitative examples, with reference to the accompanying drawings wherein:
[0031] [0031]FIG. 1 shows two diagrammatic representations of the variation of elevation (E) of a pipe as a function of abscissa (A), according to whether the abscissa is a Cartesian abscissa (ca) or a curvilinear abscissa (cu),
[0032] [0032]FIGS. 2 a , 2 b respectively show the diagrammatic topography of a W-shaped pipe in curvilinear coordinates, and an enlarged part of this topography, discretized with a suitable grid pattern,
[0033] [0033]FIG. 3 shows a mode of assigning a weight (P) to points of the topography of a pipe,
[0034] [0034]FIG. 4 shows an example of dimensionless weight spectrum (PA) as a function of length (L),
[0035] [0035]FIG. 5 shows an example of arrangement of points in decreasing weight plateaus, allowing to locate the position of a threshold and to simplify the topography of the pipe,
[0036] [0036]FIG. 6 shows an example of topography of a sea line (variation of elevation E as a function of curvilinear abscissa ca) comprising a riser at its ends,
[0037] [0037]FIG. 7 shows the simplified topography of the same line, obtained by selection of the weights,
[0038] [0038]FIG. 8 shows that, without the terminal risers, the general shape of the same line is more difficult to show,
[0039] [0039]FIG. 9 shows a typical frequency spectrum of a pipe,
[0040] [0040]FIG. 10 shows an example of a pipe section with a distribution of cells of various sizes, the smallest ones M1 being positioned at the bends, the largest ones M2 being placed in the central third, the intermediate cells M3 being interposed and resulting from an interpolation I between the others,
[0041] [0041]FIG. 11 shows a mode of forming cells of increasing size,
[0042] [0042]FIG. 12 illustrates the mode of angular division of an intermediate portion on a pipe section, and
[0043] [0043]FIG. 13 shows the grid pattern obtained by implementing the method, on a 90-km long subsea line.
DETAILED DESCRIPTION
[0044] I) Simplification of the Topography of a Pipe
[0045] The global shape of any profile is generally not difficult to bring out at first sight. The method according to the invention allows, by means of purely mathematical criteria, automatic determination of the configuration of a pipe based on a spectral analysis of the curve representative of the profile variations. Among all the spectra that can be associated with a given topography, a spectrum allowing to distinguish the portions of the profile to be simplified and the important profile portions is sought.
[0046] I-1) First Simplification Mode
[0047] In a topography, the only criteria according to which a point can be simplified in relation to another can only be the lengths of the sections surrounding it and the angular difference between them (FIG. 3). When the two (Section indices)-(Section lengths) and (Curvilinear abscissa of the points)-(Angular difference of the incoming and outgoing sections) <<spectra>> are constructed, it appears that they exhibit notable differences in their orders of magnitude, and also that these two spectra are independent so that, while simplifying negligible points in one, important points may have been suppressed in the other.
[0048] In order to group these two spectra into a single spectrum, each topographic point is assigned a weight that takes into account the section lengths and the angular differences that separate them. The following weighting is used for example:
Weight = L 1 · L 2 L 1 + L 2 ( P 2 - P 1 ) 2
[0049] where L 1 and L 2 are the lengths of the sections, and
P 1 = y 1 x 1 and P 2 = y 2 x 2
[0050] are the slopes. Thus, for the same lengths, the sections separated by the smallest slope difference will be simplified. And, for the same angles, the shortest lengths will be simplified.
[0051] Construction of the Spectrum
[0052] In most cases, the (Curvilinear abscissa—Weight) spectrum comprises a succession of peaks of all sizes. These spectra, such as the spectrum shown in FIG. 4, cannot be directly analysed generally. Under such conditions, the technique used here consists in classifying weights (P) in increasing or decreasing order and in assigning thereto the corresponding index of classification (CI) by weight from 1 to N. A (Log Weight—Index) representation is preferably used, which better shows the orders of magnitude because a jump by n on such a spectrum means a 10 n ratio on the weights. All the weights with the same order of magnitude are arranged on more or less horizontal plateaus. Two weights of different orders of magnitude are separated by a vertical segment of a line. A cascade spectrum is obtained, which allows to readily read the various orders of magnitude present in the topography. In the example of FIG. 5 for instance, the logarithmic spectrum Log P contains two distinct plateaus separated by a vertical segment.
[0053] The first triplet of consecutive points of the spectrum, defined for example by a threshold AP set on the logarithmic scale (ΔP=1 for example) between the second and the third, which follows a jump that is less than AP between the first and the second, is sought. The first two points are of the same order of magnitude. All the following points are of a negligible order of magnitude in relation to the first two points. One thus makes sure that all the weights on the right of the triplet in question will be at least 10 times smaller than the weight of the second one and therefore negligible in relation to the upstream points. The points of curvilinear abscissa corresponding to the greatest weights selected are selected in the correspondence table (weight index-curvilinear abscissa). The simplified topography will be the line passing through these points.
[0054] Three distinct parts can be seen in the topography example of FIG. 6. It starts with a 3-km long riser, followed by a 20-km long sawtoothed horizontal part and ending with a 200-m long riser, also sawtoothed. Its spectrum is the spectrum of FIG. 5. The first triplet, which meets the thresholding criterion, consists of points 4 , 5 and 6 . The simplification threshold is the point of index 6 . A jump greater than 2 in the logarithmic scale separates the horizontal plateaus on either side of points 5 and 6 . It is thus possible to check that the points on the left of index 5 have weights that are at least 100 times greater than those on the right of index 6 .
[0055] In this example, the topography is simplified by keeping only the points of curvilinear abscissa corresponding to the weights that are greater than or equal to the weight of point 6 . The simplified topography of FIG. 7 is obtained. The global shape is kept. All the slight sawtoothed variations on the 20-km long horizontal part have been suppressed. The number of points has changed from 43 initially (FIG. 6) to 6, i.e. a reduction by a factor of 7. This case is particularly well suited for thresholding since the various orders of magnitude are visible on the initial topography.
[0056] The first simplification mode that has been described is easy to implement and based on relatively simple algorithms that can be quickly executed. It is suited to topographies having several orders of magnitude, such as the previous topography that has been considerably simplified because it contained points with weights that were negligible in relation to one another.
[0057] The problem is quite different if only the central part of this topography is taken into account, the terminal risers being removed, because in this case, as can be seen in FIG. 8, the general shape of the pipe is more difficult to show. Simplification of this topography by a line connecting the starting point and the end point is not possible. The spectrum is exactly the same as the spectrum of the initial topography, apart from the fact that it starts at point 6 . No threshold is present in this part of the spectrum, the points all have the same order of magnitude. And even if the greatest weight is more than 100 times greater than the smallest, one goes from one to the other continuously.
[0058] I-2) Second Simplification Mode
[0059] For topographies with points having the same order of magnitude, that cannot be processed with the previous thresholding method, spectral filtering is carried out. The slight pipe profile variations lead to high frequencies in the Fourier spectrum of the function representative of the topography. The topography can be simplified by cutting or by attenuating the highest frequencies of the frequency spectrum thereof.
[0060] The topographic function is therefore sampled and its spectrum is determined by means of the FFT (Fast Fourier Transform) method. The sampling interval must be small enough to show all the frequency ranges while avoiding aliasing. The number of sampling points is therefore so selected that the smallest pipe section contains at least two subdivisions to ensure that the Fourier transform will act upon all the parts of the pipe, even the most insignificant ones. Attenuation of the high frequencies must of course be done judiciously and it must be adjusted so that the topographic function obtained remains representative of the initial function.
[0061] The simplest filtering method consists for example in applying a threshold, all the Fourier coefficients (FC) whose amplitude A(FC) is below this threshold being eliminated (coefficients below 40 for instance in the example of FIG. 9). Only the information contained in the frequencies below this threshold is kept. The corresponding simplified topography is reconstructed by inverse transform.
[0062] The maximum number of oscillations of the reconstructed signal is thus set by fixing a cutoff frequency. If only the first ten frequencies are kept, the reconstructed function will follow the general shape of the pipe, with a maximum of twenty extrema.
[0063] II) Selection of the Cell Sizes on Each Pipe Section
[0064] Principle
[0065] The gridding principle will consist in gridding independently the pipe sections between two imposed edges. Since the advantage of a correct gridding is to allow correct observation of the liquid accumulations in the bends, gridding is preferably fined down at the points of the topography where liquid or gas is likely to accumulate. A short cell is therefore preferably placed before and after each bend, larger ones being positioned between the bends. On the other hand, fine gridding of the intermediate parts of the sections between the bends is unnecessary.
[0066] The topography of the pipe having been previously simplified (when necessary) and reduced to a certain number of sections, a minimum size and a maximum size are fixed for the cells. The edges of each one (inlet, outlet) are first isolated by small cells, then cell edges are inserted on the central part thereof, which is longer. It is generally not necessary to fine down the grid pattern at the inlet and at the outlet outside the portions at the ends of each section, and edges can therefore be inserted over a large part of the length of each section (⅔ of the length for example) of the maximum size that has been set.
[0067] The distribution can be so selected that, for example, the size of the cells after that following a bend gradually increases over a third of the length of the section, remains constant over the following third and eventually decreases over the last third before the final short cell as shown in FIG. 10.
[0068] Definition of the Minimum and Maximum Cell Lengths
[0069] Two cell lengths are defined, a minimum length for isolating the cell edges imposed by small cells, and a maximum length for gridding the middle of the sections contained between two short cells.
[0070] All the cells that are inserted after these two stages are deduced from the initial cells by interpolation between a short cell and a long cell. They therefore have intermediate sizes. This property is interesting. It shows that the total number of cells will necessarily range between the number that would have been obtained by homogeneously gridding with the minimum length and the number obtained in the same way but with the maximum length. The total number of cells can thus be controlled from the minimum and maximum sizes.
[0071] One of the constraints of automatic gridding lies in the total number of cells. It must generate the shortest possible simulation time, while allowing good display of the physical phenomena. Experience shows, on the one hand, that a discretization of less than 40 cells does not allow good physical description of the problems. On the other hand, grid patterns with more than 150 cells generate too long simulations. Default gridding must therefore be flexible enough and comprise 40 to 100 cells.
[0072] Such a small number of cells is not always suitable. The ideal number of cells for a precise case depends on several factors taken into account in the numerical pattern. For the same topography for example, a case comprising a large number of section changes will require a finer grid. The method according to the invention allows the user considerable latitude to select the suitable total number of cells.
[0073] From this number N, the code calculates the minimum Min and maximum Max lengths as follows:
Min = L N + P Max = L N - P
[0074] Parameter P allows to reduce the difference between the minimum and maximum lengths so as to make the grid progressively homogeneous for the large number of cells.
[0075] This parameter is for example defined as follows. For a number of cells selected less than or equal to 60 for example, it is set at 60 for example. It is the default grid. The value of the parameter is 40. The value of the smallest cell will be L/100 and the value of the largest cell, L/20. The total number of cells will range between 20 and 100.
[0076] A number of cells greater than or equal to 150 means that the modelling process to be dealt with is certainly more delicate. A homogeneous grid therefore has to be constructed. The minimum and maximum sizes must then be close to one another. The parameter is therefore set at 10. The total number of cells will then range between
L N + 10 and L N - 10 .
[0077] Above 150, the desired number of cells is obtained to within 20 cells.
[0078] For the grid to become progressively homogeneous between 60 and 150 cells, the parameter is calculated by linear interpolation between the two domains, which is expressed as follows:
P= 40 if N< 60
[0079] [0079] P = - 1 3 N + 60 if 60 < N < 150
P= 10 if N> 150.
[0080] This parameter being determined, it is possible to isolate the edges imposed by short cells and to discretize the middle of the sections by long cells.
[0081] It only remains to find a means for gradually going from a short cell to a long cell. The lengths of the three cells are known, and cell edges are to be inserted on the central part. The sizes of the cells thus created must range between the sizes of the extreme cells. Starting from the smallest one, the next cell must always be longer than the previous one, but shorter than the next.
[0082] In the general case, there is no pair (f,n)ε(R,N) such that:
[0083] the size of a cell is deduced from that of the previous one by multiplying it by a factor f,
[0084] the sum of the n lengths thus created is equal to (L1+L2),
[0085] the size of the last cell can be expressed as follows: f n+1 .L 1 f.
[0086] This is also the case for a possible linear interpolation between the two cells. Knowing the three lengths imposes an overabundance of data in relation to the unknowns. It is then impossible to meet all the constraints.
[0087] In order to overcome this difficulty, a geometric type method is proposed, using the property according to which segments L 1 , L 2 , L 3 , L 4 formed on an axis by the lines of a regular pencil (with a constant angular space α in relation to one another), whose vertex is outside this axis, vary progressively (FIG. 11).
[0088] We consider (FIG. 12) a pipe section starting with a small cell (0, x1) of length L 1 and ended by a cell (x2, x3) of length L 3 >L 1 . It can be shown that there is a point on a perpendicular to the pipe section at abscissa 0 such that the cells of lengths L 1 and L 3 are seen from this point under the same angle α. The ordinate y of this vertex is given by the relation:
y = L 1 ( L 1 + L 2 ) ( L 1 + L 2 + L 3 ) ( L 3 - L 1 )
[0089] where L 2 is the length of segment (x 1 , x 2 ).
[0090] Angle β then has to be divided into N equal parts, N being equal to the entire division of β by a, i.e.
N = E ( β α ) .
[0091] Each of the N angles dividing β is always greater than or equal to α.
[0092] The principle used for inserting the cell edges is both simple and reliable. It allows, by means of a single parameter, to create either a uniform grid, or a heterogeneous grid fined down at the important points.
|
Automatic pipe gridding method allowing implementation of codes for modelling fluids carried by these pipes.
The method essentially comprises, considering a minimum and a maximum grid cell size, subdividing the pipe into sections delimited by bends, positioning cells of minimum size on either side of each bend, positioning large cells whose size is at most equal to the maximum size in the central portion of each section, and distributing cells of increasing or decreasing size on the intermediate portions of each section between each minimum-size cell and the central portion. The method preferably comprises a prior stage of simplification of the pipe topography by means of weight or frequency spectrum analysis, so as to reduce the total number of cells without affecting the representativeness of the flow model obtained with the grid pattern.
Applications: oil pipes gridding for example.
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CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application also claims benefit from Indian Complete Patent Application No. 2688/MUM/2015, filed on Jul. 15, 2015, the entirety of which is hereby incorporated by reference.
TECHNICAL FIELD
The present subject matter described herein, in general, relates to systems and methods for detection of Physical Random Access Channel (PRACH) preambles in Long Term Evolution (LTE) communication system.
BACKGROUND
A Long Term Evolution (LTE) communication system uses several channels for transferring voice and data over a network. LTE utilizes Multiple Input Multiple Output (MIMO) antenna technology and is developed to improve spectral efficiency, distance coverage, and operational costs. A LTE equipment providing network within a cell is installed over a Base Transceiver Station (BTS) or an eNodeB. A mobile device communicates with the BTS using several channels present in the LTE standard. For establishing a communication session, a receiver of the LTE equipment receives a signal from the mobile equipment. Further, the LTE receiver processes the received signal to achieve synchronization with the mobile device and thus establish a successful communication session.
FIG. 1 illustrates a conventional receiver architecture used in the LTE communication system. Received samples of a signal received by a receiver are provided to a Single Carrier-Frequency Division Multiple Access (SC-FDMA) receiver unit. The SC-FDMA receiver unit extracts SC-FDMA symbols from the received samples. Further, the SC-FDMA receiver unit discards cyclic prefixes of the SC-FDMA symbols to derive useful parts of the SC-FDMA symbols. The SC-FDMA receiver unit reverses a half-subcarrier shift performed at a transmitter station and applies a Discrete Fourier Transform (DFT) on the useful part of each of the SC-FDMA symbols in order to derive a PUxCH resource grid. The PUxCH resource grid is used by a Physical Uplink Shared Channel (PUSCH) receiver, a Physical Uplink Control Channel (PUCCH) receiver, and a Sounding Reference Signal (SRS) receiver. The PUSCH is used as an LTE uplink data channel and the PUCCH is used as an LTE uplink control channel. Further, the SRS is periodically transmitted by a terminal to a base station for uplink channel quality estimation and for maintaining synchronization, once achieved using a Physical Random Access Channel (PRACH). The conventional receiver unit also includes a functionality of frequency and timing error correction, as exemplified in the FIG. 1 .
For initially achieving synchronization between a terminal and the base station, the PRACH is used. In one case, the received samples and a FFT of the useful part of the SC-FDMA symbols are provided to a PRACH receiver, in order to achieve the synchronization. In another case, only the received samples may be provided to the PRACH receiver for achieving the synchronization. Necessary signal information derived by the PUSCH receiver, the PUCCH receiver, the SRS receiver, and the PRACH receiver is provided to a second layer (Layer 2) of the LTE communication system.
FIG. 2 illustrates a block representation of a conventional method for detecting PRACH preambles in a LTE communication system. Further, FIG. 2 explains the conventional method using the received samples and the FFT of the useful part of the SC-FDMA symbols. A signal received by a base station comprises a Cyclic Prefix (CP) and a PRACH preamble sequence part, at step 202 . The PRACH preamble sequence part (assumed not including any delay) is segmented into a plurality of segments having uniform sizes, at step 204 . In one case the PRACH preamble sequence part may be segmented into 12 segments represented by a=0 to a=11. Successively, a half-carrier shift and a Discrete Fourier Transform (DFT) may be performed on each of the 12 segments to generate frequency domain segments corresponding to the 12 segments, at step 206 .
Subsequent to generation of the frequency domain segments, PRACH frequency segments are generated by selecting PRACH frequency locations from the frequency domain segments. The PRACH frequency segments are serially concatenated, at step 208 . A Discrete Fourier Transform (DFT) operation is performed on 1536 points of the serially concatenated segments, at step 210 . An output of the FFT operation is correlated, at step 214 , with 839 points of predetermined references shown at step 212 . A correlation product is thus generated at step 216 . Subsequently, an Inverse Discrete Fourier Transform (IDFT) is performed on 1536 points of the correlation product to detect the PRACH preamble and its timing advance, at step 218 .
Thus, the conventional technique for detecting the PRACH preambles uses many transformations of the signal between time-domain and frequency-domain. Further, 1536-point IFFT is performed on the correlation product to detect the PRACH preambles. Thus, the processing done using the conventional technique requires a lot of computations being performed at the base station, resulting in high computational complexity.
SUMMARY
This summary is provided to introduce aspects related to generating Physical Random Access Channel (PRACH) reference segments in a Long Term Evolution (LTE) communication system and detecting the PRACH preambles in the LTE communication system and the aspects are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
In one implementation, a method for generating Physical Random Access Channel (PRACH) reference segments in a Long Term Evolution (LTE) communication system is disclosed. The method may comprise generating a plurality of preamble sequences using a Constant Amplitude Zero Auto Correlation (CAZAC) sequence. Each preamble sequence may have length of a valid CAZAC sequence. The method may further comprise transforming the plurality of preamble sequences into a plurality of frequency domain signals by performing a Discrete Fourier Transform (DFT) on the plurality of preamble sequences. The method may comprise generating a plurality of subcarrier mapped signals by performing subcarrier mapping of the plurality of frequency domain signals. The subcarrier mapping may be performed based on a subcarrier spacing associated with a Physical Random Access Channel (PRACH) in a Long Term Evolution (LTE) communication system. The method may comprise transforming the plurality of subcarrier mapped signals into a plurality of time domain signals by performing an Inverse DFT (IDFT). The plurality of time domain signals may be sampled at a sampling rate suitable to a receiver system and a suitable IDFT length is selected based on the sampling rate, in order to perform the transformations. The method may further comprise generating a plurality of standard PRACH preamble signals by adding a Cyclic Prefix (CP) to each time domain signal of the plurality of time domain signals. The CP may be a copy of an end-segment of the time domain signal. The method may further comprise segmenting each standard PRACH preamble signal from the plurality of standard PRACH preamble signals to generate a plurality of segments of uniform size. The segments may either be contiguous or non-contiguous. The non-contiguous segments may be separated by a time gap accommodated in between each segment of the non-contiguous segments. The method may comprise generating a plurality of frequency domain segments by performing a half-subcarrier shift and a DFT on the plurality of segments. The frequency domain segments may comprise sub-carriers spaced in accordance with a Single Carrier Frequency Division Multiple Access (SC-FDMA) signal. The method may also comprise generating a plurality of PRACH reference segments by selecting frequency locations from the plurality of frequency domain segments. The frequency locations may correspond to PRACH frequency locations.
In one implementation, a base station for generating Physical Random Access Channel (PRACH) reference segments in a Long Term Evolution (LTE) communication system is disclosed. The base station may comprise a memory coupled to a processor. The processor is connected to a plurality of units configured to perform a function. A preamble sequence generation unit may generate a plurality of preamble sequences using a CAZAC sequence. Each preamble sequence may have length of a valid CAZAC sequence. A first Discrete Fourier Transform (DFT) unit may transform the plurality of preamble sequences into a plurality of frequency domain signals by performing a DFT on the preamble sequences. A subcarrier mapping unit may generate a plurality of subcarrier mapped signals by performing subcarrier mapping of the plurality of frequency domain signals. The subcarrier mapping may be performed based on a subcarrier spacing associated with a Physical Random Access Channel (PRACH) in a Long Term Evolution (LTE) communication system. An Inverse DFT (IDFT) unit may transform the plurality of subcarrier mapped signals into a plurality of time domain signals by performing an IDFT. The plurality of time domain signals may be sampled at a sampling rate suitable to a receiver system and a suitable IDFT length is selected based on the sampling rate, in order to perform the transformations. A CP-insertion unit may generate a plurality of standard PRACH preamble signals by adding a Cyclic Prefix (CP) to each time domain signal of the plurality of time domain signals. The CP is a copy of an end-segment of the time domain signal. A segmenting unit may segment each standard PRACH preamble signal from the plurality of standard PRACH preamble signals to generate a plurality of segments of uniform size. The segments may either be contiguous or non-contiguous. The non-contiguous segments may be separated by a time gap accommodated in between each segment of the non-contiguous segments. A second DFT unit may generate a plurality of frequency domain segments by performing a half-subcarrier shift and a DFT on the plurality of segments. The frequency domain segments comprise sub-carriers spaced in accordance with a Single Carrier Frequency Division Multiple Access (SC-FDMA) signal. A first subcarrier de-mapping unit may generate a plurality of PRACH reference segments by selecting frequency locations from the plurality of frequency domain segments. The frequency locations may correspond to PRACH frequency locations.
In one implementation, a non-transitory computer readable medium embodying a program executable in a computing device for generating Physical Random Access Channel (PRACH) reference segments in a Long Term Evolution (LTE) communication system is disclosed. The program may comprise a program code for generating a plurality of preamble sequences using a CAZAC sequence. Each preamble sequence may have length of a valid CAZAC sequence. The program may further comprise a program code for transforming the plurality of preamble sequences into a plurality of frequency domain signals by performing a DFT on the plurality of preamble sequences. The program may further comprise a program code for generating a plurality of subcarrier mapped signals by performing subcarrier mapping of the plurality of frequency domain signals. The subcarrier mapping may be performed based on a subcarrier spacing associated with a Physical Random Access Channel (PRACH) in a Long Term Evolution (LTE) communication system. The program may further comprise a program code for transforming the plurality of subcarrier mapped signals into a plurality of time domain signals by performing an IDFT. The plurality of time domain signals may be sampled at a sampling rate suitable to a receiver system and a suitable IDFT length is selected based on the sampling rate, in order to perform the transformations. The program may further comprise a program code for generating a plurality of standard PRACH preamble signals by adding a Cyclic Prefix (CP) to each time domain signal of the plurality of time domain signals. The CP may be a copy of an end-segment of the time domain signal. The program may further comprise a program code for segmenting each standard PRACH preamble signal from the plurality of standard PRACH preamble signal to generate a plurality of segments of uniform size. The segments may either be contiguous or non-contiguous. The non-contiguous segments may be separated by a time gap accommodated in between each segment of the non-contiguous segments. The program may further comprise a program code for generating a plurality of frequency domain segments by performing a half-subcarrier shift and a DFT on the plurality of segments. The frequency domain segments may comprise sub-carriers spaced in accordance with a Single Carrier Frequency Division Multiple Access (SC-FDMA) signal. The program may further comprise a program code for generating a plurality of PRACH reference segments by selecting frequency locations from the plurality of frequency domain segments. The frequency locations may correspond to PRACH frequency locations.
In another implementation, a method for detecting Physical Random Access Channel (PRACH) preambles in a Long Term Evolution (LTE) communication system is disclosed. The method may further comprise receiving a signal for detecting Physical Random Access Channel (PRACH) preambles. The method may comprise segmenting the signal into a plurality of segments of uniform sizes. The plurality of segments may be one of contiguous segments or non-contiguous segments. The contiguous segments may have no time gap between one another. The non-contiguous segments may have a time-gap in between adjacent segments of the plurality of segments. The non-contiguous segments may correspond to Single Carrier Frequency Division Multiple Access (SC-FDMA) symbols associated with Long Term Evolution (LTE) standards. The method may comprise generating frequency domain segments by performing a half-subcarrier shift and a DFT on the plurality of segments. The method may further comprise generating a plurality of PRACH frequency segments by selecting frequency locations from the frequency domain segments. The frequency locations may correspond to PRACH frequency locations. The method may further comprise producing a plurality of intermediate correlation segments by multiplying values at each frequency location of the plurality of PRACH frequency segments with a complex conjugate of the values at corresponding frequency locations of a plurality of PRACH reference segments. Each intermediate correlation segment may comprise a number of sub-carriers spanning the PRACH frequency region as defined in a LTE communication system. The method may comprise generating a plurality of combined intermediate correlation results by adding the values at the corresponding frequency locations of each intermediate correlation segment. The method may also comprise generating a plurality of correlation results by performing an IDFT on the combined intermediate correlation result. The method may also comprise detecting one or more PRACH preambles by comparing peaks of the plurality of correlation results with a predefined threshold to identify one or more peak locations. Further, timing delays may be identified based on the identified peak locations.
In another implementation, a base station for detecting Physical Random Access Channel (PRACH) in a Long Term Evolution (LTE) communication system is disclosed. The base station may comprise a memory coupled to a processor. The processor is connected to a plurality of units configured to perform a function. A receiving unit may receive a signal for detecting Physical Random Access Channel (PRACH) preambles. A segmentation unit may segment the signal into a plurality of segments of uniform sizes. The plurality of segments may be one of contiguous segments or non-contiguous segments. The contiguous segments may have no time gap between one another. The non-contiguous segments may have a time-gap in between adjacent segments of the plurality of segments. The non-contiguous segments may correspond to Single Carrier Frequency Division Multiple Access (SC-FDMA) symbols associated with Long Term Evolution (LTE) standards. A third Discrete Fourier Transform (DFT) unit may generate frequency domain segments by performing a half-subcarrier shift and a DFT on the plurality of segments. A second subcarrier de-mapping unit may generate a plurality of PRACH frequency segments by selecting frequency locations from the frequency domain segments. The frequency locations may correspond to PRACH frequency locations. A multiplication unit may produce a plurality of intermediate correlation segments by multiplying values at each frequency location of the plurality of PRACH frequency segments with a complex conjugate of corresponding frequency locations of a plurality of PRACH reference segments. Each intermediate correlation segment may comprise a number of sub-carriers spanning the PRACH frequency region as defined in a LTE communication system. An adding unit may generate a plurality of combined intermediate correlation results by adding the values at corresponding frequency locations of each intermediate correlation segment. A second Inverse DFT (IDFT) unit may generate a plurality of correlation results by performing an IDFT on the combined intermediate correlation result. A PRACH detection unit may detect one or more PRACH preambles by comparing peaks of the plurality of correlation results with a predefined threshold to identify one or more peak locations. Further, timing delays may be identified based on the identified peak locations.
In another implementation, a non-transitory computer readable medium embodying a program executable in a computing device for detecting Physical Random Access Channel (PRACH) in a Long Term Evolution (LTE) communication system is disclosed. The program may comprise a program code for receiving a signal for detecting Physical Random Access Channel (PRACH) preambles. The program may further comprise a program code for segmenting the signal into a plurality of segments of uniform sizes. The plurality of segments may be one of contiguous segments or non-contiguous segments. The contiguous segments may not have a time gap between one another. The non-contiguous segments may have a time-gap in between adjacent segments of the plurality of segments. The non-contiguous segments may correspond to Single Carrier Frequency Division Multiple Access (SC-FDMA) symbols associated with Long Term Evolution (LTE) standards. The program may further comprise a program code for generating frequency domain segments by performing a half-subcarrier shift and a DFT on the plurality of segments. The program may further comprise a program code for generating a plurality of PRACH frequency segments by selecting frequency locations from the frequency domain segments. The frequency locations may correspond to PRACH frequency locations. The program may further comprise a program code for producing a plurality of intermediate correlation segments by multiplying values at each frequency location of the plurality of PRACH frequency segments with a complex conjugate of a corresponding frequency location of a PRACH reference segment. Each intermediate correlation segment may comprise number of sub-carriers spanning the PRACH frequency region as defined in a LTE communication system. The program may further comprise a program code for generating a plurality of combined intermediate correlation results by adding values at corresponding frequency locations of each intermediate correlation segment. The program may further comprise a program code for generating a plurality of correlation results by performing an IDFT on the combined intermediate correlation result. The program may further comprise a program code for detecting one or more PRACH preambles by comparing peaks of the plurality of correlation results with a predefined threshold to identify one or more peak locations. Further, timing delays may be identified based on the identified peak locations.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description is described with reference to the accompanying Figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
FIG. 1 illustrates a conventional receiver architecture used in the LTE communication system, in accordance with prior art;
FIG. 2 illustrates a block representation of a conventional method for detecting a PRACH preambles in LTE communication system, in accordance with prior art;
FIG. 3 illustrates a network implementation of a base station serving mobile terminals in a Long Term Evolution (LTE) communication system, in accordance with an embodiment of the present subject matter;
FIG. 4 illustrates a Physical Random Access Channel (PRACH) reference segment generating unit of the base station, in accordance with an embodiment of the present subject matter;
FIG. 5 illustrates a PRACH preamble detecting unit of the base station, in accordance with an embodiment of the present subject matter;
FIG. 6 illustrates a block representation of a method for detecting PRACH preambles in LTE communication system, in accordance with an embodiment of the present subject matter;
FIG. 7 illustrates a block representation of a method for detecting PRACH preambles in LTE communication system, in accordance with another embodiment of the present subject matter;
FIG. 8 shows a flowchart illustrating a method for generating PRACH reference segments in a LTE communication system, in accordance with an embodiment of the present subject matter;
FIG. 9 shows a flowchart illustrating a method for detecting PRACH preambles in a LTE communication system, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
Systems and methods for generating Physical Random Access Channel (PRACH) reference segments and detecting PRACH preambles in a Long Term Evolution (LTE) communication system are described. The method may be performed on a base station (eNodeB or eNB) of the LTE communication system. In order to generate the PRACH reference segments, the base station may generate a plurality of preamble sequences using a CAZAC sequence. Each preamble sequence may have length of a valid CAZAC sequence. The length of each preamble sequence may be one of 839 and 139. Successively, the base station may transform the preamble sequences into frequency domain signals by performing a DFT on the preamble sequences. The base station may then generate subcarrier mapped signals by performing subcarrier mapping of the frequency domain signals. The subcarrier mapping may be performed based on a subcarrier spacing associated with the PRACH. The base station may perform an Inverse DFT (IDFT) on the subcarrier mapped signals to transform the subcarrier mapped signals into time domain signals.
Post generating the time domain signals, the base station may generate a standard PRACH preamble signal by adding a Cyclic Prefix (CP) to a time domain signal of the time domain signals. Successively, the base station may segment the standard PRACH preamble signal to generate a plurality of segments of uniform size. The segments may either be contiguous or non-contiguous. The non-contiguous segments may be separated by a time gap present in between each segment of the non-contiguous segments. The base station may perform a half-subcarrier shift and a DFT on the plurality of segments to generate frequency domain segments. The frequency domain segments may comprise sub-carriers spaced in accordance with a Single Carrier Frequency Division Multiple Access (SC-FDMA) signal. The base station may select frequency locations from the frequency domain segments to generate PRACH reference segments.
Upon generating the PRACH reference segments, the base station may receive a signal for detecting PRACH preambles. The base station may segment the signal into a plurality of segments of uniform sizes. The plurality of segments may either be contiguous segments or non-contiguous segments. The base station may then generate frequency domain segments by performing a half-subcarrier shift and a DFT on the plurality of segments. The base station may select frequency locations from the frequency domain segments to generate PRACH frequency segments. Subsequently, the base station may multiply values at each frequency location of the PRACH frequency segments with a complex conjugate of the values at a corresponding frequency location of a PRACH reference segment to produce intermediate correlation segments. The base station may add the values at corresponding frequency locations of each intermediate correlation segment to generate a combined intermediate correlation result. The base station may then perform an Inverse DFT (IDFT) on the combined intermediate correlation result to generate a correlation result. Peaks of the correlation result may then be compared with a predefined threshold to identify one or more peak locations, for detecting the one or more PRACH preambles. Further, the identified peak locations may be used to identify timing delays.
While aspects of described system and method for detecting Physical Random Access Channel (PRACH) preambles in a Long Term Evolution (LTE) communication system may be implemented in any number of base stations i.e. eNodeB (eNB), different computing systems, environments, and/or configurations, the embodiments are described in the context of the following exemplary system.
Referring now to FIG. 3 , a network implementation of a base station serving mobile terminals in a Long Term Evolution (LTE) communication system 300 is shown, in accordance with an embodiment of the present subject matter. The LTE communication system 300 may comprise a base station 302 present in each cell. Mobile terminals ( 304 - 1 to 304 -N) may try to communicate with the base station 302 in order to achieve synchronization and subsequently achieve a connection with the base station 302 . Examples of the mobile terminals ( 304 - 1 to 304 -N) may include a mobile phone, a smart phone, a PDA, a tablet, or any other computing device having at least one of voice calling capability and data communication capability.
In one embodiment, the base station 302 may include processor(s) 306 , a memory 308 , interface(s) 310 , PRACH reference segment generating unit 312 , and PRACH preamble detecting unit 314 . Further, the processor(s) 306 may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the processor(s) 306 is configured to fetch and execute computer-readable instructions stored in the memory 308 . The PRACH reference segment generating unit 312 and the PRACH preamble detecting unit 314 may be indicative of a functionality of the processor 306 or may be separate hardware units functioning along with the processor 306 .
In one embodiment, the PRACH reference segment generating unit 312 may comprise a preamble sequence generation unit 402 , a first Discrete Fourier Transform (DFT) unit 404 , a subcarrier mapping unit 406 , an Inverse DFT (IDFT) unit 408 , a CP-insertion unit 410 , a segmenting unit 412 , a second DFT unit 414 , and a first subcarrier de-mapping unit 416 .
In one embodiment, the PRACH preamble detecting unit 314 may comprise a receiving unit 502 , a segmentation unit 504 , a third DFT unit 506 , a second subcarrier de-mapping unit 508 , a multiplication unit 510 , an adding unit 512 , a second Inverse DFT (IDFT) unit 514 , and a PRACH preamble detection unit 516 .
The memory 308 may include any computer-readable medium known in the art including, for example, volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes.
The interface(s) 310 may include a variety of software and hardware interfaces, for example, a web interface, a Graphical User Interface (GUI), a Command Line Interface (CLI) and the like. The interface(s) 310 may be used for configuring the base station 302 .
Further, the LTE communication system 300 may be implemented using communication standards such as IEEE 802.16 (WiMAX), 3GPP-LTE, and other standards which require an exclusive set of frequency bands and where nodes periodically send signals on each band in the exclusive set, even when no user communication is performed. For example, a communication standard may periodically communicate synchronization and control signals. These signals may be time-slotted, but they have to be transmitted on the entire frequency band, as is the case for Long Term Evolution (LTE). The invention is also understood to be applicable to various networks in which unreserved spectrum are available, as in Frequency Division Multiple Access (FDMA) deployment. The invention may be implemented using other communication standards and technologies present in the art.
The base station 302 may comprise suitable logic, interfaces, circuitry, and/or code that may be operable to communicate data and voice wirelessly by utilizing one or more cellular standards such as IS-95, CDMA2000, GSM, UMTS, TD-SCDMA, extensions thereto, and/or variants thereof. In this regard, the base station 302 may communicate with communication devices such as the mobile terminals ( 304 - 1 to 304 -N). Exemplary cellular standards supported by the base station 302 may be specified in the International Mobile Telecommunications-2000 (IMT-2000) standard and/or developed by the 3rd generation partnership project (3GPP) and/or the 3rd generation partnership project 2 (3GPP2). Additionally, the base station 302 may each comprise suitable logic, interfaces, circuitry, and/or code that may be operable to communicate over Internet Protocol (IP) capable networks.
The base station 302 may be connected to other base stations or other networks. The other networks may comprise corporate intranet, Internet, public switched telephone network (PSTN), a Serving General Packet Radio Services (GPRS) Support Node (SGSN), a Gateway GPRS Support Node (GGSN), Evolved Packet Core (EPC), and the like.
Referring now to FIG. 4 the Physical Random Access Channel (PRACH) segment generating unit 312 of the base station 302 is described, in accordance with an embodiment of the present subject matter. The preamble sequence generation unit 402 may generate a plurality of preamble sequences. In one case, the plurality of preamble sequences may be generated by using a Constant Amplitude Zero Autocorrelation (CAZAC) sequence. The CAZAC sequences are also known as Zadoff-Chu (ZC) sequences. The CAZAC sequence has best auto-correlation properties and is thus used for generating the plurality of preamble sequences. Each preamble sequence of the plurality of preamble sequences may have a length of valid CAZAC sequence. The length of each preamble sequence may be one of 839 and 139. A preamble sequence length of 839 may be used for both Time-Division Duplexing (TDD) and Frequency-Division Duplexing (FDD). Further, a preamble sequence length of 139 may be used only for TDD. The plurality of preamble sequences are generated using a below mentioned Equation 1.
x
u
[
n
]
=
ⅇ
j
π
n
(
n
+
1
)
u
N
ZC
,
n
∈
{
0
,
1
,
…
,
N
ZC
-
1
}
Equation
1
In Equation 1, u denotes a root sequence number and N ZC =839 for PRACH preamble formats 0 to 3 and N ZC =139 for PRACH preamble format 4. In case a v th cyclic shift is introduced in the Equation 1, we get Equation 2 as mentioned below.
x u,v [n]=x u [n+vN CS ] Equation 2
In Equation 2, v denotes a number of cyclic shift i.e. v th cyclic shift and N CS denotes a configurable parameter determining a gap between cyclic shifts. Post generation of the plurality of preamble sequences, the first Discrete Fourier Transform (DFT) 404 unit may transform the preamble sequences into frequency domain signals by performing a DFT operation on the preamble sequences. Subsequently, the subcarrier mapping unit 406 may generate subcarrier mapped signals by performing subcarrier mapping of the frequency domain signals. The subcarrier mapping may be performed based on a subcarrier spacing associated with a Physical Random Access Channel (PRACH) in the LTE communication system 300 .
After generation of the subcarrier mapped signals, the Inverse DFT (IDFT) unit 408 may operate on the subcarrier mapped signals. The IDFT unit 408 may transform the subcarrier mapped signals into time domain signals by performing an IDFT operation. In one case, the time domain signals may be sampled at a sampling rate suitable to a receiver system and a suitable IDFT length is selected based on the sampling rate, so as to perform transformations. Thereafter, the time domain signals may be processed by the CP-insertion unit 410 . The CP-insertion unit 410 may add a Cyclic Prefix (CP) to a time domain signal of the time domain signals for generating a standard PRACH preamble signal. Specifically, the CP is a copy of an end-segment of the time domain signal and acts as a guard interval to prevent an Inter Symbol Interference (ISI) between the time domain signals.
Subsequent to generation of the standard PRACH preamble signal, the segmenting unit 412 may segment the standard PRACH preamble signal to generate a plurality of segments. In one case, the plurality of segments may be of uniform sizes. The segments may either be contiguous or non-contiguous. The non-contiguous segments may be separated due to presence of a time gap in between each segment of the non-contiguous segments.
Consequently after generation of the plurality of segments, the second DFT unit 414 may perform a half-subcarrier shift and a DFT operation on the plurality of segments in order to generate frequency domain segments. In one case, the frequency domain segments may comprise sub-carriers spaced in accordance with a Single Carrier Frequency Division Multiple Access (SC-FDMA) signal. After generation of the frequency domain segments, the first subcarrier de-mapping unit 416 may select frequency locations from the frequency domain segments. The frequency locations may correspond to PRACH frequency locations. Upon selection of the frequency locations, PRACH reference segments are generated. Thus, the base station 302 may generate the PRACH reference segments for once, in an above described manner. Thereafter, the base station 302 may use the PRACH reference segments for detecting the PRACH preambles using a below described technique.
Referring now to FIG. 5 the PRACH preamble detecting unit 314 of the base station 302 is described, in accordance with an embodiment of the present subject matter. Simultaneously using FIG. 6 , a block representation of a method for detecting the PRACH preambles is described along with the FIG. 5 . A receiving unit 502 may receive a signal for detecting Physical Random Access Channel (PRACH) preambles, as shown at step 602 . The signal may get shifted in time domain due to propagation delays in the LTE communication system. In one case, the receiver operates assuming a known timing delay which could be 0. The signal may comprise the Cyclic Prefix (CP) and a PRACH preamble sequence part.
Post receiving the signal, a segmentation unit 504 may operate on the signal. The signal is now referred to as the PRACH preamble sequence part. The segmentation unit 504 may segment the signal into a plurality of segments, as shown at step 604 . In one case, the plurality of segments may be of uniform sizes. The plurality of segments may be one of contiguous segments or non-contiguous segments. The contiguous segments may not have a time gap between one another, as illustrated by the step 604 . But, the non-contiguous segments may have time-gap in between adjacent segments of the plurality of segments. The non-contiguous segments (l=0 to l=11) are as shown at step 704 in FIG. 7 . FIG. 7 shows a block representation of a method for detecting PRACH preambles in LTE communication system, in accordance with another embodiment of the present subject matter. The steps present in the FIG. 7 works in a similar manner as the steps described using the FIG. 6 . The non-contiguous segments, as shown in the FIG. 7 , may correspond to Single Carrier Frequency Division Multiple Access (SC-FDMA) symbols associated with Long Term Evolution (LTE) standards.
Subsequent to generation of the plurality of segments, a third Discrete Fourier Transform (DFT) unit 506 may perform a half-subcarrier shift and a DFT on the plurality of segments to generate frequency domain segments, as shown at step 606 . Thereafter, the second subcarrier de-mapping unit 508 may select frequency locations from the frequency domain segments for generating PRACH frequency segments, as shown at step 608 . Specifically, the frequency locations correspond to PRACH frequency locations. In one case, for the non-contiguous segments, the half-subcarrier shift and the DFT may be performed on a useful portion of the SC-FDMA symbols in order to generate the frequency domain segments. The frequency domain segments may comprise sub-carriers spaced in accordance with the SC-FDMA signal.
Post generation of the PRACH frequency segments, a multiplication unit 510 may multiply, at step 610 , the PRACH frequency segments with a complex conjugate of the PRACH reference segment (step 612 ) to produce intermediate correlation segments, as shown at step 614 . Specifically, the value at each frequency location of the PRACH frequency segments may be multiplied with a complex conjugate of the value at a corresponding frequency location of the PRACH reference segment. In one case, each intermediate correlation segment may comprise a number of sub-carriers spanning the PRACH frequency region as defined by the LTE communication system i.e. the LTE standard. In one case, each intermediate correlation segment may comprise 72 sub-carriers.
Upon producing the intermediate correlation segments, an adding unit 512 may add corresponding frequency locations of each intermediate correlation segment for generating a combined intermediate correlation result, as shown at step 616 . A second Inverse DFT (IDFT) unit 514 may perform an IDFT operation on the combined intermediate correlation result to generate a correlation result, as shown at step 618 . An IDFT size of 128 is used for the PRACH reference segments in the embodiments of present invention.
Subsequent to the generation of correlation result, a PRACH preamble detection unit 516 may compare peaks of the correlation result with a predefined threshold to identify one or more peak locations. The one or more peak locations may be indicative of one or more PRACH preambles detected by the PRACH detection unit 516 , as shown at step 620 .
Further, a timing advance may be derived based on the peak location. The timing advance may be used by the receiver for synchronization, which was initially considered as zero by the receiver. Thereupon, the base station 302 may use the PRACH signal to determine synchronization information to be used for achieving synchronization in communication with a/the mobile terminal 304 .
Thus, in one embodiment, the base station 302 may detect PRACH signals in the above described manner. It must be understood that the base station 302 may detect PRACH signals in other manners lying within the spirit and scope of the present subject matter.
Referring now to FIG. 8 , a flowchart 800 illustrating a method for generating PRACH reference segments in a LTE communication system is described in accordance with an embodiment of the present subject matter. The method 800 may be described in the general context of computer executable instructions. Generally, computer executable instructions can include routines, programs, objects, components, data structures, procedures, modules, functions, etc., that perform particular functions or implement particular abstract data types. The method 800 may also be practiced in a distributed computing environment where functions are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, computer executable instructions may be located in both local and remote computer storage media, including memory storage devices.
The order in which the method 800 , as illustrated in FIG. 8 , is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method 800 or alternate methods. Additionally, individual blocks may be deleted from the method 800 without departing from the spirit and scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof. However, for ease of explanation, in the embodiments described below, the method 800 may be considered to be implemented on the above described base station 302 .
At block 802 , a plurality of preamble sequences may be generated. The plurality of preamble sequences may be generated by using a CAZAC sequence. The plurality of preamble sequences may be generated by the base station 302 .
At block 804 , the preamble sequences may be transformed into frequency domain signals. The preamble sequences may be transformed by performing a DFT operation on the preamble sequences. In one implementation, the preamble sequences may be transformed by the base station 302 .
At block 806 , subcarrier mapped signals may be generated. The subcarrier mapped signals may be generated by performing subcarrier mapping of the frequency domain signals. The subcarrier mapping may be performed based on a subcarrier spacing associated with a Physical Random Access Channel (PRACH) in a Long Term Evolution (LTE) communication system. The subcarrier mapped signals may be generated by the base station 302 .
At block 808 , the subcarrier mapped signals may be transformed into time domain signals by performing an IDFT operation. The time domain signals may be sampled at a sampling rate suitable to a receiver system and a suitable IDFT length may be selected based on the sampling rate, in order to perform transformations. The subcarrier mapped signals may be transformed into the time domain signals by the base station 302 .
At block 810 , a standard PRACH preamble signal may be generated. The standard PRACH preamble signal may be generated by adding a Cyclic Prefix (CP) to a time domain signal of the time domain signals. Specifically, the CP is a copy of an end-segment of the time domain signal. The standard PRACH preamble signal may be generated by the base station 302 .
At block 812 , the standard PRACH preamble signal may be segmented to generate a plurality of segments of uniform size. The segments may either be contiguous or non-contiguous. The non-contiguous segments may be separated by a time gap accommodated in between each segment of the non-contiguous segments. The standard PRACH preamble signal may be segmented to generate a plurality of segments, by the base station 302 .
At block 814 , frequency domain segments may be generated by performing a half-subcarrier shift and a DFT on the plurality of segments. The frequency domain segments may comprise sub-carriers spaced in accordance with a Single Carrier Frequency Division Multiple Access (SC-FDMA) signal. The frequency domain segments may be generated by the base station 302 .
At block 816 , PRACH reference segments may be generated by selecting frequency locations from the frequency domain segments. Specifically, the frequency locations correspond to PRACH frequency locations. The PRACH reference segments may be generated by the base station 302 .
Although implementations for methods and systems for generating Physical Random Access Channel (PRACH) reference segments in a Long Term Evolution (LTE) communication system have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as examples of implementations for generating PRACH reference segments in the LTE communication system.
Referring now to FIG. 9 , a flowchart 900 illustrating a method for detecting Physical Random Access Channel (PRACH) preambles in a Long Term Evolution (LTE) communication is described in accordance with an embodiment of the present subject matter. The method 900 may be described in the general context of computer executable instructions. Generally, computer executable instructions can include routines, programs, objects, components, data structures, procedures, modules, functions, etc., that perform particular functions or implement particular abstract data types. The method 900 may also be practiced in a distributed computing environment where functions are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, computer executable instructions may be located in both local and remote computer storage media, including memory storage devices.
The order in which the method 900 , as illustrated in FIG. 9 , is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method 900 or alternate methods. Additionally, individual blocks may be deleted from the method 900 without departing from the spirit and scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof. However, for ease of explanation, in the embodiments described below, the method 900 may be considered to be implemented on the above described base station 302 .
At block 902 , a signal may be received. The signal may be processed for detecting PRACH preambles. The signal may be received by the base station 302 .
At block 904 , the signal may be segmented into a plurality of segments of uniform sizes. The plurality of segments may be one of contiguous segments or non-contiguous segments. The contiguous segments may not have any time gap between one another. The non-contiguous segments may have time-gap in between adjacent segments of the plurality of segments. The non-contiguous segments may correspond to Single Carrier Frequency Division Multiple Access (SC-FDMA) symbols associated with Long Term Evolution (LTE) standards. The signal may be segmented into a plurality of segments by the base station 302 .
At block 906 , frequency domain segments may be generated. The frequency domain segments may be generated by performing a half-subcarrier shift and a DFT on the plurality of segments. The frequency domain segments may be generated by the base station 302 .
At block 908 , PRACH frequency segments may be generated. The PRACH frequency segments may be generated by selecting frequency locations from the frequency domain segments. The frequency locations may correspond to PRACH frequency locations. The PRACH frequency segments may be generated by the base station 302 .
At block 910 , intermediate correlation segments may be produced. The intermediate correlation segments may be produced by multiplying the value at each frequency location of the PRACH frequency segments with a complex conjugate of the value at a corresponding frequency location of a PRACH reference segment. Each intermediate correlation segment may comprise number of sub-carriers spanning the PRACH frequency region as defined in a LTE communication system. The intermediate correlation segments may be produced by the base station 302 .
At block 912 , a combined intermediate correlation result may be generated. The combined intermediate correlation result may be generated by adding corresponding frequency locations of each intermediate correlation segment. The combined intermediate correlation result may be generated by the base station 302 .
At block 914 , a correlation result may be generated. The correlation result may be generated by performing an IDFT on the combined intermediate correlation result. The correlation result may be generated by the base station 302 .
At block 916 , PRACH preambles may be detected. The PRACH preambles may be detected by comparing peaks of the correlation result with a predefined threshold to identify a peak location. Further, a timing delay may be identified based on the peak location. The PRACH preambles may be detected by the base station 302 .
Although implementations for methods and systems for detecting Physical Random Access Channel (PRACH) in a Long Term Evolution (LTE) communication system have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as examples of implementations for detecting the PRACH in the LTE communication system.
Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include those provided by the following features.
Some embodiments may enable a system and a method to reduce number of transformations of a signal between a time domain and a frequency domain, for detecting a PRACH.
Some embodiments may enable a system and a method to use a 128 point Fast Fourier Transform (FFT) for detecting PRACH preambles.
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The present subject matter discloses a method implemented on a base station for generating Physical Random Access Channel (PRACH) reference segments and detecting PRACH preambles in a Long Term Evolution (LTE) communication system. The base station performs a series of mathematical techniques to generate the PRACH reference segments using a CAZAC sequence used for detecting PRACH preambles. Further, the base station identifies the PRACH by using a signal received by the base station. The base station segments the signal to generate contiguous or non-contiguous segments. Further, the base station uses a segment by segment multiplication and subsequent addition approach performed between values at each frequency location of PRACH frequency segments with a complex conjugate of the values at a corresponding frequency location of a PRACH reference segment. Subsequently the products are added together. The sum is then processed to detect one or more PRACH preambles and timing delays.
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CROSS-REFERENCE
[0001] This is a U.S. patent application of U.S. Provisional Application No. 61/066,235 filed on Feb. 19, 2008 for ORTHOPEDIC PLATE FOR USE ON A SINGLE RAY IN THE MIDFOOT which is hereby fully incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an orthopedic plate which is configured for the fixation of a bone or bones of the midfoot including, for example, stabilization of a fracture, dislocation or reconstruction of a deformity.
BACKGROUND OF THE INVENTION
[0003] Together the foot and ankle have over 25 bones and 33 joints along with more than 100 named muscles, tendons, and ligaments and a network of blood vessels, nerves, all residing beneath a relatively slim covering of soft tissue and skin. Structurally, the foot has three main anatomical regions: the forefoot, the midfoot, and the hindfoot. These parts work together with the ankle, to provide the body with support, balance, and mobility. A structural flaw or malfunction in any one part can result in the development of problems, which are manifested in other areas of the body.
[0004] The forefoot includes the five toes (which are also known as the “phalanges”) and their connecting long bones (or “metatarsals”). Several small bones together comprise a phalanx or toe. Four of the five toes have three phalanx bones respectively connected by two joints. The big toe (or “hallux”) has two phalanx bones distal and proximal with a joint in between called the interphalangeal joint. The big toe articulates with the head of the first metatarsal at the first metatarsophalangeal joint (the “MTP” joint) and there are two tiny, round bones called sesamoids on the plantar side of the metatarsal head. The phalanges are connected to the metatarsals at the ball of the foot. The forefoot balances pressure on the ball of the foot and bears a substantial amount of the body weight.
[0005] The bones of the midfoot from medial to lateral are the 1 st through 3 rd cuneiform, the cuboid, and the crescent shaped navicular bone posterior to the cuneiforms, which also forms a joint with the talus that forms the basis for the ankle joint at the hinged intersection of the tibia, the fibula, and the foot The five tarsal bones of the midfoot act together form a lateral arch and a longitudinal arch which help to absorb shock. The plantar fascia (arch ligament) underlays the bones of the midfoot and along with muscles, forms a connection between the forefoot and the hindfoot. The toes and their associated midfoot bones form the first through fifth rays beginning with the great toe as the first ray.
[0006] The hindfoot is composed of three joints (subtalar, calcaneocuboid & talonavicular) and links the midfoot to the ankle. The heel bone (or “calcaneus”) projects posteriorly to the talus and forms a lever arm to activate the hinged action of the foot so as to allow propulsion of the entire body from this joint. The calcaneus is joined to the talus at the subtalar joint.
[0007] The mid-foot is often the subject of trauma such as results from falls, vehicle crashes and dropped objects. These accidents often result in severe fractures and/or dislocations. A common midfoot fracture is the Lisfranc injury which was identified by a French doctor in the Napoleonic Wars. It commonly occurred when a cavalier fell from his horse with his foot caught in his stirrup and resulted in the fracture and dislocation of multiple bones of the midfoot. A Lisfranc injury has come to indicate an injury to the normal alignment of the cuneiforms and metatarsal joints with the loss of their normal spatial relationships. These types of injuries may occur from dropping a heavy object on the top of the foot or stepping on an uneven surface and falling with the foot in a twisted position. These fractures also occur in athletes when the foot is bound to an article of sports equipment such as skis or snowboards or when the foot is subject to simultaneous impact and rotation, such as skating or ballet jumps or soccer.
[0008] A common Lisfranc injury occurs at the joint primarily involving the 1st and 2nd metatarsals and the medial cuneiform. Normal alignment of the joints is lost if the ligaments are disrupted and the bones separate between the medial and mid-cuneiforms or between the 1st, 2nd metatarsal and the medial cuneiform. Failure to treat such an injury may result in joint degeneration and subsequent damage to the adjacent nerves and blood vessels.
[0009] Typical surgical treatment of the midfoot re-establishes the normal anatomy of the mid-foot while the fractured bones mend. In some cases, fusion of the joint between the first and second metatarsals and the middle and/or internal cuneiforms may be necessary, for example, where arthritis arises in patients with a prior Lisfranc or similar injury. One current surgical treatment of this injury requires that pins, wires and/or screws be inserted to stabilize the bones and joints and hold them in place until healing is complete. For example, a pin or screw may be introduced medially into the internal cuneiform and through the base of the second metatarsal bone. While the use of k-wires, pins, and screws may provide acceptable results for younger and more plastic patients, these methods of fixation are not always satisfactory.
SUMMARY OF THE INVENTION
[0010] In accordance with the present invention an orthopedic plate is provided that is a handy and elegant little plate that can be used in place of a compression staple with better pull-out values, improved compression, and less harm to the bone in which it is used. The invention can be used in a wide variety of indications including for example, lapidus bunionenctomy, calcaneolocuboid fusion, talonavicular fusion, MTP fusion, cuboid fracture, metarsocunieform fusion, chevron osteotomy, Naviculocuneioform fusion, Dwyer osteotomy, cotton osteotomy, isolated TMT fusion, Navicular fracture, Evans osteotomy and the previously mentioned Lisfranc fracture. The present invention is further specifically configured for implantation at the mid-foot and more specifically is configured for use in a single ray The plate has a dumbbell or peanut shaped, footprint which consists simply of two rounded tabs along the longitudinal axis of the plate with a narrowed waist section between the tabs. The longer of the two tabs includes a compression slot that extends in a direction and causes compression toward a locking screw hole in the opposing tab. The plate is radiused along the bottom surface along the longitudinal axis of the plate so that the plate forms a section of a cylinder, which is bilaterally symmetrical with respect to a plane passing through the longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a dorsal view of a mid-foot with an orthopedic plate in accordance with the invention is positioned for the third ray;
[0012] FIG. 2 is a top view of the orthopedic plate of FIG. 1 ;
[0013] FIG. 3 is a side view of the plate shown in FIG. 2 ;
[0014] FIG. 4 is an end view of the plate shown in FIG. 3 ;
[0015] FIG. 5 is a top perspective of the plate shown in FIG. 2 ;
[0016] FIG. 6 is a end perspective of the plate shown in FIG. 2 ;
[0017] FIG. 7 is a bottom perspective of the plate shown in FIG. 2 ; and
[0018] FIG. 8 is a side perspective of the plate shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 shows a skeletal version of a foot from the top (i.e. the dorsal view) with the midfoot plate 10 of the present invention in place between the junction of the third metatarsal and the third cuneiform (i.e. the lateral cuneiform). Thus. FIG. 1 illustrates the plate used in fixation of the bones of the third ray or 3nd TMT (tarso-metatarsal) joint. The plate can also be used for fixation of the first and second ray, that is, for fixation of the 1st TMT joint (1st metatarsal to medial cuneiform) and 2nd TMT joint (2nd Metatarsal to middle or intermediate cuneiform). Similarly, it can be used for fixation of the joints of the other rays, for example where a surgical staple might currently be used.
[0020] As viewed from the top in FIG. 2 , it can be seen that the plate 10 has two opposing tabs comprising a longer tab 12 and a second shorter tab 14 aligned along the longitudinal axis of the plate. The longer tab 12 includes a compression slot 20 , and the other 14 of the pair of tabs includes a screw hole 22 (which preferably includes locking means such as internal threads or a variable locking mechanism, so as to form a locking interface between the plate and the respective bone or bone fragment by means of the rigid fastening of the screw in the screw hole in the plate.) The compression slot is configured so as to cause compression along the longitudinal axis of the plate in the direction of the locking screw hole. The plate includes incurvatures 23 between the tabs to form a waist section which minimizes the material used and maximizes the fit of the plate, as well as allowing additional contouring of the plate in this area, should it be desired.
[0021] FIGS. 3 and 4 illustrate the edge on views of the plate in along a first length and along the second shorter length which is perpendicular to the first length. As can be seen the plate has a generally uniform thickness between the inward surface 27 which opposes and optimally, but not necessarily engages the bones, and the outward surface 29 . In addition, the inward surface 27 of the plate 10 includes a generally uniform radius of curvature 34 along the longitudinal axis. Thus, the plate has the shape of a segment of a cylinder which maximizes the ability to place the plate as desired without the need for additional pre-surgical contouring, although the plate thickness allows for bending if necessary
[0022] The screws useful with the plate of the present invention are self-starting, self-tapping screws including the option of partial or full cannulation. The screws include a cutting end having multiple flutes, and preferably 2 or 3 flutes about a conical recess. The screws further include a partial taper of the inner diameter in the proximal end over the first several thread turns, for example over 2-8, and preferably over 3-5 turns in order to increase the fatigue life of the screw as well as providing potential physiological advantages in use. The screws further include a torque driving recess. The screws have a threaded distal end and a head including a torque driving recess. The head of the locking screw includes locking means, such as a variable locking mechanism, which could be a bushing that mates with the screw head so as to lock the screw relative to the plate at a desired angle, or could include external screw threads that mate with internal threads in the locking screw hole at a pre-selected angle, in this instance, the screw axis is perpendicular to the longitudinal axis of the plate. The screw used in the compression slot has a rounded rear shoulder (such as a hemisphere, or a torroid) which mates with the concavely rounded groove of the compression slot so as to maximize surface contact between the screw head and the inclined geometry of the compression slot. The lateral edge of the compression slot further includes an inclined shoulder that slopes downward toward the bone-contacting surface of the plate and which is engaged by the screw head to cause the translation of the screw and attached bone fragment along the long axis of the slot and towards the locking hole.
[0023] The plate is formed of a biocompatible material, and preferably a metal such as surgical grade stainless steel, titanium or a titanium alloy. Preferably, the plate has a thickness of between about 1.0 and 2.0 millimeters, more preferably between about 1.25 and 1.75 millimeters, and most preferably between about 1.4 and 1.6 millimeters. The plate includes a continuous outer edge 40 which is defined between the top and the bottom surface.
[0024] In addition, the plate 10 can include a small through hole sized to receive a K-wire or other similar guide wire.
[0025] During the surgery the joints are first prepped which may include de-articulation between the bones to be fused. The proper length plate is selected and as necessary, the plate is bent to contour to the bone surface. The plate is placed and held in place using olive wires (thru compression slot and into the bone). The plate is located such that all of the screws are aimed into the targeted bones and away from the joint, fracture, or bone interface. A pilot hole is drilled, for example using a drill guide such as a guide including keyway guides (i.e. lobes) that interlock with corresponding keyway openings in the locking screw hole. The locking screw is tightly screwed into the bone. The olive wire is removed if used, and a pilot hole is drilled at the end of the compression slot farthest away from the fusion or fracture and locking hole. A non-locking screw is inserted into the pilot hole and tightened. As the screw is tightened in the compression slot, it will drive compression toward the fusion site and locking hole. The plate allows for up to 1.5 millimeters of compression. The plate is viewed radiographically, and the soft tissues are closed in the usual manner.
[0026] While in accordance with the patent statutes the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.
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An orthopedic plate is specifically configured for implantation at the mid-foot and can be used for a variety of indications. The plate has a set of tabs comprising one longer tab and one shorter tab opposing each other along the length of the plate. In each set of tabs, one tab includes a compression slot that extends in a direction toward a screw hole in the opposing tab.
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RELATED APPLICATIONS
[0001] This application claims priority to Chinese Application Serial Number 201110240463.1, filed Aug. 19, 2011, which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of Invention
[0003] The invention relates to a rotary electric machine. More particularly, the invention relates to a rotary electric machine with a structure design of magnetic steel.
[0004] 2. Description of Related Art
[0005] A preferred material for forming a magnetic steel of an electric machine is neodymium iron boron. However, currently, the price of rare earth materials is rising; and therefore in order to reduce the cost, it is expected in this industry to use permanent magnetic materials (such as ferrites) with weak magnetic properties but low price to replace the neodymium iron boron. However, since the remanence of the ferrite material is only 0.2-0.44 T, and the maximum magnetic energy product thereof is only 6.4-40 kJ/m 3 , a simple replacement may cause decrease in output power and efficiency of the electric machine.
[0006] Thus, in the prior art, a method in which the axial length of a rotor is increased (i.e., tangential magnetic steel in a rotor core is increased) is used for increasing the sectional area of the magnetic steel and improving the output power. However, this method results in the volume and cost increase of the electric machine. A composite rotor magnetic path structure is also used in the prior art. That is, magnetic steels are arranged along both the tangential and the axial directions in the rotor. However, this structure can only use a space within the rotor diameter to place the magnetic steels, and thus the space for receiving the magnetic steels limited.
[0007] In view of this, it is a problem desired to be solved by those of relevant skills in this industry regarding how to design an electric machine, in which the air gap flux density is improved, and hence the output power of the electric machine is improved without increasing the total volume thereof.
SUMMARY
[0008] In order to solve the technical issues mentioned above, an aspect of the invention is to provide a rotor including a shaft, a rotor core coaxially connected to the shaft, at least one tangential magnetic steel fixed in the rotor core along at least one tangential direction of the rotor core, a first axial magnetic steel and a second axial magnetic steel. The tangential magnetic steel has a first and a second magnetic pole. The first axial magnetic steel is disposed at one end surface of the rotor core and adjacent to the first magnetic pole of the tangential magnetic steel. The first axial magnetic steel has a third magnetic pole facing the rotor core, and the third magnetic pole and the first magnetic pole repel each other. The second axial magnetic steel is disposed at an end surface of the rotor core and adjacent to the second magnetic pole of the tangential magnetic steel. The second axial magnetic steel has a fourth magnetic pole facing the rotor core, and the fourth magnetic pole and the second magnetic pole repel each other.
[0009] Preferably, the rotor further includes a radial magnetic steel fixed in the rotor core along a direction parallel to the shaft, wherein the radial magnetic steel is adjacent to the tangential magnetic steel.
[0010] Another aspect of the invention is to provide a rotary electric machine including an electric machine stator and a rotor. The electric machine stator is formed from stator windings and a stator core, and the rotor is formed from a rotor core and a shaft, and an air gap is provided between the electric machine stator and the rotor. The rotor further includes a plurality of axial magnetic steels respectively disposed at two end surfaces of the rotor core, and a plurality of tangential magnetic steels fixed in the rotor core along tangential directions of the rotor core. Magnetic field lines of the axial magnetic steel and the tangential magnetic steel pass through the air gap.
[0011] Preferably, a magnetizing direction of the axial magnetic steel is parallel to the shaft, and magnetizing directions of two adjacent axial magnetic steels are opposite.
[0012] Preferably, the material forming the tangential magnetic steel or the axial magnetic steel is ferrite or neodymium iron boron.
[0013] Preferably, the rotor further includes a rotor bushing installed on the shaft, for fixing the axial magnetic steel on the end surface of the rotor core, wherein the rotor bushing is made of a permeable material for allowing magnetic field lines of the axial magnetic steel to pass through.
[0014] Preferably, the rotor further includes a plurality of radial magnetic steels fixed in the rotor core along a direction parallel to the shaft, wherein one radial magnetic steel is adjacent to two tangential magnetic steels.
[0015] Yet another aspect of the invention is to provide a rotor including a shaft, a rotor core coaxially connected to the shaft, a first axial magnetic steel, a second axial magnetic steel and at least one magnetic isolation groove. The first axial magnetic steel disposed at one end surface of the rotor core has a first magnetic pole facing the rotor core. The second axial magnetic steel disposed at the end surface of the rotor core has a second magnetic pole facing the rotor core. The magnetic isolation groove formed in the rotor core along the tangent is positioned between the first and the second axial magnetic steel.
[0016] Preferably, the rotor further includes a radial magnetic steel fixed in the rotor core along a direction parallel to the shaft. The radial magnetic steel has a third magnetic pole and a fourth magnetic pole. The fourth magnetic pole is disposed farther away from the shaft than the third magnetic pole, and the fourth magnetic pole and the first or the second magnetic pole repel each other.
[0017] Still another aspect of the invention is to provide a rotary electric machine including an electric machine stator and a rotor. The electric machine stator is formed from stator windings and a stator core, and the rotor is formed from a rotor core and a shaft, and an air gap is provided between the electric machine stator and the rotor. The rotor further includes a plurality of axial magnetic steels respectively disposed at two end surfaces of the rotor core; a plurality of radial magnetic steels fixed in the rotor core along a direction parallel to the shaft; and a plurality of magnetic isolation grooves formed in the rotor core along tangential directions of the rotor core for blocking magnetic field lines of the axial magnetic steel from passing through, wherein the magnetic field lines of the axial magnetic steel and the radial magnetic steel pass through the air gap.
[0018] Preferably, one or more of the plurality of magnetic isolation grooves are replaced by one or more tangential magnetic steel, so that the magnetic isolation groove and the tangential magnetic steel are mixed and arranged in the rotor core.
[0019] Preferably, a magnetizing direction of the axial magnetic steel is parallel to the shaft, and magnetizing directions of two adjacent axial magnetic steels are opposite to each other.
[0020] Preferably, the material forming the radial magnetic steel or the axial magnetic steel is ferrite or neodymium iron boron.
[0021] Preferably, the rotor further includes a rotor bushing installed on the shaft for fixing the axial magnetic steel on the end surface of the rotor core, wherein the rotor bushing is made of a permeable material for allowing the magnetic field lines of the axial magnetic steel to pass through.
[0022] To sum up, in the rotary electric machine provided by the invention, axial magnetic steels are installed at two ends of the rotor core, thereby improving the air gap flux density and hence the output power of the electric machine without increasing the original volume of the electric machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order to make the foregoing as well as other aspects, features, advantages, and embodiments of the invention more apparent, the accompanying drawings are described as follows:
[0024] FIG. 1 illustrates a cross-sectional view of an electric machine in an embodiment of the invention;
[0025] FIG. 2 illustrates a cross-sectional view of the rotary electric machine shown in FIG. 1 ;
[0026] FIG. 3 illustrates a schematic perspective view of a magnetic steel in FIG. 1 ;
[0027] FIG. 4 illustrates a schematic magnetic path view of the magnetic steel in FIG. 3 ;
[0028] FIG. 5 illustrates a schematic view of a rotor bushing in FIG. 1 ;
[0029] FIG. 6 illustrates a cross-sectional view of a rotary electric machine in another embodiment of the invention; and
[0030] FIG. 7 illustrates a cross-sectional view of a rotary electric machine in a further embodiment of the invention.
DETAILED DESCRIPTION
[0031] The invention will be described in details in the following embodiments with reference to the accompanying drawings, but these embodiments are not intended to limit the scope of the invention. The description of structure operation does not mean to limit its implementation order. Any device with equivalent functions that is produced from a structure formed by recombination of elements shall fall within the scope of the invention. The drawings are only illustrative and are not made according to the original size.
[0032] Referring to FIG. 1 , FIG. 1 illustrates a cross-sectional view of an electric machine in an embodiment of the invention. As shown in FIG. 1 , a rotary electric machine 100 includes a shell 1 , a stator core 2 , stator windings 3 , a rotor core 4 , a shaft 5 , a rotor bushing 6 , an axial magnetic steel 7 , a tangential magnetic steel 8 (as shown in FIG. 2 ), a shaft bearing 9 and an end cover 10 . An electric machine stator is formed from the stator core 2 and the stator windings 3 . A rotor is formed from the axial magnetic steel 7 , the tangential magnetic steel 8 , the rotor core 4 , the shaft 5 , the shaft bearing 9 and the rotor bushing 6 fixed at two ends of the rotor. The electric machine stator and the rotor are installed in the end cover 10 and the shell 1 . Moreover, the rotary electric machine 100 provided in the invention is a permanent magnetic electric machine.
[0033] Referring to FIGS. 2 and 3 , FIG. 2 illustrates a cross-sectional view of the rotary electric machine in FIG. 1 , and FIG. 3 illustrates a schematic perspective view of the magnetic steel in FIG. 1 . As shown in FIG. 2 , in this embodiment, the tangential magnetic steel 8 is of a 4-pole structure, and each pole includes an S pole and an N pole. However, in other embodiments, for example, the tangential magnetic steel 8 may be of a 6-pole or 8-pole structure, but not limited thereto. Additionally, it is known from FIG. 2 that an air gap 11 is provided between the electric machine stator and the rotor. As shown in FIG. 3 , the magnetic steel includes the axial magnetic steel 7 and the tangential magnetic steel 8 . The material forming the axial magnetic steel 7 and the tangential magnetic steel 8 is preferably ferrite, and for example, the material may also be neodymium iron boron, but not limited thereto.
[0034] The specific structure of the rotary electric machine 100 in this embodiment will be described with reference to FIGS. 1 , 2 and 3 hereinafter.
[0035] In this embodiment, each tangential magnetic steel 8 is installed in a respective rotor core 4 , and each tangential magnetic steel 8 has magnetic poles S and N. The axial magnetic steel 7 is installed at the end surface (in the axial zone) of the rotor core 4 and is adjacent to the tangential magnetic steel 8 . The magnetizing direction of the axial magnetic steel 7 is parallel to the shaft 5 . The magnetizing directions of two adjacent axial magnetic steels 7 are opposite to comply with a polar parallelism relation. For example, the axial magnetic steel 7 A and the axial magnetic steel 7 B have opposite polarities. In this embodiment, the axial magnetic steel 8 and the tangential magnetic steel 7 comply with a polar parallelism relation. As shown in FIG. 3 , the magnetic pole of the axial magnetic steel 7 A at the face adjacent to the rotor core 4 is an N pole, and thus the magnetic pole of the tangential magnetic steel 8 at the face adjacent to the N pole of the axial magnetic steel 7 A is an N pole, wherein the two N poles repel with each other, and vice versa, the magnetic pole of the axial magnetic steel 7 B at the face adjacent to the rotor core 4 is an S pole, and thus the magnetic pole of the tangential magnetic steel 8 at the face adjacent to the S pole of the axial magnetic steel 7 B is an S pole. Other axial magnetic steels 7 and tangential magnetic steels 8 also comply with similar polar relations, and no further description will be stated herein.
[0036] It should be noted that the number and installing position of the axial magnetic steels 7 are not limited thereto, as long as the number satisfies the polar parallelism relation, and the installing position is in the axial zone. For example, if the number of the axial magnetic steels 7 is two, the axial magnetic steels 7 may be both installed at one end of the rotor core 4 . If the number of the axial magnetic steels 7 is four, the axial magnetic steels 7 may be all installed at one end of the rotor core 4 , or every two axial magnetic steels 7 may be installed at each end of the rotor core 4 . If the number of the axial magnetic steels 7 is six, four axial magnetic steels 7 may be installed at one end of the rotor core 4 , and two axial magnetic steels 7 may be installed at the other end of the rotor core 4 . If the number of the axial magnetic steels 7 is eight, every four axial magnetic steels 7 may be installed at each end of the rotor core 4 . The foregoing descriptions are merely stated for illustration, wherein the number of the axial magnetic steels 7 may be flexibly determined in accordance with the structure of the tangential magnetic steel 8 and the actual requirements, and the installing position may also be flexibly determined. In this embodiment, preferably, eight axial magnetic steels 7 are taken as an example for explanation, which are installed at two ends of the rotor core 4 .
[0037] Additionally, the axial magnetic steel 7 is fixed at the end surface of the rotor core 4 through the rotor bushing 6 . The rotor bushing 6 is fixed on the shaft 5 . The stator formed from the stator core 2 and the stator windings 3 is installed in the shell 1 . The shell 1 and the stator core 2 abut against each other, so as to fix the stator core 2 . End covers 10 are respectively installed at two ends of the shell 1 , and the end covers 10 are installed on the shaft 5 through the shaft bearing 9 .
[0038] Referring to FIGS. 1 and 3 again, the position arrangement and relationship between the axial magnetic steels 7 and the tangential magnetic steels 8 are illustrated. The axial magnetic steels 7 are installed at the end surface of the rotor core 4 , and the magnetizing directions of two adjacent axial magnetic steels 7 are opposite. In other words, the axial magnetic steels 7 at the same end surface are arranged in a magnetically staggered manner, such as the axial magnetic steels 7 A and 7 B. The tangential magnetic steels 8 are fixed in the rotor core 4 along the tangential directions. Two tangential magnetic steels 8 facing each other magnetically repel with each other, and each tangential magnetic steel 8 is arranged tangential to the position between two axial magnetic steels 7 . Moreover, the adjacent axial magnetic steel 7 and tangential magnetic steel 8 magnetically repel with each other. For example, if the magnetic pole of the axial magnetic steel 7 A at the face adjacent to the rotor core 4 is an N pole, then the magnetic pole of the adjacent tangential magnetic steel 8 at the face adjacent to the N pole of the axial magnetic steel 7 A is also an N pole, wherein the two N poles repel with each other. Similarly, if the magnetic pole of the axial magnetic steel 7 B at the face adjacent to the rotor core 4 is an S pole, then the magnetic pole of the adjacent tangential magnetic steel 8 at the face adjacent to the S pole of the axial magnetic steel 7 B is also an S pole.
[0039] Referring to FIGS. 2 and 4 at the same time, FIG. 4 illustrates a schematic magnetic path view of the magnetic steel in FIGS. 3 . The magnetic path of the axial magnetic steel 7 is described in detail below. In this embodiment, adjacent axial magnetic steels 7 A and 7 B are taken as an example for explanation.
[0040] Firstly, the magnetic field line A 1 extends from the N pole of the axial magnetic steel 7 A (the magnetic pole adjacent to the rotor core 4 ) into the rotor core 4 , and then proceeds in the rotor core 4 along a direction parallel to the shaft 5 , and subsequently reaches the stator core 2 after passing through the air gap 11 between the stator and the rotor along the radial direction of the rotor core 4 , and then returns to rotor core 4 from the stator core 2 through the air gap 11 , and thereafter reaches the S pole of the adjacent axial magnetic steel 7 B through the rotor core 4 , and finally the magnetic field line A 1 extends from the N pole of the adjacent axial magnetic steel 7 B and returns to the S pole of the axial magnetic steel 7 A through the rotor bushing 6 , thereby forming a loop of the magnetic field line A 1 . The magnetic path of the magnetic field line A 2 is similar to that of the magnetic field line A 1 , and thus no further description will be stated herein. The magnetic field lines B 1 and B 2 are respectively symmetrical with the magnetic field lines A 1 and A 2 , and no further description will be stated herein. It should be noted that, in this embodiment, the magnetic field lines A 1 , A 2 , B 1 and B 2 of the axial magnetic steel 7 are merely depicted for illustration, and in practice, the axial magnetic steel 7 has countless magnetic field lines.
[0041] It should also be pointed out that, due to the presence of the tangential magnetic steel 8 , the magnetic field line of the axial magnetic steel 7 is prevented from extending from the N pole of the axial magnetic steel along the rotor core 4 and directly entering the S pole of the adjacent axial magnetic steel without passing through the air gap 11 and the stator core 2 . That is, the tangential magnetic steel 8 described herein has a function of magnetic isolation. Particularly, for example, the tangential magnetic steel 8 is provided between the adjacent axial magnetic steel 7 A and axial magnetic steel 7 B. It can be known from FIG. 4 (with reference to FIG. 1 ) that the magnetic pole of the axial magnetic steel 7 A at the face adjacent to the rotor core 4 is an N pole, and the magnetic pole of the adjacent tangential magnetic steel 8 at the face adjacent to the N pole of the axial magnetic steel 7 A is also an N pole, wherein the two N poles repel with each other. Thus, if the magnetic field line of the axial magnetic steel 7 A is assumed to extend towards the direction of the tangential magnetic steel 8 after entering the rotor core 4 , the magnetic field line would be blocked by the tangential magnetic steel 8 , so that the magnetic field line of the axial magnetic steel 7 A could not pass through the tangential magnetic steel 8 . That is, the tangential magnetic steel 8 here has certain functions of magnetic isolation.
[0042] The magnetic field line C of the tangential magnetic steel 8 extends from the N pole of the tangential magnetic steel 8 , and reaches the S pole of the tangential magnetic steel 8 through the air gap 11 , and subsequently returns to the N pole of the tangential magnetic steel 8 through the inner part of the tangential magnetic steel 8 . It should be noted that only one magnetic field line of the tangential magnetic steel 8 is depicted herein for illustration, and in practice, each tangential magnetic steel 8 has countless magnetic field lines similar to the magnetic field line C.
[0043] It can be known from the above description that, in this embodiment, the magnetic field lines passing through the air gap 11 not only include the magnetic field lines generated by the tangential magnetic steel 8 , but also includes the magnetic field lines generated by the axial magnetic steel 7 . That is, in comparison with the electric machine of the prior art, the magnetic field lines in the air gap 11 also include the magnetic field lines generated by the axial magnetic steel 7 , and thus the air gap flux density of the electric machine is improved, and hence the output power of the electric machine is improved without increasing the volume of the electric machine or materials of the stator core, stator windings and the rotor core.
[0044] Referring to FIG. 5 , FIG. 5 illustrates a schematic view of the rotor bushing in FIG. 1 . As shown in FIGS. 1 and 5 , the rotor bushing 6 is used for fixing the axial magnetic steel 7 at the end surface of the rotor core 4 , and in this embodiment, the rotor bushing 6 is made of a permeable material to allow the magnetic field lines of the axial magnetic steel 7 to pass through (referring to the foregoing descriptions for the details). That is, in this embodiment, the rotor bushing 6 also can be used for assisting to form the magnetic field line loop of the axial magnetic steel 7 .
[0045] The advantages of this embodiment can be verified through specific experiment data described below. If an electric machine in which the material of the magnetic steel is neodymium iron boron is taken as a reference group, wherein the specification of the electric machine includes “an outer diameter of 270 mm, a axial length of 153 mm, and an air gap length of 0.8 mm”, and the electric machine only has a tangential magnetic steel inserted in the rotor core. If the prior art merely changing the material of the magnetic steel from the neodymium iron boron to ferrite is adopted for the electric machine, the air gap flux density of the electric machine is decreased by 30%. If the electric machine provided by the invention is adopted, which not only has the tangential magnetic steel inserted in the rotor core, but also has axial magnetic steels installed at two ends of the rotor core, when the material of magnetic steel is also assumed to be ferrite, then It can be known from calculation that, when the volume of the ferrite magnetic steel is about 6.1 times as large as that of the neodymium iron boron magnetic steel, the air gap flux density of the electric machine of this embodiment using the ferrite magnetic steel is substantially equal to that of the electric machine using the neodymium iron boron magnetic steel. However, since the material of the magnetic steel used in this embodiment is ferrite with a relative low price, in comparison with the relative expensive material, neodymium iron boron magnetic steel, originally adopted by the reference group, the overall magnetic steel cost is decreased to 28% of the overall magnetic steel cost of the reference group. In comparison with the prior art in which the length of the tangential magnetic steel is increased to provide the air gap flux density (the volume of the electric machine is thus increased), the electric machine of this embodiment does not increase the volume of the electric machine. Furthermore, in comparison with the current composite rotor magnetic path structure, since the magnetic steel of this embodiment is installed at two ends of the rotor core rather than in the rotor core, no limitation will be imposed on the volume of the magnetic steel of this embodiment.
[0046] Referring to FIG. 6 , FIG. 6 illustrates a cross-sectional view of a rotary electric machine in another embodiment of the invention. As shown in FIG. 6 , the difference between a rotary electric machine 600 and the rotary electric machine 100 is that the rotary electric machine 600 adopts a composite structure. That is, in the direction parallel to the shaft 5 , the rotary electric machine 600 not only has the tangential magnetic steels 8 inserted in the rotor core 4 , but also has radial magnetic steels 8 A inserted in the rotor core 4 . The radial magnetic steels 8 A are fixed in the rotor core 4 along a direction parallel to the shaft 5 and are adjacent to the tangential magnetic steels 8 . In this embodiment, the axial magnetic steels (not shown) may also be installed at two ends of the rotor core 4 . The specific installing position and structure of the axial magnetic steels can be known with reference to FIGS. 1 and 3 , and no further description will be stated herein. The magnetic field lines of the axial magnetic steels are the same as the magnetic field lines shown in FIG. 4 (e.g., A 1 and A 2 ). In this embodiment, since axial magnetic steels are added at two ends of the rotor core 4 , the air gap flux density is further improved.
[0047] Referring to FIG. 7 , FIG. 7 illustrates a cross-sectional view of a rotary electric machine in a further embodiment of the invention. As shown in FIG. 7 , the difference between a rotary electric machine 700 and the rotary electric machine 600 is that the rotary electric machine 700 adopts a radial structure. That is, the rotary electric machine 700 has the radial magnetic steels 8 A and does not have the tangential magnetic steels.
[0048] Particularly, in this embodiment, the rotor includes the radial magnetic steels 8 A, magnetic isolation grooves 8 B and axial magnetic steels (not shown). Each of the radial magnetic steels 8 A is fixed in the rotor core 4 along a direction parallel to the shaft 5 , and has magnetic poles S and N. The magnetic isolation grooves 8 B are arranged in the rotor core 4 along the tangential directions of the rotor core 4 , and are adjacent to the radial magnetic steels 8 A. The axial magnetic steels are installed at two end surfaces of the rotor core 4 and specific details can be known with reference to FIGS. 1 and 3 . In this embodiment, the radial magnetic steels 8 A and the axial magnetic steels have certain polar relations. Particularly, in two magnetic poles of the radial magnetic steel 8 A, both the magnetic pole thereof located farther away from the shaft 5 and the magnetic pole of the axial magnetic steel at the face adjacent to the rotor core 4 repel each other. In this embodiment, the magnetic isolation groove 8 B is arranged tangential to the position between each two axial magnetic steels. Preferably, the magnetic isolation groove 8 B is an air magnetic isolation groove.
[0049] In this embodiment, the magnetic field lines of the axial magnetic steels are the same as the magnetic field lines shown in FIG. 4 (e.g., A 1 and A 2 ), and thus no further description will be stated herein.
[0050] In this embodiment, the magnetic isolation grooves 8 B are used for blocking the magnetic field lines of the axial magnetic steels from passing through, thereby preventing the magnetic field lines of the axial magnetic steels from extending from the N poles of the axial magnetic steels along the rotor core 4 and directly entering the S poles of the adjacent axial magnetic steels without passing through the air gap 11 and the stator core 2 . In this embodiment, in a similar way, the axial magnetic steels (not shown) may also be installed at two ends of the rotor core 4 .
[0051] In this embodiment, one or more magnetic isolation grooves 8 B may also be replaced by the tangential magnetic steels. That is, the tangential magnetic steel and the magnetic isolation groove 8 B are mixed and arranged in the rotor core 4 .
[0052] In view of the above, in the rotary electric machine provided by the invention, the axial magnetic steels are installed at two ends of the rotor core, thereby improving the air gap flux density and hence the output power of the electric machine without increasing the original volume of the electric machine. The rotary electric machine provided by the invention is suitable for improve the air gap flux density without increasing the volume of the electric machine, and is especially appropriate for applying magnetic steels with low magnetic energy product in the electric machine. As such, the air gap flux density is improved without increasing the volume of the electric machine, and the cost of the electric machine is reduced.
[0053] Although the invention has been disclosed with reference to the above embodiments, these embodiments are not intended to limit the invention. It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit and scope of the invention. Therefore, the scope of the invention shall be defined by the appended claims.
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A rotor and a rotary electric machine containing the rotor are provided. The rotor includes a shaft, a rotor core coaxially connected to the shaft, at least one tangential magnetic steel, a first axial magnetic steel, and a second axial magnetic steel. The tangential magnetic steel is fixed in the rotor core along a tangential direction of the rotor core, and has first and second magnetic poles. The first axial magnetic steel disposed at one end surface of the rotor core is adjacent to the first pole, and has a third pole facing the rotor core, wherein the third pole and first pole repel each other. The second axial magnetic steel disposed at the end surface of the rotor core is adjacent to the second pole, and has a fourth pole facing the rotor core, wherein the fourth pole and the second pole repel each other.
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TECHNICAL FIELD
[0001] The present application relates generally to wind turbines and more particularly relates to a family of airfoil configurations for an inboard region of a wind turbine blade.
BACKGROUND OF THE INVENTION
[0002] Conventional wind turbines generally include two or more turbine blades or vanes connected to a central hub. Each blade extends from the hub at a root of the blade and continues to a tip. A cross-section of the blade is defined as an airfoil. The shape of an airfoil may be defined in relationship to a chord line. The chord line is a measure or line connecting the leading edge of the airfoil with the trailing edge of the airfoil. The shape may be defined in the form of X and Y coordinates from the chord line. The X and Y coordinates generally are dimensionless. Likewise, the thickness of an airfoil refers to the distance between the upper surface and the lower surface of the airfoil and is expressed as a fraction of the chord length.
[0003] The inboard region, i.e., the area closest to the hub, generally requires the use of relatively thick foils (30%≦t/c≦40%). The aerodynamic performance of conventional airfoil designs, however, degrades rapidly for thicknesses greater than 30% of chord largely due to flow separation concerns. For thicknesses above 40% of chord, massive flow separation may be unavoidable such that the region of the blade may be aerodynamically compromised.
[0004] Thus, there is a need for an airfoil design that provides improved aerodynamic performance particularly with respect to the inboard region. Preferably, such a design would provide improved aerodynamic performance and efficiency while providing improved structural stiffness and integrity.
SUMMARY OF THE INVENTION
[0005] The present application thus provides a family of airfoils for a wind turbine blade. Each airfoil may include a blunt trailing edge, a substantially oval shaped suction edge, and a substantially S-shaped pressure side.
[0006] The airfoils may include a chord line extending from a leading edge to the blunt trailing edge. The substantially oval shaped suction sides and the substantially S-shaped pressure sides do not intersect the chord line. The suction sides may include non-dimensional coordinate values of X and positive Y set forth in Tables 1-4. The pressure sides may include non-dimensional coordinate values of X and negative Y set forth in Tables 1-4. Each of airfoils is connected by a smooth curve.
[0007] Each airfoil may include a first width about the blunt trailing edge, a second width moving towards a leading edge, with the second width being smaller than the first width, and a third width moving further towards the leading edge, with the third width being larger than the first width. Each airfoil may include a curved leading edge.
[0008] A first airfoil may include a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 1. A second airfoil may include a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 2. A third airfoil may include a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 3. A fourth airfoil may include a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 4. Each airfoil may be an inboard region airfoil.
[0009] The present application further describes a turbine blade having a number of airfoils. The airfoils may include a first airfoil with a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 1, a second airfoil with a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 2, a third airfoil with a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 3, and a fourth airfoil with a profile substantially in accordance with non-dimensional coordinate values of X and Y set forth in Table 4. The airfoils are connected by a smooth curve.
[0010] The X and Y values may be scalable as a function of the same constant or number to provide a scaled up or scaled down airfoil. The airfoils may include a number of inboard region airfoils. The turbine blade may be a wind turbine blade.
[0011] These and other features of the present application will become apparent to one of ordinary skill in the art upon review of the following detailed description when taken in conjunction with the several drawing and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a blade as is described herein with a number of airfoils shown.
[0013] FIG. 2 is a composite plot of the airfoils as are described herein.
DETAILED DESCRIPTION
[0014] Referring now to the drawings, in which like numerals refer to like elements throughout the several views, FIG. 1 shows a blade 100 as is described herein. The blade 100 includes the inboard region 110 adjacent to the hub (not shown), an outboard region 120 or the middle portion, and a tip region 130 . The inboard region 110 generally takes up about the first half of the blade 100 or so, the outboard region generally takes up about the next forty percent (40%) or so, and the tip 130 takes up about the final ten percent (10%) or so of the blade 100 . The figures may vary.
[0015] FIG. 2 shows a family of airfoils 140 . The airfoils 140 are designed for the inboard region 110 of the blade 100 . In this example, four (4) airfoils 140 are shown, a first airfoil 150 , a second airfoil 160 , a third airfoil 170 , and a fourth airfoil 180 . An infinite number of the airfoils 140 may be used. A chord line 190 extends from, a leading edge 200 to a trailing edge 210 of each of the airfoils 140 . In this example, the chord line 190 extends through the middle of the airfoils 140 .
[0016] In this example, the trailing edges 210 are blunt or have a “flat back”. The leading edges 200 are curved. Each airfoil 140 also includes a suction side 220 and a pressure side 230 . Each suction side 220 has a substantially oval shape while each pressure side 230 has a substantially S-shape. The suction sides 220 and the pressure sides 230 do not intersect the chord line 190 . Each of the airfoils 140 is connected by a smooth curve.
[0017] The specific shape of the airfoil 150 is given in Table 1 in the form of dimensionless coordinates. The X/C values represent locations on the chord line 190 in relation to the trailing edge 210 . The Y/C values represent heights from the chord line 190 to point on either the suction side 220 or the pressure side 230 . The values are scalable as a function of the same constant or number to provide a scaled up or scaled down airfoil.
[0000]
TABLE 1
x/c
y/c
1.00000000
0.03726164
0.90036720
0.06785235
0.80067860
0.08990651
0.70007530
0.10734770
0.60106600
0.12091980
0.50066880
0.13214710
0.40005820
0.14126440
0.30031070
0.14733190
0.20042560
0.14654610
0.10049920
0.12712570
0.00000000
0.00000000
0.10065920
−0.12659800
0.20022940
−0.14866100
0.30009620
−0.15000300
0.40096110
−0.13401000
0.50042920
−0.10618000
0.60041830
−0.07248480
0.70074310
−0.03982390
0.80018960
−0.01648170
0.90094460
−0.01118480
1.00000000
−0.03773510
[0018] As is shown at the X=1 location, the trailing edge 210 of the airfoil 140 has a given width. That width narrows towards the X=0.9 position, continues to narrow and then expands until past the X=0.3 position. The shape again narrows towards the leading edge 200 in a largely oval shape and then returns towards the trading edge 210 .
[0019] The second airfoil 160 is similar but somewhat thicker. As above, the second airfoil 160 also has the narrowing dip between the position X=1 and the position X=0.8. The shape of the second airfoil 160 is defined as follows:
[0000]
TABLE 2
x/c
y/c
1.00000000
0.07476157
0.90046010
0.10220790
0.80029790
0.12248030
0.70049780
0.13862410
0.60022080
0.15149490
0.50073840
0.16167160
0.40103380
0.16936190
0.30001950
0.17332270
0.20017300
0.16904810
0.10033560
0.14399980
0.00000000
0.00000000
0.10085420
−0.14364800
0.20034960
−0.17120100
0.30024750
−0.17597900
0.40050510
−0.16227900
0.50051480
−0.13568000
0.60100430
−0.10275700
0.70074630
−0.07116550
0.80063010
−0.04891650
0.90051680
−0.04553450
1.00000000
−0.07523460
[0020] The shape of the third airfoil 170 is similar to those described above, but again thicker. The third airfoil 170 also has the dip between the position X=1 and the position X=0.8. The shape of the third airfoil 170 is defined as follows:
[0000]
TABLE 3
x/c
y/c
1.00000000
0.11226081
0.90063769
0.13652491
0.80109208
0.15473962
0.70100077
0.16967702
0.60050336
0.18158922
0.50083265
0.19073012
0.40094014
0.19697082
0.30087793
0.19867672
0.20005762
0.19089852
0.10048941
0.16042992
0.00000000
0.00000000
0.10034881
−0.15978302
0.20060802
−0.19312702
0.30043493
−0.20132002
0.40002894
−0.18996502
0.50060705
−0.16471402
0.60057116
−0.13303101
0.70081557
−0.10227001
0.80004708
−0.08139181
0.90013649
−0.07984641
0.90125599
−0.07998141
1.00000000
−0.11273501
[0021] The shape of the fourth airfoil 180 is similar to that as described above, but again thicker. The fourth airfoil 180 has the dip between the position X=1 and the position X=0.8. The shape of the fourth airfoil 180 is defined as follows:
[0000]
TABLE 4
x/c
y/c
1.00000000
0.13726020
0.90000000
0.15989241
0.80000000
0.17787950
0.70000000
0.19334258
0.60000000
0.20609266
0.50000000
0.21607175
0.40000000
0.22261591
0.30000000
0.22363103
0.20000000
0.21369481
0.10000000
0.17827485
0.00000000
0.00002100
0.10000000
−0.17758316
0.20000000
−0.21583323
0.30000000
−0.22630101
0.40000000
−0.21557439
0.50000000
−0.19017060
0.60000000
−0.15766700
0.70000000
−0.12602585
0.80000000
−0.10435340
0.90000000
−0.10306262
1.00000000
−0.13773604
[0022] By incorporating a relatively thick trailing edge 210 , the extent of the pressure recovery on the airfoil suction surface is alleviated. Such permits the flow to remain attached so as to provide substantial lift performance. Specifically, lift coefficients greater than 3.0 have been measured. The airfoils 140 thus provide improved aerodynamic performance and efficiency with improved structural stiffness (bending moment of inertia). These improvements lead to increase energy capture and reduce blade weight. Indirectly, the airfoils 140 also minimize the aerodynamic compromise due to transportation constraints (max chord). The dip between the 1.0 and the 0.8 positions also reduces the overall weight as compared to known blunt trailing edge designs.
[0023] It should be apparent that the foregoing relates only to the preferred embodiments of the present application and that numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the invention as defined by the following claims and the equivalents thereof.
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A family of airfoils for a wind turbine blade. Each airfoil may include a blunt trailing edge, a substantially oval shaped suction side, and a substantially S-shaped pressure side.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to surface coatings, and, more particularly, to such coatings for use in a marine environment.
2. Description of Related Art
Marine coatings for application to moving watercraft and static underwater structures are known for use to preserve surfaces, improve their appearance, and reduce drag for moving watercraft. Such watercraft may comprise, but are not intended to be limited to, movable boats such as sailboats, yachts, inboard and outboard motor boats, rowboats, motor launches, canoes, kayaks, waterskis, surfboards, sailboards, waterbikes, ocean liners, tugboats, tankers, cargo ships, submarines, aircraft carriers, pontoons for sea planes, and destroyers. Underwater static structures may include, but are not intended to be limited to, wharves, piers, pilings, bridges, and other structures that may comprise wood, metal, plastic, fiberglass, glass, or concrete.
Some coatings known in the art include those described in U.S. Pat. Nos. 3,575,123; 5,488,076; and 5,554,214. Antifouling compositions have also been known to be used against such organisms as barnacles, algae, slime, acorn shells (Balanidae), goose mussels (Lepodoids), tubeworms, sea moss, oysters, brozoans, and tunicates.
Coatings may be hydrophilic or hydrophobic, the latter incurring friction between the moving surface and the water and including Teflon-like, paraffin wax, and fluorocarbon/silicone materials. The former maintains an adhering layer of water, the kinematic friction occurring with the water through which the craft moves.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method of reducing kinematic friction between a marine watercraft and the water through which the watercraft moves.
It is an additional object to provide a coating for a marine watercraft for reducing kinematic friction.
It is a further object to provide such a coating that is hydrophilic.
It is another object to provide such a coating that also possesses antifouling properties.
It is yet an additional object to provide a new use for a novolak-type polymeric composition.
An additional object is to provide a composition and method for improving fuel efficiency in marine craft.
These objects and others are attained by the present invention, a composition and method for coating marine watercraft having the property of reducing kinematic friction. The composition comprises a polymer comprising a polyhydroxystyrene of the novolak type. In a preferred embodiment the composition further comprises an antifouling agent.
A first embodiment of the method of the present invention comprises applying the composition as described above to an outer surface of a marine watercraft to achieve a coating thereof. Preferably the composition is applied in a solution in an appropriate solvent, which may comprise a low-molecular-weight oxygenated hydrocarbon such as an alcohol or ketone. The coated surface is smooth and free of tackiness and thus is not fouled by common water debris such as sand and weeds. The coating is insoluble in water and resists abrasion, giving a functional lifetime that has been estimated to be a few years of continuous use.
A second embodiment comprises a method for increasing the kinematic efficiency of a marine watercraft, including applying the composition to a submersible surface of a marine watercraft.
A third embodiment comprises a method for making the composition, including blending the polyhydroxystyrene in a low-molecular-weight oxygenated hydrocarbon solvent.
An application of the composition of the present invention to a water-submersible surface results in a hydrophilic surface having a considerably reduced contact angle. For example, when the composition is applied to a fiberglass/polyester surface with an initial contact angle of approximately 60° with water as determined by the tilting plate method (see N. K. Adam, The Physics and Chemistry of Surfaces, Oxford Univ. Press, 1941), the contact angle is reduced to about 15°. Thus the use of the coating is beneficial on watercraft to increase the speed thereof and/or to improve the fuel utilization.
The features that characterize the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description used in conjunction with the accompanying drawing. It is to be expressly understood that the drawing is for the purpose of illustration and description and is not intended as a definition of the limits of the invention. These and other objects attained, and advantages offered, by the present invention will become more fully apparent as the description that now follows is read in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
THE FIGURE illustrates the laboratory apparatus used to test the effect of the coating of the present invention upon the speed of an object falling through water.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description of the preferred embodiments of the present invention will now be presented with reference to the FIGURE.
A preferred embodiment of the composition comprises polyhydroxystyrene dissolved in methanol as a 5-20 wt/vol % solution and an antifouling agent also present at 5-10 wt/vol %. The antifouling agent comprises at least one compound selected from the group consisting of copper powder, copper oxide, zinc oxide (Kadox 911), titanium oxide (Degussa P-25), and tin oxide. A pigment may also be included.
A copolymerization of the polyhydroxystyrene with at least one other hydroxylated polymer such as polyhydroxylethylmethacrylate and polyhydroxymethylene or with another hydrophilic polymer such as polyallylamine, polyaminostyrene, polyacrylamide, or polyacrylic acid allows a variation of the coating without reducing the solubility of the copolymer in the solvent, while also not increasing the solubility of the dry coated polymer in water.
Test Apparatus
A laboratory apparatus 10 used to test the effectiveness of the coating of the present invention on a plastic bob 12 to affect the speed with which the bob 12 drops 1.3 m through sea water under the influence of gravity. An exemplary bob 12 comprises a plastic hydrophobic pointed cylinder approximately 1.26 cm in diameter and from 7.62 to 25.40 cm in length.
The apparatus 10 includes a glass tube 14 1.52 m long and having an inner diameter of 3.5 cm filled with artificial seawater 11. The bob 12 was allowed to fall from an initial position 20 to a second position 22 1.3 m apart. A photoelectric detector 16 at the initial position 20 starts a digital electronic timer 18. A second photoelectric detector 24 at the second position 22 stops the timer 18. The time recorded, typically in the second range, depending upon the size and mass of the falling bob 12, represents the time taken for the bob 12 to fall from the initial position 20 to the second position 22.
The bob 12 also has a thread 26 attached to its top end, which enables the bob 12 to be raised after resetting the timer 18 to ready it for another test. The initial position 20 should be set carefully in order to achieve reproducible results with a low standard deviation from the mean when ten identical, or as close to identical as possible, tests are averaged.
Exemplary Test Results
Tests undertaken on the apparatus described above have shown that the falling time, which ranges from 1.5 to 6 sec depending upon the size and mass of the object, decreases by 100-300 msec when a coating of the present invention has been applied (Table 1).
TABLE 1______________________________________Contact angles of water on various surfaces beforeand after coating with a solution of PolyhydroxystyreneSurface Contact Angle Before Contact Angle after______________________________________Polyethylene 56 16Stainless Steel 42 20 61 18Aluminum 70 15Fiberglass/polyester 53 22 60 17Silicone rubber 48 18Plexiglass 60 12 63 14Polystyrene 58 15Wood (oak) 33 18______________________________________
This represents an improvement in the speed of 2-8%. The maximum speed at which these tests were performed correspond to the equivalent of about 2.5 knots. This is far below the 9-20 knots of ocean tankers or the 20-30 knots of passenger ships and ocean cargo vessels. However, the results of Table 2(b) show that the degree of improvement of the coating increases as the speed of the moving object increases for a fixed suface-to-water contact area.
It has been shown that an application of a 5-20% solution of polyhydroxystyrene in methanol changes a hydrophobic surface into a hydrophilic one. The contact angle of flat metal, plastic, and wood surfaces were determined by the tilting plate method before and after application of the coating. The results are given in Table 2, where the contact angles are the averages of the advancing and receding angles. These data show that the coating causes a significant decrease in the contact angle of water with the surface. Similar data obtain when an antifouling agent such as listed previously.
TABLE 2______________________________________Some typical results showing (a) the effect polyhydroxystyrenecoatings on bobs of various materials by a determination of the timefor the bob to fall (in milliseconds, ms), and (b) the effectof speed on the improvement due to the coatings for a fixed______________________________________surface. Anti- Time (ms) Time (ms) Percentage fouling Before After Improve-(a) Material* Agent Coating Coating ment______________________________________1. Polyethylene ZnO 3869.4 ± 44 3567.0 ± 30 7.9%2. Nylon None 4283 ± 79 4179 ± 41 2.4%3. Nylon ZnO 3098.2 ± 26 2988 ± 27 3.5%4. Polyvinylchloride ZnO 4561 ± 38 4404 ± 34 3.4%5. Polyvinylchloride None 1519.3 ± 13 1489.0 ± 10 2.0%______________________________________Mass of Bob Time (ms) Time (ms) Percentage(b) Grams Before Coating After Coating Improvement______________________________________6. 32.9 5047.6 ± 56 4959 ± 72 1.8%7. 34.2 2011.7 ± 27 1947.6 ± 20 3.2%8. 38.3 1711.3 ± 21 1664.4 ± 12 6.0______________________________________ *1 & 3 were in distilled water with ZnO at 10% wt/vol %. All others were in sea water. 4 ZnO was at 15 wt/vol %. 6, 7, 8 the bob was a hollow polymethylmethacrylate pointed cylinder to which weights were added to make the bob fall faster.
The coating was also applied to a test boat having an onboard computer to monitor the power, speed, and rpm. The characteristics of this exemplary test boat are given in Table 3, and the results of three tests under different conditions of speed and rpm for the uncoated and coated boat are given, respectively, in Tables 4A and 4B, with a summary given in Table 5. For fixed power, the coating effected an increase in speed of 8%, and the fuel savings was approximately 10% when the boat was fully in the water, i.e., prior to planing. The coated boat tended to plane at lower throttle speed and felt more slippery in the water than the uncoated boat.
TABLE 3______________________________________Boat Characteristics______________________________________Gas Test Number Test 1Boat Model 26 Nova SpyderBoat Number WELP 340 E788Engine Manufacturer Mercruiser TwinEngine Model 350 MagnumStem Drive Model Alpha OneGear Ratio (X:1) 1.50:1Propshaft Hp 500Stbd Idle Timing 8 Degrees BTDCPort Idle Timing 8 Degrees BTDCStbd Adv Timing 32 Degrees BTDCPort Adv Timing 32 Degrees BTDCRpm Range 4400-4800 RPMX"Dimension 51/4 (11/4" Above)Fuel Load 60.0 Gallons 4900 Lbs AftFuel Capacity 120 Gallons 2800 Lbs FwdBoat Weight at Test 9011 Pounds 7700 Lbs TtlCenter of Gravity 104.7 Inches 24.00 Ft. Dist.Trim Tabs Bennett 9" × 12" (Performance)Exhaust System Thru-transom 100 Pounds GearDriver Willie Petrate 200 PoundsPassengers Don, Ken, Lee 640 PoundsLocation Sarasota BayWater Conditions Lite ChopWind Conditions Northwest @ 10 MPHRadar StalkerFuel Flow Meter Floscan 7000G" Meter Vericom 2000rPropeller Model QuicksilverProp Material Stainless SteelWellcraft PN 1405====Manufacturer's PN 48-163184Number of Blades Three RhDiameter 133/4"Pitch 21"True Pitch 22.0 InchesHull Constant 280,6633Minimum Rpm to Maintain Plane 2400 RPMBoat Position Angle at Rest 4 DegreesBoat List Angle at Rest 0 DegreesBow Measurement (Inches) N/A InchesTransom Measurement (Inches) N/A InchesNMMA Boat Maneuverability Test OKBackdown Test Use CautionSight Anti-ventilation Plate Well DefinedTotal Fuel this Test 12.0 GallonsTotal Engine Time this Test One HourRecommended Cruising Rpm 3500 RPMAcceleration Test Test Seconds FeetTime to plane 1 4.10 600-20 Mph 2 4.17 61Drive Trim 100% dn 3 5.00 74 Avg 4.42 65Recommended Propeller Yes______________________________________
TABLE 4A______________________________________BOAT TEST REPORTMARINE ENGINE FUEL INJECTIONTEST NUMBER: Test 1Normal Hull______________________________________1000 RPM ZERO LIST______________________________________slip % 48.4% 1 7.7 mph 83 DBmpg 1.99 2 6.6 mph 4.25 BPAtrim 100% DN 3 7.2 mph 3.6 GPHplates None avg 7.2 mph 227 RANGE______________________________________1500 RPM ZERO LIST______________________________________slip % 55.4% 1 9.9 mph 85 DBmpg 1.45 2 8.7 mph 6.5 BPAtrim 100% DN 3 9.3 mph 6.4 GPHplates None avg 9.3 mph 156 RANGE______________________________________2000 RPM ZERO LIST______________________________________slip % 66.4% 1 10.5 mph 86 DBmpg 0.77 2 8.0 mph 7.75 BPAtrim 100% DN 3 9.5 mph 12.2 GPHplates None avg 9.3 mph 87 RANGE______________________________________2500 RPM ZERO LIST______________________________________slip % 21.4% 1 27.0 mph 87 DBmpg 1.72 2 27.6 mph 3.75 BPAtrim 100% DN 3 27.3 mph 15.9 GPHplates None avg 27.3 mph 196 RANGE______________________________________3000 RPM ZERO LIST______________________________________slip % 20.8% 1 32.6 mph 88 DBmpg 1.73 2 33.4 mph 3.75 BPAtrim 20% UP 3 33.0 mph 19.1 GPHplates None avg 33.0 mph 197 RANGE______________________________________3500 Cruise RPM ZERO LIST______________________________________slip % 15.5% 1 40.7 mph 90 DBmpg 1.74 2 41.4 mph 3.50 BPAtrim 35% UP 3 41.1 mph 23.6 GPHplates None avg 41.1 mph 193 RANGE______________________________________3500 RPM ZERO LIST______________________________________slip % 15.5% 1 40.7 mph 90 DBmpg 1.74 2 41.4 mph 3.50 BPAtrim 35% UP 3 41.1 mph 23.6 GPHplates None avg 41.1 mph 193 RANGE______________________________________4000 RPM ZERO LIST______________________________________slip % 14.7% 1 47.8 mph 91 DBmpg 1.51 2 47.0 mph 3.25 BPAtrim 60% UP 3 47.4 mph 31.4 GPHplates None avg 47.4 mph 172 RANGE______________________________________4500 RPM ZERO LIST______________________________________slip % 14.5% 1 54.0 mph 95 DBmpg 1.35 2 53.4 mph 3.00 BPAtrim 70% UP 3 53.0 mph 39.5 GPHplates None avg 53.5 mph 154 RANGE______________________________________4760 MAX RPM ZERO LIST______________________________________slip % 14.3% 1 56.0 mph 97 DBmpg 1.22 2 57.2 mph 3.00 BPAtrim 80% UP 3 56.8 mph 46.6 GPHplates None avg 56.7 mph 139 RANGE______________________________________ *PHS = Polyhydroxysterene 4750 RPM STBD ENGINE 4820 RPM PORT ENGINE 0 RPM SINGLE ENGINE
TABLE 4B______________________________________BOAT TEST REPORTMARINE ENGINE FUEL INJECTIONTEST NUMBER: Test 2Hull Coated with PHS______________________________________1000 RPM ZERO LIST______________________________________slip % 48.2% 1 7.6 mph 83 DBmpg 2.06 2 6.8 mph 4.25 BPAtrim 100% DN 3 7.2 mph 3.5 GPHplates None avg 7.2 mph 235 RANGE______________________________________1500 RPM ZERO LIST______________________________________slip % 52.5% 1 9.7 mph 85 DBmpg 1.52 2 10.1 mph 7.00 BPAtrim 100% DN 3 9.9 mph 8.5 GPHplates None avg 9.9 mph 174 RANGE______________________________________2000 RPM ZERO LIST______________________________________slip % 61.2% 1 10.0 mph 86 DBmpg .90 2 11.5 mph 8.25 BPAtrim 100% DN 3 10.8 mph 12.0 GPHplates None avg 10.8 mph 102 RANGE______________________________________2500 RPM ZERO LIST______________________________________slip % 15.1% 1 29.2 mph 87 DBmpg 1.84 2 29.7 mph 4.25 BPAtrim 100% DN 3 29.5 mph 16.0 GPHplates None avg 29.5 mph 210 RANGE______________________________________3000 RPM ZERO LIST______________________________________slip % 14.1% 1 36.0 mph 88 DBmpg 1.85 2 36.4 mph 4.00 BPAtrim 20% UP 3 35.0 mph 19.3 GPHplates None avg 35.8 mph 211 RANGE______________________________________3500 Cruise RPM ZERO LIST______________________________________slip % 13.6% 1 42.1 mph 90 DBmpg 1.79 2 42.6 mph 3.50 BPAtrim 35% UP 3 41.3 mph 23.5 GPHplates None avg 42.0 mph 204 RANGE______________________________________3500 RPM ZERO LIST______________________________________slip % 13.6% 1 42.1 mph 90 DBmpg 1.79 2 42.6 mph 3.50 BPAtrim 35% UP 3 41.3 mph 23.5 GPHplates None avg 42.0 mph 204 RANGE______________________________________4000 RPM ZERO LIST______________________________________slip % 12.5% 1 49.0 91 DBmpg 1.54 2 48.7 mph 3.50 BPAtrim 60% UP 3 48.1 mph 31.5 GPHplates None avg 48.6 mph 176 RANGE______________________________________4500 RPM ZERO LIST______________________________________slip % 12.4% 1 55.0 mph 95 DBmpg 1.37 2 54.5 mph 3.50 BPAtrim 70% UP 3 54.8 mph 40.1 GPHplates None avg 54.8 mph 156 RANGE______________________________________4785 MAX RPM ZERO LIST______________________________________slip % 12.4% 1 58.0 mph 97 DBmpg 1.25 2 58.2 mph 3.25 BPAtrim 80% UP 3 58.5 mph 46.5 GPHplates None avg 58.2 mph 143 RANGE______________________________________ *PHS = Polyhydroxysterene 4750 RPM STBD ENGINE 4820 RPM PORT ENGINE 0 RPM SINGLE ENGINE
TABLE 5__________________________________________________________________________SO-BRIGHT INTERNATIONAL TEST RESULTSTest One - Prior to Chemical ApplicationTest Two - After Chemical Application TEST NR Test 1 Test 2 Changes Test 1 Test 2 Changes Test 1 Test 2 Changes__________________________________________________________________________20 Nova Spyder RPM MPH MPH IN MPH MPG MPG IN MPG RANGE RANGE IN RANGEMercruiser 1000 7.2 7.2 0.0 2.0 2.1 0.07 227 235 7.6350 Magnum 1500 9.3 9.9 0.6 1.5 1.5 0.07 166 174 8.0Alpha One 2000 9.3 10.8 1.4 0.8 0.9 0.13 87 102 15.1Sarasota Bay 2500 27.3 29.5 2.2 1.7 1.8 0.12 196 210 14.2Quicksilver 3000 33.0 35.8 2.8 1.7 1.9 0.13 197 211 14.5Stainless Steel 3500 41.1 42.0 0.9 1.7 1.8 0.05 #8 204 5.4Three Blades 4000 47.4 48.6 1.2 1.5 1.5 0.03 172 176 3.8RH(2)21" 4500 53.5 54.8 1.3 1.4 1.4 0.03 154 158 3.84760 4785 56.7 58.2 1.6 1.2 1.3 0.04 121 124 3.6ACCELERATION (0-20 MPH): Test 1 Test 2SECONDS TO PLANE: 4.4 3.9FEET TO PLANE: 65.0 57.0__________________________________________________________________________ Notes: The purpose of this test was to demonstrate the improvements we found (if any) in the performance of the boat described above. To do this we tested the boat prior to and immediately after a chemical application to the boats hull bottom. Test 1 shows results prior to and Test 2 shows results after.
The results clearly show that a boat coated with the composition of the present invention moves faster than an uncoated boat under substantially identical power consumption; similarly, for the same speed the coating reduces the rate of fuel consumption or increase the distance the boat will travel on a full tank of fuel. The difference varies with speed or power of the boat, and Table 5 shows that in the tests the maximum improvement of 17% at 2000 rpm corresponded to 10.8 miles/hour. At higher speeds the boat started to plane, resulting in less boat surface area in contact with water, and therefore a reduced beneficial effect of the coating is observed. For the case of ocean liners, cargo boats, or sailboats, which do not plane, it is expected that the beneficial effects of the coating of the present invention would continue to increase with an increase in power and speed since the surface-to-water contact area would not change under these changing conditions.
Therefore, it can be seen that the composition and methods of the present invention represent a significant increase in speed and fuel efficiency, thus conferring concomitant ecological and economic benefits.
It may be appreciated by one skilled in the art that additional embodiments may be contemplated, including analogous compositions having similar hyrophilic polymeric elements.
In the foregoing description, certain terms have been used for brevity, clarity, and understanding, but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such words are used for description purposes herein and are intended to be broadly construed. Moreover, the embodiments of the apparatus illustrated and described herein are by way of example, and the scope of the invention is not limited to the exact details of construction.
Having now described the invention, the construction, the operation and use of preferred embodiment thereof, and the advantageous new and useful results obtained thereby, the new and useful constructions, and reasonable mechanical equivalents thereof obvious to those skilled in the art, are set forth in the appended claims.
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The composition for coating marine watercraft has the property of reducing kinematic friction and includes a polymer comprising a polyhydroxystyrene of the novolak type. In a preferred embodiment the composition further comprises an antifouling agent. One of the methods entails coating an outer surface of a marine watercraft with the composition. Preferably the composition is applied in a solution in an appropriate solvent, for example, a low-molecular-weight oxygenated hydrocarbon such as an alcohol or ketone. The coated surface is smooth and free of tackiness and thus is not fouled by common water debris such as sand and weeds. The coating is insoluble in water and resists abrasion, giving a functional lifetime that has been estimated to be a few years of continuous use. An application of the composition of the present invention to a water-submersible surface results in a hydrophilic surface having a considerably reduced contact angle. Thus the use of the coating is beneficial on watercraft to increase the speed thereof and/or to improve the fuel utilization.
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FIELD OF THE DISCLOSURE
[0001] The disclosure relates to compositions and methods for improving the conductivity of middle distillate fuel compositions, particularly diesel fuels and most particularly low sulfur and ultra-low sulfur diesel fuels.
BACKGROUND OF THE DISCLOSURE
[0002] Certain middle distillate fuel compositions, particularly diesel fuels, are capable of generating static electricity, particularly when moving rapidly, such as when the fuel is being dispensed into a tanker or other bulk container or vessel. While diesel fuels are not very volatile, the tankers used to transport diesel fuels are also used to transport gasoline, kerosene and other more volatile and flammable liquids. Even after the more volatile fuel is dispensed from the tanker, the vapors may still be present and pose a risk of fire or explosion from a spark generated by the discharge of static electricity from the fuel composition.
[0003] These risks have become more acute in recent years with the increased popularity and use of low sulfur fuels and even more acute in recent months with the introduction of ultra-low sulfur diesel fuels. The process used to remove the sulfur from the fuels also decreases the concentration of other polar compounds in the fuel, which in turn reduces the ability of the fuel to dissipate a static charge.
[0004] To mitigate the risks of fire or explosion with low and ultra-low sulfur fuels, it has become common to add a conductivity improver to the fuel at or prior to the point of dispensing the fuel into a bulk container. The conductivity improver, as the name suggests, improves the conductivity of the fuel, thus permitting any static charge built up during high volume transport of the fuel to safely dissipate without generating a spark. Conductivity improvers are also known as antistatic agents.
[0005] The most common type of conductivity improver or antistatic agent used in fuels, particularly diesel fuels, has been the Stadis® brand of antistatic agents sold by Innospec Fuel Specialties, LLC, Newark, Del. However, the Stadis® brand of antistatic agents contains sulfur. Adding the Stadis® antistatic agents to the diesel fuel thus reduces the benefits of using an ultra-low sulfur fuel. In addition, these antistatic agents are quite expensive.
[0006] Moreover, sulfur-containing antistatic agents present another problem when used with additive concentrates or fuels that contain basic nitrogen. Specifically, Applicants have observed that the conductivity improvement delivered by a sulfur-containing antistatic agent dissipates very rapidly when used in additive concentrates or fuel mixtures containing basic nitrogen. Even when used at concentrations of 8 ppm, the conductivity measurement drops precipitously to less than 50 pS/m within a matter of days. This is disadvantageous because it prevents pre-blending of these antistatic agents into additive concentrates that contain basic nitrogen. Many components of a typically fuel additive concentrate include nitrogen-containing compounds, such as dispersants, detergents, cetane number improvers and the like. As a result, it is often necessary to add the sulfur-containing antistatic agents separately from the other components of the additive concentrate. Thus, these types of antistatic agents must be kept in a separate tank at the depot and added separately to the fuel. Accordingly, these types of antistatic agent, apart from their inherent additional cost, require additional costs and complexity in terms of storage, handling and dispensing.
[0007] Therefore, there is a need for compositions and methods to address the build-up and discharge of static electricity in middle distillate fuel compositions, particularly those containing basic nitrogen compounds.
SUMMARY OF THE EMBODIMENTS
[0008] In an embodiment, the disclosure provides an additive concentrate comprising a basic nitrogen component pre-blended with an antistatic agent.
[0009] In an embodiment, the disclosure provides a middle distillate fuel composition comprising a basic nitrogen component and an antistatic agent, wherein the conductivity of said fuel composition declines by no more than 50% over a period of 3 days when stored at 50° C.
[0010] In an embodiment, the disclosure provides a method comprising the step of adding an antistatic agent to a middle distillate fuel composition, wherein the conductivity in said fuel composition declines by no more than 50% over a period of 3 days when stored at 50° C.
[0011] Additional objects and advantages of the disclosure will be set forth in part in the description which follows, and/or can be learned by practice of the disclosure. The objects and advantages of the disclosure will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
[0012] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure, as claimed.
BRIEF DESCRIPTION OF THE FIGURES
[0013] FIG. 1 is a graph illustrating the relationship of conductivity versus time in an ultra-low sulfur diesel fuel.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] By improving the conductivity of the fuel, the fuel is better able to dissipate a static charge that might be generated by high volume transportation of the fuel, such as when the fuel is dispensed into a tanker truck or rail car. Because the fuel is better able to dissipate a static charge, the fuel is less likely to generate a spark, which may ignite volatile fumes that might be present in the area, either from the fuel itself or from previous fuels that may have been transported in the tanker.
[0015] The present embodiments are based on the surprising discovery by Applicants that certain antistatic agents, specifically those that are essentially free of sulfone moieties, sulfonic acid moieties, and salts thereof, provide a sustained conductivity benefit to a diesel fuel composition, even if the composition contains basic nitrogen.
[0016] The phrase “sustained conductivity benefit” is used to indicate that the conductivity of the fuel does not decline by more than 50% from its initial measure within 3 days of adding the antistatic agent and the basic nitrogen component to the diesel fuel when stored at 50° C. More preferably, the conductivity does not decline by more than 30% within that 3 day period. Still more preferably, the conductivity measure declines by no more than 30% for a period of at least 7 days after introducing the antistatic agent and the basic nitrogen component to the fuel. In some embodiments, the conductivity measure is still at least 50% of its initial measure after 21 days following the admixture of the antistatic agent and the basic nitrogen component.
[0017] The term “conductivity benefit” is used to indicate that the conductivity of the fuel is sufficient to provide a conductivity at least 25 pS/m at the time and temperature of delivery of the fuel.
[0018] The present embodiments are particularly suited for middle distillate fuel compositions. Middle distillate fuel compositions include, but are not limited to, jet fuels, diesel fuels, and kerosene. In an embodiment, the fuel is a low-sulfur fuel having less than about 500 ppm sulfur, preferably less than about 350 ppm of sulfur. In an embodiment, the fuel is an ultra-low sulfur diesel fuel or ultra-low sulfur kerosene. Ultra-low sulfur fuels are generally considered to have no more than about 15 ppm of sulfur, more preferably no more than 10 ppm of sulfur. The term “diesel fuel” is generally considered to be a generic term encompassing diesel, biodiesel, biodiesel-derived fuel, synthetic diesel and mixtures thereof. All disclosures herein to parts per million “ppm” are by mass unless otherwise indicated.
[0019] The present disclosure encompasses jet fuels, although these are conventionally not regarded as “low-sulfur” or “ultra-low sulfur” fuels since their sulfur levels can be comparatively quite high. Nevertheless, jet fuels may also benefit from the conductivity improvement of the present embodiments regardless of their sulfur content.
[0020] The terms “combustion system” and “apparatus” used in the disclosure connote any apparatus, machine or motor that utilize, in whole or in part, a combustible fuel to generate power. The terms include, for example, diesel-electric hybrid vehicle, a gasoline-electric hybrid vehicle, a two-stroke engine, any and all burners or combustion units, including for example, stationary burners, waste incinerators, diesel fuel burners, diesel fuel engines, automotive diesel engines, gasoline fuel burners, gasoline fuel engines, power plant generators, and the like. The hydrocarbonaceous fuel combustion systems that may benefit from the present disclosure include all combustion units, systems, devices, and/or engines that burn fuels. The term “combustion system” also encompasses internal and external combustion devices, machines, engines, turbine engines, jet engines, boilers, incinerators, evaporative burners, plasma burner systems, plasma arc, stationary burners, and the like which can combust or in which can be combusted a hydrocarbonaceous fuel.
[0021] The middle distillate fuel compositions contemplated by the present disclosure can contain other additives. Some of these additives are more commonly added directly at the refinery while the others form part of an additive concentrate typically added at the point of loading with the tanker. Examples of conventional fuel additives which may be used include antioxidants (such as phenolics e.g., 2,6-di-tert-butylphenol, or phenylenediamines such as N,N′-di-sec-butyl-p-phenylenediamine), fuel stabilizers, dispersants, antihaze agents, antifoams, cetane number improvers, combustion improvers, corrosion inhibitors, biocides, dyes, cold flow improvers (e.g., polyesters), smoke reducers, catalyst life enhancers and demulsifiers, lubricity agents and other standard or useful fuel additives.
[0022] Examples of common additives for middle distillate fuel compositions include non polar organic solvents such as aromatic and aliphatic hydrocarbons, including toluene, xylene and white spirit, e.g. those sold under the Trade Mark “SHELLSOL” by the Royal Dutch/Shell Group or AROMATIC 100 and AROMATIC 150 available from ExxonMobil; polar organic solvents, in particular, alcohols generally aliphatic alcohols e.g. 2 ethylhexanol, decanol and isotridecanol. Anti-foaming agents include e.g. the polyether-modified polysiloxanes commercially available as TEGOPREN™ 5851 (ex Th. Goldschmidt) Q 25907 (ex Dow Corning) or RHODORSIL® (ex Rhone Poulenc). Cetane number improvers (also called ignition improvers) include alkyl nitrates (e.g. 2-ethylhexyl nitrate and cyclohexyl nitrate). Anti-rust agents include polyhydric alcohol esters of succinic acid derivatives (e.g. commercially sold by Rhein Chemie, Mannheim, Germany as RC 4801®, or by Afton Chemical Corporation as HiTEC® 536). Suitable metal deactivators include salicylic acid derivatives, e.g., N,N′-disalicylidene-1,2-propane diamine.
[0023] Particularly preferred lubricity additives are derived from hydrocarbyl-substituted succinic anhydride and a hydroxyamine. These additives enhance the lubricating properties of the fuel without degrading other performance features of the fuel, such as detergency, ignition quality, stability, and so on. In addition, non-acidic lubricity additives posing less risk of corrosion to parts contacted by middle distillate fuel compositions and of reaction with basic components of fuel additive formulations
[0024] In one aspect, the term “hydrocarbyl” group is an alkenyl or alkyl group. The term “hydroxyamine” has general meaning encompassing either monohydroxyamine or polyhydroxyamine, such as dihydroxyamine, or mixtures thereof. Examples of useful hydrocarbyl succinic anhydride compounds include tridecylsuccinic anhydride, pentadecylsuccinic anhydride, tetradecenylsuccinic anhydride, hexadecenylsuccinic anhydride, dodecylsuccinic anhydride, tetradecylsuccinic anhydride, hexadecylsuccinic anhydride, octadecenylsuccinic anhydride, tetrapropylene-substituted succinic anhydride, docosenylsuccinic anhydride, and mixtures thereof.
[0025] Examples of hydroxyamines include ethanolamine, diethanolamine, N-alkylethanolamines, N-alkenylethanolamines, N-alkylisopropanolamines, N-alkenylisopropanolamines, isopropanolamine, diisopropanolamine, tris(hydroxymethyl)aminomethane, 3-amino-1,2-propanediol, 2-amino-1,3-propanediol, and mixtures thereof, where the alkyl and alkenyl groups, when present, contain 1 to 12 carbon atoms. Other useful hydroxyamines include 3-amino-1-propanol, 4-amino-1-butanol, 5-amino-1-pentanol, 6-amino-1-hexanol, 4-aminophenol, their isomers, and mixtures thereof. Still another group of hydroxyamines have the hydroxyl group directly bonded to the nitrogen, such as hydroxylamine, and N-alkylhydroxyamines or N-alkenylhydroxyamines where the alkyl or alkenyl group may contain up to 12 carbon atoms.
[0026] Also useful are HSA-hydroxyamine compounds in which the free hydroxyl group has been allowed to react with epoxides such as ethylene oxide, propylene oxide, butylene oxide, glycidol, and the like. The molar ratio of hydrocarbyl-substituted succinic anhydride acylating agent to hydroxyamine can be from about 1:4 to about 4:1, and more preferably is from about 1:2 to about 2:1.
[0027] Typically, the concentration of the lubricity enhancing additive used in a middle distillate fuel composition falls in the range 10 to 1000 ppm, preferably 10 to 500 ppm, and more preferably from 25 to 250 ppm. When mixtures of additives are used the overall additive concentration falls within the typical range noted.
[0028] For the sake of convenience, the additives may be provided as a concentrate for dilution with fuel. Such a concentrate typically comprises from 99 to 1% by weight additive and from 1 to 99% by weight of solvent or diluent for the additive which solvent or diluent is miscible and/or capable of dissolving in the fuel in which the concentrate is to be used. The solvent or diluent may, of course, be the low sulfur fuel itself. However, examples of other solvents or diluents include white spirit, kerosene, alcohols (e.g., 2-ethyl hexanol, isopropanol and isodecanol), and high boiling point aromatic solvents (e.g., toluene, xylene). Cetane improvers (e.g., 2-ethylhexyl nitrate) may also be used as a solvent or diluent. Of course, these may be used alone or as mixtures.
[0029] Because the sustained conductivity benefit provided by the present embodiments exists in the presence of basic nitrogen, particular detergents (also known as dispersants) which can be used in the present invention include a basic nitrogen-containing detergent. Suitable ashless detergents/dispersants include amides, amines, polyetheramines, Mannich bases, succinimides (which are preferred). Metal-containing detergents are also effective. Mixtures and combinations of detergents may also be used, if desired.
[0030] These detergents/dispersants are well known in the patent literature, mainly as additives for use in lubricant compositions, but their use in hydrocarbon fuels has also been described. Ashless dispersants leave little or no metal-containing residue on combustion. They generally contain only carbon, hydrogen, oxygen and in most cases nitrogen, but sometimes contain in addition other non-metallic elements such as phosphorus, sulphur or boron. A particularly useful ashless dispersant/detergent herein is derived from “high reactive” polyisobutylene (HR-PIB) substituted on a maleic anhydride reacted with a polyamine to achieve a level of about 5.4% nitrogen to achieve enhanced dispersancy. Such a material is available from Afton Chemical Corporation as HiTEC® 9651; HiTEC® 4247 or HiTEC® 4249. The detergent/dispersant can be used in the fuel additive concentrates at levels of from about 5 to about 50% by weight, more preferably 10-30%.
[0031] In one preferred embodiment, the detergent is a succinimide, which has an average of at least 3 nitrogen atoms per molecule. The succinimide is preferably aliphatic and may be saturated or unsaturated, especially ethylenically unsaturated, e.g. an alkyl or alkenyl succinimide. Typically the detergent is formed from an alkyl or alkenyl succinic acylating agent, generally having at least 35 carbon atoms in the alkyl or alkenyl group, and an alkylene polyamine mixture having an average of at least 3 nitrogen atoms per molecule. In another embodiment the polyamine has 4 to 6 nitrogen atoms per molecule. Preferably it can be formed from a polyisobutenyl succinic acylating agent derived from polyisobutene having a number average molecular weight of 500 to 10,000 and an ethylene polyamine which can include cyclic and acyclic parts, having an average composition from triethylene tetramine to pentaethylene hexamine. Thus the chain will typically have a molecular weight from 500 to 2500, especially 750 to 1500 with those having molecular weights around 900 and 1300 being particularly useful although a succinimide with an aliphatic chain with a molecular weight of about 2100 is also useful. Further details can be found in U.S. Pat. Nos. 5,932,525 and 6,048,373 and EP-A-432,941, 460309 and 1,237,373.
[0032] Examples of suitable metal-containing detergents useful herein include, but are not limited to, such substances as lithium phenates, sodium phenates, potassium phenates, calcium phenates, magnesium phenates, sulphurised lithium phenates, sulphurised sodium phenates, sulphurised potassium phenates, sulphurised calcium phenates, and sulphurised magnesium phenates wherein each aromatic group has one or more aliphatic groups to impart hydrocarbon solubility; the basic salts of any of the foregoing phenols or sulphurised phenols (often referred to as “overbased” phenates or “overbased sulphurised phenates”); lithium sulfonates, sodium sulfonates, potassium sulfonates, calcium sulfonates, and magnesium sulfonates wherein each sulphonic acid moiety is attached to an aromatic nucleus which in turn usually contains one or more aliphatic substituents to impart hydrocarbon solubility; the basic salts of any of the foregoing sulfonates (often referred to as “overbased sulfonates”; lithium salicylates, sodium salicylates, potassium salicylates, calcium salicylates, and magnesium salicylates wherein the aromatic moiety is usually substituted by one or more aliphatic substituents to impart hydrocarbon solubility; the basic salts of any of the foregoing salicylates (often referred to as “overbased salicylates”); the lithium, sodium, potassium, calcium and magnesium salts of hydrolysed phosphosulphurised olefins having 10 to 2000 carbon atoms or of hydrolysed phosphosulphurised alcohols and/or aliphatic-substituted phenolic compounds having 10 to 2000 carbon atoms; lithium, sodium, potassium, calcium and magnesium salts of aliphatic carboxylic acids and aliphatic-substituted cycloaliphatic carboxylic acids; the basic salts of the foregoing carboxylic acids (often referred to as “overbased carboxylates” and many other similar alkali and alkaline earth metal salts of oil-soluble organic acids. Mixtures of salts of two or more different alkali and/or alkaline earth metals can be used. Likewise, salts of mixtures of two or more different acids or two or more different types of acids (e.g., one or more calcium phenates with one or more calcium sulfonates) can also be used. While rubidium, cesium and strontium salts are feasible, their expense renders them impractical for most uses.
[0033] Emulsions tend to form in fuels having detergents/dispersants, hence the need for the demulsifier. Any reaction which deactivates or reacts with the demulsifier reduces the demulsification efficacy, leading to more emulsification. Demulsifiers (or dehazers) herein can be any of the commercially available materials such as but not limited to alkoxylated phenol formaldehyde polymers, such as those commercially as NALCO™ 7007 (ex Nalco), and TOLAD™ 9310 and TOLAD™ 9372R (ex Baker Petrolite), alkylated phenols and resins derived therefrom, oxylated alkylphenolic resin, and formaldehyde polymer with 4-(1,1-dimethylethyl)phenol, methyloxirane and oxirane, ethoxylated EO/PO resin, polyglycol ester, ethylene oxide resin. The demulsifier can have a phosphorus level of greater than 30 mg/kg of demulsifier. However, it has been discovered that by reducing the phosphorus content of the demulsifier in the additive concentrate, the stability of the fuel additive concentrate and of the resulting fuel is greatly enhanced and a significant reduction in haze is obtained. Thus, a level of phosphorus in the demulsifier of no more than about 30 mg/kg is preferred.
[0034] The compositions and methods of the present embodiments are capable of providing conductivity to a fuel of at least 25 pS/m at the time and temperature of delivery. This conductivity is sufficient to meet the proposed new ASTM standard for conductivity in diesel fuels (ASTM D975 and amendments and appendices thereto) measured according to any appropriate test procedure, including but not limited to ASTM D2622 and ASTM D4951. This level of conductivity is obtained and sustained for extended periods of time by the present embodiments.
[0035] The term “sulfur-containing compounds” used herein connotes organo-sulfur compounds; including sulfone, polysulfone, linear and branched aliphatic or aromatic sulfonates, sulfates, sulfides, sulfurized alkenes, polyalkenes, sulfurized polyphenols, sulfonic acids, and salts thereof.
[0036] The term “substantially free” when used to in connection with a reference to “sulfur” indicates that the relevant compounds contribute no more than 2 ppm of sulfur to the fuel composition when measured according to, for example, ASTM D2622 or ASTM D4951. In particularly preferred embodiments the fuel composition contains preferably no more than 10 ppm of sulfur and most preferably no more than about 5 ppm of sulfur.
[0037] Antistatic agents that provide the sustained conductivity benefits of the present embodiments include certain acrylonitrile copolymers. Most preferably the antistatic agent comprises a blend of alkylacrylate nitrilo styrene polymer with a coco alkylamine. A particularly preferred antistatic agent is TOLAD™ 3512 available from Baker Petrolite
EXAMPLES
[0038] The following examples illustrate but do not limit the present embodiments.
[0039] The following components were used in the Examples:
[0000]
A
Stadis ® 425. A conductivity improver additive available from
Innospec Fuel Specialties, LLC.
B
TOLAD ™ 3514. A conductivity improver available from Baker
Petrolite
C
TOLAD ™ 3512. A conductivity improver available from Baker
Petrolite.
D
HiTEC ® 4130SM. A modified version of HiTec ® 4130S, which is
a multi-functional fuel additive concentrate available from Afton
Chemical. It comprises a succinimide detergent, an ester-based
lubricity additive, a corrosion inhibitor, a demulsifier, aromatic
solvents and alcohol cosolvent.
HiTEC ® 4130SM has a lower level of detergent as
compared to the unmodified version (HiTEC ® 4130S).
[0040] In each example, the HiTEC® 4130SM additive concentrate was added to an ultra-low diesel fuel available from ExxonMobil in an amount of 290 ppm. The additive concentrate contains a basic nitrogen component in the form of the succinimide detergent. Then, the antistatic agents were added at concentrations of 3, 5 or 8 ppm. The conductivity was determined using ASTM D2624 after initially adding the antistatic agent to the fuel. The samples were then stored at 50° C. to accelerate the loss of conductivity and conductivity was measured periodically over several weeks. The results are reported in Table 1. The data from the examples (except the controls) is graphically illustrated in FIG. 1 . In FIG. 1 , the curves are labeled A 3 , A 5 , A 8 , B 3 , etc. which corresponds to the antistatic agent used and its concentration as reported in Table 1.
[0041] As mentioned above, the conductivity benefit provided by the present embodiments is a sustained benefit. This sustained benefit is surprising and unexpected. With reference to Table 1 and FIG. 1 , it can be seen that for the samples containing Stadis® 425 or TOLAD™ 3514, the conductivity dissipated quite rapidly with a loss in conductivity of at least 50% within 3 days. In contrast, the samples containing TOLAD™ 3512 maintained a relatively constant conductivity over an extended period of time.
[0042] This surprising and unexpected discovery will enable the antistatic agent to be pre-blended with an additive concentrate, even those containing a basic nitrogen component, for extended periods prior to adding the additive concentrate to the fuel, and still provide a conductivity improvement to the fuel composition.
[0043] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or can be presently unforeseen can arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they can be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.
[0000]
TABLE 1
CONDUCTIVITY (pS/m)
Comparative Examples
Controls (ppm)
A (ppm)
B (ppm)
C (ppm)
Day
A (3)
B (3)
C (3)
D (290)
3
5
8
3
5
8
3
5
8
0
455
330
144
8
275
404
610
275
470
785
92
155
240
3
440
290
127
7
22
44
87
72
144
335
90
152
246
4
19
29
59
55
102
233
88
137
230
5
12
25
49
50
86
185
90
135
225
6
9
20
39
46+
74
145
88
133
213
12
9
13
18
43
62
92
84
132
217
19
44
58
82
73
137
192
26
12
58
78
73
114
192
33
40
58
71
84
107
172
40
44
57
76
66
108
166
49
42
66
78
69
114
189
54
42
57
80
64
104
166
|
The disclosure provides conductivity improving concentrates and methods for improving conductivity and reducing risks associated with static discharge in middle distillate fuel compositions, particularly ultra-low sulfur diesel fuels. The conductivity improvement is provided in the presence of a basic nitrogen component and is sustained for an extended period, thus permitting the antistatic agent to be pre-blended with in an additive concentrate or to the fuel well in advance of the time when the improved conductivity might actually be needed, such as when the fuel is dispensed into a bulk container.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of The Invention
The present invention relates to alarm systems in general and, in particular to supervision circuits in a signalling, warning, or alarm system that extend between a sensor and a signalling control unit, warning control unit, or alarm control unit.
2. Background Information
Supervision circuits in such systems generally provide some capability to detect a circuit fault, and/or an attempt to defeat the circuit by manipulation of the wiring. Three forms of supervision are typically provided and will now be briefly summarized with reference to FIGS. 1A to 1D.
In a first form of supervision shown in FIG. 1A, a voltage is generated by a control unit and routed through normally closed switch contacts inside a sensor. Should the sensor be activated, i.e., "alarm" the normally closed switch contacts open, signalling an alarm condition to the control unit by a change in the current flowing therethrough. Should the supervision wiring be cut (opened), accidentally or intentionally, the control unit will also detect a change in the current flowing in the supervision circuit and signal an alarm.
This first method of supervision, however, provides no protection against compromise by someone shorting the supervision circuit wiring and effectively bypassing the sensor and cannot distinguish between a fault, "an alarm," and an intentional tampering condition.
In a second form of supervision shown in FIGS. 1B and 1C, a voltage is generated by a control unit and a current routed through a resistor located at the sensor in series or in parallel with the sensor contacts. For normally closed type sensor contacts as in FIG. 1B, this resistor is placed in series with the contacts. For normally open type sensor contacts as in FIG. 1C, the resistor is placed in parallel with the contacts. The control unit monitors the voltage and current in the supervision circuit. Activation of the sensor contacts either opens (FIG. 1B) or shorts (FIG. 1C) the supervision circuit, and this is detected at the control unit which signals an alarm. Should the supervision wiring between the control unit and the sensor be cut (opened) or jumpered (shorted) accidentally or intentionally, the control unit will detect a change in voltage and/or current and signal an alarm.
In a third form of supervision as shown in FIG. 1D, a voltage is generated by a control unit and a current routed through two resistors located at the sensor. One resistor is placed in series with the sensor contacts, and the other resistor is placed in parallel with them. Thus, regardless of the state of the sensor contacts, i.e., opened or closed, the voltage seen at the control unit will be greater than the lowest possible level, e.g., in a shorted condition, and less than the greatest possible value, e.g., in an open condition. Should the supervision wiring be cut (opened) or jumpered (shorted), accidentally or intentionally, the control unit will see the voltage change to its highest level or lowest level, respectively. In this way, the control unit can distinguish between alarm conditions generated by the sensor and trouble conditions with the supervision circuit.
This third method of supervision provides protection against compromise by jumpering or cutting, but it can still be defeated with relatively simple equipment and knowledge of the circuit. Insertion into the circuit of a regulated voltage source, for example, which can provide an appropriate voltage to the control unit, allows for removing and defeating the sensor circuit after attachment of the voltage source. Once the sensor has been removed, the protected area is of course vulnerable. A need has existed for a supervision method and/or circuitry which overcomes this vulnerability in existing systems.
The present invention was developed to overcome the limitations and thereby protect the existing circuits against such a threat without necessitating removal of existing resistive sensor devices which might already be installed, and which it might not be desirable to replace in the process of enhancing the supervision circuitry.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention to provide an improved system for supervising the wiring and sensors associated with a microprocessor based security system, i.e., a signalling, warning, or alarm system. This is accomplished by the invention in which a voltage supplied to the supervision circuits of the security system by a control unit is varied, preferably at random intervals.
The embodiments according to the invention may employ several advantageous components/sub-systems. These may include control logic in the control unit to vary the supervision voltage as an integral part of the control unit. Alternately, a separate sub-control unit to vary the supervision voltage may be interconnected with the control unit. Or, a completely independent system can be provided to vary the supervision voltage without an associated control unit.
Analog to Digital Converter (ADC) circuitry for converting voltages returned from the sensors of the supervision circuits into digital form is provided. Circuitry is provided that varies the voltage to the supervision circuit and to the ADC voltage reference input, on command from the control unit in an embodiment of the invention. By way of example, but not limitation, this circuit might vary the voltage between 5.0 Vdc and 3.3 Vdc. The number of voltages to select from is not limited to two (2), but may have some practical limitations with respect to the resolution of the ADC and the number of control lines available from the control unit circuitry. The ADC may establish a digital output value between 0 and 256 in an embodiment which uses an 8 bit converter, the digital output value representing the analog voltage present at its input with respect to a low reference voltage (ground) and a high reference voltage, i.e., the reference voltage supplied by the control unit. Therefore, changing the reference voltage at both the ADC and the supervision circuit, will cause no change in the digital output value representing the voltage present on the input, since the relative voltage of the input with respect to the reference voltage remains the same.
Timer circuitry and/or a random number generator may be provided in another embodiment, wherein this circuitry and/or generator determines what the next reference voltage will be, and over what span of time it will remain at this value, before changing to another value. By way of example, but not limitation, this circuit could be implemented by a microprocessor employing a random number generator routine.
In another embodiment, averaging circuitry or a microprocessor performed routine to correct for variations in the ADC readings resulting from changes in the reference voltage due to, for example, line capacitance and ADC settling time, may be employed. The averaging circuit or routine samples the ADC readings in real-time, and then averages the collected samples. This circuit or routine does not need to stop or delay the sampling to allow for a settling period, and therefore provides robust supervision since the sampling process is never halted.
According to one embodiment, in a microprocessor based security system, having a control unit including the microprocessor, and at least one supervision circuit including at least one alarm sensor, such an arrangement includes first means for providing a reference voltage signal to the at least one supervision circuit. Second means is provided for receiving the reference voltage signal from the first means, for receiving an input voltage signal from the at least one supervision circuit, and for producing a voltage sample signal. The input voltage signal and the voltage sample signal are dependent on the reference voltage signal and are dependent on the state of the at least one supervision circuit. Evaluating means is provided for analyzing and classifying the voltage sample signal into one of ALARM, TAMPER and SECURE categories based on predetermined criteria. Advantageously, the first means includes voltage variation means for varying the reference voltage signal under the control of the control unit.
According to a further embodiment, the second means includes analog to digital converter means for receiving as an analog input signal the input voltage signal from the at least one supervision circuit, converting the analog input signal into a digital output signal dependent on the reference voltage signal, and providing the digital output signal as the voltage sample signal.
In another embodiment, the control unit produces at least one voltage varying signal, and the voltage variation means of the first means includes a voltage regulator for providing a regulated voltage, voltage divider means, including a plurality of resistors and at least one diode, for receiving the regulated voltage and the at least one voltage varying signal, and for providing a control voltage based thereon at an output thereof, and an operational amplifier for receiving the control voltage at an input thereof, and for providing the reference voltage to the second means and to the at least one supervision circuit at an output thereof.
In another embodiment, the control unit includes third means for controlling the producing of the at least one voltage varying signal, the third means employing random number generation for selecting a level and duration for the at least one voltage varying signal. In this way, the reference voltage signal and a duration period thereof are randomly varied by the control unit.
In another embodiment, the second means includes analog to digital converter means for receiving as an analog input signal the input voltage signal from the at least one supervision circuit, converting the analog input signal into a digital output signal dependent on the reference voltage signal, and providing the digital output signal as the voltage sample signal.
And in another embodiment, the at least one supervision circuit includes a sensor input buffering unit receiving the reference voltage signal from the first means, the sensor input buffering unit providing across a capacitor at a first output thereof the input voltage signal to the second means as a function of a current flowing through lines to the sensor, and providing at a second output thereof a supervision voltage proportional to the reference voltage signal from the first means, and a sensor unit including the at least one alarm sensor and a respective resistor network through which at least a portion of a current to the sensor unit flows, the current flowing through the sensor unit being dependent on the received supervision voltage from the sensor input buffering unit and the state of contacts of the alarm sensor, wherein the input voltage signal provided to the second means by the sensor input buffering unit is dependent on the current flowing through the lines to the sensor unit and the reference voltage signal from the first means.
Other objects and advantages will become apparent from the detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1D show conventional supervision systems;
FIG. 2 is a block diagram schematic illustration of an embodiment of the invention;
FIG. 3 is a functional block diagram showing how alarm, tamper and secure decisions are made;
FIG. 4 is a block diagram showing a random number generator aspect of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 2, shown is a control unit 201 with an eight input Analog-to-Digital Convertor (ADC) 202 supplied with an appropriate reference voltage (Vref) and eight input signals (INPUTa-h) in this embodiment. Each input signal (INPUTa-h) comes from a respective supervision circuit comprising a sensor circuit 204 and a respective input buffering circuit 206. Only one of the supervision circuits, sensor/sensor input circuit pair 204/206, is shown for ease of illustration.
A voltage regulator (Vreg) establishes a +5 V reference voltage which is supplied to Op-Amp U2 through resistor R1. The output of Op-Amp U2 is supplied through resistor R4 to the reference voltage input (Vref) of the ADC 202, and is fed back, as A/D REF 210, to the inverting input of amplifier U2. This voltage is also fed through a respective resistor to each of the sensor input buffering circuits 206, as shown in the figure through resistor R5e to the illustrated supervision circuit, to establish a supervision voltage.
R4 and C1 serve as a low-pass filter to decouple transients from the A/D reference voltage 210 to ground. The time constant of R4 and C1, must be matched as closely as possible to the R5e, RSs, Rsp, R6e and C2e network to minimize deviation on the controlled potential adjustments generated by the control unit through U2.
For example, passing only deviations occurring below 1 KHz would require the following calculation to ascertain the appropriate values of the circuit components. ##EQU1##
A typical supervision circuit includes a sensor 204 with dry contact relay outputs and may be configured with normally closed (NC) sensor contacts and series (RS s ) and parallel (RS p ) resistors, as is illustrated. The sensor input buffering circuit 206 serves to establish the supervision voltage on the sensor wire pair using the A/D ref voltage 210 coupled through resistor R5e, and also functions to buffer and filter, through resistor R6e and capacitor C2e, the input signal (INPUTe) to the ADC circuit 202. Significantly, because the reference voltage supplied to the ADC (A/D ref) from the output of Op-Amp U2 is also supplied to the supervision circuit 206/204, the input signal (INPUTe) from the supervision circuit will track any change in the ADC reference voltage. Changes in the voltage at INPUTe, i.e., signals at INPUTe, which represent an alarm or a tamper condition can be detected even if the A/D reference voltage, supplied to both the ADC Vref input and to establish the supervision voltage, is varied. To achieve the invention's objectives, this A/D reference voltage is varied in a controlled fashion, thereby likewise varying the supervision voltage to the sensors, making the alarm system less vulnerable to defeat as previously described.
For the purpose of varying the reference voltage, a +V voltage varying circuit 208 is provided. The circuit 208 receives voltages at multiple inputs from the control unit 201 output lines (PA1-PAn). The resistor divider networks (ROn, R3n) serve to combine the output lines to establish various voltages at the output of circuit 208 on line 212. Thus, the voltage at the output of circuit 208 is dependent on the outputs (PA1-n) from the control unit. The +5 v from the voltage regulator (Vreg) through resistor R1, and the voltage established by the control unit 201 with the voltage varying circuit 208 on line 212, are combined at the non-inverting input of Op-Amp U2. By varying the voltage on line 212 at the non-inverting input of Op-Amp U2, the Op-Amp output voltage can be varied which, as described above, is supplied to the ADC Vref input and to the sensor buffering circuit 206e to establish the supervision voltage.
As mentioned above, the supervisory circuit is supplied with the voltage from the output of Op-Amp U2 through resistor R5e at point 1 (circled). This in turn supplies the supervision voltage to the sensor unit 204 and sensor contacts. In the illustrated embodiment this voltage is varied through varying the voltage at the non-inverting input of Op-Amp U2. Op-Amp U2 is supplied with a +5 Vdc reference from the voltage regulator Vreg. This regulated voltage is an independent stable voltage, not used by other digital functions of the control logic of the system. This +5 Vdc reference is also fed to the R1, RO1-n, D1-n voltage divider network. The voltage present at point 2 (circled) is controlled by the state of the outputs from the control unit at PA1-n as follows.
If the control logic output on the lines PA1-n, for example, is high (+5 Vdc), resistors R31-n pull the cathodes of D1-n to +5 Vdc thus stopping the flow of current through resistors RO1-n and diodes D1-n. The non-inverting input of Op-Amp U2 (point 2) is then at +5 Vdc volts and the Op-Amp U2 will transfer this voltage to its output, and in turn, through resistor R4 to the ADC reference voltage input (Vref) and to the sensor input buffering circuit 206. When the control unit subsequently varies the voltage, it drives, for example, the outputs on lines PA1-n low and causes R1 and resistors RO1-n through diodes D1-n to act as voltage dividers. The voltage appearing at the non-inverting input of Op-Amp U2, and therefore at its output, is thereby changed due to the voltage drop across resistor R1.
By varying the outputs on the lines PA1-n of the control unit 201, the voltage at the Op-Amp non-inverting input can be thus varied accordingly. The voltage divider portions established with resistors R3n and ROn can be configured so that the value of ROn is different than R3n to thereby provide the capability of establishing a desired different voltage at point 2 (circled). The number (n) of outputs (PA) and voltage divider portions (RO, R3) can be as many as desired, and is only limited based on the outputs available from the control unit 201 and the resolution of the ADC 202. Therefore, a variety of voltages can be produced and applied to both the ADC reference voltage input Vref as well as to the supervision circuit sensor input buffering circuit 206.
FIG. 3 shows a functional block diagram of how a decision regarding an Alarm, Tamper or Secure Condition would be determined in the control unit 201. An analog input signal is received at an input of the ADC 202, and a digital output is produced. The digital output is passed to an averaging functional block 302 where an average value is computed based on the present output and a number of previous digital outputs from the ADC 202. The START line indicates that the averaging block 302 starts with some first digital output and the STOP line indicates the averaging block 302 stops with some last digital output, the average being computed on the digital outputs received from the ADC 202 between the START and STOP times.
Averaging of a number of digital outputs from the ADC 202 may be necessary, for example, in order to avoid false alarm situations. For example, ambient electrical noise, caused by local electrical equipment and the like, can induce a voltage spike on the sensor lines which could be misinterpreted as a tamper condition. Also, because the voltage on the sensor lines is being changed from time to time under the control of the control unit 201, and because the sensor lines have electrical characteristics, e.g., line capacitance, different from the ADC Vref input line, a change in the sensor line voltage may lead or lag a corresponding change in the reference voltage to the ADC, leading to variations in the ADC readings. In this situation, some short time period must be allowed for the ADC input voltages to "settle" before the supervision circuit voltage at the ADC input is considered to indicate an abnormal condition.
The output of the averaging functional block 302 is an average value which is passed to a decision functional block 304 for determining whether an alarm, tamper or secure condition is present, depending on the value of the average signal from the averaging functional block 302. Upon making the decision, decision functional block 304 output either an ALARM, a TAMPER or a SECURE signal to the rest of the system which will react in an appropriate manner, by sounding an alarm signal, for example, if TAMPER or ALARM are indicated.
Referring again to FIG. 3, the averaging functional block 302 and decision block 304 may consist of hardware and/or software. In the preferred embodiment, a microprocessor operating in the control unit 201 is programmed to perform the averaging 302 and decision 304 functions, as well as controlling the varying of the supervision voltage, the reading of the ADC 202, sounding the alarm, etc.
In this embodiment, the microprocessor could execute the following routine, for example, in order to perform the averaging and decision functions to correct for variations in the ADC 202 readings:
______________________________________Begin Averaging RoutineClear Alarm, Tamper, and Reads CountersDo LoopIncrement Reads CounterRead ADC (values will be between 0 and 256)If ADC Value (>134 and <162) or (>94 and <122)Increment Alarm CounterIf Value (>162 or <94)Increment Tamper CounterLoop for 1/10th secondCheck which CaseCase Alarm Counter > Half ReadsIndicate AlarmCase Tamper Counter > Half ReadsIndicate TamperOtherwiseIndicate SecureEnd Averaging Routine______________________________________
By way of example, but not limitation, the averaging routine could be implemented to gather the maximum number of ADC conversions possible within, for example, a 0.1 second interval, and if more than fifty percent of these samples indicates that the sensor has alarmed, the routine will signal an alarm. However, if more than fifty percent of the samples indicate that the supervision circuit has been tampered with, the routine will signal a tamper condition. If neither an alarm nor a tamper is detected, then the routine will signal a secure condition.
The control unit 201 may control the supervision voltage so that is takes on a periodic form, or it may be controlled to be random. In the latter case, as depicted in FIG. 4, a random number generator block 402 produces random numbers which are used to address a read only memory (ROM) 403 and access a stored voltage to use as a next voltage value and a stored time to use as the length of time to hold the voltage value, for example. Alternatively, these voltage and time values may be calculated directly by the microprocessor using a random number as a base. Using a random variation in the supervision voltage protects against the sophisticated tamperer who may monitor the supervision voltage, detect a repetitive periodic pattern, and provide a voltage source to imitate it.
The random number function could be programmed to select a random period of time between 0.1 and 1.6 seconds, in increments of 0.1 seconds, as the time period during which the reference voltage would remain at, for example, either 5.0 Vdc or 3.3 Vdc before changing. Further, a new voltage could be selected using a second random number generator function which would point to the new value. This new value could reselect the present value for another random period, or select some new value.
It will be understood that the above description of the preferred embodiment 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.
It will be apparent to one of ordinary skill in the art that the manner of making and using the claimed invention has been adequately disclosed in the above-written description of the preferred embodiment taken together with the drawings.
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A warning or alarm sensor supervision circuit employs varying voltage levels which may vary at random intervals and to random levels.
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