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TECHNICAL FIELD
The present invention relates to a method for producing optically active 2-substituted-1,2,3,4-tetrahydroquinolines; and a novel chiral iridium catalyst used for the method.
BACKGROUND ART
Optically active tetrahydroquinolines, particularly the ones having a substituent at position 2, namely optically active 2-substituted-1,2,3,4-tetrahydroquinolines, are contained in many natural bioactive compounds such as alkaloids and are important compounds widely used as pharmaceuticals.
For efficient production of optically active 2-substituted tetrahydroquinolines, various methods involving asymmetric reduction of the corresponding 2-substituted-quinolines to give optically active 2-substituted-1,2,3,4-tetrahydroquinolines in one step have been developed. For example, known methods include a method using Hantzsch ester as a reducing agent and a chiral acid as an asymmetric catalyst (Non Patent Literature 1); a method using hydrogen gas as a reducing agent and an iridium catalyst having a chiral ligand (Non Patent Literature 2 and 3); and a method using sodium formate as a reducing agent, water as a solvent and a rhodium catalyst coordinated with TsDPEN or its related ligand (Non Patent Literature 4).
However, these methods are not necessarily satisfactory for industrial use. For example, the method using Hantzsch ester as a reducing agent (Non Patent Literature 1) requires a stoichiometric amount of very expensive Hantzsch ester and thus is difficult to apply to industrial production. The method using hydrogen gas as a reducing agent (Non Patent Literature 2 and 3) requires high-pressure conditions (for example, 40 to 50 atmospheres) for a reaction with hydrogen due to the low conversion of quinoline, and thus needs specialized equipment for large scale production, which leads to high production cost.
The method using inexpensive sodium formate as a reducing agent and water as a solvent (Non Patent Literature 4) is also industrially disadvantageous because of the following reasons: most of quinoline compounds as a starting material are poorly water-soluble; precise pH adjustment is indispensable; and rhodium complexes essential as a catalyst are expensive. In addition, a reaction of 2-methylquinoline using an iridium catalyst having a TsDPEN ligand (Non Patent Literature 4) has problems including the low enantiomeric excess of the product, which is as low as 11%.
Under such circumstances, there is a pressing need to develop methods for providing optically active 2-substituted-1,2,3,4-tetrahydroquinolines usable as a unit of many useful substances in an industrially advantageous manner.
CITATION LIST
Patent Literature
Patent Literature 1: WO 2009/005024
Non Patent Literature
Non Patent Literature 1:
Angew. Chem. Int. Ed, 2006, 45, 3683-3686
Non Patent Literature 2:
J. Am. Chem. Soc, 2003, 125, 10536-10537
Non Patent Literature 3:
Org. Lett, 2008, 10, 5265-5268
Non Patent Literature 4:
Angew. Chem. Int. Ed, 2009, 48, 6524-6528
SUMMARY OF INVENTION
Technical Problem
An object of the present invention is to provide a novel chiral iridium(III) complex; and a method for producing optically active 2-substituted-1,2,3,4-tetrahydroquinolines from 2-substituted-quinolines with the use of the chiral iridium(III) complex through a more economical and easy production process.
Solution to Problem
The present inventors already filed a patent application claiming a method for producing optically active amines from imine compounds formed of ketone and amine, comprising preparing in situ an iridium(III) complex catalyst having a chiral prolinamide compound as a ligand, and using the resulting catalyst-containing mixture as it is for asymmetric transfer hydrogenation of an imine compound in the presence of a hydrogen donor compound (Patent Literature 1). It was newly found that, by use of this method for asymmetric reduction of 2-substituted-quinolines, optically active 2-substituted-1,2,3,4-tetrahydroquinolines can be produced with fairly high conversion and enantioselectivity. In addition, in the case where an isolated and purified crystalline iridium(III) complex having a chiral prolinamide compound as a ligand is used as a catalyst for the asymmetric reduction of 2-substituted-quinolines, optically active 2-substituted-1,2,3,4-tetrahydroquinolines can be obtained with a further higher chemical yield and enantiomeric excess. The present inventors further conducted a great deal of examination and then completed the present invention. That is, the present invention provides a method for producing optically active 2-substituted-1,2,3,4-tetrahydroquinolines by asymmetric reduction of 2-substituted-quinolines in an industrially advantageous manner.
That is, the present invention includes the following.
[1] A method for producing optically active 2-substituted-1,2,3,4-tetrahydroquinolines, comprising reducing a quinoline compound represented by formula [I]:
(wherein R 1 represents an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group,
R 2 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group, an optionally substituted heteroaryl group, an optionally substituted hydroxyl group, an optionally substituted thiol group, an optionally substituted amino group, an optionally substituted carbamoyl group, an optionally substituted aryloxy group, an optionally substituted heteroaryloxy group, a carboxyl group, an esterified carboxyl group, a cyano group, a nitro group or a halogen atom,
R 2 is bound to the quinoline ring at any one of positions 5 to 8,
n is an integer of 1 to 4, and
when n is not less than 2, R 2 groups adjacent to each other may join together to form a ring),
in the presence of a hydrogen donor compound and an iridium (III) complex having a chiral prolinamide compound as a ligand to give an optically active 2-substituted-1,2,3,4-tetrahydroquinoline represented by formula [II]:
(wherein R 1 , R 2 and n are as defined in formula [I], and the symbol “*” indicates that the carbon atom is a chiral center).
[2] The method according to the above [1], wherein the chiral prolinamide compound is a compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center).
[3] The method according to the above [1] or [2], wherein the chiral prolinamide compound is (R)-proline heteroaryl amide or (S)-proline heteroaryl amide.
[4] The method according to any one of the above [1] to [3], wherein the chiral prolinamide compound is (R)—N-(6-quinolinyl)-2-pyrrolidinecarboxamide or (S)—N-(6-quinolinyl)-2-pyrrolidinecarboxamide.
[5] The method according to any one of the above [1] to [3], wherein the chiral prolinamide compound is (R)—N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide or (S)—N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide.
[6] The method according to the above [1] or [2], wherein the chiral prolinamide compound is (R)-2-pyrrolidinecarboxamide or (S)-2-pyrrolidinecarboxamide.
[7] The method according to any one of the above [1] to [3], wherein the iridium(III) complex having a chiral prolinamide compound as a ligand is represented by formula [IV]:
Cp*Ir(X)(L-H + ) [IV]
(wherein X represents Cl − , p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 , L is a compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center), and Cp* represents (1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl).
[8] The method according to the above [7], wherein the complex has a ligand of formula [III] in which R 3 is hydrogen, a 6-quinolinyl group or a 2-methoxy-3-dibenzofuranyl group.
[9] The method according to the above [7] or [8], wherein the iridium(III) complex having a chiral prolinamide compound as a ligand is an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) catalyst, or an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) catalyst.
[10] The method according to the above [7] or [8], wherein the iridium(III) complex having a chiral prolinamide compound as a ligand is an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) catalyst.
[11] The method according to any one of the above [1] to [10], wherein the iridium(III) complex having a chiral prolinamide compound as a ligand is crystalline.
[12] The method according to any one of the above [1] to [10], wherein the iridium(III) complex having a chiral prolinamide compound as a ligand is amorphous.
[13] The method according to any one of the above [1] to [12], wherein the hydrogen donor compound is formic acid.
[14] An iridium(III) complex represented by formula [IV]:
Cp*Ir(X)(L-H + ) [IV]
(wherein X represents Cl − , p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − , L is a compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center), and Cp* represents (1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl).
[15] The iridium(III) complex according to the above [14], having a ligand of formula [III] in which R 3 is hydrogen, a 6-quinolinyl group or a 2-methoxy-3-dibenzofuranyl group.
[16] An (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) complex.
[17] An (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) complex.
[18] An (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) complex.
[19] The iridium(III) complex according to any one of the above [14] to [18], which is crystalline.
[20] The iridium(III) complex according to any one of the above [14] to [18], which is amorphous.
[21] A method for producing the iridium(III) chloro complex according to any one of the above [14] to [20], comprising bringing a chiral prolinamide compound into contact with a pentamethylcyclopentadienyl iridium(III) chloride dimer in the presence of a weak base.
[22] The method according to the above [21], wherein the weak base is a tertiary amine, an alkali metal hydrogen carbonate or an alkali earth metal carbonate.
Advantageous Effects of Invention
The production method of the present invention enables low-cost and industrially advantageous production of optically active 2-substituted-1,2,3,4-tetrahydroquinolines using general-purpose equipment under simple process control.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows an IR (KBr) chart of the crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) produced in Example 4.
FIG. 2 shows a far-infrared spectrum of the crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) produced in Example 4.
FIG. 3 shows an X-ray powder diffraction pattern of the crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) produced in Example 4.
FIG. 4 shows a far-infrared spectrum of the powder produced in Reference Example 1.
DESCRIPTION OF EMBODIMENTS
Preparation of Iridium(III) Complex Having a Chiral Prolinamide Compound as a Ligand
An iridium(III) chloro complex having a chiral prolinamide compound as a ligand can be prepared by, for example, allowing a reaction of an iridium(III) compound with a chiral prolinamide compound and a base. Complexes other than the iridium(III) chloro complex, that is, iridium(III) complexes having a p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − anion can be prepared from, for example, the iridium (III) chloro complex having a chiral prolinamide compound as a ligand.
The iridium(III) complex having a chiral prolinamide compound as a ligand is a complex formed of a chiral prolinamide compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center) and
a trivalent iridium compound, and hereinafter also called an iridium(III) complex.
The iridium(III) complex having a chiral prolinamide compound as a ligand can be generally represented by the following formula:
(wherein R 3 and * are as defined in the previously described formula [III]).
Herein, the iridium(III) complex having a chiral prolinamide compound as a ligand is represented by formula [IV]:
Cp*Ir(X)(L-H + ) [IV]
(wherein X represents Cl − , p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − , L is a compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center), and Cp* represents (1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl).
Preferably, the iridium(III) complex having a chiral prolinamide compound as a ligand has a ligand of formula [III] in which R 3 is hydrogen, a 6-quinolinyl group or a 2-methoxy-3-dibenzofuranyl group.
Herein, it is also possible that the iridium(III) complex represented by formula [IV] is represented by formula [VI]:
[Cp*Ir(L-H + )] + (X) [VI]
(wherein each symbol is as defined in formula [IV]).
In formula [IV], exemplary prolinamide compounds include 2-pyrrolidinecarboxamide, exemplary prolinamide quinoline derivatives include N-6-quinolinyl-2-pyrrolidinecarboxamide, and exemplary prolinamide methoxy dibenzofuran derivatives include N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide.
Specific examples of the iridium(III) complex having a chiral prolinamide compound as a ligand include an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) complex, an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) complex, and an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) complex.
The compounds described herein can be expressed in another notation as shown in Table 1 and both expressions are interchangeable. The same holds true for the case where the ligand shown in Table 1 is replaced with a ligand other than Cl − , such as p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 . For example, Cp*Ir(PF 6 − )(R-PMDBFA-H + ) and (R)-hexafluorophosphate[(1,2,3,4,5-η)-pentamethyl-2,4-cyclo pentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) are interchangeable.
TABLE 1
Compound
Another notation
Cp*Ir (Cl − ) (R-PA-H + )
(R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-
1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III)
Cp*Ir (Cl − ) (S-PA-H + )
(S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-
1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III)
Cp*Ir (Cl − ) (R-PQA-H + )
(R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-
1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1,
κN2)iridium(III)
Cp*Ir (Cl − ) (S-PQA-H + )
(S)-chloro[(1,2,3,4,5-η)-pentamethy-2,4-cyclopentadien-
1-y](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1,
κN2)iridium(III)
Cp*Ir (Cl − ) (R-PMDBFA-H + )
(R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-
1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-
pyrrolidinecarboxamidato-κN1, κN2]iridium(III)
Cp*Ir (Cl − ) (S-PMDBFA-H + )
(S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-
1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-
pyrrolidinecarboxamidato-κN1, κN2]iridium(III)
The iridium(III) complex having a chiral prolinamide compound as a ligand may be crystalline or amorphous, but is preferably crystalline.
After the iridium(III) complex having a chiral prolinamide compound as a ligand is prepared, the resulting catalyst-containing mixture can be directly used as a catalyst for asymmetric reduction, but more preferably, an crystalline or amorphous iridium(III) complex isolated and purified from the catalyst-containing mixture is used for asymmetric reduction. This is because, when the isolated and purified iridium(III) complex in a crystalline or amorphous form is used as a catalyst for asymmetric reduction, the chemical yield and the enantiomeric excess of the product will be higher than those in the case where the catalyst-containing mixture is directly used.
The reason for this is that, during the preparation of the catalyst and the subsequent period when the resulting catalyst-containing mixture is left unused, the base in the catalyst-containing mixture causes partial epimerization of the iridium(III) complex, which results in a reduced optical purity of the catalyst. Therefore, in the case where the catalyst-containing mixture is directly used, it should be used immediately after the preparation. In contrast, in the case where the iridium(III) complex is isolated and purified from the catalyst-containing mixture, the base responsible for epimerization and the epimerized product (epimer) can be eliminated, and thus the iridium(III) complex can be obtained in a crystalline or amorphous form with high optical purity and good preservation stability.
Examples of the isolation and purification method include the following. In one example, the produced iridium(III) complex is isolated by, for example, concentration of the reaction mixture and subsequently purified by a known recrystallization or reprecipitation method. In another example, complex formation is performed in a solvent that allows highly efficient purification, and after a purification process, the resulting precipitate as the main product is collected by filtration, washed and dried. By use of any of these methods, the iridium(III) complex can be easily obtained in a crystalline or amorphous form as a chemically and optically pure product.
The isolated and purified iridium(III) complex in a crystalline or amorphous form is highly stable, the chemical purity and the optical purity thereof stay constant for a long period, and thus the complex can be preserved at room temperature for a long period. With the use of this complex as a catalyst for asymmetric reduction, the reduction product can be obtained with high chemical yield and enantiomeric excess.
The iridium(III) complex can be preferably used as a catalyst for asymmetric reduction in the production of, for example, optically active tetrahydroquinolines, optically active amines, etc.
The term “crystalline” as used herein generally means that molecules are regularly arranged in three dimensions. The term “amorphous” as used herein generally means that molecules form no space lattice and are randomly distributed.
<Iridium(III) Compound>
Examples of the iridium(III) compound used for the preparation of the iridium(III) chloro complex include a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ), acetylacetonato iridium(III) and tris(norbornadiene)(acetylacetonato)iridium(III), and particularly preferred is a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ). The iridium(III) chloro complex can be used for the preparation of other iridium(III) complexes, that is, iridium(III) complexes having a p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − anion.
<Chiral Prolinamide Compound>
Examples of the chiral prolinamide compound used for the preparation of the iridium(III) chloro complex include a compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center).
Examples of the prolinamide compound represented by formula [III] include, in addition to prolinamide, N-substituted amide such as N-alkyl amide, N-cycloalkyl amide, N-aryl amide, N-heteroaryl amide, N-aralkyl amide and N-heteroaryl alkyl amide. These substituting groups are examples of R 3 and may also have a substituting group (hereinafter also called a substituent).
The “alkyl” moiety in the N-alkyl amide is, for example, a straight or branched alkyl group having 1 to 20 carbon atoms but no chiral carbon atoms. The specific examples include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, dodecyl, pentadecyl, hexadecyl and octadecyl.
The “cycloalkyl” moiety in the N-cycloalkyl amide is, for example, a cycloalkyl group having 3 to 7 carbon atoms. The specific examples include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and cycloheptyl.
The “aryl” moiety in the N-aryl amide is, for example, an aryl group having 6 to 20 carbon atoms. The specific examples include phenyl, 1-naphthyl, 2-naphthyl, anthryl, phenanthryl, 2-biphenyl, 3-biphenyl, 4-biphenyl and terphenyl.
The “heteroaryl” moiety in the N-heteroaryl amide is, for example, a heteroaryl group having a heteroatom selected from a nitrogen atom, a sulfur atom, an oxygen atom and the like. The specific examples include furanyl, thienyl, oxazolyl, isoxazolyl, thiazolyl, isothiazolyl, pyrrolyl, imidazolyl, pyrazolyl, pyridyl, pyrimidinyl, pyrazinyl, phthalazinyl, triazinyl, indolyl, isoindolyl, quinolinyl, isoquinolinyl and dibenzofuranyl.
The “aralkyl” moiety in the N-aralkyl amide is, for example, a group which is the same as the above-defined alkyl group except for having an aryl group instead of a hydrogen atom. The specific examples include benzyl, phenylethyl and phenylpropyl.
The “heteroarylalkyl” moiety in the N-heteroaryl alkyl amide is, for example, a group which is the same as the above-defined alkyl group except for having a heteroaryl group instead of a hydrogen atom. The specific examples include heteroarylmethyl, heteroarylethyl and heteroarylpropyl.
The substituting group (substituent) in the above “alkyl”, “aryl”, “heteroaryl”, “aralkyl” and “cycloalkyl” moieties may be of any kind unless the substituting group adversely affects the reaction, and the examples include halogens (for example, a fluorine, chlorine, bromine or iodine atom, etc.), straight or branched alkyl groups having 1 to 6 carbon atoms (for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, hexyl, etc.), aralkyl groups having 7 to 12 carbon atoms (for example, phenylethyl, phenylpropyl, naphthylmethyl, etc.), straight or branched alkoxy groups having 1 to 6 carbon atoms (for example, methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, tert-butoxy, pentyloxy, etc.), alkyl halide groups (for example, monofluoromethyl, difluoromethyl, trifluoromethyl, difluoroethyl, trifluoroethyl, trichloromethyl, etc.), alkoxy halide groups (for example, fluoromethoxy, difluoromethoxy, trifluoromethoxy, trifluoroethoxy, tetrafluoroethoxy, etc.), a hydroxyl group, a mercapto group, a nitro group, a nitrile group, a carboxyl group and an alkoxycarbonyl group. Hereinafter, the substituting group (substituent) of this kind is called substituting group (A) in some cases.
The chiral prolinamide compound is preferably (R)- or (S)-prolinamide or (R)- or (S)-proline heteroaryl amide, and more preferably (R)— or (S)-proline heteroaryl amide. A preferable chiral proline heteroaryl amide compound is (R)— or (S)—N-(6-quinolinyl)-2-pyrrolidinecarboxamide, (R)— or (S)—N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide or the like because the use of these compounds as a ligand of the iridium(III) complex catalyst for a reducing reaction is advantageous in terms of the degree of conversion and the optical purity of the product.
These chiral prolinamide compounds can be used for not only the iridium(III) chloro complex but also other iridium(III) complexes, that is, iridium(III) complexes having a p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − anion.
The amount of the chiral prolinamide compound used for the complex preparation is usually about 0.1 to 10 mol, and preferably about 0.5 to 4 mol per mole of the iridium(III) compound as a starting material.
In the case where the iridium(III) compound is a dimer, the amount of the chiral prolinamide compound used for the complex preparation is usually about 2 to 3 mol, and preferably about 2 to 2.2 mol per mole of the dimer.
<Base>
The base used for the preparation of the iridium (III) chloro complex is preferably a weak base, and is more preferably a tertiary amine, an alkali metal hydrogen carbonate or an alkali earth metal carbonate. Preferable examples of the weak base include tertiary amines such as triethylamine, trimethylamine, tributylamine and N-methylmorpholine; alkali metal hydrogen carbonates such as sodium hydrogen carbonate and potassium hydrogen carbonate; and alkali earth metal carbonates such as calcium carbonate and magnesium carbonate, and particularly preferred is triethylamine. Strong bases including alkali metal hydroxides, such as sodium hydroxide and potassium hydroxide, and sodium methoxide, are not preferable for use in the catalyst preparation because strong bases accelerate the epimerization of the produced prolinamide complex, which reduces the optical purity of the product.
In the case where the iridium(III) compound as a starting material is a dimer, the amount of the base used for the complex preparation is usually about 2 to 3 mol, and preferably about 2 to 2.2 mol per mole of the dimer.
<Reaction>
The iridium(III) chloro complex having a chiral prolinamide compound as a ligand can be prepared by, for example, adding an iridium(III) compound and a base to a chiral prolinamide compound preferably dissolved in a solvent, and preferably stirring the mixture.
The reaction temperature in the present invention is not particularly limited, but is usually −30 to 200° C., preferably −10 to 100° C., more preferably 5 to 40° C., and particularly preferably room temperature.
The reaction time in the present invention is not particularly limited, but is usually 1 minute to 72 hours, preferably 3 minutes to 48 hours, and particularly preferably 10 minutes to 20 hours.
After the completion of the reaction, the desired optically active tetrahydroquinoline can be obtained by known treatments such as concentration, extraction, filtration and washing. If needed, crystallization, recrystallization, salt formation with an achiral acid such as hydrochloric acid, sulfuric acid, methanesulfonic acid, formic acid and trifluoroacetic acid, followed by recrystallization, and chemical optical resolution using chiral mandelic, tartaric, dibenzoyltartaric, ditoluoyl tartaric, 10-camphor sulfonic or malic acid may be employed to obtain the optically active tetrahydroquinoline in a higher optical purity.
In the preparation of the iridium(III) chloro complex having a chiral prolinamide compound as a ligand, it is preferable that a chiral prolinamide compound is brought into contact with a pentamethylcyclopentadienyl iridium(III) chloride dimer in the presence of a weak base.
<Metal Salt>
In the preparation of iridium(III) complexes other than the iridium(III) chloro complex, that is, iridium(III) complexes having a p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − anion, it is preferable to additionally use a metal salt represented by formula [V]:
M a X b [V]
(wherein M represents a mono- to trivalent metal cation, X represents p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B[3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − , a represents an integer of 1 to 3, and b represents an integer of 1 to 3).
The addition of this metal salt allows the replacement of the chloro anion in the iridium(III) chloro complex with the anion represented by X in the metal salt, resulting in the production of iridium(III) complexes containing the desired anion.
M is, for example, a monovalent metal cation such as a lithium ion, a sodium ion, a potassium ion, a copper(I) ion, a mercury(I) ion, a silver ion, etc.; a divalent metal cation such as a magnesium ion, a calcium ion, a strontium ion, a barium ion, a cadmium ion, a nickel(II) ion, a zinc ion, a copper(II) ion, a mercury(II) ion, a cobalt(II) ion, a tin(II) ion, a lead(II) ion, a manganese(II) ion, etc.; and a trivalent metal cation such as an aluminum ion, an iron(III) ion, a chromium(III) ion, etc. Preferred is a monovalent metal cation and more preferred is a silver ion.
Examples of the metal salt represented by formula [V] include silver hexafluorophosphate, silver trifluoromethanesulfonate, silver hexafluoroantimonate, silver perchlorate and silver tetrafluoroborate.
The amount of the metal salt used for the complex preparation is, for example, usually about 0.7 to 1.4 mol, and preferably about 0.9 to 1.1 mol per mole of the iridium (III) chloro complex.
<Solvent>
In the preparation of the iridium(III) complex, it is preferable to use a solvent. The solvent is not particularly limited and may be an inorganic or organic solvent, but preferred is an organic solvent.
Examples of the organic solvent include aliphatic hydrocarbons (for example, pentane, hexane, heptane, octane, cyclohexane, etc.); aromatic hydrocarbons (for example, benzene, toluene, xylene, etc.); halogenated hydrocarbons (for example, dichloromethane, 1,2-dichloroethane, chloroform, carbon tetrachloride, o-dichlorobenzene, etc.); alcohols (for example, methanol, ethanol, isopropyl alcohol, tert-butyl alcohol, tert-amyl alcohol, etc.); ethers (for example, dimethyl ether, ethylmethyl ether, diethyl ether, diisopropyl ether, diglyme, tert-butyl methyl ether, dimethoxyethane, ethylene glycol diethyl ether, tetrahydrofuran, 1,4-dioxane, etc.); amides (for example, N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, etc.); sulfoxides (for example, dimethyl sulfoxide etc.); nitriles (for example, acetonitrile, propionitrile, benzonitrile, etc.); ketones (for example, acetone, methyl ethyl ketone, methyl isobutyl ketone, etc.); and ester compounds (for example, methyl acetate, ethyl acetate, etc.). In the case where highly water-miscible alcohols, ethers, amides, sulfoxides, nitriles, ketones or esters are used as the solvent, the water content of the solvent may be up to about 50%. Among the above examples, more preferred is methanol, water-containing methanol, ethanol, water-containing ethanol, methylene chloride, ethyl acetate or acetonitrile.
Production of optically active 2-substituted-1,2,3,4-tetrahydroquinolines
In an embodiment of the present invention, 2-substituted-1,2,3,4-tetrahydroquinolines can be efficiently produced by the reaction route shown below. The reaction formula of the present invention is as shown below. The “hydrogen source” in the following reaction formula means a hydrogen donor.
That is, by reducing a quinoline compound represented by general formula [I]:
(wherein R 1 represents an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group,
R 2 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group, an optionally substituted heteroaryl group, an optionally substituted hydroxyl group, an optionally substituted thiol group, an optionally substituted amino group, an optionally substituted carbamoyl group, an optionally substituted aryloxy group, an optionally substituted heteroaryloxy group, a carboxyl group, an esterified carboxyl group, a cyano group, a nitro group or a halogen atom,
R 2 is bound to the quinoline ring at any one of positions 5 to 8,
n is an integer of 1 to 4, and
when n is not less than 2, R 2 groups adjacent to each other may join together to form a ring),
in the presence of a hydrogen donor compound and an iridium (III) complex having a chiral prolinamide compound as a ligand, an optically active 2-substituted-1,2,3,4-tetrahydroquinoline represented by formula [II]:
(wherein R 1 , R 2 and n are as defined in formula [I], and the symbol “*” indicates that the carbon atom is a chiral center) can be produced.
<Starting Material>
In the production of optically active 2-substituted-1,2,3,4-tetrahydroquinolines, a quinoline compound represented by general formula [I]:
(each symbol in the formula is as defined in the previously described formula [I])
(hereinafter also referred to as compound [I] in a simple way) is used as a starting material of asymmetric hydrogenation in the present invention.
In compound [I], the “alkyl” moiety in the optionally substituted alkyl group represented by R 2 is preferably a straight or branched alkyl group having 1 to 20 carbon atoms. The specific examples include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl and octadecyl.
The “aryl” moiety in the optionally substituted aryl group represented by R 1 is, for example, an aromatic hydrocarbon group having 6 to 14 carbon atoms. The specific examples include phenyl, naphthyl and anthranil.
The “aralkyl” moiety in the optionally substituted aralkyl group represented by R 1 is, for example, an alkyl group having 1 to 3 carbon atoms and being substituted by the above-defined “aryl” moiety instead of a hydrogen atom. The specific examples include benzyl, phenylethyl, phenylpropyl and naphthylmethyl.
The “heteroaryl” moiety in the optionally substituted heteroaryl group represented by R 1 is, for example, a heteroaryl group having 5 to 14 carbon atoms. The specific examples include furanyl, thienyl, oxazolyl, isoxazolyl, thiazolyl, isothiazolyl, pyrrolyl, imidazolyl, pyrazolyl, pyridyl, pyrimidinyl, pyrazinyl, phthalazinyl, triazinyl, indolyl, isoindolyl, quinolinyl, isoquinolinyl and dibenzofuranyl.
The “cycloalkyl” moiety in the optionally substituted cycloalkyl group represented by R 1 is, for example, a cycloalkyl group having 3 to 7 carbon atoms. The specific examples include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and cycloheptyl.
Examples of the substituting group (substituent) in the optionally substituted alkyl group, the optionally substituted aryl group, the optionally substituted aralkyl group, the optionally substituted heteroaryl group and the optionally substituted cycloalkyl group which are all represented by R 1 are the same as those of substituting group (A) described above.
Examples of the substituting group in the optionally substituted alkyl group, the optionally substituted aryl group, the optionally substituted aralkyl group, the optionally substituted heteroaryl group and the optionally substituted cycloalkyl group which are all represented by R 2 are the same as those of substituting group (A) described above.
Examples of the substituting group in the optionally substituted hydroxyl group, the optionally substituted thiol group, the optionally substituted amino group and the optionally substituted carbamoyl group which are all represented by R 2 include straight or branched alkyl groups having 1 to 6 carbon atoms (for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, hexyl, etc.), aralkyl groups having 7 to 12 carbon atoms (for example, phenylmethyl, phenylethyl, phenylpropyl, naphthylmethyl, etc.), alkyl halide groups (for example, monofluoromethyl, difluoromethyl, trifluoromethyl, difluoroethyl, trifluoroethyl, trichloromethyl, etc.), carbonyl groups (for example, methylcarbonyl, ethylcarbonyl, phenylcarbonyl, methoxycarbonyl, phenoxycarbonyl, etc.), sulfonyl groups (for example, methylsulfonyl, toluenesulfonyl, trifluoromethylsulfonyl, etc.), and silyl groups (for example, trimethylsilyl, triphenylsilyl, tert-butyldimethylsilyl, etc.).
Examples of the substituting group in the optionally substituted aryloxy group and the optionally substituted heteroaryloxy group which are all represented by R 2 are the same as those of substituting group (A) described above.
Examples of the esterified carboxyl group represented by R 2 include alkoxycarbonyl groups (for example, methoxycarbonyl etc.) and aryloxycarbonyl groups (for example, phenoxycarbonyl etc.).
Examples of the halogen atom represented by R 2 include a fluorine, chlorine, bromine or iodine atom.
R 2 is bound to the quinoline ring at any one of positions 5 to 8, and n is an integer of 1 to 4. Preferably, n is 1 or 2.
In the case where plural R 2 groups are present and R 2 groups adjacent to each other join together to form a ring, the ring is, for example, an aliphatic ring such as methylenedioxy, carbonate, acetonide, oxazole, oxazolinone and methyloxazole; or an aromatic ring such as furan, thiophene, pyrrole, benzene, naphthalene and anthracene, and is optionally substituted by any substituting group. In this case, examples of the substituting group are the same as those of substituting group (A) described above.
<Iridium(III) Complex Having a Chiral Prolinamide Compound as a Ligand>
The iridium(III) complex having a chiral prolinamide compound as a ligand used for the production of optically active 2-substituted-1,2,3,4-tetrahydroquinolines is preferably a compound represented by formula [IV]:
Cp*Ir(X)(L-H + ) [IV]
(wherein X represents Cl − , p-CH 3 C 6 H 4 SO 3 − , CH 3 SO 3 − , CF 3 SO 3 − , NO 3 − , BF 4 − , ClO 4 − , PF 6 − , SbF 6 − , B [3,5-di(trifluoromethyl)phenyl] 4 − or B(4-fluorophenyl) 4 − , L is a compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center), and Cp* represents (1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl).
Preferably, the iridium (III) complex has a ligand of formula [III] in which R 3 is hydrogen, a 6-quinolinyl group or a 2-methoxy-3-dibenzofuranyl group.
The iridium(III) complex having a chiral prolinamide compound as a ligand is preferably an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) catalyst, or an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) catalyst.
It is also preferred that the iridium(III) complex having a chiral prolinamide compound as a ligand is an (R)- or (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) catalyst.
The iridium(III) complex having a chiral prolinamide compound as a ligand is preferably crystalline.
The chiral prolinamide compound as the ligand of the iridium(III) complex is preferably a compound represented by formula [III]:
(wherein R 3 represents a hydrogen atom, an optionally substituted alkyl group, an optionally substituted aryl group, an optionally substituted aralkyl group, an optionally substituted cycloalkyl group or an optionally substituted heteroaryl group, and the symbol “*” indicates that the carbon atom is a chiral center).
The chiral prolinamide compound is preferably (R)- or (S)-prolinamide or (R)- or (S)-proline heteroaryl amide, and more preferably (R)— or (S)-proline heteroaryl amide. A preferable chiral proline heteroaryl amide compound is (R)— or (S)—N-(6-quinolinyl)-2-pyrrolidinecarboxamide, (R)— or (S)—N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide or the like.
The amount of the iridium (III) complex having a chiral prolinamide compound as a ligand used for the reaction is usually about 0.1 to 10 mol %, and preferably about 0.2 to 5 mol % per mole of compound [I].
<Hydrogen Donor Compound>
Examples of the hydrogen donor compound used for the production of optically active 2-substituted-1,2,3,4-tetrahydroquinolines include formic acid, ammonium formate, sodium formate, potassium formate and 2-propanol, and particularly preferred is formic acid. When formic acid is used as the hydrogen donor compound, it is preferable to use a tertiary amine such as triethylamine together therewith. The amount of the hydrogen donor compound used for the reaction is usually about 2 to 40 mol, and preferably about 4 to 20 mol per mole of compound [I].
<Reaction>
In an preferable embodiment, the reducing reaction is conducted as follows: compound [I] is preferably dissolved in a solvent as described in the section “solvent” below, an iridium(III) complex having a chiral prolinamide compound as a ligand is added and dissolved in the solution, and a hydrogen donor compound is added to allow the reaction to proceed.
The reaction temperature of this reaction is usually −70° C. or higher, and preferably about −30 to 40° C.
The reaction time in the present invention is not particularly limited, but is usually 1 minute to 72 hours, preferably 3 minutes to 48 hours, and more preferably 10 minutes to 20 hours.
After the completion of the reaction, the desired optically active tetrahydroquinoline can be obtained by known treatments such as concentration, extraction, filtration and washing. If needed, crystallization, recrystallization, salt formation with an achiral acid such as hydrochloric acid, sulfuric acid, methanesulfonic acid, formic acid and trifluoroacetic acid, followed by recrystallization, and chemical optical resolution using chiral mandelic, tartaric, dibenzoyltartaric, ditoluoyl tartaric, 10-camphor sulfonic or malic acid may be employed to obtain the optically active tetrahydroquinoline in a higher optical purity.
<Solvent>
In the production of optically active 2-substituted-1,2,3,4-tetrahydroquinolines, it is preferable to use a solvent. The solvent is not particularly limited and may be an inorganic or organic solvent. Examples of the solvent include acetonitrile, ethyl acetate, isopropyl acetate, N,N-dimethylformamide, tetrahydrofuran, dimethoxyethane, dichloromethane, alcohols such as methanol, ethanol, 2-propanol and ethylene glycol, and mixed solvents of water and the foregoing. The amount of the solvent used for the reaction is usually about 2 to 200 L, and preferably about 5 to 100 L per kilogram of compound [I].
A mixed solvent of formic acid and triethylamine can be used as the hydrogen donor compound as well as the solvent. In the case where a mixed solvent of formic acid and triethylamine is used as the hydrogen donor compound as well as the solvent, the amount of formic acid used for the reaction is usually about 2 to 40 mol, and preferably about 4 to 20 mol per mole of compound [I]. The amount of triethylamine used for the reaction is usually about 0.1 to 1 mol, and preferably about 0.2 to 0.7 mol per mole of formic acid.
<Optically Active 2-substituted-1,2,3,4-tetrahydroquinolines>
The above-described reaction produces an optically active 2-substituted-1,2,3,4-tetrahydroquinoline represented by general formula [II]:
(wherein R 1 , R 2 and n are as defined in formula [I], and the symbol “*” indicates that the carbon atom is a chiral center).
The optically active 2-substituted-1,2,3,4-tetrahydroquinoline can be used as, for example, a pharmaceutical, an agrochemical, a liquid crystal material, or an intermediate of the foregoing.
EXAMPLES
Hereinafter, the present invention will be illustrated by Examples, but is not limited thereto.
<Measurement Methods>
Melting points were measured with Micro Melting Point System MP (manufactured by Yanagimoto Manufacturing Co., Ltd.).
The elemental analyses of iridium were performed with iCAP6500 Duo ICP atomic emission spectrometer (manufactured by Thermo Fisher Scientific K.K.).
Infrared spectra (IR) were recorded on FT/IR-4100 (manufactured by JASCO Corporation).
Far-infrared spectra were recorded on IFS-66 V/s (manufactured by Bruker Japan Co., Ltd.) and the embedding medium used was polyethylene.
Nuclear magnetic resonance (NMR) spectra were recorded on Gemini-200 (manufactured by Varian Medical Systems, Inc.). The internal standard used was TMS (tetramethylsilane), the solvent used was CDCl 3 , CD 3 OD or DMSO-d 6 , and the measurement was performed at room temperature. The measured values were expressed in δ (ppm).
Specific rotations were measured with P-1020 (manufactured by JASCO Corporation).
X-ray powder diffraction patterns were measured with MiniFlexII (manufactured by Rigaku Corporation).
Optical purities were determined with a high-performance liquid chromatograph (HPLC) (LC10A; manufactured by Shimadzu Corporation) equipped with a chiral column, by calculating the peak area ratio of a pair of enantiomers.
The solvents and reagents used in the reactions described below are commercial products if not otherwise specified.
In the following examples, a (1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl moiety is abbreviated to Cp*, 2-pyrrolidinecarboxamide is abbreviated to PA, N-6-quinolinyl-2-pyrrolidinecarboxamide is abbreviated to PQA, and N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide is abbreviated to PMDBFA; or in some cases, the full names and their abbreviations are shown together.
Example 1
Synthesis of crystalline (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir (Cl − )(R-PA-H + ))
To 40 ml of methylene chloride, 1.593 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ), 502 mg of (R)-prolinamide and 425 mg of triethylamine were successively added, and the mixture was continuously stirred at room temperature overnight. To the reaction mixture, 10 ml of a 20% aqueous sodium chloride solution was added, and the mixture was stirred for about 30 minutes and then left to stand. The resulting layers were separated.
The aqueous layer was extracted with 10 ml of methylene chloride, and then the organic layers were combined and washed with 10 ml of a 20% aqueous sodium chloride solution. Further, this aqueous layer was extracted with 10 ml of methylene chloride, and then the organic layers were combined and dried over 10 g of anhydrous sodium sulfate overnight. The desiccant was filtered off and washed with methylene chloride, and then the filtrate was concentrated in vacuo. To the concentrated residue, 20 ml of tetrahydrofuran/diisopropyl ether (1/1) was added, and the mixture was stirred at 35 to 40° C. for about 1 hour. The precipitate was collected by suction filtration, washed with 10 ml of tetrahydrofuran/diisopropyl ether (1/1), and then dried in vacuo at 40 to 50° C. for 5 hours to give 1.813 g of (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(R-PA-H + )) as a yellow crystalline powder.
Melting point: 174.8° C.
Elemental analysis: C 15 H 24 ClIrN 2 O (476.01) calculated value (%) C, 37.84; H, 5.08; N, 5.88; Ir, 40.4 found value (%) C, 37.81; H, 5.07; N, 5.93; Ir40.7
IR (KBr): 3429, 3282, 1599 cm −1
1 H-NMR (200 MHz, CDCl 3 ): δ 1.60-2.28 (4H, m, 2×CH 2 ), 1.70 (15H, s, 5Me of Cp*), 2.71-2.93 (1H, m, one of NCH 2 ), 3.41-3.55 (1H, m, one of NCH 2 ), 3.89-4.01 (1H, m, NCH), 4.96 (2H, br, 2×NH).
13 C-NMR (50.3 MHz, CDCl 3 ): δ 9.1 (5Me of Cp*), 27.1 (CH 2 ), 28.2 (CH 2 ), 54.3 (NCH 2 ), 62.9 (NCH), 84.4 (ArC of Cp*), 183.5 (C═O).
Example 2
Synthesis of crystalline (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir (Cl − )(R-PA-H + ))
To a suspension of 3.59 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ) and 1.08 g of (R)-prolinamide in 90 ml of acetonitrile, 1.38 ml of triethylamine was added dropwise with stirring under argon stream at room temperature, and the mixture was further stirred at room temperature for about 1.5 hours. After removal of acetonitrile by evaporation in vacuo, 60 ml of a saturated aqueous sodium chloride solution and 30 ml of water were added to the residue, and the mixture was extracted with chloroform 3 times (the volumes of chloroform were 45 ml, 30 ml and 30 ml). The extracts were collected, washed with 45 ml of a saturated aqueous sodium chloride solution once, and dried over anhydrous sodium sulfate. The desiccant was removed, and the filtrate was concentrated in vacuo. To the residual concentrate, 15 ml of acetonitrile was added, and the solution was cooled to below freezing for crystallization.
The crystalline precipitate was collected by filtration, washed with acetonitrile/diisopropyl ether (1/3), and then dried in vacuo at 60° C. for 3 hours to give 3.289 g of (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(R-PA-H + )) as a yellow crystalline powder.
Melting point: 210° C. (with decomposition)
Elemental analysis: C 15 H 24 ClIrN 2 O (476.01) calculated value (%) C, 37.84; H, 5.08; N, 5.88; Ir, 40.4 found value (%) C, 37.82; H, 5.08; N, 5.94; Ir, 40.7
Water content (Karl Fischer method): 0.17%
Example 3
Synthesis of crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + ))
To 40 ml of methylene chloride, 1.593 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ), 502 mg of (S)-prolinamide and 425 mg of triethylamine were successively added, and the mixture was continuously stirred at room temperature overnight. To the reaction mixture, 10 ml of a 20% aqueous sodium chloride solution was added, and the mixture was stirred for about 30 minutes and then left to stand. The resulting layers were separated. The aqueous layer was extracted with 10 ml of methylene chloride, and then the organic layers were combined and washed with 10 ml of a 20% aqueous sodium chloride solution. Further, this aqueous layer was extracted with 10 ml of methylene chloride, and then the organic layers were combined and dried over 10 g of anhydrous sodium sulfate overnight. The desiccant was filtered off and washed with methylene chloride, and then the filtrate was concentrated in vacuo. To the concentrated residue, 20 ml of tetrahydrofuran/diisopropyl ether (1/1) was added, and the mixture was stirred at 35 to 40° C. for about 1 hour. The precipitate was collected by suction filtration, washed with 10 ml of tetrahydrofuran/diisopropyl ether (1/1), and then dried in vacuo at 40 to 50° C. for 5 hours to give 1.796 g of (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + )) as a yellow crystalline powder.
Melting point: 173.5° C.
IR (KBr): 3433, 3281, 1599 cm −1
1 H-NMR (200 MHz, CDCl 3 ): δ 1.60-2.28 (4H, m, 2×CH 2 ), 1.70 (15H, s, 5Me of Cp*), 2.71-2.93 (1H, m, one of NCH 2 ), 3.41-3.56 (1H, m, one of NCH 2 ), 3.88-4.00 (1H, m, NCH), 4.96 (2H, br, 2×NH).
13 C-NMR (50.3 MHz, CDCl 3 ): δ 9.1 (5Me of Cp*), 27.1 (CH 2 ), 28.2 (CH 2 ), 54.3 (NCH 2 ), 62.9 (NCH), 84.5 (ArC of Cp*), 183.6 (C═O).
Example 4
Synthesis of crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + ))
To a suspension of 3.19 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ) and 0.959 g of (S)-prolinamide in 80 ml of acetonitrile, 1.23 ml of triethylamine was added dropwise with stirring under argon stream at room temperature, and the mixture was further stirred at room temperature for about 1 hour. After removal of acetonitrile by evaporation in vacuo, 50 ml of a saturated aqueous sodium chloride solution and 25 ml of water were added to the residue, and the mixture was extracted with chloroform 3 times (the volumes of chloroform were 40 ml, 30 ml and 30 ml). The extracts were collected, washed with 40 ml of a saturated aqueous sodium chloride solution once, and dried over anhydrous sodium sulfate. The desiccant was removed, and the filtrate was concentrated in vacuo. To the concentrated residue, 12 ml of acetonitrile was added and the mixture was heated to 50° C. for dissolution. To the solution, 24 ml of diisopropyl ether was added, and the solution was cooled to below freezing for crystallization.
The crystalline precipitate was collected by filtration, washed with acetonitrile/diisopropyl ether (1/3), and then dried in vacuo at 60° C. for 3 hours to give 3.028 g of (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + )) as a yellow crystalline powder.
The IR (KBr) chart, far-infrared spectrum and X-ray powder diffraction pattern of this product are shown in FIGS. 1 , 2 and 3 , respectively.
Melting point: 210° C. (with decomposition)
Water content (Karl Fischer method): 0.30%
Elemental analysis: C 15 H 24 ClIrN 2 O (476.01) calculated value (%) C, 37.84; H, 5.08; N, 5.88 found value (%) C, 37.74; H, 5.08; N, 5.89
IR (KBr): 3433, 1609, 1449, 917 cm −1
Far-infrared spectrum: 664, 641, 604, 581, 564, 540, 468, 449, 417, 350, 270 cm −1
1 H-NMR (200 MHz, CDCl 3 ): δ 1.60-2.28 (4H, m, 2×CH 2 ), 1.70 (15H, s, 5Me of Cp*), 2.71-2.93 (1H, m, one of NCH 2 ), 3.40-3.60 ( 1 H, m, one of NCH 2 ), 3.85-4.05 (1H, m, NCH), 4.75-5.00 (1H, br, NH), 4.90 (1H, s, NH).
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.46-1.93 (4H, m), 1.63 (15H, s, 5Me of Cp*), 2.48-2.74 (1H, m, one of NCH 2 ), 3.23-3.38 (1H, m, one of NCH 2 ), 3.45-3.58 (1H, m, NCH), 5.04 (1H, br s, CONH), 6.15-6.30 (6.23 centered, 1H, br, NH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): 8.6 (5Me of Cp*), 26.1 (CH 2 ), 27.8 (CH 2 ), 53.6 (NCH 2 ), 62.1 (NCH), 83.7 (ArC of Cp*), 182.2 (C═O).
Reference Example 1
According to the method of Winfried Hoffmueller et al. (Winfried Hoffmueller, Kurt Polborn, Joerg Knizek, Heinrich Noeth and Wolfgang Beck, Z. Anorg. Allg. Chem. 1997, 623, 1903-1911), compound 10 described in this reference was prepared as a powder. The far-infrared spectrum of this product is shown in FIG. 4 .
Far-infrared spectrum: 617, 583, 539, 466, 427, 350, 266, 244 cm −1
Example 5
Synthesis of crystalline (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(R-PQA-H + ))
To 50 ml of acetonitrile, 1.593 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ), 502 mg of (R)—N-6-quinolinyl-2-pyrrolidinecarboxamide and 425 mg of triethylamine were successively added, and the mixture was continuously stirred at room temperature overnight. The precipitate was collected by suction filtration, washed successively with 15 ml of acetonitrile/water (20/1) and 10 ml of acetonitrile, and then dried in vacuo at 40 to 50° C. for 5 hours to give 2.175 g of (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(R-PQA-H + )) as a yellow crystalline powder.
Melting point: 243.8° C.
IR (KBr): 3446, 3128, 1576 cm −1
1 H-NMR (200 MHz, CD 3 OD): δ 1.37 (15H, s, 5Me of Cp*), 1.66-2.32 (4H, m, 2×CH 2 ), 3.18-3.36 (1H, m, one of NCH 2 ), 3.48-3.59 (1H, m, one of NCH 2 ), 4.06-4.14 (1H, m, NCH), 7.50 (1H, dd, J=8.2, 4.2 Hz), 7.76 (1H, dd, J=8.6, 2.2 Hz), 7.79 (1H, br s), 7.96 (1H, br d, J=8.6 Hz), 8.29 (1H, br dd, J=8.2, 1.6 Hz), 8.75 (1H, dd, J=4.2, 1.6 Hz).
13 C-NMR (50.3 MHz, CD 3 OD): δ 8.9 (5Me of Cp*), 27.9 (CH 2 ), 31.1 (CH 2 ), 56.0 (NCH 2 ), 66.3 (NCH), 87.1 (ArC of Cp*), 122.7 (CH), 125.7 (CH), 128.8 (CH), 130.2 (quaternary), 133.2 (CH), 138.0 (CH), 146.9 (quaternary), 149.2 (quaternary), 150.3 (CH), 183.2 (C═O).
Example 6
Synthesis of crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PQA-H + ))
To 50 ml of acetonitrile, 1.593 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ), 502 mg of (S)—N-6-quinolinyl-2-pyrrolidinecarboxamide and 425 mg of triethylamine were successively added, and the mixture was continuously stirred at room temperature overnight. The precipitate was collected by suction filtration, washed successively with 15 ml of acetonitrile/water (20/1) and 10 ml of acetonitrile, and then dried in vacuo at 40 to 50° C. for 5 hours to give 2.322 g of (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PQA-H + )) as a yellow crystalline powder.
Melting point: 241.8° C.
IR (KBr): 3433, 3130, 1576 cm −1
1 H-NMR (200 MHz, CD 3 OD): δ 1.37 (15H, s, 5Me of Cp*), 1.66-2.32 (4H, m, 2×CH 2 ), 3.16-3.36 (1H, m, one of NCH 2 ), 3.48-3.59 (1H, m, one of NCH 2 ), 4.06-4.14 (1H, m, NCH), 7.50 (1H, dd, J=8.2, 4.4 Hz), 7.76 (1H, dd, J=8.6, 2.2 Hz), 7.79 (1H, br s), 7.96 (1H, br d, J=8.6 Hz), 8.29 (1H, br dd, J=8.2, 1.6 Hz), 8.75 (1H, dd, J=4.4, 1.6 Hz).
13 C-NMR (50.3 MHz, CD 3 OD): δ 8.9 (5Me of Cp*), 27.9 (CH 2 ), 31.1 (CH 2 ), 56.0 (NCH 2 ), 66.3 (NCH), 87.1 (ArC of Cp*), 122.7 (CH), 125.7 (CH), 128.8 (CH), 130.2 (quaternary), 133.2 (CH), 138.0 (CH), 146.9 (quaternary), 149.2 (quaternary), 150.3 (CH), 183.2 (C═O).
Example 7
Synthesis of crystalline (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) (Cp*Ir(Cl − )(R-PMDBFA-H + ))
To 50 ml of acetonitrile, 1.593 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([CP*IrCl 2 ] 2 ), 1.361 g of (R)—N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide and 425 mg of triethylamine were successively added, and the mixture was continuously stirred at room temperature overnight. After addition of 7.0 ml of water, the reaction mixture was stirred for about 30 minutes. Then, the precipitate was collected by suction filtration, washed successively with 20 ml of acetonitrile/water (9/1) and 10 ml of acetonitrile, and then dried in vacuo at 40 to 50° C. for 5 hours to give 2.623 g of (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) (Cp*Ir(Cl − )(R-PMDBFA-H + )) as a yellow crystalline powder.
Melting point: not lower than 300° C.
IR (KBr): 3446, 3214, 1581 cm −1
1 H-NMR (200 MHz, CD 3 OD): δ 1.38 (15H, s, 5Me of Cp*), 3.93 (3H, s, OMe), 7.48 (1H, s, ArH), 7.57 (1H, s, ArH).
Example 8
Synthesis of crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) (Cp*Ir(Cl − )(S-PMDBFA-H + ))
To 50 ml of acetonitrile, 1.593 g of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ), 1.361 g of (S)—N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamide and 425 mg of triethylamine were successively added, and the mixture was continuously stirred at room temperature overnight. After addition of 7.0 ml of water, the reaction mixture was stirred for about 30 minutes. Then, the precipitate was collected by suction filtration, washed successively with 20 ml of acetonitrile/water (9/1) and 10 ml of acetonitrile, and then dried in vacuo at 40 to 50° C. for 5 hours to give 2.655 g of (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) (Cp*Ir(Cl − )(S-PMDBFA-H + )) as a yellow crystalline powder.
Melting point: not lower than 300° C.
IR (KBr): 3433, 3215, 1580 cm −1
1 H-NMR (200 MHz, CD 3 OD): δ 1.38 (15H, s, 5Me of Cp*), 3.93 (3H, s, OMe), 7.48 (1H, s, ArH), 7.58 (1H, s, ArH).
Example 9
Asymmetric Reduction of 2-methylquinoline
In 60 ml of methylene chloride, 1.00 g of 2-methylquinoline was dissolved, and 66.5 mg (2.0 mol %) of crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + )) was added. After cooling to −20° C., 8.4 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added dropwise, and the mixture was continuously stirred at the same temperature for 20 hours. Then, the reaction was completed. The reaction mixture was basified with an aqueous potassium carbonate solution and then the resulting layers were separated. The organic layer was washed with water and concentrated to give 1.05 g of 2-methyl-1,2,3,4-tetrahydroquinoline as an oil.
This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the S-enantiomer was in excess and the optical purity was 90.4% ee.
Specific rotation: [α] D 20 −78.3° (c=1.0, MeOH)
1 H-NMR (200 MHz, CDCl 3 ): δ 1.21 (3H, d, J=6.2 Hz, 2-Me), 1.58 (1H, dddd, J=12.8, 11.0, 9.9, 5.9 Hz, one of 3-H 2 ), 1.93 (1H, dddd, J=12.8, 5.5, 3.7, 2.9 Hz, one of 3-H 2 ), 2.64-2.94 (2H, m, 4-H 2 ), 3.30-3.85 (1H, br, 1-H), 3.39 (1H, dqd, J=9.9, 6.2, 2.9 Hz, 2-H), 6.44-6.49 (1H, m, ArH), 6.60 (1H, td, J=7.3, 1.2 Hz, ArH), 6.91-7.01 (2H, m, ArH).
13 C-NMR (50.3 MHz, CDCl 3 ): δ 22.6 (2-Me), 26.6 (3-C), 30.1 (4-C), 47.2 (2-C), 114.0 (ArC), 117.0 (ArC), 121.1 (quaternary ArC), 126.7 (ArC), 129.3 (ArC), 144.7 (quaternary ArC).
Example 10
Asymmetric Reduction of 6-fluoro-2-methylquinoline
The same procedures as in Example 7 were performed except that 6-fluoro-2-methylquinoline was used as a starting material, and 6-fluoro-2-methyl-1,2,3,4-tetrahydroquinoline was obtained. The S-enantiomer was in excess and the optical purity was 95.4% ee.
Example 11
Asymmetric Reduction of 6-methoxy-2-methylquinoline
The same procedures as in Example 7 were performed except that 6-methoxy-2-methylquinoline was used as a starting material, and 6-methoxy-2-methyl-1,2,3,4-tetrahydroquinoline was obtained. The S-enantiomer was in excess and the optical purity was 80.4% ee.
Example 12
Asymmetric Reduction of 2-methylquinoline
To 10 ml of methylene chloride, 55.6 mg of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ) (1.0 mol % as a dimer), 16.7 mg of (S)-prolinamide and 15.6 mg of triethylamine were added, and the mixture was stirred under argon atmosphere at room temperature for about 30 minutes to give a catalyst-containing mixture.
In 60 ml of methylene chloride, 1.00 g of 2-methylquinoline was dissolved, and the catalyst-containing mixture was added. After cooling to −10° C., 8.4 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added dropwise, and the mixture was stirred at the same temperature overnight to give 2-methyl-1,2,3,4-tetrahydroquinoline. The S-enantiomer was in excess and the optical purity was 86.4% ee.
Comparative Example 1
Asymmetric Reaction of 2-Methylquinoline Using a Crystalline Iridium Catalyst (Catalytic Amount: 0.2 Mol %)
In 60 ml of methylene chloride, 1.00 g of 2-methylquinoline was dissolved, and as a catalyst, 6.7 mg (0.2 mol %) of a crystalline (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) complex (Cp*Ir(Cl − )(R-PA-H + )) was added. After cooling to −10° C., 8.4 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added dropwise, and the mixture was stirred at the same temperature for 2 days to give 2-methyl-1,2,3,4-tetrahydroquinoline (degree of conversion: 73%). The R-enantiomer was in excess and the optical purity was 90.2% ee.
Comparative Example 2
Asymmetric Reaction of 2-Methylquinoline Using an Iridium Catalyst-Containing Mixture (Catalytic Amount: 0.2 Mol %)
To 10 ml of methylene chloride, 55.6 mg of a pentamethylcyclopentadienyl iridium(III) chloride dimer ([Cp*IrCl 2 ] 2 ), 16.7 mg of (R)-prolinamide and 15.6 mg of triethylamine were added, and the mixture was stirred under argon atmosphere at room temperature for about 30 minutes to give a catalyst-containing mixture. In 60 ml of methylene chloride, 1.00 g of 2-methylquinoline was dissolved, and a 1/10 amount of the catalyst-containing mixture (equivalent to 0.1 mol % as an iridium chloride dimer) was added. After cooling to −10° C., 8.4 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added dropwise, and the mixture was stirred at the same temperature for 2 days to give 2-methyl-1,2,3,4-tetrahydroquinoline (degree of conversion: 67.4%). The R-enantiomer was in excess and the optical purity was 85.4% ee.
Comparative Example 3
Asymmetric Reaction of 2-Methylquinoline Using an Iridium Catalyst-Containing Mixture Left Unused for One Week after Preparation (Catalytic Amount: 0.2 Mol %)
The same procedures as in Comparative Example 11 were performed except that the catalyst-containing mixture prepared in Example 11 was left at room temperature for one week after the preparation and used as a catalyst, and 2-methyl-1,2,3,4-tetrahydroquinoline was obtained (degree of conversion: 56.9%). The R-enantiomer was in excess and the optical purity was 49.8% ee.
Example 13
Asymmetric Reduction of 2-Phenylquinoline
In 30 ml of 10% hydrous methanol, 1.03 g of 2-phenylquinoline was dissolved, and 47.7 mg (2.0 mol %) of crystalline (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + )) was added. After cooling to −20° C., 6.0 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added dropwise, and the mixture was continuously stirred at the same temperature for 20 hours. Then, the reaction was completed.
The product was identified as 2-phenyl-1,2,3,4-tetrahydroquinoline by NMR. This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the R-enantiomer was in excess and the optical purity was 74.1% ee.
After the reaction, the precipitate was collected by filtration, washed with 50% hydrous methanol, and air-dried to give 406 mg of a colorless crystal. This product was (R)-2-phenyl-1,2,3,4-tetrahydroquinoline and the optical purity was 98.3% ee.
Melting point: 56.9° C.
Specific rotation: [α] D 20 −69.8° (c=1.0, MeOH)
1 H-NMR (200 MHz, CDCl 3 ): δ 1.89-2.19 (2H, m, 3-H 2 ), 2.74 (1H, H B of ABXX′ system, J AB =16.3 Hz, J BX =J BX′ =4.8 Hz, one of 4-H 2 ), 2.92 (1H, H A of ABXX′ system, J AB =16.3 Hz, J AX =10.5 Hz, J AX′ =5.9 Hz, one of 4-H 2 ), 4.04 (1H, br s, 1-H), 4.44 (1H, dd, J=9.1, 3.7 Hz, 2-H), 6.51-6.57 (1H, m, ArH), 6.65 (1H, td, J=7.3, 1.1 Hz, ArH), 6.96-7.06 (2H, m, ArH), 7.23-7.43 (5H, m, Ph).
13 C-NMR (50.3 MHz, CDCl 3 ): δ 26.4 (3-C), 31.0 (4-C), 56.2 (2-C), 114.0 (ArC), 117.2 (ArC), 120.9 (quaternary ArC), 126.5 (ArC), 126.9 (ArC), 127.4 (ArC), 128.6 (ArC), 129.3 (ArC), 144.7 (quaternary ArC), 144.8 (quaternary ArC).
Example 14
Asymmetric Reduction of 2-(3-hydroxyphenyl)-5-(3-trifluoromethoxyphenyl)quinoline
In 30 ml of methanol, 381 mg of 2-(3-hydroxyphenyl)-5-(3-trifluoromethoxyphenyl)quinoline was dissolved, and 23.8 mg of crystalline (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(R-PA-H + )) was added. After cooling to −20° C., 5.0 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added dropwise, and the mixture was continuously stirred at the same temperature for 2 days. Further, the catalyst and the mixed solvent of formic acid/triethylamine were added again in the same amounts as above, and the mixture was continuously stirred for one day. Then, the reaction was completed. The reaction mixture was concentrated in vacuo and extracted with methylene chloride. After basification with an aqueous sodium carbonate solution, the resulting layers were separated. The organic layer was washed with water and concentrated.
The resulting oil was purified by column chromatography, and the fractions eluted by methylene chloride/n-hexane (3/1) were collected and concentrated in vacuo to give 280 mg of an oil.
This product was identified as 1,2,3,4-tetrahydro-2-(3-hydroxyphenyl)-5-(3-trifluoromethoxyphenyl)quinoline by NMR. This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the R-enantiomer was in excess and the optical purity was 71.3% ee.
Specific rotation: [α] D 20 −17.3 (c=1.04, CHCl 3 )
1 H-NMR (200 MHz, CDCl 3 ): δ 1.74-1.94 (1H, m, one of 3-H 2 ), 2.01-2.11 (1H, m, one of 3-H 2 ), 2.44-2.59 (1H, m, one of 4-H 2 ), 2.73 (1H, H A of ABXX′ system, J AB =16.7 Hz, J AX =10.0 Hz, J AX′ =5.1 Hz, one of 4-H 2 ), 4.41 (1H, dd, J=8.8, 3.5 Hz, 2-H), 6.53-6.57 (1H, m, ArH), 6.58-6.61 (1H, m, ArH), 6.74 (1H, ddd, J=8.1, 2.6, 0.9 Hz, ArH), 6.84-6.87 (1H, m, ArH), 6.93 (1H, br d, J=7.8 Hz, ArH), 7.07 (1H, t, J=7.8 Hz, ArH), 7.12-7.27 (5H, m, ArH), 7.33-7.44 (1H, m, ArH).
13 C-NMR (50.3 MHz, CDCl 3 ): δ 24.7 (3-C), 30.7 (4-C), 55.7 (2-C), 113.3 (ArCH), 113.7 (ArCH), 114.4 (ArCH), 118.2 (quaternary ArC), 118.7 (ArCH), 118.9 (ArCH), 119.1 (ArCH), 121.7 (ArCH), 123.1 (CF 3 ), 126.8 (ArCH), 127.6 (ArCH), 129.3 (ArCH), 129.9 (ArCH), 140.9 (quaternary ArC), 143.8 (quaternary ArC), 144.7 (quaternary ArC), 146.7 (quaternary ArC), 148.9 (quaternary ArC), 155.8 (quaternary ArC).
Reference Example 2
In 8.0 ml of dimethyl sulfoxide, 224 mg of the product purified by column chromatography in Example 12 was dissolved, 283 mg of cesium carbonate and 139 mg of 1,1,2,2-tetrafluoro-1-iodoethane were added, and the mixture was continuously stirred under water-cooling overnight. After the reaction mixture was extracted with methylene chloride, the extract was washed with an aqueous sodium bicarbonate solution, further washed with water 5 times, and then concentrated in vacuo to give 240 mg of an oil.
The resulting oil was purified by column chromatography, and the fractions eluted by methylene chloride/n-hexane (1/10) were collected and concentrated in vacuo to give 221 mg of an oil. This product was identified as 1,2,3,4-tetrahydro-2-[3-(1,1,2,2-tetrafluoroethoxy)phenyl]-5-(3-trifluoromethoxyphenyl)quinoline by NMR. This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the R-enantiomer was in excess and the optical purity was 66.8% ee.
Specific rotation: [α] D 20 −8.6° (c=0.88, CHCl 3 )
1 H-NMR (200 MHz, CDCl 3 ): δ 1.77-1.96 (1H, m, one of 3-H 2 ), 1.99-2.14 (1H, m, one of 3-H 2 ), 2.53 (1H, H B of ABXX′ system, J AB =16.7 Hz, J BX =J BX′ =5.1 Hz, one of 4-H 2 ), 2.75 (1H, H A of ABXX′ system, J AB =16.7 Hz, J AX =10.0 Hz, J AX′ =5.3 Hz, one of 4-H 2 ), 4.21 (1H, br s, NH), 4.50 (1H, dd, J=8.9, 3.6 Hz, 2-H), 5.90 (1H, tt, 2 J HF =53.1 Hz, 1 J HF =2.9 Hz, CF 2 H), 6.61 (2H, d, J=7.7 Hz, ArH), 7.04-7.45 (9H, m, ArH).
13 C-NMR (50.3 MHz, CDCl 3 ): δ 24.6 (3-C), 30.9 (4-C), 55.5 (2-C), 107.7 (CF 2 H), 113.8 (ArCH), 116.5 (OCF 2 ), 118.1 (quaternary ArC), 118.9 (ArCH), 119.2 (ArCH), 119.8 (ArCH), 120.6 (ArCH), 121.7 (ArCH), 123.1 (CF 3 ), 124.6 (ArCH), 126.9 (ArCH), 127.5 (ArCH), 129.3 (ArCH), 129.9 (ArCH), 140.9 (quaternary ArC), 143.8 (quaternary ArC), 144.6 (quaternary ArC), 147.1 (quaternary ArC), 149.0 (quaternary ArC), 149.2 (quaternary ArC).
Example 15
Asymmetric Reduction of 2-(3-hydroxyphenyl)-5-benzyloxyquinoline
In 40 ml of methanol, 523 mg of 2-(3-hydroxyphenyl)-5-benzyloxyquinoline was dissolved, and 30.4 mg of crystalline (R)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(R-PA-H + )) was added. The mixture was cooled to −20° C. and continuously stirred for 2 days. Then, the reaction was completed. The reaction mixture was concentrated in vacuo and methylene chloride was added. After basification with an aqueous sodium carbonate solution, the resulting layers were separated. The organic layer was washed with water and concentrated. The resulting oil was purified by column chromatography, and the fractions eluted by methylene chloride/n-hexane (4/3) were collected and concentrated in vacuo to give 434 mg of an oil.
This product was identified as 1,2,3,4-tetrahydro-2-(3-hydroxyphenyl)-5-benzyloxyquinoline by NMR. This product was analyzed for optical purity with the use of an optically active column (CHIRALPAC IB; manufactured by Daicel Chemical Industries, Ltd.). As a result, the R-enantiomer was in excess and the optical purity was 78.0% ee.
Specific rotation: [α] D 20 6.5° (c=0.70, CHCl 3 )
1 H-NMR (200 MHz, CDCl 3 ): δ 1.81-2.01 (1H, m, one of 3-H 2 ), 2.04-2.18 (1H, m, one of 3-H 2 ), 2.64-2.93 (2H, m, 4-H 2 ), 4.30 (1H, dd, J=9.2, 3.1 Hz, 2-H), 5.04 (2H, s, OCH 2 Ph), 6.22 (1H, br d, J=8.1 Hz, ArH), 6.31 (1H, br d, J=8.1 Hz, ArH), 6.72 (1H, ddd, J=8.1, 2.6, 0.9 Hz, ArH), 6.81-6.85 (1H, m, ArH), 6.89-7.00 (2H, m, ArH), 7.14-7.47 (6H, m, ArH).
13 C-NMR (50.3 MHz, CDCl 3 ): δ 20.4 (3-C), 30.5 (4-C), 55.6 (2-C), 69.7 (benzylic C), 100.9 (ArCH), 107.7 (ArCH), 109.9 (quaternary ArC), 113.4 (ArCH), 114.3 (ArCH), 119.0 (ArCH), 126.9 (ArCH), 127.1 (ArCH), 127.7 (ArCH), 128.4 (ArCH), 129.8 (ArCH), 137.7 (quaternary ArC), 145.8 (quaternary ArC), 146.7 (quaternary ArC), 155.8 (quaternary ArC), 157.0 (quaternary ArC).
Example 16
Asymmetric Reduction of 2-Methylquinoline Using (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PQA-H + ))
In 5 ml of methylene chloride, 36 mg of 2-methylquinoline was dissolved, and 6.0 mg of (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](N-6-quinolinyl-2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PQA-H + )) was added. After cooling to −20° C., 1.0 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added, and the mixture was continuously stirred at the same temperature for 48 hours. Then, the reaction was almost completed. This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the S-enantiomer was in excess and the optical purity was 91% ee.
Example 17
Asymmetric Reduction of 2-Methylquinoline Using (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) (Cp*Ir(Cl − )(S-PMDBFA-H + ))
In 5 ml of methylene chloride, 36 mg of 2-methylquinoline was dissolved, and 7.3 mg of (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl][N-(2-methoxy-3-dibenzofuranyl)-2-pyrrolidinecarboxamidato-κN1, κN2]iridium(III) (Cp*Ir(Cl − )(S-PMDBFA-H + )) was added. After cooling to −20° C., 1.0 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added, and the mixture was continuously stirred at the same temperature for 48 hours. Then, the reaction was almost completed. This product was analyzed for optical purity with the use of an optically active column (CHIRALPAC IB; manufactured by Daicel Chemical Industries, Ltd.). As a result, the S-enantiomer was in excess and the optical purity was 92% ee.
Example 18
Synthesis of Cp*Ir(BF 4 − )(S-PA-H + )
In 10 ml of methanol, 238 mg of chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl] (2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + )) was dissolved, and the solution was saturated with argon. To this, 98 mg of silver tetrafluoroborate was added, and the mixture was stirred overnight. The insoluble matter was filtered off, and the filtrate was concentrated in vacuo to give 264 mg of a crystal. The crystal was suspended in a small amount of ethanol, recovered by filtration, washed and dried in vacuo at 50° C. to give 189 mg of a brown crystal.
Elemental analysis: C 25 H 24 BF 4 IrN 2 O.2H 2 O (563.40) calculated value (%) C, 31.98; H, 5.01; N, 4.97 found value (%) C, 32.00; H, 4.86; N, 5.03
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.55-1.84 (3H, m), 1.72 (15H, s, 5Me of Cp*), 1.94-2.10 (1H, m), 2.65-2.85 (1H, m, one of NCH 2 ), 3.40-3.63 (2H, m, one of NCH 2 and NCH), 5.57 (1H, br s, CONH), 6.30 (1H, br td-like, NH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): δ 8.6 (5Me of Cp*), 26.5 (CH 2 ), 29.2 (CH 2 ), 56.4 (NCH 2 ), 62.5 (NCH), 91.8 (ArC of Cp*), 183.0 (C═O).
Example 19
Synthesis of Cp*Ir(PF 6 )(S-PA-H + )
In 10 ml of methanol, 238 mg of (S)-chloro[(1,2,3,4,5-η)-pentamethyl-2,4-cyclopentadien-1-yl](2-pyrrolidinecarboxamidato-κN1, κN2)iridium(III) (Cp*Ir(Cl − )(S-PA-H + )) was dissolved, and the solution was saturated with argon. To this, 127 mg of silver hexafluorophosphate was added, and the mixture was stirred overnight. The insoluble matter was filtered off, and the filtrate was concentrated in vacuo to give 291 mg of a crystal. The crystal was suspended in a small amount of methanol, recovered by filtration, washed and dried in vacuo at 50° C. to give 177 mg of a light brownish-red crystalline powder.
Elemental analysis: C 15 H 24 F 6 IrN 2 OP.H 2 O (603.55) calculated value (%) C, 29.85; H, 4.34; N, 4.64 found value (%) C, 29.96; H, 4.17; N, 4.74
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.54-1.83 (3H, m), 1.72 (15H, s, 5Me of Cp*), 1.95-2.10 (1H, m), 2.65-2.86 (1H, m, one of NCH 2 ), 3.41-3.62 (2H, m, one of NCH 2 and NCH), 5.58 (1H, br s, CONH), 6.31 (1H, br td-like, NH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): δ 8.7 (5Me of Cp*), 26.5 (CH 2 ), 29.2 (CH 2 ), 56.4 (NCH 2 ), 62.5 (NCH), 92.0 (ArC of Cp*), 183.1 (C═O).
Example 20
Synthesis of Cp*Ir(CF 3 SO 3 − )(S-PA-H + )
The reaction of Cp*Ir(Cl − )(S-PA-H + ) with silver trifluoromethanesulfonate was conducted in a similar manner as in Example 19 to give a yellow crystalline powder.
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.56-1.84 (3H, m), 1.72 (15H, s, 5Me of Cp*), 1.96-2.10 (1H, m), 2.65-2.86 (1H, m, one of NCH 2 ), 3.41-3.63 (2H, m, one of NCH 2 and NCH), 5.58 (1H, br s, CONH), 6.30 (1H, br td-like, NH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): δ 8.6 (5Me of Cp*), 26.5 (CH 2 ), 29.2 (CH 2 ), 56.4 (NCH 2 ), 62.5 (NCH), 91.9 (ArC of Cp*), 183.0 (C═O).
Example 21
Synthesis of Cp*Ir(SbF 6 − )(S-PA-H + )
The reaction of Cp*Ir(Cl − )(S-PA-H + ) with silver hexafluoroantimonate was conducted in a similar manner as in Example 19 to give a dark brown crystalline powder.
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.54-1.84 (3H, m), 1.72 (15H, s, 5Me of Cp*), 1.95-2.10 (1H, m), 2.64-2.86 (1H, m, one of NCH 2 ), 3.41-3.62 (2H, m, one of NCH 2 and NCH), 5.57 (1H, br s, CONH), 6.30 (1H, br td-like, NH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): δ 8.6 (5Me of Cp*), 26.5 (CH 2 ), 29.2 (CH 2 ), 56.4 (NCH 2 ), 62.5 (NCH), 91.8 (ArC of Cp*), 183.0 (C═O).
Example 22
Synthesis of Cp*Ir(ClO 4 − )(S-PA-H + )
The reaction of Cp*Ir (Cl − )(S-PA-H + ) with silver perchlorate was conducted in a similar manner as in Example 19 to give a yellow crystalline powder.
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.54-1.87 (3H, m), 1.72 (15H, s, 5Me of Cp*), 1.94-2.10 (1H, m), 2.64-2.86 (1H, m, one of NCH 2 ), 3.39-3.62 (2H, m, one of NCH 2 and NCH), 5.57 (1H, br s, CONH), 6.30 (1H, br td-like, NH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): δ 8.6 (5Me of Cp*), 26.5 (CH 2 ), 29.2 (CH 2 ), 56.4 (NCH 2 ), 62.5 (NCH), 91.9 (ArC of Cp*), 183.0 (C═O).
Example 23
Synthesis of Cp*Ir(BF 4 − )(S-PQA-H + )
To 10 ml of methanol, 302 mg of Cp*Ir (Cl − )(S-PQA-H + ) was added, and the solution was saturated with argon. To this, 98 mg of silver tetrafluoroborate was added, and the mixture was stirred overnight. Then, 5 ml of water was added, and the mixture was continuously stirred for about 1 hour. The insoluble matter was filtered off, and the filtrate was concentrated in vacuo. The residual concentrate was dissolved in methanol for crystallization. The crystal was collected by filtration, washed and dried in vacuo at 50° C. to give 114 mg of a yellow crystalline powder.
Elemental analysis: C 24 H 29 BF 4 IrN 3 O.2H 2 O (690.54) calculated value (%) C, 41.74; H, 4.82; N, 6.09 found value (%) C, 41.44; H, 4.43; N, 6.16
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.36 (15H, s, 5Me of Cp*), 1.39-1.57 (1H, m), 1.62-2.23 (3H, m), 2.79-3.00 (1H, m, one of NCH 2 ), 3.54-3.78 (2H, m, one of NCH 2 and NCH), 6.75 (1H, br td-like, NH), 7.49-7.62 (3H, m, ArH), 7.98 (1H, d, J=8.8 Hz, ArH), 8.29 (1H, dd, J=8.8, 1.2 Hz, ArH), 8.84 (1H, dd, J=4.2, 1.6 Hz, ArH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): δ 8.4 (5Me of Cp*), 25.7 (CH 2 ), 29.4 (CH 2 ), 55.7 (NCH 2 ), 62.5 (NCH), 89.2 (ArC of Cp*), 121.5 (ArCH), 123.7 (ArCH), 127.9 (quaternary ArC), 128.4 (ArCH), 131.4 (ArCH), 135.3 (ArCH), 145.5 (quaternary ArC), 147.2 (quaternary ArC), 149.6 (ArCH), 182.8 (C═O).
Example 24
Synthesis of Cp*Ir(PF 6 − )(S-PQA-H + )
The reaction of Cp*Ir(Cl − )(S-PQA-H + ) with silver hexafluorophosphate was conducted in a similar manner as in Example 23 to give a yellow crystalline powder.
1 H-NMR (200 MHz, DMSO-d 6 ): δ 1.36 (15H, s, 5Me of Cp*), 1.38-1.56 (1H, m), 1.60-2.23 (3H, m), 2.79-3.00 (1H, m, one of NCH 2 ), 3.54-3.78 (2H, m, one of NCH 2 and NCH), 6.75 (1H, br td-like, NH), 7.49-7.63 (3H, m, ArH), 7.98 (1H, d, J=8.8 Hz, ArH), 8.29 (1H, dd, J=8.8, 1.2 Hz, ArH), 8.84 (1H, dd, J=4.2, 1.6 Hz, ArH).
13 C-NMR (50.3 MHz, DMSO-d 6 ): δ 8.4 (5Me of Cp*), 25.7 (CH 2 ), 29.4 (CH 2 ), 55.7 (NCH 2 ), 62.5 (NCH), 89.1 (ArC of Cp*), 121.5 (ArCH), 123.7 (ArCH), 127.9 (quaternary ArC), 128.4 (ArCH), 131.5 (ArCH), 135.3 (ArCH), 145.4 (quaternary ArC), 147.3 (quaternary ArC), 149.6 (ArCH), 182.7 (C═O).
Example 25
Synthesis of Cp*Ir(PF 6 − )(S-PMDBFA-H + )
To 20 ml of 50% hydrous methanol, 336 mg of Cp*Ir(Cl − )(S-PMDBFA-H + ) was added, and the solution was saturated with argon. To this, 126 mg of silver hexafluorophosphate was added, and the mixture was stirred overnight. The reaction mixture was heated to about 50° C. and stirred for about 30 minutes, the insoluble matter was filtered off, and the filtrate was concentrated in vacuo. The concentrated residue was dissolved in 50% hydrous methanol for crystallization. The crystal was collected by filtration, washed and dried in vacuo at 50° C. to give 190 mg of a reddish-brown crystalline powder.
Elemental analysis: C 28 H 32 F 6 IrN 2 O 3 P (781.73) calculated value (%) C, 43.02; H, 4.13; N, 3.58 found value (%) C, 43.14; H, 4.36; N, 3.91
1 H-NMR (200 MHz, DMSO-d 6 , mainly two rotamers observed in the ratio ca. 7:3): δ 1.31 (15H×0.7, s, 5Me of Cp* for the major), 1.58-2.18 (4H, m), 1.34 (15H×0.3, s, 5Me of Cp* for the minor), 2.83-3.12 (1H, m, one of NCH 2 ), 3.50-3.76 (2H, m, one of NCH 2 and NCH), 3.84 (3H×0.7, s, OMe for the major), 3.88 (3H×0.3, s, OMe for the minor), 6.89 (0.7H, br td-like, NH for the major), 7.04 (0.3H, br td-like, NH for the minor), 7.31-7.54 (2H, m, ArH), 7.38 (0.3H, s, ArH), 7.39 (0.7H, s, ArH), 7.65 (1H, br d, J=7.5 Hz, ArH), 7.77 (0.7H, s, ArH), 7.81 (0.3H, s, ArH), 8.12 (1H, dd, J=7.5, 1.1 Hz, ArH).
13 C-NMR (50.3 MHz, DMSO-d 6 , two rotamers observed): δ 8.2 (5Me of Cp* for the major), 8.3 (5Me of Cp* for the minor), 25.4 (CH 2 for the major), 25.7 (CH 2 for the minor), 29.1 (CH 2 for the major), 29.2 (CH 2 for the minor), 54.8 (CH 2 for the minor), 55.2 (CH 2 for the major), 55.4 (OMe for the minor), 56.2 (OMe for the major), 61.7 (NCH), 87.0 (quaternary ArC of Cp* for the major), 88.6 (quaternary ArC of Cp* for the minor), 95.0 (ArC), 102.3 (ArCH for the minor), 102.7 (ArCH for the major), 109.9 (ArCH), 111.5 (ArCH for the major), 112.0 (ArCH for the minor), 120.4 (ArCH for the minor), 120.8 (ArCH for the major), 122.8 (ArCH), 124.1 (quaternary ArC), 126.7 (ArCH), 137.7 (quaternary ArC for the minor), 139.1 (quaternary ArC for the major), 149.4 (quaternary ArC for the minor), 149.6 (quaternary ArC for the major), 151.0 (quaternary ArC for the minor), 151.8 (quaternary ArC for the major), 156.0 (quaternary ArC for the major), 156.1 (quaternary ArC for the minor), 183.7 (CO for the major), 184.8 (CO for the minor).
Example 26
Asymmetric Reduction of 2-Methylquinoline Using Cp*Ir(PF 6 − )(S-PA-H + )
In 5 ml of methylene chloride, 36 mg of 2-methylquinoline was dissolved, and 6.8 mg of Cp*Ir(PF 6 − )(S-PA-H + ) was added. After cooling to −20° C., 1.0 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added, and the mixture was continuously stirred at the same temperature for 48 hours. Then, the reaction was completed. This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the S-enantiomer was in excess and the optical purity was 82% ee.
Example 27
Asymmetric Reduction of 2-Methylquinoline Using Cp*Ir(CF 3 SO 3 − )(S-PA-H + )
In 5 ml of methylene chloride, 36 mg of 2-methylquinoline was dissolved, and 5.9 mg of Cp*Ir(CF 3 SO 3 − )(S-PA-H + ) was added. After cooling to −20° C., 1.0 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added, and the mixture was continuously stirred at the same temperature for 48 hours. Then, the reaction was completed. This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the S-enantiomer was in excess and the optical purity was 86% ee.
Example 28
Asymmetric Reduction of 2-Methylquinoline Using Cp*Ir(BF 4 − )(S-PQA-H + )
In 5 ml of methylene chloride, 36 mg of 2-methylquinoline was dissolved, and 6.6 mg of Cp*Ir(BF 4 − )(S-PQA-H + ) was added. After cooling to −20° C., 1.0 ml of a mixed solvent of formic acid/triethylamine (molar ratio: 5/2) was added, and the mixture was continuously stirred at the same temperature for 48 hours. Then, the reaction was almost completed. This product was analyzed for optical purity with the use of an optically active column (CHIRALCEL OJ-RH; manufactured by Daicel Chemical Industries, Ltd.). As a result, the S-enantiomer was in excess and the optical purity was 91% ee.
INDUSTRIAL APPLICABILITY
The production method of the present invention enables low-cost production of optically active 2-substituted-1,2,3,4-tetrahydroquinolines using simple equipment under simple process control and therefore is industrially useful.
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Provided are a novel chiral iridium(III) complex; and a method for producing optically active 2-substituted-1,2,3,4-tetrahydroquinolines from 2-substituted-quinolines with the use of the chiral iridium(III) complex through a more economical and easy production process. The disclosed method for producing optically active 2-substituted-1,2,3,4-tetrahydroquinolines comprises reducing a quinoline compound represented by formula [I]:
in the presence of a hydrogen donor compound and an iridium (III) complex having a chiral prolinamide compound as a ligand to give an optically active 2-substituted-1,2,3,4-tetrahydroquinoline represented by formula [II]:
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/691,790 filed Jun. 17, 2005, U.S. Pat. No. 8,221,673 issued Jul. 17, 2012, and U.S. Non-Provisional application Ser. No. 13/494,174 filed Jul. 12, 2012, each hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention is drawn to a load bearing panel member formed by a method of injection molding.
BACKGROUND
There are numerous known systems for plastic injection molding. In conventional plastic injection molding systems, plastic pellets are melted in an injection molding machine and advanced by a screw ram through an injection nozzle and into a mold cavity. The mold cavity is preferably formed between two mold halves. The molten plastic material in the cavity is allowed to cool and harden in the cavity. When the plastic material has cooled and sufficiently hardened, the two halves of the mold are separated or opened and the part is removed, typically by one or more ejector pins.
Some injection molding systems utilize a gas in the injection molding process and are commonly known as “gas-assisted injection molding” systems. In these systems, the gas is injected into the molten plastic material through the plastic injection nozzle itself, or through one or more pin mechanisms strategically positioned in the mold. It is also possible to inject the gas directly into the molten plastic in the barrel of the injection molding machine. The gas, which typically is an inert gas such as nitrogen, is injected under pressure and forms one or more hollow cavities or channels in the molded part.
Gas-assisted injected molding produces a structure having a hollow interior portion which results in saving weight and material, thereby reducing costs. The pressurized gas applies an outward pressure to force the plastic against the mold surfaces while the article solidifies. This helps provide a better surface on the molded article and reduces or eliminates sink marks and other surface defects. The use of pressurized gas also reduces the cycle time as the gas is introduced and/or migrates to the most fluent inner volume of the plastic and replaces the plastic in those areas which would otherwise require an extended cooling cycle. The pressure of the gas pushing the plastic against the mold surfaces further increases the cooling effect of the mold on the part, thus solidifying the part in a faster manner and reducing the overall cycle time.
SUMMARY
The present invention provides a method for producing a structural or load bearing injection molded panel member. According to a preferred embodiment, the panel member is a floor panel for a van having retractable rear seats wherein the panel member is adapted to cover the rear seats when fully retracted and act as a load floor. The panel member preferably includes a first portion, a second portion and an interior surface portion. The present invention will hereinafter be described according to the preferred embodiment wherein the interior surface portion is a carpet material; however, it should be appreciated that according to alternate embodiments the interior surface portion could also include, for example, a vinyl material or a textile material.
The preferred method of the present invention includes placing the carpet material into a mold cavity configured to produce the panel member. The mold cavity preferably includes a first chamber adapted to form the first portion of the panel member, and a second chamber adapted to form the second portion of the panel member. After the carpet material is inserted into the mold, molten plastic material and pressurized gas are injected into the first chamber of the mold cavity. After the molten plastic material is injected into the first chamber of the mold, molten plastic material is injected into the second chamber of the mold cavity. A sequential gating process is used to achieve this sequence of operations. The molten plastic is then cooled until it solidifies. After the molten plastic is sufficiently cooled, the pressurized gas is vented and the panel member is removed from the mold.
It should be appreciated that the order in which the steps of the preferred embodiment are performed may be varied according to alternate embodiments. For example, according to one alternate embodiment of the present invention, the molten plastic material may be injected into the second chamber of the mold cavity before molten plastic material is injected into the first chamber of the mold cavity. According to yet another alternate embodiment, molten plastic may be injected into the first and second chambers of the mold cavity simultaneously.
The present invention also provides a structural or load bearing panel member and a product by process. The load bearing panel member preferably includes a generally rectangular first portion, a generally rectangular second portion, and a carpet material. The carpet material is attached to the first portion and the second portion such that the carpet material forms an integral or living hinge at a gap therebetween. The first portion of the panel member defines a plurality of solid horizontally disposed ribs and a plurality of solid vertically disposed ribs. The first portion of the load bearing panel member also includes a plurality of hollow ribs formed by the gas assisted injection molding process. The hollow ribs are generally located around the periphery of the first portion of the load bearing panel member as well as in an X-shape originating at the center of the first portion and extending toward the corners thereof. The solid ribs and hollow ribs are adapted to increase strength and rigidity and provide substantial structural or load-bearing capability
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom view of a load bearing panel member in accordance with the present invention;
FIG. 2 is a block diagram illustrating a method of the present invention;
FIG. 3 is a sectional view of the panel member taken along line A-A of FIG. 1 ;
FIG. 4 a is a schematic sectional view of an injection molding nozzle and a plurality of valves; and
FIG. 4 b is a schematic plan view of a mold cavity.
DESCRIPTION
Referring to the drawings, wherein like reference numbers refer to like components, FIG. 1 shows a panel member 10 produced according to a method of the present invention. The panel member 10 will hereinafter be described as a floor panel for a van having retractable rear seats (not shown), wherein the panel member 10 is adapted to cover the rear seats when the seats are fully retracted and also to act as a load floor. It should be appreciated, however, that the method of the present invention may be implemented to produce other conventional panel members as well.
The panel member 10 includes a generally rectangular first portion 12 , a generally rectangular second portion 14 , and an interior or appearance surface portion 16 (shown in FIG. 3 ). The present invention will hereinafter be described according to the preferred embodiment wherein the interior surface portion 16 is carpet material; however, it should be appreciated that according to alternate embodiments the interior surface portion 16 could also include, for example, a vinyl material or a textile material. According to a preferred embodiment, the carpet material 16 is a polypropylene material with a polyester backing. The carpet material 16 is attached to the first portion 12 and the second portion 14 such that the carpet material 16 forms an integral or living hinge 18 at a gap 19 between the first portion 12 and the second portion 14 . The first portion 12 of the panel member 10 defines a plurality of solid horizontally disposed ribs 20 and solid vertically disposed ribs 21 . The solid ribs 20 and 21 are normal to each other so as to increase strength and rigidity and provide substantial load-bearing capability. According to a preferred embodiment of the present invention, the second portion 14 of the panel member 10 includes a plurality of up-standing clip attach members 22 .
The clip attach members 22 preferably each retain a metallic attachment clip (not shown) configured to mount the second portion 14 of the panel member 10 to a seat assembly (not shown). When the seat assembly is in an upright position, the hinge 18 allows the second portion 14 of the panel member 10 to fold underneath the first portion 12 and below the seat.
When the seat assembly (not shown) is fully retracted, the first portion 12 of panel member 10 is rotatable about the integral hinge 18 from an open position exposing the seat assembly to a closed position at which the seat assembly is covered. When the seat assembly is fully retracted and the first portion 12 of panel member 10 is in the closed position, the carpet material 16 (shown in FIG. 3 ) is exposed and the seat assembly is completely hidden. In this manner, the panel member 10 is adapted to provide an aesthetically pleasing carpeted interior when the seat assembly is retracted, and also provide substantial floor-strength.
Referring to FIG. 2 , a method for manufacturing the panel member 10 according to the present invention is shown. At step 50 , the carpet material 16 is placed into a mold cavity 70 (shown in FIG. 4 b ) configured to produce the panel member 10 . Optionally, at step 50 , metal inserts such as bars and/or tubes (not shown) can also be placed into the mold cavity 70 with the carpet material 16 to produce a panel member 10 with increased strength and rigidity. The mold cavity 70 of the present invention preferably includes a first chamber 72 (shown in FIG. 4 b ) adapted to form the first portion 12 of the panel member 10 , and a second chamber 74 (shown in FIG. 4 b ) adapted to form the second portion 14 of the panel member 10 . The first and second chambers 72 , 74 are preferably separated by an insert or feature 75 (shown in FIG. 4 b ) configured to produce the integral hinge 18 (shown in FIG. 3 ). At step 52 , molten plastic material 76 (shown in FIG. 4 a ) is injected into the first chamber 72 of the mold cavity 70 . The molten plastic material 76 is preferably injected in a conventional manner, such as, for example, by a reciprocating screw type injection device (not shown), through an injector nozzle 40 (shown in FIG. 4 a ), through a valve gate 42 a (shown in FIG. 4 a ), and into the first chamber 72 of the mold cavity 70 .
At step 54 , an inert gas 80 (shown in FIG. 4 b ) such as nitrogen is injected into the first chamber 72 of the mold cavity 70 (shown in FIG. 4 b ) through a plurality of gas pins 82 (shown in FIG. 4 b ) positioned at locations predefined by the desired locations of the hollow ribs 30 . The gas 80 preferably does not mix with the molten plastic material 76 , but takes the path of least resistance through the less viscous portions of the plastic melt. The molten plastic 76 is therefore pushed against the wall portions of the mold cavity 70 , which forms channels 31 and produces the hollow ribs 30 (shown in FIGS. 1 and 3 ).
Referring to FIG. 3 , a sectional view taken through section A-A of FIG. 1 is shown. It can be seen in FIG. 3 that the hollow ribs 30 define an internal channel 31 through which the gas is injected. Referring again to FIG. 1 , the gas 80 (shown in FIG. 4 b ) is preferably injected through the gas pins 82 (shown in FIG. 4 b ) into the first portion 12 of the panel member 10 at the gas injection locations 32 . According to a preferred embodiment, the hollow ribs 30 are generally located around the periphery of the first portion 12 of the panel member 10 as well as in an X-shape originating at the center of the first portion 12 and extending toward the corners thereof. It has been observed that the hollow ribs 30 formed in the manner described increase the rigidity and strength of the first portion 12 of the panel member 10 . The increased strength and rigidity is particularly advantageous for the preferred embodiment wherein the panel member 10 is implemented as a load bearing floor panel.
Referring again to FIG. 2 , at step 56 molten plastic material 76 (shown in FIG. 4 a ) is injected into the second chamber 74 of the mold 70 (shown in FIG. 4 b ). The molten plastic material 76 is preferably injected through the injector nozzle 40 (shown in FIG. 4 a ), through a valve gate 42 b (shown in FIG. 4 a ), and into the second mold chamber 74 .
A sequential gating process is preferably implemented to perform previously described steps 52 and 56 . Referring to FIGS. 4 a - 4 b , the valve gates 42 a and 42 b , which are adapted to feed the first and second mold chambers 72 , 74 , respectively, are opened using the sequential gating process. In other words, the sequential gating process is implemented to control the timing of the gates 42 a , 42 b and to coordinate the operation of valve gate 42 b with the operation of valve gate 42 a . According to a preferred embodiment, the valve gates 42 a and 42 b are configured to open and close at a predetermined time. The predetermined time at which the valve gates 42 a and 42 b open and close is generally based on the needs of the specific part to be molded and type of material being used. Alternatively, the valve gates 42 a and 42 b may be opened and closed based on the position of a screw type injection device (not shown).
Referring again to FIG. 2 , at step 58 the molten plastic material 76 (shown in FIG. 4 a ) that was injected into the first and second chambers 72 , 74 of the mold cavity 70 (shown in FIG. 4 b ) at steps 52 and 56 is allowed to cool and solidify. Thereafter, at step 60 , the pressurized gas 80 (shown in FIG. 4 b ) that was injected in to the first chamber 72 of the mold cavity 70 at step 54 is allowed to vent through the gas pins 82 (shown in FIG. 4 b ). At step 62 , the finished panel member 10 is removed from the mold cavity 70 .
It should be appreciated that the order in which the steps 50 - 62 of the preferred embodiment are performed may be varied according to alternate embodiments. For example, according to one alternate embodiment of the present invention, step 56 at which the molten plastic material 76 (shown in FIG. 4 a ) is be injected into the second chamber 74 (shown in FIG. 4 b ) of the mold cavity 70 (shown in FIG. 4 b ) may be performed before step 52 at which molten plastic material 76 is injected into the first chamber 72 (shown in FIG. 4 b ) of the mold cavity 70 . According to yet another alternate embodiment, steps 52 and 56 may be performed simultaneously such that molten plastic 76 is injected into the first and second chambers 72 , 74 of the mold cavity 70 simultaneously.
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.
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This is a divisional of application Ser. No. 07/997,594, filed Dec. 28, 1992, now abandoned.
BACKGROUND OF THE INVENTION
This is invention relates to a tool useful for the repair of brakes on automobiles, and more particularly, to a tool which is useful for installing or releasing a brake spring from a drum brake assembly.
Many motor vehicles utilize dram brakes. Typically drum brakes include a pair of opposed, arcuate brake shoes pivotally mounted at one end on a brake shoe plate affixed to the vehicle axle. The shoes are coupled with a piston which causes them to move outwardly or spread against the walls of a cylindrical drum attached to a wheel on the axle and thereby effect a brake action. The brake shoes are also biased against the force of the piston toward one another by springs which connect the spaced shoes. Usually, a brake spring includes a center coil spring with lead wires projecting from each end and terminating with a hook end that fits in openings in the brake shoe. One or more such brake springs may be prodded for each dram brake assembly.
When repairing a drum brake assembly, a mechanic may be required to remove the brake springs. Heretofore, removal of a brake spring was effected by grasping the spring with a channel lock or pliers or some other similar tool and effecting removal of the spring by manipulation of the tool. Such tools and the methods of utilization of such tools has not been entirely satisfactory. Consequently, auto mechanics have indicated the need for a special tool useful for removal or installation of brake springs of drum brake assemblies. That need has resulted in the development of the present invention.
SUMMARY OF THE INVENTION
In a principal aspect, the present invention comprises a tool which includes a handle having a shaft extending axially therefrom. The end of the shaft is threaded to receive a cylindrical collar with a slot partially extending therethrough configured to receive the lead wire of a brake spring. The tool shaft may then be rotated to tightly engage or grip the lead wire in the slot and manually manipulated to release the spring or replace the spring in engagement with a brake shoe.
Thus it is an object of the invention to provide an improved tool for installation or removal of a brake spring from a drum brake assembly.
It is a further object of the invention to provide an improved brake spring tool which is inexpensive, rugged and easy to manipulate manually.
Yet a further object of the invention is to provide an improved brake spring tool which may be utilized for both installation as well as removal of a brake spring from a drum brake assembly.
Another object of the invention is to provide a brake spring tool which may be utilized for manipulation of wire associated with a spring or with any other mechanical element or device.
These and other objects, advantages and features of the invention will be set forth in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
In the detailed description which follows reference will be made to the drawing comprised of the following figures:
FIG. 1 is a perspective view of a typical drum brake assembly which includes a pair of brake springs of the type that can be installed or removed and manipulated by means of the improved tool of the present invention;
FIG. 2 is a perspective view of the improved brake spring tool of the invention;
FIG. 3 is a perspective view illustrating the use of the brake spring tool of the invention;
FIG. 4 is a plan view of the brake spring tool of the invention;
FIG. 5 is an enlarged plan view of tip of the brake spring tool of the invention positioned to tightly retain a lead wire of a spring;
FIG. 6 is an enlarged top plan view of the construction of the tip; and
FIG. 7 is an enlarged side elevation of the tip of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a typical drum brake assembly. The assembly includes a backing plate 10 with opposed drum members 12 removably mounted thereon. The drum members 12 are generally semi-cylindrical. Each member 12 is pivotally mounted at one end on a bracket or pivot member 14. An expansion piston 15 engages the opposite end of each drum member 12. During the braking operation, the expansion cylinder 16 drives the opposite end of each drum member 12 and thereby forces the drum members 12 outwardly or away from one another in a pivoting motion about the pivot member 14. This causes the drum members 12 to frictionally engage against a brake drum (not shown) associated with a turning wheel of the vehicle thereby braking the vehicle. Brake springs 18 engage with the drum members 12 and bias those drum members 12 toward one another. A pin and clip arrangement 20 is utilized to retain the drum members 12 on the backing plate 10.
The present invention relates to a tool which is useful for installation or removal of the brake springs 18. It should be noted that the typical brake spring 18 is comprised of a center coil 22, oppositely extending end lead wires 24 and 26, and a hook 28 at each end. The hooks 28 engage with appropriate openings in the respective brake shoes 12.
FIG. 2 illustrates in greater detail the brake spring tool. The tool is designed to cooperatively engage one lead wire 24 and/or 26. The tool, as depicted in FIG. 2, includes a handle 30, an axially extending shaft 32, and a collar 34. The shaft 32 is a steel rod which includes a distal end 36 shown in FIG. 4 which is threaded. The collar 34, as illustrated in FIGS. 5, 6 and 7, is a hollow cylindrical member which is threaded at an inner end 38. The outer end 40 of collar 34 does not need to be threaded, though it may be. Most importantly, the collar 34 includes a slot 42 which extends at an acute angle with respect to an axis 44 of the collar 34. The slot 42 extends preferably at an angle of about 45° with respect to the axis 44 and is cut inwardly through the collar 34 for a distance slightly beyond the center line axis 44.
FIG. 3 depicts the manner of use of the brake spring tool. That is, the handle 30 and shaft 32 are rotated or "unthreaded" from the collar 34 to expose or open the slot 42. The slot 42 is then fitted over a lead wire 24 or 26. The handle 30 and shaft 32 are then rotated or threaded in the opposite direction to tighten the end of the shaft 32, namely the end 48 as shown in FIG. 4 and FIG. 5, tightly against lead wire 26. This retains the lead wire 26 in the slot 42 and precludes movement thereof. The mechanic or auto repair person may then place his hand or thumb against the shaft 32 to move or twist the lead wire 26 and spring 18 in a manner which will remove the hooked end 28 from the opening associated with the brake drum 12. Manual manipulation effects both removal of the brake spring 18 or installation of the brake spring 18. After the brake spring 18 is removed or manipulated in the manner described, the handle 30 and shaft 32 may again be rotated relative to the collar 34 to release the lead wire 26.
With the tool of the present invention, it is possible to engage and manipulate a lead wire or wire associated with many mechanisms, including drum brakes. It is also possible to vary the construction of the tool depicted and described above. For example, handle 32 may be constructed to conform to the shape of the operators hand. Multiple slots, such as slot 42, may be provided in the collar gauged to the size of the wire which is to be manipulated or engaged. The collar 34 may have a different configuration. The shape and extent of the slot 42 may be altered. Thus, there are variants of the invention described and the scope and meaning of the invention is to be limited only by the following claims and their equivalents.
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A method of using a brake spring tool which includes a shaft cooperative with a slotted collar. The slot may be fitted over the lead wire of the spring and the shaft tightly engaged against the lead wire to facilitate installation or removal.
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BACKGROUND OF THE INVENTION
This invention relates to a display for a navigational system for vehicles and more particularly to a display for a navigational system for small, relatively open vehicles such as motorcycles.
In recent years, there has been a growing interest for the incorporation in a vehicle of a navigational system. These navigational systems permit the operator to utilize a computer arrangement for selecting a desired destination. The system then may offer alternative routes to that destination and may, at times, determine the best route for the operator to follow from his present location to his desired destination.
These systems obviously have great advantage, but require thoroughly substantial displays inasmuch as they show the routing via a map. The display normally incorporates a color cathode ray tube or a liquid crystal display also having color capabilities.
In addition to the actual display and computer, it is also necessary to provide a device wherein certain input can be received such as maps of various locals so that the computer can select the appropriate courses. Thus, there is a fairly bulky system required in order to achieve these results. In addition, the display must be positioned in a location so that the operator of the vehicle can easily read it.
Although these goals are quite simple to obtain in large vehicles, such as automobiles, other types of vehicles, such as off the road vehicles or motorcycles, do not have the space capability for handling this type of display, particularly when considering the need to display other information to the vehicle operator.
In addition to the navigational information, the rider or operator requires additional information to be displayed for the operation of the vehicle. For example, this may include such other information as vehicle speed, distance traveled, etc. If there is a separate display provided for the navigational information, then there may be little if any space available for this necessary vehicle operational information, if the previous types of navigational displays are employed.
It is, therefore, a principle object of this invention to provide an improved vehicle navigational display that is relatively simple in nature and nevertheless affords the advantages of the more complicated systems frequently employed in other types of vehicles.
It is a further object of this invention to provide an improved and simplified navigational display system for small vehicles like motorcycles wherein the operator may be provided with not only the necessary information to reach a desired destination, but other information necessary for operating the vehicle.
In order to achieve these results, it is proposed to employ a display that has a first portion that displays vehicle operational information and a second portion that displays navigational information. However, the magnitude of information which must be displayed is generally greater than can be handled on a small display. It may be conceivable, therefore, to consider the concept of switching one of the display areas from one type of display to another so as to increase the amount of information that can be read. However, it is desirable under many circumstances to prohibit this switching of the display mode, for example, while the vehicle is being operated. Otherwise, the operator's attention may be directed away from the primary function of operating the vehicle in a safe manner.
It is, therefore, a still further object of this invention to provide a vehicle information display that includes navigational data which may be switched from one condition to another to display additional information, but that the switching is not permitted unless the vehicle is stationary.
SUMMARY OF THE INVENTION
A first feature of the invention is adapted to be embodied in a navigational system for a vehicle that is comprised of a display having two portions. There is also provided an input section for receiving inputted location data for a plurality of locations along a path to be traversed. A sensor is incorporated within the display for sensing the actual location of the display. A control sequentially shows on a first portion of the display the data from the input section as to the next location from the input section and at least the heading to the next location from the sensed location without employing a map in the display. In addition the second portion of the display indicates a vehicle operational condition.
A further feature of the invention is adapted to be embodied in a navigational system display as set forth in the preceding paragraph. In connection with this feature one of the display portions may be switched to display additional navigational information.
A still further feature of the invention is adapted to be embodied in a navigational system display for a vehicle as defined in the preceding paragraph. With this display system, the switching of the one display portion is only possible when the vehicle is stationary.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a motorcycle with rider, which motorcycle incorporates a navigational system display arrangement in accordance with an embodiment of the invention.
FIG. 2 is a perspective view of one of the hand grips of the motorcycle showing certain of the navigational system controls.
FIG. 3 is a perspective view showing the navigational system and other displays associated with it.
FIG. 4 is a front elevational view of the display showing the condition when approaching a turning point.
FIG. 5 is a partially schematic block view showing the components of the navigational system and other associated components of the vehicle and how data can be transferred to and from the CPU from and to external sources.
FIG. 6 is a three-part view showing the display in a (A) normal running condition, (B) a navigational, present position condition, and (C) an input data condition.
FIG. 7 is a view showing how the display changes during travel.
FIG. 8 is a graphical view showing how data can be input into the memory and notes added.
FIG. 9 is a partially schematic block diagram showing the relationship of certain of the components in connection with the navigational system during data transfer.
FIG. 10 is a block diagram showing how the data may be input to the system in either a time or operator selected mode.
FIG. 11 is a view, in part similar to FIG. 4, but shows another embodiment wherein the navigational system can be employed in connection with a conventional type of speedometer arrangement.
FIG. 12 is a view, in part similar to FIGS. 4 and 11, and shows another embodiment of the invention using a single display.
FIG. 13 is a three part view, in part similar to FIG. 6, and shows the varying modes for this embodiment corresponding to those of the previous embodiment.
FIG. 14 is a rear and top plan view of an embodiment showing how data can be interchanged between two motorcycles in accordance with one embodiment of the invention.
FIG. 15 is a side and top plan view showing another embodiment arrangement for exchanging information between two motorcycles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings, FIG. 1 illustrates a motorcycle, indicated generally by the reference numeral 21, as a typical vehicle with which the invention may be utilized. As should be readily apparent from the foregoing description, the invention has particularly utility in connection with a navigational system for small vehicles which are not normally completely enclosed within a body and wherein many of the components including the display may be exposed to the elements. The motorcycle 21 has a frame assembly 22 that dirigibly supports a front wheel 23. In addition, a driven rear wheel 24 is journaled by a suspension arm 25 at the rear of the frame assembly 21. A rider's seat 26 overlies this suspension arm 25 and accommodates a rider who steers the front wheel 23 through a handlebar assembly 27.
The navigational system and associated display which embodies the invention is positioned forwardly of the handlebar assembly 27 and is indicated generally by the reference numeral 28.
The display of the system 28 is shown in more detail in FIGS. 3 and 4 and includes housing assembly 29 that has a display 31 on its rear face which, in this embodiment, comprises a pair of displayed portions 32 and 33. In addition, certain setting and other controls are associated with the housing 29, as will be described later. Although two approximately equal size displays are shown, it is possible to employ only a single display.
The display portion 32 displays navigational information and is always displaying this type of information to the rider, albeit in different forms, as will become apparent. The specific details of this information will be described in more detail later, but basically the information indicates the next point on the journey, the distance to the next point, which is displayed numerically and by way of the arrow, the appropriate heading or azimuth to the next point. Under certain conditions such as when nearing a turning point, for example, the display shifts to the mode shown in FIG. 4 in a manner which will be described so as to alert the rider that a change in direction will be required shortly.
The display 33 shows primarily other vehicle information. In the running mode as shown in FIGS. 3 and 4, the speed is shown digitally and two trip odometers A and B, which can be reset, show trip distances. In addition, there is an overall mileage or odometer reading which is displayed. Furthermore, there is provided a digital clock.
As will be described later, this display section 33 can be switched, under certain circumstances, to display additional, more detailed navigational information and/or to a display which facilitates the showing of the input information and the inputting of information, as will also be described.
The components of the navigational system 28 are shown in more detail schematically in FIG. 5, and will now be described by particular reference to that figure. This description will also facilitate those skilled in the art to understand how the system operates.
The system 28 is provided with a main CPU 34 that receives certain data and which also drives the display screen 32 through a liquid crystal display driver section 35.
There is provided a read only memory (ROM) that stores data of programs and place names and other fixed information for performing specific calculating functions. This section is indicated by the reference numeral 36.
Also, there is provided a random access memory (RAM) that registers data of points along the route as will also be described.
In order to permit the system to operate so as to calculate speed and distance for driving the speedometers and odometers, there is provided a vehicle speed sensor 38 which may be of any known type, and which outputs its data to the CPU 34.
In addition, a geomagnetic sensor 39 receives magnetic signals from the Earth so as to sense the North Pole condition.
There is also provided a global positioning system (GPS) arrangement that receives satellite data through an antenna 41 which then transmits this data to a receiver 42 so as to provide the CPU 34 with an instantaneous navigational position of the sensor unit 28 and, of course, the associated motorcycle 21.
The clock display and other time functions, as will be noted later, are determined by a timer 43 that inputs a time signal to the CPU 34 so as to perform certain time functions and to indicate the actual time.
There are certain additional switches associated with this system, two of which are included directly in the navigational unit 28. These include an input data key button 44, which the operator depresses when he wishes to input data, as will be described. In addition, there is provided a mode selector switch 45 which is operative to change the display mode of the indicator portion 33.
Carried on the handlebar assembly 27 and as also seen in FIG. 2, there are provided two switches that the operator can operate without necessitating his removal from the control of the motorcycle. These include a set point button 46, which, when activated, will perform a function so as to indicate that a point in travel has been passed and switch the display 32 to indicate the next point. Also, there is provided a memory switch 47 that the operator can activate, as will be described later, to store a specific geographic point in the memory of the navigational unit 28.
Although there is a visual display to indicate when the rider should change his position or direction of travel, normal warning signals are not particularly effective in the type of vehicle with which the navigational device 28 is intended to be used. Therefore, the rider's helmet 48 may be provided with a pair of vibrator transducers 49 each associated with a respective side of the rider's head. By changing the magnitude of the vibration signals, the rider can receive a sensory indication of the change in direction which he should make.
That is, if the rider is to execute a sharp left turn, the left vibrator device may be activated while the right hand device can be deactivated. By changing the ratio of activation from one side to the other, the rider can determine the way in which he should turn when he should turn. A receiver 51 is carried by the helmet so as to receive transmitted signals from the CPU 36 so as to activate the vibrators 49 and alert the rider.
Before getting into the detail of the way in which the system operates to provide the navigational information, it should be noted that the housing 29 of the unit 28 is provided with an infrared sensor 52 which is positioned, in a preferred location, on one side or the other of the housing 29. The significance of the side on which the sensor is positioned will be described later by reference to FIGS. 11 and 12.
This infrared window 52 is adapted to receive information which the rider wishes to input as to certain navigational targets. A wide variety of types of devices can be utilized so as to input this information. For example, information may be input externally from an atlas having the longitude and latitude of the various points to be visited and transferred as a batch to the CPU RAM through the infrared sensor 52. Alternatively, a personal computer may be employed that has a program of map software or which can receive information from the Internet so as to determine points along a desired route and these can then be input as a batch through the infrared communication port 52. Obviously, other sources of data can be employed and some of those will be described shortly.
In addition to inputting data, information which the rider has placed into the RAM 37 can be output from the CPU 34 to another machine through the infrared port 52. This also will be described later by reference to FIGS. 14 and 15.
Referring now primarily to FIGS. 3 and 4, certain other components associated with the navigational device 28 and particularly its body assembly will be described. It has been noted that there are provided two trip odometers indicated at A and B, and these odometers can be selected by the switch 53 and reset by a reset switch 54.
There is also provided adjacent the navigational section 32, although other locations are possible, in addition to the input data key 44, certain vehicle indicators, such as a headlight indicator 55, turn signal indicator 56, and neutral condition indicator 57. This neutral condition indicator 57 is operated by a neutral switch 58 (FIG. 5) that senses when the transmission of the motorcycle 21 is in a neutral condition. This neutral switch is also used for another purpose, as will be described.
Finally, there is an indicator light 58 which operates in connection with the position indicator to advise the rider when he is approaching a point when a change in direction or turn should be executed. This condition also causes a switch in the display condition, as seen in FIG. 4. The illustrated example shows that the rider should be prepared to execute a left turn in a close distance such as 2/10ths of a kilometer. The distance at which the warning is given will be varied with speed. The greater the speed, the longer the warning distance. As noted above, the vibrator warning will also be transmitted to the rider's helmet.
The various displays afford by the display section 31 will now be described by reference to FIGS. 6 and 7. FIG. 6(A) shows the normal riding mode display. As has been previously noted, in the display section 32, there is provided vehicle information and time, and the indicated condition shows the speed of travel, the two trip odometer readings A and B, the total odometer reading, and the time in a digital form.
The display section 32 displays the navigational data. This permits the indication of the next point on the journey and the distance to the next point. In addition, the heading or azimuth to this point is indicated by the compass arrow.
Furthermore, a name or designation for the previous point which may be inserted by the rider appears at the lower portion of this display. A manner in which the data is input has been mentioned previously, and will be described in some more detail shortly.
Although the system may be designed so that the operation of the mode selector switch 45 is possible to change from the drive mode display 6(A) to the longitude latitude display mode FIG. 6(B), it is preferable not to permit the operator to select this display mode when the vehicle is operating. Thus, a system maybe incorporated so that the drive mode (A) is displayed automatically when the vehicle is traveling.
This can be determined by sensing the condition of a kick stand switch 59 that senses when the kick stand is extended and also by sensing when the transmission is in neutral by the neutral detector switch 58. The program may be set so as to automatically shift to the longitude latitude display mode FIG. 6(B) at this time.
As seen in this figure, the vehicle speed display disappears and the longitude and latitude at that instant are displayed in its place. Although this is a preferred mode, it can be understood that this instantaneous information also may be displayed simultaneously with the speed during travel by using a smaller display of the speed number.
The final display condition is shown in FIG. (6) and this is one that can only be engaged by the rider by operating the mode change switch and when the vehicle is stationary as determined by the neutral switch 58 and the kick stand switch 59 in the manner previously described.
In this condition, the operator may see the various set points along the trip, indicate the directions at which turns should be made on the trip, and also enter observational data such as interesting points of observation, rest stops, machine shop facilities, and other such information. This can all be entered through a suitable keyboard or by using the various switches or keys already provided on the system.
The various navigational points to be inserted can include various intersections in the road where several roads cross and the direction that the rider should turn at those points. This can be either indicated manually by the rider, or can be fed in from external sources as previously noted. These can be transmitted from a map or computer program. Furthermore, during travel, the rider may input data in a manner which will be described shortly. These added roads appear in the parentheses in FIG. 7
As a further point of information, it should be noted that the point indication on travel which appears at the left hand side or in the display portion 32 does not automatically change when the next point has been reached. Rather, this system preferably requires the operator to press the switch 46 to reset the point to the next point.
This is done so that if the rider misses a point, he will still be able to go back and find his way since the azimuth indicator will be correct when he turns the vehicle around. That is, the system automatically compensates when a point has been missed.
Also it should be noted that if the indicator is in the condition shown in FIG. 6(C) to enter information, when the rider begins to operate the motorcycle again, it will shift to the drive mode 6(A) automatically.
The manner in which the navigational information in the display 32 is changed as the vehicle, or specifically, the motorcycle 21, travels along its path can be best understood by reference to FIG. 7. This figure shows the display portion indicating the next checkpoint, beginning from the instantaneous position and the distance to the next checkpoint. In the specific example illustrated, the rider is at the point I and is 21/2 kilometers from the next point, point 1. The display at the lower portion can also have the name of the instantaneous or last point shown if the operator has added that information under the Memo section of the display, as seen in FIG. 6(C).
As the operator approaches the next checkpoint, point 1, in this example, the display continues to show the distance to the next checkpoint. In this particular instance, the next checkpoint is a point where the change of direction occurs, and this normally is at an intersection.
As seen in parenthesis to the right of the second block in this figure, the operator may have inserted data to show that there is a multi-road intersection, and rather than just a turn at this point. This can be optional.
As the point 2 is approached, the light 58 will flash, and also the audible or vibrator warning of signals by the vibrators 49 will be given. In the illustrated embodiment, there will be a signal from the left ear which is louder, and a signal from the right ear which is weaker. This will indicate that the turn should be to the left, but not a 90° turn.
After having passed the checkpoint, the operator should press the handlebar switch 46 to advance the indicator to the next point. The display will then change, as shown in the third block, to indicate that the point 1 has been passed and there is 4.2 kilometers to the next checkpoint 2.
It should be noted that each time the vehicle approaches a point on the route, the vehicle direction at that time point is detected by the geomagnetic sensor 39, and this information is compared with the actual driving direction. If there is a difference, the previously inputted absolute azimuth of the driving direction is corrected. Also, corrections will be made in the directions for following turns.
As the rider continues on, the next checkpoint comes up, and again, he will be given a warning, make the change in direction at the appropriate time, and then advance the point setting.
By permitting the operator to make these settings merely by pressing the button on the handlebar 27, he need not remove his hands from the controls, and also, his attention from the road will not be disturbed when updating the data.
Because of the way the data is input and displayed, if the operator misses a turn and must turn around, or if he approaches the point from a different direction due to some other deviation, since the geomagnetic sensor cooperates with the azimuth reading, it will be insured that his directions will always be proper and appropriate.
Although the system has been described with a requirement that the operator manually advise the system 28 that a checkpoint has been reached and passed, it also is possible to utilize automatic switching. This may have some disadvantages. For example, if the operator makes an intentional detour around a point on the route, the route guidance will thereafter become inoperative. Also, the driver may overlook when the vehicle has passed the current point on the route. In the case of manual operation, the direction indicating arrow turns in the opposite direction upon passing the current point, and this will be immediately noticed by the rider. With an automatic system, however, if the rider has inadvertently passed the point and turns back, then the route guidance for the next point may have started, and the system will give incorrect information.
The system has been described in conjunction with arrangements wherein the preset points for the navigational system are programmed in through a personal computer or some external control system. However, the device also permits a rider to select a route which he may wish to travel again while actually traversing that route.
The way this is done is that the rider will ride to a location which he finds of particular interest, either from a scenery standpoint or to get to a specific location. He then can enter data manually as to the specific location. The way this is done is that he must first stop the motorcycle, shift the transmission into neutral, and set the motorcycle on the kick stand. Only then can he operate the mode switch so as to create the display shown in FIG. 6(C).
When he reaches this display mode, he may then delete existing data or add a new data. FIG. 8(A) shows how such new data can be entered. That is, if the operator wants to make a particular notation of a particular place, he need merely read the latitude and longitude for that place and enter it, or have the device enter it automatically by pressing the memory button at that particular location. The operator then need not switch the display back to the drive mode.
However, when he either retracts the kick stand and/or shifts the transmission from neutral, the display mode 6(A) will resume. The rider may then move to the next point along his chosen path of travel and enter such appropriate information at those points so as to accumulate data for a new trip.
As another alternative, the data can be programmed to memorize certain data along a trip at fixed time intervals. FIG. 9 shows an interface arrangement for doing that, and FIG. 10 in Group A shows how the data would appear when stored. The system can operate so as to permit the taking of location data at fixed time intervals, and an interval of every half-hour is shown in FIG. 10a. Thus, the rider rides along, and at every half-hour interval, a reading of location is taken. This data is stored in the memory, and the rider may then add memo data later when stopped.
Alternatively, the operator may take this data while he is riding. He can ride along a path, and at times that he chooses, press the memory switch or button 47 on the handlebar assembly, without removing his hands. Then the data is stored as shown in FIG. 10, wherein the time at which the rider pressed the memory button and the latitude and longitude at that point then will be recorded. After completing his trip, the rider may then make such edits as he wishes in the memo section. In this mode, the rider need not remove his hands from the control, nor need he look at any display. Thus, he is able to maintain this data, or collect this data and edit it later as he sees fit.
Also, because of the inclusion of the timer, it is possible for the rider to see average speed and other data.
In the embodiment of the invention as thus far described, the unit 28 has been a unitary unit contained within a single outer housing 29. FIG. 11 shows an embodiment which is slightly different and lends itself more to the vehicle manufacturer being sable to offer the navigational device as optional equipment while maintaining a conventional type of speedometer, shown at the right hand side and identified generally by the reference numeral 101. This speedometer 101 has the display 33 of the previously noted type and includes the buttons 54, 53 and 45. These function normally as with the previously described in connection with the conventional type of speedometer control.
In this embodiment, the close indicator 58 can be a dummy indicator when the device operates only as a speedometer and the navigational system is not employed. However, when the navigational system is employed, it can be activated in a suitable manner.
In this embodiment, the navigational screen 32 and the navigational control system is contained within a single housing 29 and displays the same type of information as the previous screen. In this embodiment, the set switch 44 is contained on this housing.
With this embodiment, the speed display 33 is not switched to display any navigational information during the alternate modes. All of this information will be displayed on the screen 32.
It has been previously noted that in addition to two separate display sections, the invention can be also utilized in an arrangement wherein there is a single display that is split under some conditions. FIGS. 12-13 show such an embodiment, and this embodiment is indicated generally by the reference numeral 151. The various switches and infrared sensors are the same, but are mounted in slightly different positions on the common housing of this unit. Because of their similarity of function to that previously described, these switches and indicators have been identified by the same reference numerals and will not be described again, except insofar as is necessary to understand the construction and operation of this embodiment.
In this embodiment, there is provided a single display screen 152 which is divided, under certain conditions, as to be described, into an upper portion 153 which displays the speed, time, and distance information as in the display sections 33 of the previous embodiments. In addition, there is provided a lower display screen portion 154 that displays the navigational information provided by the screens 32 of the previous embodiment.
In this embodiment, the navigational information is displayed in the same manner previously described on the various screen portions. This is shown in FIG. 12 and FIGS. 13(A) and (B). However, when in the registration mode, FIG. 13 (C), the entire screen shifts to this mode rather than being split as with the previous embodiment. In all other regards, this embodiment is the same as those previously described and, therefore, further description is not believed to be necessary to permit those skilled in the art to practice the invention.
As has been previously noted, the infrared sensor 52 not only can receive data, but can send data. FIGS. 14 and 15 show two different embodiments, wherein the data can be transferred from one motorcycle to another. Thus, if a rider has taken a particularly interesting ride or has recorded directions to get from one place to another and wishes to share that information with another rider, the data can be transferred between the two units by their infrared sensors 52.
It has been previously noted that the sensor 52 is preferably placed on one side of the control housing 29. FIG. 14 shows an arrangement wherein there is a left-hand drive, and in this situation, the sensors 52 are placed on the left-hand side of the housing 29. Thus, when the motorcycles are at rest on kick stands and reversed relative to each other, there respective sensors 52 will be in registry, and data can be exchanged, as shown in FIG. 14. If there is a right-hand drive, then the opposite side location can be chosen.
FIG. 15 shows an arrangement wherein there are sensors on both sides, and this permits the motorcycles to be placed in side-by-side fashion and facing in the same direction, so as to transmit data.
Thus, it should be readily apparent from the foregoing description that the disclosed system provides a very simple yet highly effective navigational system display that is particularly adapted for use on vehicles that do not have the size and space accommodations of larger vehicles such as automobiles. Also, because no external wiring is required to transfer data, the system can withstand the elements without damage.
Of course, the foregoing description is of preferred embodiments of the invention, and various changes and modifications can be made without departing from the spirit and scope of the invention, as defined by the appended claims.
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A navigational system particularly adapted for use with small open vehicles such as a motorcycle. The navigational system includes a display which displays, in addition to vehicle speed and distance traveled, navigational information as to points along a pre-selected course of travel and the distance and turning direction to reach each successive point. The operator may also insert information about each point, such as observations about the point as the name of the point. The display switches from providing a first display condition that provides the travel information and a second condition that permits the insertion of data into the system. The insertion display is not enabled unless the vehicle is in a standing condition and is automatically returned to display operational conditions when the vehicle again moves.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to growing hair dolls.
2. Description of the Prior Art
In the doll art, efforts to provide life-like features and appurtenances to the doll have been made for many years. Some of the many concepts and developments in this regard include crying or tearing dolls, wetting dolls, walking dolls, talking dolls, dolls that emit a sound when spanked or fondled, dolls with movable limbs or body members, dolls with interchangeable wigs, masks or costumes to simulate known personages or fictitious characters known to the child, and growing hair dolls. In this latter category the art has developed various configurations and structural arrangements, so that a child can manipulate a lock or tuft of the doll's hair, or even the entire hairpiece, in order to change the doll's appearance by lengthening or shortening the hair. Among the many prior art patents of this nature may be mentioned U.S. Pat. Nos. 3,765,123; 3,698,134; 3,696,552; 3,696,551; 3,694,957; 3,670,451; 3,477,170 (Reissue 27,267); 3,279,122; 3,225,489; 3,162,976; 3,156,999; 3,032,923; 2,537,536; 1,557,023 and 1,498,950; and British Pat. No. 1,363,496.
SUMMARY OF THE INVENTION
1. Purposes of the Invention
It is an object of the present invention to provide an improved doll.
Another object is to provide a doll with improved simulated life-like features.
An additional object is to provide an improved growing hair doll.
A further object is to provide a doll wherein not only the hair length but also the torso may be adjusted by manipulation.
Still another object is to provide a doll with hair of adjustable length.
Still a further object is to provide a doll with internal structure at the waist which permits not only modification of the length of the hair but also of the disposition of the torso portions.
Still an additional object is to provide a doll with hair that simulates real-life hair of a child or person that grows with time.
These and other objects and advantages of the present invention will become evident from the description which follows.
2. Brief Description of the Invention
The present invention relates specifically to a growing hair doll. At the onset, it will be understood that within the context of the present invention, the adjustable hair or hair portion will be in the form of a lock, a tuft, or strands of either natural or simulated artificial hair. If the hair is natural hair, it may be derived from a human being or an animal, such as woolen threads derived from sheep or horsehair. Simulated hair may alternatively consist of natural vegetable fiber such as cotton or linen, or artificial material such as threads of rayon, nylon etc. Thus, within the context of the present invention, the term hair will be understood to encompass and include any natural hair, or hair-like material of natural or synthetic origin; in the latter instance, simulated artificial hair is contemplated as being within the scope of the invention. Typical artificial fibers usable in the present invention, besides those mentioned supra, include Dynel, a polymer containing about 40% acrylonitrile and about 60% vinylchloride, Kanekalon, a fiber containing 40-45% acrylonitrile and 55-60% vinylchloride, and Teklan, a fiber containing about 49% each of acrylonitrile and vinylchloride and 2% of other monomers. As mentioned supra, nylon, poly (hexamethylene adipamide) may be used.
The present invention basically entails a combination of structural elements which permit adjustment of both the length of the doll's hair and the disposition or configuration of the torso of the doll. Thus the present doll has both a lock of hair of adjustable length and an adjustable torso. The doll includes a hollow head having an upper opening, a hollow upper torso and a hollow lower torso. Suitable means are provided to rotatably connect the doll's head to the upper end of the upper torso. A specific structural configuration is provided at the interface region between the upper torso and the lower torso. Thus the lower end of the upper torso is provided with an inner flange which extends inwards from the lower periphery of the upper torso and terminates with an inner periphery. A shelf is provided in the upper torso above the flange. The shelf extends inwards from the upper torso and terminates with an inner circular perimeter defining a circular opening. The upper end of the lower torso is also provided with an inner flange which is contiguous with the inner flange of the upper torso. The inner flange of the lower torso extends inwards from the upper periphery of the lower torso and terminates with a circular perimeter defining a circular opening. The circular openings of the aforementioned shelf and lower torso flange are coaxial and of equal diameter, so that these two circular openings serve to define a cylindrical passage. A cylindrical cord retention tube is disposed in and extends upwards through the cylindrical passage and is contiguous with the inner perimeters of the shelf and lower torso flange. Flanges are provided, at the upper and lower ends of the tube. These tube flanges extend outwards from the lower and upper end of the tube, respectively below and contiguous with the flange of the lower torso and above and contiguous with the aforementioned shelf of the upper torso. The side wall of the tube is provided with a pair of opposed circular openings which are coaxial with opposed hubs at the front and back of the upper torso. The hubs are between the shelf and the flange of the upper torso, and the lower perimeter of each hub is preferably tangential to the flange of the upper torso. The upper torso is provided with a lower peripheral opening adjacent to its flange and connecting with a hub, and a cylindrical rod or shaft extends through the hubs and opposed tube openings and terminates at the lower peripheral opening in the upper torso. An annular external flange is preferably provided on the rod, which flange is juxtaposed with the tube. Suitable means, e.g. a key, which are extendable through the lower peripheral opening in the upper torso and into the doll, are provided to rotate the rod or shaft. A cord, which may alternatively be a string, wire or chain, is provided inside the doll. The cord extends in a generally linear orientation within the upper torso when the adjustable lock of hair provided for the doll is fully extended out of the doll, and the cord is wound on the rod when the hair is shortened and a portion of the lock of hair is disposed within the upper torso, as will appear infra. In order to accomplish this alternative disposition of the lock of hair, one end of the cord is attached to the rod within the tube. The lock or tuft of hair which is provided consists generally of any one or a mixture of strands of the hair or hairlike material described supra. The other end of the cord is attached to the lock of hair, which lock extends upwards from attachment to the cord and through the upper opening in the doll's head. Thus, the length of the lock external to the head may be increased by a child, by manually grasping the lock and pulling the lock outwards from the head. The length of the lock external to the head may be decreased, and the lock may be at least partially retracted into the doll's head and upper torso, by manually rotating the rod, e.g. with a suitable key, so that the cord winds on the rod and pulls a portion of the lock through the head and into the upper torso. The structural configuration of flanges, shelf, tube and rod concomitantly permits the upper and lower torso portions to be slidably engaged so that these portions may be rotated relative to each other, thus providing an additional life-like simulation of a real person.
With regard to various specific aspects and preferred embodiments of the invention, in most instances the doll's head will have additional locks or tufts of hair permanently emplaced thereon, with the adjustable lock of hair extending from a centralized opening in the top of the head and being surrounded by these additional permanently emplaced locks of hair, so as to simulate the well-known "pony-tail" style of hair fashion. In order to rotatably connect the head to the upper torso, a preferred configuration entails an opening at the base of the head and a hollow protuberance at the upper end of the upper torso, with the protuberance extending into the head and preferably being provided with an enlargement or the like within the head for positive retention of the head on the upper torso. This enlargement typically is in the form of a bulbous terminus having upper and lower openings to accommodate the cord and the lock of hair.
The rod or shaft is preferably rotatable by means including a non-circular recess in the end of the rod which is adjacent the lower peripheral opening in the upper torso. The recess may be of rectangular, e.g. square, elliptical, triangular or hexagonal cross-section or of any other suitable configuration. In this case a key or key-like implement havng a handle and a shank is provided, with the shank of the key having a non-circular cross-section which mates with the cross-section of the recess, so that the shank of the key fits into the recess whereby rotation of the key rotates the rod. It is preferred that clockwise rotation of the key serves to rotate the rod, to wind the cord onto the rod and thereby to pull a portion of the lock of hair into the upper torso.
The upper opening of the head may be of any suitable configuration, e.g. circular, square, elliptical, oval, etc., however it is preferred that the opening be in the shape of a generally oblong, e.g. rectangular, slot, typically with curved corners, so that the lock of hair is distributed into a flat layer external to the doll, which lock is thus comparable to the well-known pony tail style of real-life women and girls. In this case the length of the slot, being greater than the width, will generally extend laterally relative to the doll, lengthwise from side to side of the head.
The present doll provides several salient advantages. The doll is pleasing to the child when played with, because of the close simulation of a real-life person, both because of the growing hair feature of the adjustable lock of hair and also because the torso and head may be manipulated. Thus the child may adjust the lock of hair to any suitable length, i.e. the hair may be made as long or as short as the child desires, and concomitantly the torso portions may be manipulated relative to each other. The hair and especially the adjustable lock of hair may be washed by the child, typically by using a mild shampoo and blowing dry with a hair dryer on the "cool" setting. The dry hair may be brushed or styled by a child as in real life. Thus, an improved doll with improved simulated life-like features has now been provided, and more specifically an improved growing hair doll is provided by the present invention. The present doll features not only adjustment of the length of the hair but also adjustment of the torso and head by manipulation by a child. Improved internal structure is provided at the waist of the doll which permits not only modification of the length of the hair but also concomitant modification of the disposition of the torso portions. Thus, an improved simulation of a real-life person with hair that grows with time and an adjustable body is attained in the present invention.
The invention accordingly consists in the features of construction, combination of elements and arrangement of parts which will be exemplified in the article of manufacture hereinafter described and of which the scope of application will be indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings in which is shown one of the various possible embodiments of the invention:
FIG. 1 is an overall elevation view of the doll being manipulated to lengthen the lock of hair;
FIG. 2 is an elevation view of the doll showing insertion of a key to shorten the lock of hair;
FIG. 3 is an enlarged sectional elevation view of major portions of the doll with the lock of hair fully extended out of the doll's body:
FIG. 4 is an enlarged sectional elevation view of major portions of the doll with the lock of hair fully retracted into the doll's body;
FIG. 5 is a sectional elevation view taken substantially along the lines 5--5 of FIG. 4;
FIG. 6 is a sectional plan view taken substantially along the lines 6--6 of FIG. 4 and showing structural details at the waist of the doll;
FIG. 7 is a sectional elevation view taken substantially along the lines 7--7 of FIG. 4 and showing structural details at the waist of the doll;
FIG. 8 is a sectional elevation view taken substantially along the lines 8--8 of FIG. 4 and showing structural details at the waist of the doll; and
FIG. 9 is a perspective view of the rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 3, a doll 10 of the present invention has a fully extended lock of hair 12. The lock or tuft 12 has been fully extended from hollow head 14 of the doll 10, in the direction indicated by arrow 16, by manually grasping the lock 12 with hand 18 of a person, such as a small child, playing with the doll 10, and pulling the lock 12 away from the body of the doll 10 while firmly holding the body of the doll in hand 20, until a cord 22 within the hollow upper torso 24 and head 14 of the doll is fully extended, as shown in FIG. 3.
The head 14, as shown in FIG. 3, is rotatably mounted on the upper torso 24 by the provision of foraminous means through which the upper end of the cord 22 extends to attachment to the lock 12 by means of upper loop 26. The rotatable mounting means in this case consists of a hollow protuberance 28 simulating the neck of the doll, which protuberance 28 extends through a lower opening 30 in the head 14 and terminates with an upper enlargement consisting of a bulbous terminus 32 having an upper opening 34 and a lower opening 36, so that the cord 22 and the lock 12 are accommodated by a clear passage between the head 14 and the upper torso 24.
FIG. 1 also shows a key 38 having a handle 40 and a shank 42, which shank 42 typically has a non-circular cross-section. The key 38 depends from a string or cord 44 by which the key 38 is detachably secured to the wrist of hand 18. When it is desired to retract the lock 12 into the head 14 and upper torso 24 of the doll 10, as will appear infra, the shank 42 is inserted through an opening 46 in the center of the back of the doll, which opening 46 is adjacent the lower perimeter of the upper torso. The doll 10 is shown in FIG. 1 wearing a dress 48 having a skirt 50. The dress 48 is a low cut gown, so that the upper portion of the lower torso 52 of the doll is shown. As shown in FIG. 3, the lower torso 52 is hollow, as was the case with the upper torso 24 and the head 14. FIG. 1 also shows the arms 54 and 56 of the doll 10, as well as permanently emplaced hair portion 58, which as shown in FIG. 3 consists of a plurality of locks of hair permanently emplaced in the head and designated as 60.
FIG. 3 also shows details of the structure of the waist of the doll, which structure is provided in accordance with the present invention. Referring first to the lower portion of the upper torso 24, the lower end of the upper torso portion 24 is provided with an inner flange 62, which extends inwards from the lower periphery of the upper torso 24 and terminates with an inner periphery 64 which defines an opening. A pair of opposed cylindrical hubs 66 and 67 are provided within the upper torso 24 above the flange 62; as will appear infra, the lower perimeter of each hub 66 or 67 is preferably tangential to the flange 62. A shelf 68 is provided within the upper torso 24 immediately above the hubs 66 and 67. Both the hubs 66 and 67 and the shelf 68 extend inwards from the inner perimeter of the upper torso portion 24. The shelf 68 terminates with a circular inner perimeter 70 which defines a circular opening.
Referring now to the lower torso portion 52, the upper end of the lower torso portion 52 is provided with an inner flange 72 which extends inwards from the upper periphery of torso portion 52 and terminates with a circular inner perimeter 74 defining a circular opening. A cylindrical cord retention tube 76 extends through the passage defined by the perimeters 70 and 74. A lower flange 78 extends outwards from the lower end of tube 76. Flange 78 is below and contiguous with flange 72. A similar flange 80 extends outwards from the upper end of the tube 76, and flange 80 is above and contiguous with the shelf 68. It is to be noted, in addition, that the outer perimeter of tube 76 is contiguous with the perimeters 70 and 74. Thus, the upper torso 24 and the lower torso 52 are slidably engaged, so that the lower torso 52 may rotate at least partially relative to the upper torso 24.
A cylindrical rod 82 extends transversely through opposed circular openings 84 and 86 in the side wall of the tube 76. The ends of the rod 82 are mounted in the hubs 66 and 67, respectively. The end of the rod 82 which is in the hub 66 is juxtaposed with the opening 46, so that suitable means such as the key 38 are extendable through opening 46 and into the typically non-circular recess or opening 88 in the end of the rod 82, so that the rod 82 may be rotated by the key 38 or the like.
The lower end of the cord 22 is attached to the rod 82, typically by having the lower end of cord 22 extend through a hole 90 in the rod 82 and terminate with a knot 92. Thus when the shank of the key 38 or the like is inserted into the non-circular recess 88 and the key 38 is rotated, the rod 82 rotates about its axis, and the cord 22 winds onto the rod 82, thus pulling the lock 12 downwards and into the head 14 and upper torso 24 of the doll 10.
The sequence of retracting the lcok 12 into doll 10 is shown in FIGS. 2 and 4. As shown in FIG. 2, the shank 42 of the key 38 is manually inserted into opening 46. Since the recess 88 at the end of the rod 82 and the shank 42 are typically of a non-circular cross-section, e.g. square, rotation of the key 38, as shown in FIG. 4, can rotate the rod 82 and wind the cord 22 onto the rod 82, thus displacing the lock 12 into the head 14 and upper torso 24. This rotation of the rod 82 is preferably clockwise. As shown in full outline in FIG. 4, total winding of the cord 22 onto the rod 82 serves to displace the inner portion of the lock 12 downwards so that the end of the lock 12 defined by the loop 26 is juxtaposed with the tube 76. The other end of the lock 12 in this case is level with the balance of permanently emplaced locks of hair so as to simulate a short coiffure. The phantom outline of lock 12 in FIG. 4 shows partial displacement of the lock 12 into the doll.
FIGS. 2 and 4 also show an optional additional recess 94 at the end of the rod 82 opposite recess 88. This recess 94 is provided to lighten the weight of the rod 82 for easy manipulation by a child, and also to provide a flexible joint for the end of the rod 82 within hub 67, so that the rod 82 is easily rotatable.
FIGS. 3 and 4 also show a bust 96, typically provided when the doll 10 is intended to represent an adult female personage. FIGS. 3 and 4 further show a flange 97, which is an outer annular flange disposed on the rod 82 between the lower peripheral opening 64 in the upper torso 24 and the tube 76, i.e. the flange 97 is disposed between the hub 66 (and the flange 62), and the tube 76. Flange 97 serves to position the rod 82 and to prevent the rod 82 from being pushed against the front of upper torso 24 when the key shank 42 is inserted in recess 88.
FIG. 5 illustrates a typical configuration of an opening 98 in the head 14, through which the lock 12 extends out from the doll head. Thus the opening 98 is generally in the form of a slot, with the slot typically being generally oblong, and with the length of the slot extending laterally relative to the doll head 14.
FIGS. 6, 7, 8 and 9 show details of the configuration of the structure at the waist of the doll. Thus FIG. 6 illustrates the concentric circular nature of the tube 76 and upper torso 24; it will be appreciated that in practice upper torso portion 24 may be of non-circular cross-section, however in general members 76 and 24 will be coaxial. FIG. 7 illustrates the circular cross-section of rod 82 as well as a preferred square configuration of recess 88 as shown in phantom outline. FIG. 7 also shows the circular winding of cord 22 on rod 82. FIG. 8 illustrates the circular cross-section of the hub 66 as well as the coincident nature of the bottom of the hub 66 and the flange 62 at 100, i.e. the hub 66 is above and tangential to the flange 62. FIG. 8 also shows the square cross-section of the key shank 42, as well as the contiguous relationship between flange 80 and shelf 68 as well as between flange 78 and flange 72. FIG. 9 shows the disposition of flange 97 integral with rod 82.
It thus will be seen that there is provided an article of manufacture which achieves the various objects of the invention and which is well adapted to meet the conditions of practical use.
As various possible embodiments might be made of the above invention, and as various changes might be made in the embodiment above set forth, it is to be understood that all matter herein described or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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A doll with a lock of hair of adjustable length and a torso which has upper and lower portions which are rotatable relative to each other. The internal doll structure at the waist of the doll which permits the lock of hair to be adjustable in length, so as to simulate growing hair, is integral with the means at the waist which permits the torso portions to be rotatable relative to each other, e.g. the tube which holds the wound-up cord which displaces the lock of hair into the upper torso, also serves to hold the upper and lower torso portions together in slidable engagement.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to an application arrangement for a disc brake and more specifically wherein the brake lining is guided and supported by a brake lining housing. The object of the present application is also a brake lining constructed according to the teaching of the invention.
In conventional application arrangements for a disc brake, a brake lining compartment is normally provided for accommodating a brake lining which can be displaced by the application arrangement and which has two lateral guide surfaces which extend in the application direction and on which the brake lining is displaceably guided by its two lateral edges.
When the application arrangement is actuated for braking, the brake lining is displaced by it in the direction of the brake disc and finally rests by means of its friction surface against the corresponding lateral surface of the brake disc. Because of the brake friction forces, the brake lining is moved toward the downstream-side or outlet-side guide surface of the brake lining compartment and is then supported on this guide surface. In contrast, in the non-applied or brake-free condition, the brake lining rests comparatively loosely in the brake lining compartment.
As soon as, during the application of the disc brake in the initial phase of the braking operation, the brake lining rests on the brake disc and, in this case, finally, as mentioned above, touches the downstream-side guide surface of the brake lining compartment, the rotational moving force of the brake disc is transmitted to this downstream-side support of the brake lining and causes a friction force there which counteracts the application force. During the further application of the disc brake, this friction force must therefore additionally be overcome by the application arrangement.
In the most frequently used disc brakes in which the lining compartments of the above-mentioned type are normally also used, a so-called floating caliper is provided as the caliper. When the brake lining is in contact, because of the reaction forces acting in the axial direction, the caliper is displaced with the brake disc in the opposite direction and, in the process presses another brake lining situated on the opposite side also against the brake disc. Since this opposite brake lining is guided in a substantially identically constructed lining compartment, an equally large friction force occurs on its downstream-side guide surface. This additionally stresses the application arrangement.
The above-mentioned friction forces on the respective downstream-side guide surface of the lining compartment therefore have the disadvantage that the application arrangement must apply an increased braking force, whereby the overall efficiency of the disc brake is considerably reduced. In practice, the required braking force is increased between 10% and 30%.
However, another, even more serious disadvantage of these undesirable friction forces is that, as a result, the so-called circumferential diagonal wear is caused. The reason is that conventional application arrangements introduce their application force centrally into the brake lining while the respective friction force of the brake linings operates only on one side. This result in an overall asymmetrical force distribution in the brake lining so that this brake lining is pressed against the brake disc with a non-uniform force. Therefore the brake lining is worn more for a long period of time on its upstream or inlet-side area where the applied application force is larger. Thus, a wear profile which extends diagonally in the circumferential direction results which correspondingly reduces the useful life of the brake lining.
From German Patent Application DE 22 30 949 A1, an application device for a disc brake is known in which it is suggested to reduce the disadvantageous friction forces on the downstream-side guide surface of the lining compartment by a leaf spring which is stiff in the lateral direction and which is fastened at least on one side of a pressure plate of the brake lining in parallel to this pressure plate and rests with one of its ends on the downstream-side guide surface of the brake lining compartment. As soon as the brake lining during the application of the disc brake in the initial phase of the braking operation rests against the brake disc, it is supported by the end of the leaf spring on the guide surface of the brake lining compartment. Because of the small contact surface of the leaf spring, a high local friction force occurs there. Thus, during the further application, the leaf spring cannot be further displaced but bends instead. Therefore, the application device must overcome no additional friction forces so that the degree of the brake effect is clearly increased, particularly since the force required for the bending of the leaf spring is relatively low. However, a disadvantage of this known application device is the fact that the bending of the leaf spring causes a corresponding transverse position of the brake lining so that the occurrence of circumferential diagonal wear cannot be prevented.
In an alternative embodiment of the application device known from German Patent Document DE 22 30 949 A1, it is suggested to dispose the brake lining in a displaceable manner on guide rods consisting of a coil or a stack of supporting discs. When, during the application of the disc brake, the brake lining rests on the brake disc, the outlet-side guide rod is bent so that no friction forces are transmitted on the brake lining. Since the force required for the bending of the guide rod is comparatively low, the brake efficiency is increased correspondingly as in the case of the first-mentioned embodiment. However, because of the bending of the guide rod, a transverse position of the brake lining can also not be prevented, so that a circumferential diagonal wear will also occur.
It is an object of the invention to further develop an application arrangement for a disc brake in such a manner that, the brake efficiency is improved and simultaneously, a minimizing of the circumferential diagonal wear can be achieved. Furthermore, a brake lining is to be provided which is also distinguished by an improvement of the brake efficiency and is subject to only a low circumferential diagonal wear.
According to the invention, this object is achieved by forming the respective guide surface of the brake lining compartment by a plate which is disposed on the assigned wall surface of the brake lining compartment or on the lateral edge of the brake lining in such manner that it is rollably or slidably displaced with respect to the wall surface in the application direction along a predetermined path. Because of this rolling or sliding bearing, no friction forces are transmitted to the brake lining when the brake lining rests on the brake disc during the application of the disc brake. Since the friction forces occurring during the braking displace the plate displaced in the application direction toward the brake disc, the brake lining, in contrast to the known application arrangement, is displaced precisely in parallel to the brake disc. That is, the brake lining is subjected to no tilting so that any circumferential diagonal wear can be avoided.
The predetermined path along which the plate according to the invention is displaceably disposed, in practice must be selected to be at least as large as the displacement path still to be implemented when the brake lining is in contact. However, this displacement path is relatively small, so that the implementation of the displaceable bearing presents no problems.
According to the further development of the invention, it is recommended to prestress the plate against the application direction such that, after the release of the brake, it moves back into its starting position. As a result,the operability of the bearing according to the invention exists at any point in time. The desired prestressing force may be achieved, for example, by the fact that the plate is prestressed by a spring element, which preferably consists of a rubber material, against the application direction. In this case, the plate should be a part of a spring bow element. Optionally, this spring bow element may be clamped with such a large inherent elasticity that the prestressing force can be achieved without any additional spring element.
A particularly advantageous and low-cost bearing of the spring bow element according to the invention is achieved if the spring bow element is fastened on an area of the brake lining compartment which is constructed essentially with a T-shaped cross-section, for example, in a clamping fit. When the brake lining consists of a brake lining material and a pressure plate acted upon by the application device, it may, in contrast, be considered to fasten the spring bow element on the lateral edge of the pressure plate. In this case, the device according to the invention for reducing the friction forces is part of the corresponding brake lining so that, also in the case of older application arrangements, possibly within the scope of a brake lining change which is required anyhow, the advantages of the invention can be achieved without any problems.
For the purpose of the invention, different bearing arrangements are suitable, particularly slide bearings in the form of a teflon bearing or in the form of several steel lamellae or in the form of a roller bearing formed of several rollers. Particularly low-cost and robust embodiments of the steel lamellae or roller bearings according to the invention will be achieved if the steel lamellae or rollers are embedded in a rubber material, for example, by vulcanizing.
According to the further development of the invention, the friction force can be further reduced when the face of the plate facing the wall surface of the brake lining compartment is constructed as an oblique plane sloping down in the application direction. In this case, a forward component of the reaction force of the pressure force acting upon the plate, which overcomes the residual friction force, is transmitted to the brake lining.
For reasons of cost, it may finally be considered to provide the plate according to the invention only on that side of the brake lining compartment which is the outlet side during the forward driving of the vehicle. The reason is that braking operations during reverse driving of the vehicle are much rarer and, in addition, are usually connected with lower braking forces so that, as required, the absence of the plate according to the invention can be accepted there without any disadvantages.
According to the invention, a brake lining is also to be protected by the invention on the lateral edge(s) of which the plate according to the invention is provided.
In the following, the invention will be explained in detail by the description of embodiments with a reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are cross-sectional views of the schematic construction of a first embodiment of the application arrangement, of which a teflon bearing is used;
FIGS. 2A and 2B are views of an alternative embodiment of the application arrangement illustrated in FIGS. 1A and 1B;
FIGS. 3A and 3B are views of another alternative of the application arrangement illustrated in FIGS. 1A and 1B;
FIGS. 4A and 4B are views of a second embodiment of the application arrangement in which a laminated steel bearing is used;
FIGS. 5A and 5B are views of an alternative embodiment of the application arrangement illustrated in FIGS. 4A and 4B;
FIGS. 6A. to 6D are views of a third embodiment of the application arrangement in which a steel roller bearing is used;
FIGS. 7A and 7B are views of an alternative embodiment of the application arrangement illustrated in FIGS. 6A to 6D;
FIGS. 8A and 8B are views of a fourth embodiment of the application arrangement, in which an alternative embodiment of a spring bow element is used; and
FIGS. 9A and 9B are views of an embodiment of a slidably disposed plate fastened on the brake lining.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In reference to FIGS. 1 to 3, a first embodiment of the invention will now be described in detail. In this first embodiment, a spring bow element 30 is clamped onto an area 22 of a brake lining compartment 20 with the insertion of a teflon layer 41 therebetween. A brake lining 10 consists of a pressure plate 12 and a brake lining material 11 fixed to it. The surface of the brake lining material 11 which faces away from the pressure plate 12, for the braking, is brought in contact with the assigned friction surface of a (not shown) brake disc. In the drawings, it is assumed that the brake disc rotates in the direction indicated by the arrow U. An application arrangement is shown only schematically as a pressure stamp 7 which, during the application of the disc brake, that is, during the actuating of the brake, is moved in a direction indicated by the arrow Z.
First, it should be pointed out that all figures marked with the letter A indicate the inoperative condition of the brake or an initial condition of the actuating of the brake while the figures marked by the letter B show the actuating condition of the brake in which the brake lining 10 (or its brake lining material 11) under the effect of a certain brake pressure already rests against the friction surface of the brake disc. In addition, it should be noted that the brake lining compartment 20 naturally also has an area (not shown) which is opposite the area 22 and is shaped correspondingly and forms the second lateral wall of the brake lining compartment 20. If the area shown on the left represents the side of the brake lining compartment 20 which, during the forward driving of the vehicle, is the outlet side, it may under certain circumstances not be necessary to provide, on the not shown opposite lateral area, also a spring bow element 30 which is displaceably disposed on a teflon layer 41 because, during the reverse driving of a vehicle, the braking load is, as a rule, lower. If, however, the concerned disc brake has a parking device for forming a parking brake, it would be advisable to provide the lining support according to the invention on both lateral area of the brake lining compartment 20 because, particularly, during the parking of a vehicle on a slope, high braking forces may occur also in the reverse direction.
A first embodiment of the first example of the invention will now be explained in detail with reference to FIGS. 1A and 1B. In the case of this embodiment, the spring bow element 30 is essentially constructed as a U-shaped piece which is formed of a plate 30a facing a lateral edge 12c of the pressure plate 12, of a clamping section 30b facing the application arrangement and of a clamping section 30c facing the brake disc. The two clamping sections 30b and 30c reach around the T-shaped area 22 of the brake lining compartment 20 and in each case have sections 30b' and 30'c bent toward it. Because of this arrangement, the spring bow element 30 is disposed in a sufficiently fixed manner on the T-shaped area 22 of the brake lining compartment 20. Optionally, it may be considered to provide an additional fastening of the spring bow element 30, for example, by screws or by a welding onto the section 30b'.
Between the clamping section 30b and the area 22 of the brake lining compartment 20, a space 32 is provided which allows the spring bow element 30 or its plate 30a facing the pressure plate 12 to move in the application direction with respect to the wall surface 21 of the area 22, specifically along a predetermined path the length of which is essentially defined by the size of the space 32. The length of this path corresponds at least to the length of the displacement path by which the brake lining 10 can still be displaced by the application arrangement when the brake lining 10 rests against the brake disc. As soon as the pressure force exercised by the lateral edge 12c of the pressure plate 12 of the brake lining 10 on the plate 30a is eliminated during the release of the brake, the plate 30a is returned by the spring force of the clamping section 30b against the application direction Z back into the starting position of FIG. 1A.
The teflon layer 41 arranged between the plate 30a and the wall surface 21 of the brake lining compartment 20 may, for example, be a teflon slide bearing which can be obtained in a finished state and which is fastened, for example, by gluing either on the plate 30a or on the wall surface 21.
The bearing arrangement according to the invention operates as follows: At the start of the actuating of the brake, the pressure stamp 7 of the application arrangement is first displaced along a predetermined path in the application direction Z corresponding to a bleeding play of the brake. The brake lining 10 acted upon by the pressure stamp 7 is therefore also displaced toward the brake disc. Since, however, the brake lining material 11 of the brake lining 10 during this initial phase of the displacement does not yet rest against the brake disc, at this point in time, the brake lining 10 is not yet acted upon by any transverse force component for example, in the direction of the arrow U. Even if, at this point in time, the lateral edge 12c of the pressure plate 12 of the brake lining 10 already rests against the plate 30a, the friction force exercised on the plate 30a is still so low that the plate 30a is not or is only slightly brought out of its starting position illustrated in FIG. 1A. The lateral edge 12c will therefore slide along the plate 30a.
Only when, during a further application, the brake lining material 11 of the brake lining 10 rests against the brake disc, the brake lining 10 will be acted upon by means of friction by a transverse force component in the direction of the arrow U which has the result that its lateral edge 12c exercises a corresponding force onto the plate 30a. The plate 30a is therefore displaced into the position illustrated in FIG. 1B, in which case, because of the teflon bearing 41, there will almost be no friction. The advancing force generated by the pressure stamp 7 of the application arrangement is therefore hardly hindered so that the efficiency of the application does not change very significantly. Since this lateral slide bearing also causes no moment of tilt, the brake lining 10 remains in its parallel contact with the brake disc so that also any circumferential diagonal wear can be prevented.
When the application force is reduced during the release of the brake and the brake lining material 11 therefore no longer rests against the brake disc, from the lateral edge 12c of the pressure plate 12 of the brake lining 10, also no transverse force is exercised any more on the plate 30a. Therefore, as mentioned above, the plate 30a is returned by the spring force of the clamping section 30b against the application direction Z into the starting position illustrated in FIG. 1A.
A second embodiment of the first example of the invention is illustrated in FIGS. 2A and 2B. This embodiment differs from the first embodiment only because of the fact that a spring element 50 is arranged in the space 32 between the T-shaped area 22 of the brake lining compartment 20 and the clamping section 30b, which spring element 50 is, for example, made of a rubber material. Because the end of the section 30b' does not rest against the T-shaped area 22, as shown directly in FIG. 2A, the plate 30a is prestressed only by the spring element 50 against the application direction Z. In addition, the method of operation of this embodiment of FIGS. 1A and 1B corresponds to that of the above-explained embodiment so that reference can be made to the above explanations.
A third embodiment of the first example of the invention is illustrated in FIGS. 3A and 3B. This embodiment differs from the first embodiment essentially in that the surface of the plate 30a facing the wall surface 21 of the brake lining compartment 20 is constructed as an oblique plane sloping down in the application direction Z. The lateral surface plate 30a facing this oblique plane of surface 21 is constructed for this purpose as a complementarily extending oblique plane; that is, the oblique plane of the plate 30a--viewed in the application direction Z--has an ascending course. When the brake disc rotates, it exercises, because of its friction with the brake lining material 11 of the brake lining 10, a certain force on this brake lining which is transmitted to the oblique plane as parallel extending circumferential force in the direction of arrow U. This circumferential force can be split up into a normal force extending perpendicularly to the surface of the oblique plane and into a friction force extending tangentially with respect to the surface of the oblique plane when it is assumed that an equilibrium of forces exists. In the case of which the angle between the circumferential force and the normal force corresponds to the so-called friction angle (in the technical literature, this friction angle is usually call ρ). In this case, the "slope output force" on the oblique plane has exactly the same value as the friction force so that the latter is compensated. This means that the resulting force component in the application direction Z is equal to zero. The application force introduced in the center is therefore not acted upon by a moment of tilt so that the brake lining 10 is pressed completely uniformly against the brake disc and the risk of the occurrence of a diagonal wear is further reduced.
Also in the case of the embodiment illustrated in FIGS. 3A and 3B, the prestressing of the plate 30a may possibly be generated by a spring element 50 provided in the space 32.
Referring to FIGS. 4 and 5, a second embodiment of the invention will now be described in detail which differs from the first embodiment because of the fact that a laminated steel bearing is provided as the slide bearing surface. In the variant of this embodiment illustrated in FIGS. 4A and 4B, steel lamellae 42 are arranged at a right angle between the inner surface of the plate 30a and the wall surface 21 of the brake lining compartment 20. The steel lamellae 42 are embedded in rubber material 43 which, on the one hand, ensures a defined position of the steel lamellae and, on the other hand, permits a tilting movement of the steel lamellae which prevents friction. In the application position illustrated in FIG. 4B, the steel lamellae 42 are therefore sloped diagonally downward. It may be considered to provide a hardened surface 40 between the wall surface 21 and the steel lamellae 42.
The variant of this embodiment illustrated in FIGS. 5A and 5B differs from the above-described variant of FIGS. 4A and 4B in that the steel lamellae 42 are bordered only on the edge by the rubber material 43 and are sealed off simultaneously so that a larger number of steel lamellae 42 can be accommodated. This variant is therefore suitable for larger loads.
FIGS. 6 and 7 illustrate a third embodiment of the invention in the case of which a roller bearing is provided for the bearing. In the case of the embodiment illustrated in FIGS. 6A to 6D, rollers 45 of this roller bearing are in each case connected with one another by strips 46 of rubber material. These rubber material strips 46 form a quasi-cage for the rollers 45 which permits a certain rotation of the rollers 45 which is completely sufficient for the purposes of the invention. FIG. 6C is an enlarged cutout of FIG. 6A, and FIG. 6D is an enlarged cutout of FIG. 6B. The variant illustrated in FIGS. 7A and 7B differs from the above variant Of FIGS. 6A-6D only because of the fact that the rubber material 46 almost completely encloses the rollers 45. As required, care may have to be taken in this case that the rollers 45 can still rotate to a certain extent inside the rubber material 46.
Also in the case of these roller bearings, a hardened surface 40 is preferably provided between the wall surface 21 and the respective roller bearing 45.
In the case of the fourth embodiment illustrated in FIGS. 8A and 8B, an alternative embodiment of the spring bow element is used. As easily recognizable in the cross-sectional representation, this spring bow element consists of a first element 30 which faces the brake lining 10 and also forms the wall 30a, and of a second element 31 which is essentially an L-angle piece and is fastened on a correspondingly shaped section of the brake lining compartment 20, for example, by welding or gluing or by screws or rivets. The two elements 30 and 31 are fastened to one another on an area 33. The first element 30 has a section 30b which extends from there and is directed upwards, which section 30b permits a resilient yielding of the wall 30a in the application direction. In order to prevent a contamination, a rubber material 48 is provided below the section 30b and, at the same time, promotes the desired spring-back resilience. In the area between the plate 30a and the opposite section of the second element 31, a slide bearing 41 is arranged which is preferably made of teflon. However, optionally, one of the bearings illustrated in the above-described embodiments may also be used. On the lower end, a seal 49 is provided which is made, for example, of rubber. Since the method of operation of this embodiment corresponds to that of the other embodiments, the explanation does not seem to have to be repeated.
The fifth embodiment illustrated in FIGS. 9A and 9B is an alternative embodiment of the embodiment of FIGS. 8A and 8B. The spring bow element 30, 31 is not fastened on the brake lining compartment 20 but on the pressure plate 12 of the brake lining 10. However, the construction and method of operation correspond largely to the previous embodiment, so that the explanation surely does not have to be repeated. The present embodiment has the advantage that the brake lining compartment 20 does not have to be modified so that the retrofitting of already available disc brakes is easily possible. This embodiment can also be used when, for reasons of cost or manufacturing difficulties, the modification of the brake lining compartment required in the other embodiments is not possible.
Naturally, it is possible to provide the oblique plane illustrated in FIG. 3 also in the case of the other embodiments of the invention.
It does not have to be further described that it is recommended that the explained principle of the invention also be used in the case of the brake lining accommodated in the lining compartment opposite the brake disc.
Concerning other characteristics and effects of the invention, which are not explained in detail, reference is explicitly made to the drawing.
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In an application arrangement for a disc brake including a brake lining compartment having two lateral guide surfaces extending in the application direction for guiding and supporting a brake lining which can be displaced by the application arrangement, a plate is situated on the assigned wall surface of the brake lining compartment or on the lateral edge of the brake lining and is disposed so that it can be rollably or slidably displaced with respect to the wall surface along a predetermined path.
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RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 13/540,477 filed on Jul. 2, 2012, which was a continuation of U.S. patent application Ser. No. 13/109,609 filed on May 17, 2011, which was a continuation of U.S. patent application Ser. No. 12/690,794 filed on Jan. 20, 2010 now U.S. Pat. No. 7,942,559; which was a division of U.S. patent application Ser. No. 11/711,218 filed on Feb. 26, 2007 now U.S. Pat. No. 7,674,018, which claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 60/777,310, filed on Feb. 27, 2006; U.S. Provisional Patent Application Ser. No. 60/838,035, filed on Aug. 15, 2006; and U.S. Provisional Patent Application Ser. No. 60/861,789, filed on Nov. 29, 2006, each of which are incorporated herein by reference. This application is also related to U.S. patent application Ser. No. 12/690,821 filed on Jan. 20, 2010 now U.S. Pat. No. 7,993,036; and U.S. patent application Ser. No. 13/109,582 filed on May 17, 2011.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of apparatus and methods for using light emitting diodes (LEDs) or other light sources to generate predetermined wide profile two dimensional illumination patterns using a light source which has been optically modified to provide a corresponding wide profile beam or a flat array of multiple ones of such modified light sources.
2. Description of the Prior Art
The initial investment cost of LED illumination is expensive when compared with traditional lighting means using cost per lumen as the metric. While this may change over time, this high cost places a premium on collection and distribution efficiency of the LED optical system. The more efficient the system, the better the cost-benefit comparison with traditional illumination means, such as incandescent, fluorescent and neon.
A traditional solution for generating broad beams with LEDs is to use one or more reflectors and/or lenses to collect and then spread the LED energy to a desired beam shape and to provide an angled array of such LEDs mounted on a curved fixture. Street light illumination patterns conventionally are defined into five categories, Types I-V. Type 1 is an oblong pattern on the street with the light over the center of the oblong. Type II is a symmetric four lobed pattern with the light over the center of the lobed pattern. Type III is a flattened oblong pattern with the light near the flattened side of the oblong. Type IV is parabolic pattern with a flattened base with the light near the flattened base. Type V is a circular pattern with the light over the center of the circle. Any asymmetric aspect of these categorical patterns is obtained by mounting the light sources in a curved armature or fixture. By curving or angling the fixture to point the LEDs or light sources in the directions needed to create a broad or spread beam onto a surface, such as a street, a portion of the light is necessarily directed upward away from the street into the sky. Hence, all airplane passengers are familiar with the view of a lighted city at night on approach. This often dazzling display is largely due to street lights and more particularly to street lights that have canted fixtures to create spread beams and hence collectively direct a substantial amount of light skyward toward approaching aircraft. In an efficiently lighted city, the city would appear much darker to aircraft, because the street lights should be shining only onto the street and not into the sky. The dazzling city lights seen from aircraft and hill tops may be romantic, but represent huge energy losses, unnecessary fuel usage, and tons of unnecessary green house gas emissions from the electrical plants needed to generate the electricity for the wasted light.
Another technique is to use a collimating lens and/or reflector and a sheet optic such as manufactured by Physical Devices Corporation to spread the energy into a desired beam. A reflector has a predetermined surface loss based on the metalizing technique utilized. Lenses which are not coated with anti-reflective coatings also have surface losses associated with them. The sheet material from Physical Optics has about an 8% loss.
One example of prior art that comes close to a high efficiency system is the ‘Side-emitter’ device sold by Lumileds as part of their LED packaging offerings. However, the ‘side-emitter’ is intended to create a beam with an almost 90 degree radial pattern, not a forward beam. It has internal losses of an estimated 15% as well. Another Lumileds LED, commonly called a low dome or bat wing LED, has a lens over the LED package to redirect the light, but it is to be noted that it has no undercut surface in the lens for redirecting the light from the LED which is in the peripheral forward solid angle. Similarly, it is to be noted that the conventional 5 mm dome lens or packaging provided for LEDs lacks any undercut surface in the dome at all.
What is needed is an device that creates a wide angle beam, even the possibility of a nonradially symmetric beam, that can be created with a design method that allows the al designer to achieve a smooth beam profile which is not subject to the inherent disadvantages of the prior art.
BRIEF SUMMARY OF THE INVENTION
The illustrated embodiment of the invention includes a method of providing a predetermined illuminated surface pattern from a predetermined energy distribution pattern of a light source comprising the steps of defining an estimated optical transfer function of a lens shape; generating an energy distribution pattern using the estimated optical transfer function of a lens shape from the predetermined energy distribution pattern of the light source; generating a projection of the energy distribution pattern onto the illuminated surface; comparing the projection of the energy distribution pattern to the predetermined illuminated surface pattern; modifying the estimated optical transfer function of the lens shape; repeating the steps of generating the energy distribution pattern using the estimated optical transfer function of the lens shape from the predetermined energy distribution pattern of the light source, generating the projection of the energy distribution pattern onto the illuminated surface, and comparing the projection of the energy distribution pattern to the predetermined illuminated surface pattern until acceptable consistency between the projection of the energy distribution pattern and the predetermined illuminated surface pattern is obtained; and manufacturing a lens with the last obtained estimated optical transfer function.
In one embodiment the predetermined illuminated surface pattern is a street lighting pattern and the predetermined energy distribution pattern of the light source is a LED Lambertian pattern so that what is manufactured is a lens for a street light.
The method further comprises the step of assembling a plurality of light sources optically each combined with the manufactured lens to form a corresponding plurality of devices, each having an identical energy distribution pattern, to provide a linearly additive array of devices to produce the predetermined illuminated surface pattern.
In one embodiment each array is manufactured as a modular unit and the method further comprises the step of scaling the intensity of the illumination pattern on the target surface without substantial modification of the illumination pattern by modular scaling of the arrays into larger or smaller collections.
The illustrated embodiment of the invention is also an improvement in an apparatus for providing an optical transfer function between a predetermined illuminated surface pattern and a predetermined energy distribution pattern of a light source comprising a lens having a shape defined by the optical transfer function which is derived by generating an energy distribution pattern using the predetermined energy distribution pattern of the light source and then generating a projection of the energy distribution pattern onto the illuminated surface from the energy distribution pattern, which projection acceptably matches the predetermined illuminated surface pattern.
In one embodiment the predetermined illuminated surface pattern is a street lighting pattern and the predetermined energy distribution pattern of the light source is a LED Lambertian pattern.
An embodiment of the claimed invention also includes a light source combined with the lens.
The illustrated embodiment is also an improvement in a lens for use in an apparatus for providing a predetermined illuminated surface pattern from a predetermined energy distribution pattern of a light source comprising an undercut surface defined on the lens, the lens having a base adjacent to the light source, a lens axis and a surface between the base and lens axis, the undercut surface extending from the base of the lens at least partially along the surface of the lens toward the lens axis to generate an energy distribution pattern using the predetermined energy distribution pattern of the light source which will then generate a projection of the energy distribution pattern onto the illuminated surface, which projection acceptably matches the predetermined illuminated surface pattern.
The undercut surface comprises portions which refract light and which totally internally reflect light from the light source into the energy distribution pattern.
The undercut surface comprises portions which direct light from the light source into a broad spread beam.
The illustrated embodiment is also an improvement in an apparatus for providing an optical transfer function between a predetermined illuminated surface pattern and a predetermined energy distribution pattern of a light source comprising an undercut surface of a lens having a shape defined by the optical transfer function which shape is derived by generating an energy distribution pattern using the predetermined energy distribution pattern of the light source and then generating a projection of the energy distribution pattern onto the illuminated surface from the energy distribution pattern, which projection acceptably matches the predetermined illuminated surface pattern.
The illustrated embodiment is also an improvement in a lens surface for use in an apparatus for providing a predetermined illuminated surface pattern from a predetermined energy distribution pattern of a light source, where the lens is characterized by an energy distribution pattern with two opposing sides, the improvement comprising a complex prism defined as part of the lens surface, the complex prism being arranged and configured to transfer energy from one side of the energy distribution pattern to the opposing side to render the energy distribution pattern asymmetric with respect to the two opposing sides.
The illustrated embodiment is also an array for providing a predetermined illuminated surface pattern comprising a plurality of light emitting devices for providing the predetermined illuminated surface pattern, each device having an identical energy distribution pattern which produces the predetermined illuminated surface pattern, a circuit driver coupled to each of the devices, and a planar carrier in which the plurality of light emitting devices are arranged to provide a spatially organization of the array to collectively produce a linearly additive illumination pattern matching the predetermined illuminated surface pattern.
Each array is a modular unit capable of being readily combined with a like array and further comprising a collection of arrays for scaling the intensity of the illumination pattern on the target surface without substantial modification of the illumination pattern by modular scaling of the arrays into a larger or smaller collection.
The array further comprises a plurality of circuit drivers, one for each device and where the plurality of circuit drivers are mounted on or attached to the carrier. The carrier comprises a printed circuit board to which the plurality of circuit drivers and devices are coupled, a cover for sealing the printed circuit board, circuit drivers and devices between the cover and carrier. The devices are optionally provided with a flange or an indexing flange and where the devices are angularly oriented with respect to the cover and carrier by the indexing flange. The printed circuit board, circuit drivers and devices are optionally sealed between the cover and carrier by means of a potting compound disposed between the cover and carrier in which potting compound the circuit drivers and devices as coupled to the printed circuit board are enveloped to render the array submersible.
Another embodiment of the invention is a luminaire for a street light to provide a predetermined illumination pattern on a street surface comprising a lighting fixture, and a plurality of arrays of light emitting devices disposed in the lighting fixture, each array for providing the predetermined illumination pattern on the street surface.
The array in the luminaire for providing a predetermined illuminated surface pattern comprises a plurality of light emitting devices for providing the predetermined illuminated surface pattern, each device having an identical energy distribution pattern which produces the predetermined illuminated surface pattern, a circuit driver coupled to each of the devices; and a planar carrier in which the plurality of light emitting devices are arranged to provide a spatially organization of the array to collectively produce a linearly additive illumination pattern matching the predetermined illuminated surface pattern.
In one embodiment each of the light emitting devices in the luminaire comprises a light source and a lens with a lens surface, the lens for providing the predetermined illuminated surface pattern from a predetermined energy distribution pattern of a light source, where the lens is characterized by an energy distribution pattern with two opposing sides, the lens surface comprising a complex prism defined as part of the lens surface, the complex prism being arranged and configured to transfer energy from one side of the energy distribution pattern to the opposing side to render the energy distribution pattern asymmetric with respect to the two opposing sides.
In another embodiment each of the light emitting devices in the luminaire comprises a light source and a lens with a lens surface, the lens for providing the predetermined illuminated surface pattern from a predetermined energy distribution pattern of a light source, the lens for providing an optical transfer function between the predetermined illuminated surface pattern and the predetermined energy distribution pattern of a light source, the lens having an undercut surface with a shape defined by the optical transfer function which shape is derived by generating an energy distribution pattern using the predetermined energy distribution pattern of the light source and then generating a projection of the energy distribution pattern onto the illuminated surface from the energy distribution pattern, which projection acceptably matches the predetermined illuminated surface pattern.
In one embodiment each of the light emitting devices in the luminaire comprises a light source and a lens with a lens surface, the lens for providing the predetermined illuminated surface pattern from a predetermined energy distribution pattern of a light source, the lens having an undercut surface, the lens having a base adjacent to the light source, a lens axis and a surface between the base and lens axis, the undercut surface extending from the base of the lens at least partially along the surface of the lens toward the lens axis to generate an energy distribution pattern using the predetermined energy distribution pattern of the light source which will then generate a projection of the energy distribution pattern onto the illuminated surface, which projection acceptably matches the predetermined illuminated surface pattern.
In another embodiment each of the light emitting devices in the luminaire comprises a light source and a lens with a lens surface, the lens for providing the predetermined illuminated surface pattern from a predetermined energy distribution pattern of a light source, the lens having a shape defined by the optical transfer function which is derived by generating an energy distribution pattern using the predetermined energy distribution pattern of the light source and then generating a projection of the energy distribution pattern onto the illuminated surface from the energy distribution pattern, which projection acceptably matches the predetermined illuminated surface pattern.
Another one of the illustrated embodiments is a luminaire for a street light to provide a predetermined illumination pattern on a street surface, the predetermined illumination pattern having a defined horizon, comprising a lighting fixture, and a plurality of planar arrays of light emitting devices disposed in the lighting fixture, each array for providing the predetermined illumination pattern on the street surface with substantial reduction of light directed from the luminaire to the horizon or above.
The illustrated embodiment of the invention is comprised of a light source, such as a light emitting diode (LED) and a lens. It is to be understood that for the purposes of this specification that a “lens” is to be understood throughout as an optical element which is capable of refraction, reflection by total internal reflecting surfaces or both. Hence, the more general term, “optic” could be used in this specification interchangeably with the term, “lens”. The lens is characterized by directing light from the light source into a smooth, broad beam, which when projected onto an illumined surface has a 50 percent of maximum foot-candle measurement at an angle greater than 15 degrees from the centerline of the illumination pattern, i.e. a 30 degree full width, half maximum. The lens comprises a transparent or translucent “blob-like” or dimpled-puddle shape, such as plastic or glass, that encompasses the light source or LED emitter to generate a high angle intensity wide beam without, in the preferred embodiment, adding any additional surface losses, either reflective or refractive than the LED would cause itself in this configuration of the invention. Almost all the energy of the LED is directed into the beam without losses much in excess of those generated by the LED without the lens deployed.
The lens comprises a transparent or translucent “blob-like” or dimpled-puddle shape, which produces a high angle intensity wide beam without adding any additional surface losses, either reflective or refractive than the LED would cause itself in this configuration of the invention. Almost all the energy of the LED is directed into the beam without losses much in excess of those generated by the LED without the lens deployed.
In one embodiment the lens is separate from the LED and is glued, affixed or disposed on the light source or original LED protective dome with an index matching material so as to virtually eliminate the seam or any optical discontinuity between the two. In another embodiment the lens is manufactured as the protective dome of the LED.
The lens is characterized by a “blob” zone which is a small concentrating zone that is formed along the desired primary director of the lens and light source. The blob zone comprises a surface portion of the lens which collects the light rays emitted by the LED and sends them along a predetermined direction dependent on the desired beam angle. The nearby surrounding surface portion of the lens also collects light from the LED emitter and bends it toward the preferential direction.
The blob zone comprises has a central forward cross-section which smoothly apportions light from a directed zone to the centerline. The portion of the lens which collects the peripheral light of the LED emitter either bends the light rays toward the preferential direction and/or internally reflects the light rays through the forward surface of the lens.
In one embodiment the lens produces a beam that is a function of the azimuthal angle of the beam and thus the lens has a cross-section which varies as function of the azimuthal angle around the optical axis. In the illustrated embodiment the azimuthal light pattern has a multiple lobed distribution of intensity.
In one embodiment of this type the lens also directs the beam in one or more directions offset from the projected centerline of the device. The lens includes additional surface shapes or a complexly shaped prism that add further control to the beam composition. Such additional surface shapes include facets, a multiple surface Fresnel type flattening of shape or prism, diffusing techniques or other lens surface enhancements, modifications or treatments.
One major advantage of a device of the invention is the ability to generate the required beam pattern with an array of LEDs which are mounted on a flat or planar plate, which most likely would be parallel to the street or floor. Thus eliminating the need for a complex armature. The illustrated embodiment further comprises a plurality of light sources or LEDs and corresponding lenses as describe above combined into a flat array of bars or plates to provide thermal and electrical distribution required for the LEDs as well as provide means for sealing the array from environmental damage. The apparatus further comprises circuitry to drive the LEDs included in the array. It is contemplated that each of the lenses are individually rotated to create a beam pattern for the flat array that is unique from the devices themselves, including all degrees of freedom, e.g. separately determined translation, tilt and yaw for each lens. The array could comprise similarly colored LEDs, white or otherwise, or optionally various colored LEDs.
The bars or plates each comprise an extruded or die-cast bar of aluminum or other thermally conductive material to which the LEDs are bonded directly, and a printed circuit board to connect the LEDs to a power source. In one embodiment the circuit board is laminated to the extruded or die-cast bar.
Each LED optionally incorporates a skirt, which is utilized to provide a sealed array with a cover, potting compound or other covering means.
The invention further comprises a method of providing a light pattern using any one of the devices or arrays described above.
While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of one embodiment of the invention in which a section line B-B is defined. This embodiment is radially symmetric.
FIG. 2 is the side cross sectional view depicted in FIG. 1 through section lines ‘B-B’.
FIG. 3 is a polar candela plot of the embodiment of the invention described in FIGS. 1 and 2 . The zero direction is the centerline of the device.
FIG. 4 is a side view of the embodiment of the invention described in FIGS. 1-3 showing a sample of rays traced from the source of the LED emitter through the al portion of the device.
FIG. 5 is a top view of another embodiment where the device is not radially symmetric. This view illustrates an embodiment which has two horizontally opposed lobes of the ‘blob’ lens.
FIG. 6 is an isometric view of the device of FIG. 5 more clearly describing its nonradially symmetric shape.
FIG. 7 is a side plan view of the device of FIG. 5 as seen parallel to section line D-D showing the reversal or undercut in the outline of the lens.
FIG. 8 is a side plan view that is rotated 90 degrees from the side view of FIG. 7 .
FIG. 9 is a cross-sectional view through section line ‘D-D’ of the device described in FIG. 5 . This cross-section shows the LED in addition to the lens.
FIG. 10 is the two dimensional iso-footcandle plot of the device of FIGS. 5-9 . This diagram illustrates the nonradially symmetric output of the device.
FIG. 11 is the iso-candela plot of the device of FIGS. 5-9 showing multiple plots of the device in different planes.
FIG. 12 is a side view of a ray tracing of the device of FIGS. 5-9 showing the rays traced from the LED emitter through the lens.
FIG. 13 is a side view of the same ray tracing shown in FIG. 12 , from a view azimuthally rotated 90 degrees from the view of FIG. 12 .
FIG. 14 is an exploded perspective view of a light module comprised of multiple devices of a preferred embodiment of the invention.
FIG. 15 is a perspective view of the assembled device of FIG. 14 , a flat modular light bar.
FIG. 16 is a perspective view of another preferred embodiment of the invention in which the device is asymmetric and creates a light pattern that is offset from a centerline of the LED.
FIG. 17 is a top plan view of the device of FIG. 16 .
FIG. 18 is a cross sectional side view of the device of FIGS. 16 and 17 as seen through section lines E-E of FIG. 17 .
FIG. 19 is a side plan view of the device of FIGS. 17-18 .
FIG. 20 is a side plan view of the device of FIGS. 17-19 as seen from a plane orthogonal to that seen in FIG. 19 .
FIG. 21 is a perspective view of another embodiment of the invention using a complexly shaped prism. This embodiment is for streetlight and similar applications. It is azimuthally asymmetric and is oriented in the figure to show the ‘curb’ side of the streetlight or that side to which less light is directed.
FIG. 22 is a rotated perspective view of the device depicted in FIG. 21 showing the ‘street’ side of the device or that side of the device to which more light is directed.
FIG. 23 is a ‘bottom’ view of the device of FIGS. 21 and 22 showing the ‘street’ side on the right of the view and the curb side on the left of the view.
FIG. 24 is a side plan view of the embodiment of the invention described in FIGS. 21-23 showing in phantom outline the LED on which the lens of the device is mounted.
FIG. 25 is a rotated side plan view of the device of FIGS. 21-24 orthogonal to the view of FIG. 24 .
FIG. 26 is a rotated side plan view of the device of FIGS. 21-25 orthogonal to the view of FIG. 25 .
FIG. 27 is a side view of a three dimensional iso-candela mapped plot of the output of a device of FIGS. 21-26 , clearly showing the azimuthally asymmetric output of the device. The ‘street’ side of the beam is depicted to the right in the drawing and the curb side to the left. The plot illustrates that the invention can create a beam profile that generates the full-cutoff beam type required by IES standards for roadway and outdoor lighting.
FIG. 28 is a rotated perspective view of the iso-candela map of FIG. 27 showing the output of the device as seen from the ‘curb’ side and from above the device. It shows the bias of the beam toward the street and down the curb line.
FIG. 29 is a two dimensional iso-foot-candle plot of the light beam projected onto the ‘street’ from a device of the invention. This shows the non-radially symmetric output of a device of FIGS. 21-26 . The designer has the freedom to control the shape of the lens to alter the output to match the requirements of the lighting task.
FIG. 30 is a cross-sectional view of a device of FIGS. 21-26 overlaid on a sample ray trace of the energy radiating from the LED emitter. The view of FIG. 30 is the mirror image of the view of FIG. 25 . This view is upside down with the ‘street’ side facing to the left and above and shows refraction and reflection of various surfaces of the lens.
FIG. 31 is a cross-sectional view of a device of FIGS. 21-26 overlaid on a sample ray trace of the energy radiating from the LED emitter. This is a view similar to the view of FIG. 24 . FIG. 31 is a cross-sectional view of the curb side of the device.
FIG. 32 is the cross-sectional view of the device of FIGS. 21-26 as seen through section lines F-F of FIG. 23 . This view illustrates the assembly of the device of FIGS. 21-26 with the LED.
FIG. 33 is a block diagram showing the steps of a method where a transfer function is employed.
The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before turning to the specifically illustrated examples shown in the drawings, we consider the various embodiments of the invention in more general terms. The illustrated embodiment of the invention uses light emitting diodes (LED), or other light sources, in a device that directs the energy from the LED into a smooth, broad beam. A broad beam can best be described as a beam which provides an illumination pattern on the surface intended to be illuminated, (e.g. the street, sidewalk, wall, etc.) that has a 50 percent maximum foot-candle measurement at an angle greater than 15 degrees from the centerline of the illumination pattern. This is referred to in the lighting field as the half-maximum point. A light source with a 15 degree half maximum measurement is also described as a 30 degree FWHM (Full Width, Half Maximum) light source.
Since light energy dissipates as the square of the distance from the source and there is additionally a cosine falloff based on the angle of incidence with respect to the illuminated plane, a wide angle beam of light requires considerably more intensity at high angles from its centerline than at its centerline. A good metric to use to analyze the required intensity is an iso-candela map. This radial map shows intensity verses degrees from the centerline of a light source or a luminaire.
The preferred embodiment of the invention has a transparent ‘blob-like’ or complexly shaped lens, most likely of plastic or glass, that optically modifies light from the LED to generate the high angle intensity required for the wide beam angles without adding much if any additional reflective or refractive surface losses, other than what the LED packaging causes itself. The complex shape of the lens is determined by a transfer function that is disclosed below. It is the lack of additional surface losses that allow the preferred embodiment of the invention to be extremely efficient. However, it must be expressly understood that the scope of the invention contemplates designs that may depart from this efficiency standard to accommodate manufacturing artifacts or other compromises for the sake of economic production. In the preferred embodiment of the invention the lens is ‘glued’ to the original LED protective cover with an index matching material so as to virtually eliminate the seam between the two. In another preferred embodiment of the invention the lens is integrally manufactured into the protective dome or cover of the LED package.
The ‘blob’ zone is a small concentrating lens zone that is formed along the desired primary director of the device. This blob zone of the lens collects the light rays emitted by the LED and sends them along a predetermined direction, i.e. the primary director, dependent on the beam angle desired by the optical designer. In the illustrated embodiment, the lens will be first considered to be a surface of revolution with a centerline or axis aligned with the centerline of the LED light pattern. However, additional embodiments will be disclosed where this azimuthal symmetry is broken. The nearby surrounding surface of the lens to the blob zone also collects light from the LED emitter and refracts it toward the preferential direction. The shape of the central forward cross-section of the lens gently apportions the energy in the segment from the directed blob zone to the centerline. The interior cross-sectional surface of the lens that is struck by the peripheral energy of the LED emitter is in a preferred embodiment undercut to either refract the light rays toward the preferential direction and/or internally reflect the light rays through the forward surface of the lens. The undercut surface of the lens is characterized by a smaller outer diameter defined from the centerline of the lens at the base of the lens than the outer diameter of the lens in the blob zone. In other words, the surface of the lens falls away or narrows at some point as the base of the lens is approached. Typically, an undercut surface could not be made in a single-piece mold, but would require a multiple piece mold for release. In the preferred embodiment of the invention, almost all the energy of the LED is directed into the radiated beam without losses in excess of those generated by the LED without the invention deployed. Again, this is not to be understood as a limitation of the invention, which may include embodiments where greater losses than the native LED losses are permitted for various economic or manufacturing conveniences.
One of the preferred embodiments of the invention generates a beam that has a differential of angles, and therefore intensities, in its two primary axes. In this instance the ‘blob’ cross-section of the lens varies as a function of the azimuthal angle about the centerline axis. This embodiment is intended for use in street lights and walkway lights or any use where there is a requirement for an asymmetrical or anamorphic beam. The iso-candela map of such a luminaire is nonuniform about its axes. Although it would be unusual, it is nevertheless contemplated within the scope of the invention that there could be more than two lobes along the opposing axes, such as a three, four or even more ‘blob’ axes.
One LED is hardly ever enough for a street light or parking lot light, so it is the preferred embodiment of the invention that a plurality of devices would be utilized in an array. It is expected that such an array might also be devised with two or more different ‘blob’ optical configurations to enhance the overall beam pattern. In the preferred embodiment, the array is disposed in a flat or planar arrangement as a module that can be readily scaled in size.
The device is generally described as being used in the field of general lighting illumination, but it could be used in niche markets in the field of lighting and illumination as well. Uses of the invention include, but are not limited to, street lighting, parking structure lighting, pathway lighting or any indoor or outdoor venues where a broad beam of light is desired, and is either azimuthally symmetric or biased in one or more axial directions. The illustrated embodiment can also be used to advantage in mobile lighting in vehicles, aircraft, trains, vessels and the like. The number and variety of applications in which use can be made are too numerous to even attempt to list.
While the drawings may describe what appears to be a simple concept, the short distance from a relatively large emitter to small surface presents many design challenges. Even a very small, 0.002″, change in surface position or curvature or small angle change, 0.05 degree, can throw the intended beam into disarray with bad visual artifacts or ‘rings’ in the resultant beam.
In another embodiment of the invention, a beam is generated that is offset in one or more axes from the projected centerline of the device. The resultant beam can be used, for example, to generate a Type III roadway lighting luminaire which requires a beam pattern that has its primary director to be offset from its nadir. The lens appears to be a freeform shape with cross-sections that that may have tilted lobes and surfaces that cause individual rays of the beam to refract in a skewed manner. In addition to the surfaces that define the majority portion of the beam, the embodiment also includes additional surface shapes, like a complex prism, that add further control to the composition of the composite beam. It is also anticipated that facets, Fresnel type flattening of surface shapes in the form of complex prism, diffusing techniques or other surface enhancements may be added to lens to obtain a certain effect within the beam.
The term, beam, is not often associated with highly divergent illumination devices, but it is used in this specification to describe the collectively formed output of the device, and is not necessarily limited a narrow beam of light.
Turn now to FIGS. 1-4 wherein the details of the illustrated embodiment of the invention depicted is azimuthally symmetric. FIG. 1 is an orthogonal top plan view of the device, generally denoted by reference numeral 10 . FIG. 2 shows the device 10 in a cross-sectional view in position on LED 1 , which is a conventional packaged LED. LED emitter 2 is positioned on the axis of the device 10 and in the embodiment shown the emitter 2 is centered in a hemispherical cavity (not shown) defined in a transparent, hemispherical protective dome 19 of the device 10 . In this embodiment the hemispherical cavity is filled with a material whose index of refraction matches that of the protective dome 19 of the LED 1 to virtually eliminate the cavity defining interior surface of dome 19 from causing any losses or providing any refraction. In FIG. 2 three solid angles or zones of interest, A, B and C, are depicted. These zones are for reference only and some embodiments of the invention may have more or fewer zones. As shown, zone A represents surface 5 of the lens 21 into which the forward solid angle of energy emitted from LED emitter 2 is collected, represented by rays 11 and 12 . Ray 11 is transmitted within the lens 21 from emitter 2 to the surface of lens 21 and ray 12 is the refracted into zone A through the surface of the lens 21 . Zone B represents the surface 4 of the lens 21 referred to as the ‘blob’ zone. This surface 4 is situated on either side of the intended main director 6 at the approximate angle of the beam's highest desired intensity. Zone C represents the undercut surface 3 which collects the remaining peripheral forward solid angle of energy from the LED emitter 2 as represented by rays 7 , 8 and 9 . Ray 7 is transmitted from emitter 2 to the surface 3 within lens 21 , is totally internally reflected as ray 8 and then is refracted by surface 5 as ray 9 . However, it must be understood that some or, if desired, most of the rays from emitter 2 incident on surface 3 will not be internally reflected, but intentionally refracted through surface 3 as peripheral rays.
Optional flange 13 can be of most any desirable shape and is utilized for sealing the device 10 and/or any proximate portion of a light module manufactured with the device as described below. The shape of flange 13 may be configured to provide for indexing or azimuthal alignment to a fixture in which device 10 of FIGS. 1-4 or particularly device 20 of FIGS. 5-9 , whose radiation pattern is not azimuthally symmetric, is set or may provide a snap fit connection of device 10 into the fixture.
In FIG. 2 , surface 3 of the depicted embodiment of the invention 10 can be designed to be either totally internally reflective (TIR) or refractive or both. Surfaces 4 and 5 are intended to be primarily refractive.
The method used to design the embodiment shown is to first select the primary director angle .delta. for the highest intensity, shown in the polar graph of FIG. 3 as point 14 . It has been determined by empirical testing that if this director angle passes much beyond 60-62 degrees from the centerline, the resultant effect is to limit the ability of the device 10 to perform its primary task of providing a significant increase in the iso-candela plot of the off-axis energy as shown by point 14 of FIG. 3 and still achieve the goal of a smooth, useful beam. In the embodiment of FIG. 3 the maximum intensity occurs at about 52 degrees off axis.
In cross-section, surface 4 of zone B is defined as an arc which has its center disposed along the director 6 . The radius and the start and end angles of the arc defining surface 4 are variables defined by iteration with the surface definitions of zones A and C. The surface 5 is defined as a concave refractive surface intended in this embodiment to ‘spread’ the central solid angle of energy from the LED emitter 2 outward from the centerline. The merge point of surfaces 4 and 5 between zones A and B is found by construction. In the embodiment shown, surfaces 4 and 5 are tangent to each other or smooth at the merge point. However, it is not a requirement of the invention that they be tangent. Surface 3 of zone C is also defined in the embodiment shown as a surface generated by a tangent arc. It could, however, be generated by a line of revolution of any shape or slope. By using the tangent arc for surface 3 of zone C, some of the emitted rays incident on surface 3 from emitter 2 refract outward and some are totally internally reflected and proceed through the forward surfaces 4 and 5 of zones A and B. By controlling the arc radius and the segment angle of surface 3 , the resultant beam can be defined in total and will include almost all the energy emitted by LED emitter 2 . Measurements have shown that the resultant beam can include virtually the same number of lumens into an integrating sphere as the original LED does without lens 21 .
Manipulation of the shapes of surfaces 3 , 4 and 5 of FIG. 2 can be performed until the desired intensity ratios and angles of intensity are represented in a polar candela distribution plot of the design as depicted in FIG. 3 . It must be understood that surfaces 3 , 4 and 5 could be represented by any number of differently shaped surfaces including one or more which are point wise defined, rather than geometric shapes in zones as depicted. It is within the scope of the invention that the shape of the profiles of surfaces 3 , 4 and 5 could be derived by computer calculation as a function of the desired beam profile as defined in the polar candela distribution plot and the resultant surface(s) profile used as the surfaces of revolution in the case of a radially symmetric design.
FIG. 4 shows the result of a ray trace of the device 10 of FIGS. 1 and 2 . The rays have been reduced to a small percentage of those traced to better show the effects of rays as they react to the surfaces 3 , 4 and 5 of each of the above described zones A, B and C. Of course, it is understood that light rays from a ray trace only simulate the effects of light energy from a light source.
FIG. 5 shows a three quarter perspective view of another preferred embodiment 20 of the invention whereby the resultant beam energy pattern' is not azimuthally symmetric. Circular lip 18 of FIGS. 6-9 represents a sealing feature that optionally allows the device 20 to be sealed when built into a light fixture or an array. The cross sectional view of FIG. 9 is taken through section line D-D of FIG. 5 . The top plan view of the device 20 is represented by the diametrically opposing ‘blob’ segments 14 and the diametrically opposing smoother side segments 15 azimuthally orthogonal to the blob segments 14 . It is easier to understand these profiles by looking at FIGS. 7 and 8 , which show the profiles of the segments 14 and 15 from both horizontal and vertical directions respectively, and FIG. 6 which shows the device 20 in a rotated oblique view that shows its elongated profile. It can be seen in FIG. 7 that the illustrated profile in this view is similar to the device 20 shown in FIGS. 1 and 2 . However, the similarity is lost when you examine the azimuthally orthogonal profile of FIG. 8 . The ‘blob’ shape in the embodiment of FIG. 7 is defined by multiple cross-sections of segments 14 and 15 rotated about the centerline 23 in which the surface of lens 21 is lofted between cross sections of segments 14 and 15 much like the lofting of a boat hull. By manipulating the shape of cross-sections of segments 14 and 15 , the ‘blob’ or lobed segment 14 is defined as well as the smoothing of surface segments between the diametrically opposing ‘blobs’ or lobes 14 . Lofting is a drafting technique (sometimes using mathematical tables) whereby curved lines are drawn on a plan between cross sectional planes. The technique can be as simple as bending a flexible object such as a long cane so that it passes over three non-linear points and scribing the resultant curved line. or plotting the line using computers or mathematical tables. Lofting has been traditionally used in boat building for centuries. when it is used to draw and cut pieces for hulls and keels. which are usually curved. often in three dimensions.
In the view of FIG. 9 it can be seen that the ‘blob’ or lobe segment 14 is defined similarly to the device 10 shown in FIG. 2 . The zones A, B and C of the embodiment of FIG. 9 are similar as are the rays 25 , 26 and rays 32 - 34 are similar to analogous rays 12 , 11 , 7 , 8 and 9 respectively of FIG. 2 . The undercut surface 31 as shown is flat, but it could be any shape or angle that provides the desired result. The undercut surface 31 of FIGS. 5-9 or surface 3 of FIGS. 1-4 differs from undercut surfaces which can be found in conventional total internal reflectors (TIR) in that the surfaces of the conventional TIR are located in what would be termed the far field of the LED and not its near field. In the present inventions surfaces 3 and 31 are near field surfaces in that they are optically closely coupled to the LED source and ideally have no air gap or at least no substantial air gap between the LED and the surface 3 or 31 . Further, in a conventional TIR the undercut surfaces are generally used as reflective surfaces and to the extent that there are refracted rays emitted through such surfaces, the rays are lost to the useful beam or what is the intended beam of light. In the present invention the undercut surfaces 3 and 31 optically contribute to the intend beam to a material degree, both in the reflected as well as the refracted rays incident on them.
LED emitter 29 is disposed approximately at the center of the hemispherically shaped surface 17 of FIGS. 7 and 8 , which matches the shape of dome 19 . LED package 28 and the device 20 are optionally bonded with an index matching material at surface 17 of lens 21 and the dome 19 of the LED package 28 . It is contemplated by the invention that the device 20 be incorporated in the production of the LED package 28 in an alternate embodiment whereby the manufacturer of the LED does not bond a separate lens 21 to the LED; however, the lens 21 of device 20 is the protective dome of the LED package 28 itself. In either case, the resultant devices 20 shall be very similar optically. The mechanical features at the base of the device are optional and may be utilized or not.
FIG. 10 shows a two dimensional iso-foot-candle plot of the output of the device 20 shown in FIGS. 5-9 . It shows the anamorphic shape of the output beam which is nearly two times the length/width ratio of a azimuthally symmetric beam of the embodiment of FIGS. 1-4 . FIG. 11 shows the polar iso-candela plot with overlaid angles of candela data. The plot 35 is the intensity distribution as seen in the horizontal plane of FIG. 7 , plot 38 is the intensity distribution as seen in the azimuthally orthogonal plane of FIG. 8 , and plot 36 is the intensity distribution as seen in a plane at 45 degrees or half way between the views of FIG. 7 and FIG. 8 . The maximum of intensity distribution pattern decreases as the view rotates from the plane of FIG. 7 to the plane of FIG. 8 as shown in the plots 35 , 36 and 38 and the decreases in angle or rotates upwardly from about 52 degrees to about 40 degrees off axis.
FIGS. 12 and 13 are ray trace plots of the device of FIGS. 5-9 . These plots show graphically the path of energy from the LED emitter 29 in the planes corresponding to FIGS. 7 and 8 respectively. As in the device 10 of FIGS. 1 and 2 , the surface of zone C of FIG. 9 is both refractive and totally internally reflective in this embodiment of the invention.
FIGS. 14 and 15 illustrate a further embodiment of the invention which incorporates a plurality of devices 21 or 20 of the invention by which a light module 40 is provided. This light module 40 , either individually or in multiple copies, can be the basis of a flat luminaire that is used for street lighting, pathway lighting, parking structure lighting, decorative lighting and any other type of spread beam application. Light module 40 is shown as a rectangular flat bar, but can assume any two dimensional planar shape, such as square, circular, hexagonal, triangular or an arbitrary free form shape. Inasmuch as light module 40 is flat it can be mounted in its corresponding fixture parallel to the two dimensional plane that it is intended to illuminate, such as the street, walk or floor. This results in the light be directed in a spread beam toward the useful two dimensional pattern for which it is intended and not skyward or in other nonuseful directions. The light module 40 is a very simple and low cost means to provide LED lighting to luminaire manufacturers where the light module 40 can be treated in the designs of as a single ‘light bulb’. With the addition of heat sinking and power incorporated on or into module 40 , the light module 40 can be easily incorporated into existing luminaires or integrated into new designs.
The exploded view of the light module 40 in FIG. 14 shows a disassembled conventional LED package 28 and the ‘blob’ lens 21 which is disposed onto LED package 28 . FIGS. 14 and 15 further show a flat heat dissipating carrier 41 to which the LEDs 28 are attached. The flat carrier 41 , which is typically made of metal, such as a heat conductive aluminum alloy, could provide just enough heat dissipation and conduction to allow proper cooling of the LED with the addition of a properly designed heat sink or other heat dissipating means, or the carrier 41 could be the entire heat sink or other heat dissipating means itself. A printed circuit board 46 is shown as a convenient means to provide power to the LEDs 28 , however it could be eliminated and the LEDs could be wired to each other directly. Additional means of conveying power to the LEDs 28 are contemplated by the invention. The wires 42 shown are just one means of providing power to the light module 40 . Connectors, sockets, plugs, direct wiring and other means are equivalent substitutes. The light module is covered by a molded component 43 or a co-molded cover 43 or any other means of providing a seal, such as a potting compound, or optionally no seal at all. An optional potting compound, which is forced or disposed between cover 43 and carrier 41 , is just one means of providing sealing for the light module 40 , rendering it in such an embodiment as waterproof or submersible. The assembled module 40 as shown in FIG. 15 can include hold down features, alignment features as well as other conventional features desired for implementation into a luminaire.
FIGS. 16-20 depict another preferred embodiment of the invention wherein the resultant ‘beam’ of light energy is directed in a skewed fashion with respect to the centerline of the device 20 . The beam can be defined as having ‘lobes’ of intensity that are not coincident with the primary axes of the device 20 . The device shown in FIG. 16 is similar to FIG. 6 in all respects with two exceptions, first there a complexly shaped prism 50 is provided on the top of lens 21 and the second is described as follows. As best shown in the top plan of FIG. 17 lobes 14 are similar to lobes 14 in FIG. 5 while the flattened sides 15 are slightly radially extended with a central bulge. Prism 50 is complexly shaped to provide a means for directing light in zone A into a direction which is more dramatically skewed relative to centerline 23 . In addition, as best shown in FIG. 20 the top surface 5 is angled off axis to further skew the light in the same general direction to which prism 50 is directed. Prism 50 has at least four separately definable surfaces, which in plan view vaguely resemble the top plan surface of a toilet and water closet. The surfaces are empirically determined by trial and error from the desired skewed polar candela plot and are strongly dependent thereon. Therefore, the surfaces of prism 50 will not be described in greater detail other than to specify that the net effect is to redirect the light incident on prism 50 from within lens 21 toward one side of the light pattern skewed relative to the centerline 23 .
Turn now to FIGS. 21-26 wherein another embodiment of the invention is depicted. FIG. 21 is a perspective view of the device, generally denoted by reference numeral 10 . FIG. 22 shows the device 10 in another perspective view. Optional flange 30 is shown to have a keyed shape that allow the lens 21 to be rotationally indexed in an assembly or fixture (not shown). The flange 30 may also be utilized to seal the LED housed in lens 21 into an assembly by a mating part (not shown) that interfaces or interlocks with the flange 30 . Optional seal 18 is shown as a part of the flange 30 and may be incorporated into it by many different means.
Surfaces 57 and 58 of lens 21 are utilized to direct the energy from the LED's peripheral beam, which is defined as the energy radiating in the solid angular zone from a horizontal plane parallel to the plane of the LED emitter to approximately 45 degrees from the perpendicular centerline of the LED emitter, while surfaces 51 , 52 and 59 direct the energy in the solid angular zone from the LED's centerline to approximately 45 degrees from the centerline, the primary LED director. One very important element of the invention is the zone of the lens 21 depicted by surfaces 51 and 70 . The surfaces 51 and 70 form the principle parts of a complex prism on the surface of lens 21 , which is called a “Pope's hat”. The solid angle zone of the light served by surfaces 51 and 70 takes the energy from the primary directed beam of the LED's ‘curb’ side and redirects it toward the ‘street’ side.
Optional surface 53 is a blended contour between surfaces 52 and 58 . Surface 57 is mirrored across intersection 54 in FIG. 23 and is lofted in the embodiment shown to redirect the centerline energy of the LED down the ‘curb’ direction and across the centerline. Surface 57 allows for very high efficiency for the lens 21 in both the street and the curb side of its light pattern.
In FIG. 23 , surface 52 is depicted as an azimuthally symmetric surfaced defined through an azimuthal angle of about 185 degrees. While this is desirable for some applications it is well within the scope of the invention that surface 52 and its adjacent surfaces may be azimuthally asymmetric. Surface 59 is an optional feature to redirect the centerline energy of the LED. Surface 59 can take of many different forms to allow the designer freedom to shape the beam. In the embodiment of FIGS. 21-26 the shape of surface 59 is utilized to allow for a continuation of the light spreading effect of surface 52 , but constrained to keep the thickness of the device 10 within manufacturing capabilities.
In FIG. 24 , interface 62 between dome 19 and lens 21 is utilized if the lens 21 is a molded optic separate from the LED. If the lens 21 of the device 10 were molded directly on or assembled by the manufacturer on the LED emitter, interface 62 does not exist. Interface 62 is comprised of the two mating surfaces of the LED dome 19 and the inside of the lens 21 . It would be most desirable if the interface were bonded with an index matching cement or a thixtropic index matching material were retained in interface 62 . Using an index matching material, optical measurements have shown that the resultant beam from the assembled device 10 can include virtually the same number of lumens into an integrating sphere as the original LED does without lens 21 .
The nadir 74 of the device 10 is shown in FIG. 27 as well as is the horizon 72 and the ‘street’ side angle marker 73 . The rays 70 of maximum candela of the resultant beam are illustrated in the rightmost portion of the drawing. FIG. 28 is a rotated three dimensional view of the same candela map as FIG. 27 and shows the plot as it would be seen from the curb side of the pattern at the bottom portion of the view. The ability of the various surfaces of lens 21 described in FIGS. 21-26 to throw or transfer energy from one side of the Lambertian output of the conventional LED to one side of the illumination pattern is graphically illustrated. Note also that all the rays are directed in FIG. 27 in a downward direction with little if any energy in the direction of horizon 72 or upward. Sky rays are virtually eliminated.
Manipulation or modification of the shape and position of surfaces 52 , 53 , 58 , 57 , 54 , 51 , 70 and others defining lens 21 as shown in FIGS. 21-23 can be performed until the desired intensity ratios and angles of candela are represented in a ray trace of the design as depicted in FIGS. 27 and 28 or modifications thereof according to the teachings of the invention. It must be understood that the lens surfaces could be represented by any number of separate surfaces including one or more which are defined by a point wise transfer function rather than geometric segmental shapes. It is entirely within the scope of the invention that the shape of the profiles of the lens surfaces could be derived by a computer calculation derived from a predetermined beam profile and the resultant lens surface(s) profile(s) then used as the cross-section(s) of various portions of the lens 21 according to the teachings of the invention.
FIG. 29 is a plot of the two dimensional distribution of energy as it strikes the surface of the ‘street’ below the device 10 . This plot generally would be described with iso-intensity contour lines in units of energy such as foot-candle or lux. The device 10 is centered in the drawing of FIG. 29 with the ‘street’ side to the right of center and the ‘curb’ side to the left of center. The plot is symmetry about a horizontal line running from the curb to the street with identical intensity patterns in the top and bottom portions of the drawing.
FIG. 30 is a ray tracing of the device 10 of FIGS. 21-26 as seen in a side view reversed from that shown in FIG. 25 . The rays have been reduced to a small percentage of those which could be traced to better show the effects of rays as they are redirected from the Lambertian pattern of the LED housed within lens 21 by the surfaces of the lens 21 . Rays 82 correspond to the rays directed by surface 52 . Rays 83 are directed by undercut surface 58 . FIGS. 24-26 show a small undercut portion of surface 58 which extends partially around the base of lens 21 . Surface 57 in the view of FIG. 25 has no or little undercut, while the basal portions of surface 58 have a small undercut which smoothly transitions into surface 57 . It should be noted in FIG. 30 that rays 80 which are redirected from surface 51 show that surface 51 is acting as a TIR reflector of the beam energy from the LED on the ‘curb’ side to transfer energy to the ‘street’ side. Rays 81 are refracted LED energy in a direction away from the centerline of the LED beam pattern. Stray rays 81 show losses which arise in the lens 21 as a result of manipulating the beam pattern.
The emitter 29 in the LED is assumed above to be a Lambertian emitter. The concept of using a ‘floating’ reflective surface on the ‘curb’ side of lens 21 to reflect light to the ‘street’ side of a lens 21 is expressly included within the scope of the invention even when using HID or other light sources with different emission patterns. Any kind of light source now known or later devised may be employed in the disclosed combination of the invention with appropriate modifications made according to the teachings of the invention. Wherever in this description the terms associated with streetlights are used, such as ‘street’ side or ‘curb’ side, they could be substituted with other terms that describe offset beam patterns in general.
FIG. 31 is another cross-section view of a ray tracing of the embodiment of FIGS. 21-26 as seen in a frontal view of FIG. 26 . The rays radiating from the side plan view of FIG. 26 are refracted toward the street surface. Rays 91 represents the energy from the LED in the primary zone refracted outward by the surface 52 of FIGS. 21-26 . Again few if any rays directed toward the horizon are present.
FIG. 32 is a solid cross-sectional view of device 10 as seen through line F-F of FIG. 23 . FIG. 32 shows an LED with emitter 29 with lens 21 optionally glued in place with the interface 62 or seam bonded with an index matching cement. The optional flange 30 can be seen as a sealing feature to mate with additional components of an assembly (not shown). Surface 57 represents the transition between the ‘street’ side profiles and the ‘curb’ side profiles of lens 21 that mainly refract light toward the street from the peripheral Lambertian beam of the LED. More particularly, surface 57 is divided into two subsurfaces by a centerline 54 in the embodiment of FIGS. 21 , 23 and 24 , which subsurfaces spread the light in the beam outward from the centerline 54 in larger angles. For example, if in one embodiment centerline 54 were perpendicularly oriented to the curb in a street light installation, the subsurfaces would spread the beam transmitted through surface 57 in directions more parallel to the curb and away from the centerline 54 . Surface 51 primarily reflects energy from the LED primary light direction from the ‘curb’ side toward the ‘street’ side.
FIG. 33 summarizes an overall conceptualization of the methodology of the invention. The problem solved by the invention is defined by two boundary .conditions. namely the light pattern of the light source which is chosen at step 100 and the two dimensional iso-foot candle plot which is to be projected onto the surface which is intended to be illuminated in step 106 . In the illustrated embodiment the problem of providing a wide beam street light pattern is assumed for the boundary condition of step 106 and the Lambertian pattern of an LED is assumed in the boundary condition 100 . Thus. it can readily be understood that the same problem defined by different characterizations of the boundary conditions of steps 100 and 106 are expressly included within the scope of the claimed invention. For example, if has already be expressly mentioned that boundary condition 100 need not assume the Lambertian pattern of an LED, but may take as the boundary condition the three dimensional energy distribution pattern of a high intensity discharge (HID) lamp. Light sources which do not assume the Lambertian pattern of an LED. like a high intensity discharge lamp are defined for the purposes of this specification as non-Lambertian light sources.
The problem then becomes recast as how to get the shape of a lens or optic 21 which provides the needed transfer function between the two boundary conditions of steps 100 and 106 , namely the three dimensional energy distribution pattern of the light source to the projected two dimensional illumination pattern for the target surface. The problem is nontrivial.
The solution for an asymmetric broad or spread beam has been disclosed in connection with FIGS. 1-32 above and the related specification. Once a three dimensional lens shape is determined at step 102 as shown in FIGS. 1-9 , 16 - 20 and 21 - 26 , the three dimensional candela plot as shown in FIGS. 11 , 27 and 28 and as suggested by the ray tracings of FIGS. 12 , 13 , 30 and 31 can be mathematically derived using conventional optical computer aided design programs, such Photopia® sold by Lighting Technologies of Denver, Colo., assuming the three dimensional energy distribution of the light source, e.g. a Lambertian distribution in the case of an LED.
Given the three dimensional candela plots, the two dimensional iso-foot candle plots of FIGS. 10 and 29 can be mathematically derived using conventional optical computer aided design programs. The results obtained are then compared to the boundary condition of step 106 . To the extent that the boundary condition of step 106 is not satisfied, the optical designer through trial and error can modify the three dimensional shape of lens 21 in step 102 and again repeat steps 104 and 106 in a reiterative process until the desired conformity with the target two dimensional iso-foot candle plot is obtained.
The invention also includes the methodology where the needed lens shape is rendered mathematically through an analytical process or numerically through a numerical reiterative estimation process with the boundary conditions of steps 100 and 106 as numerical inputs consistent with the teachings of the invention.
It can also thus be appreciated that a plurality of such devices can then be combined into an array of devices. Each device in the array has the same three dimensional energy distribution pattern that results in the same intended two dimensional illumination pattern on the target surface or street. When a plurality of such devices are closely spaced together in the array relative to the size of the illumination pattern on the target surface or street, their respective illumination patterns are substantially linearly superimposed on each other to provide the same illumination pattern on the target surface or street as produced by a single device, but with the increased intensity of the plurality of devices in the array. Similarly, the arrays can be manufactured in a modular fashion, so that a plurality of arrays combined together can still have a relatively small size compared to the distance to or the size of the illumination pattern on the target surface or street, that the illumination pattern of each array substantially overlays the same illumination pattern of all the other arrays in the collection. Hence, the intensity of the illumination pattern on the target surface from the collection of arrays can be scaled without substantial modification of the illumination pattern by modular scaling of the arrays into larger or smaller collections.
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations.
The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.
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An apparatus and method is characterized by providing an optical transfer function between a predetermined illuminated surface pattern, such as a street light pattern, and a predetermined energy distribution pattern of a light source, such as that from an LED. A lens is formed having a shape defined by the optical transfer function. The optical transfer function is derived by generating an energy distribution pattern using the predetermined energy distribution pattern of the light source. Then the projection of the energy distribution pattern onto the illuminated surface is generated. The projection is then compared to the predetermined illuminated surface pattern to determine if it acceptably matches. The process continues reiteratively until an acceptable match is achieved. Alternatively, the lens shape is numerically or analytically determined by a functional relationship between the shape and the predetermined illuminated surface pattern and predetermined energy distribution pattern of a light source as inputs.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 10/883,469, filed 30 Jun. 2004, which is related to U.S. patent application Ser. No. 10/883,466, now U.S. Pat. No. 7,396,479, also filed 30 Jun. 2004.
BACKGROUND
[0002] Electro-osmotic pumps operate on the principle that the application of an electric field across a pumping medium, in the presence of a liquid may cause the bulk of the liquid to flow through the pumping medium. This is based on the principle electro-osmotic flow. For the case of water in contact with silicon dioxide or glass, the solid surface may acquire a finite charge density known as an electrical double layer when in contact with the aqueous solution through the deprotonation of silanol groups. As a charge is applied across the pumping medium, the ions will flow from the anode to the cathode and drag the bulk of the aqueous solution with it, creating a positive flow.
[0003] Recently, electro-osmotic pumps have been proposed for use with microelectronic devices. For instance, published U.S. patent application Ser. No. 10/053,859 to Goodson, et al., Publication No. 2003/0062149, published on Apr. 3, 2003 describes using electro-osmotic pumps for thermal regulators for microelectronics devices. The electro-osmotic pump that may be used with microelectronic devices that are capable of generating high pressure and flow without moving mechanical parts and the associated generation of unacceptable electrical and acoustical noise.
[0004] U.S. Patent Application Publication No. 2003/0147225 to Thomas William Kenny, Jr. et al., describes a method for integrating thermal management of microelectronic devices within the microelectronic device. Therefore, instead of being an “add-on” device, the electro-osmotic pump may be integrated within the microelectronic device.
[0005] Published U.S. patent application Ser. No. 10/272,048 to Juan G. Santiago et al., Publication No. 2003/0085024, published on May 8, 2003 describes a method for removing excess gases from closed loop electro-osmotic pumps. The method includes using a gas permeable membrane, which removes and vents electrolytic gases generated by the fluid chamber within the electro-osmotic pump. A catalyst may be used to recombine the electrolytic gases to form a vapor product that may be vented or condensed back to a liquid. The condensed electrolytic vapors may then be passed through an osmotic membrane back to the fluid chamber.
[0006] Published U.S. patent application Ser. No. 10/384,000 to Thomas William Kenny Jr. et al., Publication No. 2003/0173942, published on describes an apparatus that integrates the power management module and a thermal management module, such as an electro-osmotic pump, may then be affixed directly to a power consuming microelectronic device.
[0007] Published U.S. patent application Ser. No. 10/385,086 to Kenneth E. Goodson et al., Publication No. 2003/0164231, published on Sep. 4, 2003, describes an apparatus for controlling the thermal management of a microelectronic device through electrically controlling the flow of cooling liquid through the pump to minimize the spatial and temporal temperature variations that may occur on the microelectronic device.
[0008] However, high-flow electro-osmotic pumps currently for use in microelectronic devices may be constructed using sintered packed-particle porous glass frits as the pumping medium. These glass frits may have a thickness of approximately one to four millimeters, a pore diameter of approximately 1 micrometer, a porosity of approximately 0.2 and a tortuosity of about 1.4. Unfortunately, these pumping medium characteristics may not be ideal for optimizing the pumping action of a high-flow, high-pressure electro-osmotic pump. For example, it may be desirable for the pumping medium to have a pore diameter significantly smaller than 1 micron, and the tortuosity values approximately unity to achieve increased flow rates and pressure per unit area for a given applied voltage. Furthermore, the fabrication of the packed porous oxide frits currently used for electro-osmotic pumps may not be compatible with standard microfabrication processes. These drawbacks may hinder the use of electro-osmotic pumps as effective cooling systems for current and future microprocessors and Microsystems.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 is a block diagram of porous silicon in accordance with some embodiments of the present invention.
[0010] FIG. 2 is a block diagram illustrating an exemplary electro-osmotic pump using porous silicon in accordance with some embodiments of the present invention.
[0011] FIG. 3 is block diagram illustrating an exemplary operating environment using some embodiments of the present invention.
[0012] FIG. 4 is a block diagram illustrating a cross-section of a porous silicon pumping medium in accordance with some embodiments of the invention.
[0013] FIG. 5 is a block diagram illustrating a pattern for forming pores interconnected with a support structure for generating porous silicon in accordance with some embodiments of the present invention.
[0014] FIG. 6 is a logic flow diagram illustrating a method for manufacturing porous silicon for use in electro-osmotic pumps in accordance with some embodiments of the present invention.
[0015] FIG. 7 is a logic flow diagram illustrating an alternative method for manufacturing porous silicon for use in electro-osmotic pumps in accordance with some embodiments of the present invention.
[0016] FIG. 8 is a logic flow diagram illustrating a method for bonding a single crystal silicon wafer to a polycrystalline silicon wafer in accordance with some embodiments of the present invention.
[0017] FIG. 9 is a logic flow diagram illustrating an alternative method for bonding a single crystal silicon wafer to a polycrystalline silicon wafer in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION
[0018] FIG. 1 is a block diagram illustrating porous silicon pumping medium 100 in accordance with some embodiments of the invention. The porous silicon pumping medium 100 may be used as a pumping medium for an electro-osmotic pump, which is described below. Although porous silicon pumping medium 100 may be commonly fabricated for such application as optoelectronic devices, electroluminescent devices, membranes, Bragg reflectors, Fabry-Perot filters, gas sensor, sacrificial layers in micro elector-mechanical (MEMs) fabrication, active biomaterial, anti-reflective coatings, and explosives, porous silicon pumping medium 100 has not been developed as a pumping medium for electro-osmotic pumps. The porous silicon pumping medium 100 may be fabricated from single crystal silicon 105 , which after the porous silicon fabrication process contains a number of pores 110 having a diameter, D. To be effective as a pumping medium for an electro-osmotic pump, the pumping medium should contain a large number of pores, while being very thin and having a tortuosity close to unity. Additionally, the diameter, D, of the individual pores 110 of the porous silicon may be in the range of approximately 0.1 microns to 5.0 microns. The pore diameter can be altered to obtain the desired flow rate and pressure for the pump application. This allows for the porous silicon to be able to have a pore density, that is, the number of pores per unit area, in the range of approximately thirty percent (20%) to approximately eighty percent (80%). The porous silicon pumping medium 100 may be fabricated to have a thickness, L, in the range of approximately 10 microns to 500 microns. Furthermore, because porous silicon may be fabricated using well-known microelectronic fabricating techniques, the thickness, L, of the porous silicon and consequently the length of the pores, may be readily controlled to tighter tolerances than may be achieved with conventional glass frits. For example, typical glass frits may have a thickness of approximately 1-4 millimeters. However, the conventional silicon fabrication process may allow the porous silicon to have a thickness, L, and subsequently the pore length, to be manufactured in the range of approximately 10 to 500 microns. Moreover, the conventional silicon fabrication process allows for the porous silicon to have a tortuosity, T, approximately equal to unity, which may be optimal for a pumping medium in an electro-osmotic pump.
[0019] The porous silicon pumping medium 100 may also be coated with an insulating liner material (not shown) in order to prevent current from passing through the solid structure of the porous silicon and to tailor the pore diameter to produce to desired pressure and flow requirements of the pump. Electro-osmotic pumps depend upon the creation an electrical double layer, which may be characterized by a quantity known as the Zeta potential. The Zeta potential may be altered by the choice of the liner material, and consequently a suitable liner material may be deposited on the surface and inside the pores of the porous silicon substrate. For example, the thickness of the liner material may be adjusted to provide a specific operating pressure and flow rate for the electro-osmotic pump. For instance, if the electro-osmotic pump requires a high operating pressure and a low flow rate, then the thickness of liner material deposited within the pores may be increased. Conversely, if the electro-osmotic pump requires a lower operating pressure and a higher flow rate, the diameter of the pores may be increased by reducing the thickness of the liner material. The liner material may be either an oxide, a nitride, or a polycrystalline layer which is subsequently oxidized. The insulating layer may also be a polymeric material such as parylene. In one embodiment, the liner material may be silicon dioxide (SiO 2 ), which may be grown by thermally oxidizing the porous silicon substrate. In another embodiment, the SiO 2 layer may be grown by depositing at least one layer of low pressure chemical vapor deposition (LPCVD) polycrystalline silicon and then subsequently oxidizing the layer of polycrystalline silicon. In yet another embodiment, the liner material may be silicon nitride (SiN 2 ), which may be deposited through standard LPCVD processes. The liner material may have a thickness in the range of approximately 0.1 microns to 5 microns.
[0020] FIG. 2 is a block diagram illustrating an exemplary electro-osmotic pump 200 in accordance with some embodiments of the present invention. The electro-osmotic pump 200 may include a container 205 that has a first chamber 210 and a second chamber 215 . The electro-osmotic pump 200 may also have a porous silicon pumping medium 100 that may separate the first chamber 210 and the second chamber 215 . A pair of electrodes 225 may be proximate to the porous silicon pumping medium 100 to allow a voltage to be applied across the porous silicon pumping medium 100 . In some embodiments of the present invention, the electrodes 225 may be made of platinum (Pt). The container 205 may then be filled with an aqueous solution, such as de-ionized water or alcohol. As an electric field is applied across the electrode pair 225 , mobile ions in the aqueous solution are forced by the electric field to migrate from positive electrode to the negative and electrode through the porous silicon pumping medium 100 . The flow of the mobile ions may be great enough through the porous silicon pumping medium 100 to force the bulk of the aqueous solution through porous silicon pumping medium 100 from the first chamber 205 to the second chamber 210 . The flow of the aqueous solution from the first chamber 205 to the second chamber 210 may create a pressure differential across the porous silicon pumping medium 100 , wherein the pressure in the first chamber 205 may be lower than the pressure in the second chamber 210 .
[0021] Because oxygen and hydrogen molecules may be generated at the pump electrodes 225 as the result of electrolysis when a voltage is applied across the electrodes 225 , the electro-osmotic pump 200 may also include a catalytic gas recombiner to recombine oxygen and hydrogen atoms into water. The majority of the hydrogen gas molecules may be dragged with the flow of the bulk aqueous solution out through an outlet valve 235 of the second chamber 210 and through the system. The hydrogen gas may then return to the first chamber 205 through the inlet valve 230 . Once inside the hydrogen gas will rise to the top of the chamber where it and the oxygen molecules may come in contact with the catalytic gas recombiner and reform as de-ionized water. Additionally, the electro-osmotic pump may also include a membrane 240 . The membrane may be a hydrophilic TEFLON® membrane or the like. The membrane 240 may allow at least some hydrogen gas molecules that escape from the aqueous solution in the second chamber 210 to pass back to the first chamber 205 and combine with the oxygen gas molecules in the presence of the catalytic gas recombiner to form de-ionized water.
[0022] Using the porous silicon pumping medium 100 as the pumping medium in the electro-osmotic pump may provide several advantages over glass frits, which are currently used as the pumping medium in electro-osmotic pumps. First, because the porous silicon pumping medium 100 may be made much thinner than glass frits, the electro-osmotic pump may be operated at a reduced operating voltage while producing a large electric field. For instance, if the electro-osmotic pump operates at a pressure of five pounds per square inch (psi), the pumping voltage may be between 20 and 50 volts, which is reduced from the pumping voltage required for conventional glass frits. Second, the thickness of the porous silicon pumping medium may be made much thinner and the area required to obtain a specified amount of flow may be smaller for the porous silicon pumping medium 100 than the thickness of conventional glass frits thereby decreasing the volume of the pump. Additionally, the pore diameters of the porous silicon pumping medium 100 may also be made much smaller than the pores in a conventional glass frit.
[0023] FIG. 3 is a block diagram illustrating a system 300 utilizing an electro-osmotic pump 200 in accordance with some embodiments of the present invention. The system 300 may be a closed loop system, which may include an electro-osmotic pump 200 , which pumps cooling liquid through the system, a heat exchanger 310 , and a heat rejector 315 . As an electric field is applied to the electro-osmotic pump 200 , ions in the aqueous solution within the closed system 300 move across the porous silicon pumping medium 100 . The ion drag of the aqueous solution may cause the bulk of the aqueous solution to be pulled through the system 300 . The aqueous fluid may then pass through the heat exchanger 310 , which may be attached to a microelectronic device 312 , such as a microprocessor, memory device, or any other integrated chip device that requires the removal of a large amount of heat during operation. As the fluid passes through the heat exchanger 310 , the heat generated by the operation of the microelectronic device 312 , may be absorbed by the aqueous solution passing through the heat exchanger 310 . The heated aqueous solution may then pass to the heat rejector 315 , where the heat may be dissipated from the aqueous fluid so that when the aqueous fluid leaves the heat rejector 315 , it is cooled. The cooled aqueous fluid may then flow back to the electro-osmotic pump 200 , where the aqueous solution may be pumped back through the system 300 . Thus, in this manner, the cooled aqueous solution may be continually passed through the system 300 to remove excess heat from the microelectronic device 312 .
[0024] FIG. 4 is a block diagram illustrating a porous silicon pumping medium 100 in accordance with some embodiment of the present invention. The porous silicon pumping medium 100 may be fabricated from a single crystalline silicon wafer, which is described below in detail. The porous silicon pumping medium 100 may include a number of porous silicon regions 410 , which may be rectangular is shape. Although the porous silicon regions 410 are described as being rectangular in shape, those skilled in the art will appreciate that the porous silicon regions 410 within the porous silicon pumping medium 100 may be any shape, such as square, circular, oval, or any other shape without departing from the scope of the invention. In one embodiment, the porous silicon pumping medium 100 may be divided into six rectangular porous silicon regions 410 and separated by rigid support 405 . Although the porous silicon pumping medium 100 is described as being divided into six porous silicon regions 410 , those skilled in the art will appreciate that the porous silicon pumping medium 100 may be divided into any number of porous silicon regions 410 without departing from the scope of the invention.
[0025] Porous silicon may be brittle and may easily break under the pressure created during the electro-osmotic process. For instance, if the entire porous silicon pumping medium 100 was made a single, continuous piece of porous silicon, the porous silicon pumping medium 100 may lack the mechanical strength to withstand the pressure difference created in the electro-osmotic pump. If the pressure difference between the input region and the output region of the electro-osmotic pump increases too much, the porous silicon pumping medium 100 may fracture. To prevent the porous silicon pumping medium 100 from breaking, the regions of porous silicon 410 may be separated by rigid support regions 405 . The rigid supports 405 may be used to provide strength to the porous silicon pumping medium 100 . The rigid supports 405 may be formed of solid silicon by applying an appropriate mask during the etching process. However, the rigid supports 405 may also include other materials, such as metals, polymers, ceramic, and the like either embedded in the silicon wafer or adhered to the silicon wafer.
[0026] FIG. 5 is a diagram illustrating an etching pattern 500 for forming the pores of the porous regions 410 of the porous silicon pumping medium 100 according to some embodiments of the present invention. Each of the porous regions 410 may be further broken down into smaller regions 505 that may be used to form nucleation sites for the pores in the porous silicon. The liner material may be etched away allow access to the silicon to form the individual pores. In one embodiment of the present invention, the smaller regions 505 may be squares arranged in a hexagonal array. The area between each of the smaller regions 505 may be masked with the liner material so that the silicon between the smaller regions 505 will not be etched away during the formation of the pores at each nucleation site within the smaller regions 505 . The silicon between the smaller regions 505 may provide the pore walls , which in turn may provide additional mechanical strength to the porous silicon pumping medium 100 .
[0027] The sides of each smaller regions 505 may be defined by a dimension A. In some embodiments of the present invention, the dimension A may be approximately two (2) microns. Additionally, the smaller regions 505 may have a center-to-center distance of dimension B. In some embodiments of the present invention, the center-to-center length, B, may be in the range of approximately three (3) microns to eight (8) microns. Although the dimensions A and B have been described as 2 microns and 3-8 microns, respectively, those skilled in the art will appreciate that other lengths may be use for the dimensions A and B as required to obtain the necessary area for the porous silicon and the required mechanical strength without departing from the scope of the invention.
[0028] FIG. 6 is a logic flow diagram illustrating a method 600 for manufacturing porous silicon in accordance with some embodiments of the present invention. Method 600 begins at 605 , with a standard crystalline silicon wafer. A liner material may then be applied to the surface of the silicon wafer so that the liner material may enclose the silicon wafer. Examples of liner materials may be thermally deposited oxides, such as silicon dioxide (SiO 2 ) nitrides, such as silicon nitride (SiN 2 ) that may be deposited on the silicon wafer using low pressure chemical vapor deposition (LPCVD) processes. However, those skilled in the art will appreciate that other insulating materials, such as titanium oxide (TiO 2 ), tin oxide (SnO 2 ), titanium nitride (TiN 2 ) and other oxides or nitrides may be used without departing from the scope of the invention.
[0029] At 610 , a photoresist layer may be deposited on front side of the silicon wafer to define a pattern for forming the porous silicon pumping medium 100 . The pattern may consist of an array of porous silicon regions 410 separated by a number of stiffener regions 405 . For example, in one embodiment, the geometric regions may be rectangular in shape regions and may be separated by regions of solid silicon to act as stiffener regions 405 to reinforce the porous silicon pumping medium 100 . Within each porous silicon region, an additional pattern 500 may be formed that may define the nucleation sites 505 for the individual pores. The pattern may consist of a number of geometric shapes. In one embodiment, the geometric shapes may be squares. Additionally, the geometric shapes may be rectangles, circles, ovals, pentagons, hexagons, or the like. The geometric shapes may be arranged in a predefined array. In one embodiment the geometric shapes may be arranged in a hexagonal pattern array. However, those skilled in the art will appreciate that other array patterns, such as a circular array, a pentagonal array, and the like, may be used without departing from the scope of the invention.
[0030] At 615 , the liner material on the front of the silicon wafer may be etched to reveal the silicon where the porous silicon may be formed. The liner material may be etched using an anisotropic reactive ion etcher, which is known in the art. Etching the silicon liner layer may be performed using a deep reactive ion etcher. Next, the photoresist layer may be removed using standard plasma/ash etch process or any other suitable process for removing photoresist films. Once the photoresist layer has been removed, the silicon wafer may be dipped in a solution of tetramethylammonium hydroxide or potassium hydroxide (KOH) for a predetermined period of time. For example, the silicon wafer may be dipped in the KOH solution for approximately 5 minutes. The KOH solution interacts with the exposed silicon at the areas defined by the mask for the nucleation sites 505 . The KOH solution may selectively etch the crystalline silicon along the 111 planes, which may cause a small inverted pyramid to form at each nucleation site 505 .
[0031] At 630 , the liner material on the backside of the crystalline silicon wafer may be etched to reveal the crystalline silicon to define the areas where the porous silicon may be formed. The liner material may be etched using a wet etch technique or standard plasma etching techniques
[0032] At 635 , the porous silicon may be formed in the silicon wafer using standard techniques. The standard techniques will vary depending on whether the silicon is n-type of p-type. For example, if the silicon wafer is formed from an n-type silicon material, a pair of contacts may be placed on the opposites sides of the backside of the silicon wafer. The backside of the silicon wafer may then be exposed to light to generate holes in the silicon wafer. Once the holes are generated, the voltage may be applied to the electrical contacts, while an etching solution, such as ethanol and hydrofluoric acid (HF) may be applied to the topside of the silicon wafer. The tips of the inverted pyramids act as electric field concentrators and define the location of each pore. In the presence of the electric field the HF may etch the crystalline silicon along the path of the holes to form the pores. The current may be applied for a period of time to reach a desired depth for the pores. In some embodiments of the present invention, the pores may be etched at a rate of approximately 1 micron per minute. Thus, in order to obtain a desired pore length of approximate 2-400 microns, the voltage across the silicon wafer would have to be maintained for approximately 2-400 minutes.
[0033] Alternatively, if the crystalline silicon is p-type, that is it is doped with an atom such as boron, then the back side of the silicon wafer would not have to be illuminated to create the holes. Rather, only a voltage would have to applied across the silicon wafer. Once again, a voltage may be applied to the electrodes while the top of the silicon wafer is covered with HF and ethanol. The HF will etch the silicon at the pore nucleation sites and follow the hole path downward through the crystalline silicon to create the pores.
[0034] During the pore formation, the process may be stopped before the HF etches through the backside of the silicon. If the formation of pores were to break through backside the silicon wafer, the HF may spill through the silicon wafer, which may lead to contamination of the production facility. Therefore, it may be desirable to stop the pore formation, so as to leave a layer of silicon approximately 5-100 microns thick on the backside of the silicon wafer to contain the HF solution. Once the etching of the pores has reached the required depth, the HF solution is discarded.
[0035] The liner material may then be removed from the front-side of the wafer after pore formation. The liner may be removed by using wet etching techniques such as using hot phosphoric acid if the liner is silicon nitride or using hydrofluoric acid if the liner is silicon dioxide. Dry etching techniques, which are described above, may also be used.
[0036] At 640 , some of the silicon on the backside of the silicon wafer may be removed to expose the porous silicon pumping medium 100 . The silicon may be removed using standard etching techniques, such as plasma reactive ion etching, lapping or chemical-mechanical polishing. Finally, at 645 , a liner material may be deposited on top of the porous silicon substrate and within the pores of the porous silicon. In some embodiments, the liner material may be SiO 2 , which may be created by thermally oxidizing the porous silicon. Alternatively, the SiO 2 may be deposited within the pores by first depositing at least one layer of nitride through low pressure chemical vapor deposition (LPCVD), or by adding at least one layer of polycrystalline silicon through LPCVD and then oxidizing the polycrystalline silicon layer through standard techniques. The liner material may also be a polymeric material such as parylene.
[0037] FIG. 7 is a logic flow diagram illustrating another method 700 for manufacturing porous silicon in accordance with some embodiments of the present invention. Whenever porous silicon is made on the order of less than 100 microns, the porous silicon wafer may become damaged when the backside of the silicon wafer is ground away to open the pores in the porous silicon. Another method for fabricating porous silicon may use the technique of bonding a silicon wafer to a polycrystalline wafer, which may act as a substrate during the formation of porous silicon. Once the porous silicon is formed, the polycrystalline silicon may be easily removed from the porous silicon wafer while reducing the number of porous silicon pumping mediums 100 that are damaged. Method 700 begins at 705 , in which a single crystal silicon crystal may be bonded to a polycrystalline silicon wafer. A polycrystalline silicon wafer may first be fabricated by casting and directionally solidifying individual silicon crystals, which may be characterized by multicrystallinity and low cost. The fabrication of the polycrystalline silicon wafer is described in U.S. Pat. No. 6,406,981, issued on Jun. 18, 2002, and herein incorporated by reference. The polycrystalline silicon wafer may have a thickness in the range of approximately 700 microns to 750 microns. The thickness of the polycrystalline silicon wafer should be sufficient to provide a stable base for the formation of the porous silicon in the single crystalline silicon wafer. Next, a layer of oxide is formed on the single crystal silicon wafer by standard thermal deposition techniques. The oxide layer may have a thickness of up to approximately 1000 Angstroms (A). An important factor is that the oxide layer should be of sufficient length to maintain the proper electrical resistance to allow porous silicon formation. If the resistance is too high, then one may not be able to produce enough current to generate the porous silicon. Although an oxide has been described as being the bonding material between the polycrystalline silicon and the single crystalline silicon wafer, other materials may be used, such as nitrides like silicon nitride (SiN 2 ) or carbon-based films without departing from the scope of the invention.
[0038] At 710 , the single crystalline silicon wafer, which may have a thickness in the range of approximately 600 microns to 800 microns, may then be bonded to the polycrystalline silicon wafer. At 715 , the single crystalline silicon wafer may be thinned down to a desired thickness. In some embodiments the single crystal silicon wafer may be thinned down to as little as 2 microns, however approximately 100 microns may be more typical for porous silicon. The silicon wafer may be thinned using standard grinding and polishing techniques. Next, at 720 , a liner material may be deposited on the wafer in preparation for patterning the single crystal silicon wafer. Examples of liner materials may be thermally deposited oxides, such as silicon dioxide (SiO 2 ) nitrides, such as silicon nitride (SiN 2 ) that may be deposited on the silicon wafer using low pressure chemical vapor deposition (LPCVD) processes. However, those skilled in the art will appreciate that other insulating layers, such as titanium oxide (TiO 2 ), tin oxide (SnO 2 ), titanium nitride (TiN 2 ) and other oxides or nitrides may be used without departing from the scope of the invention.
[0039] At 725 , a photoresist layer may be deposited on front side of the silicon wafer to define a pattern for forming the porous silicon pumping medium 100 . The pattern may consist of an array of geometric regions, which may define the areas where the porous silicon may be formed. The geometric regions 410 may be separated by a number of rigid support regions 405 to provide additional strength to the porous silicon pumping medium 100 . For example, in one embodiment, the geometric regions 410 may be rectangular in shape regions and may be separated by rigid support regions 405 of solid silicon to act as stiffener regions 405 to reinforce the porous silicon.
[0040] At 730 , the liner material on the front of the silicon wafer may be removed to reveal the silicon where the porous silicon may be formed. The liner material may be etched using a wet etch technique or standard plasma etching techniques. Next, the photoresist layer may be removed using standard plasma/ash etch process or any other suitable process for removing photoresist films.
[0041] At 735 , the porous silicon may be formed in the silicon wafer as describe above in FIG. 6 . However, instead of stopping the formation of the pores before the pores reach the backside of the silicon wafer, the pores may be formed throughout the entire length of the silicon wafer. The formation of the porous silicon may be stopped by the SiO 2 layer, as the HF solution may not be reactive with the SiO 2 layer. At 740 , the newly formed porous silicon may be removed from the polycrystalline silicon wafer by first grinding away the polycrystalline silicon wafer. Thus, the porous silicon may be formed without having to carefully grind the single crystalline silicon wafer to expose the pores. Next, the oxide may be etched away using standard chemical etching or plasma etching techniques. Finally, at 745 , a liner material may be deposited within the pores of the porous silicon. In some embodiments, the liner material may be SiO 2 , which may be created by thermally oxidizing the porous silicon. Alternatively, the SiO2 may be deposited within the pores by first depositing at least one layer of nitride through LPCVD, then adding at least one layer of polycrystalline silicon through LPCVD and then oxidizing the crystalline silicon layer through standard techniques.
[0042] FIG. 8 illustrates a logic flow diagram illustrating a method 800 for bonding a single crystal silicon wafer onto the polycrystalline silicon wafer in accordance with some embodiments of the present invention. Method 800 begins at 805 , in which the single crystal silicon wafer may be placed on the polycrystalline silicon wafer to be thermally fused to the oxide layer. At 810 , once the single crystal silicon wafer is placed on top of the polycrystalline silicon, the wafer may be heated to a temperature in the range of approximately 600 degrees Celsius to approximately 900 degrees Celsius. In one embodiment, the wafer may be heated to approximately 800 degrees Celsius. Once the proper temperature has been reached, the wafer may be held at the appropriate temperature for a predetermined period of time to fuse the oxide to the single crystal silicon. In some embodiments, the predetermined time may be in the range of approximately 3 minutes to approximately 7 minutes and then allowed to cool. In one embodiment, the predetermined time that the wafer is held at the appropriate temperature may be approximately 5 minutes. Finally, at 815 , the single crystal silicon wafer and polycrystalline silicon wafer may be cooled.
[0043] FIG. 9 is an illustration of a logic flow diagram illustrating an alternative embodiment for bonding the single crystal silicon wafer to the polycrystalline silicon using a layer transfer process in accordance with some embodiments of the present invention. The method 900 begins at 905 , in which the single crystal silicon wafer may have either hydrogen or helium ions implanted at a depth of approximately 2 microns below the surface of the silicon wafer. The hydrogen or helium ions may create voids at the depth below the surface, which may allow the silicon wafer to be cleaved at the location of the voids. At 910 , the single crystal silicon wafer is fused to the polycrystalline silicon wafer, using the method described above in accordance with FIG. 8 . At 915 , once the single crystal silicon wafer is fused to the oxide layer, the single crystal silicon may be cleaved at the hydrogen or helium ion interface created by the implantation of hydrogen or helium ions. A thin wafer of the single crystal silicon may be left on the polycrystalline silicon wafer. The thin wafer of single crystal silicon may have a thickness of approximately 2-3 microns, depending on how deep the hydrogen or helium atoms may have been imbedded.
[0044] Other alternative embodiments will become apparent to those skilled in the art to which an exemplary embodiment pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description.
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Various embodiments of the present invention comprise systems and methods of fabricating porous silicon. One application of such porous silicon is in the fabrication of electro-osmotic pumps and electro-osmotic pump substrates. The method can comprise operations performed on a silicon wafer. A liner material can be deposited on the silicon wafer, and a photoresist layer can be deposited on the liner material. The photoresist layer can be adapted to define a predetermined pattern on the silicon wafer. Then, porous silicon can be formed on the silicon wafer according to the predefined pattern. As a result, solid silicon can support porous silicon regions of the silicon wafer, providing a support structure for the pumping medium. Other embodiments, aspects, and features are also claimed and described.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a spinneret having a non-circular cross-section capillary orifice and process for using this spinneret in the production of polyamide yarns having a circular cross-section. In particular, the invention relates to a spinneret for extruding polyamide filaments and forming yarns comprised of the same filaments.
[0003] 2. Description of the Related Art
[0004] In the manufacture of polyamide multifilament yarns, especially nylon 66 yarns, the winding of the yarn must be stopped frequently to remove undesirable deposits found around the capillary exit side of the spinneret plate. If not removed these deposits build up to a thickness of a “few millimeters (per) week” according to Fourne ( Synthetic Fibers, Chapter 4, page 359, C. Hanser Publishers, Munich 1998.) Such deposits contributed to the filament bending or “kneeing.” The bending of a majority of the filaments, if not remedied, ultimately led to filaments breaks, yarn defects or unscheduled process interruptions and poor efficiency.
[0005] A remedy practiced in the art for filament bending or kneeing is to clean these deposits off the extrusion or spinneret plate on the capillary exit face. This cleaning process is also known as “spinneret wiping.” The cycle time between spinneret wiping events, where each event is necessitated by a build up of the undesirable deposits, is the spinneret wipe life. It is desirable from a process efficiency and continuity standpoint to have a longer spinneret wiping cycle or wipe life.
[0006] In general, the cross sectional shape of a filament is determined by the cross sectional profiled shape of the extrusion orifice. For example, in U.S. Pat. No. 5,432,002 a trilobate profile filament yarn is produced by means of a spinneret plate with multiple orifices of trilobate shape. Whereas, a circular profile filament yarn is produced by a spinneret plate, illustrated at 170 in FIGS. 1 a and 1 b with multiple orifices 100 of circular shape.
SUMMARY OF THE INVENTION
[0007] Applicants have observed that wiping cycles for production of trilobal profile filaments were in general longer times than those times observed for circular profile cross-section filaments. In particular, Applicants have observed that a non-circular cross-section spinneret capillary orifice (or extrusion orifice) with a cross-sectional area substantially the same as the area of a circular cross-section spinneret capillary, but having a perimeter measure greater than the perimeter of a circular cross-section spinneret capillary, provides greater time interval between spinneret plate wiping events. This non-circular cross-sectional shape of the extrusion capillary, when used to extrude filaments of circular cross-sectional shape, extends the spinneret wipe life by lessening the amount of thermal deposits. This thereby extends the time between wipe cycles. As a result of increased wipe life, the productivity of the process is increased.
[0008] Therefore, in accordance with the present invention, there is provided a melt extrusion spinneret plate having at least one capillary orifice for producing at least a single filament of circular cross sectional shape, said capillary orifice having a non-circular shape. Preferably, the capillary orifice has a profiled shape with at least five 5 radially arranged legs, and preferably up to twelve 12 legs. More preferred are eight radially arranged legs.
[0009] Further in accordance with the present invention, there is provided a process for making a nylon filament of circular cross sectional shape comprising the steps of: supplying a polymer to a spin beam where the melted polymer is passed to a spin pack and through a spinneret plate having at least a single capillary orifice of non-circular shape, extruding at least a polymer single filament with a jet velocity substantially the same as that jet velocity employed when using a circular cross-section capillary orifice, quenching the freshly extruded filaments with conditioned air, drawing the filament, and winding the filament.
[0010] Other objects of the invention will be clear from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 a is a representation in plan view of a prior art spinneret plate having a plurality of circular cross section extrusion capillaries.
[0012] FIG. 1 b is a representation in elevation view of a prior art spinneret plate having a plurality of circular cross section extrusion capillaries.
[0013] FIG. 2 a is a representation in plan view of the invention spinneret plate having a plurality of non-circular cross section extrusion capillaries.
[0014] FIG. 2 b is a representation in elevation view of the invention spinneret plate having a plurality of non-circular cross section extrusion capillaries.
[0015] FIG. 3 a is a representation of a prior art spinneret plate with a single circular cross section extrusion capillary.
[0016] FIG. 3 b is a representation of an invention spinneret plate with a single non-circular cross section extrusion capillary.
[0017] FIG. 4 is a schematic representation of a process in which the invention spinneret plate is useful.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Throughout the following detailed description, similar reference characters refer to similar elements in all drawings or figures.
[0019] In accordance with the present invention, there is provided an apparatus comprising a melt extrusion spinneret plate comprising at least a single non-circular capillary orifice for making a nylon filament of circular cross sectional shape. A schematic representation of a single capillary orifice is shown in FIG. 3 b. The non-circular capillary orifice of the spinneret plate for producing a single filament of circular cross sectional shape has a perimeter of non-circular cross sectional shape. The perimeter is characterized by a perimeter measure p c , and an extrusion area, wherein, the perimeter measure p c , is greater than either of: 2πR and 2πr. The extrusion area for the non-circular cross sectional shape orifice is greater than πr 2 and less than πR 2 . Herein, r is the radius of the largest circle inscribed by the orifice perimeter and R is the radius of the largest circle circumscribing the orifice perimeter. This relationship is represented in FIG. 3 b.
[0020] In accordance with the present invention, the non-circular capillary orifice of the preferred melt extrusion spinneret plate has a perimeter measure p c of about 2 to about 10 times greater than either of 2πR and 2πr. The non-circular capillary orifice of the preferred melt extrusion spinneret plate has about 5 to about 12 radially arranged legs.
[0021] In accordance with the present invention, there is provided a process for making a nylon filament of circular cross sectional shape. A schematic representation of the filament spinning process is shown in FIG. 4 . The process comprises the steps of supplying a molten polymer to a spin beam (comprising elements 150 , 160 and 170 ) where a molten polymer is passed to a spin pack. The molten polymer is represented at 140 , typically the polymer has an RV in the range of 45 to 60, is conveyed to the spin beam. The polymer is then forwarded by a meter pump 150 and fed at a controlled rate to a spinning filter pack 160 .
[0022] The polymer is then extruded through a spinneret plate 170 , shown in FIGS. 2 a, 2 b and 4 . The spinneret plate has at least a single capillary orifice 110 . The capillary orifices correspond to each individual filament comprising the yarn (as represented in side elevation by FIG. 2 b and plan view by FIG. 2 a ). FIG. 3 b is a representation the capillary orifices of the present invention as compared to a circular capillary orifice of the prior art represented in FIG. 3 a. The non-circular cross-section spinneret capillary orifices (or extrusion orifice) of FIG. 3 b is designed to have a cross-sectional area substantially the same as that area of a circular cross-section spinneret capillary, represented in FIG. 3 a. At the same time, the perimeter measure p c of the invention non-circular cross-section orifice is greater than the perimeter measure 2πR of a circular cross-section spinneret capillary having a radius R. Additionally, the invention orifice is characterized, in the process of the invention, as allowing the polymer extrusion velocity to remain the same as that for a circular extrusion orifice, represented in FIG. 3 a, with a substantially similar extrusion area. The polymer extrusion velocity is the same as the filament exit velocity from the spinneret capillary. In general, for a certain polymer throughput G (e.g. in grams per minute) per capillary, the following equation applies:
G=ρ (melt) D 2 (capillary) (π/4) v (extrusion) Equation 1.
In this equation, ρ is the polymer melt density (e.g. for melted nylon 6,6@290° C. equal to 1.0 gram per cm 3 ), D (=2R) is the diameter (equal to twice the radius) of the capillary assuming a circular orifice, and v is the velocity of the filament. The extrusion velocity is given by the following equation:
v (extrusion) =G (4/π) D 2 (capiliary) ρ (melt) Equation 2.
In combination, the perimeter increase in the capillary orifice of the present invention with an unaltered extrusion velocity is thought to provide a longer length of time between spinneret plate wiping events. In a preferred embodiment the polymer is extruded at a jet velocity in the range of 20 centimeters per second to 80 centimeters per second.
[0023] In the process of the invention, the freshly extruded filaments are quenched with conditioned air in the known manner. In this step, the individual filaments 200 are cooled in a quench cabinet 180 with a side draft of conditioned air 190 and converged and oiled with a primary finish, known in the art, at 210 , into a yarn. The yarn is forwarded by feed roll 220 onto a draw roll pair 230 where the yarn is stretched and oriented to form a drawn yarn which is directed by roll 240 into a yarn stabilization apparatus 250 , commonly used in the art and here optionally employed as a yarn post-treatment step. Finally, the yarn is wound up as a yarn package at 270 , at a yarn speed in the range of 4500 to 6500 meters per minute, and preferably 5000-6000 meters per minute. The yarn RV measured is about 51 to about 54. During the course of winding at these speeds any need to interrupt the process for the purpose of cleaning the exit side face of the spinneret plate dramatically affects the productivity. Essentially all product which could have been wound up is sent to waste while the spinneret plate is wiped.
[0024] Using the spinneret plate of the invention, having extrusion orifices of non-circular cross section, to spin filaments of circular cross sectional shape provides a process with a reduced need for spinneret wiping due to bent filaments. The number of bent filaments at the exit side 175 of the face of the spinneret plate 170 with the present invention may be counted directly by observation and recorded for a typical eight-hour shift after spinneret plate wiping. The record is indicative of how robust the process is from a bent filament production rate. Similarly, the spinneret wipe life expressed as the time for 10% of all single filaments in the yarn bundle to appear bent at the exit side of the capillary on the spinneret plate face is also recorded. Measuring the time to 10% bent filaments is performed directly by observation and a direct count by an operator illuminating the spinneret plate face within the quench cabinet.
[0025] The yarn produced according to the process represented by FIGS. 4 is a drawn yarn with elongation of 22 to about 60%, the boiling water shrinkage is in the range of 3 to about 10%, the yarn tenacity is the range of 3 to about 7 grams per denier, and the RV of the yarn can be varied and controlled well within a range of about 40 to about 60. The yarn is a dull luster multifilament polyamide yarn. A preferred nylon filament of the invention is delustered with a pigment such as titanium dioxide in an amount of 0.03 to 3 percent by weight.
[0026] A derived parameter characterizing the superior properties of this yarn is called the Yarn Quality and found by the product of the yarn tenacity (grams per denier) and the square root of the % elongation, as in Equation 3.
YARN QUALITY=tenacity×(elongation) 1/2 Equation 3.
The Yarn Quality is an approximation to the measure of yarn “toughness.” As is known to those skilled in the art, the area under the yarn load elongation curve is proportional to the work done to elongate the yarn. Where tenacity is expressed in terms of force per unit denier, for example, and the elongation expressed as a per cent change per unit of length, the load elongation curve is the stress-strain curve. In this case the area under the stress-strain curve is the work to extend the yarn or the yarn toughness. The yarn quality improvement provides an apparel polyamide yarn which is more acceptable in varied applications. These applications may include, without limitation, warp knit fabrics, circular knit fabrics, seamless knit garments, hosiery products and light denier technical fabrics.
TEST METHODS
[0027] Yarn tenacity and the yarn elongation are determined according to ASTM method D 2256-80 using an INSTRON tensile test apparatus (Instron Corp., Canton, Mass., USA 02021) and a constant cross head speed. Tenacity is expressed as grams of force per denier, the elongation percent is the increase in length of the specimen as a percentage of the original length at breaking load.
[0028] Yarn Quality derived from tenacity and elongation and is calculated according to Equation 3.
[0029] Polymer relative viscosity RV is measured using the formic acid method according to ASTM D789-86.
EXAMPLES
Example of the Invention
[0030] In an example of the invention, a yarn of 40 denier (44 dtex) and 13 filaments was prepared from a nylon 66 polymer of 51.5 RV which contained 1.5% by weight TiO 2 . This polymer was melted in an extruder and fed to a spinning machine (shown schematically in FIG. 4 .) which was used to prepare the yarn, by a process of quenching in conditioned air, converging and treating the yarn with a primary spinning oil, drawing the yarn using unheated godets, stabilizing the yarn with a heated fluid, interlacing the yarn and winding on at a speed of about 5300 meters per minute. The spinneret plate had 13 non-circular cross-sectional shape cross-sectionally shaped capillaries with 9 radially protruding “legs”, as shown in FIG. 3 b. The perimeter measure of a single capillary, represented in FIG. 3 a, was 120 micrometers. Under these spinning conditions, the jet velocity of the polymer through this capillary was 100 feet per minute (50.8 cm per second). During the course of preparing the example yarns the spinneret plate 170 on the capillary exit face 175 (in plan view by FIG. 2 a .) required wiping each 10 hours of yarn winding since at least 10% of the filaments were bent. The yarn produced had a circular cross-sectional shape. The RV, the tenacity and elongation of the wound up 40-13 yarn was measured. The RV was 52.5. The tenacity and elongation measurements were used to calculate a “yarn quality” parameter using Equation 3. The parameter is related to the yarn toughness or work needed to draw the yarn and found here to be 33.1.
Comparative Example
[0031] In a comparative example of the prior art, a yarn of 40 denier (44 dtex) and 13 filaments was prepared by treating a nylon 66 polymer (51.5 RV) was melted in an extruder and fed to a spinning machine which was used to prepare the 40-13 yarn, by a process of quenching in conditioned air, converging and treating the yarn with a primary spinning oil, drawing the yarn using unheated godets, stabilizing the yarn with a heated fluid, interlacing the yarn and winding on at a speed of about 5300 meters per minute. The spinneret plate had 13 circular cross-sectionally shaped capillaries, as shown in FIG. 3 a. The perimeter measure of a single capillary, represented in FIG. 3 a, was 22 micrometers. Under these spinning conditions, the jet velocity of the polymer through this capillary was 100 feet per minute (50.8 cm per second). During the course of preparing this circular cross-sectionally shaped yarn the spinneret plate 170 on the capillary exit face 175 required wiping each 1.5 hours of yarn winding, since at least 10% of the filaments were bent. The tenacity and elongation of the wound up 40-13 yarn was measured exactly as in the example of the invention. The measured RV was of this yarn was 52.5 RV as before. The tenacity and elongation were used to calculate a “yarn quality” parameter, which was found to be 31.5 using Equation 3.
[0032] As a result of these modifications to the perimeter measure, an increase of about 6 times, and the shape of the spinneret plate capillaries an increased productivity spinning process is realized. Most importantly, the need to interrupt the process continuity is reduced to about 2 times per 24 hour period from that of 6 or more times per 24 hour period.
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A melt extrusion spinneret plate has at least one non-circular capillary orifice for producing at least a single filament of circular cross-sectional shape. This non-circular cross-sectional shape of the extrusion capillary, when used to extrude filaments of circular cross-sectional shape, extends the spinneret wipe life by lessening the amount of thermal deposits, which extends the time between wipe cycles. As a result of increased wipe life, the productivity of the process is increased.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. § 120 and is a continuation-in-part of U.S. application Ser. No. 11/081,490, filed Mar. 16, 2005, which in turn claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/568,338, filed May 5, 2004.
FIELD OF INVENTION
[0002] This invention relates to treatment compositions, processes for using such compositions and treated articles.
BACKGROUND OF THE INVENTION
[0003] Over time, articles that comprise certain colored fibers, for example, garments and linens experience a color shift. In certain instances, such color shift may be perceived as fading or even a color change. It is believed that such color shift may due in part to the non-selective deposition of materials, such as brighteners, on such articles. Brighteners are typically found in laundry and fabric care products as consumers prefer that their white fabrics maintain there whiteness and such materials can make white fabrics appear whiter. Thus, as most consumers prefer that the color of their articles, including colors other white, remain unchanged, there is a need for compositions and processes that reduce and/or inhibit such color change.
SUMMARY OF THE INVENTION
[0004] The present invention relates to compositions and processes that can reduce and/or inhibit the color change that certain colored fibers under go and articles that are treated with such compositions and according to such processes.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0005] As used herein, the term “textile products” includes, unless otherwise indicated, fibers, yarns, fabrics and/or garments or articles comprising same.
[0006] As used herein, the articles a and an when used in a claim are understood to mean one or more of what is claimed or described.
[0007] As used herein, the term “DMDHEU derivatives” mean the reaction product of DMDHEU and a one or more materials comprising one or more moieties selected from the group consisting of primary amines, secondary amines, —OH groups and combinations thereof.
[0008] Unless otherwise noted, all component or composition levels are in reference to the active level of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources.
[0009] All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.
[0010] It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
[0011] All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
Process
[0012] Applicants recognized that the materials that may be at least in part responsible for fiber color shifts are negatively charged. Thus, while not being bound by theory, Applicants believe that the color change/shift of fibers can be reduced and/or eliminated by applying a negatively charged material to such fibers.
[0013] In one aspect a process comprising applying, to a fiber, based on total fiber weight, from about 0.1% to about 10%, from about 0.3% to about 8%, or even from about 0.5% to about 5% of a treatment composition comprising a material selected from the group consisting of:
(a) a reactive agent comprising one or more reactive moieties and one or more moieties that provide a negative charge; (b) a reactive agent comprising two or more reactive moieties and an agent that comprises one or more moieties that provide a negative charge; and (c) mixtures of (a) and (b)
is disclosed.
[0017] In one aspect, said treatment composition may comprise (a) above.
[0018] In one aspect, said treatment composition may comprise (b) above.
[0019] In one aspect, the weight ratio of said reactive agent comprising two or more reactive moieties and said agent that comprises one or more moieties that provide a negative charge may be from about 1:10 to about 10:1, from about 1:5 to about 5:1, or even from about 1:3 to about 3:1.
[0020] In one aspect, said reactive agent comprising one or more reactive moieties and one or more moieties that provide a negative charge comprises a polycarboxylic acid.
[0021] In one aspect, said reactive agent comprising one or more reactive moieties and one or more moieties that provide a negative charge is selected from the group consisting of butanetetracarboxylic acid, polymaleic acid, succinic acid, malic acid and mixtures thereof.
[0022] In one aspect, said reactive agent comprising two or more reactive moieties is selected from the group consisting of dimethyloldihydroxyethylene urea (DMDHEU), DMDHEU derivatives, di-carboxylic acids, multi-carboxylic acids for example, butanetetracarboxylic acid, polymaleic acid, and mixtures thereof, and said agent that comprises one or more moieties that provide a negative charge comprises a moiety selected from a sulfonic group, carboxylic acid group, sulfuric group, phosphoric group, sulfide group and combinations thereof.
[0023] In one aspect, for (b) above, said agent that comprises one or more moieties that provides a negative charge comprises a sulfonic group.
[0024] In any of the foregoing aspects, a catalyst may be employed.
[0025] In one aspect, a process comprising applying, to a fiber, based on total fiber weight, from about 0.5% to about 5% of a treatment composition comprising a material selected from the group consisting of:
a.) a reactive agent comprising one or more reactive moieties and one or more moieties that provide a negative charge, said reactive agent comprising a material selected from the group consisting of butanetetracarboxylic acid, polymaleic acid and mixtures thereof; b.) a reactive agent comprising two or more reactive moieties, said reactive agent comprising dimethyloldihydroxyethylene urea and said agent that comprises one or more moieties that provide a negative charge comprises a material selected from the group consisting of aminomethanesulfonic acid, taurine, isethionic acid and mixtures thereof; and c.) mixtures of (a) and (b), and d.) a catalyst selected from the group consisting of acids, latent acids and mixtures thereof
is disclosed
[0030] Treatment may occur at any time but typically occurs prior to the fiber being used by the end user. Said treatment may occur in a textile mill. Such application step may comprise an operation selected from saturating, spraying, padding, exhaustion and combinations thereof. When said treatment's application step comprises padding, a sufficient amount of said textile treatment composition is typically removed from said textile product to achieve a wet pick-up of from about 30% to about 200%, from about 50% to about 150% or alternatively from about 60% to about 120%. When said treatment's contacting step comprises spraying, a sufficient amount of said textile treatment composition is typically removed from said textile product to achieve a wet pick-up of from about 10% to about 150%, from about 15% to about 100% or alternatively from about 20% to about 80%.
[0031] Useful equipment for practicing the method disclosed herein includes standard textile processing equipment including but not limited to batch, semi-continuous and continuous processing equipment and combinations thereof.
Treated Articles
[0032] Articles comprising fibers having a deposition resistance to the deposition of materials such as brighteners may be made by treating, at a minimum, the article's fibers with a composition disclosed herein. In one aspect, only a portion of said fibers may be treated. In short, fibers may be selectively treated as certain colors, such as white, may benefit from brightener deposition. In another aspect all of such fibers may be treated. Such fibers may be treated before in corporation into said article, during incorporation into said article and/or after incorporation into said article. Treatment methods include the methods disclosed in the present specification.
Treatment Compositions
[0033] Useful treatment compositions include the compositions detailed in the present specification including the process description, examples and claims. Such compositions may comprise an adjunct ingredient.
[0034] Useful reactive agents comprising one or more reactive moieties and one or more moieties that provide a negative charge include polycarboxylic acids. For example, butanetetracarboxylic acid, polymaleic acid, succinic acid, malic acid and mixtures thereof.
[0035] Useful reactive agents comprising two or more reactive moieties include dimethyloldihydroxyethylene urea (DMDHEU), DMDHEU derivatives, butanetetracarboxylic acid, polymaleic acid, other di or multi-carboxylic acids and mixtures thereof.
[0036] Useful agents that comprise one or more moieties that provide a negative charge include agents that comprise one or more of the following groups: sulfonic groups, carboxylic acid group, sulfuric group, phosphoric group, sulfide group and combinations thereof. For example, aminomethanesulfonic acid, taurine, isethionic acid and mixtures thereof.
[0037] Useful catalysts include acids, latent acids and mixtures thereof. For example, magnesium chloride for DMDHEU and its derivatives, and sodium hypophosphite for carboxylic acid reactive agent. Such catalyst may be formulated together with reactive agents or be added separately during applications.
[0038] Such agents and catalysts can be obtained from Aldrich, P.O. Box 2060, Milwaukee, Wis. 53201, USA.
[0039] In one aspect of Applicants' invention, such textile benefit compositions do not contain one or more of the following adjuncts materials: bleach activators, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, perfumes, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. Useful carriers may comprise water. For, example, a useful carrier is water.
[0040] The skilled artisan can produce the compositions of the present invention by following the teachings contained herein and in the examples as such compositions may be made by combining the requisite materials.
[0041] Commercial quantities of such compositions can be made using a variety of reaction vessels and processes including batch, semi-batch and continuous processes. Such equipment may be obtained from a variety of sources such as Lodige GmbH (Paderborn, Germany), Littleford Day, Inc. (Florence, Ky., U.S.A.), Forberg AS (Larvik, Norway), Glatt Ingenieurtechnik GmbH (Weimar, Germany), Niro (Soeborg, Denmark), Hosokawa Bepex (Minneapolis, Minn., USA).
Adjunct Materials
[0042] While certain embodiments of Applicants textile benefit compositions do not contain one or more of the adjunct materials listed herein, as such adjuncts are not essential for the purposes of the present invention, other embodiments may contain one or more adjuncts illustrated hereinafter. Such adjuncts may be incorporated in the textile benefit compositions disclosed herein, for example to assist or enhance cleaning performance, or to modify the aesthetics of such compositions as is the case with perfumes, colorants, dyes or the like. The precise nature of these additional components, and levels of incorporation thereof, will depend on the physical form of the textile benefit composition and the nature of the operation for which it is to be used and applied. Useful adjunct materials may include, but are not limited to, bleach activators, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, perfumes, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments.
EXAMPLES I-IV
[0043] Textile benefit compositions having the following formulae are made in accordance with the method described below.
Trade Example 1% Example 2% Example 3% Example 4% Material name/Supplier Formula Formula Formula Formula butanetetracarboxylic acid Aldrich 2.00% 1.00% 0.00% 0.00% polymaleic acid Monomer sourced 0.00% 0.00% 2.00% 0.00% from Aldrich. Made in house dimethyloldihydroxyethylene Freerez 0.00% 0.00% 0.20% 3.00% urea 845/Noveon, Ohio aminomethanesulfonic acid Aldrich 0.00% 0.00% 1.00% 1.00% taurine 0.00% 1.00% 0.00% 1.00% magnesium chloride Aldrich 0.00% 0.00% 0.00% 1.00% sodium hypophosphite Aldrich 0.50% 0.40% 0.75% 0.00% Wetting Agent LEOPHEN ™ N- 0.10% 0.10% 0.10% 0.10% AM/BASF Water Balance Balance Balance Balance Solution pH (adjusted by 3 3 3 4 acetic acid)
[0044] For each of Examples I-IV the requisite components are pre-dissolved and then combined in a standard batch mixing vessel.
[0000] Fabric Treatment
[0045] Four lots of fabric samples are obtained and each lots is soaked with one of the compositions of Examples I-IV of above. The fabrics are then padded via Mathis Padder (Model #HVF 52200) at 3 bars of pressure with at a rate of 2 feet per minute. The wet pick-ups are in the range of 75%-100% on weight of fabrics. Fabrics are then dried at 50° C. for 2 hours before curing. These fabrics are cured on a continuous feed dryer for 4 minutes at 150° C. oven space temperature.
[0046] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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The present invention relates to compositions and processes that can reduce and/or inhibit the color change that certain colored fibers under go and articles that are treated with such compositions and according to such processes. Such fibers may be treated in whole or in part, and may be treated before, during or after incorporation into an article such as a garment or linen.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to circumferential movement filed especially to all circumferential movement devices such as transport vehicle, toy vehicle, space vehicle, blender etc, as well as all energy-saving vehicles utilizing gravitational force.
[0002] For all traditional vehicles, their structures and driving methods are so unreasonable that they cannot sufficiently utilize gravitational force. Disclosed in the China patent application No.: 200310112992.9, a self-balanced vehicle comprises a driver cab, a pair of wheels and a pedal driving mechanism. This kind of vehicle is not safe and can not park stably. Its driving method is unreasonable and laborious and it has not any generator driving device. As described in the china patent application No.: 200410030581.x, the FIG. 70-71 show a gravitation vehicle, which consists of a driver cab, a pair of wheels and an electric generator. The vehicle has a monotonic shape. The structures and driving methods of space vehicle, toy vehicle and robot are unreasonable and laborious and waste energy. The structures and driving methods of the traditional circumferential movement device such as ball mill, concrete blender, mixing machine, rolling machine and washing machine and so on are unreasonable and laborious and do not utilize gravitational force and waste energy. The braking effect of the traditional motor vehicle is bad and unsafe.
BRIEF SUMMARY OF THE INVENTION
[0003] The object of the present invention is to provide circumferential movement devices with new structures and new driving methods, including vehicles with new structures and corresponding driving methods, braking methods and steering methods etc. The devices can utilize gravitational force sufficiently and shall be safe, saving and high efficient. The device can be used in all circumferential movement devices such as transport vehicle, toy vehicle, space vehicle and blender and so on.
[0004] The present invention is based on the theory Circumferential Law, which is founded by the inventor of the present invention. The Circumferential Law includes the following contents:
[0005] The First Law: in a gravitational field, a circumferential substance with even mass touches on a hard and horizontal supporting surface at some points or in line in an ideal manner, the gravitational force divides the mass of the circumferential substance into two equal parts, the interface of the two parts of said mass is said as Gravitational Plane.
[0006] If the circumferential substance is spherical, its Gravitational Plane is at any section plane which passes the centre of the circle. If the circumferential substance is cylindric, the Gravitational Plane is at any radial section plane which passes the centre of the circle.
[0007] The two gravitational forces at the two sides of the Gravitational Plane are equal but along two opposite directions, so the two gravitational forces balance each other. One gravitational force is resistance force to the other gravitational force. As the circumferential substance is moving, there is always a gravitational force as a resistance force and the other gravitational force as a driving force.
[0008] The strength of the inertia of the circumferential substance is irrelevant with its mass. No matter how much the mass is, the force that conquers the motionless inertia is larger than zero, and the force that conquers the motion inertia is larger than the outside force that it is acted upon.
[0009] The Second Law: for the circumferential substance according to the First Law, the strength of the acceleration is in direct ratio to the force that is acted upon and irrelevant with its mass. Any circumferential substance with different mass shall gain the same acceleration, if it is acted upon by the same outside force.
[0010] Under the circumstances, the formula f=ma shall not be correct, that is, f≠ma.
[0011] If the horizontal supporting surface disclosed in the First Law is changed into a descended surface, for a circumferential substance on the descended surface, its Gravitational Plane does not pass the centre of the circle. The two mass of the two parts at the two sides of the Gravitational Plane are not equal, so the gravitational forces of the two parts are not equal. A certain gravitational force shall become a driving force. The strength of the acceleration is in direct ratio to the force that is acted upon and in direct ratio to the mass.
[0012] If the horizontal supporting surface disclosed in the First Law is changed into an ascended surface, for a circumferential substance on the ascended surface, its Gravitational Plane does not pass the centre of the circle. The two mass of the two parts at the two sides of the Gravitational Plane are not equal, so the gravitational forces of the two parts are not equal. A certain gravitational force shall become a resistance force. The strength of the acceleration is in direct ratio to the force that is acted upon and in inverse ratio to the mass.
[0013] The Third Law: for the circumferential substance according to the First Law, when a force acts upon it:
[0014] if the fulcrum of the force is on the ground, the center of gravitational force is at the centre of the circle, the force point is at the top of the circle; When the power arm is equal with the resistance force arm, half of strength of the force shall be saved;
[0015] if the fulcrum of the force is on the ground, the center of gravitational force is under the centre of the circle, the force point is at the top of the circle; When the power arm is longer than the resistance force arm, more than a half of strength of the force shall be saved.
[0016] if the circumferential substance by swing structure supporting an object, the object can swing on the circumferential substance, the Gravitational Plane swings together with the swing structure. More than a half of gravitational force shall become a resistance force or a driving force. The force that conquers the motionless inertia of the circumferential substance or the object is larger than the friction force of the swing axes.
[0017] The even mass is an ideal condition, in fact, the Circumferential Law shall be applied for some circumferential substances with uneven masses. Said circumferential substance includes sphere, cylinder and wheel and so on, also includes noncircumferential substance with an arched bottom surface. The movement manner is swaying or swinging. Said hard and horizontal supporting surface means an ametabolic and horizontal supporting surface.
[0018] Said ideal condition means that the supporting surface is not depressed. The touched radius of the circumferential substance does not become short. The touched radius is equal with the own radius, the ratio is 1. In ideal condition, the resistance force of the circumferential substance is zero. In unideal condition, the supporting surface is depressed, the touched radius is shorter than the own radius, the ratio is smaller than 1. The ratio is smaller, the resistance force of the circumferential substance is larger. Said “the touched radius” refers to the radius from the centre of the circle to the supporting surface. Said “the own radius” refers to the radius which the circumferential substance itself owns.
[0019] Said Gravitational Plane refers to the interface of the two gravitational forces along two opposite directions. The Gravitational Plane passes the line which connects the points or the line of the supporting surface and the centre of the circle. The Gravitational Plane is invisible but existent. The First Law is called as Gravitational Plane Law and also applied to some noncircumferential substance, such as the moving of a human body is the moving of the two gravitational forces at the two sides of the Gravitational Plane of the human body.
[0020] The Circumferential Law tells us: in theory, no matter how much the mass of the circumferential substance is, the force that conquers the motionless inertia is larger than zero. Since a force larger than zero can drive any circumferential substance with any mass running, we should be able to create some tools to serve the human society.
[0021] According to Circumferential Law, the applications of this invention shall be introduced as the following.
[0022] 1. Integrated vehicle. An integrated vehicle is combined by its wheels and vehicle body to become a whole. The vehicle body shapes as cylinder, square or polygonal canister. The vehicle body shall keep a certain distance from the road surface so as to ensure the movement of the vehicle. Wheels are to be installed at the middle or two ends of the vehicle body and shall be rotated with the vehicle body at same time in movement.
[0023] Such vehicle may has one wheel only and to be installed at the middle of the surface of the vehicle body; or such vehicle has one wheel only, the width of tire reaches to ⅓ of the width of the vehicle body or above; or the tire shall include tire and part of rim. Such tire shall include all kinds of tires of Plea Known Technology.
[0024] The tire surface shall be in sufficient width to ensure the vehicle drives on road placidly. Or the whole vehicle is just a wheel. Or several wheels can be installed on the surface of the vehicle.
[0025] Or, two or two group wheels are to be installed at two ends of the vehicle body. The two ends of the body shall include the surfaces of two ends and the positions near the two ends.
[0026] The width of tire can be preset according to Plea Known Technology. One tire can be comprehended as one group tires, i.e. one tire can be substituted by two or above tires to play the role of one tire. Tire is installed on the body and is rotated with the body as well as the cargo inside the vehicle together.
[0027] The width of tire can be preset according to Plea Known Technology. One tire can be comprehended as one group tires, i.e. one tire can be substituted by two or above tires to play the role of one tire. Tire is installed on the body and is rotated with the body as well as the cargo inside the vehicle together.
[0028] The wheel includes tire and rim; here, rim includes all parts inside the tire of the wheel. But, the wheel which is installed on the integrated vehicle shall have tire only, or has tire and part of rim. The vehicle body can replace part or all rim. The wheel may include tire and part of rim.
[0029] No driving force is needed when the vehicle drives downgrade, only the driving force greater than zero is needed when the vehicle drives on flat ground theoretically, when upgrade, more energy can be saved than other vehicles with Plea Known structure due to it can utilize the gravity force better. Such vehicle is comparatively suitable to carry water, oil, cement, sand, slurry, coal, and ore, etc, and there are inlet and outlet of cargo.
[0030] A trailer rack can be installed on the integrated vehicle to be used as a trail car, the integrated vehicle is rotated relative to the trailer rack on its axis, and the trailer rack connects with the motive vehicle, the trailer rack moves on by dragging of the integrated vehicle. The integrated vehicle can be used as boxcar of a train. Several integrated vehicle with the trailer tracks can be run as a train, such train shall at least include a head and several boxcars with trailer racks and pothooks, these boxcars move and be dragged by the head.
[0031] The integrated vehicle may be driven by the engines and transmission device with Plea Known technology. There is a trailer rack on the vehicle body, the trailer rack shapes as a frame and carries one or more trailer wheels. The trailer wheel adopts Plea Known technology. An engine is fixed on the trailer rack and a transmission device is fixed on the vehicle body to receive the transmission force from the engine. For example, a rubber roller with Plea Known technology transmits the driving force to the integrated vehicle; an electromotor is fixed on the top of the trailer rack, a rubber roller is on the axis of the electromotor, there is a rubber loop on the vehicle body to receive the friction from the rubber roller, the rubber roller drives the rubber loop and pushes the vehicle to move together.
[0032] Gear wheel or gear hole driving with Plea Known technology are also be available. China Patent application number 200410030581.x<A Sort of Vehicle>, FIG. 54-59 shows a kind of gear hole driving. It is also available to adopt remote control method to operate the integrated vehicle—unpiloted driving.
[0033] 2. Swing structure: vehicle body connects with the wheel by swing structure method. There is an axis on the vehicle body and an axis at the centre of a wheel, one end of the swing bar connects with the body axis, the other end of the swing bar connects with the wheel axis. The body axis can also connect with the “dolly-car” at the bottom of the wheel, dolly-car “dolly-car” is attributed to a Plea Know technology and can be found in <A Sort of Vehicle>, China Patent number 200410030581.x, viz. a “dolly-car” in “large wheel driving method”. The vehicle body with swing structure is capable to match up the flirt of the wheel as like as pendulum and swing. As long as the barycenter of the vehicle body is not higher than the circle centre of the wheel, the swing structure can keep the vehicle in balance and stabilization.
[0034] The advantage of it can move the weight of the vehicle to the frontage of the gravity surface of the wheel and produce driving force. The position of the vehicle moves ahead can reduce the pressure to the vehicle body and change the force direction, to generate the component of forces and save energy.
[0035] The extent of swing can be controlled to keep it fore-and-aft, or only keep it go forwards, or limit the extent when it swings fore-and-aft: preset caging position on the body, swing bar or wheel, the caging device can be a stake, step or spring and set it at the side of swing bar, swing bar will be held up at a certain angle.
[0036] Another swing structure is use a swing bar with bend and concave structure as like a crank shaft in an internal-combustion engine to integrate with the axles of the body, swing bar and wheel within swing structure. The vehicle body installs inside the concave and can swing fore-and-aft, more the space of the concave, and more the swing radius of the body. The sufficient wheel diameter in such structure is necessary to ensure the swing radius.
[0037] A swing bar can be a shaft, or a wobble tray, wobble tray shapes like a circle or semicircle, or anomalous to play a role of swing bar. A swing bar can decline the barycenter of the body and increase its stability.
[0038] The stress point of the force of an engine can be at the wheel fringe. “Wheel flange transmission” and “large wheel transmission” with Plea Known technology can be driven on the top of a wheel, refer to China Patent application 200410030581.x<A Sort of Vehicle> for details of “Wheel flange transmission” and “large wheel transmission”. The vehicle body can be dragged as like as a trailer car, the body drives the swing bar, the swing bar drives the wheel and push the vehicle moves on.
[0039] 3. Eccentric swing structure—the diameter of the vehicle body axis is smaller than that of axis hole of the wheel at the circle centre. In other words, the diameter of the wheel axis hole at the circle centre is greater than that of the vehicle body (the vehicle body axis here can also be swing bar axis). The body axis connects with the wheel axis hole and be located at the fringe of the bottom of inner loop of the axis. The body axis can change its position in the axis hole when in movement, it can depart from the gravity surface and swing to the direction of forward, thus, the gravity force changes to the driving force.
[0040] Axis hole means the hole at the inner loop of the axis. The connection method between the vehicle body axis and the axis hole can use Plea Known technologies as welding, affixing and covering. The method of covering: connect the vehicle body axis with the inner loop cover which matches up to the inner loop of the axis hole, the inner loop cover shapes like a round cake, and fix it into the inner loop. The vehicle body axis is located at the fringe of the bottom of inner loop of the axis, i.e. the bottom fringe of the inner loop.
[0041] Such structure is “eccentric swing”, or “eccentric axis”. Eccentric swing can be used in the connection of swing, also can be used in all circle movements except the swing connection, e.g. wheel axis, to save energy by its gravity force.
[0042] 4. Coaxial vehicle—also can be named as “two-wheel gravitational vehicle”, “two-wheel vehicle” or “sole-wheel vehicle”. A coaxial vehicle can has two or two group coaxial wheels which are located in the two sides of the body or bottom. Wheel runs relative to the vehicle body, an engine installs on the vehicle body as well as the passenger seat. The wheel of coaxial vehicle in this invention contains the wheels with same axial direction. Coaxial means two or two group wheels share with same axis. Same axial direction means two or two group wheels with different axes are within the same straight line and same axial direction. Two sides as above said means the surfaces of two profiles of the body and the positions near to the two ends of the body.
[0043] An axis at the circle centre of the wheel connects with the vehicle body, wheel runs relative to the body, the body does not rotate. The wheel of coaxial vehicle can be larger; its diameter is similar with the height of the body. A distance of wheel radius shall keep from the ground to convenient to design sufficient space and height for the vehicle body; the vehicle body does not touch the ground when it in swing. Such vehicle may carry an anchoring plate which can be ascending and descending to act as a brake.
[0044] A coaxial vehicle may have one wheel only; such wheel is rather wide and is located at the bottom of the body, the vehicle body connects with the wheel axis and is located on the top of the wheel. “Large wheel transmission” can also be adopted to connect the vehicle body with a “dolly-car”.
[0045] A coaxial vehicle contains the wheels with the same axial direction. The wheels with the same axial direction can be in different axial positions, i.e. the wheels with the same axial direction can disposed at front and rear positions, not in a same straight line. Such structure can increase the stability of the vehicle body, but the utilization of the gravity force is not so good.
[0046] There are engine and transmission device on the vehicle body, the method of the impetus transmission: transmit the engine driving force to the position on the vehicle body above the wheel first, then transmit to the top fringe of the wheel and drive the wheel running. Or, transmit the strength of human to the top position of the wheel of the vehicle body first, then drive the wheel. For example, lay an electromotor on the top position of the wheel corresponding to the body, by transmission device or rubber roller, the engine drives the wheel running. Other methods also can be adopted, such as to use wheel engine to drive.
[0047] In the structures as above said, an electromotor can also be laid at the bottom of the vehicle body, by transmission device, to transmit the engine driving force to the wheel. It is better to dispose the human, cargo and the vehicle facilities to the bottom of the body to decline the gravity centre and ensure the stability and utilize the gravity force perfectly.
[0048] It is also possible to lay the barycenter of the vehicle body on the circle centre of the wheel so as convenient to use swing structure; such structure shall be equipped with a supplementary wheel. Such supplementary wheel shall be installed at the front or rear position of the vehicle body and to play a balance role and prevent the overturn of the vehicle body. Such vehicle belongs to “multi-wheel vehicle”.
[0049] To drive a coaxial vehicle by human power, it is only need to transmit the human power to the top of the wheel to realize “wheel flange transmission” or “large wheel transmission” by Plea Known technology. For example, by a chain and a gear of bicycle, or transmission shaft and gear, or industrial strap and strap wheel, etc, to transmit the human power to the stress point on the top of the wheel to complete the transmission by human power. The driving of engine can also adopt above structure.
[0050] The differences of this structure with <A Sort of Balanceable Vehicle> of patent No.: 200310112992.9 are the driving force and transmission method. This structure provides with a technical resolution of engine driving, transmit the driving force of the engine or human power to the top or the fringe of the wheel, sufficiently use gravity and belongs to “wheel flange transmission” or “large wheel transmission”.
[0051] The stress point of “two-wheel vehicle” is same as the force point of a lever and stress the strength to the top of the wheel; the position wheel touch the ground is same as the pivot of a lever, the pivot is at the ground; the weight of the body is at the circle centre or at the bottom of the wheel, is same as the stress point of a lever at the circle centre or the bottom of the wheel, such structure matches up the 3rd law of Circumferential Law, the energy and power can be saved. The weight of the body (include passenger and cargo) is disposed at the bottom of the body, by the role of swing, half and more gravity can change to driving force and therefore save power and energy.
[0052] The driving force of an engine stresses on the top of the wheel by the top of the vehicle body, the top of the wheel produces a counter force to the top of the vehicle body, the bottom of the vehicle body will swing by the leverage, in this way, most of the gravity of the body will transmit to the front of the gravity surface of the wheel, i.e. to the forward direction, more than half of gravity of the vehicle becomes the driving force to drive the wheel.
[0053] Compressed air can also be used as the driving force, there is a huff nozzle on the top of the vehicle body, the baffle plate, or lamina, or a concave around the wheel will receive the puffing air, puff the air to the top of the wheel to drive the wheel running by the counter force of puffing air. To use compressed air as the driving force can be adopted according to Plea Known technology.
[0054] An jet engine can also be installed on the vehicle body just as like as the jet aircraft and jet car as Plea Known, to puff the air forward the rear of the body and drive the vehicle running and as well as compressed air.
[0055] The compressed air tank and engine can fixed in the wheel and run together with the wheel, air switch controls the huff nozzle, huff the air backward when the wheel rotate to the peak and drive the vehicle go forward. Huff will halt when the wheel is over the peak.
[0056] The compressed air tank shapes like circle pipe or round cake which is suitable to the shape of tire, it shall be installed the steel rim or the position with the same axial direction outside the wheel. There are several huff nozzles with the valves around tank, the valves shall open only the wheel runs to the peak position and drive the vehicle forward.
[0057] The structure of huff switch: there is an elastic cover on the huff nozzle on the wheel, the cover can run around the axis, a baffle plate at the peak position of the wheel, when one huff nozzle runs to the peak position, baffle plate pull out the elastic cover and the high pressure air huff burst out to produce thrust. The elastic cover closes again when the nozzle runs over the baffle plate. Next nozzle will repeat the above movement. Baffle plate can be fixed on the wheel axis.
[0058] The second structure of huff switch: there is an elastic piston at the huff nozzle; the piston connects with a pull staff, the pull staff runs around the axis, and there is a baffle plate at the peak position of the wheel, when one huff nozzle runs to the peak position, baffle plate pull out the pull staff of the piston and the high pressure air huff burst out to produce thrust. The elastic cover closes again when the nozzle runs over the baffle plate. Next nozzle will repeat the above movement. Baffle plate can be fixed on the wheel axis.
[0059] The third structure of huff switch: there is a magnet at the position of baffle plate, when a huff nozzle runs to the peak position, the attraction of the magnet opens the elastic switch, high pressure air huff out and produce thrust, the elastic cover closes again when the nozzle runs over the baffle plate. Next nozzle will repeat the above movement. Baffle plate can be fixed on the wheel axis again.
[0060] The huff nozzle can be controlled by automobile and all Plea Known technology, such as gas-jet control technology of internal-combustion engine, ignition technology and touching-switch technology, etc. all relative Plea Know technology can be adopted.
[0061] The intermittent blowing, or stroke blowing can also be adopted, blow the air at each interval, e.g. per second. Continuous blowing produces smaller inertial counter force, while intermittent blowing can increase counter force and enhance the effectiveness. Of cause, the air-powered engine with Plea Known technology can be adopted as the impetus for this vehicle.
[0062] 5. Multi-wheel gravity vehicle—means the gravity vehicle with two or more wheels. There are two coaxial wheels on multi-wheel gravity vehicle, plus front and/or rear supplementary wheel. The supplementary wheel shall be installed at the front and/or rear of the body to pay the role of auxiliary movement, balance and stability, furthermore, equipped with the flex function upward and downward as well as the function of universal wheel. Automobile and train with Plea Know technology can be changed to multi-wheel gravity vehicle. Any vehicle with Plea Known technology adopts the swing connection and/or eccentric swing structure of this invention can also use “wheel flange transmission” or “large wheel transmission”, which is a kind of multi-wheel gravity vehicle. The diameter of the wheel of this kind vehicle is rather small and can be similar or same with the wheels of the vehicles with Plea Known technology.
[0063] For example, a car with Plea Known technology has four wheels, change wheels into swing connection, or only change the rear two wheels into swing connection, adopt “wheel flange transmission” or “large wheel transmission”, the impetus of engine stresses on the top of the wheel and the top of the wheel produce a forward counter force to the body, more than half of the body weight changes to impetus and together with the engine power to drive the vehicle.
[0064] For multi-wheel vehicle, each wheel can connect with the body swing, or only part of wheels connects with the body swing, e.g. only two rear coaxial wheels in a tricycle connect with the body swing, the front wheel does not. Both multi-wheel and dual wheel gravity vehicles adopt Circumferential Law to utilize gravity.
[0065] If adopt small wheel, the radius of the wheel is small accordingly, the vehicle body shall near to the ground and also less the swing extent of the body, this problem can be resolved by Plea Known technology “large wheel transmission”. Connect the body with the small swing in large wheel, there is a rack on the “dolly-car”, the rack can be same height with large wheel or higher. Because the “dolly-car” rack moves relative to large wheel, so the rack may higher than large wheel. Once such body connects with the dolly-car rack which height has been added, the swing extent can be greater. In this case, swing position limit is necessary to avoid the overturn of barycenter. Such structure is available to dual-wheel vehicle too.
[0066] “Dolly-car” can be substituted by a large bearing, that means the diameter of the bearing hole is greater than body axis, eccentric swing also adopt this kind of bearing. Bearing ball is equal to the wheel of a “dolly-car”. The body axis connects with the internal loop of the bearing as the method foresaid. Actually, such structure is a “large wheel transmission”. This invention can be adopted by a quadricycle with Plea Known technology, use swing structure and regard the front two or rear two wheels as the driving wheels and driven by the engine. Another two wheels adopt large bearing structure as above said, dragged or pushed by the driving wheels. This is also a kind of gravity and such technology can be adopted by any vehicle with Plea Known technology.
[0067] The technical classification of any integrated vehicle, swing structure and multi-wheel vehicle included in this invention is purposed to describe clearly and easy to comprehend, not mean that such technology should be used solely or synchronously. In practice, all technical resolutions and features in this invention can be utilized solely or synchronously and suitable to combine with Plea Known technology.
[0068] Any non-impetus vehicle, such as train carriage and trailer car, also can accept such eccentric axis and/or swing connection, when an external force draw the vehicle body, the body swing to the forward direction and get over the gravity surface of the wheel, such gravity changes into impetus, thus can save more energy to draw the vehicle. Eccentric axis can be used in all circumferential substance movement. Any wheel with Plea Known technology can adopt such structure.
[0069] 6. Quadricycle—has two or two group coaxial wheels as main wheels, main wheels are located at the middle bottom of the body, supplementary wheel is also carried, supplementary wheel is installed at the front and/or rear part of the body, main wheels play the roles of loading, driving, braking and turning. The coaxial wheels as foresaid include the wheels with the same axial direction, the coaxial means the same axis shared by two or two group wheels, the same axial direction means two or two group wheels with different axes but located in the same straight line and same axial direction.
[0070] For example, main wheels have two coaxial wheels and located at the middle of the body, one supplementary wheel each at the front and rear part of the body, four wheels shape like diamond. Main wheels play the roles of loading, driving, braking and turning, these functions can realized by Plea Known technology; e.g. only drive or brake one of main wheels, the vehicle can turn the direction; only brake one of main wheels in movement, the vehicle can make the round in same place and consume inertia energy to play the role of braking. Of cause, it is possible to brake the wheels at same time. Weight or the gravity of a vehicle, mainly is borne by main wheels, so as to utilize the gravity.
[0071] Supplementary wheel plays the role of stability and balance, avoid the body to touch the ground in movement, keep stability in braking; supplementary wheel can perform the feature of anchoring plate, to bear part of load when the front or rear part of the body receive the pressure downward, the above said roles can be played when the vehicle in movement or in braking. Supplementary wheel connects flexibly with the body and can turn in parallel follow the body turning. Supplementary wheel can adopt universal wheel structure with Plea Known technology. Supplementary wheel carries an elastic device and be equipped with elasticity except the elasticity of tire, it can flex follow the pressure. In running, main wheels touch the ground while the supplementary wheel is unnecessary to touch the ground or slightly touch, or touch the ground in discontinuity; or, only one supplementary wheel touch the ground in running, or only one supplementary wheel slightly touch the ground or touch the ground in discontinuity. Of cause, there are two supplementary wheels each to be installed at the front and rear part of the body, there are four supplementary wheels in total. In this way, there are six wheel, two main wheels and four supplementary wheels. The number of supplementary wheel can depend on situation.
[0072] This invention adopts the liquid wheel in the Patent application 200410030581.x<A Sort of Vehicle>, the smaller the touchdown radius of the liquid wheel, the less the resistance. A light jelly, cream or semiliquid, the kind such as like as “aerogel” can be filled in liquid tire. Aerogel is a kind of jelly with light quality; it can transmit pressure in tire according to Pascal's Law.
[0073] One of the advantages in this invention is energy saving, i.e. to sufficiently use own weight by the structures of the gravity vehicle and swing connection designed by Circumferential Law, to realize the purpose of power and energy saving. A combination of eccentric axis and swing connection can save more energy. The second advantage is the structure of all vehicles is much more simple and reasonable than described in Plea Known technology. The third advantage is there is a new structure produced by dual-wheel and multi-wheel gravity vehicles and provide with more options. The fourth advantage is the wider applicability, available to all circle movement devices, such as human powered vehicle, motor vehicle, toy vehicle and space vehicle. The fifth advantage is safer by using of new braking method and new structure, avoid overturn due to its gravity declines and enhance its security in braking. The sixth advantage is cost reducing, due to the structure is greatly simplified, the manufacturing cost reduced. Moreover, the energy can be saved greatly during movement; therefore, not only decline the operating cost, but also benefit to the protection of global resources. The advantages of this invention are also specified in the relevant contents in the whole text.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] FIG. 1 is a sketch drawing of a circumferential substance being stressed by a force.
[0075] FIGS. 2-3 are sketch drawings of a kind of swing connection structure.
[0076] FIGS. 4-6 are drawings of three kinds of swing structures.
[0077] FIGS. 7-9 are sketch drawings of eccentric axes.
[0078] FIGS. 10-12 are drawings of three kinds of integrated vehicles.
[0079] FIGS. 13-14 are drawings of a vehicle powered by compressed air.
[0080] FIG. 15 is a drawing of a vehicle powered by electric fan.
[0081] FIGS. 16-17 are drawings of structures of the connection between dolly-car and body swing.
[0082] FIG. 18 is a drawing of a structure of the circumferential substance gravity utilization (similar to the ball mill).
[0083] FIGS. 19-20 are drawings of movement of several dual-wheel vehicles.
[0084] FIGS. 21-22 are drawings of structures of a sort of dual-wheel vehicle.
[0085] FIGS. 23-25 are drawings of structures of a sort of quadricycles.
[0086] FIGS. 26-28 are drawings of structures of a sot of integrated vehicle.
[0087] FIG. 29 is a drawing of a sort of pendulum shaft with swing structure.
[0088] FIG. 30 is a drawing of a sort of wheel with part of wheel rim.
[0089] FIGS. 31-32 are drawings of a trailer rack of the integrated vehicle.
[0090] FIGS. 33-34 are drawings of an air tank with the shape of round cake & baffle installed on the axis.
[0091] FIG. 35 is a drawing of an air tank with the shape of circinal loop.
[0092] FIG. 36 is a drawing of a round cake air tank installed as the axial direction outside the tire.
[0093] FIGS. 37-38 are drawings of a circinal loop air tank installed inside the rim of the tire.
DETAILED DESCRIPTION OF THE INVENTION
[0094] FIG. 1 —Circumferential substance 1 can be a ball, or a cylinder, or a wheel and located on the load surface 3 . Its weight surface 2 is located at the center of the circle. The weight surface 2 is fictitious, but the interface of the weight is in objective reality. A circumferential substance touch with the load surface can not but produces a weight interface, i.e. the weight interface. At both sides of the weight surface 2 , the weight sizes are equal, directions are contrary. Although the weight is downward, but the both sides of the weight surface of the circumferential substance will produce two equal weights, their directions are contrary. The load surface includes the ground. If a perfect point or line of the circumferential substance touch with the firm load surface, whether different in their quality, the force to overcome the static inertia is greater than zero. The movement rule will follow Circumferential Law as foresaid in this article. This point is absolutely contrary with the Newton Law, which means Newton Law is not applicable to circumferential substance movement. It will be alternatively between us!
[0095] FIG. 2 - 3 —Wheel 101 is circumferential substance and connects with swing bar 4 at the place of wheel axis 5 , body axis 6 is at the swing bar 4 , and it is used to connect with vehicle body. When swing bar 4 in the figure moves to the left side of the weight surface 2 , the body weight will produce the gravity to the wheel 101 lean to the left side, this gravity will become the forward impetus. The circumferential substance 101 can act as the wheel for the wheels of all vehicles including train, automobile, trail car and human powered vehicle.
[0096] FIG. 4 —Wheel here is omitted, there is a limit stake 8 on the body 7 , limit pole 10 on swing bar 4 , limit stake 8 and limit pole 10 can be used alternatively or synchronously. Besides, limit spring can be used also. They can play the role to limit the body swing on the wheel within a certain extent. The ratchet structure with Plea Known technology can also be available to limit the swing forward only.
[0097] FIG. 5 - 6 —Wobble tray 401 or 402 on the wheel 101 , there are several structures for swing bar, 401 and 402 is the swing bar with different structure and with the same function of the swing bar 4 in FIG. 3 . Wobble tray 401 shapes like flat plate or a round flat plate, a piece was cut off on the top in the figure. The geometry shape of a swing bar can be changed except its function of swing bar. The role of a swing bar is to connect the body and wheel and swing the body relative to the wheel. A swing bar has other functions, such as to carry a limit device. Wobble tray 402 is also equipped with the function to increase the swing extent. There is body axis 601 on the wobble tray 402 ; it expresses that to move the body axis from the underside of the circle center of the wheel to the upside, even higher than the wheel. As long as the gravity of the body not exceeds the circle center of the wheel, the body can not be overturn. But in multi-wheel vehicles, the gravity of the body can exceed the circle center of the wheel due to the balance of the supplementary wheel; the vehicle body can not be overturn.
[0098] FIG. 7 - 9 — FIG. 8 is the inner loop cover; FIG. 9 is a left-view diagram. There is inner loop cover 11 in inner loop 13 of the bearing 100 , cover hole 12 on the inner loop cover 11 . Inner loop cover 11 is fixed on the inner loop cover 13 . Bearing 100 is installed on the wheel; bearing ball and inner loop 13 are similar with the “dolly-car” in large wheel transmission device. The body axis is fixed in the cover hole 12 , equals to connect with inner loop cover 13 . The body axis can be fixed on the inner loop by welding, covering or affixing, the figure displays the method of covering. In movement, the body axis can pull inner loop 13 to a certain angle and keep the body axis away from the weight surface of the wheel, i.e. swing the body relative to the wheel and change the gravity to forward impetus.
[0099] FIG. 10 —The vehicle body 16 combines with the wheels at its two sides and becomes an integrated vehicle 18 . the body and wheels shape round, the left-view and right-view diagrams show a small round in a larger round, so the left-view and right-view diagrams was omitted. The diameter of the body is smaller than the wheel and keeps a certain distance from the ground to ensure the movement. The body runs following the wheels. The integrated vehicle can be used to carry cargo, such as coal, ore, petroleum and gluewater, etc. the integrated vehicle. There is no inlet or outlet as well as the inspection opening for cargo in the integrated vehicle, just like a tank truck. An integrated vehicle can carry roller 14 , the trailer and vehicle tracks can be installed on it to control the movement of the vehicle. It is possible not to install engine on such vehicle and regard it as a trailer car when a trailer track installed on it. Gear 17 is used for receiving external force. The external force in this invention can be electromotor or internal-combustion engine. Such vehicle can be manned, unmanned or remote controlled.
[0100] FIG. 11 —To integrate the body 16 with the wheel 19 , the body and wheels shape round, the left-view and right-view diagrams show a small round in a larger round, so the left-view and right-view diagrams was omitted. The diameter of the body is smaller than the wheel and keeps a certain distance from the ground to ensure the movement. The body runs following the wheels. Wheel 19 is located in the middle of the body, it can be a rubber loop to receive the impetus from the rubber roller upward and drive the vehicle.
[0101] FIG. 12 —To integrate the body 16 with the wheels 20 at its two sides, the body and wheels shape round, the left-view and right-view diagrams show a small round in a larger round, so the left-view and right-view diagrams was omitted. The diameter of the body is smaller than the wheel and keeps a certain distance from the ground to ensure the movement. The body runs following the wheels. Wheel 20 carries an upstanding side 21 ; there is cargo inlet and outlet 166 on the body 16 . Such vehicle is used to drive on rail. The integrated vehicle can be used to transport water, oil, cement, coal, coal slurry and concrete, etc.
[0102] FIG. 13 - 14 — FIG. 14 is an A-A cutaway view of FIG. 13 . Body 22 connects with wheel 101 flexibly through wheel axis 5 ; these two coaxial wheels are located at the two sides of the body. It is possible to dispose tow or two group coaxial wheels at two ends of the body. The wheel can run relative to the body. The figure shows that: there is compressed air stored at the bottom of body 22 . The huff nozzle 23 is located on the top of the body; huff nozzle 23 connects with the compressed air. There is baffle plate or lamina, or a concave around the wheel as well as the air valve, the device with Plea Known technology. FIG. 13 shows the left wheel and the baffle plate around the wheel. During the vehicle moving, huff nozzle blow the air to the baffle plate or concave at upper fringe and drive the wheel running; meanwhile, huff nozzle produce counter force to the body. The counter force play the role of leverage through wheel axis 5 , the bottom of the body 22 inclines forward, and the weight shifts ahead too, the weight now changes to impetus. Again, due to the bottom of the body is heavier, cause the weight greater. The bottom of the body 22 is heavier than the top, so the vehicle can not be overturn. Such vehicle can carry supplementary wheel or anchoring plate also to avoid the vehicle overturn.
[0103] FIG. 15 —There is a storage battery 26 at the bottom of body 22 to supply the power for electric fan 25 , the electric fan blow the air backward to drive the vehicle. Electric fan 25 makes the bottom of body 22 inclines forward, shift the weight ahead and change the weight into impetus. Due to the bottom of body 22 is heavier than the top, so it is possible thon the top of body 22 is higher than the wheel. Electric fan 25 can be located at the middle or the top of the body too, electric fan blows the air backward and drive the vehicle. Electric fan can be substituted by jet engine or compressed air. Jet engine or compressed air can be installed on the body, blow the air backward and drive the vehicle.
[0104] FIG. 16 - 17 —A “dolly-car” 27 is inside the wheel 101 , the small wheel of dolly-car 27 moves at the bottom of wheel 101 . By Plea Know technology, to dispose dolly-car and wheel 101 , the body connects with two body axes 601 . Such dual-axis swing connection can bear heavier load. Two body axes swing at same time and the effect is as same as single swing. In this invention, the body axis can be one, two or more. There are two swing axes 501 , located at the upper middle position in the parallel line of wheel; due to the bottom of the body is much heavier, so dolly-car 27 can never loss its barycenter inside the wheel 101 and overturn. Such structure is of a kind of “large wheel transmission”. Wheel 101 is large wheel 101 , wheel 101 runs relative to dolly-car 27 . Just as like as there is electromotor and gear on the top of dolly-car, an internal gear ring is installed on wheel 101 , power supply is inside the body, direct supply the power to electromotor, transmit on the top of wheel and drive the wheel 101 running around the wheel axis 502 , and push the dolly-car 27 moves forward, dolly-car 27 bring the vehicle body following the wheel 101 moves forward. Due to the body can swing forward and make the weight in a status of inclining forward and change the weight into the impetus.
[0105] FIG. 17 is A-A cutaway view of FIG. 16 . Dolly-car 27 has the same circle center with large wheel 101 ; the position of large wheel 101 is limited by wheel axis 502 . Wheel 502 does not load the weight, nor limit the movement come-and-go of the large wheel, it limits the position of the large wheel 101 only to prevent it dislocate from the axial direction. Dolly-car rack also plays the role of the position limit to the large wheel 101 , the area of dolly-car rack is greater 50% and above than the large wheel 101 , it top exceeds the center parallel line of the large wheel 101 and has a caging device relative to the large wheel 101 , such as the facette, to make the position of the large wheel 101 controlled by dolly-car 27 . Wheel axis 502 can be connected with the body flexibly, there is a long round hole on the body and the wheel axis 502 can move inside the round hole, no any influence to the swing of the body or the movement of the large wheel. Wheel axis 502 also can play the role of position limit to swing bar 401 to limit its swing extent. It is possible for a vehicle to have two or more such wheels. Wheel 101 can be the wheel for any vehicle, including trail car and human powered vehicles.
[0106] FIG. 18 —Circumferential substance 102 represents a ball mill, concrete blender or a tumbling-box washing machine. The installation and the transmission method of such machines are unreasonable by Plea Know technology, no “gravity surface” and waste power. In this invention, to dispose such circumferential substance 102 on base wheel 30 , base wheel shall be installed on the base seat 31 by Plea Know technology to run the base wheel relative to circumferential substance 102 . Two or more base wheels can be disposed around the axial direction of circumferential substance 102 to bear the weight, make the bottom of circumferential substance 102 close to the ideal point or line connection of the base wheel 30 , establish a weight surface to save energy by the weight. A rotary wheel 32 can be set up at two sides of circumferential substance 102 to keep it in perfect position. To install rotary wheel 32 by Plea Known technology, make it running followed by circumferential substance 102 . It is possible to have two or more rotary wheels as same as base wheels and to be disposed around the axial direction. FIG. 18 only shows the surface, two or more base wheels and rotary wheels are same as such structure. A transmitting wheel 29 is on the top of circumferential substance 102 and to be driven by an engine to bring circumferential substance 102 running. The installation of transmitting wheel and engine can be completed by Plea Known technology. Transmitting wheel 29 can be located at the middle or the bottom of circumferential substance 102 . To use roller bearing on base seat 31 because the load of a roller bearing is greater, the pressure of a rotary wheel is less, so roller bearing is applicable. Base seat 31 can be substituted by a magnetic suspension device.
[0107] FIG. 19 —One driver is needed only for the combination of four or more dual-wheel vehicles to save human power and the space within vehicles. The connection device or method between two vehicles can adopt the method of a train, not only to be connected with pothook 34 , but also wire, water pipe and others. Change the wheels of dual-wheel vehicle 33 into the train wheel which carries the upstanding side, such vehicle can run on the rail. FIG. 20 shows: pothooks 34 are carried by body 222 at front and rear parts, each section of dual-wheel vehicle can be the head vehicle and has driver seat and runs forwardly and reversely. Each section of dual-wheel vehicle 33 can has its own driving device, it can solely run solely or run as a string as shown in the figure. When running as a string, each section can be driven by own engine and form a composition force. It is convenient for driving due to each vehicle has own controlling capability. Also, a dual-wheel vehicle does not carry own engine and to be used as a trail car, driven by the main vehicle. Main vehicle means the head vehicle, it provides impetus and controlling. Several integrated vehicles which carry trail racks or pothooks can form a train and be towed by a head vehicle.
[0108] FIG. 21 is the left-view diagram of FIG. 22 ; dual-wheel vehicle 22 is composed by large wheel 101 and body 223 as well as two anchoring plates 36 , anchoring plates 36 stands on the ground 3 to play the roles of braking and stability. Anchoring plates will be picked up pulled up during movement. The wheels of a dual-wheel vehicle are comparatively larger and close to the body. Vehicle rung shapes as a strip. Wheel axis 5 connects with wheel and body. Electromotor 39 is located on the top of body 223 , one at each side and to be installed by Plea Known technology. There is gear 38 on the electromotor; an internal gear ring matched up to the gear is carried by wheel 101 . The internal gear ring is driven by gear 38 . Although the body can swing against the wheel, but the extent is not so great, can never influence to the transmission from the gear 38 on the body to the internal gear ring on the wheel. The body can swing around the circle centre of wheel axis, the body has the same circle centre with the wheel, the swing direction and the radius of the body are consistent with that of internal gear ring of the wheel, so it can not influence to the normal operation. The counter force of gear 38 to the top of body can transmit to the bottom of the body through wheel axis 5 and makes the bottom of body inclining forward, the weight shift forward too, and change the weight into impetus. Power supply 26 is located at the base of the body to decline the barycenter and increase the effective weight. Power supply 26 provides the power to electromotor. Within the body, driver seat and relative facilities as well as the passenger seat can be set up by Plea Known technology. It is possible not to set up driver seat. As shown in FIG. 20 , it is necessary to set up connection device, such as pothook in cabin. Electric axis and electric wheel engine with Plea Known technology are also available. To brake the wheel at one side can complete the functions of turning or shut down. The broken line in FIG. 22 shows gear and internal gear ring.
[0109] No engine can be carried for a dual-wheel vehicle; such vehicle can be used as trial car or human power vehicle. The body can shape as a square, flat plate or others with Plea Know technology. To drive the vehicle by human power is also available, in this case, only need to change electromotor to human powered device. To use chain wheel device transmit the human power to the top of large wheel 101 to drive the vehicle.
[0110] FIG. 23 - 25 — FIG. 23 is the left-view diagram of FIG. 24 ; FIG. 25 is the upward-view diagram of FIG. 24 . All wheels are located at the bottom of the body. Four wheels 44 of quadricycle are disposed as diamond, two main wheels 44 are coaxial wheels and located the middle of the body, two supplementary wheels 43 are located at front and rear of the body. This is a kind of gravity vehicle. Wheel 44 can adopt the structure of FIG. 16 and “large wheel transmission”. It is also available to adopt the wheel electromotor described in <A Sort of Vehicle> of Plea Know technology document 200410030581.x. Vehicle body connects with wheel swing. Supplementary wheel can run in parallel to match up turning. Supplementary wheel carries an elastic device which flexes up and down following pressure, the wheel is unnecessary to touch the ground or slightly touch, or touch the ground in discontinuity, or, only one supplementary wheel touch the ground. Only need one main wheel can realize turning and braking, to use two main wheels at same time can brake or decelerate the vehicle.
[0111] FIG. 26 - 28 — FIG. 26 is the left-view diagram; FIG. 28 is the vertical-view diagram of FIG. 27 . An integrated vehicle 18 carries a rack 45 ; an electromotor 45 and trail wheel are on it. Electromotor 170 is located at the bottom of the rack beam 45 and on the top of integrated vehicle. Electromotor 170 drives gear 17 and pushes the vehicle forward. Trail wheel 46 plays the role of balance. Such vehicle can also be unmanned or remote controlled.
[0112] FIG. 29 —Pendulum shaft 503 shows a structure of bend and concave, wheel axis 504 is integrated with the body axis 505 , wheel axis 504 connects with wheel, and body axis connects with body. This is an axle with swing structure, pulling the body, the body swing forward and change the weight into impetus. The swing bar connects with wheel and body, the body is installed inside the structure of bend and concave.
[0113] FIG. 30 —Wheel 19 is installed on the body 16 of the integrated vehicle with tire and part of rim 199 .
[0114] FIG. 31 - 32 — FIG. 32 is the left-view diagram of FIG. 31 , trail rack 141 shapes like a semi-frame, trail rack 141 is equipped with a juncture 142 and a juncture hole 143 is on it. Trail rack 141 carries an axial hole 144 to connect with roller 14 . It is unnecessary to carry power for an integrated vehicle and to be regarded as the trail car when it is installed on a rack.
[0115] FIG. 33 - 34 — FIG. 34 is the left-view diagram of FIG. 33 . Air tank 47 shapes like a round cake, there is a huff nozzle 48 on it, wheel axis 5 carries baffle plate 49 .
[0116] FIG. 35 —Air tank 50 shapes like a hollow round loop, a huff nozzle 48 is on it.
[0117] FIG. 36 —Air tank is installed on the position of axial direction outside the wheel 101 (also can be installed on large wheel 101 shown in FIG. 22 ). Air tank can be installed on any side of the position of axial direction outside the tire.
[0118] FIG. 37 - 38 — FIG. 37 is the left-view diagram of FIG. 38 . Most part of air tank is to be installed inside the tire rim; a huff nozzle 48 is at the bare part.
[0119] This invention is applicable to all devices and method with circumferential movement, including automobile, train, space vehicle, toy vehicle, crane, trail car, blender, and ball mill, etc. all technical resolutions and technical features in this invention can be used solely or in combination and not limit to a certain example case described in this manual and the figures attached.
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The invention relates to circumferential movement field, including all circumferential movement devices such as transport vehicle, toy vehicle, space vehicle, blender etc, especially including energy-saving vehicles utilizing gravitational force. The energy-saving vehicle utilizes gravitational force as driving force, the vehicle body connects with the wheel by swing structure method or eccentric swing structure to utilize more gravitational force. The invention also provides solutions about two-wheel gravitational vehicle and multi-wheel vehicle and train connected by integrated vehicles or two-wheel vehicles.
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FIELD OF THE INVENTION
The present invention relates to a connecting element for the mechanical connection of at least two components, in particular two components of a motor vehicle door, with a bearing collar for bearing against a first component, with a crossbar having bearing flanks, wherein the bearing flanks are designed for bearing against a second component and for prestressing the latter against the first component in a rotated final assembly position, and with a shaft section for rotatably passing through corresponding openings in the components. The invention furthermore relates to a connecting arrangement comprising at least two components each having an aperture, and an abovementioned connecting element, wherein the connecting element reaches through the axially aligned apertures of the components in a final assembly position, and is rotated in relation to a first insertion angular position into a final angular position in order to produce the connection.
BACKGROUND OF THE INVENTION
A connecting element of this type is used in particular for the mechanical connection of an inside door panel of a motor vehicle to a unit carrier, for the connection of the unit carrier to a decorative support shell or for the connection of all three components. In this case, at least two plate-like components are connected to each other by means of a rapid-action fastening such that, for example, the subassemblies of motor vehicle doors can be fitted rapidly and without tools being used.
DE 198 38 560 A1 discloses a rotary rapid-action fastening in the form of a rotatable retaining element with a head section and a shaft section for the interconnection of a plurality of components, in particular for the connection of an inside door panel of a motor vehicle, a unit carrier and a decorative support shell.
EP 0 943 824 A1 furthermore discloses a mechanical connecting element with a head, with a bolt provided on one side of the head and with a web-shaped locking bar.
For the assembly, the components which are to be connected are first of all placed on one another in situ with their apertures in alignment. Subsequently, the known connecting elements are inserted into the aligned apertures of the components and rotated into the final assembly position with a clamping force being formed. The disadvantage of this process is that it is time-consuming, since the components that are to be connected frequently have to be placed onto one another in restricted space conditions and without direct sight of the connecting point. In addition, the connecting elements can easily be lost.
It is furthermore known from G 93 11 243 U1 and from U.S. Pat. No. 4,762,437 to configure a connecting element for a preassembly position on the first component, the connecting element in this case being supported with its crossbar on the first component. This reduces the outlay on assembly. In addition, the connecting element which is fastened to the first component can be repeatedly used after the second component is detached.
SUMMARY OF THE INVENTION
A primary aim of the invention is to provide a connecting element which can be fitted as easily as possible. In particular, the connecting arrangement is intended to be produced rapidly and as simply as possible. A further aim of the invention is to provide precautions which can prevent the connecting element from being lost.
A connecting arrangement according to the invention for the mechanical connection of at least two components, constructional units and/or modules in a defined assembly position and/or installed position by means of a connecting element that reaches through axially aligned apertures of the at least two components in a final assembly position and that is rotated in relation to a first insertion angular position into a final angular position is characterized in that the connecting element is held on the first component in a preassembly position in which the crossbar is located in the aperture of the first component.
The invention is based on the consideration that the known connecting arrangements which are provided with preassembly of the connecting element sometimes considerably interfere with and/or impair the assembly sequence and any assembly freedom which may be required, since the crossbar that is supported on the first component and the shaft end of the locking element protrude considerably out of the aperture of the first component in the preassembly position.
The arrangement according to the invention is now distinguished in that the crossbar of the connecting element is located in the aperture of the first component in the preassembly position. To this extent, the assembly sequence of the two components is not impaired by means of protruding corners and edges of the connecting elements pre-fitted thereto. The assembly freedom is considerably increased in comparison to the prior art.
The arrangement provided is suitable in particular for the connection of door components of a motor vehicle, in particular for the common fixing of a unit carrier and/or a decorative support shell to an inside door panel of a vehicle door. After its preliminary placing in one of the components that has a corresponding aperture for a shaft section and/or a bearing collar for the exact positioning, the connecting element is held in the component without its shaft end protruding substantially beyond the aperture. It is thereby possible to ensure that the parts can be reliably fitted even in unfavorable installation positions. After the parts that are to be connected are joined together, the connecting element is located in its position and can be brought into a locked final position in a simple manner. The locking of the connecting element can optionally take place without a tool, i.e. manually, or with the aid of a suitable tool.
The connecting element is advantageously held in the preassembly position in such a manner that it does not protrude over the rear side of the first component, which side faces the second component, in particular in such a manner that it is aligned with the rear side of the first component. This permits even easier fitting of the first component to the second component, in particular in the case of constricted installation spaces, since guidance of the first component in relation to the second component is in no way obstructed by the connecting element.
In a preferred development, the connecting element is latched to the first component. This makes it possible for the connecting element to be positioned captively on the first component such that the connecting element is reliably available at the assembly site for the final assembly.
A furthermore advantageous configuration of the connecting arrangement provides that, in the preassembly position, the connecting element at least partially reaches through the aperture of the first component and is latched in the aperture of the first component. This latching is preferably designed in such a manner that the connecting element is firstly prevented from dropping out and secondly is not pushed too far in the direction of the final assembly position by the first component so as not to impair the installation or the precisely fitting joining together of the components that are to be connected. However, if appropriate, the connecting element may protrude through the aperture of the first component in the latched preassembly position to the extent such that it can serve as a positioning aid, for example by sections of the connecting element that are locked to the second component in the final assembly position firstly only forming a more or less loose guide in order to precisely meet the second aperture of the second component, which aperture is aligned with the first aperture of the first component.
Furthermore, it is expedient if the connecting element is latched in the second aperture of the second component in the final assembly position. This latching may take place, if appropriate, without a tool. It is important that the connecting element cannot be detached by itself, and is securely locked and remains latched under all operating conditions even if the assembly lasts for a relatively long amount of time.
According to a further advantageous configuration of the connecting arrangement, the connecting element can bear with its stop collar against an axial stop of the first component in the final assembly position. This ensures a frictional and form-fitting connection. The second component is clamped to the first component via the stop surfaces bearing against each other.
In addition, the first component can have a centering device for axially and radially securing the connecting element and/or for visually displaying the insertion angular position and the final angular position. For this purpose, for example, guide elements in the form of guide webs or the like can be provided, the guide elements ensuring exact positioning of the locked connecting element and/or ensuring that the connecting element can be brought in an exactly predetermined direction into the final assembly position. The guide webs can additionally serve as a visual check for the two final angular positions of the connecting element, which is rotatable between an unlocked and locked position, for example by provision of corresponding markings that can be brought to coincide with each other by rotation of the element.
Furthermore, an additional seal can be provided in the region of the axial bearing collar, the seal being able to ensure a certain elastic prestress and sealing of the components if this is desired. An axial prestress by means of such a seal is provided in particular also to compensate for tolerances and to ensure a firm fit of the connecting element. The seal can be assigned in this case either to the connecting element or to the first component.
In an advantageous embodiment, the centering device is formed by the aperture of the first component, the aperture corresponding to the crossbar of the connecting element in the preassembly position. As an addition or alternative, the centering device can be formed by an in particular annular enclosure of the bearing collar that is attached to the first component. This brings about reliable centering and therefore a secure connection in the final assembly position. Lateral yielding of the connecting element is thereby prevented.
A reliable connection of the at least two components by means of the connecting element can be ensured in that the connecting element clamps the first component and the second component against each other with a defined clamping force in the final assembly position. For this purpose, it can be provided in particular that the connecting element engages behind the second component by means of bearing flanks in the final assembly position. The at least two components are therefore connected to each other by the bearing collar and the bearing flanks. Latching devices are expediently provided, the latching devices ensuring, in interaction with the bearing flanks or independently thereof, a slight latching of the connecting element in its final angular position such that, in addition to the prestressing force of the bearing flank, which is beveled or provided with a suitable ramp, additional protection against inadvertent detachment, for example in the case of relatively strong shaking or vibrations, is provided.
The object is furthermore achieved by a connecting element for the mechanical connection of at least two components, in particular two components of a motor vehicle door, with a bearing collar for bearing against a first component, with a crossbar having bearing flanks, wherein the bearing flanks are designed for bearing against a second component and for prestressing the latter against the first component in a rotated final assembly position, and with a shaft section, which bears the crossbar, for rotatably passing through corresponding openings in the components, with a means for fastening to the first component being formed in a defined preassembly position.
In other words, the connecting element for the mechanical connection of the at least two components has essentially three functional sections that can be connected in particular integrally to one another. The first functional section is formed here by a bearing collar that bears against the first component in the final assembly position. The second functional section is formed by a shaft section, the diameter of which corresponds to the openings of the two apertures of the components and which is rotatable therein. The third functional section comprises the bearing flanks that bear against the second component in the final assembly position and clamp the component against the first component. An additional fourth functional section of the connecting element is provided by a means for fastening the connecting element to the first component in a defined position in the preassembly position.
The means for fastening to the first component in a defined preassembly position can be provided, for example, by means of a releasable frictional connection or form-fitting connection such that the connecting element can easily be placed into the preassembly position of the first component and can also be easily transferred again during the assembly into the final assembly position.
The fastening means is advantageously provided by a latching device. The latching device can be formed, for example, by at least one latching tongue that is arranged in the region of the shaft section and that engages in a corresponding receptacle in the region of the first aperture of the first component in the preassembly position. A latching tongue of this type can protrude, for example, out of the rear side of the bearing collar of the connecting element and can be arranged in the vicinity of the shaft section and parallel to the direction of its longitudinal extent such that it is pressed elastically against the shaft section, when the shaft section is pushed into the opening provided for it in the first component, and can latch into a matching receptacle, groove or opening in the region of the circumferential surface of the aperture or at another suitable location as soon as the preassembly position is reached.
The preassembly position is expediently characterized in that the connecting element is not fully pushed into the aperture of the first component, and therefore the shaft section only partially enters it. Two or more such latching tongues that are expediently arranged symmetrically around the shaft section of the connecting element can optionally be provided.
Furthermore, it can be advantageous if the latching device comprises an additional locking device which, in interaction with an offset in the region of the first aperture of the first component, forms a means of securing against dropping out and a means of securing against rotation. The locking device can be formed in particular by at least one snap-in tongue that is arranged in the region of the shaft section and/or in the region of the bearing flank of the connecting element. When the shaft section is pushed through the aperture, such a snap-in tongue can slide along the edge of the aperture and can easily be compressed such that, after a defined insertion length, it engages behind the first component and forms a type of barb that prevents the connecting element from being able to unintentionally drop out of the aperture of the first component when the latter is in its installed position and is brought into contact with the second component. In particular, two or four of the snap-in tongues that are expediently placed in a symmetrical arrangement on the shaft section can be provided. It can thereby be prevented that the shaft section can be brought out of engagement with the first component by means of slight tilting. In order to form the barb function described, it is appropriate in particular to form the snap-in tongues with their free end against the supporting surface. This configuration at the same time brings about a means of securing against rotation, since the crossbar is held in the aperture, which makes rotation impossible. Simple assembly is therefore made possible, since the connecting element secured in this manner can be guided, without a rotational movement, through the further aperture of the second component, which aperture is axially aligned with the first aperture.
The snap-in tongues can furthermore advantageously be configured in such a manner that they can serve as an additional position and centering aid when the first component is placed on the second component.
It is furthermore advantageous if a stop to limit the rotation of the connecting element during the assembly is provided. In particular, the stop is designed in such a manner that, in interaction with the first component, it permits the rotation to at maximum 90° in relation to the preassembly position. The position that is rotated through 90° in relation to the preassembly position then corresponds to the final assembly position.
In a further advantageous configuration, in the preassembly position, the connecting element at least partially penetrates the aperture of the first component, and, in a preassembly angular position rotated against the insertion angular position, is supported in a manner such that it is latched against the contour of the aperture of the first component. This configuration ensures that the connecting element cannot be pressed through in the preassembly position in the direction of the final assembly position. This is prevented by the connecting element being located in a preassembly angular position that is rotated against the insertion angular position, with it being supported here against the contour of the aperture. By means of a latching of the rotated preassembly position, inadvertent rotation in the insertion angular position is prevented. Only when the connecting element is rotated out of the preassembly angular position to the insertion angular position is a further axial movement through the aperture possible.
Expediently, the contour of the aperture here on the first component is designed in such a manner that the connecting element is moved out of the supported, latched position during rotation from the preassembly angular position into the insertion angular position, and the crossbar can be guided axially through the aperture. In other words, in the preassembly position with a preassembly angular position of the connecting element, the crossbar of the connecting element can be introduced only as far as a stop in the contour of the aperture, with latching taking place at the same time. In this position, further pressing through the connecting element is not possible. When the connecting element is rotated from the preassembly angular position into the insertion angular position, the latching is released and the crossbar passes in the process into an angular position such that it can be passed axially through the correspondingly configured aperture. The connecting element with its crossbar can therefore only be passed through the aperture by means of a combination of a linear and a rotational movement. In this case, the contour of the aperture can in particular be designed in such a manner that the crossbar can be introduced linearly only with an orientation of the connecting element in the preassembly angular position until the connecting element strikes and latches. In the latched position, the connecting element can then be rotated into the insertion angular position in which the crossbar can then be guided linearly further through the aperture.
To configure this predetermined sequence of movement, it is expedient to form the latching device with the locking device on the connecting element by means of at least one snap-in tongue and by means of at least one radial latching pin that is arranged on the shaft section in a manner offset axially with respect to the snap-in tongue and is designed for stopping against a circumferential projection in sections of the contour of the aperture of the first component. During the initial linear movement of the connecting element into the aperture of the first component, the latching pin protruding radially from the shaft section strikes against the circumferential projection provided in sections of the contour of the aperture. The latching tongue can then be designed to latch in relation to the contour and in particular in relation to the circumferential projection in sections thereof. If the connecting element is rotated from the preassembly angular position into the insertion angular position, then the latching pin runs along the circumferential projection in sections in the circumferential direction until the circumferential projection ends. At the end of the circumferential projection, further guidance of the connecting element axially is then possible, since the latching pin has no more means of stopping it.
The latching with the circumferential projection of the contour of the aperture, which prevents the connecting element from rotating further and also from dropping out of the aperture, is expediently brought about by the snap-in tongue being designed to engage behind the circumferential projection on the first component. For this purpose, the circumferential projection that is in sectional form advantageously has an axially countersunk receiving groove in which the latching pin of the connecting element is held in the preassembly position under prestress by means of the snap-in tongue engaging behind the circumferential projection. By means of this configuration, a force has to be applied to the snap-in tongue in order to rotate the connecting element from the preassembly angular position into the insertion angular position.
In order to achieve a secure fit of the connecting element to the contour of the aperture of the first component in the preassembly position, the crossbar advantageously has at least one supporting surface, which faces away from the bearing collar, for stopping against a surface projection in sections of the aperture of the first component. In the preassembly position, the connecting element is then not only supported with the radial latching pin against the circumferential projection but at the same time is also supported via the supporting surface of the crossbar against a corresponding surface projection in sections of the aperture. By means of this repeated and also planar mounting, a secure fit of the connecting element to the first component is obtained in the preassembly position.
When, in the present context, mention is always made of at least two components that can be connected to each other by means of the connecting element, this does not in any way rule out the connection of three or more parts in the manner described. For example, an inside door lining, a door module with functional elements, such as a window opener or the like, and an inside door panel can be connected to one another in the manner described.
Further features, aims and advantages of the invention are revealed from the description below of an embodiment of the invention, which does not serve as a limiting example and makes reference to the attached drawings. In this case, identical components basically have the same reference numbers and some of them are not explained more than once.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : An illustration of a connecting element of a connecting arrangement.
FIG. 2 : A further view of the connecting element according to FIG. 1 .
FIG. 3 : A third view of the connecting element according to FIG. 1 .
FIG. 4 : An illustration of an aperture for receiving the connecting element.
FIG. 5 : A further view of the aperture according to FIG. 4 .
FIG. 6 : An illustration of the connecting element that is inserted into the aperture in a preassembly position.
FIG. 7 : A further view of the connecting element in the preassembly position.
FIG. 8 : An illustration of the locking element that is inserted into the aperture in a final assembly position but is not yet locked.
FIG. 9 : A further view of the connecting element that is in the final assembly position but is not yet locked.
FIG. 10 : An illustration of the connecting element that is in the final assembly position and is locked.
FIG. 11 : A further view of the connecting element that is in the final assembly position and is locked.
FIG. 12 : An illustration of a further connecting arrangement, with the connecting element being in a preassembly angular position.
FIG. 13 : A further connecting arrangement according to FIG. 12 from a different perspective.
FIG. 14 : A top view of the contour of the passage of the further connecting arrangement.
DETAILED DESCRIPTION OF THE INVENTION
An exemplary embodiment of a connecting arrangement 10 according to the invention is illustrated with reference to FIGS. 1 to 11 described below, the connecting arrangement comprising a connecting element 12 (cf. FIGS. 1 to 3 ) that serves for the mechanical connection of two or more components, of which, however, only a first component 14 , which has an aperture 15 (cf. FIGS. 4 and 5 ) for receiving the connecting element 12 , is illustrated for the sake of giving a better overview. The first component 14 can be fixed to a second and, if appropriate, third component (not illustrated) in a manner flush with the surface thereof by means of the lockable connecting element 12 .
The connecting element 12 has essentially three functional sections which are explained with reference to FIGS. 1 to 3 . A first functional section is formed by a bearing collar 16 that is designed as a round bearing disk and on the outer side of which a hexagon head 18 for the fitting of a tool is arranged. An additional hexagonal socket 20 is arranged in the raised hexagon head 18 such that the locking of the connecting element (cf. FIGS. 10 and 11 ) can optionally take place with a ring or fork spanner or with a hexagonal spanner. Two marking arrows 24 are arranged on the front side 22 of the bearing collar 16 , which side is visible from the outside, the marking arrows, in conjunction with corresponding markings on the outer side of the component, into which the connecting element 12 is inserted, indicating the unlocked and the locked state of the connecting arrangement 10 . On the rear side 26 of the bearing collar 16 , a sealing ring 28 which forms the supporting edge of the bearing collar 16 can optionally be provided.
On the rear side 26 of the bearing collar 16 , the connecting element 12 continues in a shaft section 30 which forms a second functional section. To the side of the shaft section 30 latching tongues 32 can be seen, the latching tongue protruding perpendicularly out of the rear side 26 of the bearing collar 16 in the vicinity of the shaft section 30 and, in interaction with the correspondingly contoured aperture 15 , being able to ensure latching of the connecting element 12 in a preassembly position in which it is not yet fully inserted into the aperture 15 . To ensure a correct and centered guidance of the connecting element 12 in the correspondingly shaped aperture 15 , the two latching tongues 32 , which are arranged symmetrically, each have small guide lugs 34 on their outer sides, the guide lugs engaging in corresponding guide grooves 36 and being able to ensure that the connecting element 12 is centered there in the aperture. Furthermore, the latching tongues 32 are each provided with latching projections 38 on the outer surfaces of their free ends, the latching projections protruding slightly over the outer contour of the aperture 15 in the relaxed state of the two latching tongues 32 such that, when the connecting element 12 is inserted into the aperture 15 , the latching tongues 32 are slightly compressed in the direction of the shaft section 30 until the latching projections 38 have passed the inner edge of the aperture 15 and spring back again into their relaxed original position.
However, this is only the case when the connecting element 12 is to be fully inserted. The preassembly state according to FIG. 6 and FIG. 7 is characterized in that the latching projections 38 each bear against the edge of the opening of the aperture 15 and in that the latching tongue 32 are not yet compressed. In order to insert the connecting element 12 into the component 14 and to bring it into the preassembly state, it is brought, albeit with the aid of the snap-in tongues 40 described below, into a locked state that is characterized in that the connecting element 12 no longer drops out of the aperture 15 of the component 14 , but forms a resistance to further insertion.
The snap-in tongues 40 are arranged on the rear side of a third functional section of the connecting element 12 , the functional section being formed by a crossbar 42 that is arranged on the shaft section 30 . The crossbar 42 serves to lock the connecting element 12 by means of rotation through an angle of approximately 90° by the components that are to be connected to one another being engaged behind. In order to produce a prestressing force at the same time as the parts are locked, the crossbar 42 is provided with two bearing flanks 44 that are arranged opposite each other and the wedge-shaped inlet flanks 45 of which slide, during rotation of the connecting element 12 into the locked final assembly position, on corresponding supporting surfaces of the second or third component (not illustrated) to be connected to the first component 14 and, as the angle of rotation increases, clamp the parts more strongly together.
Finally, two symmetrically arranged latching wedges 46 are provided at the foot of the shaft section 30 , in a manner protruding into the rear side 26 of the bearing collar 16 , the latching wedges, in interaction with correspondingly shaped latching grooves 48 in the guide surface 50 of the component 14 for the bearing collar 16 , ensuring an additional slight latching of the connecting element 12 in the locked final position. Owing to the fact that, when the final position is reached, the prestressing force applied by the bearing flanks 44 is slightly reduced by the latching wedges 46 sliding into the corresponding latching grooves 48 , a latching is provided. In order to rotate the connecting element 12 back, a correspondingly higher opening force has to be applied.
The lateral guidance of the bearing collar 16 in the fully inserted state of the connecting element 12 is assisted on the first component 14 by means of bearing webs 52 that laterally bound the guide surface 50 . The bearing webs 52 here form parts of an annular enclosure. Furthermore, two marking lugs 54 can be seen, the marking lugs identifying the locked state when the marking arrows 24 are rotated in a manner such that they are aligned with the lugs 54 (cf. FIG. 10 ).
The connecting element 12 can only be pushed in a single angular position into the aperture 15 of the component 14 . In this case, the crossbar 42 passes through the elongate aperture opening that resembles the contour of a rectangle. FIG. 6 illustrates the insertion of the connecting element 12 until the latching projections 38 of the latching tongues 32 rest on the edge of the aperture 15 (cf. FIG. 6 ). The connecting element 12 is now pushed a short distance further, with the four snap-in tongues 40 being slightly compressed (cf. FIG. 7 ) until they finally snap into the corresponding steps 56 on the opposite longitudinal sides of the aperture 15 and, in the process, are relaxed. The connecting element 12 is now located in the preassembly position, in which it is not yet rotated, but is already secured against dropping out and is slightly latched and in which the component 14 can easily be brought to its desired installation site and positioned there without there being the risk of the connecting element 12 dropping out and becoming lost. The preassembly position is therefore also suitable for transporting the components 14 from the supplier to the final assembly site. In particular, the connecting element 12 is aligned in this position with the rear side of the first component 14 such that the first component 14 with the connecting elements 12 arranged therein can easily be introduced even into narrow installation spaces. The inserted connecting elements 12 do not obstruct a movement of the first component 14 in relation to the further component to be connected to it.
FIG. 9 shows an installed state in which the connecting element 12 is already pushed onto its axial stop such that the bearing collar 16 rests on the guide surface 50 . The crossbar 42 is pushed here through a second and/or third component (not illustrated) that have openings that are largely aligned with the aperture 15 of the first component 14 . However, various functional surfaces and edges can be omitted, for example the steps 50 or the guide grooves 36 , since the elements are merely required for fixing the connecting element 12 in the first component 14 in its preassembly position. The alignment of the two components to be connected is made easier in this position, since the aperture of the further component can easily be found by the connecting element 14 protruding on the rear side of the first component 14 .
After the components are attached to one another and the connecting element 12 is rotated through approximately 90° into its final assembly position corresponding to FIG. 10 and FIG. 11 , the marking arrows 24 are aligned with the marking lugs 54 ( FIG. 10 ), and the crossbar 42 with the bearing flanks 44 is located transversely with respect to the direction of longitudinal extent of the aperture 15 such that the bearing flanks 44 are clamped (cf. FIG. 11 ) against the corresponding bearing surfaces of the further component (not illustrated). At the same time, the clamping via the seal 28 ensures a high quality of seal between a wet space and a dry space.
In order to prevent over-rotation of the connecting element 12 beyond the maximum angle of rotation of 90° and in order to ensure a mechanical stop, additional stop steps 58 are provided next to the latching wedges 46 on the base of the shaft section 30 (cf. FIGS. 2 and 3 ), the bearing of which stop steps against a mating surface 60 can be seen in the rotated final assembly position according to FIG. 11 . This mating surface 60 is also indicated particularly clearly in FIG. 5 . A further mating surface 60 for the other stop step 58 is located diagonally opposite the mating surface 60 denoted in FIG. 5 .
FIG. 12 illustrates a further connecting arrangement 10 ′ that differs from the connecting arrangement 10 according to the preceding FIGS. 1 to 11 in the configuration of the contour of the aperture 15 on the first component 14 ′ and in the functional elements corresponding thereto on the crossbar 42 and on the shaft section 30 of the connecting element 12 ′. In particular, the further connecting arrangement 10 ′ is configured in such a manner that, in the preassembly position of the connecting element 12 ′, no further pressing of the connecting element 12 ′ through the aperture 15 in the axial direction is possible. For this purpose, an additional rotation of the connecting element 12 ′ has to take place first. The operation of the further connecting arrangement 10 ′ shown is now explained in detail.
In FIG. 12 , the connecting element 12 ′ is in a preassembly angular position, which corresponds to the preassembly position, in relation to the first component 14 ′. It can be seen that, in the angular position illustrated, the crossbar 42 can be partially introduced into the contour of the aperture 15 .
Two snap-in tongues 40 , of which only one can be seen in the view shown, are arranged opposite each other at the end of the shaft section 30 . In this case, the snap-in tongues 40 are upwardly curved at their end toward the bearing collar 16 , i.e. corresponding to FIG. 12 . Two latching pins 60 protruding radially from the shaft are fitted opposite each other on the shaft section 30 , in each case at a distance in the axial direction from the snap-in tongues 40 . Again, only one of the latching pins 60 can be seen in the illustration shown.
Like the connecting element 12 , the connecting element 12 ′ shown in FIG. 12 also has a hexagonal socket 20 on the upper side of the bearing collar 16 and two marking arrows 24 for checking the alignment.
An encircling web 62 on which a continuous pinch seal 63 is fitted is located on the first component 14 ′. In a final assembly position of the connecting element 12 ′, the pinch seal 63 serves to securely seal off a wet side from a dry side. In addition, the pinch seal 63 brings about an elastic prestress such that, in the final assembly position, a secure fit of the connecting element 12 ′ is ensured irrespective of any mechanical tolerances.
In the interior of the encircling web 62 , the aperture 15 is located in an outer guide surface 50 that partially surrounds it. The guide surface 50 here serves to support the bearing collar 16 of the connecting element 12 ′. A circumferential projection 65 that has an axially countersunk receiving groove 66 is furthermore arranged in sections of the contour of the aperture 15 . The aperture 15 is overall configured point-symmetrically with respect to the central axis such that a further circumferential projection 65 with a corresponding receiving groove 66 is located on that side of the contour of the aperture 15 that faces the viewer but is not visible.
It can be seen that, upon further axial guidance of the connecting element 12 ′, which is already in the preassembly angular position, the latching pins 60 each come to a stop against the respective circumferential projection 65 . The latching pins 60 are each located here in the axially recessed receiving grooves 66 . The latching tongues 40 are configured and dimensioned in such a manner that they engage behind the corresponding circumferential projection 65 , when the latching pins 60 come to a stop in the respective recessed receiving groove 66 , as a result of which the connecting element 12 ′ is latched in relation to the first component 14 ′ in the preassembly position.
It can furthermore be seen that, upon a rotation of the connecting element 12 ′ in the clockwise direction from the preassembly angular position shown, with the latching pins 60 each lying in the receiving groove 66 , a force has to be applied in relation to the snap-in tongues 40 which each engage behind the correspondingly circumferential projection 65 .
Furthermore, further rotation is only possible in the clockwise direction when the connecting element 12 ′ is partially introduced into the aperture 15 until the latching pins 60 come to a stop on the respective receiving groove 66 . Then, upon a rotation anticlockwise, the crossbar 42 comes to a stop against a corresponding stop surface 67 on the contour of the aperture 15 .
Furthermore, guide grooves 68 are again provided in the guide surface 50 in a point-symmetrical manner with respect to the central axis and a respective latching groove 48 is provided at the end of the guide grooves. The two guide grooves 68 and the two latching grooves 48 serve here to reliably rotate the connecting element 12 ′ from its preassembly position into the final assembly position. For this purpose, two corresponding latching wedges 46 (see FIG. 13 ) are each embedded on the lower side of the bearing collar 16 and are guided along the guide grooves 68 until they finally latch in the latching grooves 48 at the end. This configuration also ensures that an over-rotation of the connecting element 12 ′ is made more difficult and/or the final assembly position is reliably indicated to the fitter by this means. In addition, a rotation back of the connecting element 12 ′ out of the final assembly position, in which the latching wedges are each latched in the latching grooves 48 , is possible only with a certain noticeable counterforce.
FIG. 13 illustrates the further connecting arrangement 10 ′ according to FIG. 12 from a different perspective. The two latching wedges 46 on the lower side of the bearing collar 16 can now be clearly seen. It is also apparent that two snap-in tongues 40 which lie opposite each other with respect to the central axis are arranged at the end of the shaft section 30 .
The circumferential projection 65 , against which a snap-in tongue 40 is latched in a preassembly position of the connecting element 12 ′, can be seen from below through the aperture 15 .
FIG. 14 shows in detail the contour of the aperture 15 of the first component 14 ′, into which the connecting element 12 ′ according to FIGS. 12 and 13 can be introduced.
The encircling web 62 and the guide surface 50 arranged in the interior of the web 62 can be seen. The two opposite guide grooves 68 , at the respective end of which a latching groove 48 for receiving the latching wedges 46 apparent in FIG. 13 is provided, can each be seen in the guide surface.
The sectional circumferential projections 65 with the respective axially countersunk receiving grooves 66 can be seen on the contour of the aperture 15 . The latching pins 60 of the connecting element 12 ′ strike against the circumferential projections 65 when introduced in the preassembly angular position. At the same time, the snap-in tongues 40 each engage behind the circumferential projections 65 .
Furthermore, it can now be seen clearly that the connecting element 12 ′ in the preassembly position cannot be moved anticlockwise. This is because the crossbar 42 , which is partially introduced into the aperture 15 , would run here against the stop surface 67 .
In order to obtain a secure fit of the connecting element 12 ′ in the preassembly position in the aperture 15 of the first component 14 ′, two surface projections 72 that lie opposite each other with respect to the central axis are furthermore provided on the contour of the aperture 15 , and the crossbar 42 with its correspondingly configured supporting surfaces 70 (see FIG. 13 ) is supported against them in the preassembly position.
It can once again be seen clearly in FIG. 14 that, when the connecting element 12 ′ is introduced axially in a preassembly angular position, it is first of all supported in a latched manner on the contour of the aperture 15 . From this position, further linear guidance of the connecting element 12 ′ through the aperture 15 is not possible. Only upon a rotation in the clockwise direction from the preassembly angular position into an insertion angular position is the crossbar 42 brought from the latched position into a position into which it can be passed through the aperture 15 .
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The invention relates to a connecting element for the mechanical connection of at least two components, in particular two components of a motor vehicle door, with a bearing collar for bearing against a first component, with a crossbar that has bearing flanks for bearing against a second component and for clamping the latter against the first component in a rotated final assembly position, and with a shaft section, which bears the crossbar, for rotatably passing through corresponding openings in the components. In this case, a means is provided for fastening to the first component in a defined preassembly position. Furthermore, the invention relates to a corresponding connecting arrangement comprising at least two components each having an aperture, and a connecting element of this type, with the connecting element being held on the first component in a preassembly position.
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BACKGROUND OF THE INVENTION
The present invention relates to a medical image service method, medical software service method, medical image central management server apparatus, medical software central management server apparatus, medical image service system and medical software service system. More particularly, the present invention relates to a medical image service method, medical software service method, medical image central management server apparatus and medical software central management server apparatus which can reduce the work of managing medical images and medical software, relative to individual management thereof, at the installation site of a medical image diagnosis apparatus, and a medical image service system and medical software service system which can reduce the work of management and image processing relative to individual management and image processing.
In general, medical images taken at a hospital are accumulated in a local storage device in the hospital for management. For example, the images are accumulated on a hard disk device attached to an MRI apparatus or a CT apparatus. So that medical images taken at one hospital can be used at another hospital, a medical information service system is known which sends the medical images from a terminal in the former hospital to a terminal in the latter hospital via a network.
In addition, a hospital installs and manages the medical software (application programs) necessary for operating its medical image diagnosis apparatuses independently of other hospitals. The medical software programs used to operate MRI apparatuses and CT apparatuses, for example, are frequently improved, so that it is necessary to install patch software to upgrade the installed medical software every time an improvement is made.
When medical images are accumulated in a local storage device as in the past, the following problems arise:
(1) An MR image or a CT image has a relatively large data size. For example, an MR image with 256×256 dots and two-byte intensity has a data size of 128 kilobytes. However, a local storage device often has a storage capacity intended only for minimum practical use in a common hospital because of restriction on cost or the like, and the device cannot perform well in a hospital which requires an especially large number of images taken or an especially long image storage period. For example, assuming that three MRI apparatuses are installed in one hospital, and each MRI apparatus takes 1,000 images (=assuming the number of patients to be 20, and the number of images taken per patient to be 50) a day, the data size will be 128 megabytes a day and will be 37.5 gigabytes a year (assuming the number of operation days to be 300), which leads to difficulty in accumulating and managing MR images over many years in the instrument having a small storage capacity.
(2) In order to use a medical information service system, it is necessary for the sender and the recipient to make a contract with each other. In other words, each party must make as many contracts as the number of partners it has, which is troublesome. Accordingly, the number of partners is limited to a small number in practice.
(3) In order to use a medical information service system, the user needs to connect the partner's address by inputting the address through a terminal. When the number of the partners is large, the user cannot remember all of their addresses. The work of searching for a partner's address therefore takes place every time the address is needed, which is troublesome. Accordingly, the number of partners is limited to a small number in practice.
Moreover, when a medical image diagnosis apparatus performs image processing on a medical image, the following problems arise:
(1) If image processing is executed simultaneously with processing for imaging of a subject, the speed of one or both of the processing operations is liable to be lowered, and the processing time is prolonged in proportion.
(2) A separate image processing program must be installed in each medical image diagnosis apparatus. In other words, only a purchaser of the image processing program can use the program.
Furthermore, when medical software for medical image diagnosis apparatuses are separately managed in individual hospitals as in the past, the following problems occur:
(1) Each time new medical software is released, the hospitals must install it separately, which is time-consuming. Moreover, the work of software version management also falls on the hospital and is not an easy task.
(2) Since medical software can be updated only after the hospital obtains it as patch software recorded on a storage medium (such as an FD or MO), the time of the actual update is delayed relative to the release date. This is especially inconvenient when new hardware is introduced (for example, a new type of RF coil is installed in an MRI apparatus).
SUMMARY OF THE INVENTION
It is therefore a first object of the present invention to provide a medical image service method and system which can alleviate the effect of restricted storage capacity in the storage of medical images, and which can deliver medical images to a multiplicity of parties via a network without need for the troublesome work of making contracts or conducting searches. It is also within this object to provide a server apparatus for this purpose.
A second object of the present invention is to provide a medical image service system which can reduce image processing load, and which can make a medical image subjected to image processing easily available.
A third object of the present invention is to provide a medical software service method and system which can reduce the work of managing medical software at the installation site of a medical image diagnosis apparatus, and which enables immediate utilization of the latest medical software at all times. It is also within this object to provide a server apparatus for this purpose.
In accordance with a first aspect, the present invention provides a medical image service method characterized in that an image-registering subscriber permitted to register medical images, an image-receiving subscriber permitted to receive medical images, and a server apparatus for centrally managing medical images are connected via a network; and said server apparatus registers medical images sent by said image-registering subscriber in a database and delivers said medical images to said image-receiving subscriber.
In the medical image service method of the first aspect, since a server apparatus registers medical images sent by an image-registering subscriber via a network in a database, the number of medical images that an image-registering subscriber can store is not restricted by its local storage capacity. Specifically, since server apparatuses are as a general practice designed for the purpose of handling enormous volumes of stored information and to have a storage medium that is enhanced in maintainability and extensibility, the restriction on the storage capacity is substantially eliminated, and a large number of medical images taken in the past can be efficiently accumulated.
Moreover, since the server apparatus delivers medical images to an image-receiving subscriber via the network, medical images can also be delivered to a multiplicity of parties without need for the troublesome work of making contracts or conducting searches.
In accordance with a second aspect, the present invention provides the medical image service method of the foregoing configuration, characterized in that said medical images are those associated with at least one of MRI (magnetic resonance imaging), X-ray CT (computed tomography), ultrasound, PET (positron emission computed tomography), digitized X-ray (digital X-ray imaging and digitization of X-ray films) and CR (computed radiography).
In the medical image service method of the second aspect, several kinds of medical images (associated with MRI, X-ray CT, ultrasound, PET, digitized X-ray and CR) can be efficiently accumulated and delivered.
In accordance with a third aspect, the present invention provides the medical image service method of the foregoing configuration, characterized in that the method comprises: transmitting the medical images compressed in data size on the network, and decompressing the transmitted data into the original data on the receiving end.
In the medical image service method of the third aspect, since the medical image is transmitted after being compressed in data size, the transmission time can be reduced.
In accordance with a fourth aspect, the present invention provides the medical image service method of the foregoing configuration, characterized in that said server apparatus checks the legitimacy of said image-registering subscriber or said image-receiving subscriber.
In the medical image service method of the fourth aspect, since the server apparatus checks the legitimacy of the image-registering subscriber or image-receiving subscriber, illegitimate image registration by a third party who is not an image-registering subscriber or illegitimate delivery to a third party who is not an image-receiving subscriber can be prevented.
In accordance with a fifth aspect, the present invention provides the medical image service method of the foregoing configuration, characterized in that said server apparatus makes a backup of the medical images registered in the database.
In the medical image service method of the fifth aspect, since the server apparatus makes a backup of medical images registered in the database, the medical images can be prevented from being lost when a failure occurs, thereby improving reliability. Moreover, since the image-registering subscribers do not need to individually make backups, the work of the image-registering subscribers can be reduced.
In accordance with a sixth aspect, the present invention provides the medical image service method of the foregoing configuration, characterized in that said image-receiving subscriber sends format information including image identifier information to a hard copy device, and said hard copy device obtains delivery of a medical image corresponding to said image identifier information from said server apparatus via said network, and makes a hard copy of the medical image.
In the medical image service method of the sixth aspect, when format information including image identifier information is sent to a hard copy device, the hard copy device obtains delivery of a medical image from the server apparatus via the network, and makes a hard copy of the medical image. Therefore, apparatuses other than the hard copy device can be released to execute other processing after a short time period.
In accordance with a seventh aspect, the present invention provides the medical image service method of the foregoing configuration, characterized in that said server apparatus sends via said network to the delivery destination of a medical image the imaging conditions for the medical image.
In the medical image service method of the seventh aspect, since the server apparatus sends via the network to the delivery destination of a medical image the imaging conditions of the medical image, imaging under the same imaging conditions as in the past can be done by a medical image diagnosis apparatus installed at the delivery destination without need for resetting.
In accordance with an eighth aspect, the present invention provides a medical software service method characterized in that a software-executing subscriber permitted to run medical software, and a server apparatus for centrally managing medical software are connected via a network; and said server apparatus registers medical software in a database and delivers said medical software to said software-executing subscriber.
In the medical software service method of the eighth aspect, since a server apparatus delivers medical software registered in a database to a software-executing subscriber via a network, the work for managing medical software at the installation site of a medical image diagnosis apparatus can be reduced, and the latest medical software can be run.
In accordance with a ninth aspect, the present invention provides a medical image central management server apparatus characterized in that the apparatus comprises: medical image registering means for, when registration of a medical image is requested by an image-registering subscriber connected via the network of the foregoing configuration, registering said medical image in a database; and medical image delivery means for, when delivery of a medical image is requested by an image-receiving subscriber connected via said network, reading the medical image from said database and delivering the medical image to said image-receiving subscriber.
The medical image central management server apparatus of the ninth aspect is suitable as a server apparatus for use in the medical image service method as described regarding the first aspect.
In accordance with a tenth aspect, the present invention provides a medical image central management server apparatus characterized in that the apparatus comprises: medical image/imaging condition registering means for, when registration of a medical image is requested by an image-registering subscriber connected via a network, registering said medical image and its imaging conditions in a database; and medical image/imaging condition delivery means for, when delivery of a medical image is requested by an image-receiving subscriber connected via said network, reading the medical image and imaging conditions from said database and delivering the medical image and imaging conditions to said image-receiving subscriber.
The medical image central management server apparatus of the tenth aspect is suitable as a server apparatus for use in the medical image service method as described regarding the seventh aspect.
In accordance with an eleventh aspect, the present invention provides a medical software central management server apparatus characterized in that the apparatus comprises: medical software registering means for registering in a database medical software for each software-executing subscriber which is connected via a network and is permitted to run medical software; and medical software delivery means for delivering said medical software (or the product of its execution) to said software-executing subscriber in response to an access by said software-executing subscriber.
The medical software central management server apparatus of the eleventh aspect is suitable as a server apparatus for use in the medical software service method as described regarding the eighth aspect.
In accordance with a twelfth aspect, the present invention provides a medical image service system characterized in that the system comprises: an image-registering subscriber permitted to register medical images via a network; an image-receiving subscriber permitted to receive medical images via the network; and a server apparatus for registering medical images sent by said image-registering subscriber in a database and delivering said medical images to said image-receiving subscriber.
The medical image service system of the twelfth aspect can suitably practice the medical image service method as described regarding the first aspect.
In accordance with a thirteenth aspect, the present invention provides a medical image service system characterized in that the system comprises: an image-sending/receiving subscriber permitted to send and receive medical images via a network; and an image processing server apparatus for applying image processing to said medical images and sending the processed medical images back to said image-sending/receiving subscriber.
In the medical image service system of the thirteenth aspect, since an image processing server apparatus applies image processing to medical images sent by an image-sending/receiving subscriber via a network, and sends the result back to the image-sending/receiving subscriber, the image-sending/receiving subscriber does not need to perform image processing.
Therefore, the work of the image-sending/receiving subscriber can be reduced and the inconvenience of lowering the speed of other processing can be avoided. Moreover, since each image-sending/receiving subscriber is freed from the need to independently purchase and install image processing programs, the subscriber can easily obtain the result of image processing.
In accordance with a fourteenth aspect, the present invention provides a medical image service system characterized in that the system comprises: an image-sending subscriber permitted to send medical images via a network; an image-receiving subscriber permitted to receive medical images via the network; and an image processing server apparatus for applying image processing to medical images sent by said image-sending subscriber and sending the processed medical images to said image-receiving subscriber.
In the medical image service system of the fourteenth aspect, since an image processing server apparatus applies image processing to medical images sent by an image-sending subscriber via a network, and sends the result to an image-receiving subscriber, medical images subjected to required image processing can be obtained without need for the image-sending subscriber or the image-receiving subscriber to perform image processing. Moreover, it is also possible for the image processing server apparatus to deliver medical images to a multiplicity of image-receiving subscribers via the network, which is efficient.
In accordance with a fifteenth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that the system comprises two or more subscribers as at least one member among said image-sending/receiving subscriber, said image-sending subscriber and said image-receiving subscriber.
In the medical image service system of the fifteenth aspect, a plurality of image-sending/receiving subscribers or image-sending subscribers can send medical images to the image processing server apparatus. Moreover, a plurality of image-sending/receiving subscribers or image-receiving subscribers can obtain medical images subjected to image processing from the image processing server apparatus.
In accordance with a sixteenth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that the system comprises a plurality of said image processing server apparatuses, and the processing is shared among said image processing server apparatuses.
In the medical image service system of the sixteenth aspect, the processing efficiency can be improved by sharing the processing load among the plurality of image processing server apparatuses.
In accordance with a seventeenth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that at least one of said image-sending/receiving subscriber, said image-sending subscriber and said image-receiving subscriber specifies the type of image processing to communicate it to said image processing server apparatus.
In the medical image service system of the seventeenth aspect, the image-sending/receiving subscriber, image-sending subscriber and image-receiving subscriber can select the required image processing from among many types of image processing, and cause the image processing server apparatus to execute the selected image processing.
In accordance with an eighteenth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said image processing server apparatus informs said image-sending/receiving subscriber or said image-receiving subscriber of the type of image processing that was applied.
In the medical image service system of the eighteenth aspect, the image-sending/receiving subscriber or image-receiving subscriber can accurately ascertain the type of image processing applied to the medical image, thereby improving reliability.
In accordance with a nineteenth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that, when said image processing is completed, said image processing server apparatus establishes communication with said image-sending/receiving subscriber or said image-receiving subscriber and sends the medical image subjected to the image processing to said image-sending/receiving subscriber or said image-receiving subscriber.
In the medical image service system of the nineteenth aspect, after the completion of image processing, the image processing server apparatus establishes communication with the image-sending/receiving subscriber or image-receiving subscriber and sends the medical image subjected to the image processing. The use time of the network can therefore be decreased to reduce communication costs.
In accordance with a twentieth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said image-sending/receiving subscriber or said image-receiving subscriber sends a request for a medical image subjected to image processing to said image processing server apparatus and receives said medical image via said network.
In the medical image service system of the twentieth aspect, since the image-sending/receiving subscriber or image-receiving subscriber sends a request for a medical image subjected to image processing to the image processing server apparatus, the need for processing by the image processing server apparatus to establish communication with the image-sending/receiving subscriber or image-receiving subscriber is eliminated.
In accordance with a twenty-first aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said image processing server apparatus stores each medical image in at least one of its form before image processing and its form after image processing.
In the medical image service system of the twenty-first aspect, the image processing server apparatus can store a multiplicity of medical images taken in the past and/or medical images obtained by subjecting such images to image processing, and provide these images to the image-sending/receiving subscribers and image-receiving subscribers for use.
In accordance with a twenty-second aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said image-sending/receiving subscriber or said image-receiving subscriber requests said image processing server apparatus to conduct image processing on part or all of the medical images stored in said image processing server apparatus, and receives the medical images subjected to the image processing from said image processing server apparatus.
In the medical image service system of the twenty-second aspect, since the image-sending/receiving subscriber or image-receiving subscriber requests image processing of medical images stored in the image processing server apparatus, the need for sending original medical images each time image processing is to be performed is eliminated, and the processing time can be reduced.
In accordance with a twenty-third aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said image processing server apparatus polls said image-sending/receiving subscribers or said image-sending subscribers via said network to collect medical images before image processing.
In the medical image service system of the twenty-third aspect, since the image processing server apparatus polls the image-sending/receiving subscribers or image-sending subscribers to collect medical images before image processing, the work of the image-sending/receiving subscribers or image-sending subscribers for sending an original medical image to the image processing server apparatus can be reduced.
In accordance with a twenty-fourth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said medical images are those associated with at least one of MRI, X-ray CT, ultrasound, PET, digitized X-ray and CR.
In the medical image service system of the twenty-fourth aspect, several kinds of medical images (associated with MRI, X-ray CT, ultrasound, PET, digitized X-ray and CR) can be efficiently accumulated and delivered, and image processing can be applied to the several kinds of medical images.
In accordance with a twenty-fifth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that the system transmits the medical images compressed in data size on the network, and decompresses the transmitted data into the original data on the receiving end.
In the medical image service system of the twenty-fifth aspect, since the medical images are transmitted after being compressed in data size, the transmission time can be reduced.
In accordance with a twenty-sixth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said server apparatus comprises security means for checking the legitimacy of said image-registering subscriber or said image-receiving subscriber.
In the medical image service system of the twenty-sixth aspect, since the server apparatus checks the legitimacy of the subscriber, illegitimate registering, illegitimate sending or illegitimate receiving of images by third parties who are not valid subscribers can be prevented.
In accordance with a twenty-seventh aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said server apparatus comprises backup means for making a backup of the medical images registered in the database.
In the medical image service system of the twenty-seventh aspect, since the server apparatus makes a backup of medical images registered in the database, the medical images can be prevented from being lost when a failure occurs, thereby improving reliability. Moreover, since the image-registering subscribers do not need to individually make backups, the work of the image-registering subscribers can be reduced.
In accordance with a twenty-eighth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said image-receiving subscriber sends format information including image identifier information to a hard copy device, and said hard copy device makes a hard copy of a medical image sent by said server apparatus via said network.
In the medical image service system of the twenty-eighth aspect, when the image-receiving subscriber sends format information including image identifier information to the hard copy device, the hard copy device makes a hard copy of a medical image sent by the server apparatus via the network. Therefore, apparatuses other than the hard copy device can be released to execute other processing after a short time period.
In accordance with a twenty-ninth aspect, the present invention provides the medical image service system of the foregoing configuration, characterized in that said server apparatus sends via said network to the delivery destination of a medical image the imaging conditions for said medical image.
In the medical image service system of the twenty-ninth aspect, since the server apparatus sends via the network to the delivery destination of a medical image the imaging conditions for the medical image, imaging under the same imaging conditions as in the past can be done by a medical image diagnosis apparatus installed at the destination without need for resetting.
In accordance with a thirtieth aspect, the present invention provides a medical software service system characterized in that the system comprises: a software-executing subscriber permitted to run medical software via the network; and a server apparatus for registering medical software in a database and for delivering said medical software to said software-executing subscriber via said network.
In the medical software service system of the thirtieth aspect, the medical software service method as described regarding the eighth aspect can be suitably practiced.
According to the medical image service method, medical image central management server apparatus and medical image service system of the present invention, since medical images are centrally managed in a database on the server apparatus and required medical images are delivered via a network, the work for managing the medical images (and storage devices storing them) at the individual installation sites of medical image diagnosis apparatuses is reduced.
Moreover, according to the medical image service system of the present invention, since an image processing server apparatus applies image processing to a medical image and sends the result to a subscriber of an image processing service (the subscriber may include a provisional type that has no specific qualifications and a type that has entered into a specific contract), inconveniences experienced in running an image processing program on a medical image diagnosis apparatus (for example, reduction in processing speed, purchase and installation work) are eliminated, and every subscriber can obtain a medical image subjected to the required image processing any time.
Furthermore, according to the medical software service method, medical software central management server apparatus and medical software service system of the present invention, since medical software programs are centrally managed in a database on the server apparatus and required medical software is delivered via a network, the work for managing the medical software (and storage devices storing them) at the individual installation sites of medical image diagnosis apparatuses is reduced.
Further objects and advantages of the present invention will be apparent from the following description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a medical image service system in accordance with a first embodiment.
FIG. 2 is a flow chart showing medical image registration processing on a medical image database in a medical image central management server apparatus.
FIG. 3 is an exemplary diagram showing the registered contents in the medical image database after the registration processing of FIG. 2 .
FIG. 4 is a flow chart showing processing for delivery of medical images from the medical image central management server apparatus.
FIG. 5 is an exemplary diagram showing a screen for specifying a delivery-requested image.
FIG. 6 is a block diagram showing a medical image service system in accordance with a second embodiment.
FIG. 7 is a flow chart showing medical image registration processing in the medical image service system in accordance with a third embodiment.
FIG. 8 is an exemplary diagram showing the registered contents in the medical image database after the registration processing of FIG. 7 .
FIG. 9 is a flow chart showing processing for delivery of medical images and imaging conditions from the medical image central management server apparatus.
FIG. 10 is a block diagram showing a medical software service system in accordance with a fourth embodiment.
FIG. 11 is an exemplary diagram showing the registered contents in a medical software database.
FIG. 12 is a block diagram showing a medical image service system in accordance with a fifth embodiment.
FIG. 13 is a flow chart showing processing for applying image processing to a medical image and sending the processed image back to an image-sending/receiving subscriber by an image processing server apparatus.
FIG. 14 is a diagram illustrating the data structure of an image processing request.
FIG. 15 is a diagram illustrating the data structure of an image processing result.
FIG. 16 is a block diagram showing a medical image service system in accordance with a sixth embodiment of the present invention.
FIG. 17 is a block diagram showing a medical image service system in accordance with a seventh embodiment.
FIG. 18 is a flow chart showing processing for applying image processing to a medical image specified by an image-sending/receiving subscriber and sending the processed image to the image-sending/receiving subscriber by an image processing server apparatus.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described in detail with reference to embodiments shown in the accompanying drawings.
FIRST EMBODIMENT
FIG. 1 is a block diagram showing a medical image service system 1000 in accordance with a first embodiment of the present invention.
The medical image service system 1000 comprises a network 1 such as the Internet, a LAN (local aria network) or a WAN (wide aria network), an A-hospital 21 , B-hospital 22 , C-hospital 23 , D-hospital 24 , E-hospital 25 , and an SR1-individual 31 and SR2-individual 32 , and a medical image central management server apparatus 100 , all connected to the network 1 . The communication medium for the network 1 may be wired, wireless or a combination thereof.
When the network 1 is the Internet, a non-subscriber 50 is also connected to the network 1 . The non-subscriber 50 is a terminal that has not concluded a contract to use the medical image central management server apparatus 100 .
In addition, it is preferred to use an SSL (secure socket layer protocol) or the like in the interest of security.
In the A-hospital 21 , MRI apparatuses (A_MRI# 1 , A_MRI# 2 ), a CT apparatus (A_CT# 1 ) and an X-ray imaging apparatus (A_X# 1 ) are installed.
In the B-hospital 22 , an MRI apparatus (B_MRI# 1 ) is installed.
In the C-hospital 23 , an MRI apparatus (C_MRI# 1 ) and a CT apparatus (C_CT# 1 ) are installed.
In the D-hospital 24 , MRI apparatuses (D_MRI# 1 , D_MRI# 2 , D_MRI# 3 ) are installed.
Moreover, at least one of ultrasound diagnosis, PET and CR apparatuses may be installed instead of, or in addition to, the aforementioned apparatuses in any hospital.
The medical image central management server apparatus 100 comprises a communication section 10 A, an input section 10 B, an output section 10 C, a security management section 10 D, a data compression/decompression section 10 E, a backup control section 10 F, a medical image database management section 10 G and a medical image database 101 , and operates under the control of a medical image central management program. The storage medium for the medical image database 101 is a mass storage hard disk, for example.
The A-hospital 21 and B-hospital 22 have entered into contracts to register as image-registering subscribers and image-receiving subscribers of the medical image central management server apparatus 100 . They act as image-registering subscribers and image-receiving subscribers by running on their terminals a registering/receiving subscriber program. This program is recorded on a storage medium (such as a CD-ROM, FD) and delivered by a manager of the medical image central management server apparatus 100 , or is delivered via the network 1 . Thus, the A-hospital 21 and B-hospital 22 are permitted to register and receive medical images via the network 1 . It should be noted that by the symbol “/” is meant “and” (α/β means α and β).
The C-hospital 23 has entered into a contract to register as an image-registering subscriber of the medical image central management server apparatus 100 . It acts as image-registering subscriber by running on its terminal an image-registering subscriber program. This program is recorded on a storage medium and delivered by the manager of the medical image central management server apparatus 100 , or is delivered via the network 1 . Thus, the C-hospital 23 is permitted to register medical images via the network 1 .
The D-hospital 24 , E-hospital 25 , SR1-individual 31 and SR2-individual 32 have entered into contracts to register as image-receiving subscribers of the medical image central management server apparatus 100 . They act as image-receiving subscribers by running on their terminals an image-receiving subscriber program. This program is recorded on a storage medium and delivered by the manager of the medical image central management server apparatus 100 , or is delivered via the network 1 . Thus, the D-hospital 24 , E-hospital 25 , SR1-individual 31 and SR2-individual 32 are permitted to receive medical images via the network 1 .
The manager of the medical image central management server apparatus 100 concludes separate contracts with the individual image-registering subscribers and image-receiving subscribers, by which the image-registering subscribers are permitted to register medical images they own, and the image-receiving subscribers are permitted to obtain delivery of medical images on request. As a result of these contracts, the subscribers do not (have no need to) conclude contracts with one another. The medical image central management server apparatus 100 performs database registration of medical images owned by the image-registering subscribers via the network 1 , and transfers medical images via the network 1 in response to delivery requests from the image-receiving subscribers. The server apparatus 100 also performs security management.
The manager of the medical image central management server apparatus 100 keeps subscriber information. The creation/updating of the subscriber information is performed as follows:
(1) A new subscriber makes a contract with the manager, and receives a storage medium containing a program corresponding to the type of contract. Alternatively, the new subscriber downloads the program via the network 1 .
(2) When the new subscriber installs the program and runs the program the first time, the program automatically accesses the medical image central management server apparatus 100 via the network 1 and requests it to update the subscriber information. The medical image central management server apparatus 100 then adds the new subscriber to the subscriber information.
(3) When a subscriber cancels its contract, the medical image central management server apparatus 100 deletes the subscriber from the subscriber information.
The manager receives a subscription fee upon making a contract. The manager also receives a management fee regularly or irregularly for services such as maintenance and update of the subscriber information. Furthermore, the manager markets the aforementioned programs. In addition, the manager receives a registration fee from each image-registering subscriber that is proportional to the storage capacity used to register the subscriber's medical images. (A storage capacity that varies with the registration fee paid can be pre-allocated and the image-registering subscriber be informed of the allocated capacity and the capacity in use, or a registration fee can be billed depending on the storage capacity in use.) Further, the manager receives a delivery fee from the image-receiving subscriber depending on the number of medical image deliveries.
FIG. 2 is a flow chart showing processing for registering a medical image in the medical image database 101 in the medical image central management server apparatus 100 by an image-registering subscriber. The flow on the left is for the image-registering subscriber (assuming the image-registering subscriber to be the A-hospital 21 ). The flow on the right is for the medical image central management server apparatus 100 .
In Step a 1 , the A-hospital 21 sends a request for registration of a medical image (any one of MRI, CT, X-ray images) to the medical image central management server apparatus 100 via the network 1 . The medical image may be a clinical image for diagnosis on a patient, or a sample image for medical education.
In Step s 1 , the medical image central management server apparatus 100 receives the medical image registration request.
In Step s 2 , the security management section 10 D of the medical image central management server apparatus 100 checks the legitimacy of the medical image registration request using an authentication technique etc., and if it is illegitimate, the process goes to Step s 3 ; otherwise to Step s 4 . The check of the legitimacy uses a known legitimacy check method for communication line connection, such as a check on a network address or a telephone number, a check on a password, or a check on an ID card. Moreover, a charge billing screen (not shown) is displayed on the terminal of the A-hospital 21 to bill a connect charge, and if an operator at the A-hospital 21 performs an operation on the charge billing screen for making payment via a direct deposit from a bank account, via a credit card or a payment agency service, the request is regarded as legitimate; otherwise as illegitimate.
In Step s 3 , the communication line is disconnected.
In Step s 4 , the medical image central management server apparatus 100 sends a request for the medical image to the A-hospital 21 via the network 1 .
In Step a 2 , the A-hospital receives the medical image request.
In Step a 3 , the A-hospital sends the medical image (including image identifier information) to be registered to the medical image central management server apparatus 100 via the network 1 . The image identifier information may be an image ID, or combined information of a patient ID, an imaging date, an apparatus ID of a medical image diagnosis apparatus or the like. At this time, data obtained by compressing the data size of the medical image by a reversible method of compression may be sent to reduce the data transmission time. The method of compression is, for example, reversible JPEG (Joint Photographic Experts Group) compression. Moreover, the latest registered image may be temporarily stored on a local storage device (such as a hard disk or memory) as a precaution against a sudden failure of the network 1 or medical image central management server apparatus 100 .
In Step s 5 , the medical image central management server apparatus 100 receives the medical image. If the medical image data is compressed, the data is decompressed into the original data at the data compression/decompression section 10 E.
In Step s 6 , the medical image database management section 10 G in the medical image central management server apparatus 100 registers the medical image in the medical image database 101 .
The registration processing in the medical image database 101 is then terminated.
FIG. 3 is an exemplary diagram showing the registered contents in the medical image database 101 after the registration processing of FIG. 2 .
In the column designated “Registrant”, the A-hospital, B-hospital, C-hospital, . . . are registered, for example, as the registrants of medical images. The registrant may be received at Step a 5 in FIG. 2 , or may be identified based on the apparatus ID of the medical image diagnosis apparatus or the like.
In the column designated “Patient ID”, A12345, B22716, B23857, . . . are registered, for example, as the patient IDs.
In the column designated “Imaging Date”, 3-23-2000 10:35, 3-23-2000 11:47, 3-28-2000 13:21, . . . are registered, for example, as the imaging dates of the medical images.
In the column designated “Apparatus ID”, A_MRI# 2 , A_MRI# 1 , A_CT# 1 , . . . are registered, for example, as the apparatus IDs of the medical image diagnosis apparatuses.
In the column designated “Image Data”, 1110010100, 1101001000, 1111010011, . . . are registered, for example, as the image data of the medical images.
It should be noted that the registered contents in the medical image database 101 undergo backup upon update or regularly by the control from the backup control section 10 F.
FIG. 4 is a flow chart showing processing for delivering a medical image from the medical image central management server apparatus 100 . The flow on the left is for the image-receiving subscriber (assuming the image-receiving subscriber to be the A-hospital 21 ). The flow on the right is for the medical image central management server apparatus 100 .
In Step a 11 , the A-hospital sends a request for delivery of a medical image to the medical image central management server apparatus 100 via the network 1 .
In Step s 11 , the medical image central management server apparatus 100 receives the medical image delivery request.
In Step s 12 , the security management section 10 D in the medical image central management server apparatus 100 checks the legitimacy of the medical image delivery request, and if the request is illegitimate, the process goes to Step s 13 ; otherwise to Step s 14 .
In Step s 13 , the communication line is disconnected.
In Step s 14 , the medical image central management server apparatus 100 sends a request for image identifier information to the A-hospital 21 via the network 1 .
In Step a 12 , the A-hospital 21 receives the image identifier information request.
In Step a 13 , the A-hospital 21 sends image identifier information to the medical image central management server apparatus 100 via the network 1 .
In Step s 15 , the medical image central management server apparatus 100 receives the image identifier information.
In Step s 16 , the medical image database management section 10 G in the medical image central management server apparatus 100 reads the medical image corresponding to the image identifier information from the medical image database 101 .
In Step s 17 , the medical image central management server apparatus 100 sends the read-out medical image to the A-hospital 21 via the network 1 . The data compression/decompression section 10 E may send data obtained by compressing the data size of the medical image by a reversible method of compression.
In Step a 14 , the A-hospital 21 receives the medical image. If the medical image data is compressed, the data is decompressed into the original data.
In Step a 15 , the A-hospital 21 displays the received medical image on a screen. The latest displayed image may be temporarily stored on a local storage device as a precaution against a sudden failure of the network 1 or medical image central management server apparatus 100 .
The medical image delivery processing is then terminated.
FIG. 5 is an exemplary diagram showing a delivery-requested image specifying screen G 1 for specifying an image requested for delivery on a terminal at the A-hospital 21 . The screen is displayed by, for example, inputting a patient ID and then clicking “Display List”. The data used for displaying the imaging date, image type, apparatus ID, site, comment and thumbnail may be stored on a local hard disk in the A-hospital 21 , or may be received from the medical image central management server apparatus 100 via the network 1 (in the latter case, the necessary data is previously stored in the medical image database 101 ). Since the thumbnail can be displayed in small data size, a multiplicity of thumbnails can be stored even in a hard disk of a small capacity.
The operator selects a delivery specification frame corresponding to the medical image whose delivery is desired, for example, an MR image having an imaging date of [3-23-2000 11:47], by a mouse etc., and then selects “Request Delivery”. Then, a delivery request is sent (see Step a 11 in FIG. 4 ), subsequently image identifier information corresponding to the specified image is sent (see Step a 13 in FIG. 14 ), and a medical image delivered from the medical image central management server apparatus 100 via the network 1 can be received (see Step a 14 in FIG. 4 ). If “Cancel” is selected before selecting “Request Delivery”, the image specification is canceled.
According to the medical image service system 1000 of the first embodiment, since medical images obtained by the hospitals are registered in the medical image database 101 in the medical image central management server apparatus 100 and are centrally managed, the problem of restricted storage capacity is substantially eliminated, and a large number of medical images taken in the past can be efficiently accumulated.
Moreover, since medical images can be shared among the hospitals, the system is capable of dealing with, for example, cases in which a physician observes a medical image at a location other than the installation site of an MRI apparatus; in which a patient transfers to another hospital and medical images for the patient are provided to a physician at the new hospital; and in which an individual patient desires to view his/her medical images on a personal computer terminal or the like (however, the individual patient must directly or indirectly enter into a contract with the manager of the medical image central management server apparatus 100 ).
Furthermore, since a backup of the medical images is made by the medical image central management server apparatus 100 , the work of the individual hospitals separately preparing backups is eliminated.
SECOND EMBODIMENT
FIG. 6 is a block diagram showing a medical image service system 2000 in accordance with a second embodiment.
A terminal 211 of an image-receiving subscriber (assumed to be an A-hospital 21 ) sends to its associated hard copy device 212 format information defining the frame position, image size and the like of a medical image to be printed on a film. It should be noted that the format information contains image identifier information for identifying the medical image for each frame. The hard copy device 212 is, for example, a multi-format camera or a laser imager.
Upon receiving the format information, the hard copy device 212 sends a request for delivery of the medical image corresponding to the image identifier information to the medical image central management server apparatus 100 via the network, and receives the medical image. Then the hard copy device 212 prints the medical image in the area corresponding to the frame position and the image size.
According to the medical image service system 2000 of the second embodiment, when the terminal 211 sends format information to the hard copy device 212 , the device 212 obtains delivery of a medical image from the medical image central management server apparatus 100 via the network 1 and prints the medical image on a film. The terminal 211 can therefore be released from the processing for the hard-copy production and return to other processing after a short time period.
THIRD EMBODIMENT
FIG. 7 is a flow chart showing processing for registering a medical image in a medical image service system in accordance with a third embodiment. The flow on the left is for the image-registering subscriber. The flow on the right is for the medical image central management server apparatus 200 (corresponding to 100 in FIG. 1 ).
Steps a 1 –a 3 are the same as the processing described with reference to FIG. 2 , and therefore the explanation thereof will be omitted.
Steps s 1 –s 5 are the same as the processing described with reference to FIG. 2 , and therefore the explanation thereof will be omitted.
In Step s 55 , the medical image central management server apparatus 200 sends a request for the imaging conditions of the medical image registered in the medical image database 101 to the A-hospital 21 via the network 1 .
In Step a 34 , the A-hospital 21 receives the imaging condition request.
In Step a 35 , the A-hospital 21 sends the imaging conditions to the medical image central management server apparatus 200 via the network 1 .
In Step s 56 , the medical image central management server apparatus 200 receives the imaging conditions.
In Step s 57 , the medical image database management section 10 G (see FIG. 1 ) in the medical image central management server apparatus 200 registers the imaging conditions in a medical image database 201 (corresponding to 101 in FIG. 1 ).
The registration processing on the medical image database 201 is then completed.
FIG. 8 is an exemplary diagram showing the registered contents in the medical image database 201 after the registration processing of FIG. 7 .
The registered contents in the columns designated “Registrant”, “Patient ID”, “Imaging Date”, “Apparatus ID” and “Image Data” are the same as those of the medical image database 101 shown in FIG. 2 .
In the column designated “Imaging Condition”, imaging conditions of the medical images are registered. For example, for an MR image, TR (repetition time)=2400, TE (echo time)=80 and the like are registered; for a CT image, p (helical pitch)=3 and the like are registered; and for an X-ray image, mAs (tube current)=26 and the like are registered.
FIG. 9 is a flow chart showing processing for delivering a medical image and imaging conditions from the medical image central management server apparatus 200 to an image-receiving subscriber. The flow on the left is for the image-receiving subscriber. The flow on the right is for the medical image central management server apparatus 200 .
The processing in Steps a 11 –a 15 are the same as those described with reference to FIG. 4 , and therefore the explanation thereof will be omitted.
Steps s 11 –s 17 are the same as the processing described with reference to FIG. 4 , and therefore the explanation thereof will be omitted.
In Step s 156 , the A-hospital 21 sends a request for imaging conditions to the medical image central management server apparatus 200 via the network.
In Step s 178 , the medical image central management server apparatus 200 receives the imaging condition request.
In Step s 179 , the medical image database management section 10 G in the medical image central management server apparatus 200 reads from the medical image database 201 imaging conditions corresponding to the medical image delivered to the A-hospital 21 .
In Step s 180 , the medical image central management server apparatus 200 sends the imaging conditions to the A-hospital 21 via the network 1 .
In Step s 157 , the A-hospital receives the imaging conditions.
In Step s 158 , the received imaging conditions are set in a medical image diagnosis apparatus. For example, if TR=2400 and TE=80 are sent as imaging conditions for an MR image, these conditions are set in an MRI apparatus. Thus, the imaging conditions do not need to be reset, and a subject can be scanned under the same imaging conditions as in the past.
The processing for delivering a medical image and imaging conditions is then terminated.
According to the medical image service system of the third embodiment, since imaging conditions are sent by the medical image central management server apparatus 200 to the delivery destination of the medical image (which may be either the hospital that took the medical image or another hospital) via the network 1 , imaging under the same imaging conditions as in the past can be performed without need for resetting.
FOURTH EMBODIMENT
FIG. 10 is a block diagram showing a medical software service system 4000 in accordance with a fourth embodiment.
The medical software service system 4000 comprises a network 1 such as the Internet, a LAN or WAN, an A-hospital 21 , B-hospital 22 , C-hospital 23 , D-hospital 24 , and a vendor 60 that develops medical software, and a medical software central management server apparatus 400 , all connected to the network 1 .
The medical software central management server apparatus 400 comprises a communication section 10 A, an input section 10 B, an output section 10 C, a security management section 10 D, a medical software database management section 10 H and a medical software database 401 , and operates under the control of medical software central management program.
When the network 1 is the Internet, a non-subscriber 50 is also connected to the network 1 . The non-subscriber 50 is a terminal that has not concluded a contract to use the medical software central management server apparatus 400 .
In addition, it is preferred to use an SSL or the like in the interest of security.
Each of the A-hospital 21 , B-hospital 22 , C-hospital 23 and D-hospital 24 has entered into a contract to register as a software-executing subscriber permitted to run medical software (for example, an application program defining a scan algorithm) registered in the database in the medical software central management server apparatus 400 . It acts as a software-executing subscriber by running on its terminal a software-executing subscriber program. This program is recorded on a storage medium (such as a CD-ROM, FD) and delivered by a manager of the medical software central management server apparatus 400 , or is delivered via the network 1 . Thus, the A-hospital 21 , B-hospital 22 , C-hospital 23 and D-hospital 24 are permitted to read medical software via the network 1 and run the medical software.
FIG. 11 is an exemplary diagram showing the registered contents of the medical software database 401 .
In the column designated “Installation Site”, A-hospital, B-hospital, C-hospital . . . are registered, for example, as the installation sites of medical image diagnosis apparatuses that use medical software.
In the column designated “Update Date”, 3-23-2000 3:35, 3-23-2000 1:47, 3-28-2000 3:21, . . . are registered, for example, as the latest dates of updates for medical software.
In the column designated “Apparatus ID”, A_MRI# 2 , A_MRI# 1 , A_CT# 1 , . . . are registered, for example, as the apparatus IDs of medical image diagnosis apparatuses.
In the column designated “Medical Software ID”, IDs pointing to medical software stored in the medical software storage section 401 S, for example, GEYMS_MR_SYSTEM_VER5.0, GEYMS_CT_SYSTEM_VER7.3, . . . are registered.
The operation of the medical software service system 4000 of FIG. 10 will now be described.
When the vendor 60 has developed new medical software or upgraded existing medical software, it registers the medical software in the medical software database 401 in the medical software central management server apparatus 400 via the network 1 . Specifically, the object medical software is stored in the medical software storage section 401 S and the contents in the columns of FIG. 11 are newly registered or updated. It should be noted that the security management section 10 D in the medical software central management server apparatus 400 comprises the function of preventing illegitimate registration by the non-subscriber 50 .
In performing imaging by a medical image diagnosis apparatus, the A-hospital 21 , B-hospital 22 , C-hospital 23 and D-hospital 24 access the medical software central management server apparatus 400 via the network 1 , read out medical software registered on the medical software database 401 , and run the medical software. It should be noted that the security management section 10 D in the medical software central management server apparatus 400 comprises the function of preventing illegitimate running of the software by the non-subscriber 50 .
According to the medical software service system 4000 of the fourth embodiment, since the medical image diagnosis apparatus in each hospital reads out medical software registered on the medical software database 401 in the medical software central management server apparatus 400 via the network 1 and runs the medical software, immediate utilization of the latest medical software is possible at all times without need for troublesome work.
It should be noted that instead of directly running medical software stored in the medical software storage section 401 S on a medical image diagnosis apparatus in a hospital, the medical software may be first installed in a local storage device and run.
Moreover, the medical software may be run in the medical software central management server apparatus 400 and the result may be delivered to a medical image diagnosis apparatus.
Furthermore, the medical software may be a product version that has been formally released, or may be a sample version released for trial. (By running the sample version, an evaluation can be made as to whether the software should be formally introduced.)
FIFTH EMBODIMENT
FIG. 12 is a block diagram showing a medical image service system 5000 in accordance with a fifth embodiment of the present invention.
The medical image service system 5000 comprises a network 1 , an A-hospital 51 , B-hospital 52 , C-hospital 53 , D-hospital 54 , E-hospital 55 , and an SR1-individual 61 and SR2-individual 62 , and an image processing server apparatus 500 , all connected to the network 1 .
When the network 1 is the Internet, a non-subscriber 50 is also connected to the network 1 . The non-subscriber 50 is a terminal that has not concluded a contract to use the image processing server apparatus 500 .
In addition, it is preferred to use an SSL or the like in the interest of security.
In the A-hospital 51 , MRI apparatuses (A_MRI# 1 , A_MRI# 2 ), a CT apparatus (A_CT# 1 ) and an X-ray imaging apparatus (A_X# 1 ) are installed.
In the B-hospital 52 , an MRI apparatus (B_MRI# 1 ) is installed.
In the C-hospital 53 , an MRI apparatus (C_MRI# 1 ) and a CT apparatus (C_CT# 1 ) are installed.
In the D-hospital 54 , MRI apparatuses (D_MRI# 1 , D_MRI# 2 , D_MRI# 3 ) are installed.
Moreover, at least one of ultrasound diagnosis, PET and CR apparatuses may be installed instead of, or in addition to, the aforementioned apparatuses in any hospital.
The image processing server apparatus 500 comprises a communication section 10 A, an input section 10 B, an output section 10 C, a security management section 10 D and an image processing section 501 , and operates under the control of an image processing program.
The A-hospital 51 and B-hospital 52 have entered into contracts to register as image-sending/receiving subscribers permitted to send/receive medical images. They act as image-sending/receiving subscribers by running on their terminals an image-sending/receiving subscriber program. This program is recorded on a storage medium (such as a CD-ROM, FD) and delivered by a manager of the image processing server apparatus 500 , or is delivered via the network 1 . Thus, the A-hospital 51 and B-hospital 52 are permitted to send and receive medical images via the network 1 .
The C-hospital 53 has entered into a contract to register as an image-sending subscriber of the image processing server apparatus 500 . It acts as an image-sending subscriber by running on its terminals an image-sending subscriber program. This program is recorded on a storage medium and delivered by the manager of the image processing server apparatus 500 , or is delivered via the network 1 . Thus, the C-hospital 53 is permitted to send medical images via the network 1 .
The D-hospital 54 , E-hospital 55 , SR1-individual 61 and SR2-individual 62 have entered into contracts to register as image-receiving subscribers of the image processing server apparatus 500 . They act as image-receiving subscribers by running on their terminals an image-receiving subscriber program. This program is recorded on a storage medium and delivered by the manager of the image processing server apparatus 500 , or is delivered via the network 1 . Thus, the D-hospital 54 , E-hospital 55 , SR1-individual 61 and SR2-individual 62 are permitted to receive medical images via the network 1 .
The manager of the image processing server apparatus 500 concludes separate contracts with the individual image-sending subscribers and image-receiving subscribers, by which the image-sending subscribers (including image-sending/receiving subscribers) are permitted to apply image processing to medical images they send, and the medical images subjected the image processing are sent to the image-receiving subscribers (including the image-sending/receiving subscribers). As a result of these contracts, the subscribers do not (have no need to) conclude contracts with one another. The image processing server apparatus 500 applies image processing to medical images sent by the image-sending subscribers and sends the medical images subjected to the image processing to the image-receiving subscribers via the network 1 . The image processing server apparatus 500 also performs security management. The image processing is, for example, image filtering processing such as smoothing, differentiation, Laplacian, edge detection and band pass, or projection processing such as addition, subtraction and MIP (maximum intensity projection).
Moreover, the manager receives any one of a fixed fee, a volume fee or a combination thereof from each subscriber. For example, the manager receives a subscription fee upon making a contract. Moreover, the manager also receives a management fee regularly or irregularly for services such as maintenance and update of the subscriber information. Furthermore, the manager markets the aforementioned programs. In addition, the manager receives a fee from the subscriber that is proportional to the volume of the medical images (the number of medical images or the data size etc.) subjected to image processing or the number of image processing sessions or the image processing time.
FIG. 13 is a flow chart showing processing for sending a medical image to the medical image server apparatus 500 and receiving the medical image subjected to the image processing, by an image-sending/receiving subscriber. The flow on the left is for the image-sending/receiving subscriber (assuming the image-sending/receiving subscriber to be the A-hospital 51 ). The flow on the right is for the image processing server apparatus 500 .
In Step a 51 , the A-hospital 51 (any one of the MRI, CT or X-ray imaging apparatuses) sends an image processing request Q containing image data of a medical image (any one of MRI, CT or X-ray images) to the image processing server apparatus 500 via the network 1 . As shown in FIG. 14 , the image processing request Q consists of a header portion H 1 (a destination Ha, a sender Hb, an image processing request command Hc and an image processing type Hd) and image data D 1 . In this example, the destination Ha is the address of the image processing server apparatus 500 . The sender Hb is the address of the A-hospital 51 . The image processing request command Hc and the image processing type Hd are bit sequences for requesting, for example, MIP processing. The image data D 1 is that, for example, of an MRI image.
In Step s 51 , the image processing server apparatus 500 receives the image processing request Q.
In Step s 52 , the security management section 10 D in the image processing server apparatus 500 checks the legitimacy of the medical image processing request using an authentication technique etc., and if it is illegitimate, the process goes to Step s 53 ; otherwise to Step s 54 .
In Step s 53 , the communication line is disconnected.
In Step s 54 , the image processing server apparatus 500 extracts the image data D 1 (see FIG. 14 ) from the image processing request Q. Then, the image processing specified in the image processing type Hd is applied to the image data D 1 by the image processing section 501 .
In Step s 55 , the image processing server apparatus 500 informs the A-hospital 51 of the image processing result R via the network 1 . As shown in FIG. 15 , the image processing result R consists of a header portion H 2 (a destination Ha, a sender Hb and an image processing type done He) and image data D 2 subjected to the image processing. In this example, the destination Ha is the address of the A-hospital 51 . The sender Hb is the address of the image processing server apparatus 500 . The image processing type done He is a bit sequence representing the MIP processing. The image data D 2 is that subjected to the MIP processing.
In Step a 52 , the A-hospital 51 receives the image processing result R.
In Step a 53 , the A-hospital 51 extracts the image data D 2 from the image processing result R, and displays the medical image subjected to the image processing (in this example, an MRI image subjected to the MIP processing).
According to the medical image service system 5000 of the fifth embodiment, the image-sending/receiving subscriber (the A-hospital 51 or B-hospital 52 ) sends a medical image to the image processing server apparatus 500 via the network 1 , and receives the medical image subjected to image processing from the image processing server apparatus 500 and displays the medical image. Therefore, during the processing for imaging by a medical image diagnosis apparatus, the apparatus can receive and display a medical image subjected to image processing without sacrificing the processing speed of imaging.
Moreover, since the need for installing an image processing program on a medical image diagnosis apparatus is eliminated, the image-sending/receiving subscriber can easily obtain a medical image subjected to image processing. Thus, for example, a customer having a specific image processing program (which may be one purchased from the vendor of the image processing section 501 or from another vendor) installed on a medical image diagnosis apparatus can easily try or use other image processing.
Although in the fifth embodiment the medical image subjected to image processing is sent back to the image-sending/receiving subscriber that was the sender, the medical image subjected to image processing can instead be sent to an image-receiving subscriber other than the sender. For example, the image processing server apparatus 500 may apply image processing on a medical image sent by an image-sending subscriber (for example, the C-hospital 53 ), and send the result to an image-receiving subscriber (any one or all of the D-hospital 54 , E-hospital 55 , SR1-individual 61 and SR2-individual 62 ). However, in this case, a delivery destination must be included in the header portion H 1 of the image processing request Q (see FIG. 14 ).
Moreover, the image processing server apparatus 500 may temporarily disconnect the communication line upon receiving the image processing request Q, establish communication with the image-sending/receiving subscriber or image-receiving subscriber after the image processing has been completed, and then send the medical image subjected to image processing. Alternatively, after the disconnection, the image-sending/receiving subscriber or image-receiving subscriber may send a request for the medical image subjected to image processing to the image processing server apparatus 500 and receive the medical image. In these cases, the use time of the network 1 can be decreased to reduce communication costs.
SIXTH EMBODIMENT
FIG. 16 is a block diagram showing a medical image service system 6000 in accordance with a sixth embodiment of the present invention.
The medical image service system 6000 comprises image processing server apparatuses 500 - 1 and 500 - 2 . The configuration of the image processing server apparatuses 500 - 1 and 500 - 2 are the same as the image processing server apparatus 500 (see FIG. 12 ) in accordance with the fifth embodiment.
In the medical image service system 6000 , image processing on medical images is shared between the image processing server apparatuses 500 - 1 and 500 - 2 . For example, when image processing is performed on 200 medical images, the image processing on the first—100 th images is performed by the image processing server apparatus 500 - 1 , and the image processing on the 101 st –200 th images is performed by the image processing server apparatus 500 - 2 . The share of the processing may be decided by the sender (an image-sending/receiving subscriber or image-sending subscriber), or may be decided by the image processing server apparatus 500 - 1 or 500 - 2 which receives the image processing request Q depending on the load status or the like.
According to the medical image service system 6000 of the sixth embodiment, the processing efficiency can be improved by sharing the load between the image processing server apparatuses 500 - 1 and 500 - 2 .
SEVENTH EMBODIMENT
FIG. 17 is a block diagram showing a medical image service system 7000 in accordance with a seventh embodiment of the present invention.
In the medical image service system 7000 , an image processing server apparatus 700 comprises a communication section 10 A, an input section 10 B, an output section 10 C, a security management section 10 D, a data compression/decompression section 10 E, a backup control section 10 F, an image processing section 501 , a medical image database management section 701 G and a medical image database 701 , and operates under the control of an image processing program and a medical image central management program.
In the medical image service system 7000 , medical images sent by an image-sending/receiving subscriber or image-sending subscriber are registered in the medical image database 701 in the image processing server apparatus 700 by database registration processing similar to that in the medical image service system 1000 in accordance with the first embodiment (see FIG. 2 ).
FIG. 18 is a flow chart showing the processing when an image-sending/receiving subscriber or image-sending subscriber makes a request to the image processing server apparatus 700 for image processing on a medical image registered in the medical image database 701 and receipt of the medical image subjected to the image processing. The flow on the left is for the image-sending/receiving subscriber (assuming the image-sending/receiving subscriber to be the A-hospital 51 ). The flow on the right is for the image processing server apparatus 700 .
In Step a 71 , the A-hospital 51 sends an image processing request to the image processing server apparatus 700 via the network 1 . However, it should be noted that no image data D 1 (see FIG. 14 ) is contained in the image processing request.
In Step s 71 , the image processing server apparatus 700 receives the image processing request.
In Step s 72 , the security management section 10 D in the image processing server apparatus 700 checks the legitimacy of the image processing request, and if the request is illegitimate, the process goes to Step s 73 ; otherwise to Step s 74 .
In Step s 73 , the communication line is disconnected.
In Step s 74 , the image processing server apparatus 700 sends to the A-hospital 51 via the network 1 an image identifier information request for requesting image identifier information for identifying the medical image to be subjected to image processing.
In Step a 72 , the A-hospital 51 receives the image identifier information request.
In Step a 73 , the A-hospital 51 sends image identifier information to the image processing server apparatus 700 via the network 1 . For example, similarly to the case described earlier with reference FIG. 5 , there is sent image identifier information of an image selected from images displayed as thumbnails on the terminal in the A-hospital.
In Step s 75 , the image processing server apparatus 700 receives the image identifier information.
In Step s 76 , the medical image database management section 710 G in the image processing server apparatus 700 reads the medical image corresponding to the image identifier information from the medical image database 701 .
In Step s 77 , the image processing server apparatus 700 applies to the medical image the image processing specified by the image processing type Hd (see FIG. 14 ) in the image processing request.
In Step s 78 , the image processing server apparatus 700 sends the image processing result R (see FIG. 15 ) to the A-hospital 51 via the network 1 . The data compression/decompression section 10 E may send data obtained by compressing the data size by a reversible method of compression.
In Step a 74 , the A-hospital 51 receives the image processing result. If the medical image is compressed data, the data is decompressed into the original data at the data compression/decompression section 10 E.
In Step a 75 , the A-hospital extracts image data D 2 from the image processing result R, and displays the medical image subjected to the image processing.
According to the medical image service system 7000 of the seventh embodiment, since an image-sending/receiving subscriber or image-receiving subscriber requests image processing on a medical image registered in the medical image database 701 in the image processing server apparatus 700 and receives the medical image subjected to the image processing, the need for sending the original medical image each time image processing is to be performed is eliminated, thereby reducing the processing time.
Although an original medical image is registered in the medical image database 701 in the image processing server apparatus 700 in the seventh embodiment, a medical image subjected to image processing may be registered instead of, or in addition to, the original medical image. In this case, the image processing server apparatus 700 does not need to perform image processing upon receiving an image processing request, and therefore the image processing result R can be sent more quickly. The registry region for medical images may be provided in a storage device managed by a computer other than the image processing server apparatus 700 .
Moreover, the image processing server apparatus 700 may poll the image-sending/receiving subscribers or image-sending subscribers via the network 1 to collect medical images which may be requested for image processing, and register the medical images in the medical image database 701 . In this case, the work of the image-sending/receiving subscribers or image-sending subscribers for sending medical images for registration can be reduced.
Many widely different embodiments of the invention may be configured without departing from the spirit and the scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in the specification, except as defined in the appended claims.
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An image processing system having a server which applies image processing to a medical image sent by a subscriber via a generally available network, such as the “internet”, and sends the results of the image processing back to that subscriber or to another subscriber as instructed upon verification of the legitimacy of the instructions. In this manner, the processing load is reduced and medical images are made more readily and easily accessible.
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TECHNICAL FIELD
[0001] The present disclosure generally relates to seat assemblies for vehicles, and more particularly, to the selective mounting of child seats to adult seats.
BACKGROUND
[0002] The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it may be described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present technology.
[0003] Child passenger safety laws and restraint requirements may vary in different jurisdictions based on age, weight, and height. Conventional infant seats are frequently at least partially immobilized, relative to an integrated, adult accommodating seat of a the vehicle, by extending a seat belt of the vehicle through at least a portion of the infant seat and/or interconnecting one or more support straps of the infant seat with a frame of the adult accommodating seat, or other structure of the vehicle.
[0004] Rearward facing seating is a primary carrying mode for infants and, to a lesser degree, toddlers riding in vehicles. Rearward facing seating allows for the distribution of inertia forces, acting on a child during a frontal impact, over a larger area against the seat back, as opposed to concentrating the force through seatbelts. Although rearward facing seating is widely required by state laws and is believed to be a superior mode, it is often difficult for children at older ages to continue with this type of seating because of their height. One problem arises because once the feet of tall infants and young toddlers touch the rear seat back; the child must bend his or her knees, which can be uncomfortable.
[0005] Accordingly, it would be desirable to provide a seat configuration that allows comfortable seating for tall infants and toddlers by accommodating their relatively longer leg length.
SUMMARY
[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
[0007] In various aspects, the present teachings provide a vehicle seat assembly selectively reconfigurable to alternately form a forward facing adult seat and a child seat mounting surface. The vehicle seat assembly may include a back rest and a seat cushion. The seat cushion may be configured to serve as the child seat mounting surface. In various aspects, the back rest may be selectively repositionable between a first orientation to provide the forward facing adult seat, and a second, substantially horizontal orientation to provide an extended lower leg support surface for a child's lower legs and feet while seated in a rear facing child seat. The back rest may also be selectively removable from the vehicle seat assembly.
[0008] According to another aspect of the present disclosure, a vehicle seat assembly includes a back rest and a seat cushion that are selectively reconfigurable to alternately form a forward facing adult seating surface and a child seat mounting surface. The vehicle seat assembly may include a rear facing child seat carried by the child seat mounting surface. In various aspects, the back rest of the vehicle seat assembly forms an extended leg support surface for a child's lower legs and feet while seated in the rear facing child seat. The back rest may also be selectively removable from the vehicle seat assembly. When removed, a horizontal upper surface of the seat cushion may provide the child seat mounting surface and the seat cushion may form a rearwardly facing bolster longitudinally spaced from an opposed forward edge surface of a fixed adjacent interior vehicle structure by a sufficient dimension to provide longitudinal clearance of a rearwardly facing child's lower legs and feet while seated in the rear facing child seat.
[0009] According to yet another aspect the present disclosure, a second row vehicle seat assembly is provided including a seat cushion and a removable back rest. The back rest may be selectively reconfigurable between a first position and a second position to alternately form a forward facing adult seating surface when in the first position, and an extended leg support surface when in the second position. A rear facing child seat may be carried by the child seat mounting surface of the vehicle seat assembly. A support mechanism may be provided, configured to fixedly interconnect the seat cushion to a host vehicle. The support mechanism may enable a selective longitudinal repositioning of the vehicle seat assembly with respect to a fixed adjacent interior vehicle structure to establish a variable longitudinal clearance there-between.
[0010] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present teachings will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0012] FIG. 1 is a side perspective view of a rear facing child seat mounted to a rear seat of a vehicle illustrating a child occupant's feet in contact with the back rest of the rear seat;
[0013] FIG. 2 is a side plan view including a rear seat of a vehicle that is configured for selective longitudinal adjustment with respect to other seats and/or a rear bulkhead of the vehicle;
[0014] FIG. 3 is a side plan view of one embodiment of the present disclosure wherein the back rest of the rear seat is folded rearwardly to provide a substantially horizontal extended leg support surface for the rear facing child seat;
[0015] FIG. 4 is a side view of another embodiment of the present disclosure wherein the back rest of the rear seat is removed, exposing a rear edge surface (e.g., bolster) of the seat cushion to provide a substantially vertical extended leg support surface for the rear facing child seat; and
[0016] FIG. 5 is a top view of one embodiment of the present disclosure illustrating the longitudinal and lateral leg/foot space afforded between the rear facing child seat and the rear bulkhead of the vehicle.
[0017] It should be noted that the figures set forth herein are intended to exemplify the general characteristics of materials, methods, and devices among those of the present technology, for the purpose of the description of certain aspects. These figures may not precisely reflect the characteristics of any given aspect, and are not necessarily intended to define or limit specific embodiments within the scope of this technology. Further, certain aspects may incorporate features from a combination of figures.
DETAILED DESCRIPTION
[0018] In the following detailed description, reference is made to the accompanying drawings, which form a part thereof, and in which is shown by way of illustrating specific embodiments in which the disclosure may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc. is used with reference to the orientation of the figures being described. Because the components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is not limiting. It should be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims.
[0019] For purposes of providing a non-limiting definition and to enable clear understanding of the present disclosure, “longitudinal” means parallel to the direction of the Y axis, “lateral” means parallel to the direction of the X axis, and “vertical” means parallel to the direction of the Z axis.
[0020] Regardless of the particular models used, the designs of child seating apparatuses has generally required parents/guardians of children to purchase an infant seat, a toddler seat, and a booster seat to accommodate the growth of the child. Once it is determined that a child has outgrown (e.g., is too tall and/or heavy to be appropriately accommodated by) an above-mentioned infant seat, the infant seat is typically removed from the vehicle and replaced by a toddler seat to sufficiently restrain a toddler and enable the toddler to ride within the vehicle. Generally similar to conventional infant seats, conventional toddler seats are at least partially immobilized, relative to an integrated, adult accommodating seat of a vehicle, by extending a seat belt of the vehicle through at least a portion of the toddler seat and/or by interconnecting one or more support straps of the toddler seat with a frame of the vehicle. The booster seats are also similarly fastened into the vehicle using a seat belt and/or one or more support straps of the booster seat.
[0021] One disadvantage of the evolution of child seat types through the growth cycle of a given child is that the rear-facing configuration almost always employed for infants is abandoned in favor of forward facing configurations frequently for toddlers and almost always for young children. This evolution results from typical rapid and irregular growth spurts of children, making them more adult-like in their seating configuration needs, as well as increased social interaction with adults typically located in the front seating positions of the vehicle.
[0022] The present disclosure provides supplemental leg room and support for a child positioned in a rear facing toddler or child seat secured to a second row (rear adult) vehicle seat assembly. The second row vehicle seat assembly can be a bucket type seat including a seat back, or back rest, affixed adjacent to a seat cushion. In various aspects, the back rest can recline about 90 degrees between a substantially vertical position and a rearward horizontal position, or about 90 degrees between a substantially vertical position and a forward horizontal position. Additionally, the back rest can be temporarily removed during use of the rear facing toddler or child seat. This arrangement will accommodate larger children who are still required to sit in rear facing seats due to anticipated future regulations.
[0023] Referring to FIG. 1 , a vehicle 10 may include a passenger compartment 12 enclosing a front row of vehicle seat assemblies 14 and a second row of vehicle seat assemblies 16 supported on an appropriate floor panel 18 . Each row of vehicle seat assemblies 14 and 16 can include bench-type seating, split bench-type seats, or individual bucket-type seats. Larger vehicles, such as passenger vans and suburban utility vehicles (e.g., SUVs) can include a third or even a fourth row of vehicle seat assemblies, not illustrated.
[0024] For purposes of the present disclosure, the vehicle 10 is illustrated having a second row vehicle seat assembly 16 consisting of a laterally opposed pair of single passenger bucket-type seats 20 and 22 disposed within the passenger compartment 12 longitudinally intermediate the front row vehicle seat assemblies 14 and a rear bulkhead 24 , separating the passenger compartment 12 from a vehicle trunk, if so equipped. In various aspects, the rear bulkhead 24 may be representative of a third row of vehicle seat assemblies or other fixed interior structure.
[0025] The passenger-side bucket seat 22 is shown having an upstanding back rest 26 operatively assembled with a substantially horizontal, forwardly directed seat cushion 28 . A rear facing infant seat 30 is mounted to the bucket seat 22 , compressively loaded downwardly upon the seat cushion 28 and longitudinally rearwardly against the back rest 26 . The rear facing infant seat 30 may be secured to the bucket seat 22 by seat belts or supplemental restraints, not illustrated. A child 32 occupying the rear facing infant seat 30 is illustrated as having outgrown the rear facing infant seat 30 such that the child's legs 34 extend rearwardly beyond the end of the rear facing infant seat 30 , and the child's feet 36 are pressed against a forward facing front surface of the back rest 26 of the bucket seat 22 , which can be uncomfortable for the child 32 .
[0026] Referring to FIG. 2 , an exemplary vehicle 38 may include a passenger compartment 40 enclosing a front row vehicle seat assembly 42 and a second row vehicle seat assembly 44 commonly supported by a vehicle floor panel 46 . The second row vehicle seat assembly 44 may be longitudinally positioned between a rear facing surface 48 of the front row vehicle seat assembly 42 and a front facing surface 50 of a rear vehicle bulkhead 52 . The second row vehicle seat assembly 44 includes a back rest 54 that may be operatively interconnected to a seat cushion 56 by a releasable, pivotal hinge mechanism 58 , or the like. When oriented as illustrated in FIG. 2 , a forward facing front surface 62 of the back rest 54 and an upwardly facing surface 64 of the seat cushion 56 together define an adult seating surface 66 .
[0027] The seat cushion 56 of the second row vehicle seat assembly 44 may be interconnected to the vehicle floor panel 46 by a support mechanism 60 that may be selectively releasable to enable bidirectional longitudinal repositioning of the second row vehicle seat assembly 44 , as illustrated in phantom.
[0028] Referring to FIG. 3 , the back rest 54 of the second row vehicle seat assembly 44 is repositioned by an approximate 90° counter clock-wise (rearward) rotation from a substantially vertical orientation (as illustrated in FIG. 2 ) to a substantially horizontal orientation presenting the front surface 62 for use as an extended leg support surface for a child's lower legs and feet. A rear facing toddler/child seat 70 is configured to form a seat cushion portion 72 . The seat cushion portion 72 may be compressively loaded against the upwardly facing surface 64 (i.e., the child seat mounting surface) of the supporting seat cushion 56 by safety belts or tethers so as to be substantially aligned with the back rest 54 . By way of example, FIG. 3 shows a first tether 76 extending between the seat cushion portion 72 and the hinge mechanism 58 , and a second tether 78 extending between the back rest portion 74 and the seat cushion 56 . A child occupant 80 of the toddler/child seat 70 may be secured by an integral seat belt system 82 , or the like.
[0029] The toddler/child seat 70 may be dimensioned and positioned in application to align the nominal child occupant's legs atop the seat cushion portion 72 of the toddler/child seat 70 , and to enable the lower leg portions and feet 90 of an out-sized child occupant 80 to extend freely rearwardly atop the extended leg support surface formed by the front surface 62 of the back rest 54 . Thus, the legs of the out-sized child occupant 80 are supported along their entire extent by either the seat cushion portion 72 of the toddler/child seat 70 or the extended leg support surface formed by the front surface 62 of the back rest 54 . Preferably, the feet 90 of the out-sized child occupant 80 will not contact any fixed barrier.
[0030] As an alternative to the embodiment of FIG. 3 , the back rest 54 of the second row vehicle seat assembly 44 can also be repositioned through a substantially 90° clock-wise (forward) rotation from a vertical orientation (in FIG. 2 ) to a horizontal orientation presenting the back surface 68 as a mounting surface for a toddler/child seat 70 (not shown). In this configuration, the seat cushion portion 72 may be compressively loaded against the back surface 68 (i.e., the child seat mounting surface) of the supporting back rest by appropriate tethers.
[0031] Referring to FIG. 4 , the back rest 54 of the second row vehicle seat assembly 44 may also be temporarily removed. In various aspects, one may use the hinge mechanism 58 as an attachment point 96 for the toddler/child seat 70 . As shown, the seat cushion portion 72 of the toddler/child seat 70 may be compressively loaded against the upper surface 64 (i.e., the child seat mounting surface) of the supporting seat cushion 56 by a first tether 76 extending between the seat cushion portion 72 and the child seat attachment point 96 formed by the hinge mechanism 58 , and a second tether 78 extending between the child seat back rest portion 74 and the seat cushion 56 . A child occupant 80 of the toddler/child seat 70 may be secured by an integral seat belt system 82 . In various aspects, the vehicle seat assembly 44 may include at least one tether that is selectively reconfigurable to serve as either (1) a lap-type seat belt when the back rest 54 is in a substantially vertical orientation to provide the forward facing adult seat, or (2) a harness for the rear facing toddler/child seat 70 when the back rest 54 is in the substantially horizontal orientation, or removed from the second row vehicle seat assembly 44 .
[0032] Referring to FIGS. 4 and 5 , in various aspects, the seat cushion 56 may form an edge portion 94 that faces, and is spaced from, the forward facing surface 50 of the rear bulkhead 52 (or third row seat) by a longitudinal depth dimension designated by an arrow “LD 1 ” when the second row vehicle seat assembly 44 is displaced longitudinally forward in anticipation of the installation of the toddler/child seat 70 . Similarly, the seat cushion portion 72 of the toddler/child seat 70 may form an edge portion 86 that faces, and is spaced from, the forward facing surface 50 of the rear bulkhead 52 by a longitudinal depth dimension designated by an arrow “LD 2 ” when mounted atop the seat cushion 56 of the second row vehicle seat assembly 44 . FIG. 5 further illustrates a width dimension of an available volume as designated by an arrow “VW” extending the maximum width of the second row vehicle seat assembly 44 .
[0033] In various aspects, the toddler/child seat 70 may be dimensioned and positioned to align and support the nominal child occupant's 80 legs atop the seat cushion 72 of the toddler/child seat 70 . Once the child occupant's 80 knee portion 88 approaches the edge region 86 of the seat cushion portion 72 , the dimensions should enable the extended lower leg portions and feet 90 of an out-sized child occupant 80 to depend freely vertically downwardly within the space created between the second row vehicle seat assembly 44 and the rear bulkhead 52 . The available vertical height dimension is designated by an arrow “VH” extending between the upper surface 92 of the seat cushion portion 72 and the vehicle floor panel 46 . The edge portion (e.g., bolster) 94 of the seat cushion 56 can serve to support and absorb frontal impact loads imposed on the lower legs of the child occupant 80 . In various aspects, the vertical height, lateral width, and longitudinal depth may be constant for a given fixed positioning of the vehicle seat assembly with respect to the interior vehicle structure, defining a clearance volume between the second row vehicle seat assembly 44 and the fixed interior vehicle structure 52 .
[0034] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations should not be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
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A vehicle seat assembly includes a back rest and a seat cushion that may be reconfigurable to alternatively form a forward facing adult seating surface and child seat mounting surface. The back rest may be provided in a substantially horizontal orientation to offer an extended lower leg support surface for a child's lower legs and feet while seated in the rear facing child seat. The vehicle seat assembly may include a support mechanism to interconnect the seat cushion to a vehicle, enabling selective longitudinal repositioning of the seat assembly with respect to fixed adjacent interior vehicle structure to establish a variable longitudinal clearance there-between. A rear facing child seat forming back rest and seat cushion portions may be carried by the child seat mounting surface of the vehicle seat assembly. The back rest may be removable from the vehicle seat assembly.
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FIELD OF THE INVENTION
The present invention relates to devices for assembling or connecting the end of a helical spring with respect to another member and more particularly, but not exclusively, to a device for assembling one of the ends of a helical spring and the lower frame of a weaving loom, the other end of said spring being associated with the heddle of a weaving system.
HISTORY OF THE RELATED ART
Each hook of a weaving system of the Verdol type is known to be associated with a multiplicity of cords constituting what is called a harness, each cord being attached to the upper end of a heddle of which the lower end is associated with the upper end of a helical spring, of which the other end is fixed.
In modern weaving systems, each hook makes a very large number of reciprocating displacements at a high rate, with the result that the springs are subjected to brutal stresses of extension which sometimes lead to resonance and break thereof. Experience has shown that such break generally occurs at some number of turns from the end of the spring which is attached to a fixed member.
Known devices for assembling or connecting the end of a helical spring and another member such as a fixed member, are generally made of a moulded plastic material and they comprise a threaded connecting piece which engages by screwing in the first turns of the corresponding end of the helical spring. Such devices further comprise means for fastening to another member.
One of the devices in question, which formed the subject matter of French Patent Application 2 674 264, further comprises a cylindrical piece of elastic material engaged by force in the corresponding end of the spring so as to dampen its oscillations.
However, such a device cannot be used, as it is extremely difficult to introduce the cylindrical piece inside the turns of the spring and the turns are very often deteriorated as the return springs for weaving loom heddles are of very small dimensions. Such a spring is, for example, made with wire of very small diameter wound to constitute turns of about 2 mm diameter.
It is an object of the improvements forming the subject matter of the present invention to overcome the drawbacks of the heretofore known devices.
SUMMARY OF THE INVENTION
To overcome the deficiencies in the prior art, the cylindrical piece forming the subject matter of French Patent Application 2 674 264 is replaced by an element constituted by at least two elastic branches adapted to cooperate to create a friction fit which eliminates the resonance of the spring when it is subjected to successive rapid movements.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood on reading the following description with reference to the accompanying drawings, in which:
FIG. 1 is a very schematic view of part of a weaving system harness of which the heddles are each returned by a helical spring.
FIG. 2 is a view in perspective illustrating a first embodiment of an assembly or connecting device according to the invention.
FIG. 3 is a view in partial section illustrating the device of FIG. 2 mounted with respect to the end of a spring and of another member in order to connect the latter to the spring.
FIG. 4 is a section, on a larger scale, along IV--IV (FIG. 3).
FIG. 5 illustrates in perspective a another embodiment of the device of FIG. 2.
FIG. 6 is a view showing the device of FIG. 5 mounted with respect to the end of a spring.
FIG. 7 is a section on a larger scale along VII--VII (FIG. 6).
FIG. 8 illustrates another embodiment of the device according to the invention.
FIG. 9 shows an assembly device according to the invention made by combining the devices of FIGS. 2 and 8.
FIG. 10 illustrates another embodiment of the invention, consisting in combining the devices of FIGS. 5 and 8.
Finally, FIG. 11 shows an embodiment of the invention consisting in an assembly device made by combining the devices illustrated in FIGS. 5 and 9.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 very schematically illustrates part of a weaving system 1 comprising a multiplicity of hooks, of which only one, 2, has been shown.
The lower end of this hook is associated with a multiplicity of cords 3 forming, in well known manner, a harness while the other end of each cord is hooked to the upper end of a heddle 4 of which the lower end is associated with the upper end of a helical spring 5. The lower end of each spring is fixed to a fixed member 6 by means of a connecting device 7. Each heddle comprises, of course, an eye 4a traversed by a warp thread 8.
As illustrated in FIG. 2, the connecting device 7 according to the invention is in the form of a device comprising firstly, in known manner, a threaded connecting piece 7a which extends downwardly by a rod 7b terminating in a harpoon-shaped element 7c adapted to engage in a perforation 6a in the fixed member 6.
It will be observed that the harpoon 7c comprises a transverse opening 7h disposed near its tip to facilitate, by contraction of the walls forming the opening, the passage of the teeth of the tip. To maintain the harpoon element perfectly in the perforation 6a in the member 6, i.e. to avoid any axial movement of said harpoon element in the perforation, it comprises a supple, preferably hollow part 7i whose outer dimensions are greater than the diameter of the hole 6a. In this way, this supple part 7i abuts elastically against the wall of the hole 6a to prevent any axial clearance.
In accordance with the invention, the threaded connecting piece 7a extends opposite the harpoon element 7c by two slightly divergent elastic branches 7d, 7e. The outer faces of the branches 7d, 7e, preferably rounded, are roughly inscribed in a circumference whose diameter is greater than the internal diameter of the spring 5. It is observed that the rod 7b comprises a stop 7g of larger diameter.
To assemble the spring 5 and the connecting device according to the invention, it suffices to engage the branches 7d, 7e by force inside the corresponding end of the spring until the first turn of the spring abuts against the beginning of the threaded connecting piece 7a. The piece 7a is then screwed with respect to the turns until it comes into contact with the stop 7g. A friction fit is thus created between the free turns of the spring which are adjacent the turns engaged with the connecting piece 7a and the branches 7d, 7e so that, during the extensions and contractions of the turns of the spring 5, they are braked or dampened and cannot enter into resonance. To that end, the device according to the invention is made by molding, advantageously by injection in one piece, of a plastic material such as a polyamide. This process of manufacture is very economical and makes it possible to obtain an assembly device which is resistant to traction (FIG. 3). It is observed in FIG. 4 that, in transverse section, the outer faces of the two branches 7d, 7e may be convex so as to cooperate as best possible with the interior of the turns of the spring 5. The outer radius of curvature of such faces being close to that of the interior of the spring.
According to a first various of the invention illustrated in FIG. 5, a connecting device 7' has been provided, of which the branches 7'd and 7'e issue from the stop 7g and extend on either side of the threaded connecting piece 7a. It is observed that the branches 7'd, 7'e are convergent, so that, on at least a part of the surface of their opposite inner faces, said such faces are spaced at a distant less than the outer diameter of the spring 5.
To assemble the spring 5 and the connecting device 7' according to this embodiment, the two branches 7'd, 7'e must be moved slightly apart, then the corresponding end of the spring 5 introduced between the branches so that the threaded connecting piece 7a threadingly engages with the turns of the end of the spring until the spring bears against the stop 7g. On releasing the two branches, they compress the spring slightly and create with its free turns a friction avoiding resonance of the spring during its extensions and contractions (FIG. 6). As illustrated in FIG. 7, the inner faces of the branches 7'd, 7'e may be provided to be concave so as to cooperate with the exterior of the turns or coils of the spring 5.
According to the embodiment of FIG. 8 which constitutes a variation 7" of the connecting device, the two branches 7"d, 7"e are curved and joined at their free ends to form a tip 7"f. As for the embodiment of FIG. 2, the outer faces of the branches 7"d, 7"e are roughly inscribed in a circumference whose diameter is greater than the inner diameter of the spring 5.
To assemble the spring 5 and the connecting device 7", it suffices to engage the branches 7"d, 7"e by force inside the spring until its first turn or coil cooperates with the beginning of the threaded connecting piece 7"a. The piece 7'a is then screwed with respect to the spring until the end of the spring comes into contact with the stop 7"g. The turns of the spring adjacent those which cooperate with the threaded connecting piece 7"a are then slightly moved apart to create a friction fit so that the spring cannot enter into resonance during its extensions and contractions.
Another variation 7"' of the connecting device according to the invention is constituted by the combination of the connections illustrated in FIGS. 2 and 8. This preferred embodiment of the invention therefore comprises, from the threaded connecting piece 7"'a, two curved elastic branches 7"'d, 7"'e joined at their free ends to form a base 7"'f from which the two similar divergent branches 7d and 7e of FIG. 2 extend.
The connecting device 7"' is positioned inside the spring 5 by successively introducing the two divergent branches and then the two curved branches inside the spring, penetration being effected until the end of the spring bears against the stop 7"'g. This structure allows a double contact with the spring turns to create better elimination of the resonance.
The connection 7"" according to FIG. 10 includes the embodiment of the connection 7" to which the two convergent branches 7'd, 7'e of connection 7' of FIG. 5 have been added. There again, two zones of frictional engagement with the spring are obtained to improve elimination of resonance.
Finally, FIG. 11 illustrates a connection 7""' combining the connection 7"' of FIG. 9 and connection 7' of FIG. 5. This connection makes it possible to create three zones of contact with the turns of the spring.
It goes without saying that the upper part or head of the devices illustrated in FIGS. 2, 5 and 8 to 11 may be manufactured separately, i.e. without the rod and the harpoon to form an overmolded connection at the stop on the lower end of one of the heddles 4 illustrated in FIG. 1. Because of this structure, the two ends of each spring 5 may be assembled in accordance with the invention on the one hand on a heddle 4, on the other hand, on a fixed member such as 6.
In accordance with another variation of the invention, a member is produced by means of two devices 7 oriented in opposition to each other by their stop, so that they may cooperate respectively with the ends of two springs in order to assemble them in line with each other and to avoid resonance.
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Connecting devices for assembling the ends of helical springs with respect to other members wherein each connecting device includes at least two elastic branches adapted to frictionally engage with the end coils of a helical spring to thereby prevent the resonance of the spring when it is subjected to extension and compression. The connecting devices are particularly adapted for use for damping springs associated with the heddles in a weaving loom.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to sanding devices, and in particular to a light weight pole sander for use in sanding dry wall that is attached to a vacuum hose to be vacuum driven and to remove sanding dust off of a wall surface and pull that dust into a vacuum canister.
2. Prior Art
The present invention contemplates a new and improved vacuum driven sander that is appropriate for mounting onto a hollow tube or pole to be manually moved over a sheet rock wall to function as a dry wall sander, providing an oscillating sanding section that mounts a sheet of sanding material. The sanding section of the sander is operated by a vacuum driven turbine to smooth a dry wall surface, creating dust that is pulled through the turning turbine blades and into the hollow tube that a vacuum hose is connected to, to vent into a vacuum canister.
Heretofore, a number of sanding tools incorporating vacuum devices for removal of sanded particles and for transporting them through a connected vacuum hose to a collection vessel have been employed. For example a number of U.S. utility patents to Mehrer U.S. Pat. No. 4,062,152; to Marton U.S. Pat. No. 4,184,291; to Romine U.S. Pat. No. 4,697,389; to Paterson U.S. Pat. No. 5,007,206; to Sanchez, et al. U.S. Pat. No. 5,193,313; to Brown U.S. Pat. No. 5,283,988; to Matchuk U.S. Pat. No. 5,605,600; and to Brown U.S. Pat. No. 5,624,305, all show examples of manual sanding devices whereto is connected a vacuum hose for drawing dust off from a surface being sanded. Similarly, a number of electric motor driven devices that connect through a hose to a vacuum or suction device have been developed and examples of such are shown in U.S. Patents to Davies U.S. Pat. No. 1,800,341; to Jones U.S. Pat. No. 3,468,076; to Hutchins U.S. Pat. No. 3,785,092; to Hutchins U.S. Pat. No. 4,052,420; to Matechuk U.S. Pat. No. 4,782,632; to Flacheneck, et al. U.S. Pat. No. 4,905,420; to Fushiya et al. U.S. Pat. No. 5,018,314; to Chu, et al. U.S. Pat. No. 5,228,224; to Smith U.S. Pat. No. 5,384,984; to Hutchins U.S. Pat. No. 5,582,541; to Heidelberger U.S. Pat. No. 5,595,530; to Everts, et al. U.S. Pat. No. 5,637,034; and in Design Patents to Taylor U.S. Pat. No. Des. 375,885; to Gildersleeve et al. U.S. Pat. No. Des. 392,861; to Fushiya et al. U.S. Pat. No. Des. 326,398; to Morey et al. U.S. Pat. No. Des 351,976; and to Stiles U.S. Pat. No. Des. 353,313. None of which sanding devices, however, provide a sanding device that includes a vacuum driven oscillating sanding disk that, additionally, provides for removal of sanded particles from the work surface through an attached vacuum hose that is like that of the invention. Similar to the invention, U. S. Patents to Brenner U.S. Pat. No. 3,722,147; to Rodowsky, Jr. et al. U.S. Pat. No. 4,399,638; to Brenner U.S. Pat. No. 3,722,147; and to Marton U.S. Pat. No. 4,616,449, shown sanding devices where an oscillating plate mounting a sheet of sand paper is air driven by a vacuum flow and also provides for removal of sanding dust off from a work surface and the moving of that collected dust through a vacuum hose into a collection container. With the patent to Rodowsky, Jr. et al., U.S. Pat. No. 4,399,638 believed to be the closest to the invention. However, while, like the invention, the '638 patent provides a turbine blade that is turned by a vacuum air flow passed over the turbine blades to operate an oscillating plate whereto a section of sanding material is attached and will pull sanding dust therethrough, the turbine bearings of the '638 patent are exposed to that vacuum air flow with entrained sanding dust particles tending to collect in the turbine bearings, greatly limiting bearing life and, accordingly, the life of the device. Whereas, the invention is arranged to provide the presence of a positive or greater than vacuum pressure across its turbine bearing assembly, prohibiting the dust contaminated vacuum air flow from traveling into which bearing assembly, greatly lengthening the life of the bearings, and further allows for passing lubricants therethrough to lubricate the bearing assembly bearings, greatly improving upon earlier vacuum sanding devices, such as the '638 patent.
Additionally, as improvements over the prior art, the invention includes a balanced split-air intake that provides a balanced driving force onto the turbine blades by drawing essentially equal air flows from both sides of the sander that also improves upon the entrainment of dust and contaminants in the air flows as are passed through the sander. Also, the turbine itself is improvement in that it incorporates a split design where the top and bottom turbine sections are not symmetrical, with the lower turbine section having the greater height to allow the bearings and bearing supports to be conveniently fitted inside the turbine mounting in the sander housing providing a turbine housing profile that is shorter than former sanders turbines and has a lower center of gravity as compared to earlier sanders. Further, the invention provides an improved pole coupling assembly whereby, the pole angle to the sander top surface can be conveniently changed and that angle can be maintained while the sander is moved up and down or along a wall surface.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a vacuum air driven turbine operated sander for attachment to a conventional vacuum line wherethrough an air flow is pulled, with the air turning the turbine that is, in turn, connected to turn an eccentric that is fitted into a bearing mounted in a sanding plate to oscillate that plate, thereby moving an attached sheet of sanding material in an orbital path over a surface to be sanded.
Another object of the present invention is to provide a vacuum driven sander that includes turbine blades and turbine bearing assembly for turning in a housing wherein a passage is provided for passing a flow of clean air at ambient pressure into the bearing assembly, providing cooling thereto, and discouraging the vacuum flow wherein sanding dust is entrained from passing to the bearings of the bearing assembly and providing for passing a lubricant therethrough into the bearing assembly, greatly extending the bearing life and the life of the device.
Another object of the present invention is to provide a vacuum driven sander having a low profile provided by an incorporation of a turbine, as the device motive power source, that is formed from two non-symmetrical halves and includes, as a bearing assembly, a pair of bearing and bearing supports, that are to be fitted into a stanchion formed within the sander housing to contain turbine section, with the turbine top and bottom sections to be fitted together to close off which turbine section in the sander housing.
Still another object of the present invention is to provide a vacuum sander having a balanced split-air intake where air is drawn from opposite sides of the housing through the turbine, efficiently picking up and entraining dust particles in the flows as are generated by oscillating movement of the sanding pad that is provided by turbine rotation.
Still another object of the present invention is to provide a vacuum sander that incorporates a hollow tube connected to the sander body to be conveniently adjusted at its mounting to the body top surface to change the sander pad surface angle to the wall being sanded, and provides for connection of a vacuum tube as a pole to the hollow tube end opposite to the sander body.
Still another object of the present invention is to provide a vacuum driven sander that is light in weight and convenient to connect to a vacuum hose to both turn an oscillating sanding plate or pad and to draw collected dust therethrough for passage to a collection container.
The present invention is in a new and improved vacuum air flow air driven oscillating sander that includes a bent hollow tube that connects to a hollow pole whereon the sander is mounted and is connected to pass the vacuum air flow therethrough and into a vacuum hose to vent that flow into a collection container. The bent hollow tube is arranged to turn axially at is connection to the top of the sander body at a collar that has a number of radially spaced cavities formed therein that selectively receive stub pivots fitted therein that are formed to extend oppositely from a ball end of the bent hollow tube. A cap having a center hole therein is provided to fit over the bent tube and is for turning onto the collar to maintain coupling of the stub pivots in the selected radially spaced cavities, allowing the bent hollow tube to be turned relative to the collar end and to be locked in place. So arranged, the angle of the sander forms to a wall can be adjusted by a repositioning of the stub pivots in the radially spaced cavities and turning the cap onto the collar.
Further unique to the invention, the sander includes a turbine that is mounted by a bearing assembly onto a stanchion located within a sander housing, and provides, by a passage formed through the housing into a bearing assembly cavity located within the stanchion, for a flow of ambient air to the bearings during operation and precludes contamination of the bearing assembly by dust entrained in the vacuum flow that has passed over the sanded surface, greatly extending bearing life over earlier air driven sanders that have exposed their turbine bearings to the dust filled vacuum air flow.
Additionally, the sander body of the invention exhibits a significantly reduced profile by an incorporation of a split design turbine that allows the bearing assembly to be conveniently fitted into and assembled in a bearing cavity in a shanchion formed in the housing. The construction of the turbine as a split design provides two turbine sections, with a lesser height upper section arranged to cap over the greater height lower section, simplifying mounting of the turbine bearing assembly in the bearing assembly cavity prior to fitting the assembled turbine thereto. The turbine is turned by passage of the vacuum air flow there through that is first passed through balanced air intakes where air is pulled across the surface being sanded and into the housing opposite ends, applying a balanced driving force to drive the turbine. The turbine, at its lower end, is connected through an eccentric to oscillate a sanding pad whereto a section of sanding material is releasably attached.
The sanding pad is formed as a plate, and the entire sander is assembled and held together by four (4) screws that are each turned through spiders attached to corners of the inner surface of the plate that are turned into the housing lid or top, maintaining the sander in its assembled state.
Still other benefits and advantages of the invention will become apparent to those skilled in the art to which it pertains upon a reading and understanding of the following detailed specification.
DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangements of parts, and a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof:
FIG. 1 is a perspective view taken from a left side and front of a vacuum sander of the invention, showing a bent tube end extending out from a housing top section collar and cap;
FIG. 2 is a side elevation exploded view of the vacuum sander of FIG. 1 :
FIG. 2A is a top plan sectional view taken along the line 2 — 2 of FIG. 2 of the turbine lower section, showing the turbine as having the equal radially spaced turbine blades;
FIG. 3 is a profile sectional view taken along the like 3 — 3 of FIG. 1;
FIG. 4 is a front elevation sectional view taken along the line 4 — 4 of FIG. 1;
FIG. 5 is a top plan view of the vacuum sander of FIG. 1;
FIG. 6 is a front elevation view of the vacuum sander of FIG. 1;
FIG. 7 is a side elevation view of the vacuum sander of FIG. 1, and showing in broken lines, the bent tube coupling neck pivoted around its pivot coupling to the sander collar; and
FIG. 8 is a view like that of FIG. 1 showing the collar mounted onto the sander top to include radially spaced slots formed therein that are to receive stub pivots formed to extend oppositely outwardly from a ball end of the bent tube coupling neck, and with the bent tube and cap shown exploded from the collar.
DETAILED DESCRIPTION
The invention is herein described with reference to a preferred embodiment shown in the accompanying drawings, with FIG. 1 showing a front elevation perspective view of the low profile vacuum driven sander 10 of the invention, hereinafter referred to as sander. As shown in the Figs., the sander 10 includes a housing 11 , having front, rear and side walls 13 a , 13 b , 14 a , and 14 b , respectively, extending at right angles from the top edges, forming a narrow rectangular box configuration having, as shown in FIGS. 3 and 4 an open bottom 15 and whereover a flat top 12 is fitted. A coupling collar assembly 16 is shown in FIGS. 1 , 3 and 4 , fitted into the center of the top 12 that includes, as shown in FIGS. 2 and 8, a pair of turbine ducts 17 a and 17 b that are shown as flat raised sections that extend oppositely from steps 18 a and 18 b to an opening in the center of the flat top 12 , and are open, as shown in FIGS. 1, 2 , 4 through 6 and 8 , to serve as ducts that pass and direct turbine exhaust air flow into a hollow bent tube 23 that is preferably bent at an angle of approximately twenty two and one half (22½) degrees, and wherethrough the flow is vented into a vacuum hose or tube.
The turbine ducts 17 a and 17 b , as shown best in FIGS. 1 and 5, are slightly greater than half semi-spherical sections and terminate, as shown best in FIGS. 1, 2 and 6 , in stepped up sections 19 a and 19 b that join into dome 20 , as shown best in FIGS. 3 and 4. The dome 20 has a center hole 21 formed therethrough, with the edge of which hole 21 to serve as a seat whereover a ball end 22 of a bent exhaust tube 23 travels. The ball end 22 to maintain sealing engagement with the hole 21 edge, with the ball and its edge serving as a ball valve. So arranged, the turbine ducts 17 a and 17 b direct the turbine exhaust flow into the dome 20 that then directs that flow into the bent exhaust tube 23 , wherefrom it is exhausted through a connecting hose or tube into the collection container, not shown.
An upper outer portion of the walls of which dome 20 , as shown best in FIG. 8, is formed into collar 20 a that has outer threads 24 and wherethrough the hole 21 is formed. Around the edge of which hole 21 are formed a number of radially equal spaced pivot cavities 25 , shown as half cylindrical sections that are to individually receive each of a pair of stub pivots 26 fitted therein. The stub pivots 26 extend oppositely outwardly from the ball end 22 of the bent tube 23 , and are to fit into individual pivot cavities 25 . So arranged, as shown best in FIGS. 3 and 4, with the pair of stub pivots 26 each fitted into a pivot cavity 25 , a cap 27 having a center hole 28 formed therein is slid along the bent tube 23 to where threads 29 thereof can be turned onto the outer threads 24 of the collar 20 a . With cap 27 turned onto collar 20 a the positioning of the stub pivots 26 in the selected pivot cavities 25 is maintained, setting the positioning of the sander body 11 relative to the bent tube 23 . Which positioning, however, is preferably not rigid in that the diameter of the hole 28 through the cap 27 is selected to be somewhat larger or greater that the bent tube 23 diameter, as shown in FIGS. 1 and 5, allowing for some pivotal movement between which sander body 11 and bent tube 23 , as during use of the sander, to minimize damage to the coupling should the sander “stick” to the wall surface. So arranged, the sander body 11 is selectively positionable relative to the bent tube 23 to facilitate the sander 10 being moved up and down or side to side or at an angle therebetween, as the operator desires. The bent tube 23 preferably has its end 23 a , shown in FIG. 2, fitted into a coupling end 31 of a vacuum pipe 30 , as shown in FIGS. 1 through 7, which coupling can be by providing interior threads, not shown, formed in the coupling end 31 for turning onto threads 32 formed in the bent tube 23 end 23 a , as shown in FIG. 8, providing a rigid coupling therebetween. Or, as required, to further facilitate sander back and forth or up and down travel, the coupling can be such as to allow partial or full axial rotation of the vacuum pipe 30 to the bent tube 23 , within the scope of this disclosure.
The sander 10 is equipped with a sanding pad 45 , as shown best in FIG. 2, that, as shown in FIGS. 3 and 4, is of a lesser length and width than the distances between the inner surfaces of housing end walls 14 a and 14 b and front and rear walls 13 a and 13 b , leaving a space therebetween that allows for passage of a vacuum air flow pulled therearound. Which vacuum air flow will both turn the turbine 63 , will pick up sanding dust off of the surface being sanding and entrain that dust in the vacuum air flow, as discussed below. To provide sanding, the sanding pad 45 is fitted with a section of sanding material 46 , as shown in FIGS. 3 and 4, that is maintained thereto, preferrably with Velcro type fasteners, adhesive sections, or the like, and the sanding pad 45 is oscillated through an eccentric 72 that is turned by the turbine 63 , as set out below.
The sanding pad 45 , shown best in FIGS. 2, 3 and 4 , includes a stiff flat rectangular plate 47 having a front or outer face 47 a arranged for releasably mounting sheets of sand paper, or other sanding material, thereover, and includes, mounted to the corner of a rear or inner face 47 b , as shown best in FIG. 3, identical spiders 48 that each having a head end 49 wherein a center hole is formed, and include like spaced straight legs 50 extending from around the head end 49 whose opposite ends are secured to the plate inner face 47 b surface. Which legs 50 are preferably formed from a semi-rigid plastic, or other appropriate light weight stiff material, to flex so as to allow the sanding pad 45 to oscillate, so as to move orbitally, while supporting the pad against collapse when pressure is applied to force the sanding pad against a surface to be sanded. For mounting the sanding pad 45 to the sander body 11 , as shown in FIG. 2, screws 51 are each aligned for fitting through holes formed through the sanding pad 45 , preferrably at the corners thereof. With the holes each aligning to pass a screw 51 into a hole 49 a formed through a spider end, as shown in broken lines in FIG. 4, and are turned into a pier 52 that is formed in to project from the bottom surface 12 a of the flat top 12 , shown also in FIG. 2 . So arranged, with each of the spiders 48 each connected to a pier 52 at its head end 49 , the sanding pad 45 is suspended by the spider legs 50 to allow the sanding pad 45 to oscillate orbitally when moved by operation of the turbine 63 turning an eccentric 72 , as set out below. Which connection of the sanding pad 45 spiders to the undersurface 12 a of the flat top 12 is a last step in the assembly process where the flat top 12 and sanding pad are fitted to the housing 11 , positioned within the walls 13 a , 13 b , 14 a and 14 b , following the installation of the turbine and bearing assembly in the housing 11 , as set out herein below.
The housing 11 is preferably formed, as by molding, or like methods, to include air intakes or air inlet cavities 55 that are arranged in both ends of the housing 11 , and are to direct inlet air passing around the sanding pad 45 into inwardly sloping sections within the housing 11 that vent into a turbine chamber 56 , striking blades 80 of the turbine 63 . The inlet flows are of approximately the same volume, providing a balanced driving force that turns the turbine 63 . The air inlet cavities 55 are each formed in the housing along with the turbine chamber 56 that, as shown best in FIG. 3, is a cavity formed around a center stanchion 57 that projects upwardly from a chamber floor 58 that is formed across the housing interior and is spaced upwardly from where the sanding pad 45 is positioned. Which housing interior chamber floor 58 has the air inlet cavities 55 and a center hole 59 formed therein that an eccentric 72 is fitted in, as set out below.
The stanchion 57 , as shown in FIGS. 3 and 4, provides an inner turbine chamber wall 60 , is flat across its top surface 61 and includes a bearing cavity 62 formed through that top surface that extends downwardly to the chamber floor 58 center hole 59 . The bearing cavity 62 is to receiving a pair of like upper and lower turbine bearings 64 and 65 of turbine 63 that align to pass a turbine axle 66 journaled therethrough. To accommodate which upper and lower turbine bearings 64 and 65 , respectively, the bearing cavity 62 is stepped inwardly at 62 a and 62 b , providing a ledge 62 c therebetween, for maintaining bearing spacing, and whose opposite ends support each of the turbine bearings.
The turbine axle 66 , shown in FIGS. 3 and 4, includes a flat head end 67 and is threaded at its opposite end 68 . With the turbine axle passed through a center hole formed through center plates of both the turbine top and bottom sections 70 and 71 and has its lower threaded end 68 turned into a threated top end 73 of eccentric 72 . The axle head end 67 fits in a cup 69 that is formed as a raised section at the center of turbine top section 70 center plate 70 a , with the axle 68 to pass through the turbine lower section 71 center plate 71 a of turbine 63 and is turned into the eccentric 72 top end 73 . The eccentric 72 is preferably a single unit formed with the threaded top end 73 wherein the turbine axle 66 threaded end 68 is turned, that extends upwardly at approximately a right angle from the center of a top surface of a disk 74 and includes an axle pin 75 that extends downwardly, at approximately a right angle, from the bottom surface of which disk 74 and is off-set from the disk center. The axle pin 75 is fitted into a bearing 76 that is maintained in a center cavity formed into the inner face 47 b of the sanding pad 45 . So arranged, turning of the turbine 63 turns the turbine axle 66 that is coupled to the eccentric 72 top end 73 to turn the eccentric axle pin 75 that is journaled in the sanding pad 45 bearing 76 , thereby imparting an oscillating motion to the sanding pad that is moved along an orbital path, in turn, moving a sheet of sand material attached thereto over a surface that it is in contact with, sanding that surface.
The turbine 63 is a split design, formed in two sections, a lower of which sections 71 has a greater height than the height of the top section 70 . So arranged, the bearing assembly including the turbine axle bearings 64 and 65 , can be easily installed in the bearing cavity 62 , the top axle bearing 64 being dropped into the top end of the bearing cavity 62 sliding along the stepped section 62 a to come to rest on the top lip of the ledge 62 c , with the lower axle bearing 65 to be fitted through the housing 11 open bottom center hole 59 to travel into the bearing cavity, sliding along the lower stepped section 62 b to where its edge engages the bottom lip of ledge 62 c.
The turbine 63 is fitted, as shown in FIGS. 3 and 4, through the open top of housing 11 to rest on the top of the top surface 61 of the stanchion, with a hole through the collar 69 to receive the axle 66 fitted therethrough to where the axle top end 67 is nested in the collar 69 , and whereafter the eccentric 72 top end 73 threaded cavity is turned onto the turbine axle 66 threaded end 68 , securing the turbine 63 to the eccentric. Thereafter, with the sanding pad 45 bearing 76 seated in the bearing cavity 77 that is formed in the sanding pad inner face 47 b , the eccentric axle pin 75 is fitted into which bearing 76 and the sanding pad 45 and top 12 are installed to the body 11 , as set out above.
The turbine 63 is preferably formed from a hard plastic material, metal, or the like, as the described upper and lower turbine halves 70 and 71 , as shown in FIGS. 2, 3 and 4 , that are joined together as by an adhesive bonding, by welding, brazing, or the like, with the assembly then fitted, as shown best in FIG. 3, into the housing turbine chamber 56 . So arranged, the turbine top half rests on a top surface of center plate 71 a of the lower turbine half 71 , and the top and bottom sections of turbine blades 80 are joined, as shown in FIGS. 3 and 4, along their contacting surfaces. So arranged, the blades 80 are spaced apart equal distances and are curved to each receive the inlet vacuum air flow at their forward edges 80 a that travels therealong to their hub ends 80 b . The curve of which blades 80 is shown best in FIG. 2 A. The spacing distance between which blades 80 is shown as reducing from their inlet ends 80 a to their exhaust ends 80 b.
In practice, an inlet vacuum flow is pulled around the sanding pad 45 to pass, as a balanced air flow, through the air inlet cavities 55 and into the turbine chamber 56 wherein the turbine 63 is journaled to upper and lower bearings 64 and 65 , with the turbine blades 80 receiving the air flow and reacting thereto by turning, to turn also the eccentric 72 that turns an off-set axle pin 75 fitted in a bearing 76 mounted in the sanding pad 45 . The sanding pad is thereby moved through an orbital path, sanding a surface. With the inlet vacuum air flow picking up sanding dust off from a working surface during its passage around the sanding pad 45 , that then passes through turbine ducts 17 a and 17 b to drive the turbine 63 , with that vacuum flow, with entrained dust collected therein, is then exhausted through the bent tube 23 , passing into the vacuum hose 30 and then to a collection container.
The vacuum air flow is, of course, contaminated with sanding dust that is entrained therein during its passage across the sanded surface and around the sanding pad 45 edges. A portion of such dust, in earlier sanders, has tended to find its way into the bearing assembly to, in short order, contaminate the bearings and greatly curtail turbine turning, thereby severely limiting the useful life of such sander and requiring, if possible, that the sander be taken apart and the collected dust removed from the bearings. The invention recognizes and solves this problem of dust contamination of the turbine bearings by effectively closing off access to the bearing cavity 62 . This is accomplished by the arrangement of the fitting of the turbine axle 66 head end 67 in the upper turbine half plate 70 a collar 69 and turning of the axle threaded end 68 into the eccentric top end 73 so as to provide a tight clamping together of the upper and lower turbine halves plates 70 a and 71 a . Thereby clamping the upper turbine bearing 64 between the undersurface of the lower turbine half plate 71 a and the upper edge of the stepped section 62 c of the bearing cavity. The lower turbine bearing 65 top edge is thereby clamped against the lower edge of the stepped section 62 c and which bearing 65 has its lower edge held against the eccentric disk 64 top surface. So arranged, dust is discouraged from passage into the bearing cavity 62 . Further, and significant to the invention, to preclude dust travel into which bearing cavity 62 , a passage 85 is formed, as shown in FIG. 3, from a passage end 85 a in the bearing cavity 62 , that is downwardly sloping through the stanchion 57 and then become a horizontal passage through the chamber floor 58 , and opens at opening 86 through the housing 11 front 13 a , as shown also in FIGS. 1, 6 and 8 . So arranged, the vacuum inlet flow through into the sander 10 creates less than ambient conditions within housing 11 and the bearing cavity 62 , causing an air flow to be pulled through a opening 86 in the housing wall 13 a that travels through the passage 85 that is formed through the chamber floor 58 and slopes upwardly through the stanchion 57 and opens at 85 a into the bearing cavity 62 . A positive pressure is thereby created within the bearing cavity 62 that blocks dust in the vacuum flow from traveling therein and provides air cooling to the bearings 64 and 64 . Additionally, this passage 85 can be used to pass oil, fed as drops into the opening 86 , that travel into the bearing cavity, to lubricate the turbine bearings 64 and 65 , providing bearing lubrication. Accordingly, by passing a clean air flow from without the sander into the bearing cavity 62 through passage 85 , and by a periodic introduction of oil through opening 86 , the sander 10 can enjoy a long and useful life.
A preferred embodiment of my invention in a low profile vacuum driven sander has been shown and described above. It will, however, be apparent to one skilled in the art that the above described embodiment may incorporate changes and modifications without departing from the general scope of the invention, which invention, it should be understood, is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims and/or a reasonable equivalence thereof.
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A low profile vacuum driven sander as is appropriate for drywall sanding, with a vacuum flow pulled therethrough to drive a turbine whose turning through an eccentric provides an oscillating movement to a sanding pad that releasably mounts a section of sanding material thereto, and with that vacuum air flow also removing sanded particles and dust off from the sanded surface and transports it through the sander and a connected pipe or hose into a catchment container. The sander housing includes a pair of spaced inlet ports that are formed to provide a balance air flow into a turbine chamber that contains a turbine that is journaled axially to bearings of a bearing assembly maintained in a bearing assembly cavity of a center stanchion, with the bearing assembly cavity separated from the vacuum air flow and is ported to without the sander housing for providing, when the sander is operating, a fresh air flow into the bearing assembly cavity, prohibiting dust as is entrained in the vacuum air flow from entering the cavity as could interfere with bearing functioning and result in a loss in sander efficiency and malfunction. The turbine is preferably formed from upper and lower sections that are of different heights for facilitating assembly of the bearings in the bearing assembly cavity to, in turn, allow the sander housing to be formed having a low profile, and includes a coupling assembly of the sander body to a vacuum tube that can be freely adjusted and locked in place at a desired angle to a surface to be sanded.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording apparatus and, more particularly, an apparatus for recording motion and still images.
2. Related Background Art
A digital VCR has hitherto been known for recording/reproducing an image signal as a digital signal on a magnetic tape. Recently, HD Digital VCR Council has presented a DV format as a format of a consumer digital VTR.
In the DV format, there are defined SD Specifications (SD mode, hereinafter) for recording an image signal of NTSC in ten tracks per one frame, and SD High Compression Specifications (SDL mode, hereinafter) for recording an image signal in five tracks per one frame. On the SDL mode, a quantity of data to be recorded is set to about ½ of that of the SD mode, a tape feeding speed is set to ½ of that of the SD mode, and data of one frame is recorded in five tracks. Accordingly, a recording period can be double as long as that of the SD mode with a tape length equal.
As a video camera integral VTR based on such a DV format, there is known one having a photomode for recording still image data of, for example 6 to 7 sec., on a tape for a predetermined period in addition to recording of normal motion image data.
As ID used to detect the still image data, photo picture ID (PPID) is defined in the DV format. The PPID must be recorded continuously for 5 sec.
In the above-described VTR capable of performing recording/reproducing on the SD mode and the SDL mode, the still image may be recorded on the SD mode and the SDL mode.
However, since the SDL mode has a smaller number of tracks per one frame compared with that of the SD mode, when the still image data is searched while the tape is fed at a speed higher than that during normal reproducing, even if the PPID data is detected and the searching operation is finished, a recording position of the target still image data is passed, making it impossible to perform accurate searching.
Furthermore, on the photomode, still image data is recorded for a period longer than that of the PPID, normally 6 to 7 sec. Accuracy during searching may vary depending on a recording position of PPID in the period of 6 to 7 sec. No ideas have been presented regarding an optimal recording position of the PPID in the photomode of the SDL mode.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above-described problems.
Another object of the invention is to accurately detect still image data recorded by a recording mode having a small quantity of information or a small number of tracks per frame.
In order to achieve the above-described object, in accordance with an aspect of the prevent invention, there is provided a recording apparatus, comprising: recording mode setting means for setting a first recording mode for recording image data having a first information quantity per unit time, and a second recording mode for recording image data having a second information quantity larger than the first information quantity per unit time; recording means for recording image data on a recording medium; and control means for controlling the recording means to record on the recording medium still image data and detection data for detecting still image according to recording instruction of the still image, wherein the control means controls the recording means to record on the recording medium the still image data of the first recording mode and the detection data for detecting the still image data for a first predetermined period when the first recording mode is set by the recording mode setting means, and to record on the second recording medium the still image of the second recording mode and the detection data for a second predetermined period different in length from the first predetermined period when the second recording mode is set, and wherein a length of the first predetermined period is set according to the first recording mode, and a length of the second predetermined period is set according to the second recording mode.
These, other objects and features of the invention will become apparent upon reading of the following detailed description of the preferred embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 , which is comprised of FIGS. 1A and 1B , is a block diagram showing a configuration of a VTR, to which the present invention is applied.
FIG. 2 is a view showing a recording format on an SD mode.
FIG. 3 is a view showing an example of a recording format on an SDL mode.
FIG. 4 is a view showing a recording format on a DL mode according to an embodiment of the invention.
FIG. 5 is a flowchart showing an operation on a photomode according to the embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, description will be made of the preferred embodiment of the present invention.
FIGS. 1A and 1B are functional block diagrams of a camera integrated VTR 100 , to which the invention is applied. The apparatuses of FIGS. 1A and 1B records/reproduces image data, audio data and the like in the above-described DV format.
In FIGS. 1A and 1B , a reference numeral 101 denotes a microphone for collecting audios; 102 an audio input processing unit for performing predetermined signal processing for an audio signal captured from the microphone 101 ; 103 an A/D converter for converting an analog audio signal into a digital audio signal; 104 an audio signal encoding unit for encoding an audio signal outputted from the A/D converter 103 ; 105 an image pickup unit for picking up an image of an object; 106 an A/D converter for converting an analog video signal into a digital video signal; 107 a video input processing unit for performing predetermined signal processing for a video signal subjected to A/D conversion according to an SD mode or an SDL mode; 108 a video signal encoding unit for encoding a video signal; and 109 a camera system control unit composed of a microcomputer or the like to control the image pickup unit 105 and the video input processing unit 107 according to instruction of a system control unit 123 .
A reference numeral 111 denotes a recording signal processing unit including a data switching unit 11 a for switching and outputting an encoded digital audio signal, an encoded digital video signal, and subcode data; 112 a mechanical unit including a magnetic head for recording a signal outputted from the recording signal processing unit 111 on a magnetic tape T, and reproducing a digital signal recorded on the magnetic tape T; and 113 a reproduced signal processing unit including a data switching unit 113 a for switching and outputting the digital audio signal, the digital video signal and the subcode data reproduced from the mechanical unit 112 . The recording signal processing unit 111 , the mechanical unit 112 , and the reproduced signal processing unit 113 constitute a recording/reproducing circuit 110 .
A reference numeral 114 a video signal decoding unit for decoding a digital video signal switched and separated by the data switching unit 113 a ; 115 a D/A converter for converting the decoded digital video signal into an analog video signal; 116 a video output processing unit for performing predetermined signal processing for the analog video signal; 118 an on screen display (OSD) control unit for superimposing various bits of information including a date, time, a menu and the like according to instruction from the system control unit 123 ; and 117 a liquid crystal monitor for multiplexing and displaying a video signal outputted from the video output processing unit 116 or the video input processing unit 107 , and information obtained from the OSD control unit 118 .
A reference numeral 119 denotes an audio signal decoding unit for decoding an audio signal outputted from the data switching unit 113 a ; 120 a D/A converter from converting the decoded audio signal into an analog audio signal; 121 an audio output processing unit for performing predetermined signal processing for the analog audio signal from the D/A converter; and 122 a speaker.
A reference numeral 123 denotes a system control unit; 124 a subcode encoding unit for generating subcode data containing a current date and time generated by a clock unit, or various ID data such as PPID according to instruction from the system control unit 123 ; 126 a subcode data detection unit for outputting subcode data from a subcode encoding unit 126 to the data switching unit 111 a , and detecting and outputting subcode data from the data switching unit 113 a to the subcode decoding unit; and 127 a subcode data decoding unit for detecting and outputting subcode data (photographing date, time data, or various ID data such as PPID) from the subcode data detection unit 126 to the system control unit 123 . The subcode encoding unit 125 , the subcode detection unit 126 , and the subcode decoding unit 127 constitute a subcode data processing circuit 124 .
A reference numeral 128 denotes a clock unit; 129 a remote control signal receiving unit for receiving a remote control signal from a remote commander R or sending a remote control code to the system control unit 123 ; 130 a camera system switch including various switches (zooming, focusing and the like) for operating a camera system; 131 a recording system switch including various switches (up-down, and left-right keys, a menu key, a reproducing key, a fast-forward key, winding and stopping keys, a recording trigger key, a photokey, a photosearch key, and the like) for a recording system and the entire VTR; and 132 a mode switch for selecting a power supply mode (camera, VTR, OFF) of the main body.
The system control unit 123 includes a microcomputer or the like, which is in charge of overall control various functions of the camera integral VTR 100 , including a timer function. The system control unit 123 mainly performs mode control, operation mode transition control of each operation block, display control of various information, storage, holding and the like of various photographing modes. Further, following switching of a normal compression recording mode/a high compression recording mode, the system control unit 123 performs system data setting in recording, recording/reproduced signal processing, control of the mechanical unit 112 , and the like.
Next, description is made of a recording operation of the camera integral VTR 100 constructed in the above-described manner.
In the digital VTR of the embodiment, a recording mode can be set between the SD mode and the SDL mode, and a user can set a recording mode by the menu selection function of the recording system switch SW 131 .
An audio signal captured from the microphone 101 is subjected to predetermined signal processing by the audio input processing unit 102 , and then converted into a digital signal by the A/D converter 103 , and outputted to the audio signal encoding unit 104 . Based on recording mode information from the system control unit 123 , the audio signal encoding unit 104 encodes the audio signal according to a currently set recording mode, i.e., the SD mode or the SDL mode, and outputs the encoded audio signal to the data switching unit 111 a of the recording signal processing unit 111 .
A video signal captured from the image pickup unit 105 is outputted to the A/D converter 106 and the video output processing unit 116 . The A/D converter 106 converts the video signal from the image pickup unit 105 into a digital signal, and outputs it to the video input processing unit 107 . The video output processing unit 116 selects on the recording mode, the video signal from the image pickup unit 105 based on a control signal from the system control unit 123 , supplies it to the liquid crystal monitor 117 to display a video image picked up by the image pickup unit 105 .
The video input processing unit 107 performs predetermined signal processing for the digital video signal from the A/D converter 106 , according to the SD mode or the SDL mode, and then outputs it to the video signal encoding unit 108 . Based on the recording mode information from the system control unit 123 , the video signal encoding unit 108 encodes the video signal according to a currently set recording mode, i.e., the SD mode or the SDL mode, and outputs the encoded video signal to the data switching unit 111 a of the recording signal processing unit 111 . In the embodiment, processing by the video input processing unit 107 and the video signal encoding unit 108 is carried out such that on the SD mode, a quantity of information per one frame can be ½ of that of the SD mode.
The system control unit 123 controls the subcode encoding unit 125 based on current date and time data from the clock unit 128 , generates subcode data containing date and time information, and other information, and outputs the subcode data through the subcode detection unit 126 to the data switching unit 111 a of the recording signal processing unit 110 .
The data switching unit 111 a switches and outputs respective data according to a tape recording format defined by the DV format such that a digital audio signal, a digital video signal, subcode data and ITI data can be recorded in predetermined areas of respective recording tracks on a tape T, and then supplies the data to the magnetic head of the mechanical unit 112 .
The mechanical unit 112 includes a capstan for feeding the tape T. The system control unit 123 controls a feeding operation of the capstan so as to switch a feeding speed of the tape T according to a set recording mode.
For example, when the SD mode is set, the tape T is fed at a speed V corresponding to the SD mode. When the SDL mode is set, the tape T is fed at a speed V/D corresponding to the SDL mode. Data indicating a recording mode is generated by the subcode encoding unit 125 , included into VAUX data by the subcode detection unit 126 , and recorded through the data switching unit 111 a in a predetermined position of each track on the tape T.
As described above, in the camera integral VTR 100 , the digital audio signal, the digital video signal, and the data indicating the photographing date thereof are simultaneously and continuously recorded digitally in different areas on the magnetic tape T.
Next, description is made of a reproducing operation of the camera integral VTR 100 .
The digital audio signal, the digital video signal, the subcode data and the ITI data are outputted to the data switching unit 113 a , and then switched and outputted in times series by the data switching unit 113 a.
The digital video signal from the data switching unit 113 a is outputted to the video signal decoding unit 114 . Based on the recording mode information from the system control unit 123 , the video signal decoding unit 114 decodes the video signal according to the recording mode of the reproduced video signal, and outputs it to the D/A converter 115 . The D/A converter 115 converts the decoded video signal into an analog signal, and outputs it to the video output processing unit 116 . Based on the control signal from the system control unit 123 , the video signal processing unit 116 selects on a reproducing mode, the video signal from the D/A converter 115 and supplies the video signal to the liquid crystal monitor 117 to be displayed.
The digital audio signal from the data switching unit 113 a is outputted to the audio signal decoding unit 119 . Based on the recording signal information from the system control unit 123 , the audio signal decoding unit 119 decodes the audio signal according to the recording mode of the reproduced audio signal, and outputs it to the D/A converter 120 . The D/A converter 120 converts the decoded audio signal into an analog audio signal, the audio output processing unit 121 performs predetermined signal processing on the converted analog audio signal to output it from the speaker 122 .
The subcode data from the data switching unit 113 a is detected through the subcode detection unit 126 by the subcode decoding unit 127 , and entered to the system control unit 123 . Then, the system control unit 123 performs time difference correction for the photographing date data based on correction information regarding a time difference, entered beforehand by the user, converts it into character display data, and outputs it to the OSD control unit 118 . The OSD control unit 118 converts this character display data into superimposition data, and outputs it with the video signal from the video output processing unit 116 to the liquid crystal monitor 117 . The liquid crystal display unit 117 displays the reproduced video and the information of photographing date/time subjected to time difference correction in a superimposing manner.
The subcode detection unit 126 detects information indicating the recording mode of the currently reproduced video and audio data from the VAUX data included in the reproduced data, and outputs it to the system control unit 123 . Based on this recording mode information, the system control unit 123 can detect the recording mode of the reproduced video and audio data.
Next, description is made of a recording operation of still image data on the photomode.
The user operates the photokey of the recording system switch SW 131 in recording pause or during motion image data recording. The system control unit 123 stores in an internal memory a image signal of one frame entered in the video input processing unit 107 at a point of time of the photokey operation. Then, the image data of one frame is repeatedly read during a period defined by the SD mode or the SDL mode as described later, and outputted to the video signal encoding unit 108 . The image data is then encoded as described above, and recorded as still image. Then, the subcode processing unit 124 and the recording/reproducing circuit 110 are controlled such that the PPID data can be recorded at a predetermined timing.
Next, description is made of an operation of recording images, in an order of a motion image A, a still image A and a motion image B, in a number of helical tracks on the magnetic tape, and searching the still image A held between motion image recording areas.
As described above, there is PPID as data for detecting still image data recorded on the photomode. This is information data for still image searching, defined by the DV format, and it is decided that recording is carried out continuously for 5 sec. In addition, on the SD mode, data of one frame is recorded in ten tracks and, on the SDL mode, data of one frame is recorded in five tracks.
That is, in comparison based on the same number frames, when recording is carried out on the SDL mode, a recording length on the magnetic tape is set to half of that during SD mode recoding.
FIG. 2 shows an example of recording motion and still images on the SD mode, where a still image A is recording in an area after a recording area 201 of a motion image A for about 6.5 sec. In this case, substantially simultaneously with still image recording, the PPID is recorded for 5 sec with being superimposed. Then, a motion image B is recorded in a recoding area 203 .
When the recorded still image A is searched from the recording area 201 of the emotion image A, the tape T is first fed forward at a speed faster by 9.5 times, the speed is reduced to a normal speed when the PPID is detected, a slowing operation is carried out, then the process is stopped in a position 205 to perform still image reproducing. Then, conversely, when the recorded still image A is searched from the recording area 203 of the motion image B, first, the tape is reversely fed at a speed after by 9.5 times, the speed is reduced to reverse normal speed when the PPIID is detected, a reverse slowing operation is carried out, the process is then stopped in a position 206 to perform still image reproducing. As apparent from the drawing, in either case, still image reproducing operation is finished within a range of the recording area 202 of the still image A.
FIG. 3 shows an example of recording motion and still images on the SDL mode, where a still image A is recorded for about 6.5 sec., subsequently to a motion image A. In this case, substantially simultaneously with still image recording, the PPID is recorded for 5 sec with being superimposed. Then, a motion image B is recorded.
When the recorded still image A is searched from a recording area 301 of the emotion image A, the tape T is first fed forward at a speed faster by 9.5 times, the speed is reduced to a normal speed when the PPID is detected, a slowing operation is carried out, then the process is then stopped in a position 305 to perform still image reproducing. Then, conversely, when the recorded still image A is searched from a recording area 303 of the motion image B, first, the tape is reversely fed at a speed after by 9.5 times, the speed is reduced to reverse normal speed when the PPIID is detected, a reverse slowing operation is carried out, the process is then stopped in a position 306 to perform still image reproducing.
As can be understood from FIG. 3 , when the searching is carried out in the forward direction, the still image reproducing is carried out in the position 305 near a boundary of the recording area 302 of the still image A and the recording area 303 of the motion image B. When the searching is carried out in the reverse direction, the recording area 302 of the still image A is passed, and the still image reproducing operation is finished completely in the recording area 301 of the motion image A. Thus, the still image searching operation fails.
Thus, when the still image is searched, control is performed in such a manner that the PPID is detected while the tape is fed at a high speed, and the tape feeding is stopped when the PPID detected. In the case of the still image recorded on the SDL mode, even if the still image is recorded for 6.5 sec., as in the case of the SD mode, since a length of its recording area is only half of that of the SD mode, the recording area of the still image may be passed. To avoid this, a tape feeding speed in searching must be slowed down. However, if the feeding speed is slow, searching time is made longer, worsening usability.
FIG. 4 shows an example of recording motion and still images on the SDL mode including the features of the invention, where after a motion image A, a still image A is recording for about 8.5 sec. In this case, PPID is recorded with being superimposed in a center position of a recording area 402 of the still image A. Subsequently, a motion image B is recorded in a recording area 403 .
Here, when the recorded still image A is searched from the recording area 401 of the emotion image A, the tape T is first fed forward at a speed faster by 9.5 times, the speed is reduced to a normal speed when the PPID is detected, a slowing operation is carried out, then the process is stopped in a position 405 to perform still image reproducing. Then, conversely, when the recorded still image A is searched from the recording area 403 of the motion image B, first, the tape is reversely fed at a speed after by 9.5 times, the speed is reduced to reverse normal speed when the PPIID is detected, a reverse slowing operation is carried out, the process is then stopped in a position 406 to perform still image reproducing.
As apparent from FIG. 4 , in either case, the tape feeding is stopped within a range of the recording area 402 of the still image A.
Therefore, according to the embodiment, when the still image is recorded on the SDL mode, by setting a still image recording period to about 8.5 sec., and the recording position of the PPID in the center position of the still image recording area, it is possible to search the still image at a high tape feeding speed equal to that in searching of the still image data recorded on the SD mode.
Next, description is made of a control operation of the system control unit 123 when the invention is applied to still image recording on the SDL mode, by referring to a flowchart of FIG. 5 .
In FIG. 5 , photokey detection for instructing starting of still image recording is carried out in S 501 and, after the photokey is depressed, the process is branched to S 502 . In S 502 , a currently set recording format is detected. If an SDL mode is selected, the process proceeds to S 503 . If an SD mode is selected, the process proceeds to S 510 . Selection of a recording mode is set beforehand by a menu operation or the like.
In S 503 , feeding of the tape T at a speed set according to the SDKL mode is started, recording of still image data encoded according to the SDL mode is started as described above, the internal counter of 1.75 sec., is started, and the process waits for an end of the counter in S 504 . After a passage of 1.75 sec., from the start of recording, recording of the PPID is started in S 505 , the internal counter of 5 sec., is started, and the process waits for an end of the counter in S 506 .
Then, after a passage of 5 sec., the recording of the PPID is finished in S 506 , the internal counter of 1.75 sec., is started again, and the process waits for an end of the counter in S 508 . After a passage of 1.75 sec., the still image recording-on a high compression recording format is finished in S 509 .
In S 510 , feeding of the tape T at a speed set according to the SD mode is started, recording of still image data encoded according to the SD mode is started as described above, and recording of the PPID is started in S 511 . Then, the counter of 5 sec., is started, and the process waits for an end of the counter in S 512 . After the end of the counter, the recording of the PPID is finished in S 513 , the counter of 1.5 sec., is started, and the process waits for an end of the counter in S 514 . After the end of the counter, the still image recording on the SD mode is finished in S 515 .
Next, description is made of an operation of searching the still image data recording in the above-described manner.
When the photo search key of the recording system switch SW 131 is operated, the system control unit 123 controls a capstan driving unit of a recorder unit 22 such that the tape T can be fed forward or backward at a predetermined high speed faster than a normal speed, for example at a speed faster by 9.5 times than that in recording.
Then, when the PPID reproduced by the recording/reproducing circuit 110 , and detected through the subcode detection unit 126 and the subcode decoding unit 127 is entered, the system control unit 123 outputs a control signal to the recording/reproducing circuit 110 as described above, the feeding speed of the tape T is reduced to a normal or reverse normal speed, and then the process proceeds to still image reproducing.
Therefore, according to the embodiment, by setting the recording period on the still image recording mode of the SDKL mode longer than that of the SD mode, and the recording position of the ID data for still image detection substantially in the center of the still image recording area, it is possible to surely detect the still image data recorded on the SD mode and the still image data recorded on the SDL mode while feeding the tape at the same feeding speed in searching.
The embodiment has been described by way of example, where the invention is applied to the VTR having the SDLK mode for recording the image data of one frame in the five tracks, and the SD mode for recording the same in the ten tracks. The invention is not limited to this, and it can be similarly applied to, for example a case where still image data is recorded on a mode for recording in an n number of tracks per one frame, and on a mode for recording in an m (m>n) number of tracks.
Furthermore, the recording periods on the photomode were respectively set to 6.5 sec., and 8.5 sec., on the SD and SDL modes. Other periods may be set as long as they are longer than 5 sec., of the recording period of the PPID, and the recording period on the SDL mode is longer.
Many widely different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in the specification, except as defined in the appended claims.
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There is disclosed a recording apparatus having first and second recording modes for recording image signals of one frame in tracks, the numbers of which are different in the first and second recording modes. On the first recording mode, a still image is recorded for a first predetermined period. On the second recording mode, a still image is recorded for a second predetermined period. Lengths of these first and second predetermined periods are respectively set according to the first and second recording modes.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application serial no. 60/201,519 filed May 2, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention generally relates to sewer lines for recreational vehicles and, more particularly, to a coupling that is used on two ends of a sewer hose to prevent leakage from the hose after the sewer hose is used to empty the sewage holding tank on the recreational vehicle. Specifically, the present invention is related to a valved sewer hose coupling having a sliding valve disposed between a pair of rigid tube sections that receive sections of flexible sewer line.
[0004] 2. Background Information
[0005] Touring in recreational vehicles (RVs) has become increasingly popular in recent years. Most new RVs include a lavatory that empties into a holding tank that temporarily holds the sewage until the tank is pumped out or emptied into an appropriate waste treatment system.
[0006] Most RV camping areas have power hook ups, fresh water hook ups, and a sewage disposal system that may be used by the owner of the recreational vehicle for a fee. The sewage disposal system typically includes an inlet disposed at ground level near the camping area. The user of the recreational vehicle connects with the sewage disposal system by using a sewer hose to connect an outlet of the holding tank to the inlet to the sewage disposal system. The outlet of the holding tank is typically valved to prevent unintended release.
[0007] Once the sewer hose is connected, the user opens the valve to the holding tank and allows the tank to empty into the sewage system. The user then closes the valve to the holding tank and disconnects the sewer hose. A problem with this system is that the residue inside the sewer hose often leaks or drips out onto the ground while the sewer hose is being stored. The result is that the ground around the RV is contaminated with sewage leaving it undesirable for camping. The contamination is especially unpleasant when the users of the RV are cooking out or sitting outside the RV. The leakage can also lead to environmental harm that may lead to liability for the campgrounds. The art thus desires a sewer hose for an RV that does not create the leaking problem of the past. Such a sewer hose must be able to be stored in the same storage container as present sewer hoses. These hoses are typically stored in the bumper of the RV. The storage container has a limited cross sectional area and length that prevents the solution from having large dimensions.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides an RV sewer hose having valved ends that allow the body of the sewer hose to be sealed to prevent residual sewage from leaking from the hose after the hose has been used to empty the holding tank of an RV. In one embodiment, the invention provides a valved sewer hose has exterior dimensions that are smaller than the interior dimensions of the RV bumper so that the valved sewer hose may be stored inside the bumper. In another embodiment of the invention, the valves disposed at each end of the sewer hose are manually-operated and include covers that prevent the user from contacting any residual sewage when the user opens the valves.
[0009] The invention also provides a valved coupling for an RV sewer hose that may be selectively connected to existing sewer hoses. In this embodiment of the invention, the invention provides a valved coupling having one end that connects to the sewer hose and another end that connects with the sewage disposal system or the outlet to the holding tank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The preferred embodiment of the invention, illustrative of the best mode in which applicant contemplated applying the principles of the invention, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.
[0011] [0011]FIG. 1 is a view of a prior art recreational vehicle hooked up to a prior art sewage disposal system with a prior art sewer line.
[0012] [0012]FIG. 2 is a perspective view of the valved coupling of the present invention.
[0013] [0013]FIG. 3 is a sectional view taken along line 3 - 3 of FIG. 2.
[0014] [0014]FIG. 4 is a view similar to FIG. 3 with the valve door in the open position.
[0015] [0015]FIG. 5 is a view similar to FIG. 1 showing a pair of the valved couplings being used with s sewer hose.
[0016] [0016]FIG. 6 is a view similar to FIG. 3 showing an alternative embodiment of the invention having a cover around the valve door.
[0017] [0017]FIG. 7 is a view similar to FIG. 4 showing the embodiment of the invention shown in FIG. 6 showing the valve door open with the cover in an expanded condition.
[0018] Similar numbers refer to similar parts throughout the specification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In the prior art arrangement depicted in FIG. 1, a recreational vehicle 10 is emptying its holding tank (not shown) into the inlet 12 of a sewage disposal system 14 . A prior art sewer hose 16 is connected to the outlet 18 of the holding tank below the valve 20 . The user opens valve 20 and allows the holding tank to empty into system 14 . When empty, the user closes valve 20 and disconnects hose 16 from system 14 . The undesirable leaking occurs when hose 16 is being disconnected and stored.
[0020] The valved coupling of the present invention is indicated generally by the numeral 50 in FIGS. 2 through 5. Coupling 50 includes a manually operable valve door 52 carried by a valve body 54 . Door 52 includes a handle 51 and a body 53 . In the preferred embodiment of the invention, handle 51 is substantially perpendicular to body 53 in order to decrease the dimensions of coupling 50 . In other embodiments, handle 51 may be a finger recess or finger hole in body 53 . First and second 56 and 58 tube sections extend outwardly from either side of valve body 54 . Tube sections 56 and 58 preferably has three inch outside diameters. Coupling 50 may be used to selectively close an end of sewer hose 16 by connecting hose 16 to one of tube sections 56 and 58 . Both ends of hose 16 may be selectively closed by connected one coupling to each end of hose 16 . The end of hose 16 may be connected to tube section 56 by sliding the end over tube section 56 and applying a tube clamp the end of hose 16 . The user may then close the ends of hose 16 before disconnecting hose 16 to prevent accidental spillage and leakage.
[0021] Body 54 includes a front wall 60 and a rear wall 62 . A pair of sidewalls 64 , a bottom wall 66 , and a top wall 68 extend between walls 60 and 62 to form body 54 . Top wall 68 defines an opening 70 that slidingly receives valve door 52 . Front 60 and rear 62 walls includes openings 72 and 74 so that fluid may flow through coupling 10 . Tube sections 56 and 58 are aligned with openings 72 and 74 . In the preferred embodiment of the invention, body 54 has a substantially square cross section. In other embodiments of the invention, body 54 may be round. Body 54 and handle 52 preferably have combined outside dimensions less than 3.75 inches by 3.75 inches so that coupling 50 may be stored in the same located as hose 16 . A common storage location is inside of the bumper 75 of RV 10 .
[0022] Seals 76 are disposed between each opening 72 , 74 and valve door 52 to prevent liquid from leaking out of coupling 50 when door 52 is open or closed. In the preferred embodiment of the invention, each seal 76 is an O-ring fabricated from a rubber or plastic material that allows door 52 to slide between the open and closed positions.
[0023] Door 52 preferably includes a stop 78 or a pair of stops 78 that prevent the user from pulling door 52 past seals 76 . Each stop 78 is preferably a protuberance that engages the upper portion of seals 76 when door 52 is in the open position.
[0024] In use, the user of coupling 50 attaches a coupling 50 to each end of hose 16 as shown in FIG. 5. Valve doors 52 are moved to the closed position. One coupling 50 is connected to outlet 18 below valve 20 with the other coupling 50 being connected to a universal sewer connector 79 . Connector 79 is attached to inlet 12 of system 14 . The user may connect tube section 58 to universal sewer connector 79 (or any other quick coupling known in the art) with a short length (4 to 6 inch) of flex hose. The connection may be made with auto hose clamps or any of a variety of other connectors known in the art.
[0025] The user then opens all valves to empty the holding tank of RV 10 . Once the holding tank is empty, the user closes valve 20 and closes doors 52 . Hose 16 and couplings 50 may then be removed and stored without the residue inside hose 16 leaking out onto the ground.
[0026] An alternative embodiment of the coupling is indicated generally by the numeral 150 in FIGS. 6 and 7. Coupling 150 includes many of the same elements as coupling 50 and the same numbers are used to refer to these elements. Coupling 150 includes a cover member 152 disposed between valve body 54 and the top end 154 of valve door 52 . Cover member 152 is flexible and moves between the collapsed position depicted in FIG. 6 and an expanded position depicted in FIG. 7. In the embodiment shown in the drawings, cover member 152 is in the form of bellows that expand and contract with the opening and closing of valve door 52 . Cover member 152 may be attached to valve body 54 with a sealed connection that prevents any liquid from exiting or entering cover member 152 . In another embodiment, cover member 152 is loosely connected to valve body 54 so that the user may wash the inside of cover member 152 .
[0027] Cover member 152 prevents the user from contacting the outer surfaces of body 53 of valve door 52 when valve door 52 is in the open position depicted in FIG. 7. The outer surfaces of body 53 can be contaminated with sewage and cover members 152 prevent the user from contacting the sewage.
[0028] In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
[0029] Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described. For example, the valve couplings of the invention may include flipper valves, pivoting valve doors, or rotating valve doors.
[0030] Having now described the features, discoveries and principles of the invention, the manner in which the improved coupling is construed and used, the characteristics of the construction, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.
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The sewer hose for a recreational vehicle includes a valve coupling disposed at both ends of the sewer hose so that the body of the sewer hose may be closed off after the sewer hose is used to empty the holding tank of the recreational vehicle. The valve couplings and sewer hose have exterior dimensions small enough to fit in the standard sewer hose storage compartment.
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This is a continuation-in-part of U.S. Application Ser. No. 07/909,559, filed Jul. 6, 1992, entitled "IMPLANT FOR ATTACHING A SUBSTITUTE TOOTH OR THE LIKE TO A JAW," now U.S. Pat. No. 5,306,149.
FIELD OF THE INVENTION
The present invention is directed generally to implants and more particularly to an implant for attaching a denture or substitute tooth to a jaw.
BACKGROUND OF THE INVENTION
WO-A-90 07 308 discloses a jaw implant comprising a carrier and a biocompatible diaphragm covering the carrier. The carrier has a central portion with a threaded bore for the attachment of an artificial substitute tooth. The diaphragm is connected to the carrier during insertion of the carrier into a hole in a jawbone so that it covers the area of the jawbone surrounding the carrier and protects it against the growing in of the gingival bindweb and the epithelium tissue, as well as against the penetration of microorganisms. The amount of jawbone available for insertion of such implants however can be so small that an adequate anchoring of the previously described implant is no longer possible. This problem frequently occurs with implants into the upper jaw.
In addition to such implants, implants for attaching a substitute tooth are generally known comprising hollow cylindrical sockets provided with apertures and a single piece head portion widening away from the socket. When a substitute tooth is to be fastened with the head portion at a jawbone, the implant is inserted into a hole of the jawbone so that it is approximately flush or slightly above the surface of the jawbone. The bore in the end side of the head portion is then closed off with a sealing screw. The implant now remains in this sealed state in the jawbone during the healing phase, which may, for instance, last for several months. The bone tissue grows during this healing phase into the cylindrical socket which is tightly anchored in the jawbone. The sealing or closing screw is subsequently removed and a secondary element is threaded into the implant. The secondary element forms a post or pillar at which the artificial substitute tooth or denture is fastened.
During the healing phase, the epithelium tissue and the gingival bindweb or connective tissue normally grows faster than the bone tissue of the alveolar extension and especially faster than the cement and the bone cells forming the desmodontal bindweb. After insertion of an implant, the epithelium tissue and the gingival bindweb grow into the gap between the jawbone and the implant and deposit themselves at the implant, whereby the growing-together of the bone tissue and the implant is delayed or even entirely prevented. Such methods however permit microorganisms to penetrate from the mouth cavity into the existing gaps and cause infections.
The problems with such previously known devices were hitherto solved in two different ways. According to one way, bone shavings obtained by a surgical intervention into the pelvic region or portions of ribs of the patient were used for thickening the jawbone. After the jawbone is thickened, one of the known implants is inserted into the intended area of the jawbone. Experiments have shown however that such intervention is very complicated, not always successful and assumes that the transplanted bone tissue grows completely together with the jawbone and the implant. The other type of treatment involves the insertion of an implant into the jawbone, increase and thickening of the bone tissue of the alveolar extension and the cement. In this type of treatment, the bone cells forming the desmodontal bindweb are promoted in a targeted manner. Cells forming this tissue can multiply at the jawbone, if it is isolated from the gingival bindweb during the bone regeneration phase. The isolation can be achieved by using a biocompatible diaphragm between the gingival bindweb and the bone tissue. Such a diaphragm would have pores permitting the passage of gases through the diaphragm and/or the deposition of cells and the growing of such cells into the diaphragm. After bone formation, one of the already known implants could be inserted into the jawbone. Such treatment however has the distinct disadvantage of having at least three chronologically separate operations which makes the entire treatment period approximately twice as long as with a normal implant. The danger of a failure is correspondingly increased.
It is therefore an object of the present invention to provide an implant that has a relatively short treatment period.
Another object of the invention is to provide an implant which permits adequate anchoring to a jawbone or the like.
Still another object of the present invention is to provide a safe implant which additionally prevents the entry of microorganisms from the mouth cavity and into the existing gaps.
Additionally, an object of the invention is to provide an implant which is particularly helpful if the jawbone area to be treated is insufficient for fixing previously known implants.
Yet another object of the invention is to provide an implant which can be replaced upon the jawbone area to be treated without prior bone formation treatment.
SUMMARY OF THE INVENTION
These and other objects of the invention which shall be hereafter apparent are achieved by an implant provided with a threaded bore for fastening a substitute tooth or dentures at the jaw. The implant comprises a carrier with at least two spikes for fastening the implant onto the jawbone and a diaphragm enabling bone formation and intended to cover the carrier. In one preferred embodiment of the invention, the carrier has a central portion containing the threaded bore and a frame surrounding the central portion. The frame comprises a base formed by transverse ribs and longitudinal ribs and at least four cross ties extending from the base edge.
Another preferred embodiment comprises a carrier with a thin base plate and a post. The post projects upward from the base plate and is provided with a threaded base.
The diaphragm enables the consolidation of the implant with the bone tissues and can consist, for instance, of a porous polytetrafluoroethylene known under the trade name GORE-TEX or some other equivalent material. The deposition of microorganisms in the region covered by the diaphragm, as well as the propagation of infection, can be inhibited by such a diaphragm. The invention provides favorable conditions for the growth of new bone tissue in an intermediate space covered by the diaphragm, wherein the deposition of bone material at the implant and its solid anchoring thereon is promoted as well as accelerated.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by the Detailed Description of the Preferred Embodiments, in connection with the drawings, of which:
FIG. 1 a perspective view of a one-piece carrier or support of an implant;
FIG. 2 is a cross-sectional view through a jawbone and an implant with an intermediate piece shown partially in section and partially in front view;
FIG. 3 is a cross-sectional view through a jawbone and an implant with a screw shown partly in section and partially in front view;
FIG. 4 is a front view of a workpiece used for the manufacture of the frame of a two-part carrier;
FIG. 5 is an enlarged view of cutout designated by V in FIG. 4; and
FIG. 6 is a front view of a two-part carrier with a frame as shown in FIG. 4.
FIG. 7 is a perspective view of another one-piece carrier; and
FIG. 8 is a cross-sectional view through the jawline and an implant with a carrier, which is shown in FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, wherein like numerals reflect like elements throughout the several views, FIG. 1 is a perspective view of a carrier comprising an elongated column-like central portion 2 and a frame 3 surrounding the central portion 2. The central portion 2 can attach a non-depicted artificial tooth or denture and has a threaded bore 2a and a spike 2c for fixing the implant into the jawbone at the closed end 2b at the bottom of the central portion 2. The frame 3 surrounding the central portion 2 comprises a base formed by lateral ribs 3a, longitudinal ribs 3b and six cross-ties 3c extending from the base edge and connected to the upper end of the central portion 2. Each cross-tie 3c has at least two cams or lugs 3d on the side facing away from the base. The base comprises six spikes 3e for fastening the implant onto the jawbone at the crossing points of the transverse ribs 3a and longitudinal ribs 3b.
A jawbone 10 and an implant 11 placed thereon in a trans-gingival manner can be seen in FIG. 2. The implant 11 has a diaphragm 12 covering the frame 3 of the carrier and is a flexible foil and has a circularly-shaped aperture 12a at its center corresponding to the bore 2a. The diaphragm 12 is fastened to the central portion 2, covers the frame 3 and rests with its outer edge segment 12b on the surface of the jawbone 20. The diaphragm 12 is held, at least in part, at a spacing from the cross ties 3c by the cams or lugs 3d.
An intermediate piece 13 is threaded into the upper end 2d of the central portion 2 so that the diaphragm 2 is clamped between this intermediate piece 13 and the central portion 2 in a fluid-tight manner. The intermediate piece 13 has an axially threaded bore 13a and a segment which widens upwards away from the middle portion 2 in an approximately cone-shaped manner that is curved slightly concavely in axial section. The intermediate piece 13 is preferably composed of the same material as the carrier and is a biocompatible material such as stainless steel, titanium or a titanium alloy or reinforced plastics material.
For insertion of the implant, the dental surgeon cuts open the epithelium tissue 15 and the gingival connecting tissue 16 at the point intended for insertion of the implant 11 and exposes the jawbone 10 by rolling away these soft layers of tissue 15 and 16. The carrier of the implant 11, comprising central portion 2 and frame 3, is placed upon the exposed spot of the jawbone 10. Small holes may be made for the spikes 2c and 3e, depending upon the hardness of the bone and to precisely position the carrier. This may be accomplished with a suitable template. Subsequently, the implant 11 comprising the carrier, the diaphragm 12 and the intermediate piece 13 is placed upon the area of the jawbone to be treated. Attention and care must be taken so that the spikes 2c and 3e penetrate into the prepared holes, if they are created. The inserted implant 11 is thereupon covered over, with exception of the intermediate piece 13, by folding the gingival bindwebs 16 and the epithelium tissue 15 back into their proper place.
The diaphragm 12 covers the free space 17 between the cross-ties 3c of the frame 3 and the jawbone 10 against the epithelium tissue 15 and against the gingival binding tissue or bindweb 16. The diaphragm 12 is flexible to such an extent that its outer edge segment 12b can sprightly adapt to the surface region of the jawbone 10 surrounding the base of the implant 11. When the soft tissue layers 15 and 16 cover the diaphragm 12, they also contribute to retain the outer edge segment 12b of the diaphragm 13 at the jawbone 10. The outer edge segment 12b can additionally be secured by holes and biocompatible screws threaded directly into the jawbone 10 and penetrating through the outer edge segment 12b to permit an infiltration beneath the gingival connecting tissue, especially with larger contour dimensions of the diaphragm 12.
After the previously described treatment, the implant 11 is left, during a time period serving as a healing phase in the state shown in FIG. 2. During this healing phase, the bone forming cells proliferate and form new bone tissue which grows into the intermediate space covered by the diaphragm 12. As explained, the formation of the bone tissue is promoted and accelerated by the diaphragm 12.
A secondary element, which is not shown here, is fastened upon the intermediate piece 13 after the healing phase. This element comprises a threaded portion which can be screwed into the threaded bore 13a of the intermediate piece 13 and which can be formed by protruding a post or pillar from the jawbone for carrying or supporting of a substitute tooth or denture which is not shown here. The secondary element can also directly receive a substitute tooth instead of the pillar or post. Naturally, there is also the possibility of removing the diaphragm 12 even prior to the insertion of the secondary element. For this, one must however cut open the soft tissue layers 15 and 16 which, in the meantime, have healed.
The implant designated as 21 and shown in FIG. 3 comprises the same carrier as the implant 11 described in FIG. 2. In treating a patient, the using of implant 21 is, for all intents and purposes, identical with the already described treatment, wherein the threaded bore 2b in the central portion 2 is closed off by a screw 22 which retains the diaphragm 23 at the central portion or part 2. After insertion of the implant 22, it is covered by the gingival bindweb 25 and the epithelium tissue 26 and the area of operation is closed by suture 27.
After the healing phase of the implant 21 shown in FIG. 3, one cuts open the tissues 25 and 26 which, in the meantime, have healed. Thereupon the screw 22 and, if required, the diaphragm 23, are removed and a secondary element, not shown here, is fastened upon the central portion 2. The secondary element is either a substitute tooth or a post protruding from the jawbone for support or carriage of a substitute tooth.
Parts of another implant are shown in FIGS. 4, 5 and 6. Carrier 41 has two single piece members and a column-like central portion 42 (see FIG. 6) comprising a threaded bore and a frame 43 surrounding, for all intents and purposes, the central portion 42. The central portion 42 is shaped identically to central portion 2 shown in FIGS. 1-3. The frame 43 is made from the workpiece shown in FIGS. 4 and 5 and has four trapeze-like frame parts 44. The frame parts 44 include longitudinal bars 44a forming two cross-ties each, a transverse bar 44b and spikes 44c for fixing the carrier 41 onto the jawbone. The frame parts 44 further comprise one basic partial element 44d. The longitudinal bars 44a forming the cross-ties as well as also the transverse bars 44b, are undulated or wave-shaped in such a way that their elevations 44e fulfill the function of the cams or lugs 3d depicted in FIGS. 1-3.
In fabricating the two-part carrier 41 shown in FIG. 6, the workpiece manufactured by punching out of the metal plate is formed into a frame 43. The frame has two longitudinal bars 44a adjoining each other and transverse bar 44b. The frame 43 is then fastened on the end of the central portion 42, by, for instance, being threaded or welded on. The base part elements 44d are thereupon bent towards the central part 42 so that the central part is held in position by the base partial elements 44d. The base partial elements 44d permit the central part 42 to pivot in such a way that its axis 45 assumes a direction deemed necessary by the surgeon and functions independently of the position of the plane defined by the spikes 44c. The treatment of a patient when using the carrier 41 is identical with the treatment methods which have already been described.
Another preferred embodiment of the invention is shown in the FIGS. 7 and 8.
FIG. 7 is a perspective view of a one-piece carrier 51, comprising an elongated column-like post 52 and a thin base plate 53. The post 52 is provided with a blind threaded bore 52a, penetrating coaxially into the post from the free end and can attach a non-depicted artificial tooth or denture in the same manner as, for example the central portion 2 of the carrier 1, of the implant shown in FIG. 1.
In contrast to this, the elongated base plate 53 comprises four spikes 54 which are arranged at the four corners of a rectangle for fastening the carrier, i.e. the implant onto the jawbone.
As it is shown particularly clearly in FIG. 8, the bottom of the post 52 is located in a central hole of the base plate 53 and is provided with a blind axial hole 52b, which penetrates into the post 52 on the side, facing away from the free end.
Furthermore, the cylindrical wall of the post 52 has at least one passage 55, which connects the outside area of the post 52 with the internal space of the hole 52b.
As illustrated in FIG. 8, an implant 60 comprising the carrier 51 is placed on a jawbone 61. The implant 60 has--as the implant 1 shown in the FIGS. 1 and 2--a diaphragm 62, which covers the carrier 51. The treatment of a patient, when the implant 60 is used, is for all intents and purposes, identical with the already described treatment, with the threaded bore 52a in the post belong closed off during the healing phase by a screw 63 which retains the diaphragm 62 at the post 52.
The diaphragm 62 covers the free space 64 against the epithelium tissue and against the gingival binding tissue and rests with its outer edge segment 62a on the surface of the jawbone 61.
As shown in FIG. 8, the outer edge segment 62a of the diaphragm 62 is additionally secured by biocompatible screws 65 threaded directly into the jawbone 61. This additional fastening prevents an infiltration of the gingival connecting tissue into the free space 64 during the healing phase, especially with larger contour dimensions of the diaphragm 62.
The diaphragm 62 is flexible to such an extent that its outer edge segment 62a can adapt to the surface of the jawbone 61. In order to form a stable cover with the diaphragm and to prevent indentation of the diaphragm into the space 64 by the gingival and epithelium tissue, which is reinforced with biostable strengthening or stiffening pieces or straps and/or reinforcing threads or fibers. These skeletforming elements are preferably manufactured of a biostable material as for example titanium.
During the healing phase, the bone forming cells proliferate and form new bone tissue 66 which grows into the intermediate space 64 covered by the diaphragm 62. As already explained, the formation of the bone tissue is promoted and accelerated by diaphragm 62. Furthermore, the bone tissue grows also into the hole 52b of the post 52 and through the passage 55. This permits a very firm anchoring of the implant in the new tissue 66.
The implant and carrier can be modified and varied in many ways. If, for instance, the carrier is manufactured of one of the previously named metals, the carrier may be covered with a thin titanium layer in order to obtain a rough surface which promotes the growing-together and consolidation of the carrier with the newly formed bone tissue.
The shapes and dimensions of the carrier or the implant can also be changed in various ways. The height of the central part of a carrier is preferably between 2 to 8 mm, the length of the base is between 4 to 16 mm and the width of the base approximately 2 to 8 mm.
While the preferred embodiment of the invention has been described in detail, various modifications and adaptations thereof may be made without departing from the spirit and scope of the invention as delineated in the following claims:
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A implant is disclosed particularly for the jawbone, including a diaphragm and a carrier having an elongated column-like central portion and a frame supporting the central portion, as well as spikes for anchoring the carrier into the jawbone. An intermediate piece for fastening the diaphragm at the end of the central portion is also disclosed. The implant facilitates favorable conditions for growth of the bone tissue so that bone material grows into a space covered by the diaphragm due to the solid anchoring of the implant into the jawbone.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of German Application Nos. 197 27 985.6 filed Jul. 1, 1997 and 198 22 886.4 filed May 22, 1998, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a regulated drawing unit for fiber material, such as a plurality of simultaneously advanced slivers (hereafter "sliver bundle") and is of the type which has at least one drawing field, a controllable and/or regulatable driving system for determining the extent of draft in the respective drawing field, a programmable control for the driving system and at least one sensor for determining the running fiber mass per length unit at a measuring location. Further, a draft-determining signal is stored over a predetermined period in a memory, and information is obtained from the stored values for adjusting the drawing unit.
In a known regulated drawing unit information is gathered for adjusting the drawing unit and/or for judging the quality of the master sliver bundles. Such information includes, for example, the CV value, the spectrogram and/or the length variation curve of the inputted sliver material. The draft-determining signal may be an output signal of a sensor or a setting signal for the drive system. It is a disadvantage of such conventional arrangements that the adaptation of the drawing unit to the regulation of the main drawing process, that is, to an rpm-regulation of the drive motors for the rolls of the drawing unit can be effected only in a limited manner. It is a further drawback that the information may be gleaned only from data concerning the inputted sliver material. Further, obtaining information is complex and also, the adaptation may be provided only for a certain processed assortment.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved regulated drawing unit as well as a control and regulating method of the above-described type from which the discussed disadvantages are eliminated and which, in particular, significantly improves the adaptation of the drawing frame for each assortment change and/or upon quality changes of the produced fiber formation.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the regulated drawing unit for drawing fiber material includes an inlet through which the fiber material passes before being drafted; an outlet through which the fiber material passes after being drafted; a first arrangement defining a drawing field including drawing roll pairs spaced from one another in a direction of advance of fiber material; a drive system operatively connected to at least one of the drawing roll pairs for setting an extent of draft of the drawing field; a programmable control system having a memory and being connected to the drive system; a sensor for determining the mass of the fiber material running through a location and for applying signals to the memory; and a second arrangement for deriving information from data stored in the memory for adjusting the roll pair. The second arrangement includes a third arrangement for forming, from the information, a spectrogram of the fiber material and for evaluating properties of the spectrogram to use such properties in adjusting the roll pair.
The measures according to the invention make possible a significant improvement in the adaptation (setting or adjustment) of the drawing unit. From the analysis of the spectrogram, based on its shape and area, undesired type and magnitude deviations from the desired values may be recognized in a simple manner. For example, machine-specific and/or fiber technological values may be detected upon each assortment change and/or upon quality changes of the produced fiber formation. Advantageously, in the simplest case, based on an on-screen optical analysis of the spectrogram, undesired deviations during operation may be recognized and may serve for the adaptation of the drawing unit, for example, to change the distances of the nip lines and/or drafts by the operating personnel. The invention also permits a computerized evaluation of the spectrogram and a corresponding adaptation of the drawing unit, based on the results of the evaluation, either by the operating personnel or automatically by computer in connection with the regulated drawing unit proper.
The invention has the following additional advantageous features:
The spectrogram of the drawn fiber material at the output of the drawing unit is being utilized.
The spectrogram of the drawn fiber material at the input of the drawing unit is being utilized.
The shape of the spectrogram is evaluated.
The area of the spectrogram is evaluated.
The evaluation includes weighting.
The basic curve (envelope curve) of the spectrogram is evaluated.
There are determined the area under the basic curve, a rectangle whose area equals to that of the basic curve, the area of the rectangle portion projecting beyond the basic curve and the position of the point representing the center of gravity of the area of the rectangle portion.
The individual shapes projecting beyond the basic curve are evaluated.
The individual configurations projecting beyond the basic curve are evaluated.
The limit value excesses of the spectrogram are evaluated.
Envelope curves are determined for the individual configurations projecting beyond the basic curve.
For each envelope curve the distance between the upper reversal point and the basic curve, the area under each envelope curve and the position of the center of gravity of the area under each envelope curve is determined.
The magnitude of the area, the projecting basic area, the above-noted distance and/or the areas are used for adjusting the drawing unit.
An evaluation is effected in zones for shape and content.
An evaluation of partial surfaces and/or partial shapes is effected.
An evaluation of the position of the partial surfaces and shapes is effected.
An evaluation of the position of the centers of gravity of the partial surfaces and shapes is effected.
For adapting the drawing unit the distances of the nip lines of the roll pairs flanking the drawing fields are adjustable.
The drawing unit is adjustable upon conversion to a new fiber assortment.
The drawing magnitudes of the drawing fields of the drawing unit are adjustable.
The total drawing magnitude is adjustable.
The optimal nip line distances are automatically adjustable, for example, after each assortment change.
A computer, for example, a microcomputer with a microprocessor is provided which is used for the evaluation of the spectrogram and for the adjustment of the drawing unit.
The fiber mass at the measuring location is determinable on-line.
An on-line spectrogram determination is effected.
The spectrogram is di splayed on a screen or printout.
A spectral analysis is effected on-line.
The regulated drawing unit is arranged at the output of a carding machine.
The regulated drawing frame is arranged between the web trumpet of a carding machine and the rotary head of a sliver coiler.
The regulated drawing unit is arranged downstream of at least one drawing unit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a regulated drawing unit, with block diagram, incorporating the invention.
FIG. 2 is a block diagram illustrating the coupling of a computer unit with a process command computer.
FIG. 3 is a spectrogram of a drafted fiber material (sliver bundle).
FIG. 4 is a diagram illustrating shapes and areas of a spectrogram, used for evaluation.
FIG. 5 is a schematic perspective view of a sliver information system incorporated in a network of carding machines and drawing frames.
FIG. 6 is a block diagram illustrating a computer-controlled, motor-driven adjustment of the nip line distances of drafting rolls in a regulated drawing unit.
FIG. 7 is a schematic side elevational view of a regulated drawing frame with block diagram for forming and evaluating spectrograms of a sliver bundle upstream of the inlet and downstream of the outlet of the drawing unit for the manual adjustment thereof.
FIG. 8 is a schematic side elevational view of a regulated drawing frame with block diagram for forming and evaluating a spectrogram of a sliver bundle downstream of the outlet of the drawing unit for the automatic adjustment thereof.
FIG. 9 is a regulated drawing frame with block diagram similar to FIG. 7 for an automatic adjustment of the drawing unit according to a variant.
FIG. 10 is a schematic side elevational view of a regulated drawing frame with block diagram for forming and evaluating a spectrogram of a sliver bundle upstream of the inlet of the drawing unit for the automatic adjustment thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a drawing unit 2 of a drawing frame generally designated at 1 which may be an HSR model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. The drawing unit 2 has an inlet 3 and an outlet 4. A sliver bundle 5 composed of a plurality of parallel running slivers enters a sliver guide 6 after running from coiler cans designated at 48 in FIG. 5 and is pulled through a measuring member 9 by delivery rolls 7, 8 in the direction A. The drawing unit 2 is a 4-over-3 drawing unit having three lower rolls I, II and III (that is, a lower output roll I, a lower middle roll II and a lower input roll III) and four upper rolls 11, 12, 13 and 14. A drawing (drafting) of the fiber material (sliver bundle) takes place in the drawing unit 2. The drafting is composed of a preliminary drafting and a principal drafting. The roll pairs 14, III and 13, II form the preliminary drafting field whereas the roll pairs 13, II and the group of three rolls 11, 12, and I form the principal drafting field. The drawn slivers pass through a sliver guide 10 and are, by the delivery rolls 15, 16, pulled through a sliver trumpet 17 in which the individual slivers are gathered into a single sliver 18 which is subsequently deposited into coiler cans designated at 49 in FIG. 5.
The delivery rolls 7, 8, the lower input roll III and the lower middle roll II which are mechanically coupled to one another, for example, by means of a toothed belt, are driven by a regulating motor 19 with an inputted desired value. The respective upper rolls 13 and 14 are frictionally driven by the respective rolls II and III. The lower output roll I and the delivery rolls 15, 16 are driven by a main motor 20. The regulating motor 19 and the main motor 20 are each coupled to a respective regulator 21 and 22. The rpm regulation is effected in each instance by means of a closed regulating circuit in which the regulating motor 19 is associated with a tachogenerator 23 and the main motor 20 is associated with a tachogenerator 24. At the inlet 3 of the drawing unit 2 a magnitude proportional to the sliver mass, for example, the cross section of the slivers of the sliver bundle 5 is detected by a measuring organ 9 of the type disclosed, for example, in German Offenlegungsschrift (application published without examination) 44 04 326. At the outlet 4 of the drawing unit 2 the cross section of the outputted sliver 18 is measured by a measuring organ 25 associated with a sliver trumpet 17 as described, for example, in German Offenlegungsschrift 195 37 983.
A central computer unit 26 (control and regulating device), for example, a microcomputer with a microprocessor, applies, to the regulator 21, a desired magnitude for the regulating motor 19. The values measured by the two measuring members 9 and 25 are, during the drafting operation, applied to the central computer unit 26. From the measuring values delivered by the measuring organ 9 and from the desired value for the cross section of the outputted sliver 18, the desired value for the regulating motor 19 is determined in the central computer unit 26. The measuring values delivered by the measuring organ 25 serve for monitoring the outputted sliver 18 (outputted sliver monitoring). With the aid of such a regulating system, fluctuations in the cross section of the inputted slivers may be compensated for by an appropriate regulation of the drawing process, whereupon a leveling (equalization) of the output product (that is, the sliver 18) may be achieved.
With the central computer unit 26 a memory 27 is associated in which signals concerning the drawing unit control and regulating system are stored for evaluation. In case the operating speed of the microprocessor in the computer unit 26 is sufficiently high, then such a high scanning rate may be selected that a spectrogram relating to the output signal delivered by the sensor 25 and/or the input signal delivered by the sensor 9 may be obtained. The evaluation of the values contained in the memory 27 may be effected as a function of time. In a spectral analysis then the time functions are transformed into frequency functions according to the Fast-Fourier-Transform process. The time required therefor depends from the computing speed of the processor and the number of frequencies (or, as the case may be, the frequency ranges) to be examined individually. For a sufficient analysis of an inputted material preferably at least 1024 individual frequency ranges are to be examined.
Such an evaluation requires a significant processing and storing capacity of the computer proper. Such may not be always available so that the analysis has to be shifted to a process command computer 29. For this purpose, a data bus 30 may be provided and the control 20 may be provided with an interface 28 to the data bus, in which case the computer 29 too, has an interface 31 to the data bus.
FIG. 3 illustrates a spectrogram for the outputted sliver 18. The spectrogram is obtained by a SLIVER INFORMATION SYSTEM TRUTZSCHLER KIT model manufactured by Trutzschler GmbH & Co. KG and schematically shown in FIG. 5. The horizontal axis (abscissa) of the diagram of FIG. 3 indicates the sliver length in meters and the vertical axis (ordinate) shows the periodic sliver mass irregularity (without dimension). The spectrogram shows a complex configuration from which numerical and weighted results are derived; for this purpose a spectrogram evaluation according to the invention is utilized. Preferably, the spectrograms obtained on-line by the measuring organ 25 are used for the evaluation since influences such as coiler can storage, period and conditions of storage have no effect. Expediently, the spectrograms for the evaluation are generated with absolute values from the thickness measurements.
The spectrogram, according to FIG. 4, is examined and evaluated numerically essentially based on two criteria;
(a) the basic shape of the spectrogram and
(b) the individual peaks projecting beyond the basic form.
As to (a), it is noted that the basic form is evaluated according to the first area under the basic form curve G. Thereafter, a rectangular area F is defined which has the same area as that of the basic form curve G. The size of the projecting basic form area D is determined. The position of the center of gravity of the area D on the x-axis is defined. The values for D represent the second criterion and the value X D represents the third criterion. It may be recognized already at this point that the smaller F and the smaller D the better the results.
As to (b), it is noted that the projecting peaks are enclosed in a simple envelope curve, in which case there is determined for each peak
1. its peak value S above the basic form curve;
2. its area J between the envelope curve and the basic form curve; and
3. the position of the center of gravity X J of the respective area J.
Here too, it may be recognized that the smaller the peak value S and the area J, the better the results. The two values, however, have different effects. From such evaluations magnitudes are obtained which are related to the desired yarn results or even to the results in the fabric structure. These magnitudes may be made dependent from the machine settings and also from quality values in the sliver, yarn and/or fabric structure with the purpose of determining good solution fields and determining norms. The final result, however, also depends from the properties of the material of the inputted slivers of the inputted sliver bundle 5. Different materials and different slivers at the inlet 3 of the drawing unit 2 result in different output values. Such a problem may be reduced by also measuring the slivers in the inlet trumpet 6 and generating a spectrogram from the measuring results. Such a spectrogram may be evaluated according to the above-described criteria. Thus, in this connection the initial condition of the slivers forming the sliver bundle 5 has been described and may be evaluated before the drafting operation. This permits a recognition and evaluation of the differences between the input and the output spectrograms. Such differences yield more accurate data for affecting the machine setting to the quality results in the drawing frame sliver. By virtue of the correlation between the setting parameters of the machine and the characteristics in the spectrogram norms are available and from these data and relationships setting instructions are processed for rapidly finding good results. Inasmuch as such instructions yield good results, automatic routines may also be carried out. Motor-driven setting members in the drawing unit control the settings based on instruction lists stored in the machine program. According to another embodiment, adjusting and verifying iteration may be effected automatically which makes it possible to seek and find the optimal machine settings by the machine with its own control system.
FIG. 5 shows sixteen carding machines 32 (which may be DK 803 models manufactured by Trutzschler GmbH & Co. KG) with which there are associated five after-connected drawing frames 1 (which may be HSR models manufactured by Trutzschler GmbH & Co. KG). The machines are combined by a network in which the carding machines 32 and the drawing frames 1 are connected to a SLIVER INFORMATION SYSTEM TRUTZSCHLER KIT, organ 25 in the sliver trumpet 17 of the drawing frames measures permanently and on-line the thickness of the sliver 18 from which, by means of the KIT system, the spectrograms and the spectrogram analyses are obtained and represented as graphs or tables and displayed on a screen 33 or a printer 34. The reference numeral 35 designates a keyboard, while 47 denotes a coiler for the carded sliver.
Also referring to FIG. 6, the operator may manually input the nip line distances K 1 and K 2 of the drawing roll pairs by means of a keyboard 42 into the computer 26 which stores the data and based thereon, controls the motors 36 and 37--which may be stepping motors--for setting the nip line distances. The motor 36 drives a pinion 43 meshing with a rack 44 attached to a carriage 38 on which the roll III is mounted, while the motor 37 drives a pinion 45 meshing with a rack 46 attached to a carriage 39 on which the roll II is mounted. In this manner the carriages 38 and 39 may be displaced in the directions B, C and D, E, respectively. The position of carriages 38, 39 may be measured by means of analog or digital measuring members 40, 41 and inputted into a read/write memory of the computer 26. The latter, in turn, compares these actual values with the inputted desired values for the carriage positions and thereafter the motors 36, 37 are operated by the computer 26 until the desired values correspond to the actual values. The optimal nip line distances K 1 and K 2 are set principally based on the staple length of the processed fibers and may thus be preset. In addition, however, properties such as fiber bulkiness, sliver unity, etc., have an effect on the optimal nip line distances which may be optimized empirically. Such an optimization may then be transferred to the computer 26 which, based on an inputted or on a continuously available program, varies repeatedly the nip line distances K 1 and K 2 and after each new setting the irregularity of the drafted and doubled sliver 18 is measured by the measuring trumpet 17, and the signal generated by the measuring funnel 17 and converted by the transducer 28 is stored over a predetermined period and evaluated. After performing such measurements and evaluation and storing the obtained data, the computer 26 computes from these data the optimal nip line distances K 1 and K 2 and provides for an automatic adjustment. The nip line distances K 1 and K 2 may also be continuously shown on display fields.
Turning to FIG. 7, the intake measuring organ 9 is connected by a transducer 50 and the outlet measuring organ 25 is connected by means of a transducer 51 with the computer 26 which, in turn, applies signals to two devices 52, 53 for forming a respective spectrogram for the inputted sliver bundle 5 and for the discharged sliver bundle 18, respectively. The devices 52, 53 are connected to an evaluating device 54 in which the spectrograms generated in the two devices 52 and 53 are evaluated as to form and area. The data on the results of the evaluation are inputted in a computer 55 in which data on known relationships (for example, shape of the spectrograms related to the machine specific and/or fiber technological parameters) are stored. The computer 55 outputs recommendations for the machine parameters and operating parameters, for example, on a display, screen or printer. Based on the recommendations, a manual setting of the machine may be effected as explained as a mode of operation in conjunction with FIG. 6.
Turning to FIG. 8, the measuring organ 25 at the outlet 4 is connected by means of the transducer 51 with the computer unit 26 which, in turn, applies signals for a device for forming a spectrogram for the outputted sliver bundle 18. The device 53 is coupled to the evaluating unit 54 in which the spectrogram generated in the device 53 is evaluated based on its configuration. The results of evaluation are inputted in the device 55 which, in turn, outputs recommendations for the machine parameters and operating parameters to the machine control and regulating device 56 for adjusting the drawing unit 2. The machine control and regulating unit 56 is connected with setting members of the regulated drawing frame 1; a setting motor 36 drives a shifting device 57 for the horizontal displacement of the roll pair 14, III, and the setting motor 37 operates a displacing device 58 for the horizontal shifting of the roll pair 13, II in directions as shown in FIG. 6. The rolls II and III are supported in respective holders 60 and 59. In this manner an automatic setting of the drawing unit 2 is effected based on the evaluation results of the spectrogram.
The embodiment illustrated in FIG. 9 essentially corresponds to that shown in FIG. 7; the computer 55, corresponding to the illustration in FIG. 8, receives signals from the machine control and regulating device 56 and is connected to the shifting elements 36, 57 and the shifting elements 37, 58 for the automatic setting of the roll pairs 14, III and 13, II, respectively. Further, the arrangement of FIG. 9 permits a comparison between the spectrograms generated in the devices 52 and 53.
The embodiment according to FIG. 10 corresponds to that of FIG. 9, except that according to FIG. 10 only signals from the intake measuring organ 9 are use d for evaluating a spectrogram corresponding to the inputted sliver bundle 5 and for the automatic setting of the drawing unit 2.
In the embodiments shown in FIGS. 8, 9 and 10, as setting members shifting elements 36, 57 and 37, 58 are used for setting the clamping line distances of the roll pairs. The evaluating results may be utilized by the machine control and regulating device 56 also for setting the regulating motor 19 and/or the main motor 20 (FIG. 1) and thus for changing the extent of draft. The evaluation s may be utilized by the machine control and regulating device 56 also for two processes, that is, for the changing the nip line distances of the drawing unit 2 and for altering the extent of draft.
A plurality of regulated drawing frames 1 may be connected to the computer 26 as illustrated in FIG. 5. According to FIG. 1, a central computer unit 26 may be provided which forms and evaluates the spectrograms and also performs the control and regulating tasks for the regulated drawing frames 1. The forming and evaluation of the spectrograms may also be performed in the computer 26 and the regulated drawing frames 1 may each have its own control and regulating device 56 as shown in FIGS. 8, 9 and 10.
The invention was described in an exemplary manner in connection with a regulated drawing frame 1. It is to be understood that the invention can find application in other machines which have a regulatable drawing unit 2, for example, a carding machine 32, combing machines and the like. The invention may also find application in a carding machine in which the fiber material is drawn on the clothed rolls in the working direction.
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 regulated drawing unit for drawing fiber material includes an inlet through which the fiber material passes before being drafted; an outlet through which the fiber material passes after being drafted; a first arrangement defining a drawing field including drawing roll pairs spaced from one another in a direction of advance of fiber material; a drive system operatively connected to at least one of the drawing roll pairs for setting an extent of draft of the drawing field; a programmable control system having a memory and being connected to the drive system; a sensor for determining the mass of the fiber material running through a location and for applying signals to the memory; and a second arrangement for deriving information from data stored in the memory for adjusting the roll pair. The second arrangement includes a third arrangement for forming, from the information, a spectrogram of the fiber material and for evaluating properties of the spectrogram to use such properties in adjusting the roll pair.
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This is a division of application Ser. No. 127,002 filed Mar. 4, 1980 now U.S. Pat. No. 4,320,065.
BACKGROUND OF THE INVENTION
Vitamin K 1 having the formula: ##STR1## and vitamins of the vitamin K 2 series having the formula ##STR2## where n is an integer of from 1 to 13 are known in part as natural substances. These vitamin K series of compounds are used as additives for feedstuffs, for investigations metabolism and other purposes. These compounds can be present, with reference to the first double-bond (viewed from the naphthoquinone ring) in the terpene chain, in Z-form (also called cis-form) or in E-form (also called trans-form) or as a mixture of these two forms. In biological investigations, the Z-form has proved to be biologically less active, if not even inactive. In the case of vitamin K, a "lack of biological activity" was ascertained for the cis-form in J. Nutr. 105:1519-1524, 1975. According to O. Isler in Angew. Chem., 71 (1959) No. 1., pages 13-15, in the case of substances of the vitamin K 1 and K 2 series, the mono-cis compounds (cis double-bond adjacent to the naphtoquinone ring system) showed a significantly lower activity than the all trans forms.
The efforts towards synthetic production of substances of the vitamin K 1 and K 2 series--the K vitamins influence the biosynthesis of prothrombin and other blood-coagulation factors--were indeed soon succesful. Thus, a process for the manufacture of vitamin K 1 (20) starting from a methylnaphthohydroquinone and the corresponding terpene alcohol with a subsequent oxidation step was already described in 1939. There was obtained a total yield of 29%, based on phytol, without disclosing the E/Z ratios in the compounds obtained.
Recent processes, as disclosed e.g. in U.S. Pat. No. 2,683,176 or in German patent application 2,733,233, start from corresponding methyl-substituted naphthohydroquinone monoether derivatives, which are reacted with the corresponding terpene alchols or terpene ethers and the resulting reaction products are oxidized. While in the former process there is obtained e.g. a yield of vitamin K 1 of 37.5%, based on phytol, with a E/Z ratio of 90 to 92.5/7.5 to 10, the latter process leads only to the E-isomeric form with good yields of vitamin K 1 .
In other processes, methylnaphthohydroquinone and the respective terpene derivatives are condensed in the presence of metals such as zinc amalgam or zinc dust. In this case, the product is obtained in low total yields with the formation of E/Z-isomer mixtures. The use of N-sulphinylamines as the condensation agent has also been described, whereby, based on phytol, yields of vitamin K 1 of only 4 to 7% have been obtained, but in the form of the pure E-isomers.
There exits thus a need for the provision of a process for the manufacture of compounds of the vitamin K 1 , and vitamin K 2 series, in which these compounds are obtained in high yield and in a relatively simple manner. Since the synthesis of the specific methyl-substituted naphthohydroquinone derivative is expensive, the discovery of such processes in which this starting material need not be employed has been desired. In this case, it is especially desirable that such processes lead stereospecifically to the exclusively or predominantly biologically active E-form.
SUMMARY OF THE INVENTION
In accordance with this invention, a process is provided for producing vitamins of the K 1 and K 2 series (i.e. compounds of formula IV-A and IV-B) by reacting a phenyl-carbene-carbonyl metal complex of the formula ##STR3## wherein R 1 is lower alkyl, acyl or benzyl, with an enyne of the general formula
CH.sub.3 --C.tbd.C--R.sup.2
wherein R 2 is dimethylallyl, geranyl, farnesyl, or an analogous isoprenoid terpenyl residue or the phytyl residue; to produce a naphthol-carbonyl-metal complex of the formula: ##STR4## wherein R 1 and R 2 are as above. The naphthol-carbonyl-metal complex of formula III is converted to the compound of formula: ##STR5## wherein R 2 is as above, by cleaving the metal-ring bond, i.e. --Cr(CO) 3 in the compound of formula III. In certain cases, cleaving may not directly produce the compound of formula IV but rather produces the corresponding naphthol derivative. If this is the case, the naphthol derivative is oxidized to the compound of formula IV.
By this process, the desired compounds of the vitamin K 1 or K 2 series are produced. The particular vitamin K 1 and K 2 compound produced dpends on the nature of the substituent R 2 . Furthermore, this process is extremely advantageous since it has been surprisingly discovered that the compounds of formula IV are produced having the E-configuration, when the enyne of formula II has an E-configuration.
Therefore, this invention provides a process for the stereospecific synthesis of compounds of the vitamin K 1 and K 2 series. Through this synthesis, these compounds can be produced specifically in the E-form in high yields. Furthermore, the process of this invention provides a simple and efficient means for producing compounds of the vitamin K series in only a few steps with the simple intermediate formation of the naphthol ring.
DETAILED DESCRIPTION OF THE INVENTION
"Aryl" designates mononuclear aromatic hydrocarbon groups such as phenyl, ect., which can be unsubstituted or substituted in one or more positions with a lower alkyl substitutent and polynuclear aryl groups such as naphthyl, anthryl, phenanthryl, azulyl, etc., which can be unsubstituted or substituted with one or more of the aforementioned lower alkyl groups. The preferred aryl groups are the substituted and unsubstituted mononuclear aryl groups, particularly phenyl.
Throughout the present specification, the term "lower alkyl" means particularly alkyl groups with 1-7 carbon atoms such as methyl, ethyl, isopropyl and the like, the methyl radical being preferred. The term "acyl" stands for particularly lower alkanoyl groups with up to 7 carbon atoms such as acetyl, propionyl, butyryl and the like, as well as for aroyl groups where aryl is defined as above. Among the preferred aroyl substituents are included benzoyl and the like.
The term "analogous isoprenoid terpenyl residue" includes such residues as ##STR6## wherein m is an integer of from 3 to 13.
In the complex of formula I, the dotted bond indicates a partial double bond. The complex of formula I designates a structure which is a resonance hybrid between the compound of formula I having a carbon to oxygen double bond and the compound of formula I having a carbon to chromium double bond.
The phenyl-carbene-carbonyl-metal complexes of formula I used as starting materials in the present process are known compounds or analogous to known compounds. These compounds can be prepared according to Darensbourg et., Inorg. Chem. 9, 32 (1970). For the purpose of the present invention, the pentacarbonyl (methoxy-phenylcarbene)chromium complex as well as the pentacarbonyl(acetoxyphenylcarbene)chromium complex are particularly preferred. All the above complexes are compounds which under nitrogen and low temperature are extremely stable.
The enynes of the general formula II used as the further reaction partner are partly known and partly new compounds. The new compounds can be prepared in an analogous manner to the preparation of the known compound and are also part of the present invention. For example the 5-methyl-4-hexen-1-yne or the 6-methyl-5-hepten-2-yne are known compounds and the new compounds, i.e. geranyl, farnesyl and phytyl derivatives, respectively, viz. 6.10-dimethyl-5.9-undecadien-2-yne; 6.10.14-trimethyl-5.9.13-pentadecatrien-2-yne and 6.10.14.18-tetramethyl-5-nonadecen-2-yne can readily be synthesized in an analogous manner. In this case one generally starts from propynylmagnesium bromide in ether and slowly adds dropwise thereto a solution of the respective terpene halide, especially terpene bromide R-Br (R=geranyl, farnesyl, phytyl) in ether. After heating under reflux for several hours, the mixture is poured onto ice and optionally diluted acid (e.g. acetic acid) and extracted with an organic solvent. After washing and usual working-up, there is then obtained the desired enyne as a crude product in good yield.
The reaction of an enyne of formula II (in the case of the use thereof in the E-form) with a metal-carbene complex of formula I leads in a one-step, rapidly proceeding reaction directly and stereospecifically to the E-type of the in each case desired vitamin K product in the hydroquinoid form of formula III, which can then with retention of the desired E-form, be transformed to the desired end product of formula IV.
In the process in accordance with the present invention the reaction of the carbene complex of formula I with the enyne of formula II is usually carried out under protective gas atmosphere, e.g. under nitrogen, argon, etc. However, an oxygen-admittance can also be avoided by any other suitable method.
In carrying out this reaction, any conventional organic donor solvent can be used as the reaction medium, with ethers being especially preferred. In this case, there can be employed with advantage high-boiling ethers, e.g. ter.butyl methy ether or dibutyl ether, the reaction then proceeding conveniently at elevated temperature.
In carrying out this reaction, temperature is not critical. Although the reaction proceeds at room temperature, it is preferred to carry out the reaction e.g. at a temperature in the range between about 25° and 80° C. and preferably between about 50° and about 60° C. The reaction proceeds well and completely with stoichiometric ratios of the reaction partners, whereby the substituted naphtholtricarbonyl-chromium complexes result in yields of at least 85% up to 100% of theory. Preferably, however, the enyne is employed in a slightly over-stoichiometric ratio, over the starting carbene compound, for example 1,1:1=enyne: starting carbene complex. However, if desired, any ratio of starting materials can be utilized.
The naphthol-tricarbonyl-chromium complexes of formula III are novel compounds and form also part of the present invention.
The cleaving of the metal-ring bond in the compounds of formula III can be carried out in different ways. Thus, this cleaving can for instance be carried out using an oxidizing agent, in which case the oxidation of the naphthol derivative to the compounds of formula IV occurs simultaneously. In carrying out this reaction, any conventional oxidizing agent can be utilized. Any of the conditions conventional in using these oxidizing agents can be utilized in this conversion. This reaction can be carried out directly following the formation of the substituted naphthol-carbonyl-metal complex of formula III in a one-pot process or also after isolation of the complex of formula III and purification thereof, insofar as this appears to be convenient.
Among the preferred oxidizing agents is included the oxidizing agent silver oxide. The use of silver oxide leaves the terpene substituent intact but is capable of cleaving the metal-ring bond and can convert the hydroquinone compound readily into the quinoid end product. In the oxidative cleavage of the metal-ring bond with Ag 2 O there can result, in addition to the desired quinone, also a small amount (e.g. 5%) of the quinone-Cr(CO) 3 complex of the formula ##STR7## wherein R 2 has the above meanings.
The occurrence of this undesirable by-product can, however, be prevented by the use of stronger oxidation agenst such as e.g. H 2 O 2 , MnO 2 , PbO 2 or NiO 2 . It is therefore preferred in many embodiments of the invention to carry out this reaction, for example, with 20% H 2 O 2 , e.g. in a non-polar solvent at room temperature.
If the oxidation is carried out directly after the formation of the complex of formula III, without isolation thereof, the oxidation can be carried out conveniently with silver (I) oxide in the presence of MgSO 4 or other water-entraining agents.
Furthermore, the cleaving of the metal-ring bond in the compounds of the formula III can in principle also be carried out with all such reagents with which usually a lower oxidation level of transition elements can be stabilized. As examples of such reagents there can be named: carbon monoxide, which is prefereably used under pressure, particularly under a pressure of from about 50 to about 100 atmospheres, phosphines, e.g. triphenylphosphine, phosphites, e.g. trimethylphosphite, isonitriles, olefines, e.g. cyclooctadiene or norbornadiene, aromatic compounds such as benzene, methyl or halogen substituted benzene, benzoic acid esters, aniline or alkyl derivatives thereof or nitrogen bases such as pyridine and the like. In using these agents, any of the conditions conventionally used can be used in this process step.
In case the cleavage of the metal-ring bond is not carried out with an oxidation agent but with one of the foregoing mentioned agents, the then obtained naphthol derivative still has to be oxidized to the compounds of the general formula IV. This oxidation can be carried out according to methods known per se, for example with silver oxide or also with air.
The chromium carbonyl obtained according to the non-oxidative cleavage of the metal-ring bond can, if desired, after treatment with carbon monoxide, be recycled in the process in the form of chromium-hexacarbonyl.
The particulars of the process of the present invention are shown on the basis of the following working directions for the manufacture of the enynes, insofar as they are not prior known, the manufacture of the complex of formula III as well as the cleavage of the metal-ring bond and the oxidation step which leads to the end products of formula IV.
EXAMPLE 1
Manufacture of the enynes of formula II
A spatula tip of copper (I) chloride is added to a solution of 30 mmol of propynylmagnesium bromide in 20 ml of ether and subsequently a solution of 30 mmol of R-Br (R=geranyl, farnesyl, phytyl) in 20 ml of ether is added slowly. After twelve-hours heating under reflux, the mixture is poured into ice and dilute acetic acid and extracted with ether. The mixture is washed neutral with dilute sodium hydroxide and water and dried over MgSO 4 . After the removal of the solvent, there is obtained the enyne as a crude product in 65 to 85% yield.
Trans-(10R,14R)-6,10,14,18-tetramethyl-5-nonadecen-2-yne: b.p. 131°-145° C./0,15 mmHg
EXAMPLE 2
Preparation of the compounds of forumula III
1 mmol of carbonyl-carbene-chromium complex is heated at 25° to 80° C. while stirring with 1,1 mmol of enyne in 5 ml of a donor solvent under protective gas (N 2 ) during 1/2 to 3 hours. After chromatography over silica gel with methylene chloride/pentane mixtures, there are obtained the substituted naphthol-tricarbonyl-chromium complexes in yields of 85 to 100%.
EXAMPLE 3
Cleavage of the metal-ring bond and simultaneous oxidation of the resulting naphthol derivatives (here after previous isolation of the obtained complexes of formula III)
The 2.3.4-trisubstituted 1-naphthol-tricarbonylchromium complex obtained from 1 mmol of carbonyl-carbene-chromium complex and 1,1 mmol of crude enyne is oxidised in ether with an excess of Ag 2 O. The chromatographical working-up on silica gel with pentane/ether mixtures at -10° to 20° C. yields 30% to 50% of 2.3-disubstituted naphthoquinone.
The batch can be increased proportionally.
EXAMPLE 4
Cleavage of the metal-ring bond with carbon monoxide
The 2.3.4-trisubstituted 1-naphthol-tricarbonyl-chromium complex obtained from 1 mmol of carbonyl-carbene-chromium complex and 1,1 mmol of crude enyne is heated in ether in a steel autoclave under a carbon monoxide pressure of about 50 to 100 atmospheres to a temperature of about 60° to about 100° C. After opening of the autoclave, the solution is filtered, the solvent is evaporated from the filtrate and the residue is chromatographed. There is obtained the desired naphthol derivative which afterwards can be transformed to the end product of formula IV by oxidation.
The working conditions set forth in the above examples can be correspondingly altered, since they only represent a preferred embodiment of the invention which is not to be understood as limiting.
Hereinafter there is now to be described the manufacture of vitamin K 1 (20).
EXAMPLE 5
Manufacture of vitamin K 1
A solution of 1 mmol of pentacarbonyl[methoxy(phenyl)carbene]chromium and 1,1 mmol of 6.10.14.18-tetramethyl-5-nonadecen-2-yne from phytyl bromide (isomer ratio (E/Z=90/10) in 5 ml of dibutyl ether is heated to 55° C. under nitrogen for 1 hour. After the removal of the solvent, the 1-naphthol-tricarbonyl-chromium complex can be isolated (yield 95%) by chromatography on silica gel at -30° C. with methylene chloride/pentane (2/1), or directly oxidised to the quinone after addition of 10 ml of ether by one-hours stirring with 1,5 mmol of silver (I) oxide in the presence of MgSO 4 . The obtained mixture is filtered, the solvent removed and the residue purified by chromatography at 10° C. on silica gel with pentane/ether (100/1). There is obtained vitamin K 1 (20) as a light yellow oil in a total yield of 56%.
Isomer ratio E/Z=87:13 (±5) ( 1 H-NMR spectroscopic determination).
The observed isomer ratio E/Z was already present (within the limits of error) in the starting enyne, whereby the proof of a strictly sterospecific course of the described addition reaction is furnished.
The end products obtained were identified by IR, NMR spectra as well as mass-spectroscopic investigations by comparison with known spectra. Also, the purity determinations as well as the establishment of the E/Z-isomer ratios were carried out on the basis of the 1 H-NMR spectroscopy and the CH analysis.
Hereinafter there are given for compounds of the K 1 and K 2 series the analysis values obtained as well as the isomer ratios E/Z as follows.
__________________________________________________________________________ ##STR8## Yield Analysis (based E/Z values on RBr)__________________________________________________________________________R.sup.2 = dimethylallyl -- calc.: C 79.97 H 6.71 51% ##STR9## found: C 80.42 H 7.35R.sup.2 = geranyl (K.sub.2(10)) 85:15 calc.: C 81.78 H 7.84 54% ##STR10## found: C 81.47 H 8.20R.sup.2 = farnesyl (K.sub.2(15)) 85:15 calc.: C 82.93 H 8.57 55% ##STR11## found: C 82.88 H 8.97R.sup.2 = phytyl (K.sub.1(20)) 87:13 calc.: C 82.61 H 10.29 56% ##STR12## found: C 82.29 H 10.63__________________________________________________________________________
The above values indicate the high yield obtained. The yields are based on highly pure product and were not optimised. At the same time, it is evident that the reaction proceeds strictly stereospecifically having regard to the exclusive formation of the desired biologically active form. This was verified in that the chosen E/Z ratio of the enyne used (geranyl bromide, farnesyl bromide and phytyl bromide with a E/Z ratio of 85:15, 85:15 and 87:13) remains preserved in the end product of the synthesis. With the use of the uniform E-forms of the enynes there thus result exclusively the desired biologically active substances of the vitamin K 1 or K 2 series in the E-form.
EXAMPLE 6
A solution of 340 mg of the tricarbonyl-(4-methoxy-2,3-methyl-phytyl-1-naphthol)chromium complex (prepared according to Example 5) in 35 ml of ether is heated in a 100 ml steel autoclave at a temperature of 80° C. during 6 hours under a carbon monoxide pressure of 85 at. After opening of the autoclave, the yellow solution is filtered and cooled to -40° C. Thereby the majority of the formed chromium hexacarbonyl precipitates and can be filtered off. After elimination of the solvent, there remains an orange colored oil, which for further purification is chromatographed on silica gel. The so obtained naphthol derivative can be oxidised to vitamin K 1 (20) in known manner.
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A process for preparing vitamins of the vitamin K 1 and K 2 series in their E-isomeric form through the reaction of a phenylcarbene metal complex with an enyne and intermediates in this synthesis.
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BACKGROUND OF INVENTION
[0001] The present invention relates generally to an in-line swivel for use in drilling and pipeline operations. More particularly, the invention relates to an in-line swivel permitting deflection when the tubular string below the swivel is deflected by relative motion from the longitudinal axis of the remainder of the tubular string. More particularly still, the invention relates to an in-line swivel permitting deflection of a pipe string resulting from “wave action” and wind changes experienced when used in conjunction with floating drilling rigs or tankers.
[0002] The use of in-line drill string swivels in drilling applications has long been known to those in the drilling industry. Often, during sea-based drilling operations on floating platforms, the drill string suspended from a drilling mast may experience movement not generally experienced by land based drilling rigs which are fixed to the ground. These floating drill rigs may have drilling masts extending hundreds of feet above the rotary table support the drill string hanging below. If the rotary table floor rotates or rocks while the in-line swivel is supporting the drill string, damage may occur to the drill string or Kelly drive. Particularly, if a drill string on a movable platform is connected to a fixed or rigid tubular string, stress and strain will build up if a provision to allow rotation and deflection therebetween is not present. Furthermore, movement of the platform or vessel from wave action or wind (or intentional movements) can overstress and even loosen a threadably connected pipe string. Finally, in addition to “drill string” applications, other applications of pipe, either threadably connected or bolted, exist where angular and rotational deflections are an issue.
SUMMARY OF INVENTION
[0003] The present invention relates to a deflection swivel providing a tubular retainer sub, a tubular swivel mandrel having an enlarged rounded head at its upper end, and a retainer nut providing an opening larger than the outer diameter of a lower end of the tubular swivel mandrel, connected to the tubular retainer sub enclosing said rounded head of the tubular swivel mandrel to permit deflection of the swivel mandrel and enclosing a bearing having an upper surface conforming to the rounded head of the tubular swivel mandrel to thereby permit rotational movement of the mandrel upon deflection of the swivel mandrel from the longitudinal axis of the retainer sub.
[0004] The hardened wear collar inserted in the interior surface of the retainer sub provides a profile conforming to the rounded head of the tubular swivel mandrel thereby permitting the rounded head to rest within the profile, evenly distributing the strain caused by lateral movement of the mast of the drilling structure, around the collar surface. The wear collar is retained between an upper edge of the bearing and the lower hemispherical surface of the swivel mandrel to permit deflection of the swivel mandrel. Alternatively, the wear collar could be formed as the upper edge of the bearing. Each embodiment can be slipped over the lower end of the mandrel member upon makeup and positioned between the retainer sub and the bottom hemispherical surface of the swivel mandrel. The wear collar moreover could be segmented to allow portions of the wear collar to be replaced without replacement of the whole.
[0005] The bearing which supports the rotation of the mandrel can be lubricated by injection of lubricant from a lower edge of retainer nut. The bearing and its lubrication are protected from the damage that can be observed from the ingress of drilling fluid into the bearing race since the present invention provides one or more seals on the upper hemispherical surface of the swivel mandrel to prevent egress of drilling fluid around the rounded head of the mandrel into the bearing supporting the mandrel in the retainer sub.
[0006] A hardened insert can be retained in a lower radial portion of the retainer sub providing a cooperating hemispherical surface conforming to the rounded upper surface shape of the swivel mandrel or this cooperating surface may be formed on the inner surface of the enlarged lower end of the retainer sub. Since this surface can experience wear from repeated deflections of the swivel from its principal longitudinal axis, a wear surface preventing premature wearing of the retainer sub is expected to be preferred. This hardened surface would provide seals to prevent drilling fluid from flowing around the hardened insert to reach the bearing.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 is a partial sectional drawing of the deflection sub in accordance with a preferred embodiment of the present invention.
[0008] FIG. 2 is a cross-sectional drawing side view of the deflection sub of FIG. 1 .
DETAILED DESCRIPTION
[0009] Referring to FIGS. 1 and 2 collectively, a deflection sub 10 in accordance with a preferred embodiment of the present invention is shown. Deflection sub 10 assembly preferably includes a tubular retainer sub 20 , a swivel mandrel, a retainer nut 50 , and a bearing 60 . Retainer sub 20 preferably includes a rotary threaded drill connection 22 at its distal end to permit connection thereto with additional threaded pipe string components. While threaded connection 22 is shown as a female connection, it should be understood that any connection known in the art may be employed to connect retainer sub 20 to other components. Additionally, retainer sub 20 preferably includes a bore 24 therethrough to allow the flow of drilling fluids from the fluid system into the drill string. Retainer sub 20 is shown including an enlarged end 26 including threads 28 on an exterior lateral surface and a recess on its interior surface providing a seat 27 for a socket bushing 40 .
[0010] Socket 40 preferably includes an exterior surface mating with seat 27 and a hemispherical interior surface 43 . A passage through socket bushing 40 permits drilling fluid to flow through into the throat of swivel mandrel 30 without obstruction. Furthermore, socket bushing 40 preferably includes exterior circumferential seals 41 and 42 to prevent the escape of fluids or the ingress of contaminants between the outer surface of socket bushing 40 and retainer sub 20 . Seals 41 , 42 may designed to allow rotation of socket bushing 40 with respect to retainer sub 20 , if a dynamic-type sealing arrangement is desired. Optionally, the cavity, if any, between seals 41 , 42 may be filled with a generally incompressible lubricant to effectuate the integrity of the seals. While seals 41 , 42 are shown schematically as o-ring type seals, it should be understood by one of ordinary skill in the art that any sealing mechanism may be employed, including metal to metal seals.
[0011] Swivel mandrel 30 is preferably constructed as a tubular member having a spherically-shaped ball end 32 . Ball end 32 is preferably configured to be substantially the same contour and profile as hemispherical inner surface 43 of socket bushing 40 . A plurality of sealing elements 33 are preferably located about the leading edge of ball end 32 to prevent leakage of fluid from bore 24 around the outer profile of ball end 32 . As mentioned above, seals 33 are shown schematically as o-ring type seals, but any sealing scheme known to one skilled in the art may be employed, including a metal to metal design. Furthermore, seals 33 are preferably designed such that relative movement of ball end 32 with respect to socket bushing 40 is permitted without compromising the integrity of the seals.
[0012] Following the installation of socket bushing and swivel mandrel into seat 27 of retainer sub 20 , a backup ring 44 is installed. Backup ring 44 is preferably designed with a semispherical profile on its leading end and a planar surface on its trailing end. With backup ring 44 securely held in place, ball end 32 of swivel mandrel 30 will be firmly held in place within retainer sub 20 . Following installation of backup ring 44 , a bearing assembly 60 is installed. Bearing assembly 60 is preferably constructed as a thrust bearing, one whereby axial loads of swivel mandrel 30 and retainer sub 20 are resisted without damaging components of deflection sub assembly 10 . Construction of bearing assembly 60 may be of any design known by one skilled in the art but should be capable of resisting the magnitude of the axial loading expected to be experienced by deflection sub assembly 10 . Bearing assembly 60 is preferably constructed to allow the rotational movement of swivel mandrel 30 and ball end 30 with respect to retainer sub 20 .
[0013] Following the installation of bearing assembly 60 , retainer nut 50 is installed. Retainer nut 50 is threaded onto retainer sub 20 and provides interior threads to correspond with outer threads of retainer sub 20 . Retainer nut preferably includes an interior lip 52 , and a pair of hydraulic ports 54 . Interior lip 53 retains bearing assembly 60 , backup ring 44 , ball end 32 , and socket bushing 40 against seat 27 of retainer sub 20 . Hydraulic ports 54 may be used to either fill cavities within the space formed between retainer nut 50 and retainer sub 20 or, in the alternative, may serve to energize bearing assembly 60 . With deflection sub assembly 10 completely assembled with retainer nut 50 tightly threadably secured to retainer sub, a grub screw 56 can be tightened to prevent the loosening thereof.
[0014] Numerous embodiments and alternatives thereof have been disclosed. While the above disclosure includes the best mode belief in carrying out the invention as contemplated by the named inventors, not all possible alternatives have been disclosed. For that reason, the scope and limitation of the present invention is not to be restricted to the above disclosure, but is instead to be defined and construed by the appended claims.
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A deflectable in-line swivel that permits axial deflection of a tubular string is presented. The in-line swivel is preferably constructed as a ball and socket design whereby the ball of a swivel mandrel is permitted to articulate within a socket of a retainer sub. The system preferably includes a thrust bearing to allow the tensile loads to be carried across the swivel.
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TECHNICAL FIELD
The present invention relates to an ultrasound-guided piercing needle for piercing a patient while detecting a position of the piercing needle utilizing the reflection of ultrasonic waves, as well as to an indwelling needle incorporating the piercing needle.
BACKGROUND ART
For example, at the time of transfusion of a high-concentration pabulum into a patient, an indwelling needle including a catheter (outer needle) and a piercing needle (inner needle) is made to pierce the patient, the piercing needle is evulsed with the catheter left in a pierced state, a guide wire is inserted through the catheter to reach a blood vessel (vein) near the heart, the catheter is evulsed, a central arterial catheter is inserted along the guide wire into the blood vessel, the guide wire is removed so that only the central arterial catheter is left indwelling in the pierced state, a transfusion line through which a pabulum, a medicinal liquid, or the like is supplied is connected to the central arterial catheter, and a transfusion is conducted.
In the case that such an indwelling needle is made to pierce a blood vessel, for example, ultrasonic waves are emitted from an ultrasonic imaging device, thereby confirming the position of the blood vessel to be pierced. In addition, the piercing needle, which is in the pierced state, is irradiated with ultrasonic waves, and a surgical procedure is carried out while confirming the position of the piercing needle through an image obtained based on the reflected waves.
Hitherto, as such an indwelling needle, indwelling needles in which an outer circumferential surface of a piercing needle (inner needle) is provided with a helical groove or a V-shaped groove in a recessed form have been known (see, for example, Japanese Patent No. 3171525 and Japanese Laid-Open Patent Publication No. 03-228748). Upon using this type of indwelling needle, the piercing needle is made to pierce a diseased part of a patient, the pierced part is irradiated with ultrasonic waves emitted from an ultrasonic imaging device, whereupon the ultrasonic waves are reflected by an air layer in the helical groove or the V groove, and the reflected waves are received by the ultrasonic imaging device in order to obtain a picked-up image (echo image) of the piercing needle.
SUMMARY OF INVENTION
Meanwhile, in order to accurately grasp the position of the piercing needle, as mentioned above, it is important to obtain a clear echo image. In order to obtain a clear echo image, reflected waves with sufficient intensity must be returned from the piercing needle to a probe of the ultrasonic imaging device. Therefore, it is desired to develop an ultrasound-guided piercing needle, which ensures that stronger reflected waves, and hence a clearer echo image, can be obtained.
The present invention has been made in consideration of the above-mentioned problems. Accordingly, it is an object of the present invention to provide an ultrasound-guided piercing needle and an indwelling needle, which ensure that ultrasonic waves can be reflected more effectively, whereby the position of the piercing needle in a living body can be confirmed assuredly and with high accuracy.
According to the present invention, there is provided an ultrasound-guided piercing needle having a ridged and grooved portion, which reflects ultrasonic waves, the ridged and grooved portion comprising a grooved portion provided on an outer circumferential surface near a distal portion having a blade face, and ridged portions provided on both sides of the grooved portion.
In this manner, since the ridged and grooved portion includes the grooved portion and the ridged portions provided on both sides of the grooved portion, ultrasonic waves are reflected not only by the grooved portion, but also by the ridged portions. Therefore, ultrasonic waves can be reflected assuredly and suitably, and can be detected by the ultrasonic imaging device. Consequently, upon piercing a patient, the ultrasound-guided piercing needle can be confirmed assuredly and with high accuracy by the ultrasonic imaging device, whereby a safe and assured procedure can be carried out while confirming the position of the ultrasound-guided piercing needle.
In addition, in the aforementioned ultrasound-guided piercing needle, the ridged and grooved portion may be formed in an annular shape on the outer circumferential surface, and a plurality of ridged and grooved portions may be provided along an axial direction of the ultrasound-guided piercing needle.
With such a configuration, the formation of the ridged and grooved portion in an annular form on the outer circumferential surface enables the entire circumference to act as a reflecting surface, so that when piercing is carried out, ultrasonic waves can be reflected effectively, irrespective of the position around the axis of the ultrasound-guided piercing needle. In addition, since plural ridged and grooved portions are provided along the axial direction of the ultrasound-guided piercing needle, the number of parts that provide suitable reflection of ultrasonic waves is increased significantly. Therefore, ultrasonic waves can be reflected effectively, and more sufficient reflected waves can be obtained. Consequently, the position of the ultrasound-guided piercing needle by the ultrasonic imaging device can be confirmed with higher accuracy.
Further, in the aforementioned ultrasound-guided piercing needle, the plurality of ridged and grooved portions may be formed such that the ridged portions of adjacent ones of the ridged and grooved portions are continuous with each other.
By forming the ridged and grooved portions continuously along the axial direction of the ultrasound-guided piercing needle, ultrasonic waves can be reflected more effectively, and more sufficient reflected waves can be obtained. As a result, the position of the ultrasound-guided piercing needle by the ultrasonic imaging device can be confirmed with higher accuracy.
In addition, in the aforementioned ultrasound-guided piercing needle, the ridged and grooved portion may be formed in a helical shape extending around the outer circumferential surface at least a plurality of times.
By forming the ridged and grooved portion in this manner, the entire circumference acts as a reflecting surface, so that when piercing is carried out, ultrasonic waves can be reflected effectively, irrespective of the position around the axis of the ultrasound-guided piercing needle. In addition, the number of parts provided for suitable reflection of ultrasonic waves is increased, so that more sufficient reflected waves can be obtained. Consequently, the position of the ultrasound-guided piercing needle by the ultrasonic imaging device can be confirmed with higher accuracy.
Further, in the aforementioned ultrasound-guided piercing needle, the grooved portion may be arcuate in cross section.
According to the above configuration, an inner wall surface of the grooved portion constitutes an arcuate reflecting surface. Thus, even if the piercing angle changes, ultrasonic waves incident on the grooved portion can be reflected in substantially the same direction as the direction of incidence. Therefore, ultrasonic waves can be reflected suitably, and as a result, the position of the ultrasound-guided piercing needle by the ultrasonic imaging device can be confirmed with higher accuracy.
In addition, in the aforementioned ultrasound-guided piercing needle, the ridged portions may be arcuate in cross section.
According to the above configuration, outer wall surfaces of the ridged portions constitute arcuate reflecting surfaces. Thus, even if the piercing angle changes, ultrasonic waves incident on the ridged portions can be reflected in substantially the same direction as the direction of incidence. Therefore, ultrasonic waves can be reflected suitably, and as a result, the position of the ultrasound-guided piercing needle by the ultrasonic imaging device can be confirmed with higher accuracy.
Further, according to the present invention, there is provided an indwelling needle including an inner needle and an outer needle in which the inner needle is inserted, wherein the inner needle is configured as an ultrasound-guided piercing needle having a ridged and grooved portion, which reflects ultrasonic waves. The ridged and grooved portion further comprises a grooved portion provided on an outer circumferential surface near a distal portion having a blade face, and ridged portions provided on both sides of the grooved portion.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an overall view showing the configuration of an indwelling needle having an ultrasound-guided piercing needle according to one embodiment of the present invention;
FIG. 2A is a plan view showing the configuration of a catheter and an outer needle hub shown in FIG. 1 ;
FIG. 2B is a partially omitted enlarged sectional view, taken along an axial direction, of a distal portion and portions in the vicinity thereof of the catheter shown in FIG. 2A ;
FIG. 3A is a plan view showing the configuration of an ultrasound-guided piercing needle and an inner needle hub according to one embodiment of the present invention;
FIG. 3B is a enlarged side view, shown partially in cross section, of an ultrasound-guided piercing needle according to one embodiment of the present invention;
FIG. 4 is a partially omitted enlarged sectional view showing a part near a distal portion of an indwelling needle having an ultrasound-guided piercing needle according to one embodiment of the present invention;
FIG. 5 is a schematic illustration showing the manner in which an indwelling needle, having an ultrasound-guided piercing needle according to one embodiment of the present invention, is made to pierce a patient while the ultrasound-guided piercing needle is detected by an ultrasonic imaging device;
FIG. 6 is an enlarged schematic illustration of a condition in which ultrasonic waves, which are irradiated on an indwelling needle having an ultrasound-guided piercing needle according to one embodiment of the present invention, are reflected;
FIG. 7 is a schematic illustration of a mode of usage, in which an ultrasound-guided piercing needle according to one embodiment of the present invention is made to directly pierce a patient;
FIG. 8 is an enlarged side view showing grooved portions of an ultrasound-guided piercing needle according to a first modification; and
FIG. 9 is an enlarged side view showing grooved portions of an ultrasound-guided piercing needle according to a second modification.
DESCRIPTION OF EMBODIMENTS
An ultrasound-guided piercing needle and an indwelling needle according to the present invention will be described in relation to preferred embodiments with reference to the attached drawings.
FIG. 1 is an overall view showing a configuration of an indwelling needle 12 having an ultrasound-guided piercing needle 10 (hereinafter referred to simply as a “piercing needle”) according to an embodiment of the present invention. Incidentally, for convenience of description, in each of the attached drawings (exclusive of some drawings), the axial direction of the indwelling needle 12 and the axial direction of each of members constituting the indwelling needle 12 are indicated by the arrow X. In addition, a direction toward distal portions of the indwelling needle 12 and members thereof is denoted by the arrow X 1 , whereas a direction toward proximal portions of the members is denoted by the arrow X 2 .
As shown in FIG. 1 , the indwelling needle 12 according to one configuration example includes a catheter 14 , an outer needle hub 16 connected to a proximal portion of the catheter 14 , a piercing needle 10 inserted into the interior of the catheter 14 , and an inner needle hub 18 connected to a proximal portion of the piercing needle 10 .
The inner needle hub 18 is configured to fit into the interior of the outer needle hub 16 . In FIG. 1 , a condition is shown in which a connected body of the piercing needle 10 and the inner needle hub 18 is fitted into a connected body of the catheter 14 and the outer needle hub 16 . In this condition, a blade face 11 , which is formed at a distal portion of the piercing needle 10 , is exposed (protruded) from a distal end of the catheter 14 . A syringe 30 can be connected to a proximal portion of the inner needle hub 18 (see FIG. 5 ).
FIG. 2A is a plan view showing a configuration of the catheter 14 and the outer needle hub 16 of the indwelling needle 12 shown in FIG. 1 . In the indwelling needle 12 according to one exemplary configuration, the catheter 14 constitutes an outer needle, which is formed, for example, from a transparent resin material. The catheter 14 has an appropriate degree of elasticity and is formed in a tubular shape so as to surround the piercing needle 10 . The catheter 14 reaches the vicinity of the distal end of the piercing needle 10 . When the distal end of the piercing needle 10 is inserted into a blood vessel, the catheter 14 also is inserted into the same blood vessel.
Examples of materials constituting the catheter 14 may include various flexible resins such as ethylene-tetrafluoroethylene copolymer (ETFE), polyurethane, and polyether nylon resin. Examples of materials constituting the outer needle hub 16 may include polyolefins such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, etc., polyvinyl chloride, polymethyl methacrylate, polycarbonates, polybutadiene, polyamides, and polyesters.
FIG. 2B is a partially omitted enlarged sectional view, taken along the axial direction, of a distal portion and a portion in the vicinity thereof of the catheter 14 . As shown in FIG. 2B , an inner circumferential surface proximate a distal portion of the catheter 14 is formed with inner circumferential grooved portions 20 , which are hollowed in a shape protuberant to the outer circumferential side. In the example shown in the drawing, the inner circumferential grooved portions 20 are substantially semicircular in cross section, are formed in an annular shape with a substantially constant depth in the circumferential direction, and are formed at predetermined intervals in the axial direction and over a predetermined range (denoted by A in FIG. 2A ).
The distance L 1 from a maximal distal portion of the catheter 14 to the inner circumferential grooved portion 20 on the distal side thereof is set, for example, from 0 to 3 mm, and more preferably, from 1 to 2 mm. The distance L 2 in the axial direction (X-direction) from the maximal distal portion of the catheter 14 to the inner circumferential grooved portion 20 on the proximal side thereof is set, for example, from 2 to 10 mm, and more preferably, from 6 to 8 mm. The depth in the radial direction of the inner circumferential grooved portion 20 is set, for example, from 10 to 25 μm. The groove pitch (the interval in the axial direction) of the plurality of inner circumferential grooved portions 20 is set, for example, from 0.2 to 0.5 mm.
Incidentally, the inner circumferential grooved portions 20 are not restricted to being formed as annular grooves, which are formed at an interval in the axial direction, but may comprise a groove, which extends helically in the axial direction. Further, the inner circumferential grooved portions 20 may be omitted.
FIG. 3A is a plan view showing a configuration of a piercing needle 10 and an inner needle hub 18 according to an embodiment of the present invention. In an indwelling needle 12 according to one exemplary configuration, the piercing needle 10 constitutes an inner needle. The piercing needle 10 comprises a hollow tube formed at a distal portion thereof with a blade face 11 , which is inclined relative to the axis of the piercing needle 10 .
The material constituting the piercing needle 10 is a material from which a sharp blade edge can be formed thereon to provide a sufficient piercing force (penetrating force), and which has strength necessary for piercing. Examples of suitable materials include stainless steel, aluminum alloys, and copper alloys.
A proximal portion of the piercing needle 10 is connected to and held by a distal portion of the inner needle hub 18 . Examples of materials constituting the inner needle hub 18 include the same materials as those of the outer needle hub 16 , as mentioned above. As shown in FIG. 3A , an outer circumferential surface in the vicinity of the distal portion of the piercing needle 10 (a predetermined range on the proximal side relative to the blade face 11 ) is formed with ridged and grooved portions 22 , for reflecting ultrasonic waves over a predetermined range along the axial direction of the piercing needle 10 .
FIG. 3B is an enlarged side view partially in cross section showing the ridged and grooved portions 22 of the piercing needle 10 shown in FIG. 3A . The outside diameter D of the piercing needle 10 is set, for example, from 0.7 to 0.8 mm. In the present embodiment, the ridged and grooved portions 22 are formed in an annular shape on the outer circumferential surface of the piercing needle 10 . Plural ridged and grooved portions 22 are provided at intervals along the axial direction (X-direction) of the piercing needle 10 . In the example shown in the drawing, the interval L 3 of the ridged and grooved portions 22 in the axial direction may be set to a constant value. In this case, the interval L 3 is set, for example, from 200 to 500 μm.
The distance L 4 (see FIG. 3A ) along the axial direction from a maximal distal portion of the piercing needle 10 to the ridged and grooved portion 22 on the distal side is set, for example, from 0.3 to 5 mm. The distance L 5 (see FIG. 3A ) along the axial direction from the maximal distal portion of the piercing needle 10 to the ridged and grooved portion 22 on the proximal side is set, for example, from 5 to 50 mm.
Incidentally, in the example of the piercing needle 10 shown in the drawing, the interval L 3 of the ridged and grooved portions 22 in the axial direction is set to a constant value. However, some or all of the intervals of the plural ridged and grooved portions 22 may be set to a different value. For instance, the interval of the ridged and grooved portions 22 may be set to be smaller on the distal side of the piercing needle 10 (or the interval of the ridged and grooved portions 22 may be set to be greater on the proximal side of the piercing needle 10 ).
As shown in FIG. 3B , the ridged and grooved portion 22 includes the grooved portion 24 , which is formed in an annular shape so as to protrude toward the inner circumferential side, and the ridged portions 26 , which are disposed on both sides (both sides in the axial direction) of the grooved portion 24 , and are formed in an annular shape so as to protrude toward the radially outer side.
In the present embodiment, the grooved portion 24 is arcuate in cross section, and is formed with a substantially constant depth over the circumferential direction. The width W 1 of the grooved portion 24 in the axial direction is set, for example, from 30 to 100 μm. The depth H 1 of the grooved portion 24 in the radial direction is set, for example, from 5 to 20 μm.
In the present embodiment, the ridged portion 26 is arcuate in cross section, and is formed with a substantially constant height over the circumferential direction. The width W 2 of the ridged portion 26 in the axial direction is set, for example, from 5 to 20 μm. The height H 2 of the ridged portion 26 in the radial direction is set, for example, from 1 to 15 μm. Thus, as clearly shown in FIG. 3B , the outer diameter of the ridged portion 26 is greater than the outside diameter D of the outer circumferential surface of the piercing needle 10 .
Incidentally, the ridged and grooved portions 22 , which are configured as described above, can be formed comparatively easily by subjecting a tubular blank material (work) to machining work, such as plastic working, cutting, and electric discharge machining.
FIG. 4 is a partially omitted enlarged sectional view showing a condition in which a piercing needle 10 according to one embodiment of the present invention is inserted into a catheter 14 , such that a distal portion, inclusive of a blade face 11 , of the piercing needle 10 is exposed (protruded) from a distal portion of the catheter 14 . The inside diameter of the catheter 14 is set to be approximately equal to or slightly larger than the outside diameter of the ridged portions 26 , so that the piercing needle 10 , provided with the ridged portions 26 thereon, can be inserted into the catheter 14 .
Further, as shown in FIG. 4 , in the present embodiment, inner circumferential grooved portions 20 and ridged and grooved portions 22 of the catheter 14 and the piercing needle 10 are formed such that, in a condition in which the distal portion of the piercing needle 10 is exposed (protruded) a predetermined length from the distal portion of the catheter 14 , the phase in the axial direction of the plurality of inner circumferential grooved portions 20 and the phase in the axial direction of the plurality of ridged and grooved portions 22 are shifted from each other.
The indwelling needle 12 including the piercing needle 10 according to the present embodiment is basically constructed as described above. Next, a method of using the indwelling needle 12 and operations and effects of the indwelling needle 12 will be described.
Prior to piercing by the indwelling needle 12 , a syringe 30 is connected to a proximal portion of an inner needle hub 18 , as shown in FIG. 5 . The syringe 30 includes a hollow cylindrical syringe main body 32 , and a plunger 34 inserted inside the syringe main body 32 . The syringe main body 32 is provided at a distal portion thereof with a connection port 36 , which is connected to a proximal portion of the inner needle hub 18 . Consequently, the syringe 30 communicates with the interior of the inner needle hub 18 through the connection port 36 .
To perform piercing using the indwelling needle 12 , first, as shown in FIG. 5 , the indwelling needle 12 inclusive of the piercing needle 10 is gripped by a health care staff worker such as a doctor or the like, and is made to pierce a blood vessel (vein) of a patient 50 . The piercing needle 10 is gradually inserted toward a desired area, whereupon the distal portion of the piercing needle 10 is advanced while cutting open a body tissue 52 . In this case, as shown in FIG. 6 , the piercing needle 10 is inserted into the interior of the catheter 14 , and in this condition, the ridged and grooved portions 22 of the piercing needle 10 are located inside the catheter 14 . Therefore, the indwelling needle 12 is allowed to pierce the patient while the ridged and grooved portions 22 of the piercing needle 10 are prevented from coming into contact with the body tissue 52 .
On the other hand, simultaneously with piercing of the patient by the indwelling needle 12 , a probe 42 of an ultrasonic imaging device 40 is pressed onto the vicinity of the pierced part of the patient 50 , and irradiation of the patient with an echo beam (ultrasonic waves) E is conducted. Incidentally, the probe 42 is configured so as to be capable of emitting the echo beam E as well as receiving reflected waves (a reflected echo) of the echo beam E.
The echo beam E is emitted in the direction from a skin surface toward the inside of the patient 50 , and a distal portion of the indwelling needle 12 is irradiated with the echo beam E. Then, as shown in FIG. 6 , the echo beam E is reflected toward the side of the probe 42 from inner wall surfaces of the inner circumferential grooved portions 20 , which are formed at the inner circumferential surface of the catheter 14 . Similarly, the echo beam E is reflected by air that is sealed inside the inner circumferential grooved portions 20 . Ultrasonic waves (reflected waves) reflected by the inner circumferential grooved portions 20 are represented as a reflection echo E 1 . In this case, the reflection echo E 1 , which is reflected by the inner wall surfaces of the inner circumferential grooved portions 20 , is not attenuated by air that exists in the inner circumferential grooved portions 20 . Therefore, the reflection echo E 1 has an intensity approximately equal to the intensity of the emitted echo beam E. The reflection echo E 1 is received by the probe 42 .
In addition, the echo beam E is transmitted through the catheter 14 , so as to be reflected from the ridged and grooved portions 22 toward the side of the probe 42 . Reflected waves reflected by the ridged and grooved portions 22 are represented as a reflection echo E 2 . The reflection echo E 2 , which is reflected by the ridged and grooved portions 22 , includes a reflection component reflected by the grooved portion 24 , and another reflection component reflected by the ridged portions 26 . The reflection echo E 2 reflected by the ridged and grooved portions 22 is received by the probe 42 .
As mentioned above, in the present embodiment, the grooved portion 24 is arcuate in cross section and the inner wall surface thereof constitutes an arcuate reflecting surface. The ridged portions 26 are arcuate in cross section and outer wall surfaces thereof constitute arcuate reflecting surfaces. Therefore, even if the piercing angle θ (see FIG. 5 ) of the indwelling needle 12 changes, the echo beam E emitted from the probe 42 can be reflected by the inner wall surfaces of the grooved portions 24 as well as by the outer wall surfaces of the ridged portions 26 toward the side of the probe 42 .
When reflected waves (reflection echoes E 1 , E 2 ) of the echo beam E are received by the probe 42 , data concerning the reception thereof is output from the probe 42 through lead wires 44 and is sent to a control unit (not shown) of the ultrasonic imaging device 40 in order to be processed and thereafter displayed as an image on a display unit 46 . More specifically, an image of the catheter 14 and the piercing needle 10 , which is displayed on the display unit 46 , is displayed in a linear form as a length along the axial direction of the ridged and grooved portions 22 , which have been detected by the ultrasonic imaging device 40 . Consequently, whether or not the distal portion of the piercing needle 10 has reached the blood vessel (vein) of the patient 50 can be confirmed by observing the display unit 46 .
As a result, the vicinity of the distal portion of the piercing needle 10 is clearly displayed as an image on the display unit 46 of the ultrasonic imaging device 40 , whereby the position of the piercing needle 10 that makes up the indwelling needle 12 can be confirmed with high accuracy.
Then, the doctor or the like moves the piercing needle 10 and the probe 42 while observing the display unit 46 , so as to guide the piercing needle 10 toward the blood vessel of the patient 50 . In this instance, the indwelling needle 12 is advanced while the plunger 34 of the syringe 30 is withdrawn appropriately. When the piercing needle 10 has pierced the blood vessel correctly, blood is introduced through the connection port 36 of the syringe 30 into the syringe main body 32 , resulting in flashback.
Once piercing of the blood vessel by the piercing needle 10 has been confirmed in this manner, the piercing needle 10 and the syringe 30 are removed, thereby leaving the catheter 14 and a guide wire (not shown) inserted in the blood vessel through the catheter 14 , after which the catheter 14 is removed. Next, a central venous catheter (not shown) is placed along the guide wire in an indwelling state in the blood vessel. Subsequently, a transfusion line (not shown) is connected to a central arterial catheter, and pabulum, a medicinal liquid, or the like is supplied into the blood vessel.
At the time of evulsing the piercing needle 10 while leaving the catheter 14 behind, the piercing needle 10 is evulsed to the exterior of the patient's body through the interior (lumen) of the catheter 14 , so that the ridged and grooved portions 22 of the piercing needle 10 are prevented from coming into contact with body tissue 52 , in the same manner as when the patient is pierced with the piercing needle.
As described above, according to the piercing needle 10 of the present embodiment, the ridged and grooved portion 22 is composed of the grooved portion 24 and the ridged portions 26 provided on both sides of the grooved portion 24 , such that ultrasonic waves are reflected not only at the grooved portion 24 but also on the ridged portions 26 . Therefore, ultrasonic waves can be reflected assuredly and suitably, so as to be detected by the ultrasonic imaging device 40 . As a result, the position of the piercing needle 10 , which is made to pierce the patient, can be confirmed by the ultrasonic imaging device 40 assuredly and with high accuracy, whereby a safe and assured procedure can be carried out while confirming the position of the piercing needle 10 .
In addition, in the present embodiment, the ridged and grooved portions 22 are disposed in an annular form. Therefore, the entire circumference of the ridged and grooved portions 22 constitutes a reflecting surface. Therefore, ultrasonic waves can be effectively reflected, irrespective of the position around the axis of the piercing needle 10 at the time of piercing. Further, since plural ridged and grooved portions 22 are provided along the axial direction of the piercing needle 10 , the number of parts provided for suitable reflection of ultrasonic waves is increased. Therefore, ultrasonic waves can be reflected effectively, and more sufficient reflected waves can be obtained. Consequently, the position of the piercing needle 10 can be confirmed with higher accuracy by the ultrasonic imaging device 40 .
Further, in the present embodiment, the grooved portion 24 is arcuate in cross section, and the inner wall surface thereof constitutes an arcuate reflecting surface. The ridged portions 26 are arcuate in cross section, and the outer wall surfaces thereof constitute arcuate reflecting surfaces. Therefore, even in the case that the piercing angle θ (see FIG. 5 ) of the indwelling needle 12 changes, ultrasonic waves emitted from the probe 42 can be reflected back toward the side of the probe 42 by the inner wall surface of the grooved portion 24 and the outer wall surfaces of the ridged portions 26 . In other words, ultrasonic waves can be reflected toward the side of the probe 42 , whereby the position of the indwelling needle 12 can be confirmed irrespective of the piercing angle θ of the indwelling needle 12 .
Furthermore, the inner circumferential grooved portions 20 are formed on the inner circumferential surface of the catheter 14 , so that ultrasonic waves also are reflected at the inner circumferential grooved portions 20 . Therefore, the intensity of the reflected waves, which are received by the probe 42 , can be enhanced, whereby a clearer echo image can be obtained. As a result, the position of a distal portion of the indwelling needle 12 can be confirmed with high accuracy.
Incidentally, while a mode of use of the piercing needle 10 according to the present embodiment has been described above with reference to a case in which the piercing needle 10 is configured as an inner needle of an indwelling needle 12 , which includes both an outer needle and the inner needle, the piercing needle 10 of the present invention also is applicable to cases in which the piercing needle 10 is made to directly pierce a patient to capture a blood vessel of the patient, without using a catheter 14 , as shown in FIG. 7 . In this case, for example, a Y hub (not shown) is connected to a proximal portion of the inner needle hub 18 , and a guide wire and a central arterial catheter are passed through the Y hub, the inner needle hub 18 , and the piercing needle 10 . Thus, a procedure, which is the same or similar to the aforementioned procedure, can be carried out. Furthermore, in such a mode of use, ultrasonic waves (the echo beam E) can be reflected by the ridged and grooved portions 22 assuredly and suitably, and the position of the piercing needle 10 , in a state of piercing the patient, can be confirmed by the ultrasonic imaging device 40 assuredly and with high accuracy, so that a safe and assured procedure can be carried out while confirming the position of the piercing needle 10 .
In addition, while a mode of use of the piercing needle 10 according to the present embodiment has been described above with reference to a case in which the piercing needle 10 is used as a guide wire introducing needle in order to place a central arterial catheter in an indwelling state by a so-called Seldinger catheter technique, the piercing needle 10 of the present invention can also be used as an indwelling needle for performing a transfusion by being set in an indwelling manner in a deletion blood vessel. The piercing needle 10 can also be used as a biopsy needle for sampling a portion of a body tissue or cells, or the like.
FIG. 8 is a side view showing the configuration of a distal portion, and portions in the vicinity thereof, of an ultrasound-guided piercing needle 10 a (hereinafter referred to simply as a “piercing needle 10 a ”) according to a first modification. In the piercing needle 10 a according to the first modification, plural ridged and grooved portions 22 may be formed such that ridged portions 26 of the adjacent ridged and grooved portions 22 are continuous (connected) with each other. By the ridged and grooved portions 22 of the piercing needle 10 being formed in this manner, the amount of reflected waves directed toward the side of the probe 42 can be increased, compared with the case of the piercing needle 10 according to the basic form thereof, as described above in relation to the aforementioned embodiment. As a result, confirmation of the position of the piercing needle 10 a by the ultrasonic imaging device 40 can be performed with higher accuracy.
FIG. 9 is a side view showing the configuration of a distal portion, and portions in the vicinity thereof, of an ultrasound-guided piercing needle 10 b (hereinafter referred to simply as a “piercing needle 10 b ”) according to a second modification. In the piercing needle 10 b according to the second modification, a ridged and grooved portion 27 having a grooved portion 28 and ridged portions 29 on both sides of the grooved portion 28 may be formed in a helical shape, which extends in the axial direction of the piercing needle 10 b , while also extending around the outer circumferential surface of the piercing needle 10 b at least a plurality of times. By configuring the ridged and grooved portion 27 in this manner, ultrasonic waves can be effectively reflected, and more sufficient reflected waves can be obtained, similar to the case of the ridged and grooved portions 22 described above. Consequently, confirmation of the position of the piercing needle 10 b by the ultrasonic imaging device 40 can be performed with enhanced accuracy.
In addition, by forming the ridged and grooved portion 27 of the piercing needle 10 b in a helical shape, when the piercing needle 10 b is inserted into the catheter 14 , it is ensured that the phase in the axial direction of the plurality of inner circumferential grooved portions 20 , and the phase in the axial direction of the ridged and grooved portion 27 can easily be shifted from each other.
Further, the inner circumferential grooved portion 20 of the catheter 14 may be formed in a helical shape having a different angle from that of the ridged and grooved portion 27 , or alternatively, the inner circumferential grooved portion 20 of the catheter 14 may be formed in a helical shape in a different direction from that of the ridged and grooved portion 27 . With such a configuration as well, the phase in the axial direction of the inner circumferential grooved portion 20 , and the phase in the axial direction of the ridged and grooved portion 27 can easily be shifted from each other.
When the phase in the axial direction of the inner circumferential grooved portion(s) 20 , and the phase in the axial direction of the ridged and grooved portion(s) 27 are shifted from each other, attenuation in the intensity of the reflected ultrasonic waves can be restrained.
Incidentally, the present invention is not restricted to the above-described embodiments, and naturally, various configurations are possible without deviating from the gist of the invention.
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An ultrasound-guided piercing needle constituting the internal needle of an indwelling needle has ridged and grooved portions which reflect ultrasonic waves. The ridged and grooved portions comprise grooves, which are disposed on the outer periphery near the tip having a blade face, and ridges, which are arranged on both sides of the grooves.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of PCT application No. PCT/EP2009/058088, entitled “BAR ARRANGEMENT FOR A MACHINE FOR PRODUCING A FIBROUS WEB”, filed Jun. 29, 2009, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a bar arrangement for a machine for the production of a fibrous web, especially a paper, cardboard or tissue web, which extends transversely to the machine direction and which comprises at least one fixed structure which is mounted directly or indirectly to a frame of the machine; at least one movable bar which is connected preferably indirectly with the fixed structure, relative to which it is preferably movable by means of a controllable/adjustable actuation device, at least between an inoperative position and an operating position in which the movable bar can be pressed against an element by means of a selectable contact force; and at least one fixed guide device which is mounted rigidly on the fixed structure or directly or indirectly on the frame of the machine and which has a guiding effect upon the movable bar and which includes several fixed c-shaped guide units located at a distance from each other, which surround the movable bar on one side in its lower area, at least in sections, with at least one fixed guide arm.
[0004] 2. Description of the Related Art
[0005] The invention further relates to a wire section for a machine for the production of a fibrous web and a machine for the production of a fibrous web. The fibrous web can in particular be a paper, cardboard or tissue web.
[0006] A bar arrangement of this type is known for example from the German disclosure document DE 40 19 884 A1. The movable bar described in this document is a forming bar and the element is a forming wire located in the area of a twin wire zone in a twin wire section. This bar arrangement comprises a fixed guide arrangement which guides the movable bar, especially the forming bar and which includes several fixed c-shaped guide units located at a distance from each other, which surround the movable bar, especially the forming bar on one side in its lower area, at least in sections, with at least one fixed guide arm.
[0007] The movable bar, in particular the forming bar disclosed in the aforementioned documentation serves among other uses to scrape away and remove water from an element, particularly a forming wire shortly after the start of the sheet formation process in a machine for the production of a fibrous web, especially a paper, cardboard or tissue web. In addition it exerts an impulse upon the fiber/water suspension in order to thereby exercise targeted influence on the sheet characteristics. In its operating position the movable bar, in particular the forming bar is for this purpose positioned and preferably pressed against the element at a controlled, or respectively adjusted selectable contact force. The positioning and lastly the pressing contact of the movable bar, particularly the forming bar, preferably the lifting movement of the movable bar, particularly the forming bar is generally conducted by an actuation device, especially by one or two tubes which are filled with a gaseous or liquid medium and which move the movable bar, particularly the forming bar forward into the operating position.
[0008] For maintenance purposes, for example replacement of the element, especially wire replacement or its own replacement, the movable bar, particularly the forming bar must be capable of being pulled back from the element, particularly from the forming wire and capable of being brought into an inoperative- or servicing position. Generally this occurs through deactivation of the actuation device and the effect of gravitation upon the movable bar, particularly the forming bar. Due, for example to the effects of frictional forces and/or contamination in the guide areas of the bar arrangement, and a possible unfavorable installation position of the bar arrangement it cannot always be assured that the movable bar, particularly the forming bar can be pulled back from the element, particularly the forming wire into the inoperative- or servicing position in a process-reliable and reproducible manner.
[0009] In addition, the friction between the guide surfaces of the lateral guides and the movable bar, particularly the forming bar causes said bar—not only at a slightly slanted installation position to not always be pulled back reliably from the element, particularly the forming wire through gravitation when discharging the medium from the actuation device.
[0010] What is needed in the art is to further develop a bar arrangement of the type referred to at the beginning so that the known disadvantages of the state of the art are largely, preferably completely removed. In particular, a process-reliable, reproducible and preferably cost effective retraction of the movable bar should be possible, particularly also during operation of the machine for the production of a fibrous web.
SUMMARY OF THE INVENTION
[0011] The present invention provides, regarding a bar arrangement of the type referred to at the beginning, at least one return mechanism to bring the movable bar from the operating position into the inoperative position, whereby the at least one return mechanism comprises at least one guided part which is located on the outside and longitudinally on the movable bar and has a slanted ascending surface whose slant is aligned with the longitudinal direction of the movable bar at an angle below the range of 5 to 60°, preferably of 20 to 45°, especially of 25 to 35°; at least one guiding part located on the inside of the c-shaped guide unit which has preferably a slanted guide surface which can be brought into contact with the slanted ascending surface of the guided part which is provided on the outside and longitudinally on the movable bar, when the movable bar is moved from the operating position into the inoperative position; and at least one preferably controllable/adjustable moving apparatus which preferably acts upon the face side of the movable bar in order to move the movable bar in its longitudinal direction.
[0012] The inventive bar arrangement with the described return mechanism totally removes the disadvantages of the current state of the art known to the expert. Also, the prerequisites are provided for a process-reliable, reproducible and cost-effective return of the movable bar, especially also during the operation of the machine for the production of a fibrous web.
[0013] The described return mechanism with the two conspiring parts and the moving apparatus causes a forced return of the movable bar from its operating position into its inoperative position.
[0014] The slant of the slanted ascending surface should be as level as possible in order to be able to keep the required return forces small. However, this necessitates a long lateral displacement path of the movable bar. This requirement is best met by the cited angle ranges for the slant.
[0015] In a first preferred embodiment the guided part with the slanted ascending surface which is located on the outside and longitudinally at the movable bar is at least a single-part plate which is connected detachably with the movable bar, especially screwed down or non-detachably, especially glued.
[0016] Because of the possible detachability of the at least single-part plate, simple replacement of same, for example due to wear and tear, is simple, fast and cost-effective. The plate may of course also be a multipart component. The plate may for example include a plate base body and an ascending surface body which may consist of a material having special gliding properties. The two bodies can be connected with each other by means, for example, of at least one screw, or glue or similar type connection.
[0017] In a second preferred embodiment the guided part with the slanted ascending surface which is located on the outside and longitudinally at the movable bar is machined, preferably milled, or non-machined, preferably formed into the movable bar. This causes a solid connection with the movable bar, has however the disadvantage that the slant can only be conditionally changed retrospectively. Since the movable bar, especially its support bar, is manufactured from glass fiber reinforced synthetic material (pultrusion profile) the glass fibers which are mostly oriented in longitudinal direction are nicked during milling. These cut surfaces must then be sealed against possible water penetration. The gliding contact between slant and guide arm therefore occurs above the sensitive seal.
[0018] With both preferred embodiments the guided part with the slanted ascending surface which is located on the outside and longitudinally at the movable bar can be located in a groove extending in longitudinal direction of the movable bar. The groove has a depth which is equal or approximately equal to, especially slightly smaller than, the part height. Also, the groove may extend along the entire length of the movable bar. The advantage of this solution is that the groove in which the plates are fastened can be produced with an appropriately shaped tool directly during the manufacture of the bar. Therefore, no expensive milling work is involved, and sealing of cut edges is not necessary. In addition, the plate can be quickly changed out when worn, or if changes occur.
[0019] In addition, the slanted ascending surface of the part located on the outside and longitudinally at the movable bar consists advantageously of a material which has good gliding properties. This material can have a friction coefficient μ≦0.3, preferably ≦0.2, especially ≦0.15. The part with the slanted ascending surface located on the outside and longitudinally at the movable bar can be a separate part mounted on the movable bar, or an integral part of the movable bar.
[0020] And the guiding part with the preferably slanted guiding surface located on the inside of the c-shaped guide unit is arranged preferably on a fixed guide arm. Here the preferred slant of the guiding surface on the fixed guide arm can be aligned to the longitudinal direction of the movable bar at an angle in the range of less than 5 to 60°, preferably 20 to 45°, especially 25 to 35°. This allows for a simple and inexpensive construction with good operational properties. Usefully, the angle assumes a lower value at the slant of the guiding surface than at the ascending surface of the part.
[0021] Here it is advantageous if the one fixed guide arm of the c-shaped guide unit which preferably has a slanted guide surface is shorter than the at least one other fixed guide arm of the c-shaped guide unit which is located opposite of the movable bar. This dimension can be in the range of 5 to 50 mm, preferably 10 to 40 mm, especially 20 to 30 mm.
[0022] The bar arrangement further has an ascending side where the element moves onto the movable bar and a descending side where the element moves off the movable bar.
[0023] The at least one return mechanism to bring the movable bar from the operating position into the inoperative position in this instance is arranged preferably at the ascending side of the movable bar. The fixed guide arm which is located on the descending side of the movable bar can therefore be longer, thereby achieving more efficient guiding of the movable bar, especially in regard to tipping stability.
[0024] In regard to an operationally appropriate design of the bar arrangement several return mechanisms are preferably provided to return the movable bar from the operating position into the inoperative position whereby they are arranged uniformly, preferably at even repeats of the c-shaped guide units, or at random. They may for example be located at each, every second, every third or even on every fourth c-shaped guide unit. As already mentioned they may of course also be arranged at random or possibly in a pattern.
[0025] In addition, the movable bar which includes an upper top bar which guides the element and a bottom support bar is equipped at the bottom side in the area of its support bar with several slots which are located preferably at equal distances from each other. This provides for a less rigid embodiment of the movable bar with the result that it can better conform transversely against the element.
[0026] The single moving apparatus ideally includes at least one drive unit with preferably a linear moving direction—for example a pneumatic or hydraulic cylinder, a linear motor, a crank mechanism or similar device. Drive units of this type have proven themselves many times in similar applications and sufficiently meet the requirements presented to them. The moving apparatus influencing the movable bar acts preferably on the front side of the movable bar; it could obviously also be located along the movable bar and act upon it directly or indirectly.
[0027] In a preferred embodiment the actuation device includes at least one tube, filled with a liquid or gaseous medium, a pneumatic or hydraulic cylinder, a V-drive, an eccentric, or another similar lifting element. Particularly a tube filled with a gaseous medium has already proven itself in other similar applications, especially in regard to the functional reliability.
[0028] The inventive bar arrangement can also be part of a wire section for a machine for the production of a fibrous web, especially a paper, cardboard or tissue web. Here, like bar arrangements are provided which are located parallel to each other and extend transversely to the machine direction; in other words they are identical in design. In addition, each movable bar which comprises an upper top bar which guides the element and a bottom support bar is equipped at the bottom side in the area of its support bar with several slots which are located preferably at equal distances from each other. Two directly adjacent and movable bars are arranged parallel to each other so that, in the operating position of the movable bar their respective slots are offset against each other, preferably center offset so that markings in the fibrous web which is to be produced are largely avoided. If they would not be offset with each other then the same rigid areas of the bars in machine direction would be positioned aligned with each other. This could result in markings in the fibrous web which is to be produced.
[0029] However, with the described wire section the problem arises that for the first, third, etc., and the second, fourth, etc. movable bar theoretically different movable bars must be used so that the slots are arranged offset to each other. If the same movable bars were to be used and were only to be offset laterally without further measures then the actuation device—viewed from the center of the wire section—would act upon different lengths. The edge areas would therefore be processed with varying forces which could again have a negative effect upon the achievable quality of the fibrous web which is to be produced. In order to alleviate this, the individual movable bar is now equipped on the bottom side in its offset area with regard to its at least one directly adjacent and movable bar with at least one filler piece located on the support bar. Viewed in machine direction the filler piece is located left on a movable bar and on the right on the next movable bar so that—viewed from the center of the wire section—always the same width X is used on the movable bars. The lateral projection of the movable bars to one side is irrelevant since it is outside the element. In this way the same base bar, in other words bars of identical design can be used for all movable bars within one wire section. On changeover of movable bars possibly only the filler pieces need to be moved from left to right or respectively from right to left. According to this solution the movable bars can be produced more cost effectively due to the larger number of same parts that are being produced. Moreover, fewer spare bars are required since there are not two different bar variations.
[0030] The inventive bar arrangement is suited ideally for use in a machine for the production of a fibrous web, particularly a paper, cardboard or tissue web. Also a wire section which utilizes the inventive bar arrangement is ideally suited for use in a machine for the production of a fibrous web, particularly a paper, cardboard or tissue web.
[0031] In the field of paper industry, especially in the area of paper manufacturing and converting there are several corresponding design forms for the movable bar and the element. The movable bar may be a forming bar or a dewatering bar which consists at least of a top bar which is in contact with the element and a support bar which is rigidly connected with the top bar. The element may be a forming wire in a wire section for a machine for the production of a fibrous web. The movable bar may also be an oil scraper bar and the element may be a press roll in a press section for a machine for the production of a fibrous web. And lastly, but not finally, the movable bar may be a scraper and the element may be a roll or a cylinder in a wire-, press- or drying section of a machine for the production of a fibrous web.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0033] FIG. 1 is a schematic cross sectional view of a bar arrangement for a machine for the production of a fibrous web according to the current state of the art;
[0034] FIG. 2A is a schematic partial longitudinal view of one design form of an inventive bar arrangement for a machine for the production of a fibrous web in one operating position;
[0035] FIG. 2B is the inventive bar arrangement illustrated in FIG. 2A for a machine for the production of a fibrous web in an inoperative position;
[0036] FIG. 3 is a schematic perspective view of the movable bar of the inventive bar arrangement illustrated in FIGS. 2A and 2B for a machine for the production of a fibrous web;
[0037] FIG. 4 is a schematic cross sectional view of the c-shaped guide unit of the inventive bar arrangement illustrated in FIGS. 2A and 2B for a machine for the production of a fibrous web;
[0038] FIG. 5 is a schematic perspective view of the c-shaped guide units of the inventive bar arrangement illustrated in FIG. 4 for a machine for the production of a fibrous web; and
[0039] FIG. 6 shows two adjacently located bar arrangements of a wire section for a machine for the production of a fibrous web.
[0040] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one embodiment of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Referring now to the drawings, and more particularly to FIG. 1 , there is shown a schematic cross sectional view of a bar arrangement 1 for a machine for the production of a fibrous web which is not illustrated in further detail in this drawing. The fibrous web may in particular be a paper, cardboard or tissue web.
[0042] Bar arrangement 1 extends transversely to machine direction M (arrow) and includes a fixed structure 2 which is mounted directly or indirectly to a machine frame 3 (which is merely indicated). It also includes a movable bar 4 which is connected indirectly with fixed structure 2 and is movable in reference to this by preferably a controllable/adjustable operating device 5 at least between a depicted operating position Y in which movable bar 4 can be pressed against an element 6 by means of a selectable contact force F (arrow) and an inoperative position Z which is not shown but which is known to the expert. Inoperative position Z can here be consistent with the servicing position in which service and replacement work of any kind can be conducted on bar arrangement 1 .
[0043] Bar arrangement 1 also includes a fixed guide unit 7 which—in the illustrated design—is rigidly mounted on fixed structure 2 or, in a design which is not illustrated here, is mounted directly or indirectly on machine frame 3 and exerts a guiding effect upon movable bar 4 .
[0044] The illustrated bar arrangement 1 includes, merely as an example, a forming bar or dewatering bar 8 as the movable bar 4 which consists at least of one top bar 9 which contacts element 6 and a support bar 10 which is rigidly connected with top bar 9 . And, element 6 is a forming wire 6 . 1 in a wire section for a machine for the production of a fibrous web. Normally a fibrous stock suspension which is not shown here would be present on element 6 which here is in the embodiment of forming wire 6 . 1 . In additional design variations which are not explicitly shown here but which are known to the expert, movable bar 4 may also be in the embodiment of an oil scraper bar and the element may be a press roll in a press section for a machine for the production of a fibrous web. In addition, movable bar 4 may also be a scraper and the element may be a roll or a cylinder in a wire-, press- or drying section of a machine for the production of a fibrous web.
[0045] In the illustrated design variation, actuation device 5 is a tube 5 . 1 filled with a liquid or gaseous medium 11 which, on the bottom side and at least in regions, is guided laterally in a shell 12 . It may however also be an already known pneumatic or hydraulic cylinder, a V-drive, an eccentric or another similar lifting element.
[0046] Fixed guiding device 7 includes several fixed c-shaped guide units 13 which are located at distances from each other and which surround movable bar 4 at least partially in its lower area on one side with respectively one fixed guide arm 14 . 1 , 14 . 2 and which, through guide surfaces 14 . 11 , 14 . 12 , 14 . 21 and 14 . 22 , exert the guiding effect upon movable bar 4 . The four illustrated guide surfaces 14 . 11 , 14 . 12 , 14 . 21 and 14 . 22 are emphasized on the drawing.
[0047] Bar arrangement 1 with movable bar 4 has an ascending side S. 1 on which element 6 runs onto movable bar 4 , and a descending side S. 2 on which element 6 runs off movable bar 4 .
[0048] FIG. 2A shows a schematic partial longitudinal view of one design variation of an inventive bar arrangement 1 for a machine for the production of a fibrous web in an operating position Y. The ascending side S. 1 of bar arrangement 1 is shown.
[0049] This bar arrangement 1 extends transversely to machine direction M (arrow) and includes a fixed structure 2 which is mounted directly or indirectly on a machine frame 3 which is merely indicated here. It also includes a movable bar 4 which is connected indirectly with the fixed structure 2 and is movable in reference to this by preferably a controllable/adjustable actuation device 5 at least between a depicted operating position Y in which the movable bar 4 can be pressed against an element 6 by means of a selectable contact force F (arrow) and an inoperative position Z (compare FIG. 2B ) which is not shown but which is known to the expert. Inoperative position Z can here be consistent with the servicing position in which service and replacement work of any kind can be conducted on the bar arrangement 1 .
[0050] Bar arrangement 1 also includes a fixed guide unit 7 which, in the illustrated design, is rigidly mounted on the fixed structure 2 or, in the design which is not illustrated here, is mounted directly or indirectly on machine frame 3 and exerts a guiding effect upon movable bar 4 .
[0051] The illustrated bar arrangement 1 includes, merely as an example, a forming bar or dewatering bar 8 as the movable bar 4 which consists at least of one top bar 9 which contacts element 6 and a support bar 10 which is rigidly connected with top bar 9 .
[0052] And, element 6 is a forming wire 6 . 1 in a wire section for a machine for the production of a fibrous web. Normally a fibrous stock suspension which is not shown here would be present on element 6 which here is in the embodiment of forming wire 6 . 1 . In additional design variations which are not explicitly shown here but which are known to the expert, the movable bar 4 may also be in the embodiment of an oil scraper bar and the element may be a press roll in a press section for a machine for the production of a fibrous web. In addition, movable bar 4 may also be a scraper and the element may be a roll or a cylinder in a wire-, press- or drying section of a machine for the production of a fibrous web.
[0053] As already known, actuation device 5 is a tube 5 . 1 filled with a liquid or gaseous medium 11 which, on the bottom side and at least in regions, is guided laterally in a shell 12 (compare FIG. 1 ). It may however also be an already known pneumatic or hydraulic cylinder, a V-drive, an eccentric or another similar lifting element.
[0054] The fixed guiding device 7 includes several fixed c-shaped guide units 13 which are located at distances from each other and which surround the movable bar 4 at least partially in its lower area on one side with respectively one fixed guide arm 14 . 1 , 14 . 2 and which, through guide surfaces 14 . 11 , 14 . 12 , 14 . 21 and 14 . 22 (compare FIGS. 4 and 5 ), exert the guiding effect upon movable bar 4 . The four illustrated guide surfaces 14 . 11 , 14 . 12 , 14 . 21 and 14 . 22 are emphasized on the drawing.
[0055] Also at least one return mechanism 15 is provided in this bar arrangement 1 in order to move the movable bar 4 from the operating position Y into the inoperative position Z (compare FIG. 2B ). In the illustrated design variation only one component unit 15 . 1 of return mechanism 15 is referenced as an example.
[0056] Return mechanism 15 includes several guided parts 16 (compare also FIG. 4 ) which are positioned at a distance from each other and are arranged longitudinally on the outside of movable bar 4 , having respective slanted ascending surfaces 17 whose slant 18 is aligned to the longitudinal direction L (arrow) of the movable bar 4 at less than an angle α in a range of 5 to 60°, preferably 20 to 45°, especially 25 to 35°. The return mechanism 15 further includes several guiding parts 19 (compare FIGS. 4 and 5 ) located at distance from each other on the inside of the single and immediately adjacent c-shaped guide unit 13 and having preferably a slanted guide surface 20 which can be brought into contact with slanted ascending surface 17 of the respectively guided part 16 which is provided on the outside and longitudinally on movable bar 4 when movable bar 4 is moved from operating position Y into inoperative position Z (compare FIG. 2B ). Return mechanism 15 further includes at least one preferably controllable/adjustable moving device 21 which acts upon the face side of movable bar 4 in order to move movable bar 4 in longitudinal direction L (arrow). Moving apparatus 21 is indicated merely schematically by an arrow. As is already known it includes at least one drive unit with preferably a linear moving direction—for example a pneumatic or hydraulic cylinder, a linear motor, a crank mechanism or similar device.
[0057] The respective guided part 16 with slanted ascending surface 17 which is located on the outside and longitudinally at movable bar 4 is located in a groove 22 (compare also FIG. 4 ) extending in longitudinal direction L (arrow) of movable bar 4 . In the illustrated design variation groove 22 extends along the entire length of movable bar 4 and has a groove depth 22 .T which is preferably equal or approximately equal to, especially slightly smaller than, the part height 16 .T (compare FIG. 4 ).
[0058] FIG. 2B illustrates the inventive bar arrangement 1 for a machine for the production of a fibrous web which is shown in FIG. 2A in an inoperative position Z. Again, element 6 , in particular forming wire 6 . 1 , is merely indicated with a dash-dot-dash line. The ascending side S. 1 of bar arrangement 1 is shown.
[0059] Movable bar 4 was moved from the operating position Y (compare FIG. 2A ) into the inoperative position Z by means of the preferably controllable/adjustable moving device 21 which acts upon the face side and serves to move movable bar 4 in its longitudinal direction L (arrow). The several guided parts 16 (compare also FIG. 4 ) which are positioned at a distance from each other and which are located on the outside and longitudinally at movable bar 4 and have a respective slanted ascending surface 17 were brought into contact with the several guiding parts 19 (compare FIGS. 4 and 5 ) which are positioned at a distance from each other and are located inside on the single and immediately adjacent c-shaped guide unit 13 . Based on the contact between parts 16 , 19 and slanted surfaces 17 , possibly in connection with slanted surfaces 20 (compare FIGS. 4 and 5 ), movable bar 4 was moved between the two positions Y, Z and thereby lifted by element 6 .
[0060] It can also be seen in the two FIGS. 2A and 2B that in mirror image to parts 16 with the slanted ascending surfaces 17 additional parts 24 with slanted surfaces 25 are provided. These parts 24 with their slanted surfaces 25 essentially serve exclusively to reliably move the movable bar 4 in and out in a machine for the production of a fibrous web. Their presence has no relevance for the current inventive layout of the bar arrangement 1 .
[0061] Parts 16 , 19 are advantageously arranged in uniform distribution on the movable bar 4 . The uniform distribution may for example provide a respective distance A in the range of 150 to 1,000 mm, preferably 200 to 750 mm, especially 250 to 500 mm. Naturally they may also be arranged at any repeat c-shaped guide unit 13 , or even at random. Also, the placement of the c-shaped guide units may be uniform or at random. Among other things this would depend upon occurring forces which among other situations also occur through redirecting the water jet scraped off by the element.
[0062] In addition, movable bar 4 which includes an upper top bar 9 which guides the element 6 and a bottom support bar 10 is equipped at the bottom side in the area of its support bar 10 with several slots 26 which are located preferably at equal distances B from each other. These slots 26 primarily serve the objective to render support bar 10 and thereby also movable bar 4 more flexible so that it can be pressed more easily against element 6 . In addition, slots 26 extend over at least 25%, preferably at least 50%, of height H of support bar 10 and with regard to physical properties have an optimum cross sectional contour.
[0063] In addition, the slanted ascending surface 17 of part 16 which is located on the outside and longitudinally on movable strip 4 consists of a material with good gliding properties. This material can have a friction coefficient μ≦0.3, preferably ≦0.2, especially ≦0.15.
[0064] Also, the respective guided part 16 with slanted ascending surface 17 which is located on the outside and longitudinally at the movable bar 4 is at least one single-part plate 23 which is connected detachably by means of an indicated screw connection with movable bar 4 . It can however be connected non-detachably with the movable bar.
[0065] Guided part 16 with slanted ascending surface 17 which is located on the outside and longitudinally at movable bar 4 is machined, preferably milled, or non-machined, preferably formed into movable bar 4 . It can therefore also be an integral part of movable bar 4 .
[0066] FIG. 3 shows a schematic perspective drawing of movable bar 4 of the inventive bar arrangement 1 illustrated in FIGS. 2A and 2B for a machine for the production of a fibrous web. Ascending side S. 1 of bar arrangement 1 is shown.
[0067] Movable bar 4 comprises a top bar 9 and a support bar which is rigidly connected with top bar 9 .
[0068] Return mechanism 15 includes several parts 16 which are guided, positioned at a distance from each other and are arranged longitudinally on the outside of movable bar 4 , having respective slanted ascending surfaces 17 whose slant 18 is aligned to the longitudinal direction L (arrow) of movable bar 4 at less than an angle α in a range of 5 to 60°, preferably 20 to 45°, especially 25 to 35°.
[0069] The respective guided part 16 with the slanted ascending surface 17 which is located on the outside and longitudinally at movable bar 4 is located in a groove 22 extending in longitudinal direction L (arrow) of movable bar 4 . In the illustrated design variation groove 22 extends along the entire length of movable bar 4 and has a groove depth 22 .T which is preferably equal or approximately equal, especially slightly smaller than the part height 16 .T (compare FIG. 4 )
[0070] Parts 16 are advantageously arranged in uniform distribution on movable bar 4 . The uniform distribution may for example provide a respective distance A in the range of 150 to 1,000 mm, preferably 200 to 750 mm, especially 250 to 500 mm.
[0071] In addition parts 24 with slanted surfaces 25 are provided in mirror image to parts 16 with the slanted ascending surfaces 17 . These parts 24 with their slanted surfaces 25 essentially serve exclusively to reliably move movable bar 4 in and out in a machine for the production of a fibrous web.
[0072] In addition movable bar 4 is equipped at the bottom side in the area of its support bar 10 with several slots 26 which are located preferably at equal distances B from each other. These slots 26 primarily serve the objective to render support bar 10 and thereby also movable bar 4 more flexible. In addition, slots 26 extend over at least 25%, preferably at least 50%, of height H of support bar 10 and with regard to physical properties have an optimum cross sectional contour.
[0073] FIG. 4 is a schematic cross sectional view of c-shaped guide unit 13 of the inventive bar arrangement 1 illustrated in FIGS. 2A and 2B for a machine for the production of a fibrous web.
[0074] The one fixed guide arm 14 . 1 of c-shaped guide unit 13 which preferably has a slanted guide surface 20 is shorter than the at least one other fixed guide arm 14 . 2 of c-shaped guide unit 13 which is located opposite of movable bar 4 . This short dimension K can be in the range of 5 to 50 mm, preferably 10 to 40 mm, especially 20 to 30 mm.
[0075] The respective guided part 16 with the slanted ascending surface 17 which is located on the outside and longitudinally at movable bar 4 is located in a groove 22 extending in longitudinal direction L (arrow) of movable bar 4 . In the illustrated design variation groove 22 extends along the entire length of movable bar 4 and has a groove depth 22 .T which is preferably equal or approximately equal to, especially slightly smaller than, the part height 16 .T.
[0076] It can also be seen that bar arrangement 1 extending transversely to machine direction M (arrow) with movable bar 4 has an ascending side S. 1 on which element 6 runs onto movable bar 4 , and a descending side S. 2 on which element 6 runs off movable bar 4 . The at least one return mechanism 15 which returns movable bar 4 from the operating position Y into the inoperative position Z which is not illustrated here, is located on the ascending side S. 1 . Theoretically, however, it could also be located on the descending side of the bar arrangement.
[0077] Actuation device 5 is a tube 5 . 1 which, as is known, is filled with a liquid or gaseous medium and which, on the bottom side and at least in regions, is guided laterally in a shell 12 . It may however also be an already known pneumatic or hydraulic cylinder, a V-drive, an eccentric or another similar lifting element.
[0078] FIG. 5 is a schematic perspective view of the c-shaped guide unit 13 of the inventive bar arrangement 1 illustrated in FIG. 4 , for a machine for the production of a fibrous web.
[0079] The fixed c-shaped guide unit 13 of the fixed guide arrangement 7 includes two fixed guide arms 14 . 1 , 14 . 2 which surround the movable bar (which is not illustrated) at least partially in its lower area, always on one side and which exert the guiding effect upon the movable bar 4 through guide surfaces 14 . 11 , 14 . 12 , 14 . 21 and 14 . 22 .
[0080] As already mentioned the one fixed guide arm 14 . 1 of c-shaped guide unit 13 of the guide arrangement 7 which has a preferably slanted guide surface 20 is shorter than the at least one other fixed guide arm 14 . 2 of c-shaped guide unit 13 which is located opposite of movable bar which is not illustrated. This short dimension K can be in the range of 5 to 50 mm, preferably 10 to 40 mm, especially 20 to 30 mm.
[0081] Guiding part 19 which is arranged on the inside of the c-shaped guide unit 13 and which is equipped with the preferably slanted guide surface 20 is located at the short fixed guide arm 14 . 1 . The preferred slant 27 of the guiding surface 20 on the fixed guide arm 14 . 1 is aligned to the longitudinal direction L (arrow) of the movable bar 4 at an angle β in the range of less than 5 to 60°, preferably 20 to 45°, especially 25 to 35°. Usefully, angle β assumes a lower value than angle α.
[0082] FIG. 6 shows two adjacent bar arrangements 1 in a wire section 28 for a machine for the production of a fibrous web. The fibrous web may in particular be a paper, cardboard or tissue web.
[0083] The illustrated wire section 28 includes two bar arrangements merely as an example. Also, additional parts and component groups of wire section 28 are not illustrated for the sake of providing a clear overview.
[0084] The respective bar arrangement 1 of wire section 28 is inventively executed as illustrated and described in FIGS. 2A , 2 B, 3 , 4 and 5 . Each movable bar 4 which includes an upper top bar 9 which guides the element 6 , especially forming wire 6 . 1 and a bottom support bar 10 is equipped at the bottom side in the area of its support bar 10 with several slots 26 which are located at equal distances B from each other.
[0085] In addition, the two directly adjacent and movable bars 4 are arranged parallel to each other so that, in the operating position Y of the movable bar 4 their respective slots 26 are arranged offset with each other, preferably center offset so that markings in the fibrous web which is to be produced are largely avoided. Offset V is preferably half the distance B between the two adjacent slots 26 . In its one sided and outside offset area W the single movable bar 4 is equipped on the bottom side with at least one filler piece 29 on the support bar 10 with regard to its at least one directly adjacent and movable bar 4 .
[0086] Viewed in machine direction M (arrow) the single filler piece 29 is arranged on a movable bar 4 on the left and on the following movable filler bar 4 on the right so that—viewed from the center of wire section 28 —always the same width X on movable bars 4 is used. This results in the already discussed advantages.
[0087] In addition bar arrangement 1 illustrated in FIGS. 2A , 2 B, 3 , 4 and 5 and wire section 28 illustrated in FIG. 6 are ideally suited for use in a machine for the production of a fibrous web, especially a paper, cardboard or tissue web.
[0088] As already explained, the illustrated actuation device 5 can be a tube 5 . 1 in all design forms, filled with a liquid or gaseous medium 11 , a pneumatic or hydraulic cylinder, a V-drive, an eccentric or another similar lifting element.
[0089] In general, movable bar 4 may be a forming bar or dewatering bar 8 , an oil scraper bar or a scraper. In contrast element 6 may be a forming wire 6 . 1 in a wire section for a machine for the production of a fibrous web, a press roll in a press section for a machine for the production of a fibrous web or a roll or cylinder in a wire-, press- or drying section for a machine for the production of a fibrous web. Movable bar 4 and element 6 come particularly from the paper industry, particularly from the field of paper manufacturing and paper converting.
[0090] In summary it should be stated that through the invention a bar arrangement of the type referred to at the beginning is further developed, so that the known disadvantages of the state of the art are largely, preferably even totally removed. In particular, a process-reliable, reproducible and cost effective retraction of the movable bar is made possible, particularly also during operation of the machine for the production of a fibrous web.
COMPONENT IDENTIFICATION LIST
[0000]
1 Bar arrangement
2 Fixed structure
3 Frame
4 Movable bar
5 Operating device
5 . 1 Tube
6 Element
6 . 1 Forming wire
7 Guide arrangement
8 Forming or dewatering bar
9 Top bar
10 Support bar
11 Medium
12 Shell
13 Guide unit
14 . 1 Guide arm
14 . 2 Guide arm
14 . 11 Guide surface
14 . 12 Guide surface
14 . 21 Guide surface
14 . 22 Guide surface
15 Return mechanism
15 . 1 Component unit
16 Part
16 .T Partial height
17 Slanted ascending surface
18 Slant
19 Part
20 Guide surface
21 Moving device
22 Groove
22 .T Groove depth
23 Plate
24 part
25 Slanted surface
26 Slot
27 Slant
28 Wire section
29 Filler piece
A Distance
B Distance
F Contact force (arrow)
H Height
K Short dimension
L Longitudinal direction (arrow)
M Machine direction (arrow)
S. 1 Ascending side
S. 2 Descending side
V Offset
W Offset range
X Width
Y Operating position
Z Inoperative position
α Angle
β Angle
[0146] While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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The invention relates to a bar arrangement for a machine for producing a fibrous web. The bar arrangement according to the invention is characterized by at least one restoring mechanism for bringing the mobile bar from the operating position into the rest position. The at least one restoring mechanism comprises at least one guided piece arranged on the mobile bar on the exterior and alongside thereof, said piece having an inclined contact surface the incline of which is directed at an angle (α) in the range of 5 to 60°, preferably of 20 to 45°, especially of 25 to 35°, relative to the longitudinal direction of the mobile bar, at least one guiding piece on the interior of the C-shaped guiding unit, which has a preferably inclined guide surface that can be brought in contact with the inclined contact surface of the guided piece arranged on the exterior and alongside thereof when the mobile bar is brought from the operating position into the rest position, and at least one displacement device for displacing the mobile bar in its longitudinal direction which acts upon the mobile bar, preferably the face thereof, and which can preferably be controlled/regulated.
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FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a measuring device for an electro mechanical brake, and to an electro mechanical brake for a motor vehicle.
In the case of electro mechanical brakes in the field of motor vehicles, the braking force is produced by electric motor and transmitted mechanically to the brake shoes. In the case of disc brakes actuated by electric motor, the force sensor is arranged in the force flux and serves the purpose of accurately measuring the force exerted on the brake disc, in order to be able to drive the motor appropriately.
DE 101 51 561 A1 dispenses a force sensor for an electro mechanical brake that is designed as a ring and provided with three projections projecting in the axial direction. Support regions extending in the radial direction of the ring are formed centrally between the projections. The force is introduced via the axial projections, the reaction forces being introduced via the support regions. Pairs of strain gauges are arranged between axial projections and support regions on the ring element. The force sensor is deformed in an undulating fashion when the braking force is applied to it. The deformation is converted into the introduced braking force by the strain gauges and by an evaluation device.
SUMMARY OF THE INVENTION
It is the object of the invention to create a measuring device for an electro mechanical brake that supplies signals of adequate magnitude as far as possible in conjunction with simple manufacture. The object is achieved according to the invention by means of a measuring device having the features of claim 1 , and by means of an electro mechanical brake. Advantageous refinements are respectively the subject matter of the sub claims.
The measuring device according to the invention has an annular force sensor and an associated strain gauge. The force sensor has the shape of a closed circular ring. The ring has in cross section a C-shaped profile with two parallel limbs arranged spaced apart from one another. In contrast with the annular force sensor already known from the above prior art, the force sensor according to the invention is designed as a ring with a C-shaped cross section and not a rectangular one. Force is introduced into the limbs in the case of the force sensor according to the invention, as a result of which the ring is deformed and the spacing between the ends of the limbs is reduced. The strain gauge is arranged at least on one of the limbs and detects the strain produced by the bending of the limb. The strain of the limb can then be converted into the magnitude of the introduced force using methods known per se. The limbs preferably point into the center of the ring.
The use of a C profile for force measurement results in a substantially higher accuracy of the signals and enables very reliable measurement of the forces occurring in the case of an electromechanical brake.
In a preferred refinement, the transition from the base of the C profile to the limbs is rounded. A radius of curvature of approximately 1.5 mm is preferably used in this case. The ring has regions for introducing a force acting between an actuating element for a brake shoe and a caliper of the brake, the regions expediently being situated at the free end of the limbs on the outside. The regions for introducing the force preferably respectively run annularly along the free end of the limbs.
A strain gauge is arranged next to the force introduction region on the outside of the limb in order to measure the force introduced. In a preferred refinement, the strain gauge is arranged on the outside of a limb which points toward the caliper.
The strain gauge is preferably arranged on one of the limbs along the circumference. The signals of the strain gauges distributed over the circumference are averaged in order to evaluate them.
The strain gauge has measurement strain resistors that advantageously extend in the radial direction of the ring. The signals of the measurement strain resistors are led out by connecting individual resistors in parallel and/or series, or by means of resistance bridges.
In a particularly preferred refinement, silicon strain gauges are provided as strain gauge. Such silicon strain gauges are known, for example, from WO 01/08227. These are semiconductor strainometers that have a resistance substrate layer and a layer, supported by the latter, made from electrically conducting silicon. A particular advantage of the silicon strain gauges is that the latter exhibit a particularly small thickness.
The force sensor preferably consists of a precipitation hardenable steel when use is made of silicon strain gauges. Steel of type 17-4PH or Inconel 718 is preferably used here. The silicon strain gauges are preferably connected to the force sensor by means of lead borate glass solder.
Overall the use of a precipitation hardenable steel (PH steel) lends the force sensor a substantially greater strength. By comparison with the steels that are suitable for the known application of thick layers for the strain measuring elements, a PH steel has more than twice the strength and tensile yield strength. All PH steels contain nickel in order to permit precipitation hardening. The nickel content lowers the hardening temperature. During cooling, each steel changes volume upon exceeding the hardening temperature; if said change in volume is below the hardening temperature of a processed thick resistance layer, the layer peels off. Consequently, despite their strength and high tensile yield strength, PH steels cannot be used with processed thick resistance layers.
The silicon strain gauges as described in WO 01/08227 are bonded to the measuring ring by means of lead borate glass solder.
The object according to the invention is likewise achieved by means of an electromechanical brake having the measuring device described above, force being introduced into the ring via projections in the caliper. In the case of the associated second region for introducing force, as well, force is preferably introduced into the ring via projections on an actuating element for the brake shoes. The projections for introducing force into the measuring device preferably have a spherical bearing surface. As a result, a circular force introduction region is defined when force is introduced in an annularly running fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
The measuring device according to the invention and the electromechanical brake are explained below in more detail with the aid of an exemplary embodiment.
In the drawing:
FIG. 1 shows the schematic diagram of an electromechanical brake,
FIG. 2 shows a view of a detail from FIG. 1 ,
FIG. 3 shows a perspective view of the force sensor according to the invention,
FIG. 4 shows a perspective view of the sectioned force sensor,
FIG. 5 shows a deformation occurring in the force sensor, and
FIG. 6 shows schematic diagram of strain resistors in the force sensor, the resistors being arranged radially.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a diagrammatic view of an electromechanical brake for a brake disc 10 . Two brake shoes 12 and 14 are arranged at the outer rim of the brake disc 10 on opposite sides thereof. The brake shoe 12 is mounted on a caliper 16 . The brake shoe 14 is supported on a pressure piston 18 . The pressure piston 18 has an inner thread, and is widened in the region of its connection to the brake shoe 14 to form a circumferential flange 20 . The pressure piston 18 is supported displaceably in a sleeve 22 . The sleeve 22 is guided through an opening in the caliper 16 . At its end pointing toward the brake shoe 14 , the sleeve 22 is provided with an outwardly projecting flange 24 . The flange 24 has on its side pointing away from the brake shoe a projection 26 whose free end is spherically rounded.
At its end pointing away from the brake disc 10 , the sleeve 22 has a base 28 that is provided with a central bore 30 . Running in an axial direction in the pressure piston 18 , which is arranged in the sleeve 22 , is a spindle 32 whose shaft 34 projects from the central bore 30 . The end of the shaft 34 pointing away from the caliper is provided with a pinion 36 . The pinion 36 is rotated by a suitably designed gear (not illustrated) that is driven by a schematically illustrated motor 38 . The spindle 32 is supported by balls 40 in the pressure piston 18 .
An annular force sensor 42 is arranged between the sleeve 22 and caliper 16 .
During operation, the motor exerts a torque on the pinion 36 , as a result of which the spindle 32 exerts an axial force on the pressure piston 18 . The brake shoes 12 and 14 are thereby pressed against the brake disc 10 with the applied force. The reaction force of the pressure piston 18 is transmitted by the bearing of the spindle 32 in the sleeve 22 onto the flange 24 where this force acts on the force sensor 42 . The force sensor 42 experiences a reaction force of the caliper 16 .
As illustrated in FIG. 2 , the caliper 16 also has a projection 44 whose end is of spherical design. As may be seen from FIG. 2 , force is introduced into the force sensor 42 via the projections 26 and 44 in an annular fashion.
FIGS. 3 and 4 show the force sensor designed as a ring. On its inside, the ring has a circumferential groove 46 that defines two limbs 48 and 50 . As illustrated in FIG. 4 , the depth of the groove 46 is preferably selected such that the base 52 of the ring has a greater thickness than the two limbs 48 and 50 .
FIG. 5 shows a diagram of the mode of operation of the force sensor 42 . The couple 54 and 56 presses the limbs 48 and 50 together such that their spacing is reduced from magnitude D to magnitude d. The bending of the limbs causes on their outer sides 58 and 60 a strain that is measured by a strain measuring system 62 (compare FIG. 2 ). The magnitude of the introduced forces 54 , 56 can be calculated from the measured strain.
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A force sensor for an electromechanical brake has a closed ring having a C-shaped profile that is open inwardly. Force is introduced along the inner circumference of the ring.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 389,111, filed June 17, 1982 and now U.S. Pat. No. 4,414,372. Related subject matter is disclosed and claimed by different inventive entity in commonly assigned application Ser. No. which is a continuation-in-part of application Ser. No. 389,110, filed June 17, 1982 and now U.S. Pat. No. 4,417,034.
DESCRIPTION
1. Technical Field
This invention relates to a process for polymerizing polar α-olefinic monomers to "living" polymers and to the "living" polymers produced by such a process.
2. Background
The 1:1 addition of α,β-unsaturated esters, ketones, and nitriles to activated "donor" compounds, for example, silicon- or tin-containing "donor" compounds, is well known. Such reactions may be referred to as Michael type addition reactions and are catalyzed by bases, such as a fluoride or cyanide, or by Lewis acids, such as zinc chloride, boron trifluoride, titanium tetrachloride, or hydrogen bromide.
K. Saigo et al., Chem. Letters, 2, 163 (1976) disclose that when methylvinyl ketone or cyclohexenone is employed as a Michael acceptor in the presence of O-silylated ketene acetals and titanium tetrachloride, the desired product is obtained in low yields and a polymeric by-product is produced. The polymer was not isolated or identified and means are disclosed for minimizing the by-product by modifying the titanium tetrachloride catalyst by including therewith tetraisopropyl titanate.
U.S.S.R. Pat. No. 717,057 discloses organosilicon acetals of the formula
RO--CH(CH.sub.3)--OSiR'.sub.3-n (OR").sub.n,
and their use as intermediates in the preparation of perfumes and in the production of polymers and flotation agents, wherein R is C 3 H 7 , C 6 H 5 , CH≡CCH 2 , CH≡CC(CH 3 ) 2 or menthyl; R' is C 1-4 alkyl or C 6 H 5 OCH(CH 3 ), and n is 0 or 1.
U.S.S.R. Pat. No. 715,583 discloses trimethylsiloxyethyl esters of the formula RC(O)X--CH(CH 3 )--OSi(CH 3 ) 3 , useful as intermediates in the manufacture of medicinals, plasticizers, and polymers, and as agricultural pesticides and perfumes and in food manufacture, wherein X is oxygen or sulfur and R is lower alkyl, chloroalkyl or optionally substituted alkenyl.
Stork et al., JACS 95, 6152 (1973) disclose the use of α-silylated vinyl ketones to prevent the polymerization of simple alkyl vinyl ketones via their enolate ions during Michael addition reactions.
The use of trialkylsilyl groups as temporary protectants for hydroxyl functions, removal by subsequent hydrolysis, is well known in the art, for example, Cunico et al., J. Org. Chem. 45, 4797, (1980).
U.S. Pat. No. 4,351,924 discloses ω- and α,ω-hydroxyhydrocarbyl-(alkyl methacrylate) polymers prepared by anionic polymerization, and block and star polymers prepared therefrom by reaction with multifunctional bromomethyl compounds.
U.S. Pat. No. 4,293,674 discloses dienyl esters of methacrylic acid, and homopolymers and copolymers thereof prepared by anionic polymerization.
Sato et al., Polymer 24, 1018 (1983) disclose syntheses of block copolymers by reacting living poly(N-phenylmethacrylamide) radicals with vinyl monomers such as methyl methacrylate.
DISCLOSURE OF THE INVENTION
For further comprehension of the invention, and of the objects and advantages thereof, reference may be made to the following description and to the appended claims in which the various novel features of the invention are more particularly set forth.
The invention resides in the process comprising polymerizing the monomer selected from the group consisting of CH 2 ═C(Y)X, ##STR1## and mixtures thereof wherein: X is --CN, --CH═CHC(O)X' or --C(O)X';
Y is --H, --CH 3 , --CN or --CO 2 R, provided, however, when X is --CH═CHC(O)X', Y is --H or --CH 3 ;
X' is --OSi(R 1 ) 3 , --R, --OR or --NR'R";
each R 1 , independently, is a hydrocarbyl radical which is an aliphatic, alicyclic, aromatic or mixed aliphatic-aromatic radical containing up to 20 carbon atoms;
R is a hydrocarbyl radical which is an aliphatic, alicyclic, aromatic or mixed aliphatic-aromatic radical containing up to 20 carbon atoms, optionally containing one or more ether oxygen atoms within aliphatic segments thereof and optionally containing one or more functional substituents that are unreactive under polymerizing conditions; and
each of R' and R" is independently selected from C 1-4 alkyl
by contacting the one or more monomers under polymerizing conditions with:
(i) the initiator of the formula (R 1 ) 3 MZ wherein:
R 1 is as defined above;
Z is an activating substituent selected from the group consisting of ##STR2## and mixtures thereof X' is as defined above for the monomer;
each of R 2 and R 3 is independently selected from H and hydrocarbyl, defined as for R above;
Z' is O or NR';
m is 2, 3 or 4;
n is 3, 4 or 5; and
M is Si, Sn, or Ge,
provided, however, when Z is ##STR3## M is Sn or Ge; and
(ii) a co-catalyst which is a source of bifluoride ions HF 2 .sup.⊖, to produce "living" polymer having repeat units of the one or more monomers, said process further characterized in that:
(a) R 1 is H, provided that at least one R 1 group is not H; and/or
(b) R is a polymeric radical containing at least 20 carbon atoms and optionally containing one or more ether oxygen atoms within aliphatic segments thereof and optionally containing one or more functional substituents that are unreactive under polymerizing conditions; and/or
(c) at least one of any R group in the monomer contains one or more reactive substituents of the formula --Z'(O)C--C(Y 1 )═CH 2 wherein Y 1 is H or CH 3 and Z' is as defined above; and/or
(d) the initiator is of the formula (R 1 ) 2 M(Z 1 ) 2 or O[M(R 1 ) 2 Z 1 ] 2 wherein R 1 and M are as defined above and Z 1 is ##STR4## wherein X', R 2 and R 3 are as defined above; and/or
(e) at least one of any R, R 2 and R 3 in the initiator contains one or more initiating substitutents of the formula --Z 2 --M(R 1 ) 3 wherein
M and R 1 are as defined above; and
Z 2 is a diradical selected from the group consisting of ##STR5## and mixtures thereof, wherein R 2 , R 3 , X', Z', m and n are as defined above, provided, however, when Z 2 is ##STR6## M is Sn or Ge; and/or
(f) Z is selected from the group consisting of --SR, --OP(NR'R") 2 , --OP(OR 1 ) 2 , --OP[OSi(R 1 ) 3 ] 2 and mixtures thereof, wherein R, R 1 , R' and R" are as defined above; and/or
(g) R 2 and R 3 taken together are ##STR7## provided, however, Z is ##STR8## and/or Z 2 is ##STR9## and/or
(h) X' and either R 2 or R 3 taken together are ##STR10## provided, however, Z is ##STR11## and/or Z 2 is ##STR12##
Other co-catalysts which have been independently discovered to be effective in the invention process include sources of fluoride, cyanide or azide ions, suitable Lewis acids, for example, zinc chloride, bromide or iodide, boron trifluoride, alkylaluminum oxides and alkylaluminum chlorides.
By "living" polymer is meant a polymer of the invention which contains at least one active terminal group and is capable of polymerizing further in the presence of monomer(s) and co-catalyst.
It will be understood by one skilled in the art that the last four members of the aforesaid group from which the activating substituent Z is selected are the respective ketene imine or enol forms of the previous four members of the group. The mixtures of such members which are operable herein include, but are not limited to, the corresponding cyano-imine or keto-enol mixtures.
The polymers produced by the process of the invention are "living" polymers of the formula ##STR13## wherein:
Z" is selected from the group consisting of ##STR14## each of a and b is independently selected from 0 or a number in the range 1 to about 100,000, provided, however, (a+b) is at least 3;
Q is the divalent radical selected from the group consisting of ##STR15## and mixtures thereof; and
all remaining symbols are as defined above, said polymer further characterized in that:
(a) R 1 is H, provided that at least one R 1 group is not H; and/or
(b) Z" is selected from --P(O)(NR'R") 2 , --P(O)OR 1 ) 2 , --P(O)[OSi(R 1 ) 3 ] 2 and --SR; and/or
(c) the "living" polymer is of the formula R p ([Z 3 PQM(R 1 ) 3-k ] 1+k (O) k ) p
wherein:
Rp is a hydrocarbyl radical which is aliphatic, alicyclic, aromatic or mixed aliphatic-aromatic containing up to 20 carbon atoms, or a polymeric radical containing at least 20 carbon atoms, of valence p, optionally containing one or more ether oxygen atoms, keto groups and/or functional substituents that are unreactive under polymerizing conditions;
Z 3 is a diradical selected from the group consisting of ##STR16## and mixtures thereof;
Z', R 2 , R 3 , X', m and n are as defined above;
P is a divalent polymeric radical of the formula ##STR17## wherein X, Y, R, a and b are as defined above;
Q, M and R 1 are as defined above;
k is 0 or 1; and
p is an integer and is at least 1 when k is 1 or at least 2 when k is 0, provided, however,
(i) when Z 3 is ##STR18## ps M is Sn or Ge;
(ii) when Z 3 is ##STR19##
R 2 and R 3 taken together is ##STR20## and
(iii) when Z 3 is ##STR21## R 2 and X' taken together is ##STR22##
It is readily apparent that the five members of the group defining Z" are the same as the first five members of the aforesaid group defining Z and are cyano or keto forms of Z. It also is apparent that Q is a "living" polymer unit provided by the starting monomers of the process of the invention, as originally depicted above, or such unit in its enol or imine form. The "living" polymers contain terminal groups --M(R 1 ) 3 at their "living" ends or, when polymerization is initiated by bifunctional initiators of the formula (R 1 ) 2 M(Z 1 ) 2 or O[M(R 1 ) 2 Z 1 ] 2 , central groups --M(R 1 ) 2 --O--M(R 1 ) 2 --. These terminal or central groups are attached to carbon if the adjacent Q unit is in its keto form, and to a hetero atom (O or N) if the adjacent Q unit is in its enol form. Both tautomeric forms may coexist in a given "living" polymer of the invention.
In the description of the further characterization of the invention, any reference to symbols "as defined above" means not only as defined above in the further characterization but also as defined anywhere hereinabove. This caveat applies particularly to the definitions of R, R 1 , R 2 , R 3 , Z and Z".
The "living" polymer of the invention can be a homopolymer or a copolymer, depending on the monomer or monomers selected for use in the process of the invention. Moreover, as will be discussed more fully hereinafter, the "living" polymer can be linear or branched and, depending on the selection of X, R p or Z" in the formulas, can be used to prepare crosslinked polymers and block copolymers.
Monomers which are suitable for use in the practice of this invention are, in general, known compounds and include, but are not limited to, the following: methyl methacrylate; butyl methacrylate; sorbyl acrylate and methacrylate; lauryl methacrylate; ethyl acrylate; butyl acrylate; acrylonitrile; methacrylonitrile; 2-ethylhexyl methacrylate; 2-(dimethylamino)ethyl methacrylate; 2-(dimethylamino)ethyl acrylate; 3,3-dimethoxypropyl acrylate; 3-methacryloxypropyl acrylate; 2-acetoxyethyl methacrylate; p-tolyl methacrylate; 2,2,3,3,4,4,4-heptafluorobutyl acrylate; methylene malononitrile; ethyl 2-cyanoacrylate; N,N-dimethyl acrylamide; 4-fluorophenyl acrylate; 2-methacryloxyethyl acrylate and linoleate; propyl vinyl ketone; ethyl 2-chloroacrylate; glycidyl methacrylate; 3-methoxypropyl methacrylate; 2-[(1-propenyl)oxy]ethyl methacrylate and acrylate; phenyl acrylate; 2-(trimethylsiloxy)ethyl methacrylate; 2-(methylsiloxy)ethyl methacrylate; allyl acrylate and methacrylate; unsaturated esters of polyols, particularly such esters of α-methylenecarboxylic acids, for example, ethylene glycol diacrylate, diethylene glycol diacrylate, glycerol diacrylate, glyceryl triacrylate, mannitol hexaacrylate, sorbitol hexaacrylates, ethylene glycol dimethacrylate, hexamethylene diol diacrylate, 1,3-propanediol dimethacrylate, 1,2,4-butanetriol trimethacrylate, 1,1,1-trimethylolpropane triacrylate, triethylene glycol diacrylate, 1,4-cyclohexanediol diacrylate, 1,4-benzenediol dimethacrylate, pentaerythritol tetramethacrylate, dipentaerythritol hexaacrylate, pentaerythritol tetraacrylates, 1,3-propanediol diacrylate, 1,5-pentanediol dimethacrylate, the bis-acrylates and methacrylates of polyethylene glycols of molecular weight 200-4000, and α,ω-polycaprolactonediol diacrylate; unsaturated N-alkylated amides, such as methylene bis-(N-methylacrylamide), methylene bis-(N-methylmethacrylamide), ethylene bis-(N-methylmethacrylamide), 1,6-hexamethylene bis-(N-methylacrylamide), bis(γ-N-methylmethacrylamidopropoxy)ethane β-N-methylmethacrylamidoethyl methacrylate; 3,3,4,4,5,5,6,6,6-nonafluorohexyl acrylate; and mixtures thereof. Preferred monomers include methyl methacrylate; glycidyl methacrylate; sorbyl methacrylate; ethyl acrylate; butyl acrylate; sorbyl acrylate; 2-(trimethylsiloxy)ethyl methacrylate; 2-methacryloxyethyl acrylate; 2-acetoxyethyl methacrylate; 2-(dimethylamino)ethyl methacrylate; N-phenyl-N-methylacrylamide; p-xylylene diacrylate; 1,4-bis(2-acryloxyethyl)benzene; pentaerythritol triacrylate; 1,1,1-trimethylolpropane triacrylate; pentaerythritol tetraacrylate; triethylene glycol diacrylate; triethylene glycol dimethacrylate; 1,1,1-trimethylolpropane trimethacrylate; 4-acryloxydiphenylmethane; and hexamethylenediol diacrylate and dimethacrylate. Methyl methacrylate is most preferred.
As indicated above in the definition of R in the formulas for the monomer, substituents that are unreactive under polymerizing conditions include those having oxygen-, nitrogen-, or silicon-containing groups which are devoid of reactive hydrogen atoms. Groups such as OSi(R 1 ) 3 and CONH 2 are nonreactive under such conditions and, therefore, can be tolerated. On the other hand, groups such as CO 2 H and OH are reactive under polymerizing conditions. In order for monomers containing such groups on the R substituent to be useful in the invention process, the groups must be chemically protected, i.e. deactivated. Monomers containing such deactivated groups are useful in the preparation of polymers which, upon treatment to remove the protective group, have functional sites along the polymer chain. Monomers which contain sufficiently sterically hindered amine and alcohol groups that remain inert under reaction conditions may be used directly without deactivation. The functional sites can impart special properties to the polymer products, including curability and photosensitivity.
The definition of R in the monomer formulas also includes substituents which are reactive under polymerizing conditions and of the formula CH 2 ═C(Y 2 )C(O)Z'-- wherein Y 2 and Z' are as defined above. These reactive substituents provide additional centers for initiation of polymerization, leading to the growth of polymeric branches. The reactive substituents are derived from (meth)acrylates or (meth)acrylamides which are themselves operable monomers in the present invention. These substituents can react with initiators of the invention to provide new initiating sites from which polymeric branches can grow in the presence of monomer(s) and cocatalyst.
Initiators which are useful in the invention process include, but are not limited to, the following: [(1-methoxy-2-methyl-1-propenyl)oxy]trimethylsilane; [(1-methoxy-2-methyl-1-propenyl)oxy]dimethyloctadecylsilane; [(1-methoxy-2-methyl-1-propenyl)oxy]methylsilane; 2-(trimethylsilyl)isobutyronitrile; ethyl 2-(trimethylsilyl)acetate; methyl 2-methyl-2-(tributylstannyl)propanoate; [(2-methyl-1-cyclohexenyl)oxy]tributylstannane; trimethylsilyl nitrile; methyl 2-methyl-2-(trimethylgermanyl)propanoate; [(4,5-dihydro-2-furanyl)oxy]trimethylsilane; [(2-methyl-1-propenylidene)bis(oxy)]bis[trimethylsilane]; [(2-methyl-1-[2-(methoxymethoxy)ethoxy]-1-propenyl)oxy]trimethylsilane; methyl [(2-methyl-1-(trimethylsilyloxy)-1-propenyl)oxy]acetate; [(1-methoxymethoxy)-2-methyl-1-propenyl)oxy]trimethylsilane; trimethyl α,α',α"-tris(trimethylsilyl)-1,3,5-benzenetriacetate; dimethyl α,α'-bis(trimethylsilyl)-1,3-benzenediacetate; [1,6-dimethoxy-1,5-hexadiene-1,6-diylbis(oxy)]bis[trimethylsilane]; [(2-ethyl-1-propoxy-1-butenyl)oxy]ethyldimethylsilane; ethyl 2-(trimethylstannyl)propanoate; [(1-cyclohexenyl)oxy]trimethylstannane; [(2-methyl-1-butenylidene)bis(oxy)]bis[trimethylsilane]; 2-(trimethylsilyl)propanenitrile; ethyl (trimethylgermanyl)acetate; [(1-((1-dec-2-enyl)oxy)-2-methyl-1-propenyl)oxy]trimethylsilane; phenyl 2-methyl-2-(tributylstannyl)propanoate; methyl 2-(triethylsilyl)acetate; dimethyl 2,5-bis(trimethylgermanyl)hexanedioate; [(2-methyl-1-cyclohexenyl)oxy]tributylstannane; [(1-methoxy-2-methyl-1-propenyl)oxy]phenyldimethylsilane; [(2-methyl-1-[2-(trimethylsiloxy)ethoxy]-1-propenyl)oxy]trimethylsilane; N,N-dimethyl-(trimethylsilyl)phosphorodiamidite; (trimethylsilyl)dimethyl phosphite; tris(trimethylsilyl) phosphite; N,N-dimethyl-P-[3-methoxy-3-((trimethylsilyl)oxy)-2-propenyl]phosphonic diamide; N,N-dimethyl-P-[3-methoxy-2-methyl-3-((trimethylsilyl)oxy)-2-propenyl]phosphonic diamide; [3-methoxy-3-((trimethylsilyl)oxy)-2-propenyl]phosphonic acid, bis(trimethylsilyl) ester; [3-methoxy-2-methyl-3-((trimethylsilyl)oxy)-2-propenyl]phosphonic acid, bis(trimethylsilyl) ester; [3-methoxy-3-((trimethylsilyl)oxy)-2-propenyl]phosphonic acid, diethyl ester; [(2-(1,1-dimethylethyl)-5-phenyl-1,3-dioxol-4-yl)oxy]trimethylsilane; [(2-methyl-5-phenyl-1,3-dioxol-4-yl)oxy]trimethylsilane; [(methoxy)(1,7,7-trimethylbicyclo[2.2.1]heptan-2-ylidene)methoxy]trimethylsilane; 1,3-bis[(1-methoxy-1-butenyl)oxy]-1,1,3,3-tetramethyldisiloxane; bis[(1-methoxy-2-methyl-1-propenyl)oxy]methylsilane; bis[(1-methoxy-2-methyl-1-propenyl)oxy]dimethylsilane.
Preferred initiators include [(1-methoxy-2-methyl-1-propenyl)oxy]trimethylsilane; [(2-methyl-1-propenylidene)bis(oxy)]bis[trimethylsilane]; trialkylsilyl nitriles; and [(2-methyl-1-[2-(trimethylsiloxy)ethoxy]-1-propenyl)oxy]trimethylsilane. Trimethylsilyl nitrile is most preferred.
The initiators used in the invention are either known compounds or can be prepared by known methods from known starting materials. Of the initiators listed above, trimethylsilyl nitrile and ethyl trimethylsilyl acetate are commercially available. Initiators of the aforesaid formula (R 1 ) 3 MZ wherein Z is ##STR23## or the corresponding ketene imine or enol isomeric forms ##STR24## wherein X' is defined as above can be prepared from nitriles (R 2 )(R 3 ) CHCN, esters, ketones, or substituted amides (R 2 )(R 3 )CHC(O)X' wherein X' is as defined above by reaction with, for example, n-butyllithium or lithium diisopropylamide, followed by reaction with a halide of the formula (R 1 ) 3 MCl wherein R 1 and M are as defined above.
Initiators of the aforesaid formula wherein R 2 or R 3 is CH 3 also can be prepared from the monomers using appropriate procedures. For example, CH 2 ═C(R 3 )C(O)X' can be reacted with (R 1 ) 3 MH wherein R 1 is as defined above to produce (R 1 ) 3 MZ wherein Z is ##STR25##
In still another method, the preferred initiators which are trialkylsilyl nitriles can be prepared in situ by treating a trialkylsilyl chloride with an excess of cyanide ion from a suitable source, such as tetraalkylammonium cyanide. The residual cyanide ion can serve as a co-catalyst for the polymerization.
Similarly, initiators of the formulas (R 1 ) 2 M(Z 1 ) 2 or O[M(R 1 ) 2 Z 1 ] 2 wherein R 1 , M and Z 1 are as defined above are either known compounds or can be prepared by the above methods employing, for example: dihalides of the formula (R 1 ) 2 MCl 2 in place of halides (R 1 ) 3 MCl in the reaction with lithium-containing intermediates as described above; or dihydrides (R 1 ) 2 HM--O--MH(R 1 ) 2 in place of (R 1 ) 3 MH in the reaction with the monomers CH 2 ═C(R 3 )C(O)X'.
Useful initiators of the invention include those wherein the activating substituent Z or Z 1 also contains one or more reactive initiating substituents, resulting in branched polymers. Such initiators can be prepared in situ by reacting a monomeric compound containing at least one reactive substituent with a "simple" initiator (R 1 ) 3 MZ, or precursor thereof, containing at least one initiating site.
It is to be understood that the useful initiators include nitriles, esters, amides, and ketones, and their corresponding ketene imine and enol forms, all of which are active in the polymerization process of this invention. Moreover, the initiators wherein the activating moiety Z contains R, R 2 , and/or R 3 can also have, like the monomer, one or more functional substituents attached to an aforesaid R group, provided such substituents do not interfere with polymerization. Functional substituents which are useful include, but are not limited to, --OSi(R 1 ) 3 , --CO 2 R, --OC(O)R, --NR'R", --C(O)NR'R", --CN, --OCH(R)OR, --OC(R)(R)0R, ##STR26## --CO 2 Si(R 1 ) 3 , ##STR27## --C(CH 3 )═CH 2 , --SR, --P(O)NR'R") 2 , --P(O)[OSi(R 1 ) 3 ] 2 and --P(O)(OR 1 ) 2 . Such substituents, either directly or after treatment, for example, hydrolysis, provide functional sites along or at the end of polymer chains suitable for cross-linking, chain extension, chain branching, or for modifying properties such as water sorption, UV absorption, and the like. In the practice of this invention, as described below, an initiator moiety forms one end of a polymer chain or branch and hence said polymers can be terminally or centrally functionalized by appropriate initiator selection and polymer treatment.
The co-catalysts used in the invention process are either known compounds or can be prepared by known methods from known compounds. Suitable, that is, effective, co-catalysts which have been independently discovered and which are useful in the invention process include zinc iodide, bromide, and chloride, mono- and dialkylaluminum halides, dialkylaluminum oxides, tris(dimethylamino)sulfonium difluorotrimethylsilicate, tris(dimethylamino)sulfonium cyanide, tetraphenylarsonium cyanide, tris(dimethylamino)sulfonium azide, tetraethylammonium azide, boron trifluoride etherate, alkali metal fluorides, alkali metal cyanides, alkali metal azides, tris(dimethylamino)sulfonium difluorotriphenylstannate, tetrabutylammonium fluoride, tetramethylammonium fluoride, and tetraethylammonium cyanide. Preferred co-catalysts include sources of fluoride ions, especially tris(dimethylamino)sulfonium difluorotrimethyl silicate and tetrabutylammonium fluoride; tetraalkylammonium cyanides; zinc bromide, and zinc chloride.
Most preferred co-catalysts are sources of bifluoride ions, such as, for example, tris(dimethylamino)sulfonium bifluoride, bifluorides of the alkali metals, especially potassium, ammonium bifluoride, tetraalkylammonium bifluorides and tetraarylphosphonium bifluorides. Tris(dimethylamino)sulfonium bifluoride may be prepared by reacting tris(dimethylamino)sulfonium difluorotrimethylsilicate with water or a lower alkanol, for example, methanol; water is preferred since higher yields are obtained.
The process of the invention is carried out at about -100° C. to about 150° C., preferably 0° C. to 50° C., most preferably at ambient temperature. A solvent is desirable but not essential.
Suitable solvents are aprotic liquids in which the monomer, initiator and co-catalyst are sufficiently soluble for reaction to occur; that is, the materials are dissolved at the concentrations employed. Suitable solvents include ethyl acetate, propionitrile, toluene, xylene, bromobenzene, dimethoxyethane, diethoxyethane, diethylether, tetramethylene sulfone, N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, anisole, 2-butoxyethoxytrimethylsilane, cellosolve acetate, crown ethers such as 18-crown-6, acetonitrile, and tetrahydrofuran. Acetonitrile and tetrahydrofuran are preferred solvents when a co-catalyst wherein the active species is an anion is used. When the co-catalyst employed is a zinc compound, suitable solvents are limited to hydrocarbons and chlorinated hydrocarbons, preferably dichloromethane or 1,2-dichloroethane.
The monomers used in the process of the invention are generally liquids and can be polymerized without a solvent, although a solvent is beneficial in controlling temperature during exothermic polymerization. When a solvent is used, the monomer may be dissolved or dispersed therein at concentrations of at least 1 wt %, preferably at least 10 wt %. The initiator is employed at a concentration such that the monomer/initiator molar ratio is greater than 1, preferably greater than 5. The co-catalyst is normally present in such an amount that the molar ratio of initiator to co-catalyst is in the range 0.1 to 10,000, preferably 10 to 100.
In the polymerization process of the invention, it is preferable to charge the initiator, co-catalyst, and solvent, if used, to the polymerization vessel before adding the monomer(s), especially if polymers of narrow molecular weight distribution are desired. In selected cases, such as the polymerization of methyl methacrylate initiated by trimethylsilyl nitrile using a relatively low concentration of cyanide or fluoride ions as the co-catalyst, polymerization takes place after an induction period of several minutes. In such cases, all materials, including the monomer(s), may be charged together or independently, and mixed in place. Such an initiator/co-catalyst system is preferred to obtain relatively monodisperse polymers. By a monodisperse polymer is meant one having a narrow molecular weight distribution, that is, M w /M n is about 1. At higher values of M w /M n the polymer is said by the art to be polydisperse.
Although, as indicated above, it is preferable to charge all necessary initiator, co-catalyst and solvent to the polymerization vessel before adding monomer(s), subsequent polymerization rate being controlled by monomer addition, further additions of co-catalyst may sometimes be necessary to sustain polymerization.
The final (non-living) polymeric product obtained by means of the process of the invention is formed by exposing the "living" polymer to an active hydrogen source, such as moisture or an alcohol, for example, methanol.
The "living" polymers of the invention will remain "living" for substantial periods provided they are protected from active hydrogen sources such as water or alcohols. Solutions of "living" polymers in inert solvents, such as hydrocarbons, are especially useful for preserving and conveying the "living" polymers. Films and fibers of the "living" polymers may be cast or spun from such solutions, or the polymer may be isolated from solution and further processed, for example, pelletized or granulated.
It is to be understood that the final (non-living) polymeric product does not include the enol or imine species of Q in the aforesaid formula for the "living" polymer of the invention. For example (as in Example 7), a "living" polymer prepared by polymerizing methyl methacrylate using [(1-methoxy-2-methyl-1-propenyl)oxy]trimethylsilane (MTS) as the initiator contains, at its living end, the enolic grouping ##STR28## which, upon quenching, is converted to ##STR29##
The process of the invention is useful for preparing homopolymers or copolymers of the monomers described above. In either case, the polymers obtained are "living" polymers which may be of high or low molecular weight and having a broad or narrow molecular weight distribution (M w /M n ). At a given temperature, M w /M n is primarily a function of the relative rates of initiation and polymerization. Rate of initiation, r i , depends on initiator and co-catalyst type and relative concentrations. Polymerization rate, r p , is a function of monomer reactivity and co-catalyst type and concentration. For monodispersity, r i /r p is equal to or greater than 1, that is, the initiation rate is at least as fast as the polymerization rate and all chains grow simultaneously. Such conditions characterize the preparation of "living" polymers by anionic polymerization techniques of the art wherein M w /M n ratios only slightly above the theoretical limit of 1 are obtainable; for example, poly(methyl methacrylate) of M w /M n of about 1.01 to 1.1 are known in the art, as are copolymers of methyl methacrylate and other alkyl methacrylates. Control of M w /M n permits useful variation in polymer physical properties, such as glass transition temperature, hardness, heat distortion temperature, and melt viscosity.
The polymerization process of the present invention involves a "living" mechanism having several similarities with anionic polymerization. For example, initiation and polymerization may be represented by conventional equations wherein the initiator moiety (R 1 ) 3 M is located at one end of the polymer chain or branch which remains "living" even when the monomer supply is consumed; the activating substituent Z is located at the other end of the polymer chain or branch. The terminal initiator moiety, unless chemically deactivated, is capable of initiating further polymerization with the same or different monomer, with resultant chain lengthening. Copolymers with specific monomer sequences, or block polymers, can thus be prepared.
Although the present process resembles anionic polymerization, there are significant differences which have commercial significance. These differences include the ability to copolymerize methacrylate and acrylate monomers, or combinations of acrylate monomers, for example, ethyl and sorbyl acrylates, to relatively monodisperse copolymers. Such copolymers are difficult or impossible to obtain by known processes such as anionic polymerization or free-radical polymerization. Moreover, whereas anionic polymerization processes which provide relatively monodisperse polymers are carried out at low temperatures, usually well below -10° C., which require expensive refrigeration equipment for commercial operation, the polymerization process of the invention is operable over a wide temperature range, from about -100° C. to about 150° C. It is conveniently operable with many commercially important monomers at about ambient temperatures.
The process of this invention can also be used to prepare polymers containing one or more specifically located functional groups which are unreactive under polymerizing conditions but are useful for subsequent preparation of block copolymers or crosslinked polymers. The functional groups may be introduced by using either a monomer or an initiator, or both, containing a protected functional substituent, or by chemically deactivating (capping) the "living" end of the polymer chain or branch with a functionalized capping agent. If the capping agent contains more than one capping site, then more than one polymer chain can be joined together or coupled to give doubled or "star"-branched polymers, similar to the doubled or star-branched polymers obtained when the initiator contains more than one initiating site, or the monomer contains more than one reactive site capable of reacting with initiators, as described previously. Even if the capping agent contains only one capping site, the agent may also contain other functional groups which provide reactive terminal sites to the polymer, useful for subsequent preparation of block copolymers or cross-linked polymers, or for otherwise modifying polymer properties. Examples of capping agents containing one or more capping sites include p-dimethoxymethylbenzyl bromide, p-chloromethylstyrene, p-methoxymethoxymethylbenzyl bromide, 1,4-bis(bromomethyl)benzene, 1,3,5-tris(bromomethyl) benzene, terephthaldehyde and toluene diisocyanate. Capping agents containing one capping site and one or more functional groups that are unreactive under capping conditions include
1-bromomethyl-4-dimethoxymethylbenzene,
1-bromomethyl-4-(methoxymethoxymethyl)benzene,
4-chloromethylstyrene,
4-(trimethylsilylcarboxy)benzaldehyde,
4-nitrobenzaldehyde, 2,5-furanyldione and
1,3-di(carbonylamino)-1,5,5-trimethylbenzene.
In general, capping agents which are useful in the process of the invention include aliphatic, aromatic or aliphatic-aromatic compounds containing one or more capping functions such as --CHO, ##STR30## --NCO, --Br, --Cl and --TiCl 3 , and which may optionally also contain non-capping functional substituents, such as --NO 2 , --OSi(R 1 ) 3 and --CO 2 Si(R 1 ) 3 . Reaction of capping agents with the "living" polymer ends proceeds similarly to known reactions of non-polymeric trialkylsilanes. The capping reaction is normally carried out in an organic liquid wherein both polymer and capping agent are soluble; frequently, the polymerization solvent is suitable. The reaction is preferably carried out in the presence of fluoride ion as catalyst; tris(dimethylamino)sulfonium difluorotrimethylsilicate is a preferred catalyst. Examples of initiators which can initiate more than one polymer chain include trimethyl α,α'α"-tris(trimethylsilyl)-1,3,5-benzenetriacetate, dimethyl α,α'-bis(trimethylsilyl)-1,3-benzenediacetate, 1,6-dimethoxy-1,5-hexadiene-1,6-diylbis(oxy)bis[trimethylsilane], and bis[(1-methoxy-2-methyl-1-propenyl)oxy]methylsilane.
In the following examples of specific embodiments of this invention, parts and percentages are by weight and temperatures are in degrees Celsius unless otherwise specified. The polydispersity (D) of the polymer products of the examples is defined by D=M w /M n , the molecular weights being determined by gel permeation chromatography (GPC). Unless otherwise specified, the "living" polymer products obtained in the invention process were quenched by exposure to moist air before molecular weights were determined.
EXAMPLE 1
Preparation of "Living" Poly(Methyl Methacrylate) and Subsequent Reactions Thereof
This example demonstrates the preparation of "living" poly(methyl methacrylate) containing active terminal trimethylsiloxy groups, and subsequent reactions thereof.
A. "Living" Poly(methyl methacrylate)
To a solution of 2.6 g (9.4 mmol) of [(2-methyl-1-[2-(trimethylsiloxy)ethoxy]-1-propenyl)oxy]trimethyl-silane in 10 ml of THF was added 166 mg of tris(dimethylamino)sulfonium bifluoride. Then, a solution of 10 g (100 mmol) of MMA in 10 ml of THF was added dropwise over 30 min. After the temperature dropped to 22°, the reaction mixture containing PMMA was separated into three equal parts, under argon, for use in Parts B, C and D below.
B. Reaction with Bromine and Titanium Tetrachloride
The reactions involved are shown below. In all equations, R is ##STR31##
(i) Bromine reacts with approximately one-half of the living polymer in the 11.1 ml aliquot of polymerization mixture from Part A: ##STR32##
(ii) The remaining living polymer in the 11.1 ml aliquot from Part A reacts with TiCl 4 : ##STR33##
(iii) Coupling: ##STR34##
One-third of the polymerization mixture from Part A (11.1 ml) was cooled to 0° and treated with 0.3 g (1.9 mmol) of bromine in 5 ml of 1,2-dichloroethane. After the red bromine color disappeared, a solution of 0.4 ml of TiCl 4 in 5 ml of 1,2-dichloroethane was added, whereupon a precipitate formed. The mixture was allowed to warm to room temperature, stirred for 1 h, and then evaporated. The residue was dissolved in 20 ml of acetone and precipitated from hexane to give 4.45 g of polymer. This was identified by HPLC, NMR and GPC to be a di(trimethylsilyloxy)-PMMA, hydrolyzable to dihydroxy PMMA. GPC: M n 3600, M w 4400, D 1.23 (theor. M n 2392).
C. Reaction with Benzyl Bromide (Capping) ##STR35##
R has the same meaning as in Part B.
An aliquot (11.1 ml) of original polymerization reaction mixture from Part A was cooled to -43° under argon. To this was added 0.7 g of benzyl bromide. The solution was stirred and allowed to warm to room temperature. After stirring for 15 min 3.5 ml of a 1.0M acetonitrile solution of tris(dimethylamino)sulfonium difluorotrimethylsilicate was added. The solution was stirred at 25° for 11/2 h, after which was added 10 ml of methanol. The solvents were evaporated and the polymer was precipitated from hexane; 4.25 g of powdery solid polymer was recovered. GPC: M n 2300, M w 3700, D 1.61 (theor. M n 1287).
D. Reaction with 1,4-Xylyl Bromide ##STR36##
R has the same meaning as in Part B.
Following the procedure of Part B, 11.1 ml of the reaction mixture was treated with 0.5 g (1.9 mmol) of 1,4-xylyl bromide, 1.1 g of tris(dimethylamino)sulfonium difluorotrimethylsilicate to give 4.31 g of α,ω-masked-dihydroxy PMMA.
GPC: M n 3400, M w 4200, D 1.24 (theor. M n 2494).
EXAMPLE 2
Preparation of Three-Branched Star Poly(methyl methacrylate)
A. To 4.41 ml (3.838 g, 12.87 mmol) of tris(trimethylsilyl)phosphite at 65° was added slowly 1.0 g (4.29 mmol) of trimethylolpropanetriacrylate (purified by extraction with hexane and passage of extract through neutral alumina). After 1 h, NMR showed no residual acrylate and was in agreement with ##STR37## a viscous oil.
Anal. Calcd. for C 42 H 101 O 15 P 3 Si 9 : C, 42.32; H, 8.54; P, 7.80; Si, 21.21. Found: C, 41.05; H, 8.17; P, 8.87; Si, 19.91.
B. To a solution of 1.91 g (1.6 mmol) of the product of Part A in 30 ml of tetrahydrofuran was added 0.1 ml of 1M tris(dimethylamino)sulfonium bifluoride/acetonitrile and 15 g (16.2 ml, 150 mmol) of methyl methacrylate. A slow exothermic reaction was observed. After stirring 18 h, the solution was evaporated in vacuo to 12.6 g (80.7%) of solid polymer.
GPC: M n 13,000, M w 28,600, D 2.20 (theoretical M n 7500).
To convert the silylphosphonate terminal groups to phosphonic acid groups, the product was stirred at reflux for 1 h with 15 ml of methylene chloride, 6 ml of methanol, and 1 ml of 1M tetrabutylammonium fluoride/tetrahydrofuran. The solution was evaporated and the residue was dissolved in methylene chloride, washed with water, dried and concentrated. The purified three-star triphosphonic acid polymer was precipitated with hexane to give 6 g of solid polymer. The NMR spectrum showed the absence of any trimethylsilyl groups.
EXAMPLE 3
Preparation of a Triblock Terpolymer of Methyl Methacrylate (MMA), n-Butyl Methacrylate (BMA), and Allyl Methacrylate (AMA), Catalyzed by Bifluoride Ion
A 250 ml reactor, fitted with an argon inlet, a stirrer, thermocouple and a syringe pump, was charged with tetrahydrofuran (50 ml), tris(dimethylamino)sulfonium bifluoride (0.05 ml, 1M in CH 3 CN) and [(2-methoxy-2-methyl-1-propenyl)oxy]trimethylsilane (1.25 ml, 6.25 mmol). MMA (10.7 g, 106.9 mmol) was then added via a syringe pump over 15 minutes. The temperature rose from 24.8° to 51.6° accompanied by an increase in the viscosity of the mixture. The reaction mixture was stirred and allowed to cool to 38.6°. Then BMA (9.0 g, 63.3 mmol) was added over 15 minutes. The temperature rose to 43.2°. The addition process was repeated with AMA (5.34 g, 42.5 mmol) and the temperature rose from 33° to 39.2°. The clear colorless mixture was stirred until the temperature dropped to 23° and then was treated with methanol (10 ml) containing phenothiazine (0.1 mg). The solvent was evaporated and the residue was dried; yield 23.72 g. M n 3800, M w 4060, D 1.07 (theoretical M n 4100). The polymer showed Tg 1 -19°, Tg 2 38°, Tg 3 108°, corresponding to poly(allyl methacrylate), poly(n-butyl methacrylate) and poly(methyl methacrylate) segments, respectively.
EXAMPLE 4
Polymerization of Methyl Methacrylate with Bis[(1-methoxy-2-methyl-1-propenyl)oxy]methylsilane and tris(dimethylamino)sulfonium Bifluoride
To a solution, in 20 ml of anhydrous tetrahydrofuran, of bis[(1-methoxy-2-methyl-1-propenyl)oxy]methylsilane (1.23 g, 5 mmol), prepared by the reaction of methyldichlorosilane with the lithium enolate of methyl isobutyrate (bp 54.8°/0.5°-57.2°/0.7 mm), and 20 μL of 1M tris(dimethylamino)sulfonium bifluoride/acetonitrile was added 10 g (10.8 ml, 100 mmol) of methyl methacrylate (purified by passage over neutral alumina under argon) containing 10 μl of 1M tris(dimethylamino)sulfonium bifluoride. An exothermic reaction persisted during the monomer addition. After 30 minutes 5.0 g (5.4 ml, 50 mmol) of methyl methacrylate was added, producing an exothermic reaction. Addition of 3 ml of methanol produced an apparent decrease in viscosity. Evaporation in vacuo gave 17.5 g of solid poly(methyl methacrylate).
Gel permeation chromatography shows M n 1410, M w 1550, D 1.10 (theoretical M n 1600).
EXAMPLE 5
Polymerization of Methyl Methacrylate with [3-methoxy-2-methyl-3-((trimethylsilyl)oxy)-2-propenyl]phosphonic Acid, Bis(trimethylsilyl) Ester and Tris(dimethylamino)sulfonium Bifluoride
A. [3-Methoxy-2-methyl-3-((trimethylsilyl)oxy)-2-propenylphosphonic acid, bis(trimethylsilyl) ester was prepared by stirring a mixture of equimolar amounts of methyl methacrylate and tris(trimethylsilyl)phosphite at 114° for 3.5 h under argon. The product was distilled in a small Vigreux column, b.p. 91°/0.23 mm, Anal. Calcd. for C 14 H 35 O 5 PSi 3 : C, 42.18; H, 8.85; P, 7.77, Si 21.14. Found: C, 42.17; H, 8.54, P, 8.07; Si 21.12.
B. To a stirred solution of 3.12 g (3.2 ml, 7.84 mmol) of the phosphonic acid ester prepared in Part A and 0.3 ml of a 1M solution in acetonitrile of tris(dimethyamino)sulfonium bifluoride in 100 ml of tetrahydrofuran under an argon atmosphere was added during 1 h 55 ml (50.9 g, 509 mmol) of methyl methacrylate (purified by passage over a short column of neutral alumina). The solution was stirred for two h after the end of the exotherm. Then, 30 ml of methanol and 2 ml of 1M tetrabutylammonium/tetrahydrofuran was added and the resulting solution was stirred at reflux for 1.5 h and concentrated in a rotary evaporator. The product was precipitated from the concentrated solution by addition to water. The polymer was filtered and dried in a vacuum oven at 100° to give 49.7 g of poly(methyl methacrylate-1-phosphonic acid). GPC: M n 5900, M w 5900, D 1.00 (theoretical M n 6650); 1 H NMR: δ(ppm from external Me 4 Si, CDCl 3 solvent) 7.9 ppm [broad, PO(OH) 2 ].
EXAMPLE 6
Polymerization of Methyl Methacrylate with Tris(trimethylsilyl)phosphite and Bifluoride Catalyst
To a stirred solution of 1.49 g (1.75 ml, 5 mmol) of tris-(trimethylsilyl)phosphite and 0.31 ml of 1M tris(dimethylamino)sulfonium bifluoride/acetonitrile in 15 ml of tetrahydrofuran under argon was added 10 g (10.8 ml, 100 mmol) of methyl methacrylate. After 20 minutes an exothermic reaction was observed, and the temperature rose to 36°. After stirring 18 h the viscous solution was evaporated in vacuo to 12.1 g of solid phosphonate-substituted poly(methyl methacrylate). GPC: M n 15,300, M w 29,400, D 1.92 (theoretical M n 2300).
EXAMPLE 7
Polymerization of Methyl Methacrylate and Isolation of Trimethylsiloxy-ended Polymer
This example demonstrates by means of carbon-13 NMR analysis the presence of silylenolate terminal groups in a "living" polymer prepared by the process of this invention.
A. To a suspension of 20 mg (0.1 mmol) of tris(dimethylamino)sulfonium bifluoride in 5 ml of THF was added, under argon, 1.0 ml (5 mmol) of MTS. Then, 2.7 ml (25 mmol) of MMA was added, whereupon the temperature rose from 22° to 50°. The mixture was stirred until the temperature dropped to 22°. Then, the reaction vessel was connected to a vacuum pump and the solvents were removed at 0.1 mm Hg using a liquid nitrogen trap. A foamy polymer, 3.5 g, was obtained. This was subjected to C-13 NMR analysis.
MTS was used as a standard and the assignment of peaks is shown below:
______________________________________ # STR38## Carbon C-13 Shielding (ppm)______________________________________C-1 49.50C-2 90.40C-3 56.17C-4 16.61, 15.84C-5 -0.20______________________________________
The most distinct and useful peaks are those corresponding to the sp 2 -hybridized carbon atoms occurring at 90.40 and 149.50 ppm. The absorption of the corresponding carbon atoms of the "living" polymer should occur in about the same spectral region.
______________________________________ ##STR39##Carbon C-13 Shielding (ppm)______________________________________C-1 151.1C-2 88.5C-3 59.6C-4 28.1C-5 -1 to -1.5______________________________________
As shown above, distinct peaks occurred at 151.1 and 88.5 ppm, corresponding to the carbon atoms of the C═C moiety. The C═O absorption of the ester groups of the polymer occurred between 175 and 176 ppm as multiplets. Integration of the peaks due to C═O versus those due to C═C gave a degree of polymerization of about 6. The isolated polymer (3.5 g) was dissolved in 10 ml of THF and then treated with 5 ml of methanol. Upon evaporation and drying, 3.3 g of polymer was obtained. GPC: M n 550, M w 600, D 1.09 (theor. M n 602).
B. Following the procedure of Part A, trimethylsiloxy-ended poly(ethyl acrylate) was isolated from the reaction of 20 mg (0.1 mmol) of tris(dimethylamino)sulfonium bifluoride, 1.0 ml of MTS, and 2.7 ml of ethyl acrylate in 5 ml of THF. The assignment of peaks in the C-13 NMR is shown below:
______________________________________ ##STR40## C-13 Shieldings (ppm)Carbon Model Living PEA______________________________________C-1 164.2 167.2C-2 107.2 108.8______________________________________
BEST MODE FOR CARRYING OUT THE INVENTION
The best mode presently contemplated for carrying out the invention is demonstrated and/or represented by Examples 1 to 4 and 7.
INDUSTRIAL APPLICABILITY
The invention process provides useful and well known polymers containing functional substituents, for example, homopolymers and copolymers of acrylate and/or methacrylate monomers, such polymers heretofore being made usually by anionic polymerization techniques. The invention process also provides a means for making certain commercially desirable, relatively monodisperse copolymers of methacrylate and acrylate comonomers, such copolymers being difficult or impossible to obtain by known processes such as anionic polymerization or free-radical polymerization. The invention process also provides "living" polymer which may be cast or spun, for example, into a film or fiber, from solution or dispersion (in or using an aprotic solvent) or isolated, processed, and then further polymerized. The solutions or dispersions may also be formulated with clear or opaque pigments and other ingredients which can be converted into protective coatings and finishes for manufactured articles, such as metal, glass and wood.
Although preferred embodiments of the invention have been illustrated and described hereinabove, it is to be understood that there is no intent to limit the invention to the precise constructions herein disclosed, and it is to be further understood that the right is reserved to all changes and modifications coming within the scope of the invention as defined in the appended claims.
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"Living" polymers and their preparation from acrylic-type or maleimide monomers and organosilicon, -tin or -germanium initiators.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention, in general, relates to food processing machinery of the kind equipped with feed screws for moving material from an intake, such as a hopper, through a processing station, such as choppers, knives and the like, and, more particularly, to a novel pressure barrel for a meat grinder provided with elongate channels or grooves extending longitudinally in the interior wall surface thereof for supporting, and improving the feed motion of, the material being processed.
2. The Prior Art
Conventionally, material to be processed in meat grinders and other cutting or chopping apparatus of that kind is fed into the machine through a feed opening, preferably a hopper, and is fed to a rotary cutting or knife assembly by a feed or pressure screw which is rotatably supported within, and substantially coaxially of the pressure barrel of such machine.
Pressure barrels of this general kind are disclosed, for instance, in German patent 620,312 and patent applications DE-AS 1,061,646 and DE-OS 3,245,414.
In the known apparatus, the pressure and feed screw and the barrel of the meat grinder serve to support and feed and to some extent compress the material being processed.
To this end the screw is given a special geometric configuration and is provided with flights of predetermined geometrical configurations and with additional elements, such as wedge-shaped gaps (Spaltkeile), further improving the action.
Reference is made to (East) German specification DD 287 661 which discloses a pressure barrel complementing such screws, the interior wall surface of which is specially configured by channels or grooves for purposes of further improvement in the actions referred to supra. These channels are intended to impart to the material the support necessary for feeding.
The best-known channels in such barrels are of rectangular cross-section and extend in the direction of the longitudinal axis of the barrel. However, rifled or helical channels are also utilized in pressure barrels. The edges of the channels may be rounded.
The pressure barrels are manufactured in different ways. For instance, they may be cast, welded or mechanically milled. In current manufacturing techniques the channels are formed in the same manner as the barrels, which is expensive or inefficient in terms of both material and labor.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a pressure barrel of the kind which satisfies the requirements of through-feed and cutting or chopping.
A further object of the invention is to provide a barrel which may be replaced or exchanged to accommodate different operating conditions.
A still further object of the invention is to provide a pressure barrel which precludes material abrasion.
Yet another object of the invention is to provide a pressure barrel precluding contamination of material in process.
It is also an object of the invention to provide a pressure barrel which may easily be cleaned to guaranty high standards of sanitation and hygiene.
Other objects will in part be obvious and will in part appear hereinafter.
SUMMARY OF THE INVENTION
The invention, in a preferred embodiment, provides for a pressure barrel of a meat grinder having an interior substantially cylindrical wall provided with elongate protrusions forming channels between them. Preferably, the protrusions extend along the length of the wall and are of uniform width. They may be of straight configuration extending substantially parallel to the axis of the barrel. In an alternate embodiment, the protrusions extend in a helical manner. They may be integral with the interior wall of the barrel. Alternatively, they may be formed as beads cold-formed in a flat metal web before it is shaped into a complete cylinder or into semi-cylindrical matching shells which together make up a cylinder. In another embodiment, the elongate protrusion may comprise staves extending between annular members. Mating members are preferably provided in the barrel and the insert to prevent rotation of the insert during operation of the assembly.
The pressure barrel in accordance with the invention comprising a basic component and a support system providing an insert with a channeled interior surface removably mounted therein results from the realization that the feeding and cutting actions in a meat grinder are depending to a substantial degree upon the configuration of the pressure barrel.
The basic component or pressure barrel is made from conventional materials whereas the insert is preferably made from a high-grade stainless steels such as, for example, a chromium-nickel-alloy steel. Other materials, such as titanium steels, may, of course also be used to suit special applications. It is important that the material chosen is such that the surface condition of the pressure barrel satisfies modern standards of sanitation and hygiene, as defined, for instance in Rz 25.
The support system insert is made from a flat metal web cold-formed to provide beads therein and thereafter rolled into a cylindrical shape in the interior surface of which the beads form protrusions forming channels between them.
The basic component or barrel may similarly be made from flat web material, such as Cr-Ni-steel with beading cold-formed therein and subsequently shaped into a cylinder from the interior wall surface of which the beading protrudes as a series of elongate protrusions forming channels between them.
The barrel insert may, in a preferred embodiment of the invention, comprise two matching semi-shells provided with elongate protrusions. When assembled the semishells will form a cylinder suited for insertion into a pressure barrel of a meat grinder.
In yet another embodiment of the invention, the insert comprises a cage-like member made up of a plurality of straight or helically extending staves affixed at their ends to rings.
When mounted within the barrel of a meat grinder such cage-like insert will provide the grooves cooperating with the smooth interior walls of the barrel for improved feeding and supporting of the material being processed.
The support system essentially absorbs axial thrust forces and the interior wall of the barrel acts as the bottom of a groove absorbing forces radially surrounding the material. The combined effect of the support system, i.e. the cage-like insert, and the barrel results in improved overall performance of pressure barrel and feed screw.
The insert is preferably positively connected to the barrel to ensure, on the one hand, an easy removability or exchangeability and, on the other hand, its secure placement and alignment within the barrel.
The apparatus in accordance with the invention makes it possible to provide basic components or barrels of relatively simple structure and to augment them with inserts of the kind herein defined selected on the basis of the number, shape and size of their channels to satisfy given operating conditions.
Thus, the apparatus in accordance with the invention advantageously provides for the adaptability of shape and arrangement of the channels and the exchangeability of the insert to suit particular operating conditions, the avoidance of abrasion in the barrel and, hence, contamination of material being processed, simple manufacture and high standards of cleanliness.
BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS
The novel features which are considered to be characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, in respect of its structure, construction and lay-out as well as manufacturing techniques, together with other objects and advantages thereof, will be best understood from the following description of preferred embodiments when read in connection with the appended drawings, in which:
FIG. 1 is a view in longitudinal section of a barrel insert inserted in the barrel of a meat grinder;
FIG. 2 is a flattened surface rendition of a pressure barrel insert in accordance with the invention;
FIG. 3 is a cross-sectional view of the embodiment of FIG. 1;
FIG. 4 is another cross-sectional view of a pressure barrel with an insert spaced therefrom by an annular gap;
FIG. 5 is a perspective view of half a shell of a barrel insert in accordance with the invention;
FIG. 6 is a longitudinal section of a cage-like embodiment of an insert;
FIG. 7 is a view, in longitudinal section, of a pressure barrel;
FIG. 8 is a cross-sectional view of the barrel of FIG. 7;
FIG. 9 is a schematic side view the basic body including a hopper; and
FIG. 10 is a frontal view of the body shown in FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, a support system 7 in accordance with the invention is removably or exchangeably mounted within the basic body of a meat grinder 1, the support system 7 being formed as an insert 2 in the pressure barrel.
The basic component for manufacturing the insert 2 preferably is a flat metal web member 5 (FIG. 2) made of a high-grade stainless steel alloyed with chromium, titanium or nickel.
The flat web member 5 is subjected to a cold-forming process to form beads 6 therein. The beads 6 are made so that, when the web 5 is formed into an insert of cylindrical configuration, they extend longitudinally along the interior wall of the insert 2 to form between them channels 3 in the interior wall.
FIG. 2 shows a portion of the web 5 provided with obliquely extending beads 6 which would form rifled or helically extending channels 3 in the barrel insert 2.
FIG. 4 depicts an advantageous embodiment of the seat of an insert 2 within the barrel 1. In this embodiment, there is provided an annular gap 4 between the interior wall of the barrel 1 and the outer wall of the insert 2.
The gap 4 serves to provide additional cooling to any material being processed in the insert, by allowing a cooling medium to be fed into it which may directly affect the material as the thickness of the wall of the insert 2 of about 1-3 mm provides for a good heat exchange.
The gap 4 may, however, also be used for installing and arranging predetermined functional elements, such as sensors for monitoring existing operating conditions. Signals derived by the sensors may be fed to a central control for evaluation and for providing signals for adjusting the process within, and operation of, the meat grinder.
As shown in FIG. 3, the cold-forming of beads 6 in the web material 5, which is efficient in terms of manufacturing and costs, makes it possible to form channels 3 of many different cross-sectional configurations which in turn affect the feeding and processing of any material in process.
The barrel insert 2 may also be formed of individual segments. It is believed that an insert made up of two semi-shells 8 is most advantageous in terms of manufacturing, utilization and sanitation.
The semi-shell 8 depicted in FIG. 5 is provided with integral channels 3, and, when matched with a second semi-shell, constitutes a complete barrel insert 2 which may be inserted into a barrel 1 in this assembled condition.
The semi-shells 8 may be secured to each other and against rotation relative to the barrel 1 of the meat grinder by a strip 9, preferably made of high-grade stainless steel, which in turn may be placed into a groove 10 provided in the interior wall of the cavity in barrel 1, and by the mutual engagement of their free elongate edge surfaces.
Securing the insert against axial displacement is accomplished at one end by the insert 2 abutting against an end surface of the barrel 1 and, at the other end, by a sleeve nut which at the same time secures the cutting set within the grinder.
This embodiment provides for a secure seating of the insert 2 within the barrel 1, and at the same time it makes it easy to remove or exchange the insert 2 since their are no additional retainers.
In large meat grinders an ejector customarily provided in such machines, may be used for removal of the insert 2.
FIG. 6 depicts a barrel insert 2 which resembles a cage. It is formed of helically extending staves 11 preferably made of high-grade stainless steel, which at their ends are fastened to rings 12;13. Metal strips 9, extending between, and connected to, the rings 12; 13 as well as to the staves 11 at their outside, impart necessary rigidity to the insert 2. As may be seen FIG. 6, the cage-like structure is dimensioned such that its outer diameter corresponds to the inner diameter of the barrel of a meat grinder housing. When in enegagement with the interior wall of the housing, the helically wound staves 11 impart the axial guidance or stabilization effect to any material necessary for its grounding or cutting, in the manner of the grooved structures described supra. In the manner discussed supra in connection with FIG. 5, the strip 9, when seated within a groove 10 in the interior wall of the barrel 1, also secures the insert 2 against rotational movement when mounted within a barrel 1.
The insert 2 may also be secured against rotational movement by providing a groove 14 in the forward ring 12, which receives a feather 15 (FIG. 7) provided in the barrel 1 for securing parts of the cutter assembly against rotation.
Removal of the insert 2 from the barrel 1 takes place either in the manner earlier described or simply by grabbing the forward ring 12 and pulling the insert 2 from the barrel 1.
In their disassembled condition the insert 2 as well as the barrel 1 may be cleaned easily. No residue of any kind will remain in or on the components. Such perfect cleanability accommodates modern standards of hygiene and health regulations.
Such standards are also accommodated by a meat grinder comprising a barrel 1 made of high-grade stainless steel and made from a web material provided with beads and shaped into a cylindrical body.
The orientation or inclination of the channels 16 resulting from the forming of the barrel 1 are circumferentially spaced in the barrel, and their cross-sectional configuration corresponds to the beads formed in the web before forming it into the substantially cylindrical barrel shape.
The channels shown are of a rounded trapezoidal cross-sectional which has proven to be advantageous for material feed as well as cleaning of the apparatus.
The channels 16 may extend in a straight configuration, or they may be extending helically; they terminate in front of the cutter assembly of a meat grinder.
FIG. 9 and 10 depict an arrangement of a hopper 17 on a barrel 1 which was found to be of particular advantage in small meat grinders.
Preferably, the beads or protrusions and, commensurately, the channels herein described, whether of straight or helical configuration, are of uniform height and width and uniformly spaced from each other. In special circumstances, they may, however, be tapered in the same direction, or the tapering may alternate between adjacent protrusions or channels.
It will be understood by those skilled in the art that certain changes and modifications may be made in any of the embodiments herein described, without departing from the scope or spirit of the invention. It is, therefore, intended that all matter herein described is to be interpreted as being exemplary only, and in no way limiting the scope of protection sought.
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An insert of substantially cylindrical configuration made of a high-grade stainless steel web for the barrel of a meat grinder is proposed which is provided with elongate members extending the length of the body of the insert and protruding into the interior thereof. Channels thus formed between the protrusions provide support for, and improve feeding of, material moved through the insert.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention generally relates to sootblowers which are used to project a stream of a sootblowing medium against internal surfaces of a combustion device. In particular, this invention concerns a hub assembly which provides sealing between a stationary sootblowing medium feed tube and a relatively moveable lance tube.
Sootblowers are used to project a stream of cleaning medium such as water, air or steam against heat transfer surfaces within a combustion device such as large scale boilers to cause slag and ash encrustations to be removed. The cleaning medium impact produces mechanical and thermal shock which causes these adhering layers to be removed. One general category of sootblowers is known as the long retracting type. These devices have a retractable lance tube which is periodically advanced into and withdrawn from the boiler, and is often simultaneously rotated such that one or more cleaning medium nozzles on the lance tube project a jet of cleaning medium tracing a helical path. In typical sootblowers, a feed tube is held stationary relative to the sootblower structure. One end of the feed tube is supplied with the cleaning medium through a poppet valve. The sootblower lance tube slidably over-fits the feed tube and its longitudinal sliding and rotational motion is controlled by a carriage. The carriage moves along a toothed rack to move the lance tube longitudinally. The sootblowing medium supplied to the feed tube in turn pressurizes the inside of the lance tube with the sootblowing medium.
To prevent the escape of sootblowing medium from any area other than the nozzles which are oriented to project the sootblowing stream in a desired manner, a packing is provided in a stuffing box between the feed tube and lance tube. This packing is typically incorporated into a hub within the sootblower carriage which is used to drive the lance tube mechanism. Various types of packing material are presently employed. In todays practice, graphite foil type packing materials are frequently used. In order to generate the desired sealing action between the hub and feed tube, it is necessary to apply an axial force on the packing material. This force is normally provided through the use of a packing gland having clamping bolts which transfer a clamping force against the packing, causing the packing to be squeezed into engagement with the feed tube and hub. As the packing material wears, the degree of initial axial force or preloading which is provided by the packing gland is often lost. This force loss can result in leakage through the packing, which is undesirable.
In order to allow a certain degree of packing wear without leakage, it is ordinary procedure that axial loads are placed on the packing at the time of adjustment which exceeds that necessary to provide proper sealing. Such excessive loads allow a degree of packing wear without causing leakage. Such excessive axial loads result in higher wearing of the packing and produces packing friction against the feed tube which exceeds that which is necessary for sealing, resulting in increased power requirements for sootblower actuation. The need to provide a desired preload on the packing is also a maintenance concern since, for many sootblowers, it is necessary to periodically, and even daily, tighten the packing gland to keep the packing from leaking.
One approach toward gaining increased life of packing without the frequent maintenance of manually setting the packing preload, is to use a compliant element such as a spring for actuation of loading of the packing. Ideally, the compliant element would be capable of a considerable degree of displacement due to packing wear while providing an actuating force transferred to the packing within a desired range. Various types of springs could potentially be used, for example, a stack of Belleville washers, coil springs or wave type springs, etc. The desired force versus displacement relationship of such springs dictates a particular free spring length. If it is desired to place a compliant element to actuate the packing in a sootblower hub, by conventional design practices, it would be necessary to provide for the ability to compress the spring from its free length as it is being installed within the hub. This requirement would dictate that the hub be sufficiently long to accommodate compressing the spring from its free length to a compressed condition at which a desired preload level is generated. Although such designs using relatively long free length springs could be incorporated into sootblower hubs, the added length of the hub necessary to initially compress the spring would constitute additional sootblower "dead space" which is of concern to boiler makers. Dead space in this context can be defined as the amount that the length of the sootblower extending from the boiler wall exceeds the distance that the lance tube is projected into the boiler.
In addition to concerns about increasing the length of the hub, live loaded spring biased packing would typically require a degree of operator skill and training in setting a desired preloaded force level. There is a constant desire to improve the reliability and repeatability of sootblower and facilitate their replacement and repair. Accordingly, the elimination of special procedures and training in packing adjustment is preferred.
In addition to the concerns expressed previously, there is a desire, when using a compliant element to load the packing material, to protect the compliant element from the hostile environment within the proximity to boiler and to shield the element from contamination and temperature extremes.
The hub assembly in accordance with the present invention provides the previously described desirable features. These features are provided by employing a novel packing gland system of the invention. One of the components is a tubular gland follower which acts on the packing through a bushing. Surrounding the gland follower is a collar which threads into the sootblower hub. Both the collar and gland follower have surfaces which engage the ends of a compression spring.
During assembly of the above mentioned components, the spring is installed and the follower and collar are forced together, compressing the spring to a level which provides the desired packing preload. Thereafter, a preload ring is installed onto the gland follower which abuts against the collar preventing these parts from becoming separated and maintaining the spring in a compressed state even before the packing gland is installed into the hub. This design enables the packing gland to be mounted into the hub, and once the elements are properly positioned with the gland follower engaging the packing bushing, the preload ring can be disengaged from the collar, allowing the spring preload to be transferred into the packing.
The hub design of this invention reduces the hub length which would otherwise be required for preloading a loading spring, and also provides a protected environment for the spring. Moreover, the system enables the packing gland to be preassembled with a desired preload level thus reducing the chance of incorrect usage or maladjustment in the field. This invention further provides improved packing performance, reduces maintenance, and improves cycle life. The features of this invention are further readily adaptable to existing sootblowers, providing retro-fit capability.
Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from the subsequent description of the preferred embodiments and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a long retracting sootblower of the type which may incorporate the hub assembly of the present invention.
FIG. 2 is a cross sectional view taken through the hub assembly of the carriage of FIG. 1 showing the elements which comprise the hub assembly of this invention, illustrated in an initially assembled condition.
FIG. 3 is a partial cross sectional view, showing the preload ring and collar disengaged when the sootblower is in an operating condition in a finally assembled condition.
FIG. 4 is a side view of the preload ring of the hub assembly of this invention.
DETAILED DESCRIPTION OF THE INVENTION
A representative sootblower which may incorporate the features of the present invention is shown in FIG. 1 and is generally designated there by reference number 10. Sootblower 10 principally comprises frame assembly 12, lance tube 14, feed tube 16, and carriage 18. Sootblower 10 is shown in its normal resting position. Upon actuation, lance tube 14 is extended into and retracted from a combustion system such as a boiler (not shown) and may be simultaneously rotated.
Frame assembly 12 includes a generally rectangularly shaped frame box 20 which forms a housing for the entire unit. Carriage 18 is guided along two pairs of tracks located on opposite sides of frame box 20, including a pair of lower tracks (not shown) and upper tracks 22. The tracks are made from angle iron stock which are connected to frame box 20 by threaded fasteners or welding. A pair of toothed racks (not shown) are rigidly connected to the upper tracks and are provided to enable longitudinal movement of carriage 18. Frame assembly 12 is supported at a wall box (not shown) which is affixed to the boiler wall or another mounting structure and is further supported by rear support brackets 24.
Carriage 18 drives lance tube 14 into and out of the boiler and includes drive motor 26 and gear box 28 which is enclosed by housing 30. Carriage 18 drives a pair of pinion gears 32 which engage the toothed racks to advance the carriage and lance tube 14. Support rollers 34 engage the guide tracks to support carriage 18.
Feed tube 16 is attached at one end to rear bracket 36 and conducts the flow of cleaning medium which is controlled through the action of poppet valve 38. Poppet valve 38 is actuated through linkages 40 which are engaged by carriage 18 to begin cleaning medium discharge upon extension of lance tube 14, and cuts off the flow once the lance tube and carriage return to their idle retracted position, as shown in FIG. 1. Lance tube 14 over-fits feed tube 16 and a fluid seal between them is provided by a packing. The details of the packing and the hub which retains it are principle aspects of the invention and are described in more detail below.
Coiled electrical cable 42 conducts power to the drive motor 26. Front support bracket 44 includes bearings which support lance tube 14 during its longitudinal and rotational motion. For long lance tube lengths, an intermediate support 46 may be provided to prevent excessive bending deflection of the lance tube. Additional details of the construction of the well-known design of "IK" types of sootblowers manufactured by assignee can be found with reference to U.S. Pat. Nos. 3,439,367 and 4,803,959, which are hereby incorporated by reference.
Now with specific reference to FIG. 2, the hub assembly according to this invention is shown which is generally designated by reference number 50. Hub assembly 50 is located within carriage 18 and is employed to drive lance tube 14 through its longitudinal and rotational movement. Hub assembly 50 is driven for rotation through bevel gear 52 and is supported by bearing assemblies 54 and 56 which support the hub assembly relative to carriage structure 58. Bevel gear 52 is driven by meshing with one or more additional gears within carriage 18 in a manner as described in assignees previously issued U.S. Pat. No. 4,803,959. Hub shell 60 is a generally tubular element having external surfaces for engaging bearing assemblies 54 and 56, and bevel gear 52. At the left hand axial end of hub shell 60, as shown in FIG. 2, external threads 62 are provided. Meshing with these threads is lance tube mounting collar 64. Lance tube mounting collar 64 is provided for connecting hub 60 to lance tube ring 66 which is welded to lance tube 14. Bolt 68 fastens the two elements together.
Internal features of hub shell 60 are provided to accommodate additional components of this invention. An internal cylindrical area defines stuffing box 70 which accommodates packing 72. A front bushing 74 has an externally stepped surface which engages with similar formations within hub shell 60, which prevents the bushing from being moved in the left hand direction from its position shown in FIG. 2. Rear bushing 76 is provided at the opposite axial end of packing 72 and combines with front bushing 74 to apply an axial compressive load onto packing 72. Packing 72 may be comprised of numerous types of packing material. One packing system in use today comprises a number of individually formed rings 78 of graphite foil material having conical end surfaces. End rings 80 and 82 are provided to "square up" the axial ends of the packing to engage flat against the bushings.
In accordance with this invention, a live loading packing gland 84 is provided which produces an axial force upon packing 72. Packing gland 84 principally comprises gland follower 86, collar 88, spring 90, and preload ring 92.
Gland follower 86 is a generally tubular element and has a radially projecting shoulder 96 near one end, and an externally threaded opposite end surface 98. Gland follower 86 engages rear bushing 76 and fits within bushing groove 102. The engagement between the two components can be an interference fit.
Collar 88 is also a tubular element which has external threads 110 which mesh with internal hub threads 104. Collar 88 overfits and surrounds gland follower 86, and is capable of axial movement relative to the gland follower. Collar 88 also defines a radially inward extending shoulder 112. One end of collar 88 is knurled and has a number of notches 115 at regularly spaced positions around the periphery of the collar which are provided for engagement by a spanner wrench (not shown). Collar 88 also includes axial threaded bores 116 which accommodates threaded set screws 118 which is provided to prevent the collar from rotating relative to hub shell 60 once installed.
Compression spring 90 is installed in the cavity bounded by gland follower 86 and collar 88 and can be of numerous types. However, these inventors have found that a wave spring configuration is well adapted for incorporation into the hub of this invention. Spring 90 acts upon radial shoulders 96 and 112 to exert a packing actuation force. It should be appreciated that although a wave type spring is illustrated, numerous other spring types could be employed in supplementing this invention such as conventional coil springs or Belleville washer stacks. In addition, it is conceivable that a number of small diameter coil springs could be used placed side-by-side around the periphery of the spring cavity.
Preload ring 92 has an internally threaded surface 122 which meshes with gland follower external threads 98. Preload ring 92 further includes a threaded bore 124 which receives set screw 126. Like collar 88, preload ring 92 defines external notches 128 at regularly spaced circumferential intervals which enable engagement and rotation using a spanner wrench.
In order to achieve the desired force versus deflection characteristics of spring 90, its free length must necessarily be long as compared with its compressed condition as illustrated in FIG. 2. In accordance with this invention, packing gland 84 enables spring 90 to be maintained in a compressed state even before packing gland 94 is installed into hub 60. During assembly of packing gland 84, spring 90 is compressed to the extent that preload ring 92 can be threaded onto gland follower threads 98. The packing gland 84 is thus a self-contained sub-assembly which restrains spring 90 in a preloaded state. In this condition, packing gland 84 can be installed simply by threading it into hub shell 60, preferably using a spanner wrench engaging collar 88. This threading is continued until gland follower 86 makes solid contact with the stacked assembly comprising the front and rear bushings 74 and 76, and packing 72. Throughout this installation process, preload ring 92 remains in contact with collar 88 under the influence of spring 90. However, once packing gland 84 is installed, preload ring 92 may be unscrewed so that it is no longer in engagement with collar 88. Once in this position, a locking screw 118 can be positioned to prevent the packing gland from inadvertently being unthreaded from hub shell 60. As preload ring 92 is backed off, the load exerted by spring 90 is transferred into packing 72. Preload ring 92 no longer serves a function during sootblower operation and can, therefore, be entirely removed. However, it is desirable to maintain preload ring 92 in an assembled condition on gland follower 86 so that it can be used to facilitate removal of the packing gland 84, for example, to replace packing material 72 or to install an additional packing ring 78.
To prevent complete removal of preload ring 92, a weld bead or deformation of gland follower threads 98 can be provided so that the preload ring cannot be entirely removed. This would also perform the important function of preventing tampering of the internal components of gland follower and more importantly, would prevent the energy stored in spring 90 from being suddenly released.
As is evident from the above description of the invention, since spring 90 is maintained in a preloaded condition, it can have a free length which is considerably greater than that which could be accommodated by the actual length of gland follower 86. Moreover, since spring 90 is maintained in a preloaded condition, it is not necessary to thread a spring actuating member along a long length of threads to achieved the desired preload. Rather, packing gland 84 can be easily installed and removed without being subjected to the forces exerted by the spring. Another advantageous feature of the hub assembly 50 of this invention is that it provides a relatively protected environment for spring 90 which, as is shown in the figures, is enclosed by cylindrical walls, both around its inner-diameter and outer-diameter. Yet another feature is the visual indication of packing wear which packing gland 84 provides. An operator can readily observe the separation between collar 88 and a fully backed-off preload ring 92 to determine the stacked length or wear of the packing 72.
While the above description constitutes the preferred embodiments of the present invention, it will be appreciated that the invention is susceptible of modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.
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A sootblower hub having packing for sealing between a sootblower feed tube and lance tube. A packing gland is used which provides a live loading feature for exerting an axial force on the packing. The packing gland is comprised of elements which can be separately assembled in a manner which maintains a preload on the packing loading spring, even when it is disassembled from the sootblowing mechanism. Once the packing gland is installed into a sootblower carriage a preload maintaining member can be actuated to enable the axial loading force created by the spring to be transferred to the packing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to German Application No. 10 2010 013 298.5, filed Mar. 29, 2010, which is hereby incorporated by reference in its entirety.
FIELD
[0002] The disclosure relates to a method for producing and/or adjusting an optical arrangement of a projection illumination system, in which at least one actuator is used to set the position of at least one optical element to be manipulated by moving the optical element incrementally with a specific increment size.
BACKGROUND
[0003] Projection illumination systems are used for the microlithographic production of microelectronic devices, in particular semiconductor devices or devices for micro- and nanotechnology. In order to produce structures with very small dimensions, it is desirable to image the structures in the projection illumination system with a high degree of accuracy. Even the smallest changes in the optical elements used in the projection illumination system with respect to their form, composition or their position in the optical arrangement can result in corresponding aberrations and thus to defectiveness of the devices to be produced.
[0004] Accordingly it is known to use methods for positioning and/or adjusting optical elements in optical arrangements of a projection illumination system, which methods conform to the highest desired properties in terms of the accuracy of the positioning. DE 102 25 266 A1, for example, describes an imaging apparatus of a projection illumination system for microlithography, in which manipulators with piezoactuators are used in order to manipulate and position relevant optical elements, such as for example optical lenses, mirrors or the like.
[0005] The disclosure of DE 102 25 266 A1 and of U.S. Pat. No. 6,150,750, which describes piezoactuators in the form of linear piezo drives, are incorporated by reference herein in their entirety.
[0006] Although a very exact positioning of optical elements is already possible with the linear piezo drives, as they are described in the previously mentioned documents, there is furthermore a desire for efficient operating methods which enable, in addition to simple and effective operation of the manipulators, at the same time extremely exact positioning with a high degree of accuracy.
[0007] It has been shown that the fact that the movement of the linear piezo drives and/or the movement of the optical elements which are moved thereby or of the gear elements such as actuating levers or the like which are possibly provided between the optical element to be manipulated and the linear piezo drive is delimited by abutment elements results in interactions with the abutment element possibly resulting in influences on the optical element. When the abutment element comes into contact in the peripheral movement region of the manipulation apparatus, the optical element can be negatively affected with corresponding negative effects on the imaging properties. It is desirable for this reason to use a corresponding positioning method which takes into account these possible negative influences.
SUMMARY
[0008] The disclosure seeks to provide a method for producing, setting and/or adjusting an optical arrangement, in particular for positioning an optical element in an optical arrangement of a projection illumination system, in which exact positioning is possible in a simple and effective manner by way of incremental movement of the optical element. In addition, a negative influence of abutment elements, which delimit the movement region, is intended to be avoided.
[0009] The disclosure proceeds from the knowledge that for exact and effective positioning of an element in an optical arrangement of a projection illumination system, in the case of an incremental movement of the optical element by at least one (preferably more than one) actuator (such, as for, example piezoactuators, and preferably linear piezo drives), the problems described above can be solved in a simple manner by setting the increments and by detecting the deviation from a pre-specified increment size.
[0010] Accordingly, according to a first aspect of the present disclosure, the incremental movement of the optical element is intended to be performed such that the increment size is set as a function of the distance of the optical element from the desired position, with the distance of the optical element from the desired position being represented by a distance value. This distance value can be given by a simple displacement value or by a displacement vector, which additionally gives the corresponding directions. In particular it is possible, however, preferably when using a simple one-dimensional displacement value as the distance value, that the disclosure (as will be described below for example for an individual linear piezo drive) is designed for a plurality of linear piezo drives at the same time, which linear piezo drives are responsible for the movement in different independent spatial directions, such as for example in the directions of the X-, Y- and Z-axes of a Cartesian coordinate system.
[0011] According to the disclosure, the increment size for approaching the optical element to be manipulated from an instantaneous position to a desired position should initially be set as a constant increment size, for example the maximum increment size of the actuator, as long as the distance value is above a first threshold value. If the distance value is below the threshold value, the increment size is reduced in accordance with the decrease of the distance value. Owing to the first approaching movement with a constant, especially maximum, increment size up to a first threshold value, a fast approaching movement to the desired position can take place. Once the distance value falls below the first threshold value, the increment size is reduced in order to enable an exact approaching movement to the desired position. Exact positioning can be carried out by way of repeated performance of the corresponding approaching cycle with a check of whether the distance value is below or above the first threshold value, that is to say what the instantaneous position relative to the desired position is, and of a corresponding performance of the movement increments according to the result of the check.
[0012] According to a further aspect of the present disclosure (which can be implemented itself and/or in conjunction with the first aspect of the disclosure noted above), a deviation of the increment size from the pre-specified increment size and/or the deviation of an increment size change rate from a pre-specified increment size change rate, that is to say the deviation of the movement velocity from a pre-specified movement velocity or the deviation of a movement acceleration or deceleration from a pre-specified movement acceleration or deceleration, is used as an indication of the optical element approaching an abutment element, such that either an appropriate warning signal can be emitted and/or the movement can be stopped. If the optical element is moved by the manipulators into the region of an abutment element, an additional movement of up to a size range of 0.5 μm can take place due to appropriate matching processes after first contact of the optical element, or the actuator and gear devices that are connected in-between, before the final physical stop of the optical element occurs. However, negative effects on the optical element are assumed from the very first contact, and therefore this first contact can already be determined by the method according to the disclosure.
[0013] Accordingly, this advantageous method can also be used independently of an actual positioning and/or adjustment of an optical element for ascertaining the movement region. In this case, the movement in the direction of the abutment element is performed with a pre-specified or maximum increment size until first contact can be ascertained on the basis of the deviation of the increment size or the increment size change rate from pre-specified values. In other words, with a pre-specified constant movement velocity, that is to say a constant increment size per movement increment, the deviation from this constant movement velocity outside a pre-specified acceptable range can be taken as an indication of a contact with the abutment element, such that this first contact point can already be used to determine the end of the movement region.
[0014] In the method according to the disclosure for the production and/or adjustment of an optical arrangement of a projection illumination system, the movement increments can be performed repeatedly, wherein individual approaching cycles can contain a plurality of movement increments or individual movement increments. The approaching cycles can be performed repeatedly until the desired positioning is achieved.
[0015] Moreover, a control loop and at least one position sensor, preferably a plurality of position sensors, in particular capacitive position sensors, can be provided, wherein a corresponding distance value can be ascertained by way of ascertaining the instantaneous position of the optical element to be manipulated using the position sensors and comparing it to the desired position, which distance value can in turn serve the control loop for the determination of the increment size in the next approaching cycle or in the next movement increment. Alternatively, the distance value can also be input directly, if no position sensors are available and the distance value can be ascertained by another mechanism.
[0016] The first threshold value can be in particular be given by the maximum increment size of the actuator or actuators. Accordingly, it is possible, if a distance value is above this first threshold value, to always perform a movement increment with the maximum increment size of the actuator, without running the risk of going beyond the desired position.
[0017] If a distance value is below this first threshold value, it is possible to perform a movement increment with a correspondingly reduced increment size as a function of the distance value.
[0018] The positioning method according to the disclosure can be supplemented by determining a second threshold value that corresponds to a distance value which is greater than the first threshold value. If the distance value, which is input into the system or determined by the control loop or the position sensors, of the actual position of the optical element from the desired position is greater than the second threshold value, a first approaching movement can take place by way of the distance value being reduced by a specific factor and by way of a plurality of movement increments with maximum increment size being performed in accordance with this reduced distance value, which results in a position, which corresponds to the reduced distance value, being reached or approached. Reducing the distance value by a specific factor in turn ensures that the desired position is not overshot.
[0019] If the distance value is below the second threshold value, a second phase of the approaching movement can occur, in each case by way of a movement increment with maximum increment size being performed until the first threshold value is reached.
[0020] The real behavior, or non-ideal behavior, of the manipulator or of the actuators can be taken into account by the actually traveled section of the previous movement increment and/or the pre-specified increment size of the previous movement increment being used as the input variables for determining the increment size of the next movement increment. In this manner it is possible to take into account the actual and under certain circumstances different conditions for various actuators in the method, which results in an improved positioning accuracy and effectiveness of the positioning method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Other advantages, characteristics and features of the present disclosure will become apparent in the following detailed description of an exemplary embodiment with reference to the appended drawings. Here, the drawings show, purely schematically,
[0022] FIG. 1 a distance time graph, the time being plotted as increment numbers; and
[0023] FIG. 2 a velocity time graph, the time again being plotted as increment numbers.
DETAILED DESCRIPTION
[0024] According to an embodiment of the present disclosure, an optical element is positioned by way of the optical element incrementally approaching the desired position. To this end, first the instantaneous position of the optical element is determined, with the result that a distance value can be ascertained from a comparison between the instantaneous position and the desired position. The distance value can in this case include a pure displacement value or a plurality of displacement values and also directional information in the manner of a distance vector.
[0025] According to an exemplary embodiment of the disclosure, a check is carried out in a first step whether the distance value is above a second threshold value, that is to say if the instantaneous position is further removed from the desired position than the second threshold value. In this case, the distance from the instantaneous position to the desired position is thus still so great that initially a further approaching movement toward the instantaneous position is desirable. This is performed in that the distance value is reduced by a specific factor, for example is multiplied by the factor 0.8 or 0.6, and, in accordance with this reduced distance value, the number of movement increments with maximum increment size of the actuator or actuators to be used is ascertained, which are desired to travel the reduced distance value. If, for example, the distance of the instantaneous position from the desired position is set to 40 μm and the second threshold value is set to 30 μm, then following a multiplication of the distance value 40 μm by the factor 0.6, the reduced distance value 24 μm is ascertained. As a result, for a maximum increment size of 3 μm for a movement increment, eight movement increments with an increment size of in each case 3 μm are performed. If the movement increments were performed according to the theoretical values, the optical element to be positioned and manipulated would thus approach the instantaneous position to a distance of up to 16 μm. However, since the real performance of the movement increments can contain deviations, the actual instantaneous position can deviate from the theoretical instantaneous position, with the result that a distance value greater or smaller than 16 μm is conceivable for the next approaching cycle.
[0026] Accordingly, in the next approaching cycle, first the actual instantaneous position is ascertained using position sensors. Any sensors which are suitable for ascertaining the actual position can be used as position sensors, in particular capacitive sensors, for example.
[0027] From this ascertained second instantaneous position, a distance value, which can now be 16.5 μm, for example, is determined in turn for the second approaching cycle. This second distance value of the second approaching cycle is below the second threshold value of 30 μm, such that no plurality of movement increments with maximum increment size is performed in the second approaching cycle anymore, but only one individual movement increment. However, first a check is carried out whether the distance value of 16.5 μm is above or below the first threshold value. For a maximum increment size of the actuator of 3 μm, the first threshold value can be fixed at 3 μm. Accordingly, for the second approaching cycle, the second distance value of 16.5 μm is above the first threshold value, and therefore a movement increment with maximum increment size of 3 μm is performed. Theoretically this leads to an approaching movement through 3 μm in the direction of the instantaneous position, with the result that the distance value should now be 13.5 μm. However, it is again possible for the real movement increment to deviate here, with the result that once more the actual instantaneous position is determined using the position sensor(s).
[0028] Further approaching cycles are performed below, wherein the current distance value is repeatedly determined and compared to the first threshold value. As long as the current distance value is greater than the first threshold value, in each case a movement increment with the maximum increment size of 3 μm is performed. However, as soon as the ascertained distance value is below the first threshold value in an approaching cycle, the increment size of the movement increment to be performed is adapted accordingly, that is to say reduced. In this form, further approaching cycles are performed until the ascertained instantaneous position of the optical element is within a pre-specified deviation range which is tolerated and permissible. The positioning of the optical element during production or setting of a corresponding optical arrangement and the corresponding adjustment of the optical element in the optical arrangement is then complete.
[0029] In the preferred exemplary embodiment, piezoactuators, in particular linear piezo drives, are used as the actuators, such as are described, for example, in DE 102 25 266 A1 and U.S. Pat. No. 6,150,750 A. The entire disclosure of each of these documents is incorporated herein by reference.
[0030] The piezoactuators are actuated via the application of specific stresses, in particular shear stresses, such that the procedure described above for specific distances and path sections or increment sizes can also be performed on the plane of the stresses to be applied. This means that a stress value for the actuation of the piezoactuator can be ascertained directly from the distance value, for example, which can correspondingly likewise be changed in accordance with the preceding description.
[0031] In an exemplary embodiment according to the disclosure, a non-ideal behavior of the manipulator or actuator can be taken into account by incorporating the section of the last movement increment into the calculation of the next movement increment.
[0032] In addition, in particular in the last phase of the approaching movement in the direction of the desired position, the set increment size of the last movement increment or the set stress value can be stored for the actuation of the piezoactuator and used to calculate the increment size of the next movement increment or the corresponding stress value, for example as a corresponding start value.
[0033] In this way it is possible to realize a reliable and exact approaching movement or setting of the optical element in the desired position using the method according to the disclosure.
[0034] Furthermore, a corresponding control loop can be realized, which uses the instantaneous positions of the object to be manipulated, as ascertained by position sensors, for determining the movement increments to be performed. A corresponding control loop can be realized by way of known electrotechnical/information-technological embodiments.
[0035] A corresponding manipulation or positioning of an optical element should typically be performed such that the optical element to be manipulated can be moved freely. However, in most cases the movement region of the optical element is delimited, wherein abutment elements, which delimit the movement region, can be provided for the optical element or the corresponding actuators or gear devices connected thereto such as actuating levers and the like in order to avoid damage and the like.
[0036] In this case it can happen that the desired position to be set is located near an abutment. If contact with an abutment element takes place, what are referred to as parasitic defects can be introduced into the optical element in this way, which can lead to a worsening of the imaging behavior, such as astigmatism, tilting of the optical element and so on. These defects can in particular already be produced upon first contact with the abutment although the optical element can still travel a limited section, such as a distance of 0.5 μm or the like. Accordingly, it is important to ascertain the location or the time of first contact with an abutment element even before the final stop position of the optical element or of the actuator apparatus at the abutment element (abutment position) in order to prevent further movement of the optical element in the direction of the abutment element and thus avoid the introduction of corresponding defects.
[0037] This is shown in FIGS. 1 and 2 . FIG. 1 shows a distance time graph, in which an optical element is moved using a piezoactuator with maximum increment size in the direction of an abutment. The distance time graph initially has a linear region, in which the optical element can move freely and the corresponding effects on the optical element and thus the defect generation is low. A correspondingly linear region is present up to an increment number 20.
[0038] From first contact of the optical element or the actuators or corresponding gear devices with the abutment element, the movement velocity changes, that is to say the increment size per movement increment up to the final stop of the movement. The movement velocity or the increment size per movement increment accordingly resets to 0. In this second region of the reduced movement velocity, however, an interaction with the optical element takes place already, which can lead to what is referred to as parasitic defects and the worsening of the imaging properties. Accordingly, and according to a second aspect of the present disclosure, the first contact point of the optical element or the actuators or corresponding gear devices with an abutment element is determined during the production or setting or adjustment of an optical element or an optical arrangement in a projection illumination system and/or independently thereof in a separate method in order to delimit the movement region accordingly and to avoid the influencing of the optical element which can lead to parasitic defects.
[0039] This can be determined in particular with the aid of a velocity time graph, as is shown in FIG. 2 . Here, the increment size is plotted against the increment number, resulting in a velocity time graph. In the linear region, the velocity is constant, for example at a value of 0.03 μm, as shown in an exemplary embodiment. As soon as an interaction with the abutment element occurs, the increment size or the movement velocity changes, for example by departure from a pre-specified velocity range, so that the first contact point can be simply determined in terms of space or time. In the same way, it would also be possible to use an acceleration time graph for ascertaining the first contact point, which graph would result from the differentiation of the velocity time graph with respect to time.
[0040] In the graph in FIG. 2 , accordingly an upper and a lower threshold are given, which specify the permissible deviation of the increment size. If the increment size deviates beyond these thresholds, contact with the abutment element is accordingly assumed.
[0041] The method for determining the first contact of an optical element to be manipulated with an abutment element can be performed both separately, as is shown in FIGS. 1 and 2 , or can be integrated in the above method for positioning an optical element. In a separate embodiment, the optical element is preferably moved with maximum increment sizes in the direction of the abutment element until the contact with the abutment element is ascertained by way of the ascertained change in the increment size or the velocity or the change in the acceleration or the increment size change rate.
[0042] In the case of integration into the positioning or adjustment method, the detection, according to the disclosure, of the deviation of the movement velocity or acceleration or deceleration beyond a pre-specified value can be used as a warning signal of interaction with an abutment element for alerting the operator and/or avoiding any further movement.
[0043] It is possible in this way using the method according to the disclosure to perform very exact positioning of an optical element and to avoid the introduction of undesired defect sources.
[0044] Although the present disclosure has been described in detail with reference to exemplary embodiments, it is self-evident for a person skilled in the art that the disclosure is not restricted to these exemplary embodiments but rather that modifications are possible of the kind such that individual features can be omitted or the features can be used in different combinations, as long as there is no departure from the scope of protection of the appended claims. In particular, the present disclosure includes all combinations of all the disclosure features presented.
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The present disclosure relates to a method for the production and/or adjustment of an optical arrangement of a projection illumination system, in which at least one actuator is used to set the position of at least one optical element to be manipulated by moving the optical element incrementally with a specific increment size. The increment size of the movement increments is set as a function of the distance of the optical element from the desired position, with the distance being represented by a distance value. If the distance value is above a first threshold value, a substantially constant increment size is set, while the specific increment size decreases as the distance from the desired position decreases if the distance value is below the first threshold value. Alternatively or additionally, a pre-specified deviation from the specific increment size and/or from a pre-specified increment size change rate results in a warning signal and/or ceasing of the movement.
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PRIORITY CLAIM
[0001] This application is a continuation of U.S. patent application Ser. No. 12/579,763 filed on Oct. 15, 2009 which claims priority from earlier filed U.S. Provisional Patent Application Ser. No. 61/106,531 filed Oct. 17, 2008. The foregoing applications are hereby incorporated by reference in their entirety as if fully set forth herein.
COPYRIGHT NOTICE
[0002] This disclosure is protected under United States and International Copyright Laws. © 2008-2009 BioTech Data Systems, Inc. All Rights Reserved. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure after formal publication by the USPTO, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
Reference To Appendix
[0003] This application includes a computer program listing appendix filed on a compact disc as a text file entitled “code.txt” (0.99 MB, created Oct. 17, 2008). The computer program listing appendix is incorporated herein by reference.
FIELD OF THE INVENTION
[0004] This invention relates generally to system and method of technology data management more specifically, related to the aggregation and management of data generated during the various stages of research, development, technology transfer, and commercialization of new therapies, compounds, and compositions, and more specifically within a regulatory submission framework. Research fields to which this invention pertains include but are not limited to, Pharmacology, Agro-Technology, Bio-Chemistry, Bio-Control, Bio-Dynamics, Bio-Engineering, Biology, Bio-Materials, Bio-Technology, Bio-Medical Engineering, Bio-Medical Systems, Bio-Molecular Engineering, Bio-Physics, Cell Biology, Ecology, Environmental Sciences, Genetics and Genomics, Molecular Biology, Nanotechnology.
BACKGROUND OF THE INVENTION
[0005] Biotechnology and other related research endeavors generate tremendous amounts of data at a rate which has never been seen in any other discipline of science. One of the biggest issues in research and development relates to the difficulties in organizing the vast amounts of rapidly generated data, channeling that data to the appropriate parties for review, and reviewing the information in an actionable manner. The common data generating systems in which scientists and researchers operate are generally free-form. For example, a local-area network in a research institute consists of information producers (researchers, scientists and staff) who enter information in an arbitrary format, using any of the commonly-available or proprietary applications programs, such as word processors, spreadsheets, databases etc. The lack of a unified and integrated data management structure leads to increases in time and expense in the research pipeline and often results in unfinished, lost, and/or unanalyzed results, duplicative efforts amongst research teams, underreporting of failed experimental attempts, missed collaborative opportunities, and the like.
[0006] One previous approach to dealing with some of the issues in the research sphere includes Microsoft Dynamics AX for Life Sciences data management including systems to manage financial processes, in particular, those designed to shorten the budget cycle and generate accurate financial forecasts using budgeting and forecasting tools. Microsoft Dynamics AX for Life Sciences also addresses regulatory compliance initiatives with a framework for storing, categorizing, and searching compliance documents, tracking document modifications, and ensuring that managers have the necessary data and materials to maintain compliance.
[0007] Other examples of similar solutions include Siemens Teamcenter® for Medical Devices which teaches unifies the entire medical devices product lifecycle from product ideation through product retirement. The Teamcenter® solution takes a holistic approach to compliance management that captures, manages, tracks and reports on a medical device's regulatory requirements as these requirements evolve across a product lifecycle that includes an enterprise's design, manufacturing, test and service operations.
[0008] TranSenda Office-Smart Clinical Trial Manager™ solutions are another category of software which is basically the result of blending a clinical study application with the Microsoft® Office System. To make Clinical Trial Manager™ “Office-Smart”, TranSenda has taken a “line-of-business” (LOB) application—in this case a clinical trial management system (CTMS)—and optimized it to interoperate with the Microsoft Office System in ways that make the most sense for study professionals. Microsoft® calls a solution that connects LOB applications, systems, processes and people with the familiar Microsoft® Office interface an Office Business Application (OBA). Office-Smart Clinical Trial Manager is essentially an OBA-based CTMS.
[0009] Another approach is exemplified by Ross Enterprise approach which incorporates a series of Enterprise Resource Planning applications, Supply Chain Planning (SCP) applications, Supply Chain Execution (SCE) applications, Customer Relationship Management (CRM) applications, and Enterprise Performance Management (EPM) applications.
[0010] Prior approaches however have collectively failed to address problems related to pipeline data management in the research and development sectors and specifically the provision of real-time data awareness at the executive level. As a group, the expense of implementation prohibits emerging companies from appropriately leveraging technologies such as social networking and community feedback techniques to research and development cycles, resulting in ad hoc data management at critical time-points in the development lifecycle when a cohesive strategy is most beneficial.
[0011] In addition, prior approaches have failed to effectively aggregate all of the critical data, by focusing on one part or another of the business process. As a result, the body of knowledge is often incomplete not actionable, and multiple data points must be referenced in order to compile an accurate representation of the data in question.
[0012] What is needed is a system and method to enable all users in a research and development pipeline with real-time interactive functionality that aggregates a body of knowledge and provides interaction amongst working groups irrespective of the geographical location of the working groups. This is increasingly important as companies look to outsourcing enterprise processes to help defray rising development costs.
SUMMARY OF THE INVENTION
[0013] A system and method that supports Enterprise Resource Planning, Laboratory and Research Management, Product Lifecycle Management, Decision Support Management, Regulatory Document Management, and all internal corporate documents and data into a single, Web-based extranet, which is a repository for the complete, real-time Body of Knowledge of an organization.
[0014] An embodiment of the present invention comprises a BioTech Data Portal (BTDS) system for collaboration between researchers and management facilitating critical decisions regarding research and company direction to be made at the executive level, based on real-time data awareness, based on data entry by a researcher.
[0015] In accordance with some examples of the invention the BTDS system can be a company-wide resource, allowing personnel to share data and access a complied and aggregated body of knowledge, which can be inclusive of in-house and/or institutional knowledge irrespective of the geographical location of the personnel.
[0016] In accordance with an exemplary embodiment of the invention, Web 2.0 Social Networking and Community Feedback methods can be applied to clinical research and development cycles, allowing rich collaboration between participants.
[0017] In accordance with still further examples of the invention Real-time data awareness at the Executive level can be accomplished by combining comprehensive data-monitoring and customizable threshold-based alerts with email and Instant Message notification into the BTDS RDA (Rapid Data Awareness) system.
[0018] In accordance with still further examples of the invention mobile-device User Interfaces enable personnel to access critical information from different geographical locations. These features in tandem with the above-mentioned data awareness functionality can provide a method for informing critical business decisions at the highest levels of an organization, based on real-time data generated at any point of the company's business process.
[0019] In accordance with still further examples of the invention, a Fluid Assay Builder (FAB) allows research personnel to create custom assay datasets and input interfaces created when needed and/or responsive to user, eliminating the need for specialized programming knowledge when initializing a new assay in the laboratory environment.
[0020] In accordance with still further examples of the invention, Drag & Drop functionality allows word-processing, and/or data-handling documents (e.g., spreadsheets), for example, but not limited to, Microsoft® Office Excel documents to be imported easily into the FAB, creating relational datasets and user interfaces based on legacy document files.
[0021] In accordance with still further examples of the invention a BTDS Lab-Toaster laboratory instrument interface allows for data output from laboratory and/or research instruments and/or devices to be transformed into an XML document corresponding to an electronic common technical document (eCTD) specification for inclusion in the regulatory process, for example, submission to government agencies such as the U.S. Food and Drug Administration, for approval procession.
[0022] In accordance with still further examples of the invention the BTDS AutoCTD component can assemble and compile a complete eCTD for electronic submission to regulatory agencies with the click of a button.
[0023] In accordance with still further examples of the invention the BTDS LAB-IP system automatically compiles an XML-based document from compound genesis data to be used in the Intellectual Property protection process. Used in conjunction with the RDA component, LAB-IP can notify legal personnel when a new compound is ready to enter the IP protection process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:
[0025] FIG. 1 is a flowchart of a “Chemistry LAB-IP”, “Rapid Data Awareness (RDA) module, and “Lab-Toaster Data Capture Process” module of an exemplary embodiment of the BioTech Data Portal (BIDS) system;
[0026] FIG. 2 is flowchart of a “Biology” module inclusive of a “Fluid Assay Builder (FAB)” module and a “Assay Data Entry Process” module of an exemplary embodiment of the BioTech Data Portal (BTDS) system;
[0027] FIG. 3 is flowchart of an “Inventory & Supply Management” module inclusive of an “User Interaction with Inventory Objects” module of an exemplary embodiment of the BioTech Data Portal (BTDS) system; and
[0028] FIG. 4 is flowchart of a “Regulatory Document Management” module of an exemplary embodiment of the BioTech Data Portal (BIDS) system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The BioTech Data Portal (BTDP) system combines a wide array of research and development, regulatory, and business process data into a single repository, accessible through a comprehensive Web-based user interface in a controlled environment. The following describes an exemplary application of the BTDP in an emerging pharmaceutical research and development organization. It is to be understood that the modules are integrated and interactive between the different components and therefore the steps in the exemplary embodiment described here can be applied in a logical and fluid order, although not necessarily in the order described in the exemplary embodiment described herein.
[0030] In an exemplary embodiment as is shown in FIG. 1 a LAB-IP System for the chemistry research and discovery workflow module, is described, inclusive of the preliminary steps of compound synthesis and formulation, through validation.
[0031] In an exemplary embodiment, as is shown in “Lab-Toaster Data Capture Process” compound synthesis can be contracted to a 3rd party vendor. Following compound creation, the chemists can log the compound structure, composition, and production notes into a legacy desktop-based application. This application provides compound modeling functionality, and serves as a replacement for paper-based data storage.
[0032] As described and in this exemplary embodiment, a legacy application can be deployed on a server, located, for example, in the laboratory where the work is performed, creating a data silo, which in an example can be inaccessible to anyone outside the laboratory working group. Report generation in the BTDS system can decrease the amount of time from the formulation steps to the analysis by downstream researchers and/or users of the system by eliminating the manual assembly and delivery of reports to the appropriate personnel.
[0033] Referring again to the LAB-IP module, entering and/or storing the data from compound synthesis into the BTDS system can trigger an automated data import and alerting process in the Rapid Data Awareness (RDA) subsystem. For example, the data import process can be initiated by the RDA alert system which can monitor the legacy database for creation and update events. When an update or creation event is triggered the agent monitoring the chemistry software sends a data package containing the updates to the BTDS central data repository. Such changes in the BTDS can for example, be automatically accepted into the BTDS system, and/or reviewed and accepted on a case by case basis. A user who is responsible for managing the compounds can be notified on an interval basis on the number of changes that have occurred in the system since their last login. This approval and import system can also have an audit trail for each transaction approved into the system.
[0034] In an exemplary embodiment the BTDS system can implement a Web Service, built on Microsoft Windows Communication Foundation (WCF), to handle importing compound data into the central data repository. Data sent from the agent to the central service is encrypted using a PKI (Public Key Infrastructure) encryption scheme and transmitted using a 128-bit SSL (Secure Socket Layer).
[0035] In another embodiment, the BTDS Lab-Toaster subsystem interfaces with an array of laboratory appliances that, for example, are utilized during compound genesis in accordance with, for example the RS-232 protocol connecting data terminal equipment and exemplary data circuit-terminating equipment. A custom XML schema (conforming to the eCTD standard) can provide a method for transforming instrument-specific output to a common format which complies with regulatory requirements and is able to exist as relational data in the central database. The instrument output data can be added to the local server and included in updates to the central repository, as indicated above, including encryption and secure transmission.
[0036] Referring now to FIG. 4 when a compound creation event is detected in the central BTDS data repository, an electronic Common Technical Document (eCTD) object can be created in a Regulatory Document Management module, wherein the document created can be specific to the individual compound. The BTDS AutoCTD function can selects the correct XML schema based on compound parameters and create an XML document by applying schema to newly imported compound data (eCTD XML Schemas and DTDs are managed in the AutoCTD Manager). The created eCTD becomes the framework on which future data relating to this compound is structured, and also can establish a data chain for the compound at a designated and defined time point in the research and development cycle.
[0037] In another embodiment, the BTDS LAB-IP module can also be structured on the eCTD model as described above. For example, when a new compound is detected in the central data repository, the LAB-IP module can initiate the creation of an XML-based intellectual property registration document. A data record pertaining to compound synthesis can be generated, compiling data into a template-based form, ready for use in the IP protection process. In another embodiment of the invention, upon completion of the IP registration process, the BTDS LAB-IP system can trigger the BTDS RDA (Rapid Data Awareness) module to commence notification procedures. In this exemplary embodiment the RDA module can use a combination of alerting mechanisms, for example, email, text/instant messaging, and RSS feeds, to alert company personnel to events as they occur in the central data repository. RDA services can be based on the Web 2.0 model, for example such services can be offered on a subscription basis, allowing approved personnel to subscribe to various events which pertain to the user's role in the organization. In one exemplary embodiment, the RDA module can alert appropriate personnel to facts, such as a new compound registration, thereby enabling the IP protection process to be initiated. In an alternative embodiment the RDA can be triggered, for example, by user-customizable thresholds set on research and business process data, enabling a user selected system event to trigger the RDA module.
[0038] Turning now to FIG. 2 , in an exemplary embodiment a biological and/or medical research and discovery workflow module is described, from the preliminary steps of pre-clinical experiments to clinical trials, and FDA regulatory approval.
[0039] In an exemplary embodiment, a biological research component consists of a BTDS FAB (Fluid Assay Builder) tool and Assay Data Entry Process module. In this example, the BTDS FAB, is a XML-based component allowing researchers to create custom templates using a drag-and drop interface to assemble experiment criteria, data points, and output parameters into an XML schema in compliance with the eCTD specification. Once defined the assay schema joins the schema library, where it is available for use during the data import process. As experiments are performed, data can be correlated to the appropriate subject compound by using the compound's unique identifier.
[0040] In another embodiment, a data entry process is initiated, wherein, and as one step, an assay schema can be selected. Next, the FAB can examine the schema to determine the structure that the data entry form should take. XML metadata in the schema informs the FAB which user controls are required in the form, and the form can be built dynamically on the Web server and made available for data entry.
[0041] In another embodiment, and in addition to creating custom assay result sets manually, the FAB can be used to generate XML assay schemas based on legacy documents, such as, but not limited to, Microsoft® Office Excel documents. For example, when an Excel file is dropped into the FAB interface the document can be converted to an XML file. A schema can be generated from XML file from containing the data, and validated against the eCTD specification. Upon approval of a user the schema can be added to the library and data import can be performed.
[0042] In another embodiment, subsequent data importation of similar documents, such as Excel spreadsheets, can be achieved by selecting an assay schema and dropping the file into the FAB interface. The XML transformation process occurs and the data can be aggregated using the selected schema for validation.
[0043] In another exemplary embodiment and using a dynamic form building functionality of the FAB, researchers can generate data entry forms based on schemas extracted from legacy documents, such as, but not limited to, Excel files. The dynamic form building functionality allows the researcher to create an assay schema from the selected file, enter the legacy data by dragging and dropping the spreadsheet files into the interface, and perform future data entry tasks in the BTDS FAB interface.
[0044] In another embodiment of the invention, FAB functionality can include the ability to specify that custom data transformations to be applied to research data. For example, researchers can manipulate and analyze data sets, entering data points into equations, and specifying a variety of charting and graphing options to analyze the data as manipulated. Data transformations can be applied individually to specific datasets, or across the entire data repository, to all data that matches the corresponding schema. This can allow users to analyze data sets repeatedly with different criteria, without having to alter embedded formulas and regardless of the date of the original experiment.
[0045] In another embodiment of the invention, transformed data can be assembled into an XML document conforming to the XML file. The eCTD specification document can be made available to authorized personnel comprising, for example, the organization's research community.
[0046] In another embodiment of the invention a dataset document can become the seed for a community forum thread, exposing the document for discussion in the BioTech Data Portal forums. In this example, a document can be signed and locked, and a discussion thread can be added to the prospect compound's eCTD for inclusion in regulatory submission applications.
[0047] In another embodiment, users can navigate through research documents and can vote on, for example, the viability of each candidate compound based on analysis of the data. An exemplary embodiment of the system can implement a polling protocol to establish community consensus regarding the path future research should follow, for example utilizing the Web 2.0 technique.
[0048] Another embodiment of the invention can utilize a forum-based research discussion and polling process, wherein the social networking functionality of link-sharing can be leveraged to allow researchers to share data that they regard as interesting and/or worthy of future investigation and/or development.
[0049] In another embodiment, the BTDP provides a means by which researchers can participate in a live chat room, and share ideas in real-time. When the chat session concludes, the host can be able to designate that the transcript from the session be added to the eCTD for the subject compound. In an exemplary embodiment, the record can be transformed to an XML document conforming to the appropriate eCTD schema.
[0050] In another embodiment of the invention, researchers are able to bookmark interesting and/or relevant data, and post these bookmarked results to the rest of a community and/or working group through a comprehensive role-based user profile framework.
[0051] In an exemplary embodiment of the invention the functionalities described above and others can collectively harness Web 2.0 methodologies to produce a dynamic research community while maintaining a strict audit trail and the data integrity required by regulatory agencies. As mentioned above, research data, forum discussions, chat room manuscripts, and other electronic data and communications can be XML-based and in compliance with the eCTD schema and DTD parameters.
[0052] In an another embodiment of the invention, metadata included with data containing documents identify the prospect/candidate compound, and allows a rich taxonomy to be applied to the data. The BTDS AutoCTD system can compile XML-based documents from a plurality of data sources containing a variety of data types in the repository, including, for example, non-XML based relational data from legacy applications. AutoCTD can use taxonomy keywords to correlate relevant data per the user's requirements and assemble XML-based documents that can conform to, for example, the document-level schema and the overall eCTD specifications.
[0053] Turning now to FIG. 4 , in another embodiment of the invention, data-containing documents can be created by a plurality of individuals throughout, for example a company and/or a working group on a variety of word-processing platforms. A BTDS document management system (Ultra-DMS) can provide a semantic framework in which these data-containing documents may be aggregated, classified, and/or utilized during, for example, the entire chemical compound life-cycle—and in particular in compliance with regulatory requirements.
[0054] In another embodiment of the invention, a document import process can be initiated by the user when a document is dropped into the Ultra-DMS interface. The user can be prompted to set values for a variety of document variables, at which time the Ultra-DMS can encapsulate the document in an XML wrapper. A plurality of document variables, for example, and including access and chain of custody record variable, can be stored as metadata within the XML wrapper. In this manner a historical record of the document can be become an integral component of the document itself.
[0055] The Ultra-DMS interface can also allow the importation into the BTDP system of reporting documents, such as Clinical Study Reports (CSR). An array of data-conversion functionalities can provide a means to make proprietary Study Report formats available to the BTDP system as relational data, which can then be manipulated and processed by the user upon command. Within its XML wrapper, the CSR can be accessible to the BTDS AutoCTD system for easy inclusion in the regulatory submission framework.
[0056] In an exemplary embodiment of the invention, taxonomy is applied to documents in the BTDP repository in multiple ways. For example, a rigid system-controlled vocabulary can be associated with each document schema, and referenced when manipulating data on a system wide level, such as when preparing reports or compiling the eCTD. In another example, documents derived from research data, forums, and the like, can be associated with a specific taxonomy assigned by the system. System-level taxonomy phrases can be stored as metadata in the document's XML wrapper.
[0057] In another embodiment, free-taxonomy can provide the users with the flexibility to create their own vocabularies and assign taxonomy phrases to their research, forum discusions, chat sessions, and the like and/or in a manner that makes most sense to each individual user. These taxonomies are associated with the user's profile, and provide a method for researchers to make sense of even enormous amounts of data that they navigate on a daily basis.
[0058] Document revision can be handled in a controlled fashion. In one embodiment, users can check a document out of the BTDS repository, wherein the system determines when and if and only a user can access a document at a time, thereby limiting access. The document can then be checked back into the system before other users are allowed access to the revised document. Each revision can be logged separately, establishing a complete record of changes made by users during the history of the document. In this example, and because of a restricted check-out/check-in policy, changes to the document can be tracked, for example, when the changes were made, what changes were made, and by whom the changes were made.
[0059] When document collaboration is concluded the contents can be verified for accuracy, preferably by an author or a manager of the content. Once verification occurs, the document can be signed, for example, electronically by either entering a secret PIN number and/or by using a biometric device such as a thumbprint scanner. Signed documents can be automatically locked in the BTDS database so that other revisions are disallowed without a signor's approval.
[0060] In another embodiment, data-containing documents can be published in a variety of formats to suit international publishing standards as required in a global marketplace. For example, the AutoCTD system can compile an XML document using a pre-defined XSLT template that conforms to local publishing parameters. Once compiled, the document can be sent to a printer, and/or converted to the Adobe PDF format for electronic distribution.
[0061] As described in FIG. 4 , a central feature of the BTDS Regulatory Document Management system is the BTDS AutoCTD. This system uses the eCTD schema and DTD required by regulatory agencies for electronic submission of applications. The AutoCTD system can examine metadata associated with data objects to determine which data to include in the eCTD submission. When a user initiates eCTD compilation, AutoCTD can compile non-XML based data into XML documents, using the document-level schemas associated with the data. Once data relating to the subject compound has been aggregated into XML-based documents, the system can insert those documents into the eCTD, using the eCTD specification to determine the correct correlation of data. AutoCTD can deliver a complete record of compound creation, pre-clinical research, and clinical trial data in the required eCTD format, in a nimble and convenient way while also ensuring that only the most current versions of documents and data are used in the submission. Once the eCTD has been compiled, AutoCTD can perform an automated validation routine against the applicable regulatory agency's schema and DTD to ensure a seamless submission process.
[0062] After the eCTD has been compiled and validated, a built-in eCTD viewer provides an intuitive user interface for browsing the complete eCTD. This exemplary interface can provide an overall view of the document structure providing the means by which a user can find and examine sections of the document. The Web-based interface and role-based user access controls allow the completed document to be accessible to outside reviewers such as regulators, investors, and outside research partners.
[0063] In another embodiment of the invention, a barcode-based inventory control process is initiated when new compounds are detected in the system. New compounds can be assigned unique inventory IDs, and these IDs can be utilized by all processes throughout the research, development, and commercialization lifecycle to correlate data to the corresponding compound. The inventory IDs also serve to establish parent-child relationships between the compounds in the system, so that a clear and concise record of compound genesis is available to the user, IP protection, and regulatory components of the system.
[0064] Upon completion of compound synthesis and corresponding documentation procedures, the user is able to interact with the newly created inventory object using the interface. Here, the user can perform a variety of tasks, such as print barcode labels and ship or receive compounds.
[0065] When a compound is selected for shipping, the inventory management system can generate a child inventory object with attributes such as mass, destination, and the like. This object can be further divided for shipping if required, each division generating yet another child object and establishing the relationship hierarchy. User interactions with inventory objects, such as shipping, receiving, and use events, can, in an exemplary embodiment, require a digital signature, to be logged and audited. The record of this chain of control can be made available to the AutoCTD for inclusion in the regulatory submission process.
[0066] In another embodiment of the invention, the BTDS system can also include functionality that allows researchers to track the physical location of biological, chemical, and/or other research samples within the laboratory environment, including visualizations that assist in locating samples within vast storage matrices.
[0067] During the research process, compound usage can be tracked and counted against the master sample store. User-customizable thresholds can be set on compound quantities trigger the BTDS RDA system to alert the appropriate personnel as levels near depletion. This functionality can function to maintain a steady supply of subject compound samples to the research partner laboratories, thus eliminating delays in the research and development cycle which can be both costly and time consuming.
[0068] In another embodiment of the invention, the BTDP system can combine all of the systems functionality described above into a simple and user-friendly Web-based interface/portal. This exemplary interface can make use of technologies such as, but not limited, to Microsoft® ASP.Net, AJAX, JSON, and Microsoft® SilverLight™ to provide a rich, seamless user experience. In an exemplary embodiment upon verification of login credentials, the user can be directed to their home page. This page can be a user-customizable dashboard, incorporating process oversight, reporting, site navigation, system RSS feeds and alerts, and social networking (e.g., chat, forum) and community feedback (e.g., polling) functionalities. From this dashboard, the user can all access BTDS components such as the FAB (Fluid Assay Builder), AutoCTD, and their customizable RDA (Rapid Data Awareness) settings and alert logs. In addition to the functionality provided by a full version of the BTDP system web-based interface, a streamlined, compact edition can be available to mobile device users, delivering crucial data to highly mobile personnel. For example, and when combined with the BTDS RDA system, the mobile interface can provide real-time data awareness across all levels of the company or organization.
[0069] Source code illustrating and implementing various aspects and embodiments pursuant to 37 CFR §§1.52 and 1.96 follows.
[0070] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment.
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An embodiment of the invention is a system and method that supports Enterprise Resource Planning, Laboratory and Research Management, Product Lifecycle Management,
Decision Support Management, Regulatory Document Management, and internal corporate documents and data into a comprehensive, Web-based extranet, that can be a repository for a complete, real-time Body of Knowledge of an organization.
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BACKGROUND OF THE INVENTION
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of Co-pending application Ser. No. 799,000, filed May 20, 1977, now abandoned.
Field of the Invention
The present invention relates to a method of and a member for adding a treating agent in the molten-metal treating process, for example, desulfurization or deoxidation, or in a component adjusting process.
Description of the Prior Art
In the case of desulfurization, for example, recently the requirements for limitation on sulfur content (hereinafter referred to as S content) have become very severe, and depending on applications, a so-called low-sulfur steel with an S content of less than 50 ppm is demanded. Therefore, with the present-day steel making method using a blast furnace-converter system, and theoretically, it is necessary to carry out sufficient desulfurization in the converter, that is, on the stage prior to steel making, so as to prepare a molten metal with an S content below the limit which allows refining in the steel making process. On the other hand, the circumstances of materials in the blast furnace are assuming an aspect which does not warrant optimism, making it difficult to obtain a molten metal with an S content below the refinable limit as described above.
It is the outside-furnace desulfurization of molten iron that has made its advent as the most effective method of pre-treatment of or low-sulfur steel making from a molten metal which has a high S content due to such circumstances of the blast furnace. At present, various outside-the-furnace desulfurization systems have been invented and put to use. For example, the addition and agitation method, blowing-in method, etc. are usually employed.
The addition and agitation method uses a plunging member to plunge a desulfurizing agent and auxiliary agent packed in a drum can or the like into molten steel taken out into a ladle and agitate the same. With this, however, the initial cost is high owing to the installation of the drive unit, etc., and on top of this, the plunging member has to be frequently replaced since it can be easily melt-wise damaged, thus involving high running cost. Further, the sulfur which has once floated up to the surface of the melt as a slag tends to return to the molten steel or some of the desulfurizing agent and auxiliary agent burn out before they reach suitable positions in the molten steel, so that more amounts of desulfurizing agent and auxiliary agent than is necessary are consumed.
According to the blowing-in method, after a desulfurizing agent and auxiliary agent are charged into molten steel by a plunging member or the like, desulfurization is carried out by blowing N 2 gas into the molten steel with the ladle sealed. In this case also, drawbacks similar to those described above in connection with the addition and agitation method remain unsolved.
In brief, in the conventional methods, the yield of a desulfurizing agent and its auxiliary agent (hereinafter referred to as treating agent) is generally low and the treating operation requires a long residence time (20-25 minutes), involving a loss of the thermal energy of the molten steel. Further, what should be particularly noted is that while recent researches have developed various types of desulfurizing agents, no decisive method of use, or addition, of such agents has been established. As a result, the costs of expensive installation and replaceable members such as plunging members and the useless consumption of more than necessary amount of treating agent have extremely raised the initial cost and the running cost.
Further, since a large amount of treating agent is charged into molten steel at a single place therein, the resulting chemical reaction is violent, involving danger and producing smoke and dust in large amounts, incurring the possibility of causing environmental pollution, such as air pollution. On top of this, the treating effect is good only at the charged place and agitation for a prolonged period of time is required in order to uniformly distribute the treating effect throughout the molten metal in the ladle.
Further, referring to the outside-the-furnace deoxidizing of molten steel, among the most general methods of adding a deoxidizing agent is one in which it is formed into a lump which is then charged into molten steel and another in which it is formed into a shell which is then shot into molten steel. With these methods, however, the deoxidizing agent tends to burn or float up (depending upon specific gravity) before it produces chemical reactions in the molten steel for deoxidation and hence it has been usual practice to charge more than the necessary amount of treating agent but the scattering of deoxidation yield cannot be avoided. Thus, in the conventional methods, stabilized deoxidation yield cannot be obtained despite the use of a large amount of treating agent.
SUMMARY OF THE INVENTION
An object of the present invention is to remedy or eliminate the drawbacks heretofore involved in adding treating agents to molten metal.
Another object of the invention is to prevent the return of sulfur and the burn-out loss of treating agent caused before it comes into molten meal, thereby improving the treating effect and the yield of treating agent.
A further object of the invention is to dispense with the plunging member, agitating member and drive unit therefor, thereby reducing the initial cost and running cost involved in the treatment of molten metal.
An additional object of the invention is to cut down the residence time of molten metal in the treating process, which tends to cause a loss of the thermal energy of molten metal.
Yet another object of the invention is to protect the quality of the treating agent by preventing the weathering thereof due to its time-dependent changes or by preventing spontaneous ignition during storage or transport.
A feature of the invention is that a capsule made of a self-burnable and self-eruptive material harmless to molten metal with a treating agent contained therein, that is, a treating agent adding member is dropped or plunged into molten metal and the self-burnable and self-eruptive actions of the capsule are utilized to cause agitation and convection of the treating agent and molten metal. Thereby, the equipment including the agitating member and drive therefor can be dispensed with. Since molten metal is not forcibly agitated, even if a plunging member is used the surface of the melt is maintained undisturbed and the return of sulfur which has once slagged is prevented.
Another feature of the invention is that a plurality of said treating agent adding members each packed with suitable amount of treating agent are plunged into molten metal once or several times, thereby uniforming the addition of the treating agent and cutting down the treating time and hence minimizing the loss of the thermal energy of the molten metal.
A further feature of the invention is that a treating agent adding member comprises a tubular body made of a self-burnable and self-eruptive material, for example, kraft paper cylindrically wound in layers, with an air layer being formed between adjacent paper layers, a lid and a weight each made of a material which, even if melted, is harmless to molten metal. This arrangement protects the treating agent packed in the interior from pre-burning and denaturing and improves the yield of treating agent. Further, it enables the efficient addition of the treating agent by adjusting the burning initiation time and burning time by adjusting the weight of said weight and the thickness of said paper tube. The tubular body is spirally wound in layers, with an air layer formed between the edges of the adjacent spiral layers.
Other numerous novel points and special qualities which characterize the present invention will be described in detail with reference to the accompanying drawings illustrating embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 3 and 4 are longitudinal sections of treating agent adding members showing embodiments of the invention which are used according to the present method of adding a treating agent;
FIG. 2 is a front view of the member shown in FIG. 1;
FIG. 2a is a perspective view of the treating agent adding member paper tube, partially unwound;
FIGS. 5 and 6 show how to treat molten metal by using the members shown in FIGS. 1 through 4;
FIG. 7 is a longitudinal section of a treating agent adding member according to a further embodiment of the invention;
FIG. 8 shows a manner of treatment using the member shown in FIG. 7;
FIG. 9 is a longitudinal section of a treating agent adding member according to another embodiment of the invention;
FIG. 10 is a front view of the member shown in FIG. 9;
FIG. 11 shows a manner of treatment using the member shown in FIG. 9;
FIGS. 12 and 13 are longitudinal sections showing modifications wherein the member shown in FIG. 9 is improved;
FIG. 14 is a longitudinal section of a treating agent adding member showing another embodiment of the invention;
FIGS. 15 and 16 show a modification wherein the member shown in FIG. 14 is improved, in which FIG. 15 is a longitudinal section and FIG. 16 is a front view;
FIG. 17 is a longitudinal section of a treating agent adding member showing another embodiment of the invention; and
FIGS. 18 and 19 show a member for adding a treating agent for molten metal according to another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2 showing a treating agent adding member according to a first embodiment of the invention, a treating agent is designated at 1 and 2 designates a paper tube containing the treating agent 1, with its opposite ends tightly closed by a lid 3 and a weight 4.
The paper tube 2 is formed of a self-burnable and self-eruptive material, for example, kraft paper cylindrically wound in layers. An air layer is formed between adjacent paper layers, and it takes some time for combustion to proceed from the outermost to the innermost paper layer, whereby the self-burning oxidation, that is, the loss of the treating agent 1 packed in the interior is prevented from occurring before the treating agent reaches a suitable position in molten metal. As seen in FIG. 2a, the paper 2d is spirally wound in layers with air layer 2e formed therebetween. The self-burning of the paper tube is carried out by virtue of the existence of the air layers 2e. The combustion time of the paper tube 2 varies with its wall thickness. According to experience with a conventer, in the case of a wall thickness of 3 mm, the paper tube traveled for 10 seconds while receiving radiant heat in the furnance and combustion in molten steel at 1600°-1700° C. took about 3 seconds before it completed. The material of which the lid 3 and weight 4 are made should be such that it will not adversely affect the components of molten metal to be treated, and the weight 4 has its front end shell-shaped so that it is capable of breaking through molten metal surface when it enters the molten metal.
In FIG. 5 showing the manner of treatment in this case, the treating agent adding member, that is, capsule of the above construction, is designated at A. When the capsule A is dropped into molten metal B taken into a ladle C, the treating agent 1 reaches a suitable reaction start position in the molten metal B without self-burning and oxidizing in advance. Such reaction start position can be suitably determined by adjusting the weight of the weight 4 or the wall thickness of the paper tube 2 according to calculations of the specific gravities of the capsule A and molten metal B. The self-burning of the paper tube 2 and the resulting emission of combustion gas at a suitable position in the molten metal B induce the agitation and convection of the molten metal and enhance the addition of the treating agent.
In order to make more effective the agitation and convection of the molten metal, as shown in FIG. 3, the paper tube may be arranged in multiple construction (double construction in the illustrated example) including a central paper tube 2b having a hollow space 2c, with the treating agent 1 packed in a hollow space defined by the outer paper tube 2a. The outer paper tube 2a functions to prevent the loss of the treating agent 1 until it reaches the reaction start position, while the inner paper tube 2b enhances the blowing of the treating agent 1 by its combustion and by the concomitant emission of the air in the hollow space 2c and hence it enhances the agitation of molten metal. Further, in order to make uniform the addition of the treating agent, several capsules each packed with a suitable amount of treating agent may be charged into molten metal at suitable positions.
In the past, when the amount of molten metal to be treated was increased, the treating equipment became larger in size and more complicated and the treatment took a longer time. According to the present invention, however, no complicated apparatus is required and the operating time can be cut down.
The embodiment shown in FIG. 6 utilizes an improvement in a conventional device, wherein D designates a plunging member and A designates said capsule packed with a treating agent. When the capsule A is plunged into the molten metal B by the plunging member D, the self-burning and eruptive actions of the paper tube 2 cause the agitation and convection of the molten metal B, so that there is no need for the plunging member D to execute agitating motion and hence the surface of the melt can be kept undisturbed. Therefore, there is no possibility that the sulfur which has formed into slag b will return to the molten metal. Further, if the front end portion of the plunging member D is covered with a special heat-resistant paper tube D', the plunging member D will not be melt-wise damaged and it is only necessary to replace the inexpensive special paper tube D' and hence the running cost can be reduced.
In the embodiment shown in FIG. 4, designated at 5 are sealing members for protecting the quality of the treating agent 1 contained in the paper tube 2 by preventing the spontaneous ignition due to its time-dependent changes or by preventing the weathering of the treating agent due to its time-dependent changes. The sealing members are made of a material, which when melted, is harmless to the molten metal and they are, for example, in the form of tubes of thin metal foil or asbestos paper which cover the inner and outer peripheral surfaces of the paper tube 2 or which are wrapped around together with kraft paper when the latter is wound. Thus, the sealing members keep the treating agent 1 in the capsule A out of contact with the outside air to protect it from denaturing and enable it to be used in the most effective condition.
In FIG. 7, showing another embodiment, a treating agent adding member 10A comprises a capsule 12 made of a material which, when melted, is harmless to molten metal and having a treating agent 11 enclosed therein, and an auxiliary member 6 projecting from the upper end of the capsule 12 for contact with the holder D of a plunging device. The auxiliary member 6 is cylindrically formed by winding kraft paper in layers. However, it is not limited thereto and it may be formed by similarly shaping asbestos paper or by boring wood so long as it is made of a self-burnable and self-eruptive material.
As for the manner of treatment in this case, as shown in FIG. 8, the adding members 10A are suspended from the holder D of the plunging device and plunged into molten metal B in a ladle C, the capsules 12 are melted to allow the treating agent 11 to be dispersed in the molten metal B, while some of the treating agent which tends to float up to the surface of the melt before it reacts with the molten metal is caused to stay in the molten metal by the self-burning of the auxiliary member 6 and by the fact that the concomitant emission of the combustion gas causes bubbling. At the same time, the agitation and convection of the molten metal B are induced and the treating agent 11 reacts and is added.
FIGS. 9 and 10 show a treating agent adding member according to another embodiment of the invention, wherein 22 designates a tubular body; 23, a lid; and 28 designates a connecting tube for connection to the holder of a plunging device or agitating device. The tubular body 22 and connecting tube 26 are cylindrically formed by winding a self-burnable and self-eruptive material, for example, kraft paper in layers as in the case of the paper tube 2 described above. However, no treating agent is packed therein. Therefore, as shown in FIG. 12, the lower end of the tubular body 22 may be left open without providing a lid.
As for the manner of treatment in this case, as shown in FIG. 11, the treating agent adding members 20A of the above construction are suspended from the holder D of a plunging device and they are plunged into molten metal B taken out into a ladle C as soon as a treating agent is charged thereinto in the conventional manner. Then, the self-burning of the tubular bodies 22 in the molten metal B and the concomitant emission of gas induce bubbling, causing the agitation and convection of the molten metal B whereby the molten metal and the treating agent are agitated. In addition, if the plunging device is rotated, the effect of addition of the treating agent is further enhanced.
In order to effectively carry out the agitation described above, it is necessary to adjust the combustion time by adjusting the wall thickness of the tubular body 22. For example, if the combustion time of the tubular 22 is made substantially equal to the time necessary to chemical reaction between the treating agent and molten iron, this is most effective and the loss of the thermal energy of the molten iron can be minimized.
Further, depending upon the volume of the molten metal B, etc., not less than two members 20A may be installed, and according to this arrangement, even if the plunging device is to be rotated, there is no possibility of the driving device, etc. having to be made larger in size at the sacrifice of the increase of the initial cost, since the resistance encountered during agitation is small as compared with that for a conventional iron vane even if the volume of the molten iron is large. Further, in embodying the present invention, as shown in FIG. 13, it is necessary to provide a number of small holes at two places on the tubular body 22" for example, one place immersed in molten metal and the other above the surface L of the melt. The absence of such small holes would involve the danger of the tubular body 22" being disengaged from the holder D by the expansion of the air in the hollow space of the tubular body 22". When the inside air is expanded, it is the small holes 7a in the upper region that allow the air to escape, while the small holes 7b existing in the molten metal B serve to increase the combustion area. It is preferable that a band 8 made of a refractory material or the like be provided on the tubular body 22" between the molten metal B and the outside air to prevent the holder from being damaged by the creeping up of the molten metal.
In FIG. 14, showing a further embodiment of the invention, an adding member 30 comprises tubular 32 bodies, a lid 33 and a connecting tube 36, with a suitable amount of treating agent 31 packed therein. The tubular bodies 32 and connecting tube 36 are cylindrically formed by winding a material which, when melted, has no adverse influences on the components of the molten metal, for example, kraft paper in layers. The connecting tube 36 is used for connection to the holder of a plunging device.
The manner of treatment in this case is similar to that described in connection with FIG. 11. Thus, a suitable number of treating agent adding members 30A of the above construction are each packed with a suitable amount of treating agent 31 and they are suspended from the holder D of a plunging device and plunged into molten metal B taken out into a ladle C. The members 30A carry the treating agent 31 contained therein to suitable positions in the molten metal B and then the self-burning of the tubular bodies 32 in the molten metal B and the concomitant emission of combustion gas produce bubbling which, in turn, induces the agitation and convection of the molten metal, whereby the molten metal B and treating agent 31 are agitated and react with each other. Thereafter, the plunging operation described above is repeated several times.
In addition, in the illustrated example, two treating agent adding members are used, but when the amount of molten metal is relatively small, a single member may be repeatedly plunged. Further, when the amount of molten metal is large, not less than two members may be disposed at several places and plunged simultaneously or successively one by one, two by two, and so on.
By the operation described above, the addition of a treating agent can be made relatively simply and effectively carried out.
In practice, the member is arranged as shown in FIGS. 15 and 16. More particularly, the resistance of the molten metal B during agitation is concentrated on a region of the connecting tube 46 near the surface L of the melt and said region is accompanied by a splash phenomenon. If the connecting pipe 46 is broken thereby, the agitation effect would be decreased. Therefore, it is necessary to reinforce the same from the standpoint of strength and in view of splash. To this end, the region of the connecting tube 46 near the surface L of the melt is covered with a metal barrel or a refractory material 48.
With the combustion of the tubular bodies 42 and the emission of gas, the treating agent 11 is spouted into the molten metal, but some of the treating agent tends to float up to the surface of the melt before it reacts with the molten metal. In order to prevent this and improve the efficiency of addition, small holes 47b are formed in the connecting tube 46 below the surface of the melt. Then, combustion gas is emitted vigorously particularly around said small holes 47b, whereby the treating agent which tends to float up to the surface of the melt can be retained in the molten metal.
As the combustion of the tubular body 42 advances, the agitating action causes the molten metal B to fill the connecting tube 46 and the metal can easily stick to the front end d of the holder. In order to prevent this, small holes 47a are formed in the connecting tube 46 below the front end d of the holder. These small holes 47a allow the air filling the connecting pipe 46 to escape therethrough to the outside of the connecting tube 46. The fact that the molten metal B enters the connecting tube 46 means that the combustion of the tubular bodies 42 has advanced and hence the treating agent 41 has been spouted into the molten metal and its reaction with the latter has advanced. At this point of time, therefore, even if the connecting tube 46 is broken at the region of said small holes 47a or 47b, this does not cause any trouble. Further, since addition is accelerated in two ways, i.e., by agitation due to the entire treating agent adding member 40A and by the agitation and convection of the molten metal due to the self-burning and eruptive action of the tubular bodies 42, not only is the improvement of the treating effect achieved but also the loss of the energy of the molten metal is minimized by reduced operating time and the combustion of the agitating member 10.
FIG. 17 shows a treating agent adding member 50A according to the invention used for deoxidation. Tubular bodies 52 and a connecting member 56 are cylindrically formed by winding in layers a material which, when melted, is harmless to the components of molten metal, for example, kraft paper together with a deoxidizing material formed into a thin sheet or wire, for example, an aluminum foil 52b. Therefore, in a treating process, the self-burning of the tubular bodies 52 in the molten metal and the concomitant emission of combustion gas produce bubbling which, in turn, induces the agitation and convection of the molten metal, whereby the metal consisting of the molten metal and the treating agents, namely, the deoxidizing agent 51 and aluminum foil 32b is agitated. In this case, addition is accelerated in two ways, i.e., by the synergistic effect of the deoxidizing material included in the tubular bodies 52 and the deoxidizing agent enclosed in the interior and by the agitation and convection of the molten metal brought about by the self-burning and eruption of the tubular bodies 52.
In the embodiment shown in FIGS. 18 and 19, a treating agent member is designated at 60A and 62a designates a tubular body and 66 designates a connecting tube, these being arranged in multiple construction (double construction in the illustrated example) wherein a plurality (four in the illustrated example) of containers 62b each containing a suitable amount of treating agent 61 are received in a hollow space 9 defined between the tubular body 62a and the connecting tube 66. The tubular body 62a and connecting tube 66 are cylindrically formed by winding, for example, kraft paper in layers, while the containers 62a are in the form of barrels of different materials (for example, a paper barrel made of a self-burnable and self-eruptive material similar to that for said tubular body 62a and connecting tube 66, a barrel of thin metal, a barrel of refractory material and a barrel of asbestos paper) or barrels of the same material with different wall thicknesses. Such materials should, of course, be harmless to molten metal when melted.
According to this arrangement, the containers 62a are successively melted in the order of decreasing melting rate to allow the treating agent 61 in each container to be spouted and the molten metal and treating agent are agitated and react with each other. In brief, there is a time lag in chemical reaction of the treating agent due to differences in the melting rate of the containers 62b in molten metal, whereby a diffusion effect is obtained, improving the treating effect and saving the operation time.
While there have been described herein what are at present considered preferred embodiments of the several features of the invention, it will be obvious to those skilled in the art that modifications and changes may be made without departing from the essence of the invention.
It is therefore to be understood that the exemplary embodiments thereof are illustrative and not restrictive of the invention, the scope of which is defined in the appended claims and that all modifications that come within the meaning and range of equivalency of the claims are intended to be included therein.
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A method of and a member for adding a treating agent for molten metal, wherein an additive or treating agent such as a desulfurizing agent or a deoxidizing agent is enclosed in a container made of a self-burnable and self-eruptive material and the container is inserted into the molten metal by dropping it or by making use of a support rod or a plumbing device to produce physical and chemical reactions, which induce agitation and convection in the molten metal, the synergistic effect of such actions causing the treating agent to be effectively added to the molten metal.
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CLAIM OF PRIORITY
[0001] The present patent application claims the priority benefit of the filing date of Australian Patent Application No. 2009902072, filed May 11, 2009, the entire content of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a steam iron, and in particular a steam iron operable to deliver a shot of steam.
BACKGROUND OF THE INVENTION
[0003] Irons for ironing clothes and other material are known.
[0004] At a basic level such irons include a heating arrangement for heating a soleplate which can be slid over the material being ironed to remove wrinkles and creases.
[0005] Steam irons include further componentry such that water is heated to steam and emitted from apertures in the soleplate while ironing. The steam emitted assists in the removal of wrinkles/creases from the material being ironed.
[0006] Some steam irons also allow a user to operate the iron to deliver a shot of steam, passing water vapour at greater pressure through the material being ironed, further assisting in the ironing process. A shot of steam is a conventionally activated by depressing a button on the iron which causes a charge of water to be heated to steam and emitted from the apertures in the soleplate (this may be in addition to the constant steam being emitted).
[0007] When using a steam shot function on a steam iron the user perception is often that a high-pressure shot of steam will be delivered at the front of the iron adjacent the tip of the soleplate. In many conventional irons, however, this is not the case. While steam is emitted from apertures in the soleplate at the front of the iron, the steam generation and delivery arrangement of the iron is such that the greatest steam pressure of a steam-shot is delivered through apertures in the rear of the iron soleplate, with the pressure decreasing towards the front of the iron.
[0008] It would be desirable to provide a steam iron adapted to emit a steam-shot of relatively high pressure from the front of an iron.
[0009] Reference to any prior art in the specification is not, and should not be taken as, an acknowledgment or any form of suggestion that this prior art forms part of the common general knowledge in Australia or any other jurisdiction or that this prior art could reasonably be expected to be ascertained, understood and regarded as relevant by a person skilled in the art.
SUMMARY OF THE INVENTION
[0010] In one aspect the present invention provides an electric steam iron including: a water reservoir; a soleplate including: a base; a heating element; a constant steam chamber in fluid communication with a plurality of constant steam chamber apertures passing through the base; a steam shot chamber including a front cavity and a steam shot channel in thermal communication with the heating element and in fluid communication with the front cavity, the front cavity including at least one steam shot chamber aperture passing through the base, the steam shot channel defining at least one re-entrant flow path substantially overlying the heating element; the iron further including a constant steam chamber water delivery means for delivering water from the water reservoir into the constant steam chamber; and a steam shot chamber water delivery means for delivering water from the water reservoir into the steam shot chamber in the soleplate.
[0011] The total length of the steam shot channel is preferably longer than the length of the heating element, and may be at least twice the length of the heating element.
[0012] The soleplate may be of unitary construction.
[0013] The iron may include a pair of flow paths, each flow path having a re-entrant shape.
[0014] The pair of re-entrant flow paths may be symmetrical and meet at a confluence, and wherein the steam shot chamber water delivery means deposits water from the water reservoir into the confluence, the flow of the delivered water being split by a flow splitter so as to be divided between the flow paths.
[0015] The constant steam chamber may include a central cavity in fluid communication with a pair of lateral channels in which the constant steam chamber apertures are located, the central cavity adapted to receive water from the constant steam chamber water delivery means and vent the received water as steam from the constant steam chamber apertures.
[0016] The central cavity and lateral channels of the constant steam chamber and the steam shot channel and front cavity of the steam shot chamber may be defined by one or more walls extending normally from the soleplate.
[0017] The iron may further include a soleplate cover adapted to seal the constant steam chamber and the steam shot chamber.
[0018] The soleplate cover may include a first aperture through which the constant steam chamber water delivery means passes, and a second aperture through which through which the steam shot chamber water delivery means passes.
[0019] The steam shot chamber may be in fluid isolation from the constant steam chamber.
[0020] The steam shot chamber water delivery means may include a pump operable by a user to deliver water from the water reservoir to the steam shot chamber.
[0021] The constant steam chamber water delivery means may include a constant flow-rate valve for delivering water from the water reservoir to the constant steam chamber at a predefined rate, the water delivered to the constant steam chamber vented as steam from the constant steam chamber apertures to provide a constant steam flow.
[0022] In a second aspect the present invention provides an electric steam iron including: a water reservoir; a soleplate, the soleplate being of unitary construction and including: a base; a heating element; a constant steam chamber in fluid communication with a plurality of constant steam chamber apertures passing through the base; a steam shot chamber including a front cavity and a steam shot channel in thermal communication with the heating element and in fluid communication with the front cavity, the front cavity including at least one steam shot chamber aperture passing through the base, the steam shot channel defining at least one flow path substantially overlying the heating element, the at least one flow path having a re-entrant shape; the iron further including a constant steam chamber water delivery means for delivering water from the water reservoir into the constant steam chamber; and a steam shot chamber water delivery means for delivering water from the water reservoir into the steam shot chamber in the soleplate.
[0023] The total length of the at least one flow path may be greater than the length of the heating element.
[0024] The at least one flow path may include a pair of flow paths, each flow path in the pair of flow paths substantially overlying the heating element, and each flow path in the pair of flow paths having a re-entrant shape.
[0025] In a third aspect the present invention provides an electric steam iron including: a water reservoir; a soleplate including: a base; a heating element; a constant steam chamber in fluid communication with a plurality of constant steam chamber apertures passing through the base; a steam shot chamber including a front cavity and a steam shot channel in thermal communication with the heating element and in fluid communication with the front cavity, the front cavity including at least one steam shot chamber aperture passing through the base, the steam shot channel defining at least one flow path substantially overlying the heating element, the at least one flow path having a re-entrant shape, the total length of the at least one flow path being greater than the length of the heating element; the iron further including a constant steam chamber water delivery means for delivering water from the water reservoir into the constant steam chamber; and a steam shot chamber water delivery means for delivering water from the water reservoir into the steam shot chamber in the soleplate.
[0026] The at least one flow path may include a pair of flow paths, each flow path in the pair of flow paths substantially overlying the heating element, and each flow path in the pair of flow paths having a re-entrant shape.
[0027] The soleplate may be of unitary construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] An embodiment of the invention will be described with reference to the accompanying figures in which:
[0029] FIG. 1A shows a plan view of an iron soleplate in accordance with an embodiment of the invention;
[0030] FIG. 1B shows a partial diagrammatic view of the walls of the soleplate of FIG. 1A , and the cavities and channels defined thereby.
[0031] FIG. 1C shows the iron soleplate of FIG. 1A with the element illustrated;
[0032] FIG. 2 shows a perspective view of the soleplate of FIG. 1A ;
[0033] FIG. 3 shows a bottom view of the soleplate of FIG. 1A ;
[0034] FIG. 4 shows a partial perspective view of an iron fitted with the soleplate depicted in FIG. 1A ;
[0035] FIG. 5 shows a partial perspective view of the iron of FIG. 4 with a cover fitted to the soleplate;
[0036] FIG. 6 shows a sectional elevation view of the iron of FIG. 4 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0037] FIGS. 1 to 3 respectively provide a plan view, a perspective view, and a bottom view of a soleplate 100 in accordance with an embodiment of the invention. The soleplate 100 is for use with a steam iron which (as described in more detail below) can be operated to provide constant steam as well as a shot of steam.
[0038] In the preferred embodiment the soleplate 100 is a single, integral Die casting. By providing a unitary soleplate 100 the complexities of soleplate assembly are minimised, facilitating a cost effective steam iron construction. The soleplate 100 will typically be cast from an aluminium alloy.
[0039] The soleplate 100 includes a base portion 102 which has an underside surface 104 for ironing. As is known in the art the base portion 102 may be provided with a non-stick/low friction coating such as Teflon by DuPont, or a synthetic fluoropolymer such as polytetrafluoroethylene or polytetrafluoroethene (PTFE). The low friction coating allows the soleplate base to slide easily over the material being ironed. Alternatively, the base portion 102 may not be provided with a coating and, for example, the aluminium alloy (or other construction material) may simply be polished.
[0040] On the upper side 106 of the base an outer wall 108 , a middle wall 110 , an intermediate wall 112 , an inner wall 113 (joined to the middle wall 110 ), and two bridging walls 114 (extending between the outer and middle walls 108 and 110 towards the front of the soleplate 100 ) are formed. Walls 108 to 114 each extend normally from the base portion 102 . While walls 108 to 114 are, for the purposes of illustration, described as separate features, the soleplate 100 of the preferred embodiment is (as noted above) of unitary construction and as such the outer, middle, intermediate, inner and bridging walls 108 to 114 are not in fact separate components but part of a single casting.
[0041] As can be seen, the outer wall 108 forms a closed loop defining an inner chamber 116 in which the middle wall 110 , intermediate wall 112 , inner wall 113 , and bridging walls 114 are located. The middle wall 110 , inner wall 113 and the bridging walls 114 serve to separate the inner chamber 116 into a forward steam shot chamber 118 used in the generation of a steam shot and a rear constant steam chamber 120 used in the generation of constant steam. When assembled into an iron the forward and rear chambers 118 and 120 are in fluid isolation from each other and, as described below, the steam shot chamber 118 is used for providing a shot of steam and the constant steam chamber 120 for providing constant steam.
[0042] FIG. 1B shows a partial diagrammatic view of the walls ( 108 , 110 , 112 , 113 , and 114 ) and the channels ( 123 and 136 ) and cavities ( 122 and 134 ) defined by the soleplate of FIG. 1A . The dotted arrows in FIG. 1B indicate the direction of flow of steam.
[0043] The steam shot chamber 118 is divided into a front cavity 122 and a steam shot channel 123 . As can be seen, the middle, intermediate and inner walls 110 , 112 and 113 define the steam shot channel 123 to be effectively two re-entrant flow paths 126 joined at a confluence 128 , each flow path 126 feeding into the front cavity 122 at a channel opening 130 . The middle, intermediate and inner walls 110 , 112 and 113 are each provided with offset protrusions 127 (not shown in FIG. 1B ) which protrude into the re-entrant flow paths 126 and reduce the volume of the flowpaths 126 , thereby increasing pressure build-up in the flowpaths 126 .
[0044] The front cavity is provided with a number of steam shot chamber apertures 132 (not shown in FIG. 1B ) extending through the base portion 102 of the soleplate 100 . In the embodiment illustrated five steam shot chamber apertures 132 are depicted, however more or fewer could be provided as desired.
[0045] The constant steam chamber 120 is divided into a central cavity 134 and a pair of lateral channels 136 . The central cavity 134 is in fluid communication with the lateral channels 136 , the lateral channels 136 extending between the outer wall 108 and the middle wall 110 and terminating at the relevant bridging wall 114 . The central cavity 134 is provided with a number of vanes 138 extending normally from the base portion 102 which, in use, assist in dividing water/steam between the two lateral channels 136 and act to draw water up the vanes 138 to aid the conversion of the water to steam. Each of the lateral channels 136 is provided with a number of constant steam chamber apertures 140 (not shown in FIG. 1B ) extending through the base portion 102 of the soleplate 100 .
[0046] The soleplate 100 also carries a heating element 142 which is cast into position in the soleplate 100 at the time of manufacture. The heating element 142 is a sheath type heating element in which a coiled resistance wire extends through a protective tubular sheath and is insulated therefrom by a compound such as granulated and compressed magnesium oxide. Alternative heating elements could be used if desired. The heating element 142 includes a pair of terminals 144 which (when the soleplate 100 is assembled into an iron) connect with a power source of the iron.
[0047] In FIG. 1C , the outline of the heating element 142 is shown, and as can be seen the heating element 142 is essentially U-shaped. Each arm of the heating element 142 extends below the re-entrant flow paths 126 of the steam shot channel 123 , with the U-bend of the heating element 142 proximate the confluence 128 of the steam shot channel 123 . As can be seen, the each of the re-entrant flow paths 126 doubles-back over the element 142 , allowing steam passing through the steam shot channel 123 to remain in close proximity to (and be heated by) the element 142 for a far larger distance than would be the case if non-re-entrant flow paths were used. This, in turn, allows the element 142 to heat the steam in the steam shot channel 123 for a longer period of time, thereby increasing the pressure of the steam shot eventually delivered. In one embodiment, the total length of the steam shot channel 123 (i.e. the combined length of the re-entrant flow paths 126 ) is longer than the length of the element 142 .
[0048] The soleplate 100 is also provided with a plurality of mounting bores 148 by which an iron incorporating the soleplate 100 can be assembled. Some of the mounting bores 148 are provided in the walls 108 to 114 and some extend from the base portion 102 of the soleplate 100 as stand-alone bores. The bores 148 may be threaded for receiving screws or similar, or may be adapted to receive fabricated metal brackets which facilitate the mounting of moulded covers.
[0049] The soleplate 100 may be provided with additional or alternative features depending on the particular arrangement of the iron with which the soleplate 100 is to be used. By way of example, the illustrated soleplate 100 includes a dial mount 150 which may be used (as shown in FIG. 4 ) to mount a rotary mechanical thermostat by which a user operates the iron. The illustrated soleplate 100 also includes a disc mount 152 to which a bi-metallic disc may be secured to facilitate operation of an anti-drip valve assembly, preventing premature flow of water into the constant steam chamber 120 before the appropriate temperature is reached.
[0050] Turning to FIGS. 4 to 6 , partial depictions of an iron 400 including a soleplate 100 are provided. For the purpose of illustration the body 402 of the iron 400 has been depicted as being transparent, and not all components of the iron 400 are shown.
[0051] Those components of the iron 400 illustrated include a handle 404 defined in the upper portion of the body 402 and a control dial 406 housed in the body 402 below the handle 404 . As is known the control dial 406 may be used by a user to set the iron temperature and/or mode of operation of the iron. At the front of the handle 404 a pair of triggers 408 and 410 are provided which operate (in this instance) a mechanical pump assembly 412 . Depressing one of the triggers (e.g. the left trigger 410 ) provides a spray mist to be generated via the nozzle 414 , and depressing the other trigger (e.g. right trigger 408 ) provides a shot of steam as discussed further below.
[0052] In addition to the components of the iron 400 illustrated, the iron also includes a power source and cord (which exits the iron from cable guide 416 ) for providing power to the iron.
[0053] As shown in FIG. 5 , when iron 400 is assembled the top of the soleplate 100 (i.e. the tops of walls 108 to 114 ) is provided with a cover 502 which serves to seal the soleplate 100 (and in particular the inner chamber 116 ) from a water reservoir 506 that is defined within the body 402 of the iron. The cover is provided with a plurality of securing apertures 504 which align with a selection of the bores 148 to allow the cover 502 (and iron body/componentry) to be secured in place—e.g. with screws. The cover 502 is also provided with a number of component apertures through which necessary components (described below) pass without allowing water from the water reservoir to leak into the inner chamber 116 or, conversely, water/steam in the inner chamber 116 to escape through the cover 502 .
[0054] In one mode of operation the iron 400 is configured to provide a constant outlet of steam through the constant steam chamber apertures 140 . This is achieved by a drip valve 405 (or similar) which passes through the cover 502 and allows a regulated flow of water from the water reservoir 506 to the constant steam chamber 120 . The specific regulated flow rate for the drip valve will depend on the size and construction of the iron and the desired volume of constant steam to be emitted. In one embodiment the flow rate may, for example, be approximately 30 millilitres/minute. In an alternative embodiment the flow rate may be approximately 35 millilitres/minute. In a further alternative embodiment the flow rate may be approximately 40 millilitres/minute. Still further alternative flow rates, either within or outside the range of 30-40 millilitres/minute, may, of course, be implemented.
[0055] The drip valve deposits water into the central cavity 134 of the constant steam chamber 120 where it is heated by heat from the heating element 142 (either directly or transferred through the soleplate 100 ) to generate steam. As pressure in the central cavity 134 builds up the steam is directed into the lateral channels 136 (via vanes 138 ) where it exits the iron 400 via the constant steam chamber apertures 140 . In addition to providing constant steam, the iron 400 may also be operated to generate a shot of steam through the steam shot chamber apertures 132 . To generate the shot of steam an amount of water from the water reservoir 506 is delivered to the steam shot channel 123 , and in particular to the confluence 128 of the steam shot channel 123 . In the illustrated embodiment this is achieved by the user depressing the steam-shot trigger (e.g. 408 ) which operates the pump 412 to pump water from the water reservoir and deposit it in the steam shot channel 123 (via a conduit 418 which passes through the soleplate cover 502 ). The specific volume of water to be deposited in the steam channel 123 will depend on a number of factors, including the desired volume of steam to be emitted in a single steam shot. In one embodiment the volume for a single shot of steam may be approximately 0.5 millilitres. In an alternative embodiment the volume for a single shot of steam may be approximately 0.6 millilitres. Further alternative volumes, either within or outside the range of 0.5 to 0.6 millilitres may, of course, be used.
[0056] As noted above, the confluence 128 of the steam shot channel 123 (i.e. the point at which water from the water reservoir 506 is delivered) and the re-entrant flow paths 126 substantially overlay the heating element 142 . When water is delivered to the confluence 128 where it is heated to steam, the flow of the steam being divided between the re-entrant flow paths 126 (the bend in the inner wall 113 acting as a flow-splitter). The re-entrant shape of the flow paths 126 provides for a relatively long flow path, and as the entire length is in close proximity to the heating element 142 the water is quickly boiled to steam, and the pressure of the steam increased. The steam eventually exits the re-entrant flow paths 126 into the front cavity 122 , and from there is “shot” (by virtue of the pressure) out the steam shot chamber apertures 132 .
[0057] It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.
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An electric steam iron is described. The iron includes a water reservoir and a soleplate. The soleplate includes a base, a heating element, a constant steam chamber in fluid communication with a plurality of constant steam chamber apertures passing through the base, and a steam shot chamber. The steam shot chamber includes a front cavity and a steam shot channel in thermal communication with the heating element and in fluid communication with the front cavity, the front cavity including at least one steam shot chamber aperture passing through the base, the steam shot channel defining a pair of flow paths substantially overlying the heating element, each flow path having a re-entrant shape. The iron further includes a constant steam chamber water delivery means for delivering water from the water reservoir into the constant steam chamber, and a steam shot chamber water delivery means for delivering water from the water reservoir into the steam shot chamber in the soleplate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of priority to Chinese patent application No. 201520193597.6 titled “TENT”, filed with the Chinese State Intellectual Property Office on Apr. 1, 2015, the entire disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
The present application relates to the technical field of outdoor recreation, and in particular to a tent.
BACKGROUND
Outdoor recreation has become a favorable and popular relaxing exercise, and a tent has become a necessity of the outdoor recreation. The tent mainly consists of a tent fabric and a supporting frame for supporting the tent fabric, and an inner expansion space is formed by pulling the tent fabric and the supporting frame via windproof ropes and tent pegs.
For expanding the usable space in the tent, multiple supporting poles are generally used in a conventional tent to form a cross structure to hold up a top space. A common structure is a cross shaped or a cross-like shaped supporting structure which is formed by two cross supporting poles. However, such cross structure requires multiple supporting poles, which increases the weight of the whole tent, causing carry difficulties to the tent. Moreover, both of the two cross supporting poles are required to be bent and supported onto the ground, thus the top space of the tent is reduced in structure. Another tent, known as a transverse lined top tent, uses a transverse pole as a top pole to form a support in a transverse direction at the top of the tent. Although the tent with such a structure has a large bottom space, the top of the transverse lined top tent is unable to form a supporting surface at the top, thus the usable space in the tent cannot be expanded.
SUMMARY
For solving the problem that a supporting surface cannot be formed at the top of a tent and a usable space inside the tent cannot be expanded in a conventional tent, a tent is provided by the present application.
A tent includes a tent fabric and a supporting pole, and the supporting pole is connected to the tent fabric for supporting the tent fabric.
The tent further includes a first top pole and a securing and connecting device. The securing and connecting device is connected to the tent fabric. In a case that the tent is put up, the first top pole is inserted into the securing and connecting device and the first top pole and the supporting pole are crosswise arranged, and the securing and connecting device is located in an extension direction of the first top pole.
Since the first top pole and a middle portion of the supporting pole form a cross structure at a top of the tent, and the first top pole is secured by the securing and connecting device on the tent fabric. A supporting plane is formed at the top of the tent when the tent is put up, thereby expanding the usable space at the top of the tent.
Preferably, the tent further includes multiple second top poles. In a case that the tent is put up, the second top poles are arranged at two sides of the supporting pole respectively, and the second top poles are arranged inside the tent fabric, or are hinged to the first top pole.
The second top poles are arranged at two sides of the first top pole, and the first top pole and the second top poles cooperate to support the tent to allow a space of the tent at the left and right directions, of two free ends of the first top pole, to be at a substantially same plane with the first top pole, thus further expending the space at the top of the tent.
Preferably, the securing and connecting device is a securing plate, and the securing plate is connected to a body of the tent fabric. The securing plate is provided with a through-hole. An end portion of the first top pole has a first locking groove. When the tent is put up, an inner edge of the through-hole is stuck in the first locking groove. Or, the securing plate and connecting device is a rigid ring, and each of two ends of the first top pole has a cone shaped surface to be stuck in the rigid ring.
Preferably, a size of the end portion of the first top pole is greater than a size of the through-hole, and the first top pole is unable to be disengaged from the securing plate.
By employing the locking groove to be stuck in the inner edge of the securing plate or the cone shaped surface to be stuck in the rigid ring, the first top pole can be easily assembled. Since the size of the first top pole is greater than the size of the through-hole in the securing plate, the first top pole cannot be disengaged from the securing plate. The first top pole can directly slide along the through-hole to be superposed with the second top pole when the tent is folded up. The first top pole is directly folded inside the tent fabric, preventing being lost, and easy to operate.
Preferably, the supporting pole includes a transverse pole and multiple standing poles, and the transverse pole and the standing poles are connected by a connecting member.
Preferably, the transverse pole and the standing poles are respectively hinged to the connecting member, and in a case that the tent is folded up, the transverse pole and the standing poles can be rotated around respective articulated shafts to be folded together.
Preferably, another securing plate is also provided at positions, corresponding to the standing poles, at a bottom of the tent fabric. An end portion of each of the standing poles is provided with a second locking groove. In a case that the tent is put up, an inner edge of the trough-hole of the securing plate, at the bottom of the tent fabric, is stuck in the second locking groove.
Preferably, each of the standing poles is a multi-section pole, and the multiple sections of the standing pole can be folded and/or stretched out and drawn back.
Preferably, the tent further includes a third top pole, and the third top pole is hinged to the connecting member. In a case that the tent is put up, free ends of the third top pole are at two sides of the transverse pole. In a case that the tent is folded up, the third top pole is rotated around a corresponding articulated shaft to be folded with the transverse pole.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a tent in an open state according to a first embodiment of the present application;
FIG. 2 is a perspective view of the tent in the open state according to the first embodiment of the present application;
FIG. 3 is a schematic view of a supporting frame of the tent according to the first embodiment of the present application;
FIG. 4 is a schematic view of a supporting pole in a first folding step according to the first embodiment of the present application;
FIG. 5 is a schematic view of the supporting pole in a second folding step according to the first embodiment of the present application;
FIG. 6 is a schematic view of the supporting pole in a third folding step according to the first embodiment of the present application;
FIG. 7 is a schematic view of the supporting pole in a folded state according to the first embodiment of the present application;
FIG. 8 is a schematic view showing the connection relationship between a first top pole and a securing plate of the tent according to the first embodiment of the present application; and
FIG. 9 is a schematic view of a tent in an open state according to a second embodiment of the present application.
Corresponding relationships between reference numerals and components in FIGS. 1 to 8 are as follows:
1
tent fabric,
2
supporting pole,
21
transverse pole,
22
upright pole,
221
lower pole,
222
middle pole,
223
upper pole,
3
first top pole,
31
first locking
groove,
4
securing plate,
41
securing plate
42
through-hole,
body,
43
connecting
5
second top pole,
6
fastening.
rope,
DETAILED DESCRIPTION
For those skilled in the art to better understand technical solutions of the present application, the present application is described in detail in conjunction with drawings and embodiments hereinafter.
A first embodiment of the present application is described as follows.
FIGS. 1 to 8 are schematic views of a tent and components thereof according to the first embodiment of the present application. As shown in FIG. 1 , the tent according to this embodiment includes a tent fabric 1 , a supporting pole 2 , a first top pole 3 and securing plates 4 . The supporting pole 2 is connected to the tent fabric 1 for mainly supporting the tent fabric 1 . The securing plates 4 are located at two sides of the supporting pole 2 , respectively, and are buckled to the tent fabric 1 via a buckle or are directly sewed to the tent fabric 1 via sewing threads. Each of the securing plates 4 includes a securing plate body 41 and a through-hole 42 on the securing plate body 41 . A first locking groove 31 is provided at each end portion of the first top pole 3 . In a case that the tent is put up, an inner edge of the through-hole 42 on the securing plate body 41 is stuck in the first locking groove 31 , thereby the first top pole 3 is connected to the tent fabric 1 . At the same time, the first top pole 3 contacts the supporting pole 2 , holding up a top space of the tent fabric 1 together. The connection between one securing plate 4 and the first top pole 3 is clearly shown in FIG. 8 . In this embodiment, the securing plate 4 is sewed to the tent fabric 1 via a connecting rope 43 , and a size of the through-hole 42 in the securing plate 4 is gradually decreased to a free end of the securing plate from a connecting end where the securing plate 4 is connected to the tent fabric 1 , as shown in FIG. 8 . The size of a portion of the through-hole 42 close to the tent fabric 1 may allow the first top pole 2 to pass through the through-hole 42 , and the size of a portion of the through-hole 42 away from the tent fabric 1 is smaller, thus an edge of the portion of the through-hole 42 away from the tent fabric can be stuck in the first locking groove 31 at the end portion of the first top pole 3 .
It will be appreciated that employing the securing plate 4 to connect the first top pole 3 and the tent fabric 1 is a preferable manner. Other manners in the field via which the tent fabric 1 can be connected to a pole for supporting the tent fabric 1 may also be employed to connect the first top pole 3 and the tent fabric. For example, a rigid ring is commonly used in the field for connecting the tent fabric and pole. The rigid ring is directly sewed onto a corresponding position of the tent fabric, and a cone shaped surface is provided at an end portion of the first top pole 3 for being stuck in the rigid ring. In a case that the tent is required to be put up, the end portion of the first top pole 3 is inserted into the rigid ring so that the cone shaped surface can be stuck in the rigid ring. Apparently, a long groove sewed in the tent fabric may also realize a stuck connection similar to the rigid ring.
To better support the space at the top of the tent, the tent according to this embodiment further includes multiple second top poles 5 , and the second top poles 5 are installed inside the tent fabric 1 . When the tent fabric 1 is put up, the second top poles 5 are arranged at two sides of the supporting pole 2 for forming the space at the top of the tent together with the first top pole 3 and the supporting pole 2 . In this embodiment, the second top poles 5 are directly sewed onto the inner side of the tent fabric 1 , and a middle position of each of the second top poles 5 corresponds to the position where the securing plate 4 is connected to the tent fabric 1 . When the tent is put up, the second top poles 5 are in parallel with a middle portion of the supporting pole 2 . It will be appreciated that, in this way, a middle supporting area in FIGS. 2 and 3 is formed by the first top pole 3 , the second top poles 5 and the middle portion of the supporting pole 2 , thereby expanding an area of the top and the space. In other embodiments, the second top poles 5 may be installed inside the tent fabric 1 by other ways. The first top pole 3 may be hinged to the second top pole 5 via an articulation piece, and the articulation piece is capable of securing the first top pole 3 and the second top poles 5 at a position where a certain angle is formed between the first top pole and the each of second top pole, and when the hinging action of the articulation piece is removed, the first top pole and the second top poles may be rotated to be superposed together. And in a case that the tent is put up, each of the second top poles may be secured to the tent fabric by securing two ends of the second top pole to the tent fabric via the securing plate or the rigid ring. Or, the second top poles 5 may be dispensed, thus the space at the top of the tent is directly formed by the first top pole 3 and the supporting pole 2 . Considering that tent pegs and windproof ropes may be used in the putting up process of the tent, the windproof ropes may be used for pulling a corresponding portion of the tent to expand the space at the top of the tent.
For facilitating carrying and mounting the first top pole 3 in this embodiment and further facilitating putting up and folding up the whole tent, a size of the end portion of the first top pole 3 is greater than a size of the through-hole 42 in the securing plate 4 , thus the first top pole 3 cannot be disengaged from the securing plate 4 . The first top pole 3 can be folded up along a direction of the second top pole 5 when the tent is folded up. Other components are folded up after the first top pole is nearly superposed with the second top poles 5 . Apparently, in other embodiments, the first top pole 3 may be disengaged from the securing plate 4 when the tent is folded up, thus the first top pole is separately put away.
It will be appreciated that the first top pole 3 and the supporting pole 2 in this embodiment are not connected, but just in contact in the actual using process. In a specific application, the first top pole 3 may be located above the supporting pole 2 , or below the supporting pole 2 .
The supporting pole 2 according to this embodiment includes a transverse pole 21 and multiple standing poles 22 . All the two ends of the transverse pole 21 and the standing poles 22 are hinged to a connecting member 6 for further being rotated around respective shafts. In this embodiment, the connecting member 6 is connected to two standing poles 22 . When the tent is folded up, the two standing poles 22 may be rotated to be superposed with each other and then rotated to be superposed with the transverse pole 21 together. Apparently, in other embodiments, the transverse pole 21 and the standing poles 22 may be connected by other manners, for example, the transverse pole 21 and the standing poles 22 may be connected by an elastic rope or a plug connector capable of forming a plug-in connection. In other embodiments, more standing poles 22 may be provided according to a volume of an actual tent and the requirement for supporting stability.
In this embodiment, each of the standing poles 22 may be a pole having three sections. The connection between a lower pole 221 and a middle pole 222 is of a telescopic type, and a buckle is provided between the lower pole 221 and the middle pole 222 , and the lower pole 221 and the middle pole 222 can be stretched out and drawn back when the buckle is opened. The middle pole 222 and an upper pole 223 are hinged with each other. The middle pole 222 and the upper pole 223 may be rotatably unfolded or folded by an intermediate articulation piece. It should be noted that, after the standing poles 22 are fully extended, the buckle and the intermediate articulation piece should have a capability of certain position-limiting so as to prevent the lower pole 221 and the middle pole 222 moving or rotating with each other and further allow the tent to be in a complete put up state. Apparently, in principle, the standing pole 22 may be formed by one piece, or secured by other methods to complete a relative positioning, for example, using the above elastic rope to thread the three sections of the upright pole 22 .
FIGS. 4 to 7 shows a folding manner of the supporting pole 2 in this embodiment. Firstly the buckle between the lower pole 221 and the middle pole 222 is opened so that the lower pole 221 and the middle pole 222 are superposed to the fullest; then the articulation piece between the middle pole 222 and the upper pole 223 is opened so that the middle pole 222 and the upper pole 223 are rotatably superposed; and then, the two standing poles 22 at the same side of the connecting member 6 are folded so that the folded standing poles 22 are rotated around the connecting member 6 to be superposed with the transverse pole 21 to a degree shown in FIG. 7 .
A bottom portion of the tent fabric 1 requires to be securely connected to bottom portions of the standing poles 22 to further extend the bottom portion of the tent to the fullest. In this embodiment, the standing poles 22 and the tent fabric 1 are also connected via the securing plates 4 . An end portion of each of the standing poles 22 , i.e., a free end of the lower pole 221 , has a second locking groove, and an inner edge of the through-hole 42 of one securing plate 4 , located at a corresponding position of the bottom portion of the tent fabric 1 , is stuck in the second locking groove. In other embodiments, other securing manners may be adopted, such as the above ways of using the rigid ring or the ropes.
In other embodiments of the present application, a third top pole may be provided. The third top pole is connected to the connecting member 6 , and forms a certain angle with the transverse pole 21 of the supporting pole 2 . When the tent is put up, two free ends of the third top pole are respectively at two sides of the transverse pole 21 , and a certain space may be formed by the free ends of the third pole. When the tent is folded up, the third top pole may be hinged to the connecting member 6 , and can be rotated to be superposed with the transverse pole 21 , which is easy to be folded.
In the embodiment of the present application, all of the first top pole 3 , the second top pole 5 and the third top pole are fiber poles, which have a good elasticity, thus making the put up tent look plump and firm. Similarly, the supporting pole 2 may also be a fiber pole, especially the transverse pole 21 , the upper pole 223 and the middle pole 222 of the supporting pole 2 . Apparently, in other embodiments, a hollow aluminum pipe and other materials commonly used in the field may be employed to make each of the above poles.
After the tent according to this embodiment is put up, a main body of the tent fabric 1 is connected to the supporting pole 2 or each top pole by a corresponding buckle or connecting rope, and is tightly pulled by windproof ropes and tent pegs. When the tent is folded away, the tent fabric 1 may be folded up separately or together with supporting components.
A second embodiment of the present application is described as follows.
FIG. 9 is a schematic view of a tent in an open state according to the second embodiment of the present application. As shown in the Figure, a general structure of the tent in this embodiment is the same as the structure of the tent in the first embodiment, which also includes a tent fabric 1 , a supporting pole 2 , a first top pole 3 and a securing plate 4 . However, the supporting pole 2 according to this embodiment directly employs a foldable long pole, rather than employing the connecting member 6 to connect the standing poles 22 at the two sides of the transverse pole 21 respectively in the first embodiment. In this embodiment, after a main frame for supporting the tent fabric 1 is formed by the supporting pole 21 and the transverse pole 21 , the windproof ropes and tent pegs are also required to connect the tent fabric 1 to secure the tent in each side.
The tent in the embodiments of the present application is described in detail hereinbefore. The principle and the embodiments of the present application are illustrated herein by specific examples. The above description of embodiments is only intended to help the understanding of the spirit of the present application. It should be noted that, for the person skilled in the art, a few of improvements and modifications may be made to the present application without departing from the principle of the present application, and these improvements and modifications are also deemed to fall into the scope of the present application defined by the claims.
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A tent includes a tent fabric and a supporting pole. The supporting pole is connected to the tent fabric for supporting the tent fabric. The tent further includes a first top pole and a securing and connecting device, and the securing and connecting device is connected to the tent fabric. When the tent is put up, the first top pole is inserted into the securing and connecting device, and the first top pole and the supporting pole are crosswise arranged, the securing and connecting device is located at an extension direction of the first top pole. Since a cross structure is formed at a top of the tent and the first top pole is secured by the securing and connecting device, a supporting plane can be formed at the top of the tent when the tent is put up, expending the usable area at the top of the tent.
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BACKGROUND
1. Technical Field
The present disclosure relates generally to the game of golf, and particularly to a universal pull cart attachment device and method to enhance golf play.
2. Description of the Related Art
There are several traditional methods of traversing a golf course during play. These traditional methods include: (1) walking the entire course while carrying one's clubs, (2) walking the entire course pulling a pull cart with one's clubs attached, and (3) riding in a motorized cart with one's clubs retained in the motorized cart. Each of these methods suffers from constraints which lead to slow golf play, thus resulting in reduced player enjoyment and reduced revenue for golf course associations and owners. For example, when walking a course, golfers inherently travel at slower speeds and can suffer from fatigue over the length of the course resulting in slower play and reduced enjoyment.
The use of a cart does not necessarily speed play when compared to walking. When using a motorized cart, golfers generally strap their clubs to the cart and thus become bound to the cart when making club selections. Following a shot, a golfer's ball is often located on areas of the course where carts are not permitted or unable to travel. Golfers must leave their cart behind and travel to their ball by foot, thus slowing game play. This problem is compounded when a golfer makes the wrong club selection and must return to the cart. Furthermore, because each golfer's clubs are retained in the cart, each golfer is generally bound to the particular cart in which his clubs are located and thus, when playing in a foursome (which is typical), each golfer is unable to conveniently switch carts to travel with another golfer whose ball may be in an area proximate to his own ball.
Some devices have been developed in attempt to facilitate or speed the play of golf; however, such devices suffer from a number of deficiencies.
U.S. Pat. No. 3,237,968 discloses a connector that is particularly adapted for use in trailing pull carts behind a self-powered vehicle. The device is intended to facilitate play of a foursome where two golfers travel via the self-powered vehicle and two golfers travel via foot. The connector does not allow for quick disconnect of the pull carts and thus does not overcome limitations resulting from methods of play in which golfers are essentially bound to a particular motorized cart.
U.S. Pat. No. 6,705,624 discloses a motorized golf cart with automated lifting of detachable devices such as pull carts. The automated lifting device requires actuation of a linear actuator to lift pull carts from the ground to an elevated position. The time required to actuate the device takes away from game play and results in slower play. In addition, the lifting device requires custom pull carts and thus fails to provide a universal attaching system for a wide variety of pull carts.
A universal pull cart attachment device is needed for attaching a wide variety of pull carts having varied handle designs and wheel sizes to motorized golf carts to provide a versatile system of playing golf in which a golfer may quickly detach a pull cart from a motorized golf cart to reach a subsequent shot location and may quickly reattach the pull cart to the same or another golf cart for traversing to yet another shot location.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view of a universal pull cart attachment, according to one embodiment.
FIG. 2 shows the universal pull cart attachment of FIG. 1 partially disassembled.
FIGS. 3 and 4 show the universal pull cart attachment of FIG. 1 mounted to a motorized golf cart with a pull cart engaged therein.
FIGS. 5-8 illustrate a system of playing golf utilizing a universal pull cart attachment device.
FIGS. 9 and 10 provide representative data of potential revenue gains associated with the system of playing golf illustrated in FIGS. 5-8 .
FIG. 11A is a perspective view of a universal pull cart attachment in an unassembled condition, according to one embodiment.
FIG. 11B is a perspective view of the universal pull cart attachment of FIG. 11A in an assembled condition.
DETAILED DESCRIPTION
FIGS. 1-16 depict a universal pull cart attachment device suitable for attaching a conventional pull cart to a motorized golf cart, according to one embodiment. As shown in FIG. 1 , the attachment device 10 includes a base member 20 and an extension member 30 . The base member 20 of the illustrated embodiment is configured to mount to a motorized golf cart via a plurality of mounting holes and corresponding hardware. The base member 20 can be pre-installed on a motorized cart or attached as an add-on feature. In an alternate embodiment, the universal pull cart attachment 10 is formed integrally with the motorized golf cart. For example, the base member 20 of the pull cart attachment may be molded into a golf cart frame.
The extension member 30 is coupled to the base member 20 such that the extension member 30 can be selectively extended to facilitate design variations in motorized golf carts. The extension member 30 can extend from a right side of the motorized cart or from a left side, or both. The extension member 30 allows selective placement of the device such that a golfer may access one or both sides of a pull cart when attached thereto. In a preferred embodiment, two extension members 30 are provided for attachment of two pull carts. In the illustrated embodiment, the base member 20 is steel square tubing and the extension member 30 is steel u channel, although numerous structural shapes (e.g., round stock) and materials are contemplated (e.g., stainless steel, composite materials). The base member 20 includes an aperture proximate at least one end thereof to receive a fastener 24 for coupling to one of a series of spaced apertures 32 in the extension member 30 . In an alternate embodiment, the base member 20 and extension member 30 are integral.
The extension member 30 includes a cylindrical mounting stem (not shown) that defines a first axis of rotation A. The mounting stem is sized for insertion into a first retention member 40 . The first retention member 40 includes a hook 42 and a cylindrical sleeve 44 for mating with the mounting stem of the extension member 30 to allow rotational movement about the first axis of rotation A. The rotational movement of the first retention member 40 may be limited by stops. In the illustrated embodiment, an internal dowel (not shown) engages slots in the mounting stem of the extension member 30 to limit rotational travel. Other features for limiting rotational movement are well known in the art.
The hook 42 is sized and shaped to retain a handle of varying sizes as commonly found on conventional pull carts. In an alternate embodiment, the hook 42 is selectively adjustable to provide selective engagement with the handle of a pull cart. In one embodiment, a cushioning material may be placed on an under surface of the hook 42 to provide protection against chafing, absorption of vibration, and/or adaptation to various handle configurations.
A second retention member 50 having a cylindrical stem 52 and support surface 54 is coupled to the first retention member 40 via a cylindrical insert 60 and extension spring 70 . The cylindrical insert 60 is press-fit or otherwise fastened to the cylindrical stem 52 of the second retention member 50 and sized to slidably engage the sleeve 44 of the first retention member 40 . The insert 60 may include a groove in the face thereof to engage a surface feature of the sleeve 44 so as to prevent relative rotational movement between the sleeve 44 and the insert 60 . The first and second retention members 40 , 50 are able to at least partially rotate about the first axis of rotation A to enable a pull cart attached thereto to turn in combination with the motorized cart.
The second retention member 50 translates along the first axis of rotation A from an engaged position to a disengaged position and is biased towards the engaged position by the extension spring 70 that is retained in the first retention member 40 and secured to the second retention member 50 . The bias force of the extension spring 70 is selected such that a user can easily displace the second retention member 50 to the disengaged position by hand. Extension features 56 , 58 at opposing ends of the second retention member 50 provide levers for displacement of the second retention member 50 to the disengaged position.
In the engaged position, the hook 42 of the first retention member 40 cooperates with the support surface 54 of the second retention member 50 to retain the handle of a pull cart while simultaneously allowing the handle of the pull cart to rotate, such that the pull cart is able to pitch up and down. Edges of the support surface 54 may be contoured to reduce chafing or abrasion of the pull cart handle. When a handle of a pull cart is engaged, the wheels of the pull cart remain in contact with the ground. Because the wheels remain in contact with the ground, it is preferable to use the universal pull cart attachment device with pull carts having larger diameter wheels that are better adapted for traveling at higher speeds.
FIGS. 11A and 11B depict a universal pull cart attachment device suitable for attaching a conventional pull cart to a motorized golf cart, according to another embodiment. Similar to the device described above, the attachment device 10 includes an extension member 30 for attaching to a base member (not shown), which is configured to mount to a motorized golf cart via a plurality of mounting holes and corresponding hardware. The illustrated extension member 30 includes a series of spaced apertures 32 for coupling to the base member in such a manner that the extension member 30 can be selectively extended to facilitate design variations in motorized golf carts. In this manner, the extension member 30 may allow for selective placement of the attachment device 10 such that a golfer may access one or both sides of a pull cart when attached thereto.
The extension member 30 further includes a cylindrical mounting stem 36 that defines a first axis of rotation A and that is sized for insertion into a first retention member 40 . The first retention member 40 includes a hook 42 and a cylindrical sleeve 44 for mating with the mounting stem 36 of the extension member 30 to allow rotational movement about the first axis of rotation A. The rotational movement of the first retention member 40 about axis A may be limited by stops. In the illustrated embodiment, a dowel 34 is coupled to the first retention member 40 , for example, by welding, such that the dowel 34 comes into contact with sidewalls of the extension member 30 during operation. Other features for limiting rotational movement are well known in the art.
In accordance with the illustrated embodiment, the first retention member 40 includes a threaded insert (not shown) fixedly attached within cylindrical sleeve 44 for coupling the first retention member 40 to the extension member 30 . In particular, a threaded rod 38 of extension member 30 mates with the threaded insert of the first retention member 40 to couple the components together while allowing for rotational movement therebetween. As can be appreciated from FIGS. 11A and 11B , dowel 34 is coupled to the first retention member 40 after having attached the first retention member 40 to the extension member 30 .
A second retention member 50 having a cylindrical body 62 and support surface 54 is coupled to the assembly of the first retention member 40 and extension member 30 via an extension spring 70 , such that the second retention member 50 may be displaced vertically from the first retention member 40 along axis A against a bias force of the spring 70 . The extension spring 70 may be attached at one end to a nut 68 that is sized to engage threaded rod 38 of the extension member 30 and may be attached at the other end via a retaining rod 64 that is welded or otherwise coupled to the second retention member 50 .
The cylindrical body 62 of the second retention member 50 slidably engages the cylindrical sleeve 44 of the first retention member 40 to maintain these components about a common rotation axis A. An additional alignment feature may also be included to keep the first and second retention members 40 , 50 aligned with respect to each other throughout rotational movement. For example, a fastener received in a threaded hole formed on the cylindrical sleeve 44 of the first retention member 40 may engage a vertical slot (not shown) formed in cylindrical body 62 of the second retention member 50 . Alternatively, a stud or other projecting feature located on the cylindrical sleeve 44 may similarly engage a vertical slot formed in the cylindrical body 62 . In this manner, the first and second retention members 40 , 50 are able to at least partially rotate together about the first axis of rotation A to enable a pull cart attached thereto to turn in combination with the motorized cart.
As described above, the second retention member 50 may be displaced vertically from the first retention member 40 along axis A against a bias force of the spring 70 . More particularly, the second retention member 50 translates along the first axis of rotation A from an engaged position to a disengaged position, the second retention member being biased towards the engaged position by the extension spring 70 . The bias force of the extension spring 70 is selected such that a user can easily displace the second retention member 50 to the disengaged position by hand. Extension features 56 , 58 at opposing ends of the second retention member 50 provide levers for displacement of the second retention member 50 to the disengaged position.
In the engaged position, the hook 42 of the first retention member 40 cooperates with the support surface 54 of the second retention member 50 to retain the handle of a pull cart while simultaneously allowing the handle of the pull cart to rotate, such that the pull cart is able to pitch up and down. Edges of the support surface 54 may be contoured to reduce chafing or abrasion of the pull cart handle.
A universal pull cart attachment device, such as, for example, the embodiment shown in FIGS. 1-4 or the embodiment shown in FIGS. 11A and 11B , is used to provide a novel method for coupling a conventional pull cart to a motorized golf cart. The method includes the steps of displacing a retention member of the universal pull cart attachment device from a first engaged position to a second disengaged position, inserting a handle of a pull cart beneath a hook of the universal pull cart attachment device, and releasing the retention member such that the handle of the pull cart is retained in the attachment device while allowing wheels of the pull cart to remain in contact with a ground surface. Employing such a method allows a user to attach a wide variety of pull carts to a motorized golf cart without customizing the pull cart for attachment thereto. Nor is a user required to lift the pull cart. Wheels of the pull cart remain in contact with the ground, thus facilitating quick withdraw of the pull cart from the motorized golf cart.
FIGS. 5-8 illustrate examples of a method of playing golf using a universal pull cart attachment device that allows for quick disconnection so players are never separated from their clubs and similarly allows for quick reconnection so players can quickly traverse a golf course via a motorized cart on long fairways or between holes. For the purposes of clarity and ease of comprehension, the method of play using a universal pull cart attachment device, such as, for example, the embodiment shown in FIGS. 1-4 , will be explained with reference to a foursome of golfers A, B, C, and D and their respective carts, Cart 1 and Cart 2 .
Each of Cart 1 and Cart 2 is outfitted with a universal pull cart attachment device on both the left and right side. Each golfer's clubs are retained in a respective pull cart that is initially attached to each universal pull cart attachment device. In any given hole, each of golfer A, B, C, and D will take a tee shot and then one of three scenarios will happen: (1) each golfer will stay with his respective cart and they will proceed to their respective shot location without disengaging the pull carts from the attachment device, as illustrated in FIG. 5 ; (2) each golfer will stay with his respective cart and proceed to one shot location and then one golfer will disconnect his pull cart while the other golfer, using the motorized cart, moves on to his shot location, as illustrated in FIG. 6 ; or (3) one golfer in Cart 1 and one golfer in Cart 2 will switch carts before leaving the tee box and each pair of golfers will proceed in their motorized cart to their ball location, as illustrated in FIG. 7 . Subsequent shots feature the same scenarios above in various combinations. For example, FIG. 8 illustrates one possible outcome of a par five hole using the method of play described herein.
The method of play allows each golfer the freedom to continue moving forward towards the green at all times while eliminating the need to traverse laterally or across the course, or to return to one's cart to retrieve a club. Unnecessary travel is eliminated resulting in faster game play and increased revenues. FIGS. 10 and 11 illustrate potential revenue gains associated with the system of playing golf illustrated in FIGS. 5-8 . It has been calculated that using a universal pull cart attachment in accordance with the method of playing golf described above will substantially reduce playing time. For example, playing time for a foursome on a eighteen hole course may be reduced by ninety minutes or more. Such a reduction in play time can equate to an increase in the number of golfers that can play during a given day in upwards of 10 foursome a day. As shown in FIG. 10 , based on a $40 greensfee, an additional 10 foursomes a day can generate $160,000 in revenue over the span of 100 days. As can be appreciated, the universal attachment device not only generates increased revenue for golf course associations and owners, but enhances a player's golf experience by eliminating unnecessary travel.
Moreover, aspects and features of the various embodiments described above can be combined to provide further embodiments. In addition, U.S. patent application Ser. No. 12/430,781, filed Apr. 27, 2009, and U.S. Provisional Application No. 61/125,799, filed Apr. 28, 2008, are incorporated herein by reference for all purposes and aspects of the invention can be modified, if necessary, to employ features, systems, and concepts disclosed in these applications to provide yet further embodiments.
These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled.
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This disclosure generally relates to a universal pull cart attachment device and method to enhance golf play. In some cases, a universal pull cart attachment device having a displaceable member is coupled to a motorized golf cart to allow users to displace the member to interchangeably receive a handle of a conventional golf bag pull cart. A method of playing golf using such a universal pull cart attachment device is also provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a gear constructional unit in particular with an essentially cylindrical interior space and bar form guide elements for mounting gear elements.
2. Description of the Related Art
Gear constructional units are known in a large number of executions. These can be executed as
a) a mechanical gear component
b) a hydrodynamic-mechanical compound gear component.
Hydrodynamic-mechanical compound gear components are known, for example, from the following publications:
Buksch, M: ZF five-gear automatic gears for passenger cars, VDI report 878 (1991)
Mitescko, G: Four-gear planetary gears for passenger cars with the hydrodynamic torque converter in the power branch, Automobilindustrie (1995) 5, pages 597-602
Klement, W.: The development of the DIWA gears, Verkehr und Technik (1997) 7, pages 301-303
Gear components which have either only purely mechanical transmission components or else consist of a combination of a hydrodynamic converter or of a hydrodynamic coupling with a downstream mechanical gear set, have as a rule a housing which in respect to its inner contour is adapted to the shape of the individual gear elements and to their connection to the housing and they have, as a rule, interior insets which undesirably reduce the inside diameter. For example, one known gear uses a threading of the gear elements onto six rods which are allocated to the interior space of the gear circumferentially at uniform intervals. This makes possible, to be sure, a very simple assembling of the components or gear elements, but the arrangement of the six bars in circumferential direction with constant spacing between two bars, as well as the number of these rods considerably reduces the inside diameter of the gear system, since the upper bars in installation position determine the structural height and therewith also the possible usable planetary diameter.
Underlying the invention, therefore, is the problem of creating a possibility for the formation of gear components, especially gear housings, with which in firmly prescribed installation as high as possible torques can be transmitted. In detail, there, emphasis is to be given to a reduction of the constructive and above all of the manufacturing technical expenditure as well as a minimizing of the required number of components.
BRIEF SUMMARY OF THE INVENTION
According to the invention the gear component, which comprises a gear housing and has a substantially cylindrical interior space, has at least two bar-form elements for the tying-on of gear elements in radial direction with respect to the gear axis, or in peripheral direction. The bar-form guide elements extend there essentially over a range in which there are arranged the gear elements provided for the tying-on. The bar-form guide elements are assigned to the cylindrical interior space and are arranged outside of this, in which the allocation occurs in such manner that the bar-form guide elements are provided outside of a zone which, as viewed in installation position of the gear, corresponds to the greatest dimension of the interior space in elevation direction of the gear component.
This means that none of the guide elements is arranged in installation position above the greatest dimension of the interior space in elevation direction, in the gear housing, but rather they are in the zones formerly more intensive in material for the gear housing, with an essentially quadrangular gear external contour with cylindrical interior space.
Under a further aspect of the invention there occurs there an arrangement of the bar-form guide elements with respect to the cylindrical interior space in a zone which is bounded by the installation position
Under a further aspect of the invention there occurs there an arrangement of the bar-form guide elements with respect to the cylindrical interior space in a zone which is bounded by the minimal and maximal dimensions of the cylindrical interior space. This means that there does not occur an arrangement directly above the greatest dimension in elevation direction, or underneath the lowest dimension of the cylindrical interior space in elevation direction, on the symmetry line of the cylindrical interior space running in elevation direction, as viewed in installation position. This offers the advantage that the housing builds relatively in elevation direction and therefore does justice optimally to the increasingly raised demands on the utilization of the available construction space.
With the solution according to the invention, therefore, the inside diameter or the inside contour of the gear housing can be made noticeably greater with constant installation measures for the gear component. By the guidance of the bar-form guide elements in the recesses which are connected with the cylindrical interior space, the cylindrical interior space can be utilized completely by the gear elements in respect to their radial extent. For example, with execution of the gear elements as a lamellar coupling the surface describable by the cross section surface of the interior space can serve more completely as possibly usable friction surface. Since the bar-form guide elements do not collide with the interior space, the other rotating gear elements, for example planetary wheel sets, can also be laid out in such manner that the entire interior space is completely utilized in radial direction. This leads to the result that because of the diameter increase with the same construction length, a greater torque can be transferred. It is possible to dispense with additional interior insets for the bearing, which reduce the diameter of the interior space. The suspension on the, bar-form guide elements prevents a twisting of the individual gear elements in circumferential direction and, in addition, limits the movability in radial direction with respect to the gear axis.
Compulsorily required are only two bar-form elements; at most four are required and preferably four bar-form guide elements are set in. The arrangement occurs in this case, as viewed in the cross section of the gear housing, in the corners zones, which (cross section) is describable by the section amount between the cylindrical interior space and a theoretically generatable square Q theoretical with a side dimension greater than or equal to the diameter of the interior space, the theoretically generatable square Q theoretical and the interior space having identical axes of symmetry. In this case, especially with a rectangular housing with cylindrical interior space, the material-intensive corner zones are used for the reception of the guide elements. The guide elements are guided there in recesses that are connected with the cylindrical interior space. Preferably the arrangement of the guide elements, however, occurs always symmetrically. This offers the advantage that the production expenditure for the gear elements and the gear housing can be minimize, as can also the assembling expenditure, since it is not necessary to take care of how the individual recesses or the passage openings on the gear elements have to be formed for the reception of the guide elements. Furthermore, the hosing base body can be made with the recesses independently of the latter actual installation position.
As gear elements there can be regarded, for example, brake arrangements in the form of lamellar brakes, partitions, actuating elements for braking or coupling devices, for example in the form of cylinders, pistons or cylinder-piston units, lamellae carriers or the like.
The bar-form elements preferably have over their axial extent, a like or constant diameter. This offers the advantage that the assembling can take place independently from the installation direction of the bar-form elements. There is conceivable also, depending on the formation of the total gear component, the use of bar-form elements with different diameter over the axial extent. In this case, however, as a rule, an assembling will occur as a rule from two sides.
By bar-form elements there are meant there guide elements the profile of which is constructed as a solid or hollow profile, or constitutes a combination of the two.
The guide elements, further, depending on the connection, can function as shaft or axles.
It is conceivable, for example, to execute a guide element as a hollow axle which encloses, for example, a shaft for the drive of additional units or an axle.
The cross section of the bar-form guide element is preferably circular. There are conceivable, however, also executions with tetragonal cross section or arbitrary cross section.
In regard to the bearing of the bar-form guide elements the following variants can be used:
a) Bearing on the housing in housing wall projections, for example at the beginning and/or end of the housing
b) Bearing in intermediate walls, which are threaded onto the guide elements
c) Suspended bearing on a wall projection or an intermediate wall, for example on the face sides of the gear, for example over covers
d) Bearing over wall projections (lugs)
The gear component can be constructed as a purely mechanical gear component. In this case each bar-form guide element extends preferably over the entire axial extent of the gear component. In the execution of the gear component as a hydrodynamic-mechanical compound gear, the bar-form guide element is provided with an axial length which corresponds to the axial extent of the mechanical gear part, with respect to the total gear component. It is always required, however, that the axial extent of the guide elements corresponds to the axial extent of the gear element supported on this.
A further possibility for the bearing of the bar-form elements lies in using the housing cover. In the especially preferred forms of execution, however, this possibility is dispensed with, in order to keep the housing cover free from forces, especially axial forces.
In an especially preferred gear component unit devices for the resetting of actuating elements of the lamellar brake- and/or coupling-arrangements are led through the bar-form guide elements. Between the two friction surface-carrying elements which are couplable with one another indirectly by frictional closure, there is provided at least one spring storage arrangement, which is likewise led over the bar-form guide elements and is laid out in such manner that on generation of the frictional closure between the friction surface-carrying elements and the intermediate element the spring storage arrangement is pre-stressable. By friction surface carrying elements there are meant there the elements which are couplable with one another over an intermediate element. In each case a friction surface-carrying element and a friction surface-carrying intermediate element form, on pressing-on a friction surface pair. By friction surface there is meant there the surface or the surface zone which participates in the friction closure. The friction surface there can be a component of the friction surface carrying element or of the intermediate element or it can be allocated to this as a separate element, for example in the form of a covering. The friction surface or the surface zones functioning as friction surface of a friction surface-carrying element or intermediate element can be generated, further, by a coating or surface treatment. The function of friction surface-carrying elements can be taken over there both by the outer as well as also by the inner lamellae. By reason of the effect of the spring storage unit between the individual friction surface-carrying elements, on relaxation of the actuating element in each case there acts an oppositely directed force on the friction surface-carrying elements, so that a rapid separation becomes possible with complete release of the frictional closure. The spring storage arrangements, therefore act indirectly, over a friction surface-carrying element, upon the actuating element. The actuating element itself can be executed, for example, as a piston, which preferably can be acted upon hydraulically or pneumatically. This possibility of arranging the spring storage elements between the friction surface-carrying elements offers the advantage that the dimensions of the friction surface carrying elements in radial direction are no longer dependent on the size of the inner dimensions of the gear housing under consideration for the required construction space for the device, at least for the indirect resetting of the actuating elements. The arrangement of spring storage units between the friction surface-carrying elements connectable with one another over an intermediate element offers the advantage of a space-saving execution of the resetting device, especially of the piston of a cylinder/piston unit in axial direction, which again affects the gear length in use of the brake arrangements in lamellar construction in a gear. In regard to the arrangement of the spring units between the friction surface-carrying elements, a large number of possibilities are conceivable:
a) Arrangement of spring units between each of the two adjacent friction surface-carrying elements;
b) Arrangement of the spring unit in force-flow direction between the friction surface-carrying elements in the zone of the force introduction (in the zone of the in each case outside-lying friction surface-carrying elements with respect to the installation position of the braking arrangement in a gear component);
c) Arrangement of the spring unit between two friction surface-carrying elements adjacent to one another with respect to the axial extent of the braking arrangement in the middle zone of the latter;
d) Arrangement according to b) in combination with c);
e) Arrangement of spring units in correspondence to the possibilities described in a) to d);
f) Combination of e) with the possibilities a) to d).
As spring storage units there are preferably used spring elements which have a characteristic line characteristic with an essentially constant force flow over a certain spring excursion. Preferably, therefore, cup springs are used. The execution of the spring units as a shaft spring ring is likewise thinkable. The actuating arrangements can be executed as cylinder-piston arrangements, which are actable upon hydraulically or pneumatically. In correspondence to the arrangement of the piston for the resetting device over the friction surface-carrying elements, especially lamellae on the piston are active, either in the zone of the piston surface or outside of the piston surface. In regard to the formation of the piston there are distinguished executions with
a) one piston
b) a plurality of pistons.
The appertaining cylinders can be formed there by a cylinder-carrying element or by a plurality of cylinder-carrying elements. This possibility for the piston resetting offers the advantage of a minimal space required in radial as well as in axial direction. In combination with the solution according to the invention there is given the possibility of creating a gear component with the possibility of high torque transmission with the structural height remaining constant, or with a reduced structural height.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The solution according to the invention is explained in the following with the aid of the figures. In these, the following is represented:
FIG. 1 a is a schematic diagram of the inventive gear unit;
FIG. 1 b is a section view of the inventive gear unit of FIG. 1 a taken along line A—A of FIG. 2; and
FIG. 2 is a section view of the inventive gear unit of FIG. 1 a taken along line B—B of FIG. 1 b.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 explains the solution according to the invention by way of example, with the aid of a certain gear type in axial section. The gear construction unit is executed as hydrodynamic-mechanical compound gear 1 .
The hydrodynamic-mechanical compound gear 1 comprises a first hydrodynamic gear part 2 in the form of a hydrodynamic speed/torque converter 3 and a second mechanical gear part 4 . The mechanical gear part 4 comprises a mechanical speed/torque converter 5 and a group set engaged downstream to this in force flow direction. The mechanical speed/torque converter 5 is executed as a modified Ravigneaux-planetary wheel set. This comprises a first planetary wheel set 7 and a second planetary wheel set 8 , which have a planetary wheel carrier 9 used in common. This establishes the coupling between a gear element of the first and of the second planetary wheel set. The first planetary wheel set 7 comprises a sun wheel 7 . 1 , planetary wheels 7 . 2 and a hollow wheel 7 . 3 . The second planetary wheel set 8 comprises a sun wheel 8 . 1 , planetary wheels 8 . 2 and a hollow wheel 8 . 3 .
The group set 6 comprises at least one planetary wheel set 10 , which has a sun wheel 10 . 1 , planetary wheels 10 . 2 , a hollow wheel 10 . 3 and a web 10 . 4 .
The hydrodynamic-mechanical speed/torque converter 3 comprises a turbine wheel T, a pump wheel P, a first guide wheel L 1 , and a second guide wheel L 2 , and it is covered by a housing 11 . The pump wheel P is connected with a gear input shaft E, which is couplable at least indirectly with a drive device serving for the driving, preferably with a flywheel 12 of an internal combustion engine in such manner that the force from the flywheel 12 is transferred to the pump wheel P. The turbine wheel T is joined untwistably with a turbine wheel shaft 13 . In order to use the advantages of the hydrodynamic torque transfer with bridging coupling, which in the following would be:
automatic stageless setting-in of the relation between the drive- and off-drive-speed corresponding to the load on the off-drive side
availability of the maximum torque for a starting operation with high acceleration;
possibility of head lead-off by outside or surface cooling
separation of the hydrodynamic speed/torque converter from the off-drive, especially from the vehicle at low drive speeds and transfer of a low residual torque, so that a choking of the drive device from the off-drive side is not possible
wear-free power transfer
and simultaneously . . . (Sc. to avoid) the disadvantages of a hydrodynamic power transmission, which essentially has an often no sufficiently attainable efficiency, in order to be able to work with a hydrodynamic gear alone, since power loss constituents that comprise friction and impact losses reduce the transferrable total power, and the transformation ranges achieved are often insufficient for the vehicle use, the hydrodynamic speed/torque converter 3 is used only in the lower gear stages, preferably only during the starting operation, for the power transfer. For the improvement of the transmission efficiency, therefore, the hydrodynamic speed/torque converter 3 is taken out of the power transmission, preferably by bridging. For this purpose, between the turbine wheel T and the flywheel 12 or the gear input shaft there is arranged a bridging coupling 14 .
The first guide wheel L 1 is arranged on the turbine side between the turbine wheel T and the pump wheel P and is borne by a freewheeling. The first guide wheel L 1 is untwistably connectable with a first guide wheel shaft 15 , there being provided between the first guide wheel L 1 and the guide wheel shaft 15 a freewheeling 16 , which is laid out in such manner that it transfers a torque onto the first guide wheel shaft 15 when the first guide wheel L 1 turns in opposite direction, i.e. in a rotation direction opposite that of the turbine wheel T, and which runs without load when the first guide wheel L 1 rotates in normal direction, i.e. in the same direction of rotation as the turbine wheel T. The second guide wheel L 2 is arranged between the turbine wheel T and the pump wheel P and is couplable, over a second guide wheel shaft 17 , with the housing 11 . Between the second guide wheel L 2 and the second guide wheel shaft 17 there is arranged a freewheeling 18 , by means of which the second guide wheel L 2 can be coupled with the second guide wheel shaft 17 , but only when the second guide wheel L 2 rotates in a direction opposite that of the turbine wheel T.
The pump wheel P is untwistably connected with a pump wheel shaft 19 , which is turnably borne over a bearing in the housing 11 .
For the execution of the individual gear stages and the design of the individual gears, switching elements are allocated to the individual elements of the hydrodynamic-mechanical compound gear system 1 . Between the hydrodynamic gear part 2 and the mechanical gear part 4 there are provided a first coupling arrangement K 1 and a first braking arrangement B 1 .
The turbine wheel T and the turbine wheel shaft untwistably couplable with it, are coupled with the sun wheel 8 . 1 of the second planetary wheel set 8 of the mechanical speed/torque converter 5 . Preferably the turbine wheel T and the sun wheel 8 . 1 of the second planetary wheel set 8 are arranged on a common shaft, here the turbine wheel shaft 13 ; the turbine wheel shaft 13 carries there also the coupling (clutch) disk 20 of the first coupling K 1 . The first coupling K 1 has, further, a coupling disk 21 , which is coupled with the first guide wheel shaft 15 . Further, the first glide wheel L 1 is connectable, over the first guide wheel shaft 15 , with the sun wheel 7 . 1 , of the first planetary wheel set 7 of the mechanical speed/torque converter 5 . The coupling disk 21 is connected with the first guide wheel shaft 15 . The first guide wheel shaft 15 is executed as a hollow shaft, which encloses the guide wheel shaft 13 in circumferential direction.
With the coupling covering 21 of the first coupling K 1 there is connected a preferably disk-form element 22 , and forms with this a constructive unit on the outer circumferential zone 23 of which the first braking arrangement B 1 can engage. The first braking arrangement B 1 serves there for the fixing into place of the first guide wheel L 1 over the guide wheel shaft 15 and/or of the first sun wheel 7 . 1 of the first planetary wheel set 7 of the mechanical speed/torque converter 5 . Further switching elements, here the switching elements in the form of braking arrangements B 2 and B 3 are allocated to the individual planetary wheel sets 7 and 8 of the mechanical speed/torque converter 5 . In the case represented the second braking element B 2 is allocated to the hollow wheel 7 . 3 of the first planetary wheel set 7 , and the third braking element B 3 is allocated to the hollow wheel 8 . 3 of the second planetary wheel set 8 of the mechanical speed/torque converter 5 . The coupling of the mechanical speed/torque converter 5 with the gear input shaft E over the hydrodynamic speed/torque converter 3 or its bridging over the bridging coupling 14 , occurs thereby by coupling of the turbine wheel T or the turbine wheel shaft 13 with a first gear element of the mechanical speed/torque converter 5 and of the first guide wheel L 1 with a further second gear element of the mechanical speed/torque converter 5 . As first gear element of the mechanical speed/torque converter 5 there functions here the sun wheel 8 . 1 of the second planetary wheel set 8 . As second gear element there functions the sun wheel 7 . 1 of the first planetary wheel set 7 . The shafts coupled with the two sun wheels 7 . 1 and 8 . 1 , here the first guide wheel shaft 15 and the turbine wheel shaft 13 , function as input shafts of the mechanical speed/torque converter 5 . A further third gear element is connected over the group set 6 with the gears output shaft A. As third gear element there functions the planetary carrier 9 , which is used in common by both planetary wheel sets 7 and 8 . The third gear element of the mechanical speed/torque converter 5 is connected with the input, which is formed by a first gear element of the group set 6 . Preferably this connection is realized over an untwistable coupling of the third gear element of the mechanical speed/torque converter 5 and the first gear element of the group set 6 . Both are preferably arranged on a common connecting shaft 24 . The first gear element of the group set 6 is formed by its planetary carrier 10 . 4 . A second gear element of the group set 6 is untwistably joined with the gear output shaft A of the hydrodynamic-mechanical compound gear system 1 . As second gear element there functions, in the case represented, the hollow wheel 10 . 3 of the planetary wheel set 10 of the group set 6 . While the mechanical speed/torque converter 5 serves for the execution of three gear steps in combination with the hydrodynamic speed/torque converter 3 , in the case represented six gear steps can be obtained by the combination of the hydrodynamic speed/torque converter 3 (and) of the mechanical speed/torque converter 5 with the group set 6 . For this purpose there are allocated to the group set 6 in each case a further coupling arrangement, here the second coupling arrangement K 2 and a further braking arrangement, here the fourth braking arrangement B 4 . The fourth braking element serves there for the fixing into position of the sun wheel 10 . 1 of the group set 6 . The second coupling arrangement K 2 makes possible the rigid coupling between the planetary carrier 10 . 4 and the sun wheel 10 . 1 of the planetary wheel set 10 of the group set 6 .
In the cut represented in FIG. 1 b , from a possible axial section of the gear component 1 it is to be seen how individual gear elements which are fastened to or borne on the housing are fastened to this housing 11 in the manner of the invention. The individual braking arrangements B 1 to B 4 are executed in laminar construction. These comprise in each case at least two friction surface-carrying elements which are joined with one another by friction closure over a friction surface-carrying intermediate element. The friction surface-carrying elements, there, are designated as follows for the individual braking arrangements:
B 1 : B 11 , B 12 , B 1n
B 2 : B 21 , B 22 , B 2n
B 3 : B 31 , B 32 , B 3n
B 4 : B 41 , B 42 , B 4n
The intermediate elements are designated in each case with B 1z , B 2z , B 3z and B 4z . There, the friction surface-carrying elements B 1n to B 4n form the outer lamellae. The fixed positioning of the outer lamellae occurs over the bar-form guide elements 40 . These extend preferably at least over the axial extent of the mechanical gear part 4 . The housing 11 has in this section an inside diameter 4 essentially constant over the axial extent. Preferably, as represented in FIG. 2, four bar-form guide elements 40 . 1 to 40 . 4 are provided, which are arranged, in circumferential direction in the gear housing 11 , for example with constant spacing to one another. The gear housing 11 itself, for example, at least in the zone which receives the mechanical gear part 4 , is formed in such manner that it has a substantially cylindrical inner cross section. Preferably the gear housing, as viewed in axial direction, has a substantially constant inside diameter in the zone of the mechanical gear part 4 . The inside diameter is designed in such manner that essentially the rotating gear elements and components can rotate freely, utilizing the maximally possible construction space. The individual guide element 40 is preferably executed in one piece, but can also consist of several sections. In the unmounted state of the mechanical gear part 4 , the inner part of which is designated here with 41 , is essentially empty. For the assembling, first the bar-form guide elements are brought into the corresponding positions or suspended onto the gear housing in a corresponding manner, and the individual gear elements are successively threaded on these guide elements in correspondence to the desired arrangement. From the separation point T, all the components of the mechanical gear part can be threaded one after another to the housing cover 42 in the assembling. This offers the advantage that with the threading-on technique and the constant inside diameter the individual components in the mechanical gear part 4 can be exchanged among one another, and therewith in a simple manner with constant gear housing or like dimensions of the gear component intermediate off-drives, or all-wheel off-drives can be achieved. The assembling occurs only from one side and, namely, in the case represented, from the side of the cover 42 . The assembling is simple in form and can be executed within the shortest time. The individual planetary wheel sets can be exchanged among one another in respect to their arrangements. Further, different off-drive variants are possible.
The axial fixing into position of the individual gear elements occurs there by security means, for example in the form of security rings 64 or stops 67 . Besides the outer lamellae there are also governed so-called partitions 44 , 45 , 46 and 47 . Further there occurs, likewise over the guide elements 40 . 1 to 40 . 4 , the fixed arrangement or supporting of gear elements, for example lamellae carriers or the like.
FIG. 2 explains a cross section corresponding to a view A—A according to FIG. 1 . There is evident the gear housing 11 , which can be subdivided in the case represented into two partial zones 50 and 51 . The first partial zone 50 forms there in installation position the upper housing part, the second partial zone forms the housing part arranged underneath the gear symmetry axis S in installation position. The gear housing 11 has, as already explained in the statements for FIG. 1, a substantially cylindrical inner contour 53 , which encloses an interior space 41 . The inner contour 53 can be described by the diameter d 1 . This extends as already thoroughly explained in the statements for FIG. 1, essentially over the entire axial extent of the mechanical gear part 4 .
Means are provided for the reception and binding-on of the gear elements in radial direction, and for the security with respect to twisting in circumferential direction. These means are formed by the guide elements 40 . 1 to 40 . 4 . These are allocated to the inner circumference 53 described by the diameter d 1 in such manner that these in installation position of the gear unit 1 , are arranged at a height H 1 to H 4 which, in respect to the dimensions, is less than the dimension H 5 described by the maximal extent of the inner contour 53 in installation position in elevation direction. The guide elements, therefore, as explained in FIG. 2, are arranged in the corner zones 54 , 55 , 56 and 57 of the housing 11 , the corner zones so that they make it possible to describe an allocation of a quadrate or rectangle to the inner contour 53 . The corner zones 54 to 57 are described there in installation by allocation of the quadrate (square) Q theoretical in which the diameter d 1 circumscribed by the inner contour is arranged in the quadrate and both, the theoretical quadrate Q theoretical cited for consideration, as well as the inner diameter d of the inner contour 53 of the housing, have the same symmetry axes S 1 and S 2 , respectively.
For the reception of the guide elements, corresponding recesses are provided in the housing. These are designated here in each case with 60 . 1 to 60 . 4 for the individual guide elements. The arrangement of these recesses 60 . 1 to 60 . 4 in the housing occurs there outside of a range on the gear housing which is described by, the respective symmetry of the gear component axis in elevational and in width direction, respectively, i.e, with use of a substantially rectangular housing outer form and an essentially cylindrical housing inner contour 53 , only the material-intensive corner zones 54 to 57 of the housing 11 are used for the reception of the guide elements 40 . 1 to 40 . 4 . Additional construction space in elevational or width direction is not needed. The interior space 41 can be formed with the maximally possible diameter d 1 , since in height and width directions no additional construction space has to be provided for the tying-on of the gear elements. The gear housing 11 itself can be equipped with a relatively thin housing wall in the zones free from the worked-in recesses 60 . 1 to 60 . 4 .
The recesses 60 . 1 to 60 . 3 form so-called engagement pockets into which the guide elements 40 . 1 to 40 . 4 can be inserted. Preferably in each case in axial direction, as explained in FIG. 1, there is provided a possibility for the suspension or for the floating bearing of the guide elements 40 . 1 to 40 . 4 . This is designated in FIG. 1 with 62 . In addition, the guide elements can also be guided in the partitions which extend over the entire interior space in radial direction. FIG. 2 explains, for example, the tying-on of the friction surface-carrying element B 31 . For the attaching to the guide elements 40 . 1 to 40 . 4 , in FIG. 2 four possible variants of execution are represented, schematically simplified. Preferably for the axial fixing into position of an elements there are used equal axial security elements. On the guide element 40 . 1 the axial securing occurs by use of shims, in the guide element 40 . 3 by means of a security ring 64 and on the guide element 40 . 4 by sleeves 65 .
For the threading of the individual gear elements onto the bar-form guide elements 40 . 1 to 40 . 4 , the individual gear elements have corresponding passage openings 66 . Preferably the gear elements are constructed in such manner that these have projections 63 in addition to their circular cross section, on which projections there are also recesses or passage openings 66 . This offers the advantage that the remaining construction space, especially the cylindrical interior space 41 can be, essentially fully utilized and contains no additional troublesome elements. Especially in the attaching of the outer lamellae in correspondence to FIG. 2, for the force transfer a surface can be used which corresponds essentially to the surface describable by the inner diameter d 1 .
Preferably the attaching of the gear elements occurs in all four possible corner zones 54 to 57 . The guide elements 40 . 1 to 40 . 4 and the corresponding projections on the gear elements are arranged with constance spacing viewed in circumferential direction with respect to the inner contour 53 of the gear component 1 . There exists, however, also the possibility of finding a substantially symmetrical arrangement which differs from the arrangement in the corner zone. Further, it is not compulsorily necessary to perform an attachment in all four corner zones. For the twist safeguarding in circumferential direction at least two guide elements are required.
Preferably the braking arrangements B 1 to B 4 are equipped with a device for the resetting of actuating elements. For this purpose, between in each case two friction surface-carrying elements adjacent to one another, a spring storage unit is provided which according to FIG. 1 is likewise guided by the guide elements, to the guide element 40 . 1 , and (which) is pre-tensionable, on generation of the frictional closure between the friction surface-carrying elements and the intermediate element. In the case represented, between the friction surface-carrying elements of the braking arrangement B 1 , there are provided a spring storage unit F 1 or B 2 , F 2 , B 3 -F 3 and B 4 , F 4 , respectively. The spring storage units there are always arranged outside of the friction surface-carrying intermediate elements, so that in this respect no collision of any kind can arise between the spring storage units and the friction surface-carrying intermediate elements. Preferably at least between the first two friction surface-carrying elements adjacent to one another in force flow direction of a braking arrangement, corresponding spring storage arrangements are arranged. This execution offers the advantage that by reason of the action of the spring storage unit, between the individual friction surface-carrying elements forces directed oppositely to these act in each case, so that a rapid separation becomes possible with complete dissolving of the friction closure. The spring storage arrangement acts, therefore, at least indirectly over the friction surface-carrying elements on the actuating element, in particular (on) a piston. The actuating elements, i.e. the pistons, can be acted upon, for example, hydraulically or pneumatically. The individual friction surface-carrying elements and the intermediate elements then no longer have to become released (sich freikleiden). There always occurs a forced separation by compulsion, at least in the zone in which the spring storage element is arranged.
The arrangement of the spring storage units between the individual friction surface-carrying elements offers, further, the advantage that the dimensions of the friction surface-carrying elements in radial direction are no longer dependent, because of the size of the interior dimensions of the gear housing under consideration, on the requisite construction space of the device for the at least indirect resetting of actuating elements. The arrangement of the spring storage units between the friction surface-carrying elements, connectable with one another under friction closure over an intermediate element offers, further, the advantage of a space-saving execution of the resetting device in axial direction, which again has a positive effect on the gear construction length.
The solution according to the invention is not restricted to one gear type as described in FIG. 1, but for this type of gears it offers an especially advantageous possibility of assembling, which also by reason of the exchangeability of individual gear elements as viewed in axial direction, results in a universal usability of a certain basic gear type.
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A gear constructional unit with a gear housing is provided. In order to make the effective diameter of the inner gear elements greater, as well as to ensure a simple assembly and exchangeability of the individual gear elements, for example coupling arrangements and planetary wheel sets, there are provided at least two bar-form guide elements, which extend, as viewed in an axial direction, over at least a part of the axial extent of the cylindrical inner space, on which a large number of gear elements are mounted in fixed position with respect to the housing. The bar-form guide elements are located adjacent to the cylindrical inner space, outside of a zone having the greatest dimension of the cylindrical inner space relative to the gear housing dimension, and are arranged in recesses in the gear housing which are connected with the inner space.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a drum type washing machine, and more particularly, to a drum type washing machine having a short time for drying laundry and a drying method thereof.
[0003] 2. Description of the Related Art
[0004] Generally, a drum type washing machine is designed such that a cylindrical drum in a washing tub is rotated to drop laundry from the upper side of the drum to the lower side of the drum to wash the laundry during the rotation of the drum.
[0005] The drum type washing machine has properties such that damage of the laundry caused by tangling of the laundry is relatively less than that in a pulsator type washing machine and an agitator type washing machine and the quantity of washing water used in washing the laundry is relatively less than that in the pulsator type washing machine and the agitator type washing machine.
[0006] The drum type washing machine dries the laundry that is completely washed using a dryer including a drying heater and a blower fan and a condenser for, removing moisture in air by condensing humidity in air. The drying process is as follows.
[0007] FIG. 1 is a flowchart illustrating a drying cycle of a conventional drum type washing machine.
[0008] In the conventional drying method of the drum type washing machine, as shown in FIG. 1 , when a user selects a drying mode using a mode selection key (not shown) of a key panel installed in the drum type washing machine (S 10 ), whether or not a whole washing cycle, including a washing cycle, a rinsing cycle, and a dehydrating cycle, is finished, is determined (S 20 ).
[0009] At this time, if the whole washing cycle is not yet finished, the remaining cycle is continued, or if the whole washing cycle is finished, the drying cycle starts.
[0010] In the drying cycle, air in the drum is heated by the drying heater of the dryer, the heater air is circulated within the drum by the blower fan (S 30 ) such that the high-temperature dry air contacts the laundry to evaporate moisture contained in the laundry, resulting in drying the laundry.
[0011] Simultaneously, the humidity, contained in the air due to moisture separated from the laundry, is condensed by condensing water introduced into the condenser (S 40 ) and is exhausted out of the drum type washing machine (S 50 ).
[0012] Since air in the drum is heated and circulated during the drying of the laundry, the conventional drying method can increase drying efficiency of the laundry and it is possible to prevent undesired power consumption and excessive use of condensing water.
[0013] However, since the laundry is always dried at the same temperature in the conventional drying method, the laundry may be damaged as the drying cycle is carried out when the laundry is dried at high temperature, and it may take a long time for drying laundry when the laundry is dried at low temperature.
[0014] Moreover, since when the laundry is completely dried cannot be detected, the drying cycle may be finished before the drying of laundry is not yet finished, resulting in incomplete drying of the laundry. Otherwise, the drying cycle is continued even after the drying is finished so that the laundry may be damaged.
[0015] Thus, in order to prevent laundry from damage, the conventional drying method dries the laundry at low temperature and as a result, it takes a long time to dry laundry. Moreover, the laundry may be incompletely dried so that the drying efficiency may be deteriorated.
SUMMARY OF THE INVENTION
[0016] Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a drying method of a drum type washing machine of controlling temperature of air supplied into a drum, RPM of the drum, and switching a drying heater on or off according to the temperature of air to reduce time for drying laundry and a drum type washing machine using the same.
[0017] It is another object of the present invention to provide a drying method of a drum type washing machine of preventing laundry from damage due to heat of air and reducing power consumption by switching a heater on or off and a drum type washing machine using the same.
[0018] In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of a drum type washing machine including a tub including a drum into which laundry is put, a drum motor for rotating the drum, a drying duct installed to communicate with the tub and to provide a path through which air, heated by a drying heater that is installed therein, flows, a blower installed at a side of the drying duct to supply air heated by the drying heater to the tub through the drying duct, a first temperature sensor installed in the drying duct to detect temperature of air to be supplied to the tub, and a microcomputer for dividing the temperature of air in the tub during a drying cycle into a first temperature range and a second temperature range, maintaining the temperature of air to be supplied to the tub within the first and second temperature ranges by controlling the drying heater during drying processes corresponding to the first and second temperature ranges, and controlling an RPM of the drum motor, when the first temperature sensor detects temperature of the drying duct.
[0019] Moreover, the drum type washing machine further includes a condenser for supplying condensing water to a wall of a condensing duct disposed between the tub and the blower to condense water vapor, in the wet condensing duct, formed during the drying cycle, and the first temperature sensor is installed at a side of the tub.
[0020] Additionally, the drum type washing machine further includes a second temperature sensor for detecting temperature in the tub and outputting the detected temperature to the microcomputer, wherein the second temperature sensor is installed between the tub and the drum to control the RPM of the drum motor based on the temperature detected by the second temperature sensor.
[0021] A method of drying laundry according a first preferred embodiment of the present invention includes the steps of (1) detecting temperature in a tub by a second temperature sensor for detecting the temperature in the tub when a drying mode is selected, (2) rotating a drum within a first motor driving range for a first predetermined time by a drum motor for rotating the drum when temperature detected by the second temperature sensor is less than a reference temperature, and of rotating the drum motor within a second motor driving range after that and heating and supplying air in a drying duct within a first temperature range by a drying heater and a blower which are installed in the drying duct communicated with the tub for a second predetermined time, (3) supplying condensing water to a wall of a condensing duct disposed between the tub and the blower to condense water vapor in the drying duct, when the second predetermined time has elapsed, and (4) rotating the drum within the first motor driving range by the drum motor for the first predetermined time when the second predetermined time has elapsed, and of rotating the drum motor within the second motor driving range and heating and supplying air in the drying duct by the drying heater and the blower for the second predetermined time.
[0022] Preferably, when the temperature, detected by the second temperature sensor for detecting inner temperature of the tub, is equal to or greater than a reference temperature, preferably 50 degrees centigrade, only a sub-step (b) among sub-steps (a) and (b) is carried out.
[0023] Here, the reference temperature is 50 degrees centigrade, the first predetermined time is 10 minutes, the first motor driving range is 1000 RPM to 1200 RPM, the second motor driving range is 40 RPM to 60 RPM, he first temperature range is 110 degrees centigrade to 120 degrees centigrade, and the second temperature range is 95 degrees centigrade to 105 degrees centigrade.
[0024] In the step (2), the drum motor is driven at an allowable maximal RPM of the drum type washing machine.
[0025] Each of methods of drying laundry according to second, third, and fourth preferred embodiments of the present invention includes the steps of (1) detecting temperature of air in a tub including a drum and a drying duct communicating with the tub by a first temperature sensor when a drying mode is selected, (2) controlling a drying heater based on the temperature detected by the first temperature sensor to heat air in the drying duct within a first temperature range and to supply the heated air to the tub using a blower, (3) supplying condensing water to a wall of a condensing duct disposed between the tub and the blower to condense water vapor in the drying duct, and (4) controlling the drying heater based on the temperature detected by the first temperature sensor to heat air in the drying duct within a second temperature range such that the heated air is supplied to the tub by the blower.
[0026] The step (1) includes the sub-step of measuring eccentricity of the drum and performing an detangling cycle when the measure eccentricity is equal to or greater than a predetermined reference eccentricity.
[0027] The step (2) includes the sub-steps of (a) driving a drum motor for rotating the drum within a first motor driving range, and (b) driving the drum motor within a second motor driving range. The step (1) further includes the sub-steps of measuring the quantity of laundry when a completely drying mode is selected from the drying modes and the sub-step (a) is finished, and of estimating and displaying an expected remaining time of a drying cycle according to the measured quantity of laundry.
[0028] Preferably, in the step (2), when temperature, detected by a second temperature sensor for detecting inner temperature of the tub, is equal to or greater than a reference temperature, preferably 50 degrees centigrade, only the sub-step (b) among the sub-steps (a) and (b) is carried out.
[0029] Moreover, in the step (2), a slope with respect to temperature change in the tub, which is detected by the second temperature sensor for detecting the inner temperature of the tub, is estimated, and when the detected slope is equal to or greater than a predetermined reference slope, the step (3) is carried out.
[0030] Preferably, the sub-steps (a) and (b) are carried out for a predetermined time within the first motor driving range and the second motor driving range, respectively.
[0031] Here, the first motor driving range is 1000 RPM to 1200 RPM, the second motor driving range is 40 RPM to 60 RPM, the first temperature range is 110 degrees centigrade to 120 degrees centigrade, and the second temperature range is 95 degrees centigrade to 105 degrees centigrade.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0033] FIG. 1 is a flowchart illustrating a drying cycle of a conventional drum type washing machine;
[0034] FIG. 2 is a sectional view illustrating a drum type washing machine according a preferred embodiment of the present invention;
[0035] FIG. 3 is a block diagram illustrating the drum type washing machine according to the preferred embodiment of the present invention;
[0036] FIG. 4 is a flowchart illustrating a drying cycle of a drum type washing machine according to a first preferred embodiment of the present invention;
[0037] FIGS. 5 and 6 are flowcharts illustrating respective drying cycles in FIG. 4 ;
[0038] FIG. 7 is a flowchart illustrating a drying cycle of a drum type washing machine according to a second preferred embodiment of the present invention;
[0039] FIGS. 8 , 9 , and 10 are flowcharts illustrating respective drying cycles in FIG. 6 ;
[0040] FIG. 11 is a graph illustrating the relation between temperature and time during the drying cycle of the drum type washing machine according to the second preferred embodiment of the present invention;
[0041] FIG. 12 is a graph illustrating the relation between temperature and time with respect to the quantity of laundry during the drying cycle of the drum type washing machine according to the second preferred embodiment of the present invention;
[0042] FIG. 13 is a flowchart illustrating a drying cycle of a drum type washing machine according to a third preferred embodiment of the present invention; and
[0043] FIG. 14 is a flowchart illustrating a drying cycle of a drum type washing machine according to a fourth preferred embodiment of the present invention.
DESCRIPTION OF REFERENCE NUMERALS FOR MAIN COMPONENTS OF THE DRAWINGS
[0000]
100 : drum type washing machine
112 : drying duct
114 : air discharging part
115 : first temperature sensor
116 : condensing duct
118 : condenser
120 : drier
121 : blower
122 : drying heater
130 : drum
131 : tub
132 : second temperature sensor
140 : drum motor
152 : exhaust pipe
160 : microcomputer
180 : display
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] Hereinafter, a drum type washing machine and a method of drying laundry according to preferred embodiments of the present invention will be described in detail by reference to the accompanying drawings.
[0061] FIG. 2 is a sectional view illustrating a drum type washing machine according a preferred embodiment of the present invention, and FIG. 3 is a block diagram illustrating the drum type washing machine according to the preferred embodiment of the present invention.
[0062] The drum type washing machine 100 according to the preferred embodiment of the present invention, as shown in FIG. 2 , washes laundry by rotating a cylindrical drum within a washing tub and by dropping the laundry from the upper side of the drum to the lower side of the drum. The drum type washing machine 100 includes a housing 111 for forming an external appearance of the drum type washing machine 100 , a tub 131 installed in the housing 111 , a drum 130 rotated within the tub 131 to serve as the washing tub, a drum motor installed in the rear side of the drum 130 to rotate the drum 130 , a drier 120 for drying the laundry, and a condenser 118 for removing moisture contained in internal air.
[0063] Above the tub 131 , a washing water supplying pipe 105 is provided to supply washing water from the exterior, and the washing water that is supplied through the washing water supplying pipe 105 is supplied into the tub 131 via a detergent container 106 for accommodating detergent. In the lower side of the tub 131 , an exhaust pump 151 and an exhaust pipe 152 are provided to exhaust the washing water, used during the washing process, to the exterior. Moreover, in order to put or withdraw the laundry into or from the drum 130 , a door 102 is installed in the front side of the drum type washing machine 100 . Here, the front side means the left side in FIG. 2 and the rear side means the right side in FIG. 2 .
[0064] Meanwhile, although not depicted in the drawings, in the circumference and the rear side of the drum 130 , a plurality of holes is formed such that the washing water and air may flow therethrough. Through the holes formed in the drum 130 , air in the drum 130 flows into a space formed between the drum 130 and the tub 131 .
[0065] In the drum type washing machine 100 according to the preferred embodiment of the present invention, after a washing process is finished by repeating a washing cycle and a dehydrating cycle, the drier 120 jets warm air into the drum 130 to dry the laundry. In other words, the drier 120 heats and circulates air in order to dry the laundry in the drum 130 .
[0066] The drier 120 includes a drying heater 122 as a heating device for heating air and a blower for circulating air heated by the drying heater 122 . The blower includes a blower fan motor (not shown) and a blower fan (not shown). The blower fan motor is driven to rotate the blower fan such that air heated by the drying heater 122 as described above is supplied into the tub 131 via the drying duct 112 when a drying cycle is carried out.
[0067] Moreover, the drier 120 includes a drying duct 112 for providing a path through which the heated air flows into the tub 131 and an air discharging part 114 communicated with the inside of the tub 131 . An end 123 of the drying duct 112 is opened such that the heated air flows into the tub 131 . Here, the end 123 of the drying duct 112 may be installed to allow the heated air to flow into the drum 130 .
[0068] In the drying duct 112 , a first temperature sensor 115 is installed to detect temperature of air heated by the drying heater 112 and to output a detected data to a microcomputer 160 shown in FIG. 3 . As described above, since temperature of the heater air may be stably and precisely detected at the air discharging part 114 , the first temperature sensor 115 is preferably installed at a side of the tub 131 , that is, a side of the air discharging part 114 .
[0069] Thus, the drying heater 122 and the blower 121 of the drier 120 are turned on or off, according to a control signal outputted from the microcomputer 160 caused by the detected data that is inputted from the first temperature sensor 115 , to perform the drying cycle in the washing machine of the present invention. This will be described in detail with reference to FIG. 3 .
[0070] Additionally, the drying heater 122 is installed in the drying duct 112 between the blower 121 and an air introducing port 123 . As the drying heater 122 , an electric heater for generating heat using electric current is used, and temperature of the drying heater 122 is controlled by a thermistor 125 that is installed in the air discharging part 114 .
[0071] Meanwhile, during the above-described drying cycle of the laundry, moisture must be removed so that smooth drying can be achieved. If high temperature air contacts a low temperature object, moisture in air is liquefied so that moisture contained in air in the drum 130 is removed.
[0072] The condenser 118 is disposed between the blower 121 and the tub 131 to remove moisture from the heated air using the principle as described above. In other words, the condenser 118 is connected to the washing water supplying pipe 105 that is installed in the upper side of the drum type washing machine 100 through which condensing water, supplied through a condensing water supplying pipe 113 , can flow toward a wall of a condensing duct 116 such that high-temperature-and-high-humidity air in the condensing duct 116 contacts the condensing water with a relative lower temperature so that water vapor is condensed, resulting in removing moisture in the drum 130 .
[0073] Moreover, between the tub 131 and the drum 130 , a second temperature sensor is installed to detect washing temperature. The second temperature sensor 132 detects temperature of air in the tub 131 and outputs detected data to the microcomputer 160 . The microcomputer 160 performs the drying cycle according to the detected data inputted from the second temperature sensor 132 .
[0074] In other words, the drum type washing machine 100 according to this preferred embodiment of the present invention supplies the heated air from the drying duct 112 to the tub 131 for drying the laundry, and air discharged from the tub passes through the condensing duct 116 and meets the condensing water, and then is liquefied into water. The liquefied water is exhausted out through the exhaust pipe 151 via the lower side of the tub 131 .
[0075] Moreover, the drum type washing machine 100 includes an air discharging part 114 for discharging humid air to the exterior. In order to discharge air in the tub 131 to the exterior, a side of the air discharging part 114 is communicated with the tub 131 and the other side 117 a of the air discharging part 114 is communicated with the exterior. At an end of the other side of the air discharging part 114 , an extension part 117 where a fan (not shown) driven by a motor (not shown) is installed and a filter 119 is installed in the extension part 117 .
[0076] Finally, the display 180 displays key manipulations performed by a user, key manipulation result, and time of manipulation result. In this preferred embodiment of the present invention, the display 180 is structured to display an expected remaining time of the drying cycle that is estimated by the microcomputer 170 such that the user can confirm time of finishing the drying cycle, when the user selects a complete mode among the drying mode through key input section 170 .
[0077] For reference, the drying mode is divided into a complete drying mode and a time drying mode. The complete drying mode is a mode where the drying cycle is continued until the laundry is completely dried, and the time drying mode is a mode where the drying mode is carried out only for a predetermined time. In the complete drying mode, it is advantageous that the drying cycle is carried out until the laundry is completely dried, but it takes a lot of time for the complete drying of the laundry and a great deal of electric power is required. On the other hand, the time drying mode has advantages and disadvantages opposite to those of the complete drying mode.
[0078] The microcomputer 160 of the drum type washing machine, as shown in FIG. 3 , determines whether or not temperature of air in the tub 131 that is inputted from the second temperature sensor 132 is equal to or greater than a reference temperature when the user selects the drying mode through the key input section 170 of the drum type washing machine 100 . The microcomputer 160 performs the corresponding drying process according to whether or not the inputted air temperature is equal to or greater than the reference temperature, and controls the drum motor 140 and the drier 120 to perform the drying process of the present invention during respective drying processes.
[0079] The operation of the microcomputer 160 will be described in detail with reference to FIGS. 4 to 11 illustrating the drying method according to the preferred embodiment of the present invention.
[0080] For reference, the drying method of the drum type washing machine according to the preferred embodiment of the present invention is roughly divided into a main drying step and an auxiliary drying step. The preferred embodiments of the present invention will be described in detail according to whether the drum motor 140 is rotated at high speed within a first motor driving range and the drying heater 122 supplies heat simultaneously or for a time interval, based on an allowable current when the user selects the drying mode through the key input section 170 .
[0081] For reference, in a case of rotating the drum motor 140 at high speed within the first motor driving range and supplying heat by the drying heater 122 simultaneously, the allowable current must be 15 A. However, in a case of rotating the drum motor 140 at high speed within the first motor driving range and supplying heat by the drying heater 122 for a time interval, 10 A is sufficient for the allowable current.
[0082] Here, a first preferred embodiment of the present invention of performing the high speed rotation of the drum motor 140 and the heat supply by the drying heater 122 for a time interval will be described with reference to FIGS. 4 , 5 , and 6 .
[0083] Moreover, second, third and fourth preferred embodiments of the present invention of simultaneously performing the high speed rotation of the drum motor 140 and the heat supply by the drying heater 122 are carried out differently from each other according to mode selected from the completely drying mode and the time drying mode. FIGS. 7 to 12 illustrate the second preferred embodiment of the present invention carried out by selecting the completely drying mode, FIG. 13 illustrates the third preferred embodiment of the present invention carried out by selecting the time drying mode, and FIG. 14 illustrates the fourth preferred embodiment of the present invention of performing the auxiliary drying step and the main drying step according to a magnitude of a slope by estimating the slope with respect to temperature changes.
[0084] On the other hand, the first preferred embodiment of the present invention can be applied to the completely drying mode and the time drying mode like the second, third, and fourth preferred embodiments of the present invention. FIG. 4 illustrates the completely drying mode, and the same description as that of the time drying mode will be omitted.
1. Embodiment 1
[0085] FIG. 4 is a flowchart illustrating the drying cycle of the drum type washing machine according to the first preferred embodiment of the present invention, and FIGS. 5 and 6 are flowcharts illustrating respective drying cycles in FIG. 4 .
[0086] The drying method of a drum type washing machine according to the first preferred embodiment of the present invention is a method in which heat is not applied to the laundry when the drum motor 140 is driven with the first motor driving range, but in which heat is applied when the drum motor 140 is driven within a second motor driving range after that. As shown in FIG. 4 , the user firstly selects the drying mode through the key input section 170 (S 710 ), and selects the completely drying mode of the drying modes, and then an eccentricity is measured (S 720 ).
[0087] There are several methods of measuring the eccentricity, one of estimating duty of a pulse width modulation (PWM) control signal, and the other one of measuring time required to reach and fall from a specific RPM related to the quantity of laundry and current flowing through the motor. Since these methods can be easily employed by a person skilled in the art, their description will be omitted herein.
[0088] Meanwhile, when the eccentricity is measured, the measured eccentricity is compared with a predetermined reference eccentricity. Whether the measured eccentricity is equal to or greater than the reference eccentricity is determined (S 730 ), and when the measured eccentricity is equal to or greater than the reference eccentricity, a detangling cycle is performed (S 735 ) to adjust the eccentricity.
[0089] On the contrary, when the measured eccentricity is less than the reference eccentricity, the detangling cycle is not carried out and the second temperature sensor 132 detects temperature in the tub 131 (S 740 ) to output the detected data to the microcomputer 160 . The microcomputer 160 determines whether or not the measured temperature in the tub 131 is equal to or greater than a reference temperature, preferably, 50 degrees centigrade, based on the detected data (S 750 ).
[0090] At this time, when the temperature in the tub 131 is less than the reference temperature, the auxiliary drying step (S 760 ) is carried out, but when the temperature in the tub 131 is equal to or greater than the reference temperature, the supplying of condensing water and the exhaust of water (S 770 ) and processes after these processes are carried out.
[0091] Particularly, that the second temperature sensor 132 detects the inner temperature of the tub 131 and the detected temperature is compared with the reference temperature such that the next processes are carried out, is to prevent the laundry from damage when air heated in the auxiliary drying step is supplied because the laundry is sufficiently heated when the inner temperature of the tub 131 is equal to or greater than the reference temperature, and to perform a power failure compensation when the electricity is cut off during the drying cycle.
[0092] For example, since, although the electricity is cut off during the drying cycle, temperature in the tub 131 does not rapidly fall, when temperature detected by the second temperature sensor 132 when the power is supplied again is equal to or greater than the reference temperature, the auxiliary drying step is not carried out and the processes after detecting the quantity of laundry is carried out so that power consumption for repeating the same process can be prevented.
[0093] Additionally, during a first auxiliary drying process, if the user stops the drum type washing machine and commands to perform the drying cycle again, since the inner temperature of the tub 131 is sufficiently high when the auxiliary drying step is carried out at the state where the temperature detected by the second temperature sensor 132 is equal to or greater than the reference temperature, excessive heat is applied to the laundry and as a result of this, the laundry may be damaged. In order to prevent this, when temperature detected by the second temperature sensor 132 is equal to or greater than the reference temperature, the auxiliary drying step is not carried out and the processes after that, that is, the supply of the condensing water and the exhaust of water are carried out.
[0094] Meanwhile, when the inner temperature of the tub 131 is less than the reference temperature, the auxiliary drying step is carried out (S 760 ). In the auxiliary drying step according to the first preferred embodiment of the present invention, differently from those according to the second, third, and fourth preferred embodiments of the present invention which will be described later, the drum motor 140 is driven within a first motor driving range, 1000 RPM to 1200 RPM and a second motor driving range, 40 RPM to 60 RPM for a time interval, and when the drum motor 140 is driven within the second motor driving range, the drying heater 122 and the blower fan are driven within a temperature range where temperature detected by the first temperature sensor 151 is within the first temperature range.
[0095] Meanwhile, the first motor driving range may be variously determined according to models of the drum type washing machine. The first motor driving range is increased as the capacity of the drum type washing machine is increased. Particularly, the drum motor 140 is driven at a maximal RPM allowed in the corresponding drum type washing machine.
[0096] Thus, the drum motor 140 of the drum type washing machine is preferably driven, for example, at the allowable maximal RPM, 1200 RPM when the drum type is of an 11 Kg model, and at 1400 RPM when the drum type washing machine is of a 14 Kg model.
[0097] When the drum motor 140 is driven within the first motor driving range, it is possible to obtain dehydration effect at high speed rotation. However, when the drum motor 140 is driven within the second motor driving range and the drying heater 122 is driven, the laundry is heated to a temperature where the laundry is easily dried.
[0098] In other words, as shown in FIG. 5 , when the drum motor 140 is driven such that the inner temperature of the tub 131 is maintained within the first motor driving range (S 761 ), whether or not a first predetermined time, preferably, 10 minutes has elapsed is determined (S 762 ), the drum motor 140 is continuously driven within the first motor driving range until the first predetermined time has elapsed.
[0099] At this time, when the first predetermined time has elapsed, the quantity of laundry is detected (S 763 ), and the expected remaining time of the drying cycle is estimated through the detected quantity of laundry and displayed (S 764 ).
[0100] When the expected remaining time of the drying cycle is displayed, the drum motor 140 is driven such that the inner temperature of the tub 131 is maintained within the second motor driving range and the drying heater 122 and the blower fan are driven (S 765 ).
[0101] Simultaneously, time is counted and whether or not a second predetermined time, preferably, 40 minutes has elapsed is determined (S 766 ), and it is continued until the second predetermined time has elapsed.
[0102] When the auxiliary drying step is finished, the supply of condensing water and the exhaust process are started such that the condensing water is supplied through the condensing water supplying pipe 113 to remove moisture contained in air during the condensing process, and the condensed water is exhausted to the exterior through the exhaust pipe 152 via the lower side of the tub 131 (S 770 ).
[0103] When the supply of condensing water and the exhaust process are started, the main drying step is performed (S 780 ). In the main drying step, as shown in FIG. 6 , the drum motor 140 is driven within the first motor driving range (S 781 ) and whether or not the first predetermined time, 10 minutes, has elapsed is determined (S 782 ) such that the drum motor 140 is driven within the first motor driving range until the first predetermined time has elapsed.
[0104] When the first predetermined time has elapsed, the drum motor 140 is driven within the second motor driving range and the blower fan and the drying heater 122 are driven such that the temperature detected by the first temperature sensor 151 is maintained within the second temperature range (S 783 ).
[0105] The above-described processes are carried out until a specific drying rate where it can be determined that the laundry is completely dried (S 780 to S 790 ).
[0106] Meanwhile, differently from the completely drying mode, since time for drying cycle is predetermined in the drying method according to the time drying mode so that it is not need to estimate the expected remaining time of the drying cycle, the process of detecting the quantity of laundry, estimating and displaying the expected remaining time of the drying cycle is not carried out and a complete drying cycle is finished when the time of the drying cycle has elapsed during the main drying step.
2. Embodiment 2
[0107] FIG. 7 is a flowchart illustrating a drying cycle of a drum type washing machine according to a second preferred embodiment of the present invention, FIGS. 8 , 9 , and 10 are flowcharts illustrating respective drying cycles in FIG. 7 , FIG. 11 is a graph illustrating the relation between temperature and time during the drying cycle of the drum type washing machine according to the second preferred embodiment of the present invention, and FIG. 12 is a graph illustrating the relation between temperature and time with respect to the quantity of laundry during the drying cycle of the drum type washing machine according to the second preferred embodiment of the present invention.
[0108] The drying method of a drum type washing machine according to the second preferred embodiment of the present invention includes the steps of selecting the drying mode through the key input section 170 by the user (S 110 ), and measuring the eccentricity when the user selects the completely drying mode of the drying modes (S 120 ).
[0109] As described above, when the eccentricity is measured, the measured eccentricity is compared with the predetermined eccentricity and whether or not the measured eccentricity is equal to or greater than the reference eccentricity is determined (S 130 ). When the measured eccentricity is equal to or greater than the reference eccentricity, the detangling process is carried out (S 132 ) to adjust the eccentricity.
[0110] On the contrary, when the measured eccentricity is less than the reference eccentricity, the detangling process is not carried out.
[0111] Next, the second temperature sensor 132 detects the inner temperature of the tub 131 (S 140 ) and outputs the detected data to the microcomputer 160 . The microcomputer 160 determines whether the detected data, that is, the inner temperature of the tub 131 is equal to or greater than the reference temperature, preferably, 50 degrees centigrade (S 150 ).
[0112] At this time, when the inner temperature of the tub 131 is less than the reference temperature, the first auxiliary drying process is carried out. However, when the inner temperature of the tub 131 is equal to or greater than the reference temperature, the first auxiliary drying process is not carried out and the process of detecting the quantity of laundry (S 180 ) and the processes after that are carried out.
[0113] Particularly, that the second temperature sensor 132 detects the inner temperature of the tub 131 and the detected temperature is compared with the reference temperature such that the next processes are carried out based on the compared result, is to prevent the laundry from damage when air heated in the auxiliary drying step is supplied because the laundry is sufficiently heated when the inner temperature of the tub 131 is equal to or greater than the reference temperature, and to perform a power failure compensation when the electricity is cut off during the drying cycle.
[0114] For example, since, although the electricity is interrupted due to electricity failure during the drying cycle, temperature in the tub 131 does not rapidly fall, when temperature detected by the second temperature sensor 132 when the power is supplied again is equal to or greater than the reference temperature, the first auxiliary drying process is not carried out and the processes after detecting the quantity of laundry are carried out so that power consumption for repeating the same process can be prevented.
[0115] Additionally, during the first auxiliary drying process, if the user stops the drum type washing machine and commands to perform the drying cycle again, since the inner temperature of the tub 131 is sufficiently high when the first auxiliary drying process is carried out at the state where the temperature detected by the second temperature sensor 132 is equal to or greater than the reference temperature, excessive heat is applied to the laundry and as a result of this, the laundry may be damaged.
[0116] In order to prevent this, when temperature detected by the second temperature sensor 132 is equal to or greater than the reference temperature, the first auxiliary drying process is not carried out and the processes after that, that is, the supply of the condensing water and the exhaust of water are carried out.
[0117] Meanwhile, in the first auxiliary drying process (S 160 ), as shown in FIG. 8 , the drum motor 140 is driven within the first motor driving range, preferably, within 1000 RPM to 1200 RPM and the drying heater 122 and the blower 121 are driven (S 161 ). Here, the drum motor 140 starts to drive within the first motor driving range and as time is simultaneously counted.
[0118] As such, as the drum motor 140 is driven at high speed and the drying heater 122 and the blower 121 are driven, air in the drying duct 112 is heated by the drying heater 122 and the heated air is supplied into the tub 131 through the air discharging part 114 by the blower 121 .
[0119] Thus, since the heated air is supplied while the drum motor 140 rotates at high speed, the washing water is dehydrated from the laundry which is heated at temperature where moisture is easily separated.
[0120] Meanwhile, the first temperature sensor 115 detects temperature of air heated by the drying heater 122 and outputs the detected temperature to the microcomputer 160 . The microcomputer 160 controls the temperature of air heated by the drying heater 122 so as to maintain it within the predetermined first temperature range T 2 to T 1 .
[0121] In other words, the first temperature sensor 115 detects the temperature of air heated by the drying heater 122 and continues to output the detected temperature of air to the microcomputer 160 . The microcomputer 160 determines whether or not the detected data, that is, the detected temperature inputted from the first temperature sensor 115 is greater than the predetermined temperature T 1 (S 163 ). When the temperature of air is greater than the first predetermined temperature T 1 , preferably, 120 degrees centigrade, the microcomputer 160 stops the drying heater 122 (S 165 ) and determines whether the detected data is equal to or less than the second predetermined temperature T 2 after stopping the drying heater 122 (S 167 ). After that, when the air temperature is equal to or less than the predetermined temperature T 2 , preferably, 110 degrees centigrade caused by the stopping of the drying heater 122 , the microcomputer 160 repeats the process of driving the drying heater 122 (S 169 ). Thus, during the first auxiliary drying process, temperature of air supplied to the tub 131 is maintained within the first temperature range T 2 to T 1 , that is, 110 degrees centigrade to 120 degrees centigrade.
[0122] After the beginning of the first auxiliary drying process, whether or not a predetermined time t 1 , preferably, 20 minutes has elapsed is determined, the first auxiliary drying process is continued until the predetermined time t 1 has elapsed.
[0123] For reference, when the first auxiliary drying process (S 160 ) is finished, it is possible to obtain approximately 60% drying effect based on the quantity of 10 Kg of laundry.
[0124] Meanwhile, when the first auxiliary drying process (S 160 ) is finished or temperature of the tub 131 detected by the second temperature sensor 132 is less than the reference temperature, the first auxiliary drying process is not carried out and the process of detecting the quantity of laundry (S 170 ) is carried out. At this time, from experimental data obtained from repeated experiments, the expected remaining time of the drying cycle corresponding to the detected quantity of laundry is estimated and displayed on the display 180 (S 180 ).
[0125] In other words, the quantity of laundry is detected by detecting the humidity of the laundry after driving the drum motor 140 within the first motor driving range. By taking the dehydration rate similarly appeared at a specific RPM into consideration, the drying time at the weight of laundry is displayed as an experimental value to obtain the expected remaining time of the drying cycle. Particularly, the detected quantity of laundry may be used as a reference data by taking the dehydration rate similarly appeared at a specific RPM into consideration when whether or not the laundry is completely dried is checked.
[0126] As such, when the expected remaining time of the drying cycle is displayed, a second auxiliary drying process is carried out as a next process (S 190 ).
[0127] In the second auxiliary drying process (S 190 ), as shown in FIG. 9 , the drum motor 140 is driven at the second motor driving range, 40 RPM to 60 RPM (S 191 ), and the drying heater 122 and the blower 121 are driven (S 191 ). Here, the drum motor 140 starts to drive within the second motor driving range and simultaneously counts time.
[0128] As such, as the drum motor 140 is driven at low speed and the drying heater 122 and the blower 121 are driven, air in the drying duct 112 is heated by the drying heater 122 and the heated air is introduced into the tub 131 through the air discharging part 114 by the blower 121 .
[0129] Thus, since the drum motor 140 rotates at low speed and the heated air is supplied, the washing water is separated from the laundry and simultaneously temperature is increased to a degree where the moisture is easily extracted from the humid laundry.
[0130] Meanwhile, the first temperature sensor 115 detects temperature of air heated by the drying heater 122 and outputs the detected temperature of air to the microcomputer 160 . The microcomputer 160 controls temperature of air heated by the drying heater 122 to be maintained within the first temperature range T 2 to T 1 .
[0131] In other words, the first temperature sensor 115 detects the temperature of air heated by the drying heater 122 and continues to output the detected temperature of air to the microcomputer 160 . The microcomputer 160 determines whether or not the detected data, that is, the detected temperature inputted from the first temperature sensor 115 is greater than the predetermined temperature T 1 (S 193 ). When the temperature of air is greater than the first predetermined temperature T 1 , the microcomputer 160 stops the drying heater 122 (S 195 ) and determines whether the detected data is equal to or less than the second predetermined temperature T 2 after stopping the drying heater 122 (S 197 ). After that, when the air temperature is equal to or less than the predetermined temperature T 2 caused by the stopping of the drying heater 122 , the microcomputer 160 repeats the process of driving the drying heater 122 (S 199 ) again. Thus, during the second auxiliary drying process, temperature of air supplied to the tub 131 is maintained within the first temperature range, that is, 110 degrees centigrade to 120 degrees centigrade.
[0132] After the beginning of the first auxiliary drying process, whether or not a predetermined time t 2 , preferably, 20 minutes has elapsed is determined, the first auxiliary drying process is continued until the predetermined time t 2 has elapsed. Thus, to carry out the first auxiliary drying process and the second auxiliary drying process, it takes about 40 minutes.
[0133] Here, the reason why the predetermined time t 2 is set to 20 minutes and time until the second auxiliary drying process is finished is set to 40 minutes, is that it takes 40 minutes until the second auxiliary drying process is finished according to a curve of a reference temperature experimentally performed with respect to a general quantity of 10 Kg of laundry. The determined time t 2 can be variously determined.
[0134] As described above, since the drum type washing machine is driven within the first temperature range for the time periods when the first and second auxiliary drying processes are carried out, as illustrated in FIG. 11 , temperature suddenly rises a little during the predetermined times t 1 and t 2 . On the other hand, in a time period where the main drying step is carried out after that, since the drum type washing machine is driven according to the second temperature range, temperature is maintained to have a relatively slow slope.
[0135] When the predetermined time t 2 has elapsed and the second auxiliary drying process (S 190 ) is finished, the supply of the condensing water and the exhaust of water are carried out.
[0136] The condensing water, as described above, is supplied through the condensing water supplying pipe 113 by a valve for controlling the supply of the condensing water and moisture contained in air is removed during the condensing process. The condensed water is exhausted to the exterior through the exhaust pipe 152 via the lower side of the tub 131 .
[0137] As such, after the beginning of the supply of the condensing water and the exhaust of water, the main drying step (S 210 ) is carried out.
[0138] In the main drying step (S 210 ), as shown in FIG. 10 , the drum motor 140 is driven within the second motor driving range, preferably, 40 RPM to 60 RPM, and the drying heater 122 and the blower 121 are driven (S 211 ).
[0139] As such, as the drum motor 140 is driven at low speed and the drying heater 122 and the blower 121 are driven, air in the drying duct 112 is heated by the drying heater 122 and the heated air is introduced into the tub 131 through the air discharging part 114 by the blower 121 .
[0140] Thus, the drum motor 140 rotates at low speed and the heated air is supplied. Since the laundry is heated at temperature suitable to dry during the first and second auxiliary processes, the laundry is easily dried.
[0141] Meanwhile, the first temperature sensor 115 detects temperature of air heated by the drying heater 122 and outputs the detected temperature of air to the microcomputer 160 . The microcomputer 160 controls temperature of air heated by the drying heater 122 to be maintained within a second temperature range T 4 to T 3 , preferably, 95 degrees centigrade to 105 degrees centigrade.
[0142] In other words, the first temperature sensor 115 detects the temperature of air heated by the drying heater 122 and continues to output the detected temperature of air to the microcomputer 160 . The microcomputer 160 determines whether or not the detected data, that is, the detected temperature inputted from the first temperature sensor 115 is greater than the predetermined temperature T 3 , that is, 105 degrees centigrade (S 213 ). When the temperature of air is greater than the predetermined temperature T 3 , the microcomputer 160 stops the drying heater 122 (S 215 ) and determines whether the detected data is equal to or less than the predetermined temperature T 4 , that is, 95 degrees centigrade after stopping the drying heater 122 (S 217 ). After that, when the air temperature is equal to or less than the predetermined temperature T 4 caused by the stopping of the drying heater 122 , the microcomputer 160 repeats the process of driving the drying heater 122 . Thus, during the main drying step, temperature of air supplied to the tub 131 is maintained within 95 degrees centigrade to 105 degrees centigrade.
[0143] After the beginning of the main drying step, it is determined whether or not the expected remaining time of the drying cycle, by detecting the quantity of laundry, has elapsed (S 220 ), and the main drying step is continued until the expected remaining time has elapsed.
[0144] Meanwhile, when the expected remaining time of the drying cycle has elapsed, it is determined whether or not a drying rate reaches a specific drying rate indicating the completion of drying. When the drying rate reaches the specific drying rate, the drying cycle is finished. When the drying rate does not reach the specific drying rate, the main drying step (S 210 ) is preferably carried out for a predetermined time, for example, 10 minutes to 20 minutes.
[0145] The drying method according to this preferred embodiment of the present invention, as shown in FIG. 12 , may be carried out in various ways according to the quantity of laundry. As described above, according to the quantity of laundry, time when the second auxiliary drying process is finished is different from time when the main drying step is started. The slopes with respect to the temperature change during the first and second auxiliary drying processes are different from each other.
[0146] In other words, as the quantity of laundry is small, the slope with respect to the temperature change until the second auxiliary drying process increases and time of starting the main drying step is shortened.
[0147] Particularly, since the expected remaining time is varied according to a range of the respective quantities of laundry, it is possible to determine a completion time A of the drying cycle when the completion of drying is achieved from the above-mentioned graph, that is, the completely drying time can be determined from the time period where temperature suddenly rises after the complete drying.
3. Embodiment 3
[0148] Next, a drying method according to a third preferred embodiment of the present invention will be described with reference to FIG. 13 .
[0149] FIG. 13 is a flowchart illustrating a drying cycle of a drum type washing machine according to the third preferred embodiment of the present invention.
[0150] The drying method of a drum type washing machine according to the third preferred embodiment of the present invention is similar as that according to the second preferred embodiment of the present invention. However, the drying method according to the third preferred embodiment of the present invention relates a drying method in a case of selecting the time drying mode different from the case of selecting the completely drying mode when the user selects the drying mode in the first preferred embodiment of the present invention.
[0151] Thus, it will be described in brief with respect to the same as that in the second preferred embodiment of the present invention, and other aspects will be described in detail.
[0152] Firstly, when the user selects the drying mode (S 310 ) and after that selects the time drying mode, the eccentricity of laundry is measured (S 320 ). When the measured eccentricity is equal to or greater than the reference eccentricity, the detangling cycle is carried out (S 332 ). When the measured eccentricity is less than the reference eccentricity, the detangling cycle is not carried out and the second temperature sensor 132 detects temperature of air in the tub 131 (S 340 ) and outputs the detected temperature.
[0153] It is determined whether or not the temperature detected by the second temperature sensor 132 is equal to or greater than a reference temperature, preferably, 50 degrees centigrade (S 350 ). When the temperature detected by the second temperature sensor 132 is less than the reference temperature, the first auxiliary drying process (S 360 ) is carried out for the predetermined time t 1 within the first motor driving range of 1000 RPM to 1200 RPM (S 360 to S 370 ).
[0154] On the contrary, when the temperature detected by the second temperature sensor 132 is equal to or greater than the reference temperature, the first auxiliary drying process (S 360 ) is not carried out but the processes after the first auxiliary drying process (S 360 ) are carried out.
[0155] Next, the second auxiliary drying process (S 370 ) is carried out. In the second auxiliary drying process (S 370 ), a process of drying laundry is carried out until the predetermined time t 2 has elapsed by driving the drum motor 140 within the second motor driving range, preferably, 40 RPM to 60 RPM and maintaining temperature of air to be supplied to the tub 131 at the first temperature range T 2 to T 1 .
[0156] As such, when the second auxiliary drying process (S 370 ) is carried out, the supply of the condensing water and the exhaust of water are carried out (S 380 ). Simultaneously, the drum motor 140 is driven within the second motor driving range of 40 RPM to 60 RPM and temperature of air to be supplied to the tub 131 is maintained within the second temperature range T 4 to T 3 , preferably, 95 degrees centigrade to 105 degrees centigrade so that the main drying step (S 390 ) of drying laundry is carried out according to the time drying mode until the drying time has elapsed (S 400 ).
[0157] In the drying method according to third preferred embodiment of the present invention, the drying time is set and the drying process is carried out only for the drying time. Thus, the process of obtaining the expected remaining time of the drying cycle by detecting the quantity of laundry is not carried out unlike the second preferred embodiment of the present invention, and it is not determined whether or not the laundry is completely dried. Therefore, when the predetermined drying time has elapsed, the drying process is finished by force.
4. Embodiment 4
[0158] A drying method according to a fourth preferred embodiment of the present invention will be described with reference to FIG. 14 .
[0159] FIG. 14 is a flowchart illustrating a drying cycle of a drum type washing machine according to the fourth preferred embodiment of the present invention.
[0160] In the drying method according to the fourth preferred embodiment of the present invention, when the drum motor 140 is driven without performing the first and second auxiliary drying processes for the predetermined times t 1 and t 2 unlike the second and third preferred embodiments of the present invention, a slope is estimated with respect to temperature change detected by the second temperature sensor 132 , and the first and second auxiliary drying processes are carried out based on the magnitude of the slope and a starting time of the main drying step is determined.
[0161] Particularly, since the drying method according to this preferred embodiment of the present invention can be applied without determining whether the drying mode is the completely drying mode or the time drying mode, the drying method according to this preferred embodiment of the present invention will be described with respect to, for example, a case of selecting the completely drying mode. Since the case of selecting the time drying mode is similar as that of the completely drying mode and has been described in the third preferred embodiment of the present invention, its detail description will be omitted herein.
[0162] In the drying method of a drum type washing machine according to the fourth preferred embodiment of the present invention, as shown in FIG. 14 , when the user selects the completely drying mode after selection of the time drying mode (S 510 ), the eccentricity is measured (S 520 ) and it is determined whether or not the measured eccentricity is equal to or greater than the reference eccentricity (S 530 ). When the measured eccentricity is equal to or greater than the reference eccentricity, the detangling cycle is carried out (S 532 ). When the measured eccentricity is less than the reference eccentricity, the second temperature sensor 132 detects temperature of air in the tub 131 (S 540 ) and outputs the detected temperature.
[0163] It is determined whether or not the temperature detected by the second temperature sensor 132 is less than the reference temperature, preferably, 50 degrees centigrade (S 550 ). When the detected temperature is less than the reference temperature, the first auxiliary drying process is carried out such that the drum motor 140 is driven within the first motor driving range, that is, at high speed of 1000 RPM to 1200 RPM and temperature of air to be supplied to the tub 131 is maintained within the first temperature range T 2 to T 1 , preferably, 110 degrees centigrade to 120 degrees centigrade (S 560 ). At this time, it is determined whether or not the slope with respect to the temperature change detected by the second temperature sensor 132 is greater than a predetermined reference slope (S 570 ). When the slope is equal to or greater than the reference slope, the first auxiliary drying process is finished and the next processes are carried out.
[0164] On the contrary, when the temperature detected by the second temperature sensor 132 is equal to or greater than the reference temperature, the first auxiliary drying process is not carried out (S 560 ) and the processes after the first auxiliary drying process ($ 560 ) are carried out.
[0165] This is carried out according to features of the laundry, and is because, in a case of putting dry laundry or laundry that is easily dried into the drum, the laundry may be damaged when high temperature air is supplied for the predetermined times t 1 and t 2 like those in the first, second, and third preferred embodiments of the present invention.
[0166] Thus, in this preferred embodiment of the present invention, it is possible to perform the first auxiliary drying process for the predetermined times t 1 and t 2 as well as based on the slope with respect to temperature change. In this case, although the first auxiliary drying process is carried out for the predetermined time t 1 , if the slope with respect to the temperature change is equal to or greater than the reference slope, the first auxiliary drying process is not carried out further and the next processes may be carried out even when the predetermined times t 1 is not elapsed. Thus, by performing the above-mentioned two drying methods, time of the drying cycle can be reduced and the laundry can be effectively dried without damage.
[0167] This is identical to when the second auxiliary drying process is carried out (S 600 ).
[0168] When the first auxiliary drying process (S 560 ) is finished or temperature detected by the second temperature sensor 132 is less than the reference temperature, the first auxiliary drying process ( 9560 ) is not carried out and the process of detecting the quantity of laundry (S 580 ) is carried out. At this time, from experimental data obtained from repeated experiments, the expected remaining time of the drying cycle corresponding to the detected quantity of laundry is estimated and displayed on the display 180 (S 590 ).
[0169] When the expected remaining time of the drying cycle is displayed, the second auxiliary drying process is carried out as a next process (S 600 ).
[0170] In the second auxiliary drying process (S 600 ), it is determined whether or not the slope with respect to the temperature change detected by the second temperature sensor 132 is equal to or greater than the predetermined reference slope (S 610 ), like the first auxiliary drying process. When the slope with respect to the temperature change is less than the reference slope, a process of drying laundry is carried out by driving the drum motor 140 within the second motor driving range, that is, at low speed of 40 RPM to 60 RPM and maintaining temperature of air to be supplied to the tub 131 within the first temperature range T 2 to T 1 . When the slope with respect to the temperature change is equal to or greater than the reference slope, the next processes are carried out.
[0171] Next, the condensing water is supplied through the condensing water supplying pipe 113 to remove moisture contained in air during the condensing process, the condensed water is exhausted to the exterior through the exhaust pipe 151 via the lower side of the tub 131 by performing the supply of condensing water and the exhaust of water (S 620 ). When the supply of condensing water and the exhaust of water are completed, the main drying step (S 630 ) is carried out.
[0172] In the main drying step (S 630 ), the drum motor 140 is driven within the second motor driving range, that is, at low speed of 40 RPM to 60 RPM and temperature of air to be supplied to the tub 131 is maintained within the second temperature range of T 4 to T 3 , preferably, 95 degrees centigrade to 105 degrees centigrade. The main drying step is carried out until the expected remaining time of the drying cycle has elapsed (S 640 to S 650 ).
[0173] Meanwhile, when the expected remaining time of the drying cycle has elapsed, it is determined whether or not a drying rate reaches a specific drying rate indicating the completion of drying. When the drying rate reaches the specific drying rate, the drying cycle is finished. When the drying rate does not reach the specific drying rate, the main drying step (S 630 ) is further carried out for a predetermined time, for example, 10 minutes to 20 minutes (S 640 to S 650 ).
[0174] Drying rates in the first, second, third, and fourth preferred embodiments of the present invention will be described with reference to Table 1 as follows.
[0000]
TABLE 1
Drying rates according to the respective preferred
embodiments
Weight
of
Weight
Weight
laundry
of dry
of humid
Drying
after
laundry
laundry
time
drying
Drying
Item
(Kg)
(Kg)
(min)
(Kg)
rate (%)
Conventional
5.02
9.03
300
5.55
90.45
art
Embodiment 1
4.99
9.03
223
5.19
96.05
Embodiments
5.02
9.03
180
5.25
95.70
2, 3, 4
[0175] The drying rates in the drying method according to the preferred embodiments of the present invention and the convention drying method will be described with reference to Table 1. At a state when weight of humid laundry is 9.03 Kg in the respective preferred embodiments of the present invention and in the conventional drying method, the conventional drying method is carried out. At this time, when the drying time of 300 minute has elapsed, weight of dried laundry is 5.55 Kg. Thus, the drying rate indicating weight of laundry after the drying with respect to weight of dry laundry is 90.45%.
[0176] On the contrary, when the drying method according to the first preferred embodiment of the present invention is carried out, weight of laundry after the drying when the drying time of 223 minutes has elapsed is 5.19 Kg and the drying rate is 96.05%. Moreover, when the drying methods according to the second, third, and fourth preferred embodiments of the present invention are carried out, weight of laundry after the drying when the drying time of 180 minutes has elapsed is 5.25 Kg and the drying rate is 95.70%.
[0177] As described above, in comparison to the conventional drying method, when the drying methods according to the preferred embodiments of the present invention are carried out, a great deal of moisture can be removed within a short time so that a high drying rate can be achieved within a short time.
[0178] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
[0179] According to the drying method of the present invention, based on temperature of external air to be supplied into the tub, RPM of the drum motor and switching on/off of the heater are controlled to reduce time for drying laundry.
[0180] Moreover, it is possible to prevent laundry from damage due to heat of air in the tub and power consumption can be reduced by switching the heater on/off.
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A nonvolatile semiconductor memory device which is superior in writing and charge holding properties, including a semiconductor substrate in which a channel formation region is formed between a pair of impurity regions formed with an interval, and a first insulating layer, a floating gate, a second insulating layer, and a control gate over an upper layer portion of the semiconductor substrate. It is preferable that a band gap of a semiconductor material forming the floating gate be smaller than that of the semiconductor substrate. For example, it is preferable that the band gap of the semiconductor material forming the floating gate be smaller than that of the channel formation region in the semiconductor substrate by 0.1 eV or more. This is because, by decreasing the bottom energy level of a conduction band of the floating gate electrode to be lower than that of the channel formation region in the semiconductor substrate, carrier injecting and charge holding properties are improved.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention generally relates to a system for transparent or tinted window framing systems. More particularly, the present invention relates to a window framing system in which the window frame itself, instead of merely the window, is transparent, translucent, or tinted.
[0004] Windows have been employed in the exterior walls of structures, such as dwellings for example, for hundreds of years. Windows may serve many uses, such as providing for ventilation, but one of the main advantages of windows is the admission of natural light into the interior of a structure. Light passing through a window may be useful for practical purposes, such as to provide illumination to the interior of the structure, or may additionally be useful to increase the aesthetic appeal of the window.
[0005] A typical window may be employed as part of a wall in a residential, commercial, or industrial structure. The window includes an exterior frame set into the wall, a transparent portion, such as glass, and an interior frame supporting the transparent portion within the exterior frame. The interior frame may be movable within the exterior frame to allow the window to be opened. Many alternatives to the typical window exists, for example, double hung windows which may include two interior frames, each including a transparent portion and each movable within the exterior frame.
[0006] In the present day, most window frames are fashioned by extrusion of metal, such as aluminum for example, wood, or a plastic material, such as vinyl or polyvinyl chloride (PVC) for example. Most recently, PVC has become an especially popular material for window frame construction because PVC is white, opaque, UV-stable, and easy to manufacture and process. Also, very recently, some manufacturers have begun to employ injection molding processes to manufacture window frames. However, these techniques also typically employ PVC because of its above-noted properties and its tradition of use in the industry. PVC may be either extruded or injection molded to form articles in any of a number of colors, but the formed articles, although colored, are opaque.
[0007] Although many embodiments of window frames may be employed, one important characteristic of most window frame systems is the amount of light that penetrates the window into the interior of the structure. Typically, windows allowing more light to penetrate into the interior of the structure provide brighter illumination and are often more desirable by consumers. Some techniques employed in the industry to increase total light penetration through a window include increasing the transparency of the window or shrinking the size of the window frame. However, both the transparency of the window and the size of the frame have practical limitations, such as structural stability, the necessity to attach to the surrounding wall, or the enclosure of opening or locking components which may provide a bottom limit for the size of the window frame. Additionally, many windows employ screens which may also serve to reduce the light transmitted through the window.
[0008] Thus, a window system that provides for additional light penetration has long been desired commercially, by consumers and, therefore, by manufacturers as well. More particularly, a window system providing additional light penetration while maintaining structural stability, environmental sealing, and aesthetic merit has long been desired.
SUMMARY OF THE INVENTION
[0009] A preferred embodiment of the present invention includes a non-opaque window framing system. The window framing system may be transparent, translucent, or tinted. In a preferred embodiment, the window frame itself may be transparent, translucent, or tinted. Because the window frame is light permeable, additional light may enter the interior of the structure. However, the structural integrity of the window is not compromised because the window frame remains solid and sturdy. Additionally, a transparent screen may be employed in the window frame to further increase light penetration.
[0010] Preferably the window framing system of the present invention is formed using injection molding. Alternatively, the window framing system of the present invention may be formed using extrusion. Preferably, the transparent material of the window framing system may be transformed into translucent material through the use of color additives. Alternatively, the transparent material of the window framing system may be tinted using color additives. The window framing system may be composed of a plastic material, such as LEXAN polycarbonate or nylon, for example.
[0011] These and other features of the present invention are discussed or apparent in the following detailed description of the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 illustrates a perspective view of a non-opaque hopper vent according to a preferred embodiment of the present invention.
[0013] [0013]FIG. 2 illustrates several embodiments of non-opaque window framing systems for windows and doors according to the present invention.
[0014] [0014]FIG. 3 illustrates additional embodiments of non-opaque window framing systems for windows and doors according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] In describing a preferred embodiment of the present invention as illustrated in the accompanying drawings, specific terminology, such as top, bottom, left, right, interior and exterior, for example, will be utilized for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes a multitude of equivalents.
[0016] The preferred embodiments of the present invention relate to a window framing system, such as a hopper vent, for example. FIG. 1 illustrates an interior perspective view of a non-opaque hopper vent 100 according to a preferred embodiment of the present invention. The hopper vent 100 includes an exterior frame 110 , an interior frame 120 , a transparent insert 130 , and a screen 140 . The hopper vent 100 also includes a window lock 155 and a window spring 150 . In the preferred embodiment of FIG. 1, the window lock 115 secures the interior frame 120 to the exterior frame 110 and the window spring 150 aids in the positioning of the interior frame 120 within the exterior frame 110 . The exterior frame 110 and interior frame 120 are preferably comprised of four injection molded pieces which may be snapped together to form the exterior frame 110 and the interior frame 120 .
[0017] As shown in FIG. 1, the exterior frame 110 of the hopper vent 100 may be attached to a surrounding glass block window, for example. The exterior frame 110 encloses and is attached to the interior frame 120 . The interior frame encloses and supports the transparent insert 130 . The screen 140 is removably fixed to the top and bottom of the exterior frame 110 .
[0018] In a conventional hopper vent, light passes only through a transparent window mounted in an opaque frame. In the hopper vent 100 of FIG. 1, light passes through the transparent insert 130 , but also passes through the exterior frame 110 and interior frame 120 directly because the frames 110 - 120 are also transparent. That is, in a preferred embodiment, the hopper vent 100 is light permeable, and light is able to substantially pass through the exterior frame 110 and interior frame 120 , as well as the insert 130 .
[0019] The structure of the hopper vent 100 is further described in great detail in a pending patent application entitled “Improved Hopper Vent” which was filed on Aug. 17, 2000, and is incorporated herein by reference in its entirety.
[0020] In practice, the hopper vent 100 may be included as part of a glass block window typically located as part of an exterior wall of a structure and separating the interior of the structure from the exterior of the structure. The glass block window, and thus also the present invention, may then be understood to include an interior side, viewable from inside the structure, and an exterior side viewable from outside the structure.
[0021] In general, the light permeable hopper vent 100 is composed of a transparent, translucent, or tinted material, such as LEXAN polycarbonate or NYLON, for example, although other materials may be employed, and is preferably injection molded. That is, the exterior frame 110 , interior frame 120 , and screen 140 are composed of the transparent, translucent, or tinted material, but may include additional elements such as the window lock 155 or the window spring 150 , for example, which may be composed of the transparent, translucent, or tinted material, or may alternatively be a non-opaque material such as a metal, for example. The transparent insert 130 is preferably composed of a transparent material, such as glass or other glazing material, for example.
[0022] In a typical injection molding process, plastic material, such as powders or pellets of plastic, for example, is mixed and heated until the plastic material liquefies. Next, the liquefied plastic material is introduced into a shaped mold. Then, the mold is allowed to cool. As the mold cools, the liquefied plastic material solidifies and conforms to the shape of the mold.
[0023] In a typical extrusion process, plastic material, such as powders or pellets of plastic, for example, is mixed and heated until the plastic material partially liquefies. The partially liquefied plastic material then passes through a die, and lengths of the material are extruded and then cut. The cut lengths of material may then be further manufactured into a desired article.
[0024] Because the hopper vent 100 is substantially manufactured from a transparent, translucent, or tinted material, such as LEXAN polycarbonate or NYLON, for example, the hopper vent 100 is transparent when completed through injection molding, extrusion, or other such process. Alternatively, the hopper vent 100 may be tinted to any of a variety of colors through the addition of a commercially available color additive, such as polycarbonate coloring additive to the LEXAN polycarbonate, for example, prior to injection molding. For example, a powdered color additive may be added to the plastic powder and then mixed and heated. Additionally, the transparency of the hopper vent 100 may be altered through the addition of other commercially available additives, such as polycarbonate additives to the LEXAN polycarbonate, for example, prior to injection molding. Alternatively, color additives or other additives may be added to extruded plastic material as well.
[0025] The preferred embodiment of the present invention is injection molded rather than extruded. As shown in FIG. 1 and described above, the hopper vent 100 may be simply and easily snapped together without the use of many fastenings. Because the hopper vent 100 minimizes the use of fastenings, the hopper vent 100 preferably includes relatively few interior elements that may interfere with the passage of light through the exterior frame 110 or interior frame 120 of the hopper vent 100 or with the aesthetic appeal of the hopper vent 100 .
[0026] In an alternative embodiment, the hopper vent 100 or other window may be mounted in an exterior wall. When mounted in an exterior wall, an opaque strip of material may be positioned around the perimeter of the exterior frame 110 of the hopper vent 100 to increase aesthetic appeal by preventing an observer from seeing through the exterior frame 110 and into the interior of the wall.
[0027] [0027]FIG. 2 illustrates several embodiments of non-opaque window framing systems for windows and doors according to the present invention. Examples shown in FIG. 2 include a double hung window 205 , a single hung window 210 , a picture window 215 , a dual or single sliding window 220 , a glass block window/wall/prefab shown frame system 225 , a dual sliding patio door 230 , and a single sliding patio door 235 . The examples shown in FIG. 2 represent only a small number of the alternative embodiments of the present invention that may be developed by one skilled in the art.
[0028] [0028]FIG. 3 illustrates additional embodiments of non-opaque window framing systems for windows and doors according to the present invention. Examples shown in FIG. 3 include a casement window 305 , a dual hinged swinging patio door 310 , a hinged/fixed swinging patio 315 , a sliding screen 320 , a fixed screen 325 , a hopper window 330 , and an awning window 335 . The examples shown in FIG. 3 represent only a small number of the alternative embodiments of the present invention that may be developed by one skilled in the art.
[0029] LEXAN polycarbonate or other light permeable materials may have been previously employed in other fields, for example, commercially available photograph frames for framing photographs for display. However, the use of a transparent, tinted, or translucent material to form a window frame is new. Thus, the present invention includes the concept of maximizing light penetration through a window system while maintaining structural stability, environmental sealing, and aesthetic value.
[0030] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted 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 its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
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A window frame system with transparent, tinted, or translucent window frames is provided. The window frame itself is transparent, tinted, or translucent, instead of merely the enclosed glass window. Because the frame of the window is light permeable, additional light may pass through the window frame yielding an increase in the overall brightness of the window. Additionally, the structural and environmental integrity of the window is preserved because the window frame remains solid. A transparent screen may also replace a conventional screen to further increase light transmission.
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BACKGROUND OF THE INVENTION
[0001] This application claims priority of provisional patent application Ser No. 60/433,898, filed Jan. 21, 2003.
[0002] In general, antimicrobial chemicals have been used for years to preserve plastics and textile materials. Furthermore, the prior art teaches the use of antimicrobials in pulp and paper manufacture. In some instances, the antimicrobial chemicals are applied as slime control agents and in the paper production. However, these slime control agents are normally extracted during the paper manufacturing process and are not considered to be of any value in protecting the finished paper.
[0003] The production of antimicrobial paper has most often accomplished by producing the desired paper in sheet form and coating the sheet with an antimicrobial coating in order to inhibit growth of fungi and bacteria thereon. For example, U.S. Pat. No. 2,833,669 is directed to a cellulosic product, the type used for medical, industrial, hygienic, and other similar purposes. This patent discloses the use of a bactericidal coating having a particular affinity for fiber substances. In particular, the patent teaches spreading the bactericidal coating across the paper product just before the fibrous web has been subjected to a drying process as part of the overall paper manufacture. The patent further discloses that the bactericidal layer may be applied to one or both sides of the web. The problem inherent in this type of process is the fact that the bactericidal coating may be easily rubbed off or otherwise destroyed, for example, during storage or shipping. Once the coating has been destroyed, there is no further antimicrobial or anti-bacterial material along the paper product for inhibiting micro-organism growth.
[0004] U.S. Pat. No. 4,533,435 teaches incorporating an antimicrobial additive into the binding agent of a heavy duty paper product. The antimicrobial additive thus migrates from within the binding agent onto the paper fibers in order to significantly eliminate the growth of micro-organisms thereon. Particularly, the antimicrobial additive described in U.S. Pat. No. 4,533,435 is chosen to be compatible with the binder material such that it resides in a colloidal suspension within the amorphous zones of the polymeric material which makes up the binder rather than being cross-linked with the polymeric material. Nonetheless, despite the improvements provided by this patent, the teaching of this patent is less than desirable because a substantial amount of antimicrobial chemical must be used in order for a sufficient amount of antimicrobial to be present along the surface of the paper.
[0005] Another problem with respect to prior art antimicrobial paper products is that it is necessary to incorporate large quantities of antimicrobial chemicals into the pulp. As a result, the paper manufacturing process becomes significantly uneconomical. In addition, if the antimicrobial chemicals are introduced at the wet end of the paper making process, they may be introduced into the waterway stream and thus contaminate rivers or water sheds, lakes, streams and even cause damage to wildlife as well as plant life. Thus, additional water treatment facilities may be necessary in order to neutralize the chemicals, thereby increasing the cost in the manufacturing process.
SUMMARY OF THE INVENTION
[0006] Generally speaking, in accordance with the invention, conventional paper used for printing or for fabrication into envelopes, file folders, forms and the like, is prepared by having antimicrobial agents added into the sizing during the manufacturing process. The antimicrobial agent provides protection to the paper from fungi, mildew and bacteria that could otherwise destroy the paper or be harmful. to the user thereof. Particularly, the antimicrobial agent will be suitable for actively attacking various microbes, including bacteria as well as viruses, that could use conventional paper as “food” for growth and multiplication. The incorporated antimicrobial agents will also kill bacteria, viruses, fungi and mildew, thus providing protection to those persons handling the paper product, in whatever form it may be prepared.
[0007] Significantly, in manufacture, a sizing mixture is used in preparing the paper product; the mixture contains both antimicrobial agents and sizing, as well as water. The ratio of antimicrobial chemicals to sizing is between about 0.1:100 and 1.0:100. These agents may be selected form organic antimicrobial chemicals, such as phenols, for example, Triclosan, organic silanes, as well as inorganic antimicrobial chemicals such as silver ion zeolites and silanes.
[0008] Accordingly, it is an object of the invention to provide an improved antimicrobial paper product.
[0009] Still another object of the invention is to provide an improved antimicrobial paper product in which the antimicrobials are incorporated into the sizing during the manufacturing process.
[0010] Yet another object of the invention is to provide an improved antimicrobial paper product having an enhanced effectiveness.
[0011] Still other objects and advantages of the invention will become obvious in view of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a fuller understanding of the invention, reference is made to the following description, taken in connection with the accompanying drawings, in which:
[0013] FIG. 1 is a front elevational view of a size press installation system used in the manufacture of the antimicrobial paper product of the invention.
DETAILED DESCRIPTION
[0014] The antimicrobial paper product of the invention may be used for various types of applications, for example, for paper intended for printing forms, such as forms for medical and dental offices, that must be suitable for lithography as well as copying with laser and ink jet printers; the antimicrobial paper may also be used for heavier grades of folder type paper, commonly referred to as “manila.”
[0015] In accordance with the invention, the paper product is produced by first forming the paper from a pulp slurry. In particular, water is extracted from the pulp by, for example, vacuum, pressure and/or heat, as is well known, thus forming a paper web comprising paper fibers having interstices which, while still somewhat damp, passes through a machine called a size press 11 of the type known to those skilled in the art and depicted generally in FIG. 1 . The size press is comprised typically of two squeeze rollers 13 between which the paper web 15 is passed. As part of the process, a sizing material or mixture, which is composed primarily of sizing and water, is dispensed, for example, through hoses 23 emanating from one or more mixing tanks 21 and directed between the nips of the squeeze rollers. The squeeze rollers normally have a gap between them that defines the thickness of the paper web. Thus, by setting the gap to a size equal to or smaller as compared to the thickness of the paper web, the sizing mixture is thus forced into the interstices of the paper fibers.
[0016] The use of a sizing mixture in the paper manufacturing process is significant in that, when the paper web is dried, the sizing mixture adds surface characteristics such as printability, durability, wet or dry strength, smoothness, brightness, and other well know characteristics. In general, the amount of sizing that is utilized when dispensing the sizing mixture in accordance with the inventive process ranges from between about 20 to 100 lbs. per ton of produced paper (after drying).
[0017] In order to prepare the sizing mixture, a mixing tank with a propeller type blade may be used, as is alluded to above. Water is introduced and then sizing is added to the mixture along with antimicrobial chemicals. The amount of water is selected so that the resulting sizing mixture is suitable for flow to and ultimate deposition on the paper web, as described hereinafter. The sizing is selected from soaps, animal glues, starch paste, synthetic glues, latex products and combinations thereof. Mixing is complete in about twenty minutes utilizing a water temperature range of between about 700 to 2000 Fahrenheit. Application temperature of the sizing mixture during the paper manufacturing process should be at a temperature range of between about 70°-180° Fahrenheit.
[0018] Turning once again to the paper manufacturing process, the size press passes the prepared sizing mixture into the interstices of the paper fibers from either one or both sides of the paper web, depending upon whether antimicrobial protection is desired along both sides of the finished paper product. Penetration and distribution of the antimicrobial chemicals is thus achieved throughout a substantial portion of the thickness of the paper. The ratio of antimicrobial chemicals to sizing in the sizing mixture is from between 0.1:100 and 1:100 and the amount of sizing to be ultimately deposited on the paper web is in the range of between 20 and 100 pounds per ton of produced paper. This achieves the application of antimicrobial chemicals of between about 0.02 and 1 pound per ton of paper.
[0019] It is important to note that the particulate antimicrobial chemicals that are selected for incorporation within the sizing mixture usually have a particle size of about three microns or less. Therefore, the antimicrobial chemicals are easily carried into the interstices of the paper fibers, with the pressure of the squeeze rollers pressing the sizing mixture into the paper. Accordingly, an integrated coating of the antimicrobial chemicals is achieved across the paper fibers during the manufacturing process.
[0020] Suitable antimicrobial chemicals to be added to the sizing mixture in accordance with the inventive system include particulate organic antimicrobial agents including phenols, such as Triclosan, which is 5-chloro-2-(2,4-dichlorophenoxy) phenol, supplied by Ciba Specialty Chemical Corporation of Tarrytown, N.Y., and liquid antimicrobial agents including organic silanes such as 3-(trimethoxysilyl) propyldimethyloctadecyl ammonium chloride (an organic quaternary ammonium salt compound) and chloropropyltrimethoxysilane. Other organic quaternary ammonium salts (particulate or liquid form), such as dialkyl dimethyl ammonium chloride, alkyldimethyl ethylbenzyl ammonium chloride and alkyldimethyl benzyl ammonium chloride, as well as those of the type identified in U.S. Pat. Nos. 5,049,383, 4,444,790 and 4,450,174, incorporated herein by reference, may also be used. Phenol antimicrobials are particularly effective in inhibiting or killing both gram-positive and gram-negative bacteria and are also effective in inhibiting the growth of mold and mildew. Inorganic particulate antimicrobial agents can also be used, such as silver zeolites, namely, Irgaguard B5000, which is a combination of zinc oxide and DHT-4A-2 and AgZn zeolite II), Irgaguard B8000, which is AgZn zeolite II, both of which are supplied by Ciba Specialty Chemicals Corporation of Tarrytown, N.Y., as well as AlphaSan RC 5000, which is silver sodium hydrogen zirconium phosphate, supplied by Milliken Chemicals of Spartanburg, S.C. In accordance with the invention, any antimicrobial chemical may be used so long as it can be carried by a sizing mixture and can be incorporated within the interstices of the paper fibers following deposition of the sizing mixture along the paper web.
[0021] Turning once again to the paper manufacturing process, after passing the paper web through the sizing press, the paper web, now, of course, impregnated with the antimicrobial chemicals from the sizing mixture, is passed over a heated drying drum that evaporates the remaining water. The paper is then ready to be rolled up and delivered for production into paper sheets, forms, folders and the like, as is well known in the art.
[0022] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the processes and products described herein without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be incorporated as illustrative and not in a limiting sense.
[0023] It is also to be understood that the following claims are intended to cover all of the generic and the specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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A conventional paper product used for printing or for fabrication into envelopes, file folders, forms and the like, is prepared by having antimicrobial agents added into the sizing during the manufacturing process. The antimicrobial agent provides protection to the paper from fungi, mildew and bacteria that could otherwise destroy the paper or be harmful to the user thereof.
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CROSS REFERENCE TO OTHER APPLICATIONS
The present application is a continuation of pending International patent application PCT/EP2006/006717, filed Jul. 10, 2006 which designates the United States and was published in German, and which claims priority of German patent application 10 2005 034 424.0, filed Jul. 13, 2005. The disclosure of the above applications is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is related to the field of manually operated presses which are conventionally used for pressing workpieces together.
The invention, further, is related to a method for protecting a manually operated press against mechanical overload and for aborting an insufficiently executed pressing operation.
More specifically, the invention is related to a manually operated press comprising an actuation member coupled to a shaft, an actuation of the actuation member being transformed into a stroke movement of a press ram coupled to the shaft and, accordingly, into a change of a relative displacement position of the press ram, and a clutch for interrupting a flow of force between the actuation member and the press ram.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 7,080,595 B2 discloses a manually operated press into which a backstroke inhibitor is electronically implemented, such as known e.g. from U.S. Pat. No. 6,755,124 B2.
Manually operated presses of the kind described above are conventionally used for piece-work workplaces. As in manually operated presses the exerted force increases towards the end of the pressing stroke, some operating persons tend to exert too much force and, thereby, produce pressed workpieces of bad quality or even damaged workpieces.
For many conventional manually operated presses no documentation is produced, in contrast to automatically executed pressing operations for which numerically controlled presses are conventionally used. The lack of documentation, however, is nowadays no longer acceptable for many fields of application, in particular when production processes are to be certified under the ISO 9000 standard.
In order to make sure that one can distinguish between “good” and “bad” parts, European patent specification 0 960 017 B1 teaches to provide a press with a sensor for the pressing stroke (displacement position) as well as with another sensor for the pressing force for generating a displacement-force diagram for any pressing operation being characteristic for a good and for a bad pressing. If a measured displacement-force curve lies within a given tolerance band, then the respective part is identified as well pressed. If not, the part is identified as a bad part that must be disposed of.
In order to be able to determine the pressing force exerted during a pressing operation, e.g. on a Seeger circlip ring, a bearing, a pinion, a sealing etc., a press ram of the press is configured as a force sensor. The force sensor has a force measuring system, for example a strain gauge strip, integrated therein. The strain gauge is connected to a press control unit of the press which, in turn, may be connected with a rotation sensor, for example, for sensing the rotation angle of the actuation lever and, hence, the ram displacement position. The control unit then processes the sensed data to enable the above-mentioned differentiation between good and bad parts once the pressing operation is executed.
If the examination shows that a bad part was pressed, the press may switch off automatically when the bad part is still within the press. This is likewise made upon a respective command from the control unit.
To start with, there is a first problem that during conventional manual pressing operations, in contrast to automatically executed pressing operations, there may unintentionally occur high pressing forces which, for example, are caused by negligence of the operating person. High pressing forces may likewise occur when the parts which are to be pressed together, are already sufficiently joined, however, the mechanical final position of the pressing stroke has not yet been reached. In such a situation, the operating person “feels” that the actuation lever may still be moved further in the pressing direction, and, therefore executes such movement to its end. In such a case a too high pressing force may be executed resulting in a “bad” pressing.
It is, therefore, necessary that the exerted pressing force be measured as precisely as possible in order to be able to optimally execute the quality examination based thereon. For that purpose highly sensitive force measuring systems are used which, however, are destroyed or at least damaged at too high mechanical overloads. Moreover, high overloads may occur from time to time that exceed admissible overload specifications by 100 or 200%.
As already mentioned above, the prior art teaches to record the force as a function of the displacement position for making a quality evaluation (good/bad) once the pressing operation is finished. As the pressing operation is effected manually, each pressing operation is effected with different pressing force. For that reason some work pieces which shall be pressed together, may already be joined sufficiently “well” before the press ram has reached its mechanical final position, or some work pieces may be sufficiently joined only at the final position. In the event that the sufficient joining has already been achieved prematurely, it would be desirable to abort the pressing operation before the final (mechanical) press ram position has been reached.
SUMMARY OF THE INVENTION
It is, therefore, an object underlying the invention to improve a manually operated press of the type specified at the outset such that the above-discussed problems are avoided. In particular, a manually operated press shall be provided in which admissible overloads can be limited to a predetermined threshold value, and in which a force sensor is protected against overload. Moreover, the pressing operation shall be aborted prematurely in the event that the desired pressing force has been reached prematurely. “Bad” pressings shall be avoided.
In a press of the type specified at the outset, this object is achieved according to the invention in that the lever shaft is at least a two-piece construction, namely configured with an input shaft and an output shaft, and that the clutch is adapted to separate the input shaft from the output shaft depending on the pressing force and/or the relative displacement position of the press ram.
The object underlying the invention is, thereby, entirely solved.
Due to the fact that in contrast to the prior art the shaft of the invention is configured two-piece, one now has, unlike before, the option to interrupt the flow of force between the actuation member and the press ram at will, namely independent from the effective actuation of the actuation member. The prior art until now only teaches to brake or to immobilize a one-piece shaft upon occurrence of a failure, in particular when the back stroke is initiated prematurely.
According to the present invention the flow of force between the press ram and the actuation lever can be interrupted at any moment in time by means of the clutch, namely by separating the shafts from each other. In the event that a desired pressing force is exerted already before a (mechanical) final position of the pressing operation has been reached, the shafts may be separated from each other depending on that event. If an inadmissibly high pressing force is exerted during a pressing operation which would damage a force sensor or would result in a “badly” pressed work piece, the shafts could likewise be separated from each other, again—depending on these events.
For that purpose it is advantageous to additionally provide a first sensor for sensing the pressing force and/or a sensor for sensing the relative position of the press ram.
If only a pressing force sensor is provided, a force measuring system of the press can be protected against overload. Should only a sensor for sensing the relative position of the press ram be provided then one can determine from the executed stroke displacement which pressing force was exerted, provided that all required further parameters as needed therefore are known, as, for example, the transmission of the lever movement into the press stroke, properties of the work pieces to be pressed together, etc.
If both sensors are used in combination, one can record a force vs. displacement curve for each pressing operation so that it is possible to make a good/bad distinction already during the course of the pressing operation. In particular, one may determine when a “good” pressing has occurred. If the force is recorded vs. the displacement, one can, for example, decide by means of a higher level control that the pressing operation shall be aborted already before a (mechanical) final position of the press ram has been reached, because a desired pressing force has been reached. In such a way “bad” pressings are generally avoided.
Preferably, a control unit is provided for that purpose which is coupled to the first and/or the second sensor and also to the clutch for supplying respective clutch signals to the clutch.
The control unit samples the force sensor(s) for outputting clutch signals to the clutch as a response to signals produced by the sensors.
The control unit, preferably, outputs a clutch signal for keeping the clutch closed when the sensed pressing force or the sensed relative displacement position of the press ram is smaller than a predetermined threshold value.
When the clutch is open, no flow of force may occur between the actuation member and the press ram. If the actuation member is not in its predetermined initial position, a pressing operation is not allowed at all due to the open clutch. This enhances pressing safety.
It is, further, preferred, when the control unit supplies a clutch signal for opening the clutch when the pressing force or the relative displacement position of the press ram is greater than or equal to a predetermined threshold value. The threshold value may be an admissible maximum pressing force, at which a force sensor is not damaged, and/or may be a minimum pressing stroke displacement at which a “good” pressing is obtained.
The control unit is, in particular, provided with means for determining whether a predetermined pressing force limit was exceeded or a desired pressing force has been reached. If the limit is exceeded, then a signal for opening the clutch is generated. Thereby, the flow of force between the actuation member and the press ram is interrupted.
According to a preferred embodiment of the invention, the manually operated press is provided with a stroke stop for immobilizing the input shaft, wherein the stroke stop, in particular, comprises a brake disc and a brake magnet.
With a stroke stop so configured the actuation of the actuation member may be immobilized in the forward as well as in the backward direction. The actuation lever is rigidly connected with the input shaft, such that an immobilization of the input shaft results in an immobilization of the actuation lever.
In a preferred configuration of the stroke stop using a brake disc cooperating with a brake magnet, the brake disc is, preferably, secured against rotation to the input shaft, and the brake magnet is secured in a stationary manner to the press. Considering that the stroke stop in that case is an electrically operated brake assembly, the brake assembly may likewise be controlled by the above-mentioned control unit, by sending corresponding signals from the control unit to the stroke stop or its elements.
Further, it is preferred when a third sensor is provided for sensing the relative displacement position of the input shaft, wherein the brake disc may be configured such that the third sensor senses the relative displacement position in cooperation with the brake disc.
By means of the third sensor one can generate a signal according to which the clutch is closed, provided that the actuation member is in its corresponding initial position. The initial position may be sensed by means of the brake disc or a disc flange, being connected to the input shaft for rotation therewith and, hence, also to the actuation member. Thereby it is always guaranteed that the flow of force is only established between the actuation lever and the press ram when the actuation lever is in its initial position. Hence, it is guaranteed that the displacement that can be made by the actuation lever is sufficient to effect the press stroke required for making a sufficient pressing operation. In particular, the clutch is closed only when also the press ram is in its initial position.
Further, it is advantageous when a return assembly, in particular a spring, is provided being coupled to the input shaft.
By this measure one may effect that the actuation member is automatically moved back into its initial position, in particular when the clutch is separated, i.e. the flow of force between the actuation member and the press ram is opened and the operating person may have released the actuation lever. For an automatic return movement of the actuation lever it is, of course, necessary that the stroke stop is not immobilized.
According to another preferred embodiment of the invention, the actuation member is a manually operable lever, the input shaft is an inner manual lever shaft and the output shaft is an outer hollow shaft.
By this measure one can obtain a manually operated press with short dimensions because the input shaft constitutes an inner shaft being arranged coaxially to the outer hollow shaft.
In particular, the second sensor may be a linear incremental displacement position measuring system sensing displacement position marks coupled to the press ram.
By coupling the position marks to the press ram, the measurement of the effected displacement is made on the press ram without any inaccuracies caused e.g. by transmissions, in contrast to the prior art where the displacement is sensed by means of a rotary sensor at the input shaft.
Here, too, it is advantageous when the two shafts are interconnected by the clutch in a form-fitting manner for transforming the stroke movement. By the additional form-fitting connection one can constitute a mechanical overload protection in which spontaneous overloads of (very) high intensity can be absorbed before they destroy a force sensor.
For that purpose one preferably uses a toothing having a latch position being configured such as to open automatically from a closed state at a predetermined torque that is effected via the actuation member. The latch position is, preferably, reached when the shafts are in their respective initial positions.
If, suddenly, an inadmissibly high torque appears at the shafts being coupled by the toothing, an automatic separation of the coupling is effected by this kind of coupling. The closing force exerted by the clutch is no more sufficient for compensating a decoupling force caused by the toothing. In that case the clutch opens spontaneously, i.e. without the intervention of a higher level control, for interrupting the flow of force.
It will be understood that the features of the invention mentioned above and those yet to be explained below can be used not only in the respective combination indicated, but also in other combinations or in isolation, without leaving the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are explained in more detail in the following description and are represented in the drawings, in which:
FIG. 1 shows a highly schematical side elevational view (partially broken away) of an embodiment of a manually operated press according to the present invention;
FIG. 2 shows a latch toothing of a first and of a second shaft section according to the present invention; and
FIG. 3 shows a schematic force ratio at the location of the toothing according to FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 reference numeral 10 as a whole designates a manually operated press of essentially known design.
Press 10 has a base member 12 standing on an appropriate base, for example a work bench. Posts 14 extend upwardly from base member 12 to a head member 16 , also referred to as shifting member because head member 16 is adapted to be adjustable in the direction of posts 14 depending on the desired stroke. An actuation lever 18 is arranged laterally at head member 16 and is connected to a shaft 22 journalled within shifting member 16 by means of bearings 20 . Shaft 22 is adapted to be rotated about its axis 24 by actuation lever 18 , as indicated by an arrow 26 . FIG. 1 shows the initial position of lever 18 .
A transmission 28 shown extremely schematically is provided within shifting member 16 . Transmission 28 , in the simplest case, may be a pinion-rack assembly. The assembly is provided for transmitting the rotary movement of shaft 22 into a vertical stroke movement of a press ram 32 as indicated by an arrow 30 .
During a pressing operation, the lower front surface 34 of press ram 32 comes to rest on an upper work piece 36 of a pair of work pieces 36 , 38 which shall be pressed together.
Press 10 is provided with a brake disc 40 being rigidly connected for rotation with shaft 22 . Immediately adjacent brake disc 40 there is provided a second disc 42 configured as a ring for allowing shaft 22 to be guided through second disc 42 . Second disc 42 is rigidly connected to shifting member 16 and, therefore, is hereinafter referred to as stationary.
Reference numeral 44 designates a first clutch having a brake magnet being electrically connected to an electronic control unit 46 . Control signals may be fed from outside, for example from a numerical control unit, to electronic control unit 44 via inputs 48 for constituting an electronic back stroke stop as disclosed in U.S. Pat. No. 7,080,595 B2. This function is likewise possible with the present press 10 . For further details reference is made to U.S. Pat. No. 7,080,595 incorporated herein by way of reference.
The stroke stop configured by first clutch 44 is essentially characterized by the magnet clutch effect of electro magnet exerted on clutch discs 40 and 42 . This “magnetic brake” may, however, be likewise constituted by a pneumatic or a hydraulic brake interconnecting discs 40 and 42 in a frictional manner for preventing a rotation of shaft 22 about its axis 24 .
Press ram 32 may be provided with a force sensor 49 by which the actually effective pressing force may be sensed. Force sensor 49 , too, is connected to electronic control unit 46 . Press ram 32 may insofar serve as a force sensor for a strain gauge strip integrated therein. Sensor 49 , however, may likewise be provided at another location, for example at base member 12 .
Other force measuring systems, for example inductive force sensors or magnetoelastic force sensors or piezo-electric sensors etc. may likewise be used.
Insofar, press 10 is of conventional design.
In contrast to prior art presses, press 10 is provided with a second (outer) hollow shaft 50 being journalled coaxially to shaft 22 . First shaft 22 is hereinafter referred to as the inner manual lever shaft because it is guided through outer hollow shaft 50 . Outer hollow shaft 50 is directly connected to a toothed wheel or pinion constituting the transmission designated 28 . Press ram 32 has corresponding teeth 52 meshing with the pinion or toothed wheel of outer hollow shaft 50 . Preferably, the teeth of outer hollow shaft 50 and of press ram 32 engage one another directly. However, one could also provide further transmission elements therebetween.
Outer hollow shaft 50 can be connected to inner manual lever shaft 22 in a form-fitting or a frictional manner via a second clutch 54 , preferably an electromagnetic clutch. Second clutch 54 is also connected to electronic control unit 46 .
Inner manual lever shaft 22 constitutes an input shaft that is coupled to outer hollow shaft 50 via second clutch 54 .
The operation of press 10 according to the present invention shall now be explained in further detail.
By means of a third sensor 56 being, for example, located near brake disk 40 and cooperating with the latter, one can determine the relative position of manual lever shaft 22 . For that purpose, sensor 56 may likewise be connected to electronic control unit 46 . As actuation lever 18 is connected to shaft 22 (for rotation therewith), as is also disc 40 , one can, therefore, also draw conclusions on the position of lever 18 .
If it is determined that manual lever shaft 22 as well as press ram 32 are in their respective initial positions, from which on a pressing operation may be initiated, a signal is outputted from control unit 46 to second clutch 54 , such that second clutch 54 closes, i.e. inner shaft 22 and outer shaft 50 are connected with one another at least frictionally. Thereby, a flow of force is possible between lever 18 and press ram 32 .
Thereupon, lever 18 is rotated in the direction of arrow 26 for pressing work pieces 36 and 38 together.
Under normal conditions, i.e. when no inadmissibly high pressing force occurs, that can be measured with force measuring system 49 , lever 18 and, hence, also press ram 32 eventually reaches its (electronic or mechanical) final position. The mechanical final position is reached when press ram 32 has run through the maximum possible press stroke, or when lever 18 has been moved against a corresponding mechanical stop. The electronic final position has been reached when either lever 18 has been rotated about a predetermined angle or when press ram 32 has run through a predetermined (stroke) displacement.
The electronic final position could on the one hand be detected by sensor 56 by configuring brake disc 40 , for example, in an area corresponding to the final position such that stationary sensor 56 could detect the final position. If an inductive sensor is used as sensor 56 , brake disc 40 in this area could be configured more or less thick in axial direction 24 .
The electronic final position could also be defined such that a desired pressing force (depending on the displacement of press ram 32 ) has been reached, i.e. work pieces to be pressed together have been sufficiently “well” be pressed together. For that purpose a distance or displacement measuring system 58 can be provided depicted schematically in FIG. 1 as a dashed line. The displacement measuring system detects displacement position marks 59 coupled to press ram 32 .
When the final position has been reached, control unit 46 —depending on the pressing force and/or the effected stroke displacement—can cause second clutch 54 to open, whereby the flow of force between lever 18 and press ram 32 is interrupted. Ram 32 can, in particular, be returned to its initial position corresponding to the initial position of lever 18 , by means of a gas spring not shown in FIG. 1 . It is advantageous when press ram 32 is coupled with displacement mark 59 for determining the relative position of press ram 32 because conclusions may be drawn from that information with regard to the pressing force that has been reached. By determining the relative position of press ram 32 one can, moreover prevent that a subsequent pressing operation is effected before press ram 32 is in its initial position.
This additional displacement measuring system 58 could be configured as a linear incremental measuring system having, for example, a resolution of 5 μm. Displacement marks 59 can be sensed by a measuring head being, preferably, positioned within head member 16 and being likewise connected to control unit 46 .
Brake disc 40 may be connected to a return assembly, in particular a spring 57 . The spring 57 is then connected to stationary head member 16 . In the initial position, the spring 57 is biased. In the final position it is tensed such that, if an operating person should let lever 18 loose, lever 18 is returned automatically into its respective initial position. For that purpose, second clutch 54 should be open.
As soon as press ram 32 and lever 18 have reached their respective initial positions, a new pressing operation can be performed.
In the event that during a pressing operation the admissible pressing force is exceeded so that there is the risk of a damage on the force measuring system 49 , the invention allows to open second clutch 54 before the final position of the pressing operation has been reached. In that case the flow of force between lever 18 and press ram 32 is interrupted. The force may no more act on force sensor 49 . Force sensor 49 is, hence, protected against overload.
Similarly, a prematurely completed pressing operation that has been classified “good”, may be terminated. This means that the flow of force is also interrupted if the pressing operation has been completed before the final position has been reached. The pressing force exerted via actuation lever 18 can be registered by means of sensor 49 by (higher level) control 46 . Control 46 may, for example, comprise an appropriately prepared microprocessor. In the event that control unit 46 , on the basis of a force-displacement measurement, determines that the work pieces 36 and 38 to be pressed together have actually been combined “well”, control unit 46 interrupts the flow of force between lever 18 and ram 32 by means of an appropriate signal for second clutch 54 .
The displacement measurement in this case is, preferably, effected via linear incremental displacement measuring system 58 .
The pressing operation may also be aborted solely depending on the relative position of press ram 32 without actually measuring the pressing force. For that purpose, however, it is necessary that the force-displacement characteristics of the press be known so that one can determine solely on the basis of the stroke displacement whether or when a “good” pressing has been obtained.
In order to avoid the operating person moving lever 18 “into emptiness”, which could result in injury to the operating person, the first clutch 44 is, preferably, actuated first.
More specifically, this is effected as follows: Force sensor 49 senses the pressing force exerted via lever 18 ; the sensed pressing force is sampled in predetermined time intervals by control unit 46 ; subsequently, control unit 46 determines, whether there is an inadmissibly high pressing force that would damage force sensor 49 , by determining, for example, whether the sensed pressing force is greater as or equal to a predetermined threshold value, or, when a “good” pressing of work pieces 36 and 38 has occurred (for example a desired pressing force has been reached); if the sensed pressing force exceeds the predetermined threshold value or if the desired pressing force has been reached, control unit 46 , preferably, first outputs a signal for first clutch 40 to stop the movement of lever 18 more or less abruptly; subsequently a clutch signal is outputted by control unit 46 for second clutch 54 for opening second clutch 54 ; second clutch 54 opens; the flow of force between lever 8 and press ram 32 is, hence, interrupted; as an option, the brake may be released again.
Similar considerations apply when only the stroke displacement is measured.
Depending on whether the operating person still operates lever 18 , lever 18 can be moved further to the mechanical stop, without, however, being in frictional connection with press ram 32 , so that there is no danger of damaging force sensor 49 . Or, the operating person has already let lever 18 go. If the operating person has let lever 18 go, and if there is the above-mentioned return assembly between brake disc 40 and head member 16 , then lever 18 will automatically return into its initial position.
In the switched-off condition of press 10 there is, preferably, no connection between lever 18 and press ram 34 which results in a higher process safety. For making a connection, second clutch 54 must first be energized with current. It goes, however, without saying that second clutch 54 could operate just the other way round, i.e. second clutch 54 could also be closed in the non-activated condition, wherein control unit 46 first interrupts such connection before a pressing operation can be effected and then makes the above-mentioned check on the initial position. In such a way it is always guaranteed that the respective initial positions of lever 18 and of press ram 32 are assumed at the beginning of a pressing operation.
Instead of the type of transmission mentioned at the outset in which a rack meshes with a pinion or a toothed wheel, one might also use a planetary gear train, a worm drive, a chain drive, a belt drive a conical wheel drive, a toggle lever, a shoe lever, a hydraulic transmission or the like.
According to another embodiment of the present invention, inner manual lever shaft 22 and outer hollow shaft 50 are not only interconnected frictionally but also in a form-fitting manner.
FIG. 2 shows a highly schematic cross-sectional view perpendicularly to a coupling plane between inner manual lever shaft 22 and outer hollow shaft 50 .
The drawing plane of FIG. 2 corresponds to the plane extending perpendicular to the drawing plane of FIG. 1 . The tooth pair 60 shown in FIG. 2 , preferably, comprises one (latch) tooth 62 only which, in the embodiment shown is configured with outer hollow shaft 50 , and a corresponding recess 64 in inner manual lever shaft 22 . FIG. 2 shows a condition, in which second clutch 54 (cf. FIG. 1 ) is open, such that shafts 22 and 50 may freely be rotated with respect to each other. Should second clutch 54 close, shafts 22 and 50 will move relatively towards each other along axis 24 such that tooth 62 comes into engagement with recess 64 .
It goes without saying that tooth 62 , as an alternative, can also be configured with inner manual lever shaft 22 and recess 64 at outer hollow shaft 50 . Instead of one tooth pair only, several such pairs 62 , 64 could also be provided. Embodiments with one (latch) tooth, however, are preferred as will be explained further below.
Tooth pair 60 may, additionally, be used for determining the initial position of press ram 32 . This means that only if shafts 22 and 50 are correctly oriented relative to one another, i.e. if hollow shaft 50 and, hence, press ram 32 are in their initial position, then tooth 62 and recess 64 may engage. If press ram 32 is not (yet) in its initial position, no coupling between shafts 22 and 50 is possible.
Further, in FIG. 3 there are schematically shown forces acting on shafts 22 , 50 and their respective tooth, recess 62 , 64 , pair along a tooth flange extending parallel to an imaginary line 66 .
Assuming that for closing second clutch 54 (cf. FIG. 1 ), a magnetic force F M ( FIG. 3 ) is required for, for example, moving outer hollow shaft 50 or its tooth 62 , in the direction of inner hollow shaft 22 or its recess 64 . The (closing) force F M of the clutch magnet may be resolved with the help of a force parallelogram into two force components F E and F S1 , wherein F E represents the coupling force acting along imaginary line 66 and F S1 represents the force acting perpendicularly to the toothing flange.
If both shafts 22 , 50 are coupled with each other and actuation lever 18 is actuated by an operating person, inner manual lever shaft 22 will transmit a rotary force F D onto outer hollow shaft 50 as is also shown in FIG. 3 . Rotary force F D may likewise be resolved into two force components F A and F S2 , wherein F A represents the decoupling force and F S2 represents the force acting perpendicularly to the tooth flange.
As long as the rotary force does not exceed a certain threshold value, decoupling force component F A is smaller than coupling component F E . If, however, the operating person (spontaneously) exerts a very high force onto shaft 22 , rotary force F D will increase abruptly, resulting in an increase of decoupling force FA. If force component F A becomes greater than force component F E , an opening of tooth pair 60 results even if clutch 54 is closed or not yet opened. The force at which tooth pair 60 opens automatically depends on its design parameters, in particular on the flange angle α. Second clutch 54 then acts as an overload clutch.
With this measure one can effect that, if a spontaneous torques occur which cannot be compensated for at that speed by the control unit, the coupling between shafts 20 , 50 opens automatically. This, in turn, means that the flow of force between actuation lever 18 and press ram 32 is separated such that a force sensor is again protected against overload.
Instead of a tooth pair one could likewise use rollers or the like.
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A manually operated press comprises an actuation lever coupled to a shaft assembly. An actuation of the actuation lever is transformed into a stroke movement of a press ram. A clutch assembly is provided for interrupting a flow of force between the actuation lever and the press ram. The clutch is adapted to separate an input shaft from an output shaft depending on predetermined pressing parameters. The input shaft extends as an inner shaft through the output shaft. The clutch assembly has a first clutch designed as a stroke stop for immobilizing the input shaft with a press housing depending on the pressing parameter, and a second clutch designed as an overload clutch for interrupting a flow of force between the input shaft and the output shaft.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an earth current detector for detecting transient earth currents that occur in advance of an earthquake or the like.
2. Description of Prior Art
Over the years there have been many reports of anomalous phenomena being observed prior to the occurrence of earthquakes: abrupt changes in earth currents (earth potential) and the electrical resistance of earth crust, luminous phenomenon, abnormal animal behavior, and earthquake clouds, to name a few.
In Greece, earthquake prediction based on the detection of earth currents is being conducted with a fairly high rate of success. According to the Greek method, a number of electrode-pairs are buried several meters under ground at locations separated East-West and North-South by several tens or several hundreds of kilometers, and the electrical potential between pairs of these electrodes is monitored. The signals obtained are passed through a 0.1 Hz low-pass filter, converted from analog to digital and transmitted in real time via telephone circuits to a central observation point, where they are recorded and displayed. The occurrence of an earthquake is predicted when a change in potential exceeds a prescribed level. (P. Varotsos and M. Lazaridou; Tectonophysics, 188 (1991) P321-347.)
In Japan, an attempt is being made to use a measurement electrode consisting of a buried 600 m casing pipe and a total of 140 m of electrically conductive wire arrayed around the pipe as a measurement electrode for detecting, as earthquake precursors, anomalies in three radio wave frequency bands: DC--0.7 Hz, 0.01-0.1 Hz and 1-9 kHz. (Yukio Fujinawa, Kozo Takahashi, Sadaharu Kumagaya, Earthquakes Vol. 43, No. 2 (1990) P287-290.)
U.S. Pat. No. 4,904,943 teaches an earthquake prediction method in which earth currents are simultaneously observed at four points, the detected signals are processed to determine the origin and intensity distribution of the earth currents, and the hypocenter region, scale, and time of occurrence of an earthquake are predicted from changes over time in the origin and intensity.
U.S. Pat. No. 4,837,582 teaches a method of detecting radio waves generated by a hypocenter region. When the method is used on land, a linear antenna is buried to a depth of at least 1,000 m and a radial antenna centered on the linear antenna is laid out on the earth's surface. When applied in the sea, an insulated electrically conductive cable is laid on the sea bottom at a depth of 200 m or more for use as an antenna. In either case, the occurrence of earthquakes is predicted on the basis of radio waves picked up by the antenna.
The Greek method of earthquake prediction mentioned earlier is also being tested in Japan, but with less success in an industrialized and populated region. This is thought to be because of differences in the intensity of man-made electrical noise near cities. Moreover, since the measurements in this method are affected by both natural phenomena such as rain and lightning and by artificial electrical noise, it is necessary to rely on human judgment in determining whether or not a detected signal is an indication of an impending earthquake.
The graph of FIG. 6 shows the results obtained when an electrode was buried to a depth of 2 m at each of two locations, a rock dynamiting site and a point about 70 m away from the site, and the earth current between the two points was measured at the time rock was dynamited. As shown in FIG. 6(b), the explosion occurred about 23 seconds after the start of the measurement. As can be seen from FIG. 6(a), the earth current produced by the explosion could not be detected because it was masked by an interfering noise signal produced by commercial power line current frequency electromagnetic waves.
As will be understood from the foregoing, methods involving the measurement of the potential difference, electric current, or the resistance between two surface points have the drawback of being affected by unpredictable factors such as changes in the weather (e.g. rain and lightning) and man-made electromagnetic noise. Conditions thus vary from one measurement region to another. This means that different observers may, depending on their experience, come to different conclusions regarding whether a particular signal is caused by one of these disturbances or is a sign of an impending earthquake. Moreover, since the measurement instruments have their results of measurement recorded by a pen recorder, their sensitivity to fracture-induced current and other such rapidly fluctuating signals is low. In view of this situation, there is a need for an earth current detection method that is not affected by the climate and human activity in the region being monitored and is not dependent on the judgment of the observer.
In addition, when the aforesaid method of predicting earthquakes on the basis of low-frequency band electromagnetic waves is used in urban areas where the level of artificial electromagnetic noise is high, the effect of the noise has to be reduced by conducting the measurement at great depth underground because the electromagnetic disturbance from the man-made noise penetrates the ground to a considerable depth. Moreover, the need to use a large antenna for picking up the low-frequency electromagnetic waves results in high equipment costs.
Where earthquake detection is conducted on the basis of underground radio waves received by an antenna extending to a depth of 1,000 m or more below the ground surface as taught by the earlier mentioned U.S. patent, the cost of installing the antenna becomes prohibitively high at sites other than at abandoned mines and wells. The points at which measurement can be conducted are thus severely limited.
SUMMARY OF THE INVENTION
This invention was accomplished in light of the foregoing circumstances and has as one of its objects to provide an earth current detector which enables earth currents to be detected substantially unaffected by the climate or human activities in the region being monitored, is not highly dependent on human judgment, and, as such, is capable of simple and reliable earth current detection even in urban areas.
For achieving this object, the invention provides an earth current detector comprising a detection electrode disposed in the ground at a depth deeper than that to which commercial power line frequency electromagnetic waves produced on the Earth's surface penetrate, a second electrode installed such that the electrical resistance between itself and the detection electrode amounts to more than several tens of thousands of ohms, and a charge detector for detecting only the high-frequency components of the earth current flowing between the two electrodes.
When a fracture indicative of an impending earthquake occurs at some part of the Earth's crust, the earth current that is produced and propagated through the ground owing to the radiation of fracture-induced electric charges is detected by the detection electrode. Since the detection electrode is located at a depth below that reached by surface electromagnetic waves, the detected signal includes hardly any noise. A signal representing the detected earth current is sent to the charge detector, which is constituted by a preamplifier and a main amplifier. The preamplifier blocks signals that fluctuate slowly and converts to a voltage signal only the high-frequency components, which are not very susceptible to the effect of manmade noise. The main amplifier divides the voltage signal resulting from the conversion at prescribed time intervals and amplifies and integrates the divided signals for judging whether or not a fracture in the Earth's crust has occurred. It is therefore possible to detect earth currents resulting from crust fractures with high reliability. Moreover, since the two electrodes can be installed as separated vertically from each other, the effect of man-made electromagnetic noise and differences in geology is minimal. In addition, the strength of current propagated through rock is inversely proportional to the distance between the point of rock fracture (the hypocenter) and the measurement point, and is approximately proportional to the size of the hypocenter. (See P. Varotsos and M. Lazaridou; Tectonophysics, 188 (1991) P321-347.) By taking measurements at a number of points it is therefore possible to identify the location of the epicenter.
The above and other features of the present invention will become apparent from the following description made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing the configuration of an embodiment of the earth current detector according to the invention.
FIG. 2 is a schematic view showing the configuration of another embodiment of the earth current detector according to the invention.
FIGS. 3(a) and 3(b) are graphs showing current propagation through granite.
FIG. 3(c) is an explanatory view showing how the current propagation of FIG. 3(a) and FIG. 3(b) is measured.
FIG. 4 is a graph showing how the strength of current flowing through granite varies in inverse proportion to the distance of the measurement point from the source.
FIG. 5(a) is a graph showing earth current measured with a detector according to the invention.
FIG. 5(b) is a graph showing the amount of vibration detected by a seismograph over the same time period as that in FIG. 5(a).
FIG. 6(a) is a graph showing earth current propagated near the Earth's surface.
FIG. 6(b) is a graph showing the amount of vibration detected by a seismograph.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention has been accomplished on the basis of the results of an experiment in which it was detected that electric charge radiation occurring during the progress of small-scale explosion of rock propagated within the rock as a rapidly fluctuating transient current signal [Y. Enomoto & H. Hashimoto, "Nature" Vol 346, No. 6285 (1990) pp. 641-643].
Differing from a prior art method for the detection of low-frequency signals, the research made in the aforementioned paper is characterized by picking up the electric charge fluctuation of high-frequency components (not less than 1 MHz as virtual effective value). At the site of explosion of the rock dynamited as described above, an attempt was made to detect a transient current signal at a depth of about 2 m from the ground surface. As a result, it was impossible to pick up the transient current signal that would be produced by the rock explosion. The reason for this was that the transient current signal was included in a noise signal resulting from the interference with commercial power line frequency.
In FIG. 1, reference numeral 1 designates an earth current detector according to an embodiment of the present invention. The earth current detector 1 comprises a detection electrode 2 buried in the ground at a depth (skin depth) deeper than that reached by commercial power line frequency electromagnetic waves, a charge detector 4 constituted by a preamplifier 4a installed in an insulating pipe 7 which protrudes from a magnetically shielded room 3 and a main amplifier 4b installed within the magnetically shielded room 3, and a second electrode 5 separated vertically from the detection electrode 2. The detection electrode 2 is made of a corrosion-resistant electrically conductive material. For enabling it to effectively detect rapid charge fluctuations radiated at the time of rock fracture, it is installed at a ground stratum 11 or rock bed 12 that is at a depth (the sub-surface depth) deeper than the maximum depth reached by radio waves of a commercial power line frequency of 50 or 60 Hz in Japan or higher that are present in the atmosphere or at the surface of the Earth. When propagated current is mainly detected, for example, the skin depth z at which the detection electrode 2 is installed is given by ##EQU1## where ρ is the resistivity of the ground and f is the frequency of the radio waves apt to interfere with the measurement.
Therefore, if the resistivity ρ of the wet ground is 50 Ω·m, the maximum depth reached by the aforesaid 50 Hz and higher frequency radio waves is found from this equation to be 500 m or more. Ground containing a lot of ground water may have a low resistivity of, say, 0.5 Ω·m, in which case the maximum depth reached by the 50 Hz and higher frequency radio waves is 50 m or more. On the other hand, the skin depth of a 1 Hz electromagnetic field is about 3,500 m at a ground resistivity of 50 Ω·m and about 350 m at a ground resistivity of 0.5 Ω·m.
It is therefore preferable to select as the signal to be detected the highest frequency component charge signal possible, because this enables the detection electrode to be installed at a shallower depth, which is economical, and also limits the noise sources, making them easier to avoid.
The humidity and temperature of the electromagnetically shielded room 3 have to be maintained constant so as to avoid their affecting the measurement. For avoiding radio wave noise, the magnetically shielded room 3 is constructed of metal material with high electrical conductivity and is grounded to keep it at the same electrical potential as the surrounding ground surface.
The insulating pipe 7 buried under the electromagnetically shielded room 3 is made of a good insulating material such as vinyl chloride. Its upper end opens into the electromagnetically shielded room 3 and its lower end has the detection electrode 2 mounted thereon. To counteract the buoyancy of ground water on the insulating pipe 7 and to prevent water from getting into the pipe through the joint between it and the detection electrode 2, the lower portion of the pipe is filled with an insulating material 8 such as alumina cement, pebbles, or an epoxy type bonding agent.
The second electrode 5 provides a reference potential (substantially zero). Since the electrical resistance between it and the detection electrode 2 need only be 10 KΩ or greater, the second electrode 5 can be vertically separated from the detection electrode 2. As it is preferably located at a place where it is little affected by man-made noise, in the present embodiment it is installed inside the magnetically shielded room 3.
The preamplifier 4a mounted inside the insulating pipe 7 is designed to block slowly varying frequency components below a prescribed predetermined level in view of the depth at which the detection electrode is installed, the resistance of the ground, etc., and converts only the rapidly varying charge signal components to a voltage signal which it then amplifies. The main amplifier 4b, which is designed to have an effective sensitivity to frequencies of 100 kHz or more, divides the voltage signal received from the preamplifier 4a at prescribed time intervals and then amplifies the signal segments. Main amplifier 4b may be exempliefied by an amplifier comercially available as product code number CFE-500 by COMTEC, Inc., however any equivalent amplifier comprising means for sampling an input signal at prescribed time intervals and amplifying the sampled signal may be implemented as main amplifier 4b without departing from the scope of the present invention.
The main amplifier 4b and the detection electrode 2 are connected via the preamplifier 4a in the insulating pipe 7 by a lead line 6. The lead line 6 in the insulating pipe 7 is a coaxial cable whose center wire interconnects the detection electrode 2 and the charge detector 4 and whose outer shielding is connected with the second electrode 5 so as to be maintained at zero potential. The ground side of the main amplifier 4b is connected to the magnetically shielded room 3 so as to maintain an equipotential therebetween.
The second electrode 5 is directly connected to the ground side of the charge detector 4. The equivalent circuit of the detection system constituted by the two electrodes and the charge detector is thus isolated from external electromagnetic and climatic disturbances. Since low-frequency signals are effectively shut out by the circuitry and only the high-frequency components of electrical noise are allowed to pass through the charge detector due to oxidation-reduction reaction at the electrode surface, any artificial electric signal is minimized. It becomes, therefore, possible to measure minute earth currents at a high signal-to-noise ratio.
The signal from the charge detector 4 is integrated by a computer 9 and stored in memory in a computer 9 and, if required, displayed on a display 10 and transmitted to a central observatory.
FIG. 2 schematically illustrates another simple embodiment of the earth current detector 1 according to the present invention. In this embodiment, the second electrode 5 is installed at an intermediate point on the insulating pipe 7 which extends into the ground and has the detection electrode 2 mounted at its distal end. The second electrode 5 is positioned deeper than the aforementioned electromagnetic field sub-surface attenuation depth and establishes a resistance between itself and the detection electrode 2 of at least several tens of thousands of ohms. Specifically, where the commercial power line frequency is 50 Hz and the ground contains ground water, the detection electrode is sunk to about 100-150 m and the second electrode to about 60 m directly above the detection electrode. The installation of both the second electrode 5 and the detection electrode 2 at a depth greater than that reached by surface radio waves has a marked noise elimination effect. The preamplifier 4a and main amplifier 4b constituting the charge detector 4 are installed within the magnetically shielded room 3.
Detection of ground currents with the earth current detector 1 configured in this manner will now be explained. Ground currents generated owing to the fracture-induced charge emission occurring at the time of rock fractures at the epicenter pass through the rock bed 12 and the ground stratum 11 and enter the detection electrode 2. The current signal entering the detection electrode 2 passes to the preamplifier 4a through the lead line 6, where only its high-frequency components are converted to a voltage signal that is sent to the main amplifier 4b. At the main amplifier 4b the voltage signal is divided at prescribed time intervals and amplified, whereafter it is sent to the computer 9 for processing, storage in memory and, if required, display on the display 10 and transmission via a telephone circuit or the like to an observatory located outside of the shielded room.
When an abnormal signal has been detected by an earth current detector according to the invention, the judgment as to whether the signal is the result of fissuring of the Earth's crust that portends an earthquake or of local man-made noise can be made easily and reliably by referring to the signals detected at a plurality of observation points.
In addition, the strength of current propagated through rock is inversely proportional to the distance between the point of rock fracture (the epicenter) and the measurement point, and is proportional to the size of the hypocenter. By taking measurements at a number of points it is therefore possible to identify the location of the rock bed fracture.
The results of a test conducted for confirming that the strength of an earth current propagating through rock is inversely proportional to the distance between the rock fracture point and the measurement point are shown in FIG. 3(a) and (b). One electrode was positioned 5 cm and another 105 cm from the portion of a 30 (w)×30 (h)×110 (1) cm granite slab to be fractured in the test (FIG. 3(c)). The slab was fractured by using a press to apply pressure to a chisel set at the intended fracture point. The current detected 5 cm from the fracture point is shown in FIG. 3(a) and that detected 100 cm from the fracture point is shown in FIG. 3(b). It will be noted that the electrode located further from the fracture point was also able to detect the current with no trouble.
In another test, an electrode was attached to one end of each of two 2 (w)×2 (h)×30 (1) cm square bars of different kinds of granite (coarse grain and fine grain) and the currents produced in the square bars when they were fractured near one end were measured. The results are shown in FIG. 4.
The results for a coarse-grain granite bar can be approximated by curve (a), which corresponds to Q=7×10 -8 /x (mm) wherein x is the distance between the fracture point and the detecting electrode. The results for a fine-grain granite bar can be approximated by curve (b/), which corresponds to Q=0.4×10 -8 /x (mm). In either case, the signal strength is inversely proportional to the distance x between the fracture point and the measurement point.
FIG. 5(a) shows the results obtained by integrating an earth current signal detected on Aug. 27, 1992, using an earth current detector according to FIG. 2 in which the detection electrode was installed at a depth of 65 m and the second electrode at a depth of 6 m, in ground containing ground water. FIG. 5(b) shows the signal output by a seismograph over the same time period. The skin depth with respect to 50 Hz radio waves at the test location was about 50 m.
As will be noted at the extreme left of the graph of FIG. 5(a), a high-strength transient current was observed over a period of about two hours (the period marked (c)). About 18 hours later, an earthquake with a magnitude of 4.8 occurred at a distance of about 10 km from the point where the transient current was measured. The epicenter was 50 km beneath the surface. The signal output by a seismograph at this time is marked (d) in FIG. 5(b).
As is clear from FIG. 5(a), the earth current detector according to this invention was able to selectively detect the earth current produced at the time that a fracture of the Earth's crust signifying an impending earthquake occurred. This evidences the invention's utility in reliable earthquake prediction.
As explained in the foregoing, the earth current detector according to the invention enables "single-site" measurement utilizing an electrode buried in the ground at a depth where it is little affected by electromagnetic waves present at the Earth's surface. It is therefore substantially immune to man-made surface noise, variation in geological conditions between two points, and the like. In addition, since the charge detector selects and amplifies only the high-frequency components, it suffices to install the electrode at a shallow depth, which is advantageous from the point of cost and achieving high measurement sensitivity. As a result, the earth current detector according to the invention can be used with good results even in cities and other areas where there is a high level of man-made electromagnetic disturbance. That is to say, it is able to suppress the effect of man-made electromagnetic disturbance and measure minute earth currents at a high signal-to-noise ratio.
Moreover, once a sufficient amount of data has been accrued regarding the relationship between earth current signals and the occurrence of earthquakes, the earth current detector according to the invention will be useful in earthquake prediction. It also has the capability of enabling determination of earthquake epicenters when a number of the detectors are installed at different points.
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An apparatus for measuring transient earth current includes a detection electrode and a second electrode disposed beneath the surface of the earth in vertical alignment with one another at depths greater than those to which electromagnetic waves generated above the surface of the earth having commercial power line frequencies penetrate, such that the electrical resistance between the detection electrode and the second electrode is on the order of several tens of thousands of ohms, and a charge detector for detecting only high frequency components of a current flowing between the detection electrode and the second electrode. On the basis of these detected high frequency components, the likelihood of an occurance of an earthquake may be determined.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for tuning Film Bulk Acoustic Wave Resonators by applying adaptive manufacturing techniques to tuning elements associated with the resonators.
BACKGROUND OF THE INVENTION
[0002] A thin Film Bulk Acoustic Resonator (FBAR) is a technology that creates a frequency shaping element found in many modern wireless systems. When an alternating electrical potential is applied across the FBAR, a layer within the FBAR expands and contracts, creating a vibration. The vibrating membrane creates a high Q mechanical resonance. An FBAR may thus be used for a filter, duplexer, resonator, or the like.
[0003] It is, however, difficult to manufacture FBARs to the rigorous standards required by industry. Minute variations in the thickness of the layers which comprise the FBARs may result in unacceptable deviations in the operating frequency of the FBAR, resulting in an unacceptable product.
[0004] One technique to address the concern of manufacturing variations has been pioneered by Nokia and is explained in U.S. Pat. No. 6,051,907, which is hereby incorporated by reference in its entirety. While the techniques described in this patent are adequate, commercial need dictates that alternate approaches be made available for increased competitive opportunities.
SUMMARY OF THE INVENTION
[0005] The present invention manufactures Film Bulk Acoustic Resonators (FBARs) and applies adaptive manufacturing techniques to the tuning elements associated with the FBAR. By changing the capacitors and inductors associated with the FBAR, the filter response of the FBAR may be tuned to the desired response without needing to alter the layer thickness of the resonator itself.
[0006] In an exemplary embodiment, the FBAR is manufactured and tested to determine its resonant frequency. The resultant resonant frequency will be placed into a bin corresponding roughly to “correct,” “too high,” or “too low” values. Finer gradations may also be used. The FBAR is then combined with variable inductors or capacitors as needed to tune the FBAR to the desired frequency response. The inductors and capacitors are tuned through an adaptive manufacturing technique to further tune the FBAR to the desired frequency response.
[0007] Those skilled in the art will appreciate the scope of the present invention and realize additional aspects thereof after reading the following detailed description of the preferred embodiments in association with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0008] The accompanying drawing figures incorporated in and forming a part of this specification illustrate several aspects of the invention, and together with the description serve to explain the principles of the invention.
[0009] [0009]FIGS. 1A and 1B illustrate alternate conventional FBARs such as may be used with the present invention;
[0010] [0010]FIG. 2 illustrates schematically an exemplary FBAR with an inductive tuning circuit;
[0011] [0011]FIG. 3 illustrates schematically an exemplary FBAR with a narrow band ladder filter;
[0012] [0012]FIG. 4 illustrates schematically an exemplary FBAR with a capacitive tuning circuit;
[0013] [0013]FIG. 5 illustrates a flow chart embodying the methodology of an adaptive manufacturing process;
[0014] [0014]FIG. 6 illustrates a flow chart embodying the methodology of the present invention as applied to FBARs;
[0015] [0015]FIG. 7 illustrates an alternate presentation of the circuit of FIG. 4;
[0016] [0016]FIG. 8 illustrates an expanded view of the circuit of FIG. 7;
[0017] [0017]FIG. 9 illustrates a first schematic of connections between elements for the circuit of FIG. 8; and
[0018] [0018]FIG. 10 illustrates the circuit of FIG. 9 after a mask has been applied.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the invention and illustrate the best mode of practicing the invention. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the invention and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
[0020] Film Bulk Acoustic Resonators (FBARs) are well known in the electronics industry. An exemplary, conventional FBAR 10 is illustrated in FIG. 1A, wherein the FBAR 10 is positioned on a wafer 12 . The FBAR 10 includes a top electrode 14 , a bottom electrode 16 , a piezoelectric layer 18 , and a bridge or “membrane” layer 20 . The wafer 12 may have a recess or hole under the piezoelectric layer 18 so as to avoid “loading” the resonating layer. In an exemplary embodiment, the top and bottom electrodes 14 , 16 may be Molybdenum (Mo) and the piezoelectric layer 18 may be zinc-oxide (ZnO). The bridge layer 20 may be silicon-dioxide (SiO 2 ). An alternate construction, shown in FIG. 1B uses a solid wafer 12 with an acoustic mirror 21 . The acoustic mirror 21 is composed of alternating half wavelength layers of high density and low density material that create an acoustical “high-reflective” coating.
[0021] During manufacturing, the FBAR 10 may have an actual resonant frequency somewhat removed from the desired resonant frequency. To correct for this, a tuning circuit may be used in conjunction with the FBAR 10 . Such tuning circuits may be formed from capacitors and/or inductors as is well understood in the field of circuit design. FIGS. 2 - 4 illustrate exemplary tuning circuits. FIG. 2 illustrates a ladder filter 22 using inductors L 1 -L 5 to resonate out parasitic capacitance. FIG. 3 illustrates a two pole narrow band ladder filter 24 with two FBARs 10 and a capacitor C 1 . FIG. 4 illustrates a bandpass filter 26 using FBAR 10 resonators and capacitors C 2 -C 6 for coupling and tuning.
[0022] It should be appreciated that other tuning circuits may be used as needed or desired depending on the intended purpose of the FBAR 10 . Further, the adaptive manufacturing techniques of commonly owned U.S. patent application Ser. No. 09/545,128, filed 07 April 2000, now U.S. Pat. No. ______, which is hereby incorporated by reference in its entirety, may be used to refine the tuning. For simplicity, some of the incorporated application is herein repeated.
[0023] Variation in wafer processing has a negative impact throughout the design, processing, and application of the final device. Variation in certain processes may be compensated for by changing the nature of subsequent processes, if the parameter in question can be measured in time for such a compensation to be made.
[0024] The basic manufacturing process according to the incorporated application is presented in FIG. 5. Typically, semiconductor circuitry is designed with known process variations in mind. Preferably, a primary circuit is designed with one or more modifications configured to compensate for anticipated process variations (block 50 ). Once the primary circuit is designed with modifications in anticipation of process variations, the primary circuit is fabricated during a semiconductor process to allow for modifications as necessary in subsequent processing (block 52 ).
[0025] Once the primary circuit design is implemented, an electrical test is conducted during the fabrication process to measure a component or overall circuit parameter (block 54 ). During the testing, it may be determined if the parameter is within design tolerances, too high, or too low. Based on this determination, the circuit, or a component within the circuit, may be modified during another round of processing to compensate for variation in the parameter based on wafer or fabrication techniques (block 56 ). After modification, the semiconductor processing is finalized (block 58 ) to provide a semiconductor device that is compensated for variation in the parameter.
[0026] Against that general backdrop, the more specific adaptive manufacturing techniques may be applied with some specificity to the present invention. A detailed explanation, as used with respect to FBARs 10 , for the semiconductor manufacturing process used to tune FBARs 10 according to the present invention is presented with reference to FIG. 6. The FBAR 10 is created (block 100 ) using conventional manufacturing techniques, such as a sputter deposition technique, those outlined in U.S. Pat. No. 6,060,818, which is hereby incorporated by reference, or the like. The FBAR 10 may have a resonant frequency that is the result of manufacturing that is different from a desired resonant frequency, and thus, the next step of the manufacturing process is to test the resonant frequency of the one or more FBARs 10 on the silicon chip being manufactured. To do this testing, measurement contacts are added to one or more FBARs 10 (block 102 ).
[0027] Concurrently with the creation of the FBARs 10 , reactive tuning elements such as capacitors and inductors may also be created. The reactive elements may be capacitors or inductors and may form circuits comparable to circuits embodying filters 22 , 24 , 26 or the like as previously described. It should further be noted that the reactive elements are manufactured on the same wafer 12 as the FBAR 10 , and thus may be part of a single integrated semiconductor circuit. Further, the reactive elements should be fabricated in such a manner that modifications thereto are readily accomplished in keeping with block 52 of FIG. 5. Thus, for example, one or more of the capacitors C 2 -C 6 may in fact be varactors of sorts as illustrated in FIG. 7, and more particularly may be segmented into three capacitive elements C x ′, C x ″, and C x ′″, where x is the capacitor number as illustrated in FIG. 8. Electrical taps that allow connections to segments of the capacitive elements are generally labeled TPx. A circuit design may contemplate the capacitors C x ′, C x ″, and C x ″′ arranged in parallel as shown, or in series as needed or desired.
[0028] After addition of the measurement contacts to the FBAR 10 , the FBAR 10 may be tested for the frequency response (block 104 ). This testing may also be considered testing for a parameter in keeping with block 54 of FIG. 5. Other parameters may also be tested, if needed. Connection points P 1 and P 2 (in the example of the circuit of bandpass filter 26 in FIGS. 7 - 10 ) may be used to conduct an electrical test of the whole circuit, or taps P 3 and P 4 may be positioned on either side of an FBAR 10 or an FBAR device may be constructed in an isolated test structure. The testing device may be connected to a computer or other data processing device such that measurements may be recorded and processed as needed or desired. There are essentially three possible results from the on-wafer testing. The FBAR 10 is placed in bins according to which category they fall into (block 106 ). This step is also referred to herein as “binning.” The first, and preferred, response (at least from a manufacturing point of view) is that the frequency response is “acceptable,” in which case no changes are made (block 108 ) and the wafer is processed normally (block 110 ). The other two responses, i.e., the frequency response is “too high” or “too low,” cause the data processing device to calculate a needed correction (block 112 ).
[0029] Armed with the knowledge of the needed correction, an appropriate mask may be selected (block 114 ), and the reactive elements are adjusted according to the mask selected (block 116 ). The masks may be pre-selected configurations designed to impart known corrections to the FBAR circuits.
[0030] Modifications to the circuit by the masks are made by selectively connecting the taps associated with the capacitive elements to control the final capacitance, and thus the resonant frequency of the circuit of bandpass filter 26 (in this example). The taps TPx may be used to connect a capacitance to the circuit or to connect an element to another part of the circuit. While the example is made using the capacitors C 2 -C 6 , it should be appreciated that similar efforts may be performed on the inductors as needed or desired. The inductors would likely be connected in series, and shorts or open circuits added as needed or desired. Inductors may be adjusted by moving metal shunts that short various segments or turns in the metal pattern of the inductors to add or subtract inductance. Equivalently, the line length of the inductor may be adjusted in a trombone type structure. More information on masks may be found in the previously incorporated '128 application.
[0031] Continuing the example of the modification to the circuit of bandpass filter 26 , FIG. 9 represents the circuitry of FIG. 8 as formed on a semiconductor wafer. FBARs 10 are shown in block form and metal traces connecting the various elements are shown in darkened lines. The taps TP 1 through TP 12 are shown as metal posts or pads connecting the various capacitive elements to one another and to the metal traces as necessary.
[0032] An exemplary top metal mask (TOPM) illustrated in FIG. 10 may short one or more tap points, effectively bringing the capacitive element into the circuit. In the embodiment illustrated in FIG. 10, TP 1 and TP 2 , as well as TP 5 and TP 6 are shorted, connecting the capacitances of C 6 ′ and C 6 ′″ for C 6 . Likewise, shorts exist between TP 9 and TP 10 , connecting the capacitance of C 3 ″ for C 3 . Depending on the needed capacitance to provide the desired resonant frequency, other shorts may be used as is further explained in the '128 application.
[0033] Once the modifications have been made, the semiconductor processing is finalized. While three bins are contemplated, the number of bins may be increased if greater resolution is needed to tune the FBAR 10 properly.
[0034] Those skilled in the art will recognize improvements and modifications to the preferred embodiments of the present invention. All such improvements and modifications are considered within the scope of the concepts disclosed herein and the claims that follow.
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An adaptive manufacturing process for a Film Bulk Acoustic Resonator (FBAR) tests the FBAR circuit during manufacturing to determine a resonant frequency thereof. Reactive tuning elements may be adjusted as needed depending on the testing to change the resonant frequency to a desired resonant frequency. In an exemplary embodiment, predetermined masks may be applied to modify the tuning elements.
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This application is a continuation, of application Ser. No. 376,090, filed May 7, 1982 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a variable valve timing apparatus for use in a four-cycle internal combustion engine, and more particularly, to a type thereof capable of selectively shifting valve timing between low speed and high speed regions.
According to a conventional valve timing apparatus, a rocker arm disposed between a camshaft and an intake or exhaust valve has a shiftable pivot point to alter valve timing. Alternatively, a plurality of rocker arms are provided to selectively actuate one of them to change valve timing. In both cases, the resultant structures become complicated and complex.
Further, the rocker arm is normally provided with a means for adjusting a tappet clearance such as an adjusting screw. With this construction, the position of the adjusting means may determine the length of the rocker arm. Therefore, suitable positional relationship between the rocker arm and the adjusting means has been investigated. Sometimes, the position of the adjusting means causes the length of the rocker arm to be long, so that compact and light-weight structure may not be obtainable.
SUMMARY OF THE INVENTION
It is therefore, an object of this invention to overcome the above-mentioned drawbacks and to provide an improved variable valve timing apparatus.
Another object of the invention is to provide such apparatus capable of providing a simple and compact structure.
Still another object of the invention is to provide such apparatus incorporating a means for further controlling valve timing at high speed running of a vehicle.
These and other objects of the invention will be attained in accordance with the present invention by providing a pair of camshafts juxtaposed on a common camshaft holder. Each of the camshafts has one end provided with a gear, and each of the gears are in meshing engagement with each other. One of the camshaft has a longitudinal extension connected to a shaft drive means. The camshaft integrally mounts thereon at least one cam for low speed, and the other camshaft integrally mounts thereon at least one cam for high speed. With this construction, selective contact between a rocker arm and one of the cams between two cam shafts is attained by a selective actuation means.
According to a first embodiment of the invention, the camshaft holder is mounted stationary on a cylinder head, and the selective actuation means comprises a clutch means disposed between the other camshaft and the corresponding gear. The rocker arm has an upper surface adjacent to a pivot point thereof in contact with the low speed cam during clutch OFF state, while the rocker arm has an upper free end surface in contact with the high speed cam during clutch ON state.
According to a second embodiment of the invention, the camshaft holder is pivotally supported about the one of the camshafts, and the selective actuation means comprises a hollow shaft having one end integral with the holder and coaxial with the one of the camshafts, and having the other end connected to an upper end of an arm. The lower portion of the arm is connected to a horizontal rod. Upon movement of the horizontal rod, the arm pivots about the camshaft, to thus integrally rotate the camshaft holder. The movement of the rod provides first and second positions of the holder. The rocker arm has an upper surface adjacent to a pivot point thereof in contact with the low speed cam at the first position of the camshaft holder, and the rocker arm has an upper free end surface in contact with the high speed cam at the second position of the holder.
Further, according to the present invention, an arm control means is provided to control the pivotal position of the arm, to thus control the pivotal position of the camshaft holder. Furthermore, according to the second embodiment, two cams are integrally mounted on the other camshaft, and the rocker arm has a free end portion being subdivided into two splits to contact with the corresponding two cams. These cams provide a space therebetween to allow extension of a tapet clerance adjuster therethrough.
These and other object of the invention will become apparent from the description of the drawings and the preferred embodiments which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the apparatus according to a first embodiment of this invention;
FIG. 2 is a sectional view taken along the line II--II of FIG. 1;
FIG. 3 is a sectional view taken along the line III--III of FIG. 2;
FIG. 4 is a diagram showing the operating characteristics of the apparatus shown in FIGS. 1 to 3;
FIG. 5 is a front elevational view of the apparatus according to a second embodiment of this invention;
FIG. 6 is a sectional view taken along the line VI--VI of FIG. 5;
FIG. 7 is a sectional view taken along the line VII--VII of FIG. 6;
FIG. 8 is a view similar to FIG. 7, but showing the apparatus in a different position; and
FIG. 9 is a top plan view of the rocker arm in the apparatus shown in FIGS. 5 to 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of this invention is shown in FIGS. 1 to 4, wherein an intake or exhaust valve 1 in a four-cycle engine is opened and closed by a rocker arm 2 associated with the upper end of the valve 1, and a camshaft assembly 3 provided above the rocker arm 2. The camshaft assembly 3 comprises a camshaft 3a for low speed operation, and a camshaft 3b for high speed operation. The camshafts 3a and 3b are juxtaposed in a common camshaft holder 4 in a cylinder head, or other frame 5.
According to the first embodiment of this invention, the camshaft holder 4 is stationary instead of being tiltable; therefore, the camshafts 3a and 3b are always in engagement with the rocker arm 2. As shown in FIG. 3, the camshaft 3a for low speed operation is engaged with a slipper 2a defined by the upper surface of the rocker arm 2 adjacent to the base thereof, while the camshaft 3b for high speed operation is engaged with a slipper 2b defined by the upper surface of the rocker arm 2 adjacent to the free end thereof.
The camshafts 3a and 3b can be driven selectively. A gear 6 is connected to each of the camshafts 3a and 3b, and the gears 6 are engaged with each other so that the camshafts 3a and 3b may be rotated together. The camshaft 3a for low speed operation has a longitudinal extension which carries a cam sprocket 7 associated operationally with a crankshaft on the engine to drive the camshafts 3a and 3b. A clutch 8 is disposed between the camshaft 3b for high speed operation and the gear 6 provided thereon. If the clutch 8 is opened, only the camshaft 3a for low speed operation is driven, while the camshaft 3b for high speed operation is simultaneously driven if the clutch 8 is closed.
If the clutch 8 is opened, only the camshaft 3a for low speed operation is driven, and the valve 1 is opened and closed by the rocker arm 2 in accordance with a valve lift curve which is by way of example shown at a in FIG. 4. If the clutch 8 is closed, the camshaft 3b for high speed operation is also driven, and the valve 1 is opened and closed by the rocker arm 2 in accordance with a valve lift curve which is by way of example shown at b in FIG. 4.
According to the first embodiment of this invention, the necessary switchover of the valve operation can be effected only if the camshafts for low speed operation and for high speed operation are driven selectively by means of the clutch, and therefore, the valve can be actuated smoothly and accurately.
A second embodiment of this invention is shown in FIGS. 5 to 9 wherein like parts and components are designated by the same reference numerals and characters as those used in FIGS. 1 to 3. The second embodiment also includes a camshaft assembly 3 which comprises a camshaft 3a for low speed operation and a camshaft 3b for high speed operation, and a common camshaft holder 4' on which the camshafts 3a and 3b are juxtaposed. The holder 4' is supported on a cylinder head, or other frame 5, and is integral with a shaft 10 which is coaxial with and rotatable about the camshaft 3a. The camshafts 3a and 3b can be driven selectively by the pivotal movement of the holder 4'.
The camshaft 3a includes a cam projection 3c facing a slipper 2a' defined by the upper surface of a rocker arm 2' adjacent to the base or pivotal point thereof, while the camshaft 3b likewise includes a cam projection 3d facing a slipper 2b' defined by the upper surface of the rocker arm 2' adjacent to the free end thereof. The holder 4' is vertically pivotable about the camshaft 3a. If the holder 4' is moved upwardly, the cam projection 3c of the camshaft 3a engages the slipper 2a' of the rocker arm 2' to actuate the same as shown in FIG. 8. If the holder 4' is lowered, the cam projection 3d of the camshaft 3b engages the slipper 2b' of the rocker arm 2' to actuate the same as shown in FIG. 7.
The shaft 10 is integrally connected to a downwardly extending arm 11 to which a horizontally movable rod 12 is connected. A stop 13 is provided ahead of the arm 11 to restrict forward movement of the rod 12. If the rod 12 is moved horizontally, the arm 11 rotates the shaft 10 about the camshaft 3a, to thus rotate the holder 4'. An arm control device 14 is provided at the lower end of the arm 11 and confronting with the stop 13. The device 14 comprises an adjust screw 14a which is engagable with the stop 13, and a nut 14b on the screw 14a. The control device 14 serves to adjust the clearance between the camshaft assembly 3 and the rocker arm 2' to enable them to function smoothly. These arrangements ensure variable valve timing for the high speed operation of the engine.
According to another aspect of the second embodiment of this invention, the cam projection 3d comprises at least two halves 3d' which are spaced apart from each other by an appropriate distance as indicated at l in FIG. 6, and the rocker arm 2' is provided with a clearance adjusting device 15 within the gap l. The device 15 comprises an adjust screw 15a extending downwardly through the rocker arm 2', and a nut 15b bearing against the rocker arm 2' adjacent to the upper end of the adjust screw 15a. The slipper 2b' comprises two split halves with which the split halves 3d' of the cam projection 3d are respectively engageable, as shown in FIGS. 6 and 9. The clearance adjusting device 15 is provided at a point where the split halves of the slipper 2b' meet each other. These arrangements permit control of the tappet clearance for the low speed operation of the engine.
The camshafts 3a and 3b effect a valve lift which is characterized as shown by way of example in FIG. 4. In FIG. 4, curve a shows a valve lift for the low speed operation, and curve b shows a valve lift for the high speed operation. The curves a and b are in the same phase, as is the case with the first embodiment of this invention.
When the engine is driven at a low speed, the camshaft holder 4' is in its upwardly tilted position as shown in FIG. 8. Only the camshaft 3a for the low speed operation of the engine is engaged with the rocker arm 2', so that the valve 1 may be actuated in accordance with curve a in FIG. 4. If it is desired to drive the engine at a high speed, the holder 4' is lowered as shown in FIGURE 7. The camshaft 3b is brought into engagement with the rocker arm 2' to actuate the valve 1 in accordance with the characteristics shown by curve b in FIG. 4. When the camshaft holder 4' is lowered to place the camshaft 3b in its operative position, the lowermost position of the holder 4' is defined by the stop 13, and can be adjusted by the control device 14, whereby the clearance between the rocker arm 2' and the camshaft assembly 3 is adjustable as required.
According to the second embodiment of this invention, the valve timing can be changed only by the pivotal movement of the holder. Therefore, the apparatus is very simple in construction, as it essentially comprises two camshafts juxtaposed on a common rotatable holder, and accordingly, eliminates the aforementioned drawbacks of the conventional apparatus. When the camshaft assembly is selectively brought into its operative position, the clearance between the rocker arm and the camshaft assembly is adjustable as required to ensure that they function smoothly. This adjustment is easy to achieve by the control device associated with the camshaft holder and the stop. The rocker arm can be of relatively small length, while the cam projection on one of the camshafts is divided into at least two appropriately spaced apart halves, and the clearance adjusting device is provided between those two halves. This contributes to reduction in size of the apparatus as a whole.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent for those skilled in the art that various changes and modifications can be made therein without departing from the scope and spirit of the invention.
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An apparatus for varying valve timing for use in an four-cycle internal combustion engine having two camshafts. These camshafts are juxtaposed on a common camshaft holder supported within a cylinder head. Each of the camshafts mounts thereon at least one cam adapted to slidingly contact with a rocker arm. The apparatus is provided with a means for selectively urging said rocker arm by the selective actuation of the cams between two camshafts.
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This application is a continuation of application Ser. No. 08/831,942 filed Apr. 2, 1997, now U.S. Pat. No. 5,997,943.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a composition for a non-wettable coating and its application on a substrate. It also relates to the various products prepared from the composition. More specifically, it relates to the manufacturing process for glass provided with a non-wettable coating.
2. Description of the Background
The wettable nature of a substrate referred to the fact that polar or non-polar liquids adhere to the substrate and form a bothersome film. Wettability means the tendency of the substrates to retain frost, as well as dust and stains of all types, fingerprints, dirt, insects, etc.
The presence of water, frost and/or stains is detrimental to the appearance of the substrate, a possible reduction in transparency of the substrate, as well as an impairment of vision through the substrate. The latter are particularly bothersome when the substrate is glass used in vehicles.
Different types of non-wettable coatings are known, including a non-wettable layer obtained from fluorous organosilanes. This layer can be obtained by applying on the surface of a substrate a solution containing fluorous organosilanes in a non-aqueous organic solvent. As a non-aqueous organic solvent, document 492,545 cites, in particular, n-hexadecane, toluene, xylene, etc. These solvents are particularly appropriate for a fluorochlorosilane. It is also possible, according to this document, to use a methyl or ethyl alcohol as a solvent when the fluorous silane is a fluoroalkoxysilane. However, it is necessary to deposit the layer in the absence of moisture, which is difficult to implement.
SUMMARY OF THE INVENTION
An object of the invention is a composition for coating a substrate, where the wettability properties of the coating are satisfactory and for which the deposition process is simple and practical.
Another object of the invention is a composition deposited on the surface of a substrate in the presence of moisture, particularly in the ambient atmosphere with no moisture restrictions.
These objects are provided by a hydrophobic and oleophobic composition comprising at least one fluoroalkoxysilane, the alkoxy moieties of which are directly bonded to a silicon atom, an aqueous solvent system and at least one catalyst selected from an acid and/or a Bronsted base.
In addition to the hydrophobic, oleophobic, anti-rain, anti-frost, anti-stain, anti-dirt, etc. effects obtained by this composition, other advantages are gained when underlying functional layers are included, or with stacks. This case refers in particular to application A1-0 682,463 describing a glass comprising a glass substrate, an anti-reflection, low-emission and/or conducting functional stack, overlaid with a hydrophobic and oleophobic layer.
In such a configuration, the composition of the invention protects the functional stack from climatic conditions, or a possible chemical or hydrolytic assault. In the latter case, there is an improvement in holding quality in warm, moist atmospheres and by superior results in neutral saline fog tests. An increase in durability is obtained, or even a guaranteed quasi-permanence of the underlying anti-reflection or low-emission function.
The anti-adherent property of the hydrophobic and oleophobic coating according to the invention is particularly important when it overlays an anti-reflection layer or stack, since anti-reflection layers and stacks are typically plagued by the presence of undesirable markings on their surfaces.
Aqueous solvent system for use in the present invention are any type of solvent capable of both solubilizing and hydrolyzing the fluoroalkoxysilane. Preferably, it is a mixture of two components: a solvent capable of solubilizing the fluoroalkoxysilane and optionally a catalyst, and an aqueous compound capable of hydrolyzing the silane in the presence of a catalyst. An alkanol, for example an alkanol of low molecular weight, such as methanol, ethanol, butanol or isopropanol, is preferred as a solvent. An aqueous compound is a compound capable of releasing H + (protons), preferably water.
The fluorous silanes used according to the invention comprise a hydrolyzable moiety, capable of forming silanols with the formula Si—OH. The nature of this moiety affects the speed of hydrolysis of the silane. It is selected so as to allow the deposition of the compound on the substrate in an ambient atmosphere, preferably an alkoxy moiety.
The fluorine groups of the alkoxysilane impart to the layer obtained a particularly marked hydrophobia and oleophobia. The fluorine groups further impart a good resistance to ultraviolet light. The fluoroalkoxysilanes used according to the invention are preferably perfluoroalkoxysilanes having the formula:
with:
m=0 to 15
n=1 to 5
p=0, 1, 2
R is an alkyl
R′ is an alkyl or H
The alkyl of R or R′ may be C 1-100 or C 1-30 . Each R and R′ may be selected independently.
The organosilane carbon chain is preferably relatively long. Preferably, the number of —CF 2 — moieties is larger than the number of —CH 2 — moieties in order to impart a greater fluorine density on the outside: m is preferably at least 2×n.
The fluoroalkoxysilane are preferably selected from the following alone or in combination:
A perfluorotrialkoxysilane, having the formulas:
CF 3 —(CF 2 ) 5 —(CH 2 ) 2 Si(OR) 3 ; CF 3 —(CF 2 ) 7 —(CH 2 ) 2 Si(OR) 3 ; CF 3 —(CF 2 ) 9 —(CH 2 ) 2 Si(OR) 3
Where R is an alkyl, preferably methyl or ethyl; a perfluorodialkoxysilanes having the formulas:
CF 3 —(CF 2 ) 5 —(CH 2 ) 2 SiH(OR) 2 ; CF 3 —(CF 2 ) 7 —(CH 2 ) 2 SiH(OR) 2 ; CF 3 —(CF 2 ) 9 —(CH 2 ) 2 SiH(OR) 2
where R is an alkyl, preferably methyl or ethyl.
The proportion of fluoroalkoxysilane in the composition may range from 0.05 to 5%, by weight with respect to the composition, preferably, 1 to 3% by weight.
The proportions of the various components of the composition affect the wettability of the coating. The proportion of the aqueous compound, for example water, with respect to the solvent itself, for example an alcohol, ranges from 3 to 20% by volume, and preferably is on the order of 10% by volume. Thus, it is possible that the alkoxysilanes present in an aqueous solvent system may begin to hydrolyze, forming silanols capable of reacting with the reactive groups on the surface of the substrate. An excessively large proportion of hydrolyzed silanes may lead to homopolymerization. The number of alkanols capable of reacting with the surface of the substrate is then reduced. Likewise, an excessively small proportion of hydrolyzed silanes may lead to an excessively small number of silanes affixed to the surface of the substrate.
A catalyst catalyzes the hydrolysis reaction. The catalyst may be a Bronsted acid and/or base; it is capable of releasing an H + or an OH − ion, for example, hydrochloric or acetic acid. The proportion of catalyst in the composition also affects the wettability nature of the coating, and preferably is present in from 0.005 and 20% by weight with respect to the composition, and more preferably, on the order of 10% by weight with respect to the composition.
The coating is obtained through reaction of the hydrolyzed alkoxysilanes with reactive groups on the surface of the substrate, forming a covalent bond. The overall structure of the layer is, for an organosilane, covalent bonding at the point of fixation on the surface of the substrate, and one or two covalent bonds with neighboring organosilane molecules, through other hydrolyzable moieties.
The thickness of the layer obtained ranges from 10 to 150 angstroms, preferably 10 to 100 angstroms. The layer preferably does not impair the transparency of, or vision through, the substrate.
The composition according to the invention is applied on at least one portion of a surface of a substrate, comprising, in particular OH groups capable of reacting with the hydrolyzed silane of the compound. The substrate may be made of a mineral glass, a plastic material, such as polycarbonate for example, or a base coated with at least one mineral and/or inorganic layer. Examples of mineral an/or inorganic layers include functional layers such as anti-streaking, anti-abrasion, anti-reflection layers, decorative and low-emission layers, as indicated above. These layers may also be organic.
The composition according to the invention also may be deposited on a layer which is at least partially degraded. This degradation may be due, for example, to natural aging or to a mechanical or chemical abrasion. Abrasion may be due to the rubbing of windshield wipers or to the impact of rain, hail, or shock. As the surface on a degraded layer is as effective as the initial surface, it is not necessary to prepare the surface, such as with abrasion, or polishing, prior to deposition of the composition of the invention.
Nonetheless, the durability of the layer according to the invention, preferably, may be improved by a preliminary treatment of the substrate with a priming compound of the type SiX 4 , where X is a hydrolyzable group, for example chloride or alkoxy. X may be other halides, such as bromine. The alkoxy may have 1-100 carbon atoms. Priming increases the reactivity of the glass, which results in an improvement in attachment of the fluorous silane. In addition, the priming disorganizes the fluorous layer and thus makes it possible to form it with a greater thicknesses, at least equal to 100 angstroms, without, however, exceeding 500 angstroms: it does not refer to a monomolecular layer. The increase thus obtained in the amount of fluorine deposited results in an increased durability under conditions of exposure to ultraviolet radiation. Moreover, at the above-mentioned thickness values for the fluorous layer, a scratch in the layer is not visible to the naked eye.
The invention also relates to the process for manufacture of glass provided with a hydrophobic and oleophobic coating.
The process for manufacture of the glass more specifically comprises the following steps:
preparing the composition capable of forming the hydrophobic and oleophobic layer,
preparing, optionally, the priming compound,
depositing the composition on at least a portion of the surface of the glass which, optionally, has been treated with the priming compound.
The preparation of the compound comprises, in particular, mixing of a fluoroalkoxysilane of the invention with an aqueous solvent system and at least one catalyst. This mixing may be performed in the presence of moisture, in particular in the ambient atmosphere. The product obtained is a reactive solution, for example, for 24 hours after preparation. This solution is deposited on at least a portion of the glass, preferably from 10 minutes to one hour after its preparation. Deposition is performed by placing the glass in contact with the solution, by any means, for example by casting, spraying, centrifugation, immersion, dipping, by means of a coating roller or a brush or, preferably, by wiping. The substrate may be at room temperature or heated to a temperature of up to 300° C. Beyond 300° C., there is a risk that the layer will be degraded.
The priming treatment may be accomplished by using the same deposition process as that used for the deposition of the hydrophobic and oleophobic layer, and by using the same aqueous solvent and catalyst system. The priming compound may contain from 0.001 to 5% by weight of SiX 4 . The treatment with the priming compound has the effect of increasing the number of reactive sites (hydroxylated sites) on the surface of the substrates.
The glass contemplated according to the invention is glass comprising mineral and/or organic glass. It is used, in particular, in the aeronautical, railroad or automobile areas. It also can be used in construction or in interiors, for example, as decorative panels, for furnishings, etc. The substrate on which the compound of the invention is capable of being applied moreover may be made up of any material comprising surface hydroxylated groups, such as glass products coated or not coated with mineral and/or inorganic, ceramic, vitroceramic layers (for example, heating plates), vitrified products, concrete or flagstones. The invention is applicable in areas as different as those of glazing, electric domestic appliances, building (windows), cooking utensils, sanitary fixtures (washbasin, bathtub), construction materials, etc.
The surface of the glass to be coated must be clean. The cleanliness of the glass determines the number of reactive sites on the substrate capable of reacting with the hydrolyzed alkoxysilane groups. Its purpose is to avoid the presence of any contaminations, essentially organic, adsorbed on the surface of the substrate and capable of resisting reaction with the hydrolyzed alkoxysilanes on the reactive sites of the substrate. The surface of the glass is cleaned beforehand, for example with the aid of a tensioactive agent.
The substrates prepared with the layers of the invention are both hydrophobic and oleophobic. They have good resistance to ultraviolet radiation, chemical assaults and mechanical abrasion. They are used advantageously as anti-rain, anti-frost, anti-stain, anti-contaminant, anti-dirt substrates, etc. They are used particularly on glass in land and aeronautical vehicles or for buildings.
DETAILED DESCRIPTION OF THE INVENTION
The following nonrestrictive examples illustrate the characteristics and advantages of the invention:
Example 1 illustrates the non-wettable nature of the layer according to the invention;
Example 2 is a comparative example for Example 1;
Example 3 illustrates the resistance to abrasion of an embodiment of the invention;
Example 4 is a comparative example for Example 3; and
Examples 5a and 5b illustrate a preliminary treatment of the substrate with a priming compound.
The resistance to abrasion of the layer is measured by the so-called “windshield wipes” test. The samples are subjected to the action of a wiper blade approximately 50 cm long and exerting a force of 45 newtons on the sample. After a given number of forward and backward motions of the wiper blade, the angle of contact of a drop of water is measured.
EXAMPLE 1
Four samples of float silico-sodo-calcareous glass were cleaned.
This sample was treated with a solution containing a mixture of perfluorotrialkoxysilanes with the formulas:
CF 3 —(CF 2 ) 5 —(CH 2 ) 2 Si(OC 2 H 5 ) 3 ; CF 3 —(CF 2 ) 7 —(CH 2 ) 2 Si(OC 2 H 5 ) 3 ; CF 3 —(CF 2 ) 9 —(CH 2 ) 2 Si(OC 2 H 5 ) 3
in an aqueous solvents system comprising ethanol and water, and a catalyst (acetic acid). The solution is applied by wiping only the proportions of these different components vary according to the samples. Ninety-five percent ethanol is used. In the following table, the proportions of 95% alcohol have been converted into corresponding percentages of pure alcohol and water. The hydrophobia of the layer thus formed is quantified by measuring the angle of contact θ of a drop of water on the layer. All amounts are volumne percents, here and in the other Examples.
The results are as follows:
Sample
% pure ethanol
% water
% acetic acid
% silane
θ water
1
85.5
4.5
10
0.1
90°
2
85.5
4.5
10
3
105-110°
3
76
14
10
0.1
100-105°
4
76
14
10
3
105-110°
It is considered that the non-wettable nature of the layer is satisfactory when the initial angle of contact of a drop of water on said layer is at least of 90°.
This example illustrates the hydrophobic nature of the layer obtained.
EXAMPLE 2—COMPARATIVE EXAMPLE
This example is a comparative example for Example 1.
Four samples were treated in the same manner as in Example 1, except that the compositions used did not comprise any catalyst. The proportions of the components of the solvent system also vary. The ethanol used is 95% ethanol. In the table below, the proportions of 95% alcohol have been converted into corresponding percentages of pure alcohol and water.
The results are as follows:
Sample
% pure ethanol
% water
% silane
θ water
1
95
5
0.1
61-70°
2
95
5
3
56-80°
3
85.5
14.5
0.1
40-70
4
85.5
14.5
3
70-80
The non-wettability nature of the layers obtained is not fully satisfactory: the angles of contact of a drop of water on the layer are less than 90°.
EXAMPLE 3
A sample of float glass of the silico-sodo-calcareous type was given four successive treatments with a solution identical to that used to treat sample No. 4 in Example 1. The sub-layer on which the compound of the invention was deposited by wiping was, each time, degraded by the so-called “windshield-wiper” test.
The results are the following:
Wettability of the sub-layer
Wettability of the layer
Number of
obtained
windshield cycles
θ after the
used to degrade
windshield-
θ
the layer
Initial θ
wiper test
1 st treatment
—
—
105-110°
60° (50,000
cycles)
2 nd treatment
60°
50,000
100-105°
65° (70,000
cycles)
3 rd treatment
65°
70,000
110°
70° (100,000
cycles)
4 th treatment
70°
100,000
115°
70° (100,000
cycles)
It is considered that the resistance to abrasion of the layer is satisfactory if the angle of contact of a drop of water on the layer is in excess of 60° after the windshield-wiper test.
This example illustrates the improved resistance of the layer obtained on a sub-layer which has been at least partially degraded.
Regenerations on layers previously degraded with the aircraft windshield-wiper test show holding qualities at least equivalent, and in some cases superior, to those of the initial layer. Initially, the contact angle of water θ≈60° after 50,000 aircraft windshield-wiper cycles. After 3 or 4 cycles of abrasion with an aircraft windshield wiper and reapplication of the anti-rain layer, the contact angle of water θ≈60° is obtained after 100,000 aircraft windshield-wiper cycles.
EXAMPLE 4—COMPARATIVE EXAMPLE
This example is a comparative example for Example 3. A sample of float glass of the silico-sodo-calcareous type was twice treated with a solution containing 0.5% by volume of a fluorochlorosilane with the formula: CF 3 —(CF 2 ) 7 —(CH 2 ) 2 SiCl 3 in a nonaqueous solvent such as decane. As in Example 3, the first layer obtained by the first treatment is degraded with the aid of the so-called “windshield-wiper” test prior to depositing the second layer.
The results are as follows:
Wettability of the sub-layer
Wettability of the layer
Number of
obtained
windshield cycles
θ after the
used to degrade the
windshield-
θ
layer
Initial θ
wiper test
1 st
—
—
100-105°
70° (50,000
treatment
cycles)
2 nd
65-80°
50,000
95-110°
55° (70,000
treatment
cycles)
This example illustrates the poor resistance to abrasion of a layer of the prior art deposited on a sub-layer at least partially degraded: the angle of contact of a drop of water on a layer which has undergone 50,000 windshield-wiper cycles is less than 60° on the average.
EXAMPLES 5a AND 5b
The procedure used was the same as in sample 4 of Example 1, except that the substrate was treated beforehand with a priming compound containing 76 parts pure ethanol, 14 parts water, 10 parts acetic acid and 1 part type SiX 4 silane (one part Si(OCH 3 ) 4 , for Example 5a and one part Si(OC 2 H 5 ) 4 for Example 5b).
The results are as follows:
θ after the windshield-
Example
Initial θ
wiper test
5a
105°
100° after 250,000 cycles
5b
110°
90° after 100,000 cycles
Compared to the first treatment in the table for Example 3, a significant improvement is noted in the holding quality of the hydrophobic and oleophobic layer in the windshield-wiper test.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
The priority documents of the present application, French Patent Application No. 96/04095 filed on Apr. 2, 1996, and French Patent Application No. 96/06972 filed on Jun. 6, 1996, are hereby incorporated by reference.
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A composition for coating can be made by mixing a fluoroalkoxysilane containing an alkoxy moiety directly bonded to a silicon atom, an aqueous solvent system, and a catalyst. The composition can be used to form a hydrophobic and oleophobic layer on a substrate.
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BACKGROUND OF THE INVENTION
The invention relates to a system of magnets for a selection block in textile machines, particularly a bistable system of magnets for selecting needles, magnetically operated control flaps being provided for selecting the needle allocated to the system of magnets, as well as to a selection block with such systems of magnets.
In modern knitting machines (circular knitting machines and flat knitting machines), magnet systems, which are generally combined into so-called selection blocks, are provided for selecting the needles. In order to knit a particular pattern, certain knitting needles must be selected and other needles not at a particular point in time. The selection medium is triggered electronically in modern knitting machines and it is customary to speak of an electronic selection of needles.
The desired pattern is deposited in an electronic memory and is read during the knitting of the textile part, and the needles are selected correspondingly over the interface of the selection block.
In the selection block there are energy converters, which convert the electrical triggering signal into a mechanical change in position of the control flaps, which are required for selecting the needles and protrude from the selection block. The selection blocks generally are supplied with a number of control flaps, each control flap serving one selection plane. Each control flap is provided with a cam, which interacts with needle butts or sinker butts. The control flap can assume two positions, namely, the "basic, non-selecting position" and the "working or selecting position".
In the `non-selecting` position, the sinker butts run past the control flaps and are not contacted. If a control flap is moved into the `selecting` position, the allocated sinker butt runs onto the cam and is pressed in the direction of the knitting cylinder or the needle bed. Due to the change in the position of the lifting wire, so accomplished, the condition is created mechanically so that the lifting (selecting) from the `non-knitting` position into the `knitting` or `tucking` position is brought about.
Preferably, small solenoids are used to drive and position the control flaps into the two positions.
Such a selection block is known from the EP-O 219 029-B1. However, when small solenoids are employed, which are inserted as, in themselves, independent magnetic systems into the selection block, only relatively large distances between the control flaps, which are disposed adjacent to one another or one above the other, can be realized. Accordingly, flap intervals (pitch intervals), which are significantly smaller than 5 mm, cannot be realized with the known systems. Finally, the electromagnetic capability of the driving magnets (power, change-over time, dissipated power, service life), required for the application, also depends on the volume of the electromagnet. In minimizing the volume of an optimally dimensioned electromagnet, a lower boundary is rapidly encountered, below which one cannot go. Accordingly, for a particular number of selection planes and for a particular pitch interval, the volume of the selection block is practically specified and cannot just be reduced further.
In the case of the well-known selection block, two bearings are provided for each driving system, namely one bearing for the magnet armature and one for the respective control flap. At both of these bearings, frictional losses occur. An additional place of friction, is the connection site between the magnet armature and the respective control flap, where frictional losses occur. Due to the necessary clearance in the bearings and in the connection site, there is also a not inconsiderable rebounding of the control flaps, as they reach their end positions. This rebounding is greater at higher operating speeds/cycle frequencies of the knitting machine.
In addition, the known system is constructed of a plurality of small magnets, individual parts and components, which must be adjusted specially and make the installation of the selection block expensive and cost intensive.
SUMMARY OF THE INVENTION
An object of the invention therefore is to develop a system of magnets of the initially named type in the direction that the driving power required is reduced and the volume can therefore be reduced. In addition, a simple and inexpensive installation, as well as a reduction in the pitch distance between adjacently disposed magnet systems are to be achieved.
This objective is accomplished owing to the fact that armature of the magnet system is constructed in one piece directly as a control flap.
The advantages, achieved with the invention, consist in particular therein that, due to the omission of a beating as well as of the connecting site between the magnet armature and the control flap, the frictional losses of the system of magnets are decisively reduced, as a result of which, for example, a lesser driving power is required for operating the respective control flap. In the final analysis, this means that the volume of the system of magnets can be reduced, as a result of which, in turn, smaller pitch intervals can be realized.
Furthermore, the inventive system of magnets also has less wear and therefore a longer service life.
In addition, due to the lesser number of bearings/connection sites, there is also less rebounding of the control flaps, so that the system of magnets can be operated at higher cycle speeds.
Finally, due to a simple construction of the system of magnets or of a complete selection block, a reduction in the installation costs is also achieved.
An embodiment of the invention is described in greater detail in the following and shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B, and 1C show views of a selection block,
FIG. 2 shows a sectional view of the selection block of FIG. 1 taken along the line 2--2 in FIG. 1A,
FIG. 3 is a view of an open selection block,
FIG. 4 is a perspective view of an open selection block,
FIGS. 5A and 5B are views of a control flap,
FIGS. 6A and 6B are views of a modified control flap, and
FIG. 7 is a view of a coil former with inserted magnetic core.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A selection block 1 for a textile machine is shown in various views in FIGS. 1A, 1B, and 1C. The selection block consists essentially of a cuboid housing, in which several systems of magnets are disposed, which in each case affect control flaps 2 for controlling the needles of the textile machine. In the representation of FIG. 1A, the control flaps 2 protrude from the left side of the selection block. On the opposite side, the selection block is provided with a connector 3, over which the electrical signals for operating/controlling the individual systems of magnets are carried.
The control flaps can be moved in each case in two different positions. In the drawing, the second possible position of the lower control flap is indicated by broken lines. The front edge of the control flap covers a distance of about 2 mm. The adjacent control flaps 2 are disposed at pitch intervals P of about 5 mm. In this connection, it should be mentioned here that smaller intervals are also readily possible.
The selection block 1 consists essentially of two half shells 4, 5, in which the magnet systems 6 are inserted. FIG. 2 shows a section through the selection block and FIG. 3 shows a view of the one half shell 4 with the inserted magnet systems.
So that the details can be identified better, a half shell, in which only one magnet system is inserted, is shown in perspective view in FIG. 4.
The magnet systems 6 consist essentially of a coil former 8, which is provided with an iron core 7 and on which the exciting winding 9 is wound. The magnet systems are inserted positively into corresponding recesses of the half shell, the lower end of the core being connected in a magnetically conducting manner with the half shell, which consists of a magnetically conducting material. In the front region of the magnet system, lateral pole pieces 11 are constructed in the half shell and also serve as stops for the movement of the control flap 2.
The control flap, which is shown on an enlarged scale in FIGS. 5A and 5B, is mounted so that it can rotate about an axle 12. The end of the control flap, pointing to the end face 13 of the iron core 7 of the magnet system, is provided with a permanent magnet 14.
The polarization direction of this permanent magnet runs transversely to the end face of the iron core 7. Due to the action of the permanent magnet, the end of the control flap, which is provided with the permanent magnet and is disposed between the two pole pieces 11, is initially pulled against one of the two pole pieces and remains there because of permanent magnetic attraction. By supplying the exciting coil of the magnet system by appropriately oriented current, the permanent magnetic attraction to this pole piece is cancelled and the end of the control flap, which is provided with a permanent magnet, is rejected by the adjacent pole piece and attracted by the other pole piece, where it remains also once again due to permanent magnetic attraction, when the exciting current is switched off. At the same time, the front end of the control flap, which is provided with control surfaces 15 for controlling the needles, was moved from a first position into a second position.
The control flap 2, shown in FIGS. 5A and 5B, is a bent component punched out from steel. It is provided with an offset bearing area 16 for accommodating the axle 12 and an offset region 17, at which the control surfaces are formed. The opposite region of the control flap is provided with a contour with undercut 18 and borehole 19. The contour can be sheathed and a plastic pipe 20 is gated to it. The plastic part is provided with a recess, in which a permanent magnet is inserted and fastened.
A modified control flap 2' is shown in FIGS. 6A and 6B. A basic body 21, produced by injection molding from a plastic material, is provided here. It contains the plastic part 20' with the recess for accommodating the permanent magnet, as well as the bearing region 16'. A steel part 22, which is provided with the control surfaces 15 for controlling the needles of the knitting machine, is inserted (sheathed) at the front end of the basic body.
The coil former 8 with the iron core 7 of the magnet system is shown in FIG. 7 in sectional representation. The coil former is injection molded from plastic and provided with gated snap-in pins 23 and centering means 24. When the coil former/the system of magnets is inserted into the recesses of the half shell, the snap-in pins 23 and centering means 24 lock behind appropriate locking shoulders and hold the system of magnets positioned in the half shell.
The magnet systems are inserted in the half shells at a mutual interval of 2 P. The magnet systems of the one half shell are then offset by the pitch interval P from the magnet systems of the other half shell, so that, when the two haft shells are assembled, the control flaps have a total pitch interval P. Due to this arrangement, it is possible to provide the magnet systems of a half shell, regarded by themselves, at an interval, which is twice the pitch interval P finally achieved. As a result, volume advantages arise for each magnet system.
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Apparatus for operating needles of a textile machine includes magnetically operated control flaps for operating the needles, and magnetic controls operable to actuate the control flaps. The control flaps include a flap structure and an armature disposed on the flap structure, the magnetic controls being operable to magnetically actuate the armature to thereby effect movement of the flap structure, whereby the movement of the flap structure actuates the needles.
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BACKGROUND OF THE INVENTION
A common way of manufacturing patterned textile fabrics such as carpeting is through the use of yarns or fibers of various colors. Melt or solution dyed yarns are easily distinguishable in the fabric manufacturing process, as their built-in colors are visible to a process operator. The process operator, then, can positively determine from the pattern design if the correct yarn is being fed to the proper segment of the process. This method is quite satisfactory, but requires a large inventory of yarn for different styles and combinations of colors. The inventory requirement usually results in a limited amount of colors.
Another means of manufacturing fabrics with patterned effects involves printing the pattern after formation of the fabric. This technique is useful for woven or knitted fabrics. Techniques have been developed for printing of tufted fabrics. This latter technique is slow and requires sophisticated machinery.
It is also known to tuft carpet fabrics with greige yarns having different dye affinities to form patterning effects. The difficulty with the use of such yarns is the similarity in their before-dye appearance--the yarns are sufficiently similar in color to create confusion in separating the yarns for patterning during processing.
The industry has heretofore resolved this problem by overspraying each different type of yarn with a fugitive tint. Overspraying is a means by which a fugitive tint in a solvent is applied to the surface of fibers. With four common dye variants--light, deep, cationic, and regular --three must be tinted in order to distinguish the four from each other during simultaneous processing.
The problems encountered with tinting the ends in this method are that the tints are unstable and may migrate during processing to other fibers. Further, the tint may interfere with dyeing if the migration pools the tint in any one locale. Further, deep dye polymers are quite receptive to dyes and often the overspray may become permanently affixed in processing.
THE PRESENT INVENTION
In that the overspray tints have different affinities for the variable dyeing materials, the intent of this invention is to take advantage of the affinity. Nylon containing predominantly amino end groups reacts with acid type dyes. Acid-reacting nylon is referred to as "light", "regular", or "deep" depending on the number (10-70) of amino end groups present. Nylon containing predominately sulphonic end groups is referred to as "cationic" and reacts with basic type dyes. The present invention provides a coloring matrix for forming patterned fabrics from greige yarns comprising imparting a permanent tint to the fiber with the highest dye affinity, leaving the cationic fiber in greige state and overspray tinting the light and regular dye fibers. In this manner, the four ends can be distinguished from each other during the fabric manufacturing process. The fabric can thereafter be scoured to remove the fugitive overspray tint from the light and regular dye fiber and the combination thereafter dyed in a single dyebath. The invention also includes combinations of two, three or four dye variants which include a dark dye fiber end.
DETAILED DESCRIPTION OF THE INVENTION
Utilizing a permanently pigmented tint in the deep dye fiber permits adjustment in the dyebath to achieve a given dye level, as the color level of the original fiber is a known constant. A "deep dye" fiber herein shall mean a polyamide fiber having a high amine end group content; i.e. greater than 60 meq/kg. The original fiber color level can be achieved by either pigment tinting all fibers in the deep dye fiber at a particular low level or blending a deeper pigmented fiber with natural (non-tinted) fibers to obtain the same level of color.
The type and color of the pigment may be varied provided that the pigment is stable under processing conditions. The pigment should also be observable in fabric manufacturing.
EXAMPLE I
Nylon 6 polymer was loaded with pigment, by mixing the pigment either in powder form or with a polyethylene carrier, with the nylon chip just prior to the melt extrusion during the fiber melt spinning operation. The pigment may be in the form of a raw powder or combined with a carrier such as polyethylene. The pigment colors are as follows: phthalo blue (Chemical Index pigment blue 15 number 74160); carbon black (c.i. pigment black 7); tan (zinc ferrite). The DE value was recorded using an ACS Spectro-Sensor II spectrophotometer using large area view. Color differential (DE) is a comparison in color space defined by the measurement system (C.I.E. L*a*b*) developed by the International Commission on Illumination. The color differential refers to pigmented versus nonpigmented fibers. curves of the fibers were measured. The CIE color coordinates for each sample were calculated along with the color differences of each sample from a white standard under illuminant D65 using
ΔE.sub.ab.sup.8 =[.sup.* ΔL.sup.*).sup.2 +(Δa.sup.*).sup.2 +(Δb.sup.*).sup.2 ].sup.1/2
the CIE 1976 L * a * b * (CIELAB) color difference equation.
The values for the equation are as follows:
L.sup.* =116(Y/Y.sub.n).sup.1/3 -16
a.sup.* =500[(X/X.sub.n).sup.1/3 -(Y/Y.sub.n).sup.1/3 ]
b.sup.* =200[(Y/Y.sub.n).sup.1/3 -(Z/Z.sub.n).sup.1/3 ]
Here X n , Y n , and Z n are the tristimulus values of the reference white. For values of X/X n , Y/Y n , or Z/Z n less than 0.01: ##EQU1## where f(Y/Y n )=(Y/Y n ) 1/3 for Y/Y n greater than 0.008856 and f(Y/Y n )=7.787(Y/Y n )+16/116 for Y/Y n less than or equal to 0.008856; f(X/X n ) and f(Z/Z n ) are similarly defined.
The reverse transformation (for Y/Y n >0.008856) is ##EQU2##
TABLE I______________________________________Pigment Color % Pigment Loading DE Value______________________________________1) Phthalo Blue 0.0020 11.42) Carbon Black 0.0033 15.43) Carbon Black 0.0025 11.24) Zinc Ferrite 0.0270 11.15) Phthalo Blue 0.0030 15.3______________________________________
The polymers were then spun into fiber and thereafter tufted into a carpet in greige form. A control carpet was made from fibers having no tint. Both carpets were acid dyed in shades that are commonly found in deep dye components. The color difference (DE) between the pigmented carpet and natural untinted control is set forth in Table II.
TABLE II______________________________________ Overdye Color (DE)Pigment Red Gray Blue Brown Average______________________________________1) Phthalo 0.2 1.9 0.3 1.2 0.9 Blue2) Carbon 1.3 2.2 2.3 1.0 1.7 Black3) Carbon -- -- -- -- -- Black4) Zinc 1.4 2.5 1.7 1.0 1.7 Ferrite5) Phthalo -- -- -- -- -- Blue______________________________________
The overdyed carpets were then exposed to 100 hours xenon lamp exposure and measured again for color difference. The results are reported in Table III. A control section lacking the xenon lamp exposure was also measured.
TABLE III______________________________________ Overdye Color After Exposure (DE)Pigment Red Gray Blue Brown Average______________________________________1) Phthalo 3.1 4.2 5.8 3.6 4.2 Blue2) Carbon 3.7 2.7 5.0 2.7 3.5 Black3) Carbon -- -- -- -- -- Black4) Zinc 4.4 4.2 5.0 3.2 4.2 Ferrite5) Phthalo -- -- -- -- -- Blue6) Non-Pigmented 1.5 2.5 5.5 4.2 3.4 Control______________________________________
Samples of the yarns were visually evaluated during the tufting process. Phthalo blue 1) had marginal visibility; phthalo blue 5) had sufficient pigment loading to be detectable in process. Neither the carbon black sample nor the zinc ferrite tan sample could be detected visually in process. Since the DE levels were comparable, this indicates that background plays an important part in color perception. At the same loading level, phthalo blue was more visible and is the preferred pigment. Other pigment colors that may be satisfactory include emerald green, orange, crimson.
EXAMPLE II
This example shows the effect of blending a conventional pigmented fiber with non-pigmented natural fibers to obtain a level of color identifiable in processing. A nylon 6 polymer containing phthalo blue pigment was formed into a carpet fiber, blended with non-pigmented fibers, carded and pin drafted. The resultant yarns were formed into knit tubes and DE values measured.
TABLE IV______________________________________ % Identifier DE______________________________________ 0.5 4.5 1.0 7.1 3.0 15.3 5.0 18.1 10.0 23.9______________________________________
The data reflected in Table IV indicates that a 3% level of phthalo Blue pigmented fiber results in a blend equal to Blue 5) in Example I.
Thus, it can be seen that a permanently tinted polymer, preferably phthalo blue, yields a good identifier for processing. Its use in a deep dye fiber with other dye variants is indicative of its flexibility and diversity in overdyes of variant dyeing polymeric fibers.
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A method of distinguishing two or more variant dye fibers in greige form is disclosed. The technique involves adding sufficient pigment to one of the fibers to make it visible to the eye.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a Continuation Patent Application which claims priority to U.S. Utility patent application Ser. No. 15/297,113, filed on Oct. 18, 2016, entitled “Thermal break system and method for door and windows” which is a Continuation-In-Part Patent Application which claims priority to U.S. Utility Pat. No. 9,470,037, filed on Aug. 23, 2015, entitled “Thermal break system and method for door and windows”, issued October 18, 2016, which claims priority to U.S. Provisional Patent Application Ser. No. 61/926,412, filed on Apr. 9, 2015, 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 is provided including lock plates and latch plates, wherein the lockset is offset and positioned entirely in the inside steel panel 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 crating 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 the 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 op 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 I 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 stip. 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 e 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 facility 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.
[0026] 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.
[0027] 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.
[0028] 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, i.e. side 1 . 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.
[0029] 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 84 and threshold as well known in the art.
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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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FIELD OF THE INVENTION
[0001] The present invention relates to a method for preparing copper oxide, especially to a method for preparing copper oxide nano-particles
BACKGROUND OF THE INVENTION
[0002] The copper oxide is a dark brown powder, its use is quite widespread, including as the coloring agent for the glass and porcelain, the polishing compound for the optical glass, the catalyst for the organic synthesis and the catalyst for the rapid combustion of the rocket propulsion. In addition, the copper oxide also has good thermal conductivity, and lower price than noble metals, e.g. gold, silver, etc. Thus, the copper oxide is frequently used in the heat transfer fluid. The conventional heat transfer fluids include, for example, the working fluids used in the heat exchanger, the engine, the refrigeration and air-conditioning system. The biggest limitation in the application of the conventional heat transfer fluids results from its low thermal conductivity. In order to overcome this limitation, therefore the heat transfer fluids of new generation are developed. By dispersing the nano-particles of the metal or the metal oxide with excellent thermal conductivity into the working fluid, i.e. so-called nanofluid, the efficiency of the heat conduction can be largely enhanced. Here the nano-particles are the particles with the major dimension less than 100 nm. As an example the spherical particles, the main dimension is the diameter of the spherical particle. For an example of the non-spherical particles, the main dimension is the longest dimension of the particles. When the dimension of the particle is reduced, the ratio of its surface area to volume will increase. For example, when the particle size is reduced from 10 μm to 10 nm, the ratio of its surface area to volume will increase by 1000 times, indicating a thousand-fold surface area per unit volume for conducting heat. Therefore, compared with micron particles, the nano-particles will provide much better thermal conductive effect for the working fluids. Generally, the preparation methods of the nano-fluids can be divided into two methods, i.e. methods of the single step and the multi-steps. As to the method of the single step, it is disclosed in the U.S. Pat. No. 6,221,275B1 (2001) that the nano-particles are generated by the physical vaporization method under high temperature and high vacuum conditions inside the airtight reactor, and then directly introduced into the working fluid. The advantage of the single step method is that the nano-particles in the nano-fluid can be easily dispersed with less agglomeration. However its major drawback is that it is hard to control the compositions of the nano-particles, and the production rate is too slow. Thus, it is not suitable for mass production. In the multi-step method, the nano-particles are synthesized first, and then dispersed into the working fluid by using a specific dispersing method. Composition of the nano-particles can be accurately controlled by the synthesizing step. Besides, solid content of the nanofluid can be altered, and different type of nano-particles and working fluids can be matched up in various ways for different applications. Meanwhile, the multi-step method has the potential for mass production.
[0003] In the resent years, the researches and developments of the high-gravity system have solved a lot of issues that can not be solved in the gravity field. The high-gravity system can use rotating packed bed reactor and the spinning disk reactor. By using the rotating packed bed or spinning disk under high speed, the high-gravity force with hundred or even thousand times of the earth gravity is generated, and can disperse the liquid in the system into tiny droplets or thin liquid film so as to enhance the mass transfer rate and the mixing efficiency. The high-gravity system can be applied to the preparation of powders for facilitating the achievement of the powders with small sizes and narrow size distribution. In addition, the high-gravity system has the advantages of small dimensions, high production rate, and continuous operation, and hence it has the commercial potential. Currently, there is a method for preparing the nano-fluid by using rotating packed bed system. In this method, the liquids with different phases, e.g. water phase and organic phase, are contacted in the reactor of the rotating packed bed system, and the reaction occurs there. The mixed solution after the reaction can be phase-separated, and the nano-fluid containing metal oxide nano-particles dispersed in the organic phase can be directly obtained. However, the raw material in this method is the metal organic acid salt, which price is expensive and can not be easily acquired.
[0004] In order to solve the above mentioned problems, the new concepts and production methods are disclosed in the present invention, where the normal metal salts can be used as the raw materials, the copper oxide nano-particles can be mass-produced by continuous operation, the production cost can be largely reduced, and the produced copper oxide nano-particles have high quality of very small particle size and narrow size distribution.
SUMMARY OF THE INVENTION
[0005] The present invention provides a method for preparing a copper oxide nano-particle by adopting the high-gravity system which has advantages of high mass transfer rate and high mixing efficiency. The copper oxide nano-particles of various specifications can be produced with continuous operation mode and high production rate.
[0006] In accordance with one aspect of the present invention, a method for preparing copper oxide nano-particles is provided. The method comprises providing a copper salt solution; providing an alkaline solution; and mixing the copper salt solution and the alkaline solution by using a high-gravity force provided by a high-gravity device to obtain a precursor of the copper oxide nano-particle.
[0007] Preferably, the step of mixing the copper salt solution and the alkaline solution forms a slurry having a solvent, and the method further comprises a step of removing the solvent of the slurry to obtain the precursor of the copper oxide nano-particle by a centrifuge.
[0008] Preferably, the copper salt solution comprises at least one selected from a group consisting of a copper sulfate, a copper nitrate, a copper chloride and a copper bromide, and the copper salt solution has a solvent being a water.
[0009] Preferably, the alkaline solution comprises at least one selected from a group consisting of a sodium carbonate, a potassium carbonate, a lithium carbonate and a sodium hydroxide, and the alkaline solution has a solvent being a water.
[0010] Preferably, the copper salt solution has a concentration in a range of 0.01M to 1M, and the alkaline solution has a concentration in a range of 0.01M to 1M.
[0011] Preferably, the high-gravity force provided by a high-gravity device is in a range of 2 g to 1000 g.
[0012] Preferably, the high-gravity force is preferably in a range of 200 g to 1000 g.
[0013] Preferably, the first three steps are performed under a room temperature.
[0014] Preferably, the precursor comprises Cu 2 (OH) 2 CO 3 , and the high-gravity device comprises one of a rotating packed bed system and a spinning disk system.
[0015] Preferably, the method further comprises a step of calcining the precursor to obtain the copper oxide nano-particle.
[0016] Preferably, the step of calcining the precursor further comprises heating the precursor by gradually increasing a heating temperature to a calcining temperature higher than 300 degree C., and keeping the calcining temperature for a calcining period to obtain the copper oxide nano-particle.
[0017] In accordance with another aspect of the present invention, another method for preparing a copper oxide nano-particle is provided. The method comprises providing a precursor of the copper oxide nano-particle; and heating the precursor at a calcining temperature to obtain the copper oxide nano-particle.
[0018] Preferably, the step of heating the precursor is performed by gradually increasing a heating temperature up to a calcining temperature higher than 300 degree C., and keeping the calcining temperature for a calcining period.
[0019] Preferably, the calcining temperature is preferably one of higher than and equal to 500 degree C.
[0020] Preferably, the calcining period is longer than 5 minutes.
[0021] Preferably, the calcining period is preferably one of longer than and equal to 60 minutes.
[0022] The above objects and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed descriptions and accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is the schematic diagram showing the system for preparing the copper oxide nano-particles by using the high-gravity device in the present invention;
[0024] FIG. 2 is the schematic diagram showing the flowchart for preparing the copper oxide nano-particles in the present invention;
[0025] FIG. 3 is the schematic diagram showing the average particle sizes of the copper oxide nano-particles vs. the concentrations of the reactant solutions in the present invention; and
[0026] FIG. 4 is the schematic diagram showing the X-ray diffraction pattern of the copper oxide nano-particles produced in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for the purposes of illustration and description only; it is not intended to be exhaustive or to be limited to the precise form disclosed.
[0028] The system for preparing copper oxide nano-powders by using a high-gravity device is shown in FIG. 1 . The specific embodiment of the present invention is illustrated by referring to FIG. 1 as follows. First, the copper salt solution and alkaline solution with the same concentration in the range between 0.01 to 1 M are prepared. Then the two solutions are poured into the storage tank 1 and tank 2 , respectively. The solution of copper salts from the storage tank 1 is transported by using the liquid pump 3 , and flows through the flow meter 5 , inlet 7 and liquid distributor 9 to the center of the spinning disk 11 , which is rotating around an axis. At the same time, the alkaline solution from the storage tank 2 is transported by using the liquid pump 4 , and flows through the flow meter 6 , inlet 8 and liquid distributor 10 to the center of the spinning disk 11 , which is rotating. Two solutions are pumped into the spinning disk by the same flow rate in the range between 0.2 to 5 L/min. The spinning disk 11 with the diameter of 19.5 cm made of stainless steel is driven by the variable-speed motor and rotating in the plane perpendicular to the horizontal plane under high speed. The operational rotating speed can be chosen between 500 to 4000 rpm so as to produce the high-gravity field. The high-gravity force can be adjusted in the range between 2 g to 1000 g, preferably between 200 g to 1000 g.
[0029] The above copper salt solution can be selected from at least one of copper sulfate, copper nitrate, copper chloride, copper bromide solutions, or other copper-containing inorganic or organic solutions, the solvent of which can be water, other polar solvents, or mixed solvents consisting of water and other solvents. In this embodiment, the solvent is water. The above alkaline solution can be selected from at least one of sodium carbonate, potassium carbonate, lithium carbonate solutions, etc., the solvent of which can be water, other polar solvents, or mixed solvents consisting of water and other solvents. In t his embodiment, the solvent is water.
[0030] The above two solutions are spread on the disk under the high-gravity force to form a thin liquid film. The reaction occurs to generate the precursor of copper oxide, e.g. copper hydroxide carbonate (Cu 2 (OH) 2 CO 3 ), when the two solutions are mixed. The slurry containing precursor particles is thrown outwardly through the outer edge of the spinning disk 11 , is stopped by the housing 12 of the reactor, and flows into the collection tank 14 along the inner wall of the housing 12 of the reactor through the outlet 13 . The housing 12 of the reactor can be made of the plates of acrylic, aluminum, stainless steel or other materials. Subsequently, the slurry with the precursors is centrifuged for 10 minutes at the rotation speed of about 10,000 rpm. Then the liquid in the upper portion is removed and the precursor particles can be obtained. The chemical reaction to obtain the precursor of copper oxide, e.g. copper hydroxide carbonate (Cu 2 (OH) 2 CO 3 ), can be illustrated in the following chemical equation:
[0000] 2CuSO 4 +2Na 2 CO 3 +H 2 O→Cu 2 (OH) 2 CO 3(s) +2Na 2 SO 4 +CO 2
[0031] Then, the precursor particles are washed twice by using the mixture of the deionized water and acetone in a volume ratio of 1:1, and then washed once by using the acetone. The n, after drying, the dried precursor particles are placed inside the high-temperature furnace. The furnace temperature is increased from room temperature up to 100° C. (i.e. solvent boiling point) at the heating rate of 10° C./min, and then maintained for about 30 min to further remove residual moisture. After then, the furnace temperature is further increased to 500° C. (at least higher than 300° C.) at the previous heating rate, and then maintained for 60 min (at least 5 min or longer). Finally, the furnace temperature is cooled down to room temperature at the cooling rate of 10° C./min, and the product, i.e. the copper oxide nano-particles, can be taken out of the furnace. In addition, alternatively, the precursor particles after washing can be delivered into the high-temperature furnace, and the furnace temperature can be gradually increased to 500° C. at the heating rate of 10° C./min for calcining to obtain the copper oxide nano-particles. Of course, the above heating rate or cooling rate can be appropriately adjusted depending on the quantity of the precursor particles and the practical requirements of the mass production.
[0032] To sum up, this invention provides methods for preparing the copper oxide nano-particles, and the methods can be summarized into the major steps as shown in the flowchart of FIG. 2 . Please refer to FIG. 2 . Firstly, the copper salt solution and alkaline solution are provided. Secondly, the copper salt solution and alkaline solution are mixed by using the high-gravity force provided by the high-gravity device to form slurry. In the following, the solvent in the slurry is removed in order to obtain the precursors of the copper oxide nano-particles. Finally, the precursors are calcined to obtain the copper oxide nano-particles. The chemical reaction by calcining the copper oxide precursor, e.g. copper hydroxide carbonate (Cu 2 (OH) 2 CO 3 ), to obtain the copper oxide can be illustrated in the following chemical equation:
[0000] Cu 2 (OH) 2 CO 3(s) →2CuO (s) +CO 2 +H 2 O
[0033] In the present invention, the copper oxide nano-particles in several desired particle sizes can be produced by changing the operation variables, including the concentrations of the reactant solutions, flow rate of the reactant solution, rotation speed of the spinning disk, etc. The results are described as follows.
[0034] According to the concept of the present invention, the above mentioned spinning disk can be substituted by the rotating packed bed or any other device, which can provide the high-gravity force.
[0035] The effect of the concentrations of the reactant solutions: when investigating the effect of the concentrations of the reactant solutions, the highest rotation speed of the spinning disk is fixed at 4000 rpm, the flow rate is adjusted at 0.2 L/min at minimum, and the concentrations of the reactant solutions are changed from 0.01 to 0.4 M. There is not much difference in the yield of the resulted copper oxides, and all yield rates are higher than 90%. The volumetric average and number average of particle sizes vs. the concentrations of the reactant solutions is shown in FIG. 3 . It is known from FIG. 3 that the volumetric average particle sizes remain between 60 and 70 nm when the concentrations of the reactant solutions are below 0.1 M. However, when the concentrations of the reactant solutions are raised to 0.4 M, the volumetric average particle size increases to about 170 nm, while the number average particle sizes falls between 40 and 80 nm in the concentration range investigated.
[0036] In addition, if other operation variable, e.g. flow rate of the reactant solution or the rotation speed, is changed, the nano-particles with the average particle size in the range of 20 to 200 nm can be obtained, depending on the operation variables.
[0037] The X-ray diffraction patterns of the copper oxide nano-particles prepared in the present invention are shown in FIG. 4 . The copper oxide nano-particles prepared in the present invention have quasi-spherical shapes. In addition, after comparing the X-ray diffraction patterns of the obtained copper oxide nano-particles in the present invention with those of the standard samples, it is confirmed that the obtained copper oxide nano-particles have the monoclinic crystal structure.
[0038] To sum up, the present invention provides novel methods for preparing the copper oxide nano-particles. The copper oxide nano-powders can be mass-produced with continuous operation mode. The production cost can be significantly reduced. The produced copper oxide nano-particles have high qualities of very small particle sizes and narrow size distribution. Furthermore, the particle sizes of the copper oxide nano-particles can be tuned by adjusting the concentrations of the reactant solutions, the flow rates of the reactant solutions and the rotating speed of the spinning disk.
[0039] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
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A method for manufacturing the copper oxide nano-particles is provided. The method includes the steps of providing a copper-contained salt solution, providing a alkaline solution, mixing the copper-contained salt solution and the alkaline solution by using a high-gravity force provided by a high-gravity device to generate a slurry, removing the solvent in the slurry to obtain a precursor of the copper oxide nano-particles, and calcining the precursor to produce the copper oxide nano-particles.
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FIELD OF THE INVENTION
The invention relates to a control means for a drug delivery device and also a drug delivery device including a control means.
BACKGROUND OF THE INVENTION
A number of therapeutic treatments are administered by inhalation and thus, primarily, are directed to the upper respiratory tract ie the nose and throat. Accordingly, a number of conventional devices exist for this purpose. In some instances, for example where a therapeutic agent may be dangerous when a given dose is exceeded, or alternatively where a therapeutic agent may be potentially addictive, it is important to regulate the administered dose or dose regime. It is therefore important to try and prevent the inadvertent overdosing of a given therapeutic agent or the inadvertent addiction to a given therapeutic agent.
Conventional dispensers typically include a dispensing means which controls the amount of therapeutic agent delivered per use, or application, of the dispense. For example, a pump and associated chamber can be used to control the delivery of a selected amount of therapeutic agent, typically in the form of a therapeutic fluid, thus the volume of fluid dispensed is determined by the geometry of the chamber on which the pump acts and therefore for each pumping action a given volume of fluid is dispensed. In this provided an individual only uses the dispenser, or pump, a specified number of times over a given period, the dose of therapeutic agent should fall within a dose regime.
However, it is not uncommon for individuals to forget how much of a given quantity of therapeutic agent has been inhaled in any given period and therefore to inadvertently exceed a dosage. Additionally, given that pump operated dispensers sometimes need to be primed for a correct amount of therapeutic agent to be dispensed an individual may not receive a correct dosage of therapeutic agent. And indeed in these circumstances it is possible for an individual to inadvertently exceed his or her recommended dose by following this partial dose, with a full dose and thus run the risk of inadvertent overdose or addiction.
A further complication concerns the fact that increasingly new and effective therapeutic agents are becoming hazardous and therefore if a partial dose, due to inadequate priming, is not taken it is not always advisable to simply dispense into the atmosphere by a technique known as air priming the partial dose. Additionally, it is not always advisable to air prime because of the considerable expense that may be associated with the use of certain therapeutic agents in this way.
It can therefore be seen that there is a need to provide a means for controlling the dispensing of therapeutic agents; and a device including same.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a control means in, or for use in a dispensing device whereby the dose regime of a dispensed therapeutic can be reliably controlled.
According to a first aspect of the invention there is provided a drug delivery device for the delivery of a fluid carrying or, comprising a therapeutic agent said device comprising: a reservoir for storing said fluid, and in fluid connection therewith a regulatable pump means for dispensing said fluid via an outlet means; wherein a control means is further provided for selectively controlling the pumping mode of said pump means such that in a first mode said pump means acts to dispense said fluid and in a second mode said pump means acts such that substantially no fluid is dispensed.
In a preferred embodiment of the invention said reservoir comprises an exit portion comprising a dispensing chamber and associated dispensing channel which is in fluid connection with a storage portion of said reservoir.
In a preferred embodiment of the invention said pump means comprises a selectively controllable bypass valve which has a dual mode of operation. In a first mode when the bypass valve is closed fluid in said reservoir can be dispensed from said device. Alternatively, or additionally, in a second mode when said bypass valve is opened fluid in said reservoir is diverted from an exit portion of said reservoir to a storage portion of said reservoir.
More preferably still said bypass valve comprises an aperture covered by a flexibly membrane that allows the passage therethrough or thereby of therapeutic fluid when said bypass valve is in said second mode.
In yet a further preferred embodiment of the invention said bypass valve comprises an aperture in said dispensing chamber and/or said dispensing channel and a means for releasably sealing same such that when the device is to dispense a dosage of therapeutic agent said aperture is closed; and when the device is to prevent dispensing of said therapeutic agent the aperture of the bypass valve is opened thus enabling therapeutic agent in said dispensing chamber to be diverted to the storage portion of said reservoir. Ideally, said releasable sealing means comprises an urging means which is ideally controlled using electrical means, and most ideally comprises a solenoid.
It will therefore be apparent that when the urging means acts so as to apply sufficient pressure to the releasable sealing means the aperture in the dispensing chamber is sealed and this ensures that therapeutic agent can be dispensed from the device. Alternatively, when the urging means does not act to apply sufficient pressure to the releasable sealing means the aperture in the dispensing chamber is opened and the therapeutic agent is therefore directed towards the reservoir storage portion.
It therefore follows that the selective control of the urging means status will determine the pumping mode of the pump and so the ability of the deliverer device to dispense medication.
In yet a further preferred embodiment of the invention control means ideally in the form of an electronic circuit with at least one microchip is provided so that the number of times the device can dispense a therapeutic agent can be controlled over a set period of time. Additionally, and advantageously, said control means is adapted to record information relating to use of the dispensing device and also to respond to interrogation of same so that, with the provision and use of a suitable display means, an individual can enquire as to how frequently the device may be used over a remaining period of time or how much medication has already been administered. Additionally further still an interface means is provided whereby data stored on said control means can be down-loaded to another compatible device for further use/analysis. This is useful for determining drug regime compliance either from the perspective of a GP or clinical trials coordinator.
An additional advantage intrinsic in the device of the invention concerns an ability to prime the pump means without dispensing the therapeutic agent. As will be well known to those skilled in the art, the loss of prime in pumps is a consequence of fluid leaking out of the relevant chamber, in this instance the dispensing chamber. This typically occurs when the device is jostled or laid on its side. Thus the amount of fluid in the dispensing chamber is decreased and an insufficient dose is administered on use. In order to ensure that a correct dose is administered the conventional device is repeatedly operated at least once, to refill the dispensing chamber. This involves effecting additional cycles of the device and thus dispensing some therapeutic agent to the atmosphere. However with the device of the invention it is possible to prime the pump with the bypass valve open and thus divert the therapeutic fluid in the dispensing chamber to the reservoir storage portion. In this way, the device can be primed without loss of medication or fluid.
It therefore follows that the control means could be further programmed to enable a user to prime the device each time before usage. For example, it is possible to program the control means so that at least one pump operation is provided, for the purpose of priming with the bypass valve open, and then a further pump operation is provided with the bypass valve closed so as to ensure that on a selected pump operation the device dispenses a desired amount of therapeutic agent.
It can therefore be seen that the device of the invention not only enables one to control the number of times a therapeutic agent is dispensed from the device but also it enables repriming without the disadvantages associated with air priming.
According to a second aspect of the invention there is provided a drug delivery device for the delivery of the fluid carrying or comprising a therapeutic agent. The said device comprising: a reservoir for storing said fluid, and in fluid connection therewith a regulatable pump means for dispensing said fluid via an outlet means; wherein a primer control means is further provided for selectively controlling the pumping mode of said pump means such that in a first mode said pump means acts to dispense said fluid and in a second mode said pump means acts to return fluid to said reservoir.
A single embodiment of the invention will now be described by way of example only. It is notable that this single embodiment is not intended to limit the scope of the application but merely serve for the purpose of comprehension.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiment of the invention will be described with reference to the single FIGURE which is a part sectional, part peeled-back, perspective view of a device in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The device comprises a generally cylindrical body member attached to a dispensing nozzle 2 in conventional manner. Nozzle is provided with an actuator member 3 which is adapted to enable a user to apply pressure thereto using the fingers of one hand. The lower part of body 1 comprises a storage reservoir 4 into which a selected volume of therapeutic fluid can be stored. Centrally located in reservoir 4 there is provided a cylindrical dispensing channel 5 which communicates with, and is in fluid connection with, a dose regulation chamber 6 via a releasable ball closure means 7 . Dose regulation chamber 6 s in fluid connection with dispensing channel 8 upon depression of breakback piston 9 as will be described hereinafter. Dispensing channel 8 terminates at the outermost tip of nozzle 2 . This arrangement ensures that the fluid stored in reservoir 4 travels through the device to be dispensed via nozzle 2 .
Notably, the dimensions of dose regulation chamber 6 and dispensing channel 8 determine the dosage of fluid dispensed upon operation of the device. Thus the dimensions are suitably selected for a given concentration of therapeutic fluid. Or, alternatively, the concentration of a given therapeutic fluid is determined having regard to the dimensions of said dose regulation chamber 6 and channel dispensing means 8 .
Actuator 3 is operatively connected to breakback piston 9 in conventional manner such that the depression of actuator 3 results in the downward movement of breakback piston 9 . As piston 9 is moved downwardly it travels into the dose regulation chamber 6 and the pressure in same increases until w hat is known as a break pressure is reached. At this point part of the piston assembly breaks away thus ensuring that the dose regulation chamber 6 is in fluid connection with the dispensing channel 8 and the pressurised fluid then exits the dispensing device.
The exact arrangement for ensuring fluid connection between dose regulation chamber 6 and dispensing channel 8 can be selected from conventional devices, including permutations or variations thereof, and is not intended to limit the scope of the application.
Indeed, the exact arrangement of the pumping mechanism may be selected from conventional devices, including permutations or variations thereof, and is not intended to limit the scope of the application.
In the device of the invention the dose regulation chamber 6 or, alternatively, the dispensing channel 8 is provided with a bypass valve 10 . Bypass valve 10 comprises a cavity provided in the wall of the dose regulation chamber 6 and a releasable closure means in contact therewith. In a preferred embodiment of the invention the releasable enclosure means comprises a flexible (or resilient) covering for the aperture typically in the form of a flexible (or resilient) band which is placed about the outer surface of the dose regulation chamber 6 and also an associated urging means which can be made to selectively press against the releasable band ideally in the region of the aperture. In the embodiment of the invention shown in the FIGURE the releasable urging means comprises a solenoid 11 which can be activated/deactivated, depending on the configuration of the solenoid so as to press against the resilient band. However, in an alternative mode of operation the deactivation/activation of the solenoid will have the opposite effect and the urging member of the solenoid will be positioned remote from the resilient band enabling fluid to escape from dose regulation chamber 6 when a given pressure is reached. Clearly the flexibility or resilience of the band is selected with this in mind. In alternative embodiments of the invention more than one bypass valve may be provided or alternatively at least one bypass valve is provided in either or both the dose regulation chamber 6 or the dispensing channel 8 .
The dispensing device is suitably provided with an electronic circuit means (not shown) which can be programmed to control the operation of said bypass valve in accordance with the dispensing requirements of the device. Additionally, display means (not shown) may be provided so that information stored can be viewed by a user. Additionally, and advantageously, the electronics may be programmed for interrogation so that a user may enquire as to the status of the device or the number of doses dispensed over a given period of time and thus the remaining number of doses to be dispensed over a given period of time or indeed any other information that may be beneficial to the successful use of the device. Additionally, interface means may be provided so that the device can be used in association with other equipment for the purpose of data analysis.
Typically therefore, in use, the device is filled with an appropriate amount of selected therapeutic fluid and the electronics is programmed so that, for example the bypass valve is opened for at least one operation of the pump and closed for the next subsequent permitted operation thus ensuring that a full dose of therapeutic fluid is dispensed on the selected operation of the pump. Additionally, a timer may be incorporated into the electronics so that the bypass valve remains open for a predetermined time interval so that in this predetermined time interval although the pump may be operated no medication is dispensed. Once a predetermined time interval has elapsed the electronics are programmed so that following priming of the pump on subsequent operation of the pump a dosage of therapeutic fluid is dispensed if permitted. Thus in this way, at the correct time interval, the user is able to operate the pump at least once in order to prime same and then operate the pump a further time in order to dispense a reliable amount of medication. The aforementioned cycle of the working of the device can be repeated for a given number of times or alternatively, the predetermined time interval may be varied accordingly to a user's requirements so as to provide for a constant and repeatable cycle of medication dispensing or a variable cycle of medication dispensing.
It can therefore be seen that the invention concerns a novel dispensing means for controlling the administration of a therapeutic agent.
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A drug delivery device for the delivery of a fluid carrying or including a therapeutic agent. The device including a reservoir for storing the fluid, and in fluid connection therewith a regulatable pump for dispensing the fluid via an outlet. A control device is further provided, for selectively controlling the pumping mode of the pump such that in a first mode the pump acts to dispense the fluid and in a second mode the pump acts such that substantially no fluid is dispensed.
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RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Application No. 60/449,887, filed on Feb. 25, 2003, and is also related to U.S. Provisional Application 60/450,131, filed on Feb. 25, 2003. The entire teachings of the above application are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the selective absorption of electromagnetic radiation by small particles, and more particularly to solid and liquid composite materials that absorb strongly within a chosen, predetermined portion of the electromagnetic spectrum, such as ultraviolet band, while remaining substantially transparent outside this region.
[0003] The effect of exposure to ultraviolet radiation of most organic and some inorganic substances can be damaging. To gain protection, sun shields, umbrellas, clothing, windows, lotions, and creams are used.
[0004] Protection of skin against ultraviolet radiation has, in the past, been achieved with sun lotions containing organic substances such as melanin, benzophenore, Patimate-O®, avobenzone, or inorganic compounds, such as zinc oxide or titanium dioxide. In many cases, while the sun lotion appears visually transparent, the deposit looks distinctly white.
[0005] Another type of UV-absorbing material is described in U.S. Pat. Nos. 5,534,056 and 5,527,386. This material features silicon nanoparticles particles that absorb UV radiation due to the phenomena of band-gap electron transitions as well as “entrapment” of the electromagnetic waves by total internal reflection. While rendering UV protection, silicon, unfortunately, also absorbs slightly in the blue region of the visual spectral band, thus causing a yellow tint on the deposition surface such as human skin.
[0006] Because sun lotions decompose in ultraviolet (UV) light, and/or wash off quickly in salt water, the need exists for new materials that are stable in UV light and transparent in the visible spectrum. It is also desirable to increase the degree of protection that the currently available compositions can offer.
SUMMARY OF THE INVENTION
[0007] In a preferred embodiment the present invention is an ultraviolet radiation-absorbing material that comprises particles constructed of an outer shell and an inner core wherein either the core or the shell comprises a conductive material. The conductive material has a negative real part of the dielectric constant in a predetermined spectral band. Furthermore, either (i) the core comprises a first conductive material and the shell comprises a second conductive material different from the first conductive material; or (ii) either the core or the shell comprises a refracting material with a refraction index greater than about 1.8. In other embodiments, given a specific material, and for a fixed inner core diameter, selecting a specific shell thickness allows for shifting the peak resonance, and thus peak absorption, across the spectrum.
[0008] Sunscreens, UV blockers, filters, ink, paints, lotions, gels, films, textiles, wound dressings and other solids, which have desired ultraviolet radiation-absorbing properties, may be manufactured utilizing the aforementioned material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0010] FIG. 1 is a plot of the real parts of the dielectric constants of TiN, HfN, and ZrN as functions of wavelength.
[0011] FIG. 2 is a 3-dimensional plot that shows absorption cross-section of ZrN spheres as a function of both radius and wavelength.
[0012] FIG. 3 is a 3-dimensional plot that shows the absorption of a specified amount of TiN spheres as a function of both radius and wavelength.
[0013] FIG. 4 is a plot of absorption cross-section of TiN spheres in three different media with different refraction indices.
[0014] FIG. 5 is a plot of absorption (solid) and extinction (dash) cross-sections of spheres with titanium nitride cores and silver shells.
[0015] FIG. 6 is a plot of absorption (solid) and extinction (dash) cross-sections of spheres with ZrN cores and silver shells.
[0016] FIG. 7 is a plot of absorption (solid) and extinction (dash) cross-sections of spheres with ZrN cores and aluminum shells.
[0017] FIG. 8 is a plot of absorption (solid) and extinction (dash) cross-sections of spheres with aluminum cores and TiO 2 shells in the UV range.
[0018] FIG. 9 is a plot of light transmission as a function of wavelength through a coating containing spheres with Al cores and TiO 2 shells of variable thickness at the indicated load factor.
[0019] FIG. 10 is a plot of light transmission as a function of wavelength through a coating containing spheres with Al cores and TiO 2 shells of the indicated thickness for a range of load factors.
[0020] FIG. 11 is a plot of light transmission as a function of wavelength through a coating containing spheres with Al cores and Si shells of variable thickness at the indicated load factor.
[0021] FIG. 12 is a plot of absorption (solid) and extinction (dash) cross-sections of spheres with Al cores and aluminum oxide shells of variable thickness.
[0022] FIG. 13 is a plot of absorption (solid) and extinction (dash) cross-sections of spheres with Al cores and silver shells of variable thickness.
[0023] FIG. 14 is a schematic representation of the manufacturing process that can be used to produce the particles of the present invention.
[0024] FIG. 15 shows a detailed schematic diagram of the nanoparticles production system.
[0025] FIG. 16 depicts the steps of particle formation.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Prior to discussing the details of the preferred embodiments of the present invention, certain terms used herein are defined as follows:
[0027] An electrical conductor is a substance through which electrical current flows with small resistance. The electrons and other free charge carriers in a solid (e.g., a crystal) can to possess only certain allowed values of energy. These values form levels of energetic spectrum of a charge carrier. In a crystal, these levels form groups, known as bands. The electrons and other free charge carriers have energies, or occupy the energy levels, in several bands. When voltage is applied to a solid, charge carriers tend to accelerate and thus acquire higher energy. However, to actually increase its energy, a charge carrier, such as electron, must have a higher energy level available to it. In electrical conductors, such as metals, the uppermost band is only partially filled with electrons. This allows the electrons to acquire higher energy values by occupying higher levels of the uppermost band and, therefore, to move freely. Pure semiconductors have their uppermost band filled. Semiconductors become conductors through impurities, which remove some electrons from the full uppermost band or contribute some electrons to the first empty band. Examples of metals are silver, aluminum, and magnesium. Examples of semiconductors are Si, Ge, InSb, and GaAs.
[0028] A semiconductor is a substance in which an empty band is separated from a filled band by an energetic distance, known as a band gap. For comparison, in metals there is no band gap above occupied band. In a typical semiconductor the band gap does not exceed about 3.5 eV. In semiconductors the electrical conductivity can be controlled by orders of magnitude by adding very small amounts of impurities known as dopants. The choice of dopants controls the type of free charge carriers. The electrons of some dopants may be able to acquire thermal energy and transfer to an otherwise empty “conduction band” by using the levels of the uppermost band. Other dopants provide the necessary unoccupied energy levels, thus allowing the electrons of an otherwise full band to leave the band and reside in the so-called acceptor dopant. In such semiconductors, the free charge carriers are positively charged “holes” rather than negatively charged electrons. Semiconductor properties are displayed by the elements of Group IV as well as compounds that include elements of Groups III and V or II and VI. Examples are Si, AlP, and InSb.
[0029] A dielectric material is a substance that is a poor conductor of electricity and, therefore may serve as an electrical insulator. In a dielectric, the conduction band is completely empty and the band gap is large so that electrons cannot acquire higher energy levels. Therefore, there are few, if any, free charge carriers. In a typical dielectric, the conducting band is separated from the valence band by a gap of greater than about 4 eV. Examples include porcelain (ceramic), mica, glass, plastics, and the oxides of various metals, such as TiO 2 . An important property of dielectrics is a sometimes relatively high value of dielectric constant.
[0030] A dielectric constant is the property of a material that determines the relative its electrical polarizability and also affects the velocity of light in that material. The wave propagation speed is roughly inversely proportional to the square root of the dielectric constant. A low dielectric constant will result in a high propagation speed and a high dielectric constant will result in a much slower propagation speed. (In some respects the dielectric constant is analogous to the viscosity of the water.) In general, the dielectric constant is a complex number, with the real part giving reflective surface properties, and the imaginary part giving the radio frequency absorption coefficient, a value that determines the depth of penetration of an electromagnetic wave into media.
[0031] Refraction is the bending of the normal to the wavefront of a propagating wave upon passing from one medium to another where the propagation velocity is different. Refraction is the reason that prisms separate white light into its constituent colors. This occurs because different colors (i.e., frequencies or wavelengths) of light travel at different speeds in the prism, resulting in a different amount of deflection of the wavefront for different colors. The amount of refraction can be characterized by a quantity known as the index of refraction. The index of refraction is directly proportional to the square root of the dielectric constant.
[0032] Total internal reflection. At an interface between two transparent media of different refractive index (glass and water), light coming from the side of higher refractive index is partly reflected and partly refracted. Above a certain critical angle of incidence, no light is refracted across the interface, and total internal reflection is observed.
[0033] Plasmon (Froehlich) Resonance. As used herein, plasmon (Froehlich) resonance is a phenomenon which occurs when light is incident on a surface of a conducting materials, such as the particles of the present invention. When resonance conditions are satisfied, the light intensity inside a particle is much greater than outside. Since electrical conductors, such as metals or metal nitrides, strongly absorb electromagnetic radiation, light waves at or near certain wavelengths are resonantly absorbed. This phenomenon is called plasmon resonance, because the absorption is due to the resonance energy transfer between electromagnetic waves and the plurality of free charge carriers, known as plasmon. The resonance conditions are influenced by the composition of a conducting material.
[0000] Introductory Information on Froehlich (Plasmon) Resonance.
[0034] The property which is of importance here is the fact that in many conductors, the real part of the dielectric constant is negative for ultraviolet and optical frequencies. The origin of this effect is known: free conduction electrons in a high frequency electric field exhibit an oscillatory motion. For unbound electrons, this electron motion is 180 degrees out of phase with the electric field. This phenomenon is well known in many resonators, even simple mechanical ones. A mechanical example is provided by the motion of a tennis ball attached by a weak rubber band to a hand moving rapidly back and forth. When the hand is in its maximum positive excursion on an imagined x-axis, the tennis ball would be at its maximum negative excursion on the same axis, and vise versa.
[0035] The weakly bound or unbound electrons in a high frequency electric field act basically in the same way. Electronic polarization, i.e. a measure of the responsiveness of electrons to external field, is therefore negative. Since in elementary electrostatics it is known that the polarization is proportional to ε−1, where ε is a so-called “dielectric constant” (actually, a function of wavelength, or frequency, of an external field), it follows that ε has to be smaller than one—it may in fact even be negative.
[0036] As mentioned above, the dielectric constant is a complex number, proportional to the index of refraction. In tables of optical constants of metals one finds usually tabulated the real and imaginary parts of the index of refraction, N and K, as a function of wavelength. The dielectric constant is the square of the index of refraction, or
ε real +jε imag =( N+jK )= N 2 −K 2 +2 jNK
or
ε real =N 2 −K 2
ε imag =2 NK
and thus it may be seen that ε real is negative when K is larger than N. A look at the above-alluded tables of optical constants reveals that indeed this condition is frequently satisfied.
[0037] It is also possible to estimate electrical field inside a small dielectric sphere using an electrostatic approximation. Consider a case where the wavelength of the incident electromagnetic wave is much larger than the sphere radius. In this case, the sphere is surrounded by an electric field, which is approximately constant over the dimensions of the sphere. From elementary electrostatics we obtain the magnitude of the field inside of the sphere:
E inside = E outside 3 ɛ outside 2 ɛ outside + ɛ inside
where E outside is the surrounding field, E inside is the field inside the sphere and ε inside and ε outside are the relative dielectric constants inside the sphere and in the surrounding medium, respectively. From the above equation it is apparent that the field inside the sphere would become infinitely large if the condition
2ε outside +ε inside =0
would be satisfied. Since the dielectric constants are not real, the field would become large but not infinite.
[0038] In case of an oscillating electric field that is a part of the light wave, that large field would of course also result in a correspondingly large absorption by the metal. This field enhancement is the cause of strong absorption peaks produced in metals nanospheres. Taking into account the complex dielectric constant, one can calculate the approximate absorption cross-section, provided that the imaginary part of the dielectric constant is small. Leaving out a few steps, one finds for for the cross-section Q abs :
Q abs = 12 × ɛ medium ɛ imag ( ɛ real + 2 ɛ medium ) 2 + ɛ imag 2
In the above equation ε medium is the dielectric constant of the medium, ε real and ε imag are the real and imaginary parts of the dielectric constant of the metal sphere. The quantity x is given by
x= 2 πrN medium /λ
where r is the sphere radius and λ is the wavelength. Again when that part of the denominator that is in brackets becomes zero, a maximum absorption is expected. For large values of absorption with a distinct and clearly delineated absorption region ε imag should stay small. It can be seen that the maximum absorption wavelength shifts when the dielectric constant of the medium is changed. This is one of the ways of fine-tuning the absorption range for a given conductor.
[0039] Since, for different materials, ε real are different functions, the resonant absorption due to plasmon effect occurs at different wavelengths, as shown in FIG. 1 . FIG. 1 shows the real dielectric constant of three metallic Nitrides exhibiting a Froehlich Resonance. The Froehlich resonance frequency is determined by the position where the epsilon (real) curves intersect the line marked “−2 epsilon (medium)”.
[0000] The Shape and the Size of a Particle
[0040] The shape of the particle is important. The field inside an oblate particle, such as a disk, in relation to the field outside of that particle is very different from the field inside spherically shaped particle. If the disk lies perpendicular to the direction of the field lines then
E inside = ɛ outside ɛ inside E outside
Here the resonance with the large absorption would occur at such a wavelength, where ε inside =0. If the disk were thin and aligned with the field, then E inside =E outside and no singularity and thus no resonance would occur at all. In general, the shape of the particle is preferably substantially spherical in order to prevent anisotropic absorption effects.
[0041] There is a small shift in wavelength of the absorption that comes from particle size. As the particle becomes larger the above simple assumptions break down. Without proof, increase in particle size shifts the absorption peak slightly towards the red, i.e. longer wavelengths. Larger particles also become less effective as absorbers because the material occupying the innermost portion of the sphere never sees the electromagnetic radiation that they might absorb because the outer layers have already absorbed the incident resonance radiation. For larger spheres the resonance character gradually vanishes. The absorption and extinction cross sections start to be less pronounced as the size of the sphere grows. Absorption and especially extinction shifts also more to the longer wavelengths.
[0042] For further illustration of the behavior of the absorption cross-sections see the three-dimensional plot in FIG. 2 , which shows a 3-dimensional plot of absorption cross-section of ZrN plotted against radius and wavelength. To actually determine optimal particle sizes, it is best to plot transmission, absorption and extinction. While the absorption cross-section decreases for small particles, there are many more small particles present per unit weight than big particles. Interestingly, it appears that small particles of a given total mass absorb just about as well as somewhat larger particles with the same total mass. Most importantly small particles do not scatter. These points are illustrated for TiN with FIG. 3 showing the absorption coefficient of 1 g of TiN spheres suspended in 1 cm 3 of solution with an index of N=1.33. Small particles give the best absorption, and below a critical radius of about 0.025 micrometer it does not matter how small the particles are.
[0000] The Effect of the Media
[0043] There is also an absorption shift that depends upon the dielectric constant of the medium carrying the particles of the present invention. The Drude theory gives an approximate value for the real part of the dielectric constant that varies as
ɛ real = 1 - v plasma 2 v 2
where v plasma is the so-called plasma frequency and v is the frequency of the light wave. The plasma frequency usually lies somewhere in the ultra violet portion of the spectrum. Gold spheres have an absorption peak near 5200 A. TiN, ZrN and HfN, which look golden colored, have a peaks at shorter and longer wavelengths as we shall show below. TiN colloids have been seen to exhibit blue colors due to green and red absorption.
[0044] The above described behavior of the dielectric constants allows us to estimate how much the absorption peak shifts when the dielectric constant of the medium is changed. Using a simple Taylor series expansion of the above expressions up to the first order, we obtain:
Δ λ = λ 0 Δɛ medium 3
If the absorption maximum occurs at 6000 A, and we increase the dielectric constant of the medium by 0.25, then the absorption peak shifts up by 500 A to 6500 A. If we decrease the dielectric constant then the absorption shifts to shorter wavelengths. This point is illustrated in FIG. 4 , which shows absorption cross-section for TiN spheres with a radius of 50 nm in media with three different indices of refraction: 1, 1.33, and 1.6.
PREFERRED EMBODIMENTS OF THE INVENTION
[0045] The present invention relates to composite materials capable of selective absorption of electromagnetic radiation within a chosen, predetermined portion of the electromagnetic spectrum while remaining substantially transparent outside this region. More specifically, in the preferred embodiment, the instant invention provides small particles, said particles having an inner core and an outer shell, wherein the shell encapsulates the core, and wherein either the core or the shell comprises a conductive material. The conductive material preferably has a negative real part of the dielectric constant of the right magnitude in a predetermined spectral band. Furthermore, either (i) the core comprises a first conductive material and the shell comprises a second conductive material different from the first conductive material, or (ii) either the core or the shell comprises a refracting material with a large refraction index approximately greater than about 1.8.
[0046] For example, in one embodiment, the particle of the instant invention comprises a core, made of a conducting material, and a shell, comprising a high-refractive index material. In another embodiment, the particle comprises a core of high-refractive index material and a shell of conductive material. In yet another embodiment, the particle of the present invention comprises a core, composed of a first conducting material, and a shell comprising a second conducting material, with the second conductive material being different from the first conducting material.
[0047] In one preferred embodiment, the particle exhibits an absorption cross-section greater than unity in a predetermined spectral band. In another embodiment the particle is spherical or substantially spherical, having a diameter from about 1 nm to about 150 nm. The preferred shell thickness is from about 1 nm to about 20 nm.
[0048] Any material having a refractive index greater than about 1.8 and any material possessing a negative real part of the dielectric constant in a desirable spectral band may be used to practice the present invention. In the preferred embodiment these materials comprise Ag, Al, Mg, Cu, Ni, Cr, TiN, ZrN, HfN, Si, TiO 2 , ZrO 2 , Al 2 O 3 and others.
[0049] The shift of the resonance absorption across a predetermined spectral band is achieved, in one embodiment, by varying the thickness of the shell, and in another embodiment, by varying the materials of the shell and/or the core. In yet another embodiment, both may be varied.
[0050] If two conducting materials are used, one in the core and the other in the shell, the particle will usually have resonance absorption at a wavelength that is between the peaks of each of the conducting materials. This makes it possible, by selecting the materials of the core and of the shell and/or by adjusting the ratio of the thickness of the shell to the diameter of the core, to shift the peak of absorption in either direction across both visible and UV bands. For example, while TiN has its resonance peak in the visible range, silver exhibits resonance absorption near the edge of the UV band. As illustrated in FIG. 5 , which shows absorption (solid line) and extinction (dashed line) cross-sections for 20 nm-radius TiN spheres coated with either 1 m or 2 nm thick shell of silver, adjusting the thickness of the silver shell shifts the peak toward the shorter wavelengths.
[0051] In the figures described below, the solid lines represent absorption and the dashed lines represent extinction.
[0052] FIG. 6 shows that the resonant absorption peak of a ZrN core, radius 22 nm, coated with a silver shell, can be shifted depending on the thickness of the shell. The shift is toward the shorter wavelengths. Shells are 0 nm, 1 nm, and 2 nm thick.
[0053] FIG. 7 shows that the resonant absorption peak of a ZrN core, radius 22 nm, coated with an aluminum shell, can be shifted depending on the thickness of the shell. The shift is toward the shorter wavelengths. Shells are 0 nm, 1 nm, and 2 nm thick.
[0054] In one embodiment, the core comprises a conducting material and the shell comprises a high refractive index material. This embodiment is illustrated in FIG. 8 , which shows absorption (solid line) and extinction (dashed line) cross-sections for aluminum cores, radius 18 nm, coated with a shell of TiO 2 of 2 nm, 4 nm, and 5 nm. As can be seen, the absorption peak may be shifted across the UV spectral band without excessive absorption in the visible range.
[0055] In another embodiment, the particles are dispersed in a carrier at a desired mass loading factor. As illustrated in FIG. 9 , the particles, comprising aluminum cores, radius 18 nm, coated with shells of titanium oxide of variable thickness (2 nm, 3 nm, 4 nm, or 5 nm), dispersed in a carrier at a mass loading factor of about 5×10 −6 g/cm 2 , substantially block the transmission of radiation in the ultraviolet range, while remaining transparent in the visible range.
[0056] The present invention contemplates a range of mass loading factors that the particles can be dispersed at. FIG. 10 illustrates that the preparation of a carrier and particles of aluminum cores and titanium oxide shells (core radius 18 nm, shell thickness 4 nm) remain absorbent in the UV range at loading factors that vary from 2.0×10 −5 g/cm 2 to 2.5×10 −6 g/cm 2 .
[0057] In yet another embodiment, illustrated in FIG. 11 , particles of aluminum core, radius 18 nm, coated with a silicon shell of variable thickness (1 nm, 2 nm, 3 nm, or 4 nm) are dispersed in a carrier at the mass loading factor of about 2.5×10 −6 g/cm 2 . Such preparation is substantially absorbent in the UV range, yet substantially transparent in the visible band.
[0058] For minimizing visible absorption, the thinner coating of 1 nm to 2 nm are preferred. FIG. 12 shows a particularly simple method of tailoring UV absorption by oxidizing Al nanoparticle core.
[0000] Applications
[0059] The present invention can be used in a wide range of applications that include blockers, filters, ink, paints, lotions, gels, films, solid materials, and wound dressings that absorb within the ultraviolet spectral band.
[0060] It should be noted that resonant nature of the radiation absorption by the particles of the present invention can result in (a) absorption cross-section greater than unity and (b) narrow-band frequency response. These properties result in an “optical size” of a particle being greater than its physical size, which allows reducing the loading factor of the colorant. Small size, in turn, helps to reduce undesirable radiation scattering. Low loading factor has an effect on the economy of use. Narrow-band frequency response allows for superior quality filters and selective blockers. The pigments based on the particles of the present invention do not suffer from UV-induced degradation, are light-fast, non-toxic, resistant to chemicals, stable at high temperature, and are non-carcinogenic.
[0061] The particles of the present invention can be used to block radiation in ultraviolet (UV) spectral band, defined herein as the radiation with the wavelengths between about 200 nm and about 400 nm, while substantially transmitting radiation in the visible band (VIS), defined herein as the radiation with the wavelengths between about 400 nm and about 700 nm. As a non-limiting example, particles of the present invention can be dispersed in an otherwise clear carrier such as glass, polyethylene or polypropylene. The resulting radiation-absorbing material will absorb UV radiation while retaining good transparency in the visible region. A container manufactured from such radiation-absorbing material may be used, for example, for storage of UV-sensitive materials, compounds or food products. Alternatively, a film manufactured from a radiation-absorbing material can be used as coating.
[0062] Suitable carriers for the particles of the present invention include, among others, polyethylene, polypropylene, polymethylmethacrylate, polystyrene, polyethylene terephthalate (PET) and copolymers thereof as well as various glasses.
[0063] A film or a gel, comprising ink or paints described above, are contemplated by the present invention.
[0064] The particles of the present invention can be further embedded in beads in order to ensure a minimal distance between the particles. Preferably, beads are embedded individually in transparent spherical plastic or glass beads. Beads, containing individual particles can then be dispersed in a suitable carrier material.
[0065] The particles of the present invention can also be used as highly effective UV filters. Conventional filters often suffer from “soft shoulder” spectral absorption, whereby a rather significant proportion of unwanted frequency bands is absorbed along with the desirable band. The particles of the present invention, by virtue of the resonant absorption, provide a superior mechanism for achieving selective absorption. The color filters can be manufactured by dispersing the particles of the present invention in a suitable carrier, such as glass or plastic, or by coating a desired material with film, comprising the particles of the present invention.
[0066] The present invention can furthermore be utilized to produce lotions that protect human skin against harmful UV radiation. In this case, the particles are uniformly dispersed within a pharmacologically safe viscous carrier medium, numerous examples of which are readily available and well known in the cosmetics and pharmaceutical arts. For example, as noted above, particles with metallic cores and shells satisfactorily block UV radiation in the UVA, UVB and UVC spectral regions while transmitting light of longer, i.e. visible, wavelengths; such particles also exhibit little scatter when small enough, thereby avoiding an objectionable milky appearance. A gel or a lotion can be manufactured, for example, comprising the particles of the present invention.
[0067] The present invention can also be utilized to produce UV radiation-absorbing wound dressing. The particles or a carrier, in which the particles are dispersed, can be incorporated in or deposed as a coating on a textile, textile-like, or a foam matrix, such as gauze, rayon, polyester, polyurethane, polyolefin, cellulose and its derivatives, cotton, orlon, nylon, hydrogel polymeric materials, or any suitable pharmacologically safe material. Such material can be used as a layer in multi-layer wound dressing or as an absorbent layer attached to a self-adherent elastomeric bandage.
[0068] Combining particles of different types within the same carrier material is also contemplated by the instant invention.
[0069] Cores and shells comprising metals and conducting materials, such as Al, Ag, Mg, TiN, HfN, and ZrN, as well as high-refracting index materials can be used to produce particles absorbing in UV band. Radiation-absorbing properties of the particles can be adjusted by independently selecting the material, radius and thickness of the core and the shell.
[0070] Although particles suitable for use in the applications described above can be produced through any number of commercial processes, we have devised a manufacturing method for vapor-phase generation. This method is described in U.S. Pat. No. 5,879,518 and U.S. Provisional Application 60/427,088.
[0071] This method, schematically illustrated in FIG. 14 , uses a vacuum chamber with heated wall cladding in which materials used to manufacture cores are vaporized as spheres and encapsulated before being frozen cryogenically into a block of ice, where are collected later. The control means for arriving at monodispersed (uniformly sized) particles of precise stoichiometry and exact encapsulation thickness relate to laminar radially expanding flow directions, temperatures, gas velocities, pressures, expansion rates from the source, and percent composition of gas mixtures.
[0072] Referring to FIG. 15 , in a preferred embodiment, a supply of titanium may be used, as an example. Titanium or other metallic material is evaporated at its face by incident CO 2 laser beam to produce metal vapor droplets. The formation of these droplets can be aided, for narrower size control, by establishing an acoustic surface wave across the molten surface to facilitate the release of the vapor droplets by supplying amplitudinal, incremental mechanical peak energy.
[0073] The supply rod is steadily advanced forward as its surface layer is used up to produce vapor droplets. The latter are swept away by the incoming nitrogen gas (N 2 ) that, at the central evaporation region, becomes ionized via a radio frequency (RF) field (about 2 kV at about 13.6 MHz). The species of atomic nitrogen “N + ” react with the metal vapor droplets and change them into TiN or other metal nitrides such as ZrN or HfN, depending on the material of the supply rod.
[0074] Due to vacuum differential pressure and simultaneous radial gas flow in the conically shaped circular aperture, the particles travel, with minimum collisions, first into a radially expanding conical orifice, and then into an argon upstream to reach several alternating cryogenic pumps which “freeze out” and solidify the gases to form blocks of ice in which the particles are embedded.
[0075] The steps of particle formation are shown in FIG. 16 . Here we begin with metal vapor plus atomic nitrogen gas to form metal nitrides. By imparting onto the particles a temporary electric charge, we can keep them apart, and thus prevent collisions, while beginning to grow a thin shell around the nitride core. As non-limiting examples, silicon or TiO 2 can be used, wherein the thickness of the shell is controlled by the rate of supply of silane gas (SiH 4 ) or a mixture of TiCl 4 and oxygen, respectively.
[0076] In a subsequent passage zone, silane gas or a TiCl 4 /O 2 mixture are condensed on a still hot nanoparticle to form a SiO 2 or TiO 2 spherical enclosure around each individual particle.
[0077] If required, a steric hindrance layer of a surfactant, such as, for example, hexamethyl disiloxane (HMDS), can be deposited on the beads to keep the particles evenly dispersed through a carrier of choice, such as, for example, oil or polymers. Other surfactants can be used in water suspension.
[0078] With this manufacturing method, a variety of encapsulated nanoparticles can be produced in large quantities, generating in one single process step the desired resonant-absorption particles and assure their collectability and their uniform size.
[0079] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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Composite materials that can be used to block ultraviolet radiation of a selected wavelength range are disclosed. The materials include dispersions of particles that exhibit optical resonance behavior, resulting in absorption cross-sections that substantially exceed the particles' geometric cross-sections. The particles are preferably manufactured as uniform nanosize encapsulated spheres, and dispersed evenly within a carrier material. Either the inner core or the outer shell of the particles comprises a conducting material exhibiting plasmon (Froehlich) resonance in a desired spectral band. The large absorption cross-sections ensure that a relatively small volume of particles will render the composite material fully opaque (or nearly so) to incident radiation of the resonance wavelength, blocking harmful radiation. The materials of the present invention can be used in manufacturing sunscreens, UV filters and blockers, ink, paints, lotions, gels, films, textiles, wound dressing and other solids having desired ultraviolet radiation-absorbing properties. The materials of the present invention can be used in systems consisting of reflecting substances such as paper or transparent support such as plastic or glass films. The particles can be further embedded in transparent plastic or glass beads to ensure a minimal distance between the particles.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application which claims priority to U.S. Non-provisional application Ser. No. 11/869,455 filed on Oct. 9, 2007.
FIELD OF INVENTION
[0002] The present invention relates to the field of bicycle safety equipment, and in particular to an apparatus for illuminating a bicycle crank and/or pedal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 shows a side view of tubular housing and tube for illuminating a bicycle crank.
[0004] FIG. 2 shows a side view of an exemplary embodiment of an apparatus for illuminating a bicycle crank and pedal.
[0005] FIG. 3 shows a side view of an exemplary embodiment of an apparatus for illuminating a bicycle crank.
[0006] FIG. 4 shows a side view of one embodiment of a tubular housing.
[0007] FIG. 5 shows a sectional view of one embodiment of a tubular housing.
[0008] FIG. 6 shows an alternate embodiment of an apparatus for illuminating a bicycle crank.
[0009] FIG. 7 shows a side view of a magnet-mounted apparatus for illuminating a bicycle crank.
[0010] FIG. 8 shows an alternate embodiment of an apparatus for illuminating a bicycle crank.
[0011] FIG. 9 shows an alternate embodiment of an apparatus for illuminating a bicycle crank which contains multiple LED components.
GLOSSARY
[0012] As used herein, the term “light-emitting diode” or “LED” means an electronic light source.
[0013] As used herein, the term “bumper component” means any object or construction that slows down, accelerates or stops an object from maintaining its position within the tubular housing. Examples of bumper components include flexible tubes, levers, springs (including star springs with a memory, sponges and geo springs), fluid pressure, pressure-sensitive devices, electronic devices adapted to receive pressure input, one or more magnets, and combinations thereof.
[0014] As used herein, the term “magnet” or “magnetic component” means any material or object that produces a magnetic field, either natural or induced. Examples include, but are not limited to anisotropic sintered ceramic containing neodymium and boron (NdB) or neodymium, iron and boron (NdFeB), a samarium-cobalt (SmCo) magnet, an aluminum nickel cobalt alloy (AlNiCo) magnet, a ceramic magnet, flexible magnets, magnet assemblies, or any other magnet capable of generating a magnetic field.
[0015] As used herein, the term “bicycle crank” means an arm component of a bicycle which changes reciprocating motion into rotational motion used to drive the chain of the bicycle which in turn drives the rear wheel. The bicycle crank is connected to the bicycle pedal and can vary in length to accommodate different sized riders. A bicycle crank may be constructed of an aluminum alloy, titanium, carbon fiber, steel or any other suitable material.
[0016] As used herein, the term “crank pedal” means a pedal which operates a crank only.
[0017] As used herein, the term “crank” is a component of a bicycle wheel which turns a gear to drive a rear wheel, and which is generally made of non-magnetic material or which is shielded to counter magnetic effect.
[0018] As used herein, the term “gear drive pedal” means a pedal on a bicycle which operates the rear wheel of a bicycle by exerting pressure on the crank, spider and gears of the bicycle.
[0019] As used herein, the term “spider” means a component of a bicycle wheel which is an integrally molded or a separate component that connects a bicycle chain to the rear wheel axle of a bicycle.
BACKGROUND
[0020] Bicyclists are often required to train or commute in the dark. Because bicycles are less visible than cars, this presents a hazard. Risk of being hit by a motor vehicle or another rider is a problem known in the art.
[0021] In addition to the reflectors on their bicycles, bicyclists often wear reflective clothing or add reflective tape to their bicycles and/or helmets. Reflectors, reflective clothing and reflective tape; however, are only visible when a car's headlights or another light source is shining on the reflective material. By the time a driver notices a bicyclist, it may be too late for the driver to avoid a collision.
[0022] There are battery-operated pedals and headlights on the market. However, batteries must continually be charged or changed and the device must be turned on or off to conserve battery power. Battery-powered devices thus are not reliable. Other devices which generate light in an alternative manner are generally not bright and may provide intermittent illumination.
[0023] There are many types of safety lighting devices known in the art and commonly used by bicyclists, and in particular, devices incorporated into bicycle pedals.
[0024] One example of a safety lighting device for bicycles known in the prior art is taught by U.S. Pat. No. 5,702,172 (Kilburn '172). Kilburn '172 incorporates LED technology and electrical components into bicycle pedals creating rapidly flashing lights on a bicycle pedal without utilizing mechanics. It is desirable to incorporate LED technology into one or more parts of a bicycle without the need for one or more electrical components and/or batteries.
[0025] U.S. Pat. No. 5,902,038 (Curry '038) discloses another example of a lighted bicycle pedal. Curry '038 discloses a lighted bicycle pedal which has a hub and a pair of space-apart threads disposed on either side of the hub. A light source is mounted on the pedal frame and includes a light emitter to flash on and off, and a time-out mechanism. Also included are a gravity activated switch, which activates LEDs when pedals rotate to a given position, and a power supply (e.g., AA batteries). It is desirable to have an apparatus which illuminates a bicycle pedal which begins operating when the bicycle is placed in motion; however, it is further desirable not to require batteries.
[0026] U.S. Pat. No. 6,703,716 (Chiu '716) discloses a light for a bicycle which is not battery powered. Chiu '716 discloses a generator for a bicycle which includes a rotor which abuts the wheel of the bicycle. A coil is mounted in the rotor and electrically connected to two bearings that are mounted on the opposite sides of the rotor by two inner wires. A stator has a shaft extending through the two bearings and a permanent magnet sleeved into the shaft and corresponding to the coil. Two metal rings are respectively sleeved onto opposite ends of the shaft and electrically connected to the bearings. A light is mounted on the bicycle and electrically connected to the metal rings via outer wires. The coil rotates with the rotor relative to the stator when the bicycle is moving generating electricity that is transmitted to the light. It is desirable to have a self-generating mechanism to power an LED which does not require the use of external wires or extensive altering of existing bicycle components to include internal wiring.
[0027] U.S. Pat. No. 6,104,096 (Hicks '096) discloses a generator mounted within the tread portion of a bicycle pedal. Power is generated as two meshing gear wheels of unequal diameters are rotated within a gearbox as the bicycle is pedaled. The small generator is designed to provide a sufficient output voltage to illuminate an array of LEDs and charge a capacitor which will keep the LEDs illuminated while the pedals are temporarily stationary. It is desirable to have an apparatus which illuminates a bicycle pedal which has few mechanical components and adds minimal bulk/weight to the bicycle pedal. It if further desirable to have an apparatus that illuminates a bicycle pedal which does not require the purchase of pedals, but rather can be fitted to existing pedals.
[0028] U.S. Pat. No. 6,418,041 (Kitamura '041) discloses circuitry designed to harness AC power generated by an unspecified generator, convert the AC to DC, and then supply that electricity to one or more electrical bicycling accessories. The bicycle power supply circuit taught by Kitamura '041 requires the use of multiple terminals, a full-wave voltage rectifier circuit, a storage device, a voltage regulator, a switch, and a switch control circuit. It is desirable to have an apparatus that illuminates a bicycle pedal which is capable of utilizing the energy in the form which it is generated.
SUMMARY OF THE INVENTION
[0029] The present invention is an apparatus and method for illuminating a bicyclist from the front and the rear which continuously generates power from the motion of the pedal. Various embodiments of the invention may be mounted on or within the bicycle crank, on the bicycle spokes, gears and spiders or any other component of a bicycle wheel. Excess power from the system and method described herein may be used to power auxiliary devices located on another component of the bicycle.
[0030] A magnetic coil is coiled around a portion of a tubular structure which houses a magnetic component. The magnetic component moves slidably inside the tubular structure passing through the magnetic coil. The tubular structure is housed in an outer housing which encases a bicycle crank or fits within a specially designed bicycle crank. When the bicycle crank rotates, the magnet slides back and forth through the magnetic coil generating an electric current which is used to power an LED.
DETAILED DESCRIPTION OF INVENTION
[0031] For the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of a lighted bicycle pedal, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent components, materials, and mechanisms may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
[0032] It should be understood that the drawings are not necessarily to scale; instead emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements.
[0033] Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related.
[0034] FIG. 1 shows a side view of outer tubular housing 10 of apparatus for illuminating a bicycle crank 100 . Outer tubular housing 10 encases inner tubular structure 20 . In the embodiment shown, outer tubular housing 10 is square and inner tubular structure 20 is round. In other embodiments, inner tubular structure 20 is of any shape which can accommodate the components of apparatus for illuminating a bicycle crank 100 (e.g., square, rectangular). Outer tubular housing 10 may be of any shape which accommodates inner tubular structure 20 and which can be attached to or fit within bicycle crank 60 .
[0035] In various embodiments, apparatus for illuminating a bicycle crank 100 may include capacitor 27 located within tubular housing and capacitor wires 28 and 29 which are connected to circuit board 40 . Capacitor 27 may be any capacitor known in the art which can more efficiently store power and maintain illumination when a rider is gliding (not pedaling) or not moving. In various embodiments of the invention, circuit board 40 may include on-off switches and otherwise direct power to the capacitor 27 and LED 45 , and may connect charging wires to any other component(s) of an apparatus for illuminating a bicycle crank 100 .
[0036] Visible in outer tubular housing 10 is inner tubular structure 20 . Both outer tubular housing 10 and inner tubular structure 20 are made of non-magnetic material such as plastic, aluminum, carbon composites and wood.
[0037] Located inside inner tubular structure 20 are magnet 30 , and bumper component 35 . Coil 25 is wrapped around a segment of inner tubular structure 20 . In other embodiments, coil 25 may be located inside inner tubular structure 20 or may surround another component. In the embodiment shown, coil 25 is copper coil and magnet 30 is comprised of neodymium and is of a shape similar to that of inner tubular structure 20 . In other embodiments, coil 25 may be another material which is capable of generating an electrical current. In the embodiment shown, bumper component 35 is comprised of rubber. In other embodiments, bumper component 35 is an opposing magnetic or any other material capable of slowing down and/or stopping magnet 30 so that it can fall in the opposite direction as bicycle crank 60 rotates. In the embodiment shown, the crank pedal and gear pedal may be positioned in various manners to allow illumination of a bicycle rider from the front, back or side.
[0038] Outer tubular housing 10 further includes circuit board 40 . Connected to circuit board 40 is LED 45 . In the embodiment shown, surrounding LED 45 is reflector 50 which reflects the light from LED 45 allowing for greater visibility. In other embodiments, more or fewer reflectors and/or magnifiers are used and may be of another shape or located in another position. In other embodiments, apparatus for illuminating a bicycle crank 100 further includes one or more capacitors and/or a switch to power LED on/off.
[0039] FIG. 2 shows an exemplary embodiment of an apparatus for illuminating bicycle crank 100 and pedal 70 . In the embodiment shown, outer tubular housing 10 fits inside mounting orifice 65 of bicycle crank 60 . Pedal 70 is attached to bicycle crank 60 . When a bicyclist pedals, bicycle crank 60 rotates. The rotation causes magnet 30 to travel through coil 25 , i.e., when the end of outer tubular housing 10 having LED 45 is facing downward, magnet 30 falls along the length of inner tubular structure 20 toward circuit board 40 . As magnet 30 falls toward circuit board 40 , it passes through coil 25 . Magnet 30 continues to move inside inner tubular structure 20 passing through coil 25 as bicycle crank 60 rotates, i.e., when the end of outer tubular housing 10 having LED 45 is facing upward, magnet 30 falls along the length of the inner tubular structure 20 toward bumper component 35 . As magnet 30 passes through coil 25 , electricity is generated. The resulting electrical current passes through circuit board 40 where is used to power LED 45 .
[0040] In the embodiment shown, LED 45 and reflector 50 extend past the surface of bicycle crank 60 which allows LED 45 to be visible. In other embodiments, outer tubular housing 10 does not have LED 45 and the electric current generated by the passing of magnet 30 through coil 25 is used to power an LED in another location (e.g., on the pedal).
[0041] In the embodiment shown, coil 25 is a copper coil, magnet 30 is comprised of neodymium, and bumper component 35 is comprised of rubber.
[0042] In the embodiment shown, bicycle crank 60 is comprised of carbon fiber with a fiberglass interior so that outer tubular housing 10 is separated from the carbon fiber by a layer of fiberglass. In other embodiments, bicycle crank 60 is made of another material or combination of materials which are strong enough to withstand pedaling and crashing and that will not corrode inner tubular structure 20 or an aluminum bicycle crank.
[0043] Also visible in FIG. 2 is second LED 75 and reflector 80 located on the end of pedal 70 . Power wire 85 extends through bicycle crank 60 (power wire not visible) and though the shaft of pedal 70 connecting circuit board 40 to second LED 75 . In other embodiments, one or more LEDs are located in a position other than on outer tubular housing 10 or pedal 70 . In the embodiment shown, LED 75 is rounded and protrudes from the surface of the bicycle crank, but may be of alternate shapes and sizes in other embodiments. Other embodiments may include multiple LED components. For example, one embodiment includes a “rope light” known in the art which supports multiple LED components.
[0044] FIG. 3 shows an exemplary embodiment of an apparatus for illuminating bicycle crank 50 . In the embodiment shown, outer tubular housing 10 is attached to bicycle crank 50 . Outer tubular housing 10 is secured to bicycle crank 50 by clamps 15 a , 15 b , 15 c , 15 d . In other embodiments, outer tubular housing 10 is secured to bicycle crank 50 by a means other than clamps, such as magnets, snaps or any other structural configuration.
[0045] In other embodiments, apparatus for illuminating a bicycle crank 100 is attached to a location other than the bicycle crank, such as the gear, a wheel spoke(s), a pedal, the spider and/or any other location on the bicycle. In addition to LED 45 , apparatus for illuminating a bicycle crank 100 may be used to power an LED in addition to LED 45 when placed on the gear, a wheel spoke(s), a pedal, the spider or any other location. For example, apparatus for illuminating a bicycle crank 100 may be secured to a wheel spoke and power one or more LEDs located on bicycle pedal 70 .
[0046] FIG. 4 shows a side view of one embodiment of outer tubular housing 10 . In the embodiment shown, outer tubular housing 10 is comprised of carbon-fiber. In other embodiments, tubular housing is comprised of aluminum, plastic resin, epoxy, fiberglass, or any material capable of withstanding crashing.
[0047] FIG. 5 illustrates a sectional view of one embodiment of inner tubular structure 20 encased in outer tubular housing 10 . In the embodiment shown, inner tubular structure 20 is comprised of aluminum and outer tubular housing 10 is comprised of carbon fiber. In between inner tubular structure 20 and outer tubular housing 10 is barrier material 18 . In the embodiment shown, barrier material 18 is fiberglass. In other embodiments, barrier material 18 is plastic, resin, epoxy or any other material which prevents the corrosion of inner tubular structure 20 .
[0048] In other embodiments, bicycle crank 50 (not shown) is comprised of aluminum, outer tubular housing 10 is comprised of carbon fiber and inner tubular structure 20 is comprised of plastic. In such embodiments, a layer of fiberglass would be placed in between bicycle crank 50 and outer tubular structure 10 to prevent corrosion of the aluminum bicycle crank.
[0049] FIG. 6 illustrates an alternate embodiment of apparatus for illuminating a bicycle crank 100 which attaches to sprocket 75 of a bicycle and which can be selectively removed and attached to sprocket 75 . In the embodiment shown, apparatus for illuminating a bicycle crank 100 is attached to sprocket 75 using magnets 87 , 88 or any other magnets known in the art. In the embodiment shown, magnets 87 , 88 are neodymium magnets. In alternative embodiments, alternative but functionally equivalent attachment means, such as bolts or interlocking and complementary structures may be used to secure apparatus for illuminating a bicycle crank 100 to a bicycle.
[0050] In the embodiment shown, two magnets are used, but in other embodiments, more or fewer magnets, bolts or interlocking structures may be used. In still other embodiments, apparatus for illuminating a bicycle crank 100 and magnets 87 , 88 may be enclosed by a housing or cover (not shown). In the embodiment shown in FIG. 6 , LED 45 illuminates a rider from both the front and the rear.
[0051] FIG. 7 illustrates a side view of a magnet-mounted apparatus for illuminating a bicycle crank 100 , which requires sufficient space between sprocket 75 and magnets 87 , 88 to prevent external mounting magnets 87 , 88 from being attracted to internal magnet 30 .
[0052] FIG. 8 illustrates an alternate embodiment of apparatus for illuminating a bicycle crank 100 . In the embodiment shown, LED 45 flashes in one direction.
[0053] FIG. 9 illustrates an alternate embodiment of apparatus for illuminating a bicycle crank 100 . In the embodiment shown, apparatus for illuminating a bicycle crank 100 includes multiple LEDs 48 a , 48 b , 48 c , 48 d , 48 e , 48 f configured in a “rope light” arrangement. LEDs 48 a , 48 b , 48 c , 48 d , 48 e , 48 f are attached to a flexible, plastic tube. In other embodiments, LEDs 48 a , 48 b , 48 c , 48 d , 48 e , 48 f may be configured in another arrangement and/or mounted using an alternate means of attachment.
[0054] In an exemplary embodiment, apparatus for illuminating a bicycle crank 100 is attached to a spoke of the bicycle wheel using plastic or metals clips or any other means of attachment known in the art. Apparatus for illuminating a bicycle crank 100 may be attached to a spoke on the front or rear wheel of a bicycle and a wheel may contain multiple apparatuses for illuminating a bicycle crank 100 . As the wheel turns, magnet 30 passes through coil 25 (not shown) generating an electrical current. Also visible in FIG. 9 are bumper components 35 and circuit board 40 .
[0055] Also included in the embodiment shown, is an opposing magnet (not shown) which is attached to the fork of the bicycle or other comparable location. The opposing magnet ensures that magnet 30 continues to pass through coil 25 (not shown) as the wheel rotates.
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The present invention is an apparatus and method for illuminating a bicycle crank. A magnetic coil is coiled around a portion of a tubular structure which houses a magnetic component. The magnetic component moves slidably inside the tubular structure passing through the magnetic coil. The tubular structure is housed in an outer housing which encases a bicycle crank or fits within a specially designed bicycle crank. When the bicycle crank rotates, the magnet slides back and forth through the magnetic coil generating an electric current that is used to power an LED.
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BACKGROUND OF THE INVENTION
This invention relates to orthopedic cerclage devices for use in stabilizing fractured bones. Cerclage devices, in the form of plastic or metal straps, bracing devices, wires or bands have been proposed and used to secure together and stabilize the segments of a fractured bone. The cerclage technique has advantages over more conventional techniques for stabilizing fractured bones such as skeletal traction. Skeletal traction typically requires the patient to remain in bed for a long time, often in excess of three to four months. Such prolonged period of immobilization is undesirable and can be particularly hazardous for elderly patients. Thus, there has been a need for an effective cerclage device which can avoid, or at least reduce, the requirement for skeletal traction. Although a number of cerclage devices have been proposed in recent years, and while some of them have had a limited degree of use, they have presented a number of difficulties which have detracted from their use.
For example, the earlier cerclage devices, such as the Parham steel band, were little more than wires or metal straps wrapped and secured tightly about the bone segments. In order for the Parham band to grip bone segments sufficiently tightly to stabilize them, the band would tend to be so tight about the bone as to cut off substantial portions of the vascular circulation within the bone. Cutting off circulation in the bone eventually leads to death of the affected parts of the bone and possibly the entire bone. Thus, in most instances where a Parham band or similar constricting wire has been used it was usually necessary to remove the band or wire within a number of weeks after the initial placement. That, of course, subjects the patient to a second operation with its inherent risks and complications.
In an effort to avoid the difficulties caused by the Parham steel band other cerclage devices have been proposed. One such device is described in U.S. Pat. No. 4,119,091. It is in the form of a nylon strap having small projections on its undersurface to hold the strap away from the bone. The object of the nylon device is to reduce the area of contact with the bone so as to reduce the constricting effect on the bone vascularization. That device, however, may not provide sufficient stability for the fractured bone segments. An additional difficulty presented by the prior devices which remained implanted in the patient is that as the bone heals the pressure of the device may inhibit the quality and size of the callus which forms around the region of the fracture and could affect the strength of the bone when it is healed.
Another desirable characteristic of a cerclage device is that it should be easily manipulated, placed and handled by the surgeon. The devices which have been proposed in the prior art typically have been formed from a stiff material such as metal or plastic and have had less than ideal handling characteristics.
Thus, a need has existed for an improved cerclage device for securing and stabilizing fractured bone segments. It is among the primary objects of the invention to provide such a cerclage device.
SUMMARY OF THE INVENTION
Our invention includes a cerclage device in the form of an elongate strip adapted to be wrapped tightly and secured about the fragmented bone segments. The strip is formed from a fabric. The strip is provided with a bone engaging surface and has a plurality of transversely extending fabric ribs spaced at intervals along the length of the strip. When the cerclage device is wrapped about the bone segments to be stabilized the major proportion of the constricting force is applied to the bone through the fabric ribs. The band segments between the ribs apply minimal constricting force and do not interfere with the vascularization of the bones.
The fabric is designed so that it will have interstices which enable bone tissue to grow intimately in between and through the fabric as the bone heals. This results in a stronger bone in the healed region, with reduced bulk.
The device includes a fastening clip secured to one end of the strip and which receives the other end of the strip when the strip is wrapped about the bone. The fastening clip may be clipped to lock the strip in the bone encircling configuration.
The cerclage fabric is formed of a special knitted structure, preferably a warp knit fabric. The fabric is a two-needle bar fabric and is of special construction to form the ribs while also providing an extremely strong cerclage device capable of stabilizing fractured bone segments.
In a preferred embodiment of the invention the fabric is formed on a warp knit Raschel two-bar knitting machine. The fabric may be considered as having a front panel and a back panel, formed on the front and back needle bars respectively, with the front and back panels being interconnected by a chain stitch. The front panel is a two guide bar fully threaded panel. The front panel forms the external surface of the cerclage band.
The back panel, which forms the inner ribbed surface of the cerclage device, is made on the back needle bar. The back panel is made up of two groups of yarns. The first group of yarns alternately lay in and cast stitches at predetermined course intervals. The stitches are arranged in groups along a selected course and the group of stitches at that course form a region of bulk which defines a transversely extending rib. The yarns in the second group of yarns in the back panel are laid in walewise except at that course where a rib is formed by a row of stitches. The yarns in the second group are laid in course-wise at that course. The portion of the yarns in the second group which are laid in course-wise are trapped between the underlap and overlap of the stitches formed by the first group of yarns in the back panel and form a more massive underlying support for the stitches in the first group of yarns. Thus, the course wise laid in segments of the yarns in the second group provide support and tend to raise the rib-defining stitches in the first group, thereby defining a more pronounced and reinforced walewise rib.
The front panel and back panel are connected to each other by a chain stitch associated on each needle and on each wale. The chain stitch runs front panel to back panel on every course and on every wale.
It is among the objects of the invention to provide improved orthopedic cerclage device.
Another object of the invention is to provide a cerclage device which does not cut off the bone vascularization yet which provides sufficient strength to stabilize the fractured bone segments.
A further object of the invention is to provide a cerclage device which is porous and which permits bone tissue to grow intimately into the pores of the device upon healing.
Another object of the invention is to provide a cerclage device in which the bone engaging surface of the device is defined by a fabric.
A further object of the invention is to provide a cerclage device the use of which is simplified in comparison to previous cerclage devices.
Another object of the invention is to provide a fabric for use as a cerclage device in which transverse extending longitudinally spaced ribs are formed on the fabric.
Still another object of the invention is to provide a cerclage device which is easy to handle and place by the surgeon.
DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and advantages of the invention will be appreciated more fully from the following further description thereof, with reference to the accompanying drawings wherein:
FIG. 1 is a perspective illustration of a cerclage device in accordance with the invention;
FIG. 2 is a side elevation of the device;
FIG. 2A is a sectional illustration of the attaching clip seen along the line 2A--2A of FIG. 2.
FIG. 3 is an illustration of the device secured about bone segments to stabilize the segments;
FIG. 4 is a sectional illustration as seen along the line 4--4 of FIG. 3;
FIG. 5 is a somewhat diagrammatic illustration, greatly enlarged, the front panel of the fabric of which the cerclage device is formed and including portions of the chain stitch yarn which interconnect the front panel to the back panel of the fabric;
FIG. 6 is an illustration of the back panel of the fabric, greatly enlarged, with the chain stitch yarns omitted for clarity;
FIG. 7 is a side elevation of the needle beds and guide bars in the Raschel knitting machine illustrating the manner in which the chain stitch yarn interconnects the front and back panels of the fabric;
FIG. 8 is a somewhat diagrammatic side view of a portion of the back panel segment as seen along the line 8--8 of FIG. 6;
FIG. 9 is a point pattern diagram for the component yarns of the fabric; and
FIG. 10 is a Raschel threading diagram for use in the manufacture of the illustrative embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2 the device includes an elongate strip of fabric 10. The fabric may be considered as having an internal surface 12 and an external surface 14. The fabric strip preferably is provided with a fastening clip 16 which may be securely sewn to one end of the strip 10. The internal surface 12 of the strip 10 is provided with a plurality of transversely extending ribs indicated generally at 18. The ribs are spaced longitudinally along the length of the strip 10. By way of example, the ribs may be spaced about 0.75 to 1.0 cm. In the embodiment shown the ribs 18 are regularly spaced longitudinally along the strip 10 defining a series of regular intermediate segments 20. In the embodiment shown the ribs 18 extend continuously and regularly along the length of the strip. In other embodiments, however, the ribs 18 may be provided in groups in which the length of the intermediate segments 20 may vary between groups. The strip may be made in various widths, for example 0.5, 1.0 or 1.5 cm.
The height of the ribs 18 in the illustrative embodiment is substantially greater than the height of the intermediate segments 20. The ribs 18 extend substantially the full width of the strip 10.
FIGS. 3 and 4 illustrate the manner in which the device is used to secure the segments of a fractured bone together to stabilize the segments while the fracture heals. After the bone segments, 22, 24 have been positioned properly with respect to each other one or more of the fabric strips 10 is wrapped about the bone, drawn tight and secured by the fastening clip 16. As illustrated more clearly in FIG. 4 the device is applied about the bone with the internal surface facing the bone so that the ribs 18 can bear against the outer surface of the bone. When the device is drawn tight and secured about the bone the ribs 18 supply the primary constricting force to the bone. Because the ribs 18 and strip 10 are formed from fabric, the ribs 18 may compress somewhat so that the internal surface 12 of the intermediate segments 20 may contact the outer surface of the bone. In the event such contact occurs it is relatively light and will not be under a sufficient pressure to have any constricting effect on the vasculature within the periosteum of the bone. The principal constricting force on the bones is applied through the ribs 18.
The fastening clip 16 may be formed from metal, such as an appropriate surgical steel which can be crimped in appropriate tools such as pliers. The clip 16 is in the form of a band having an inside wall 26, an outside wall 28 and a pair of connective sidewalls 30. The band defines an internal opening 32. A pair of transversely extending feet 34 extend from the inside wall 26 and face the external surface 14 of the strip 10. This can be seen from FIG. 4, when the device is in place the feet 34 will extend parallel to the bone, parallel to the ribs 18. The space between the feet 34 serves to reduce the area of pressure contacts which might be applied to the bone as a result of the clip 16. The clip 16 is attached to the strip 10 by a loop 35 formed at the end of the strip 10. The loop 35 is passed through the internal opening 32 in the clip 16 and the end of the loop 35 is attached to the strip 10 as by stitches 37.
As illustrated in FIGS. 3 and 4 the strip is securely wrapped about the bone by passing the free end 39 through the internal opening 32 of the clip 16, drawing the band tightly about the bone and while holding the band in tightly wrapped configuration, crimping the outside wall 28 of the clip 16 to grip securely the free end 39 of the strip 10. It may be noted that the facing portions of the strip which are received within the opening 32 of the clip 16 will engage each other ribbed surface to ribbed surface. Interlocking of the facing ribs within the clip may enhance the locking of the device in its bone encircling configuration.
As described, a preferred embodiment of the invention utilizes a fabric which is very strong, preferably in the form of a warp knit fabric and may be manufactured on a double needle bed Raschel machine. The fabric may be considered as having a front panel, knit on the front needle bed of the machine and a back panel knit on the back needle bed of the machine with the front and back panels being intimately interconnected by yarns formed in a chain stitch associated on each needle and on each wale. The chain stitch runs front panel to back panel on every course and on every wale to connect together each stitch on the front panel with a corresponding stitch on the back panel. The front panel defines the relatively smooth external surface 14 of the fabric strip 10. The back panel is formed to define the ribbed internal surface 12 of the fabric strip 10. The manufacture of a fabric in accordance with the illustrative embodiment is described below with reference to the illustrative diagrams.
FIG. 5 illustrates, somewhat diagrammatically, and on an enlarged scale, the stitch configuration of the front panel, indicated generally by the reference character 36 (see also FIG. 7). FIG. 6 illustrates diagrammatically and also in greatly enlarged scale the stitch pattern in the back panel, indicated at 38 in FIG. 7. The manner in which the front panel 36 and back panel 38 are knitted together to define the composite fabric is suggested somewhat diagrammatically in FIG. 7 which illustrates the manner in which a yarn, guided by guide bar 6 and illustrated in FIG. 7 without shading is knitted in a chain stitch whose underlaps 40 run between the front and back panels 36, 38 to knit the front and back panels 36, 38 together and secure them in a unitary stable fabric.
The construction of the front and back panels 36, 38 of the fabric and their interconnection with the chain stitch yarn will be apparent to those of ordinary skill in the art from the following tables and related threading and point pattern diagrams for a Raschel machine. As is well known to those skilled in the art the Raschel knitting machines are double needle bed machines having a front needle bed and a back needle bed which rise and fall alternately in knitting action. The machine includes a number of guide bars each carrying a plurality of yarn guides, numbered 1 through 6 in FIG. 7. As is well understood by those skilled in the art the guide bars swing to and fro from the front to the back needle bars and also are moveable laterally as controlled by pattern links on a pattern chain to control all the yarn guides on that bar in unison. In the following description yarns will be referred to by the number of the guide bar which controls the yarn, thus, the unshaded yarn in FIG. 7 will be the "bar 6" yarn. As may been seen from FIG. 7 the front panel 36 is knitted from two yarns including the bar 1 yarn and the bar 2 yarn. The back panel 38 is knitted from the three yarns identified as the bar 3, the bar 4 and bar 5 yarns. The bar 6 yarn alternates between the front and back yarns, forming a chain stitch at each course and each wale to knit the front and back panels together in a unitary stable structure. It will be understood the the respective needle beds rise and fall alternately to receive yarn guided by the yarn guides carried by the guide bars, each by having as many yarn guide eyes as there are needles in a row, although various eyes may be left unthreaded.
Table I sets forth the chain readings and starting points for a preferred embodiment of the invention.
TABLE I______________________________________GUIDE BAR PATTERN STARTING POINTNO. LINK BETWEEN NEEDLES______________________________________1 6/8 3,42 2/0 1,23 2/2 1,24 8/8 4,55 0/0 0,16 2/0 1,2______________________________________
FIG. 10 is a threading diagram for the Raschel machine for manufacture of the illustrative embodiment of the invention. Yarn is threaded through those guides on the respective guide bars as indicated by small circles in FIG. 10. It will be apparent to those skilled in the art that a number of strips of fabric may be made simultaneously on the same Raschel knitting machine, the number of strips which can be made being limited only by the total number of needle positions in the machine. The description herein is of a single strip and may be duplicated if it is desired to manufacture multiple strips at the same time. Table II sets forth the pattern chain readings for the chain links used to control the shogging movements of the guide bars to knit the fabric of the preferred embodiment of the invention.
TABLE II______________________________________ GUIDE BAR NO.NEEDLEBED 1 2 3 4 5 6______________________________________F 6/8 2/0 2/2 8/8 0/0 2/0B 4/4 4/4 0/0 6/6 2/2 0/2F 2/0 6/8 0/0 6/6 2/2 2/0B 4/4 4/4 2/2 6/6 2/2 0/2F 6/8 2/0 2/2 6/6 2/2 2/0B 4/4 4/4 2/0 8/8 0/0 0/2F 2/0 6/8 0/0 8/8 0/0 2/0B 4/4 4/4 2/2 0/0 8/8 0/2F 6/8 2/0 2/2 0/0 8/8 2/0B 4/4 4/4 0/0 2/2 6/6 0/2F 2/0 6/8 0/0 2/2 6/6 2/0B 4/4 4/4 2/2 2/2 6/6 0/2F 6/8 2/0 2/2 2/2 6/6 2/0B 4/4 4/4 2/0 0/0 8/8 0/2F 2/0 6/8 0/0 0/0 8/8 2/0B 4/4 4/4 0/0 8/8 0/0 0/2______________________________________
FIG. 9 is a stitch diagram for each of the six guide bars 1-6 used in manufacture of the fabric. Guide bars 1 and 2 stitch only on the front needle bed (see also FIG. 7) to form the front panel 36 of the fabric. Guide bars 3, 4 and 5 knit only on the back needle bed and in conjunction with guide bar 6 form the back panel 38. Guide bar 6 stitches alternately on both the front and back beds in a chain stitch which interconnects the front and back panels. Guide bar 6 is fully threaded and stitches continuously along each wale, alternating from the front needle bed to the back needle bed so as to connect the front and back panels at each wale along each course.
FIG. 5 depicts, somewhat diagrammatically, the configuration of stitches of a representative portion of the front panel as seen from the overlap side of the panel (from the left in FIG. 7). The panel formed on the front needle bed is a two-bar fully threaded panel. As can be seen from the stitch diagram of FIG. 9 and Table II each of the bar 1 underlaps 42 (solid in FIG. 5) and each of the bar 2 underlaps 44 (stippled in FIG. 5) crosses over four needles which adds body to the panel. The technical face of the front panel 36 as seen in FIG. 5 consists essentially of overlaps of the bar 1 and bar 2 yarns and is essentially flat and smooth. It defines the external surface 14 of the fabric strip 10. FIG. 5 also illustrates the bar 6 yarns and their overlap portions 46 as well as segments of their underlaps 40. It should be noted that in FIG. 5 the appearance of the bar 6 underlaps 40 is somewhat distorted from the appearance they would have in the composite fabric. Thus, FIG. 5 is somewhat diagrammatic and is intended primarily to illustrate the stitch pattern for the primary bar 1 and bar 2 yarns of the front panel.
The stitch configuration for the back panel may be seen from FIGS. 6 and 8, in which FIG. 6 illustrates the back panel as seen from its underlap side (from the left in FIG. 7). In the back panel the bar 6 yarn 48 formed a continuous chain stitch along each wale. For clarity of illustration the back panel the bar 6 yarn is illustrated in a manner which omits the connection of the underlaps of the bar 6 yarn to the front panel. It will be understood that in the actual knitted fabric the underlaps of the bar 6 yarn in the back panel will have been drawn toward and knitted in a stitch in the front panel at each wale and course of the front panel as suggested in FIG. 7.
The back panel may be considered as being made up of two groups of yarns (not including the bar 6 chain stitch yarn). The first group of yarns in the back panel are the bar 3 yarns, indicated at 50 and shown in a stippled pattern which alternately lay in except with a cast stitches, indicated at 52, at predetermined intervals along the length of the fabric. The stitches 52 are arranged in groups which extend transversely along a course-wise line. Each transverse line of stitches 52 defines a line of bulk which forms the ribs 18. The second group of yarns in the back panel are those guided by bars 4 and 5. The bar 4 and 5 yarns indicated at 56 (cross hatched) and 58 (unshaded), respectively, are laid in yarns. The bar 4 and 5 yarns 56, 58 are laid in wale-wise except where they reach the region of the rib 18, defined by the row of stitches 52 of the bar 3 yarn. At the region of the transverse row of stitches 52 the bar 4 and 5 yarns are laid in course-wise and are trapped between the underlap and overlap of the stitches 52 formed by the first group of yarns (the bar 3 yarns). Thus the bar 4 and bar 5 yarns 56, 58 form a more massive underlying support for the stitches 52 in the first group of yarns (bar 3) and help to raise and define the wale-wise extending ribs 18. FIG. 8 illustrates in side view the manner in which the bar 4 and bar 5 yarns 56, 58 are laid in course-wise and are trapped between the underlap and overlap of the stitches 52 so as to provide a raised supported region of bulk to define a transversely extending rib 18.
Although, as may been seen from the stitch diagram, tables and notations the ribs are spaced at each four courses in the illustrative embodiment, other spacings may be developed as may be desired.
It is preferred that the yarns used in the back panel 38 are substantially heavier than the yarns in the front panel 36 and the bar 6 chain stitch yarn. Use of comparatively heavier yarns to form the transverse row of stitches 52 and the underlying course-wise filler results in a firmly supported and well defined rib capable of transmitting the necessary pressures to the bone to stabilize it.
Although the preferred embodiment contemplates use of coursewise fillers formed from yarns knitted into the fabric, in some instances it may be desired to provide a supplemental or substitute filler extending transversely of the fabric. In all cases, however, it is important that the bone-engaging internal surface 12 of the device be in the form of a fabric face capable of defining a multiplicity of interstices into which bone tissue may grow.
From the foregoing it will be appreciated that the cerclage device provides numerous advantages over the prior devices. It should be understood, however, that the foregoing description of the invention is intended merely to be illustrative of the invention and that other modifications and embodiments may be apparent to those skilled in the art without departing from its spirit.
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An orthopedic cerclage device for binding and stabilizing fractured bone segments is formed from an elongate fabric strip adapted to be tied tightly about the bone to secure the fractured bone parts together. The fabric strip has a plurality of transverse ribs raised from one face of the fabric. The strip is wrapped tightly about the bone with the ribbed surface engaging the bone. The strip is secured in place by a locking member. The primary pressure applied to the bone by the device is at the ribs so that the segments of the strip between the ribs do not adversely cut off vascular circulation in the bone. The fabric structure of the device also allows bone tissue to grow into the interstices of the device thereby incorporating it intimately into the healed bone. Also disclosed is a novel knitted fabric in which the ribs are knitted integrally into the stitch pattern of the fabric.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of application Ser. No. 10/833,386, filed Apr. 28, 2004 now U.S. Pat. No. 6,878,919.
FIELD OF THE INVENTION
The invention relates generally to the field of solid-state image sensors, and more particularly to the process of forming a lightshield and the interconnection layers for a solid-state image sensor.
BACKGROUND OF THE INVENTION
Image sensors are made of an array of pixels. Within each pixel, some regions are specifically designed to be photosensitive, and other regions are protected from light by a lightshield. Regions are protected from light because light absorbed in these protected regions causes degraded performance through mechanisms such as color crosstalk, smear, or reduced blooming control.
In U.S. patent application Ser. No. 10/641,724, filed Aug. 15, 2003, entitled “Light Shield Process For Solid-State Image Sensors,” by Eric G. Stevens, a thin lightshield process is described for providing a lightshield from one of the layers of a bi-layer metallization process. The aluminum layer in this process is usually patterned with a chlorine-based plasma chemistry which leaves chlorine-containing residue on the wafers after the etch. Further, this residue may react with the aluminum or TiW, especially where the aluminum and TiW meet, causing corrosion of these films, and degradation of their electrical properties or optical light-shielding properties. In addition, U.S. patent application Ser. No. 10/641,724 requires that the etch of the bottom layer of the bi-layer metal be masked in some regions by the top layer of the bi-layer metallization. This requirement may restrict the use of certain metals for the bi-layer metallization.
Consequently, a need exists for producing image sensors that overcome the above-described drawbacks.
SUMMARY OF THE INVENTION
The present invention is directed at overcoming the problems described above. The invention resides in an image sensor comprising (a) a substrate having photosensitive areas; (b) an insulator spanning the substrate; and (c) a first and second layer of a multi-layer metallization structure, wherein the first layer forms light shield regions over selected portions of the photosensitive area as well forming circuit interconnections and barrier regions to prevent spiking into the substrate or gates at contacts in the non-imaging area; and the second layer spanning the interconnections and barrier regions of the first layer only over the non-imaging areas and the second layer overlays edges of the first layer.
The above and other objects 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 elements that are common to the figures.
Advantageous Effect of the Invention
The present invention has the advantage of a thin lightshield and an interconnect metallization layer using a process that minimizes corrosion of the aluminum and TiW layers. A second advantage is that the patterned second layer of a bi-layer metallization is not used as a mask for the etch of the first layer of the bi-layer metallization.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in cross section of an image sensor of the present invention illustrating initial steps in producing the image sensor;
FIG. 2 is a drawing illustrating a step in the manufacturing process after FIG. 1 ;
FIG. 3 is a drawing illustrating a step in the manufacturing process after FIG. 2 ;
FIG. 4 is a drawing illustrating a step in the manufacturing process after FIG. 3 ;
FIGS. 5 a and 5 b are an alternative embodiment of the present invention;
FIG. 6 is also an alternative embodiment of the present invention; and
FIG. 7 is a perspective view of a digital camera for illustrating a typical commercial embodiment to which the ordinary consumer is accustomed.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a typical image sensor 10 consists of an array of photosensitive elements or pixels 30 in an image area. Within each pixel are regions that are exposed to light so that an electrical signal may be created in response to the incident light. In addition, there are regions within the pixel, which are prevented from receiving light because the light will degrade the imaging performance. A typical image sensor 10 also provides dark reference pixels 32 that are insensitive to light because they are covered with a light shield.
The signal from these dark reference pixels 32 are used in the signal processing portion of the camera to indicate the signal of photosensitive pixels when no light is incident upon them. In addition, interconnects are provided within the image sensor to electrically connect various parts of the imager and to provide means to connect the imager to external circuits.
Referring to FIG. 1 , there is shown an initial stage of forming an image sensor 10 of the present invention. This stage includes providing a substrate 20 having a plurality of photosensitive sites 30 that convert incident light into charge packets. An insulator 40 spans and covers the substrate 20 and includes an opening 45 therethrough for forming a contact hole, and the first layer 60 of a bi-layer metallization structure is deposited on the insulator 40 . In the preferred embodiment, the first layer of the bi-layer metallization is a titanium and tungsten alloy, and a bi-layer metallization is described. However other metals or combination of metals and/or their compounds can be used. The important properties of this first layer are that it is opaque in order to be used as a light shield, and that the metal can be used as part of a bi-layer metallization process where this first layer provides a barrier preventing the interaction of the silicon substrate with the upper and more conductive layer. Other first layers may be tungsten, or tungsten silicide, or molybdenum, or molybdenum silicide. Photoresist is selectively disposed on the TiW layer (not shown) to form a mask to prevent the etching of the underlying TiW layer. The exposed regions of the TiW layer are then etched using a fluorine-based plasma etchant.
Referring to FIG. 2 , there is shown the resulting cross-section after the selective etching of the titanium and tungsten alloy layer 60 , and the removal of the photoresist. The titanium and tungsten alloy 60 covers those regions of the pixel that should not be exposed to light for forming a light shield. The titanium and tungsten alloy 60 may also cover dark reference pixels 32 . In addition, the titanium and tungsten alloy 60 remains where metallization interconnects and bus lines, generally region 80 , are to be provided. The present invention includes the capability to separately pattern the titanium and tungsten alloy 60 so that it may be used as a local interconnect to electrically connect different parts of the imager that are not required to conduct high current levels, or to connect parts of the imager that are very close to each other, or other instances where the high conductivity of aluminum is not required. This local interconnect has the advantage of lower capacitive coupling to other parts of the imager and its circuitry because the total interconnect height is less than the bi-layer metallization. An example is shown in FIG. 6 . An aluminum layer 90 (see FIG. 4 ) will be used in combination with the titanium and tungsten alloy 60 as the interconnect for other circuits elements, as will be described hereinbelow. A floating diffusion 100 is connected via the titanium and tungsten alloy 60 to a gate of a transistor 75 that forms a portion of an image sensor output structure.
Referring to FIG. 3 , after patterning the titanium and tungsten alloy 60 , a layer of aluminum or alloy of aluminum 90 such as an alloy of aluminum and silicon, or an alloy of aluminum, silicon, and copper is deposited. This aluminum alloy layer 90 covers the patterned titanium and tungsten alloy 60 and the insulator 40 where the titanium and tungsten alloy 60 have been removed. It is noted for clarity that the combination of the titanium and tungsten alloy 60 and the aluminum 90 form the bus line 80 .
Referring to FIG. 4 , next, photoresist is selectively disposed spanning and covering the aluminum alloy layer 90 that is in the non-imaging areas, such as the dark reference pixels 32 , and the interconnect region or bus line 80 . This photoresist then masks a chlorine-based etch of the aluminum alloy layer 90 . The chlorine-based plasma etch selectively etches aluminum layer 90 , but does not etch the titanium and tungsten alloy 60 , nor the insulator 40 . The photoresist is then removed. The aluminum alloy 90 no longer covers the imaging area or photosensitive site 30 . The aluminum 90 does cover the titanium and tungsten alloy 60 over interconnect region 80 , and therefore forms the bi-metal interconnect wiring used for bus lines and other electrical connections. In the bi-layer structure, the aluminum alloy 90 can cover both the top and the sides of the titanium and tungsten alloy 60 so that corrosion of the interconnect wiring is minimized. In particular, it is noted that the aluminum alloy covers the edges 95 of the titanium and tungsten alloy 60 . The aluminum alloy 90 may also be patterned to cover the light shielded dark reference pixels 32 with or without the underlying titanium and tungsten alloy layer 60 if the titanium and tungsten alloy layer 60 does not provide sufficient opacity in this region. The aluminum alloy 90 does not cover the local interconnections made with the titanium and tungsten alloy 60 only. For clarity of understanding, it is noted that the titanium and tungsten alloy 60 form a barrier region to prevent intermixing between the gate region and the aluminum layer 90 and to prevent intermixing of source and drain regions with the aluminum layer 90 . The remaining steps needed for completion of a commercially usable image sensor are well known in the art and need not and will not be discussed in detail herein.
A second embodiment provides the same advantages, but instead of a continuous bi-layer metallization, the titanium and tungsten alloy 60 is patterned so that it is placed only in the contact holes and an overlap around the contact holes. The overlap of the contact holes ensures that the contact hole is completely covered by the titanium and tungsten layer within alignment variations of the process. The aluminum alloy alone is used for the interconnect layer in regions away from the contact hole. In this embodiment, the conductivity of the interconnect is about the same as the first embodiment, and junction spiking and electromigration at the contact holes is prevented by the barrier layer (the titanium and tungsten alloy), but reduces the thickness of the metallization interconnect over much of the device. FIGS. 5 a and 5 b show an example where the titanium and tungsten alloy 60 are patterned to cover only the contact hole 105 , while the aluminum alloy 90 alone is used in regions away from the contact hole 105 .
Referring to FIG. 7 , there is shown an electronic device, such as a digital camera 110 , for illustrating a typical commercial embodiment for the image sensor 10 of the present invention.
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
10 image sensor
20 substrate
30 photosensitive elements (image area) or pixels
32 dark reference pixels
40 insulator
45 opening
60 titanium and tungsten alloy layer (1 st layer)
75 transistor
80 interconnect region or bus line
90 aluminum alloy layer
95 edges
100 floating diffusion
105 contact hole
110 digital camera
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An image sensor includes a substrate having photosensitive areas; an insulator spanning the substrate; and a first and second layer of a multi-layer metallization structure, wherein the first layer forms light shield regions over selected portions of the photosensitive area as well forming circuit interconnections and barrier regions to prevent spiking into the substrate or gates at contacts in the non-imaging area; and the second layer spanning the interconnections and barrier regions of the first layer only over the non-imaging areas and the second layer overlays edges of the first layer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to commonly assigned U.S. Pat. No. 6,456,243, filed on 26 Jun. 2001, which is incorporated herein by reference.
This applications is related to commonly assigned U.S. Pat. No. 6,323,810, filed on 6 Mar. 2001, which is incorporated herein by reference.
This Application is related to commonly assigned U.S. patent application Ser. No. 10/298,870, filed on 18 Nov. 2002, which is incorporated herein by reference.
This Application is related to commonly assigned U.S. patent application Ser. No. 10/328,799, 24 Dec. 2002, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to the field of antennas, and more particularly to the design of differential mode capacitively loaded magnetic dipole antennas.
BACKGROUND
For an antenna to function in a particular environment it may be necessary that the antenna impedance be matched to the environment. For two different environments, an antenna design may need to be flexible enough to permit antenna impedance to be changed. However, in the prior art, changing antenna impedance invariably impacts an antenna's resonant frequency. The present invention improves over prior art antenna designs.
SUMMARY OF THE INVENTION
The present invention includes one or more differential mode capacitively loaded magnetic dipole antenna design and method of use.
In one embodiment, a device comprises an antenna, the antenna defined by a plurality of portions, wherein one or more of the plurality of portions are coupled in a first geometrical relationship that effectuates one or more antenna frequency, and wherein one or more of the plurality of portions are coupled in a second geometrical relationship that effectuates one or more antenna impedance, wherein a change in the first geometrical relationship effectuates a change in the one or more antenna frequency, wherein a change in the second geometrical relationship effectuates a change in the one or more antenna impedance, and wherein a change of the one or more antenna frequency or the one or more antenna impedance may be effectuated without a corresponding change in the one or more antenna impedance or the one or more antenna frequency. One or more of the portions may comprise a circuit. In one embodiment, an article may comprise a plurality of portions, wherein one or more of the plurality of portions are coupled to define a differential mode capacitively coupled dipole antenna. One or more of the plurality of portions may be coupled to define one or more radiative portion, and one or more of the plurality of portions may be coupled to define one or more impedance matching portion. One or more of the plurality of portions may be coupled in a first geometrical relationship that effectuates one or more antenna frequency, wherein one or more of the plurality of portions are coupled in a second geometrical relationship that effectuates one or more antenna impedance. A change in the first geometrical relationship may effectuate a change in the one or more antenna frequency, wherein a change in the second geometrical relationship effectuates a change in the one or more antenna impedance, and wherein a change of the one or more antenna frequency or the one or more antenna impedance may be effectuated without a respective corresponding change in the one or more antenna impedance or the one or more antenna frequency. One or more of the portions may comprise a circuit. One or more of the portions may comprise a rectifier circuit. One or more of the portions may comprise a coding circuit. A circuit may be coupled to a radiative portion and to an impedance matching portion. A circuit may be coupled to one or more impedance matching portion. One or more of the portions may comprise a circuit, wherein each circuit comprises a different code.
In one embodiment, a method of using a capacitively coupled dipole antenna may comprise the steps of: placing the antenna in a radiative field; exciting the antenna with the radiative field to provide a signal at a resonant frequency; and detecting the signal. The method may further comprise the step of providing the signal at one of a plurality of antenna impedances. The method may further comprise the step of providing elements of the antenna in a geometrical relationship; and changing a geometrical relationship between some of the elements to change an impedance of the antenna. The method may further comprise the step of changing the impedance of the antenna independent of the resonant frequency.
In one embodiment, a method of using an antenna in an environment may comprise the steps of: placing the antenna in one or more radiative field; exciting the antenna to provide one or more signal at a resonant frequency, wherein each signal corresponds to a particular radiative field. The method may further comprise the step of providing elements of the antenna in a geometrical relationship; and changing a geometrical relationship between some of the elements to change an impedance of the antenna. The method may further comprise the step of providing the signals at one of a plurality of antenna impedances. The method may further comprise the step of changing the impedance of the antenna independent of antenna resonant frequency.
In one embodiment, a method of using an antenna with an article may comprise the steps of: coupling the antenna to the article; providing the antenna with one or more impedance matching portion to match an impedance of the antenna to an impedance of the article; placing the article in a radiative field; using the radiative field to excite the antenna to radiate a signal at a resonant frequency; and detecting the signal. The method may further comprise the step of providing elements of the antenna in a geometrical relationship that defines a capacitively loaded magnetic dipole antenna. The method may further comprise the step of changing a geometrical relationship between some of the elements to change an impedance of the antenna. The method may further comprise the step of changing the impedance of the antenna independent of the resonant frequency. In one embodiment, the article may comprise a paper roll.
In one embodiment, an antenna may comprise: resonant frequency means for providing one or more antenna resonant frequency; and antenna impedance matching means for providing one or more antenna impedance.
Other embodiments are contemplated and should be limited only by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrate respective three-dimensional and side views of an embodiment of a capacitively loaded magnetic dipole antenna.
FIG. 2A illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna.
FIG. 2B illustrates views of embodiments of a differential mode capacitively loaded magnetic dipole antenna.
FIG. 3 illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna.
FIG. 4 illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna.
FIG. 5 illustrates an embodiment wherein additional portions ( 32 ), ( 53 ), and ( 54 ) are coupled to a differential mode capacitively loaded magnetic dipole antenna.
FIG. 6 illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna.
FIGS. 7 and 8 illustrate views of embodiments wherein the presence of a differential mode capacitively loaded magnetic dipole antenna is detected within a radiative field.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for purposes of explanation and not limitation, details and descriptions are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced in other embodiments that depart from these details and descriptions.
FIGS. 1A and 1B illustrate respective three-dimensional and side views of an embodiment of a capacitively loaded magnetic dipole antenna ( 99 ). In one embodiment, antenna ( 99 ) comprises a top ( 1 ), a middle ( 2 ), and a first lower ( 3 ) portion. In one embodiment, the top portion ( 1 ) is coupled to the first lower portion ( 3 ) by a first coupling portion ( 11 ), and the first lower portion ( 3 ) is coupled to middle portion ( 2 ) by a second coupling portion ( 12 ). In one embodiment, antenna ( 99 ) comprises a feed area, generally indicated as feed area ( 9 ), whereat input or output signals are provided by a feedline ( 8 ). In one embodiment, the first coupling portion ( 11 ) and the second coupling portion ( 12 ) are disposed relative to each other in a generally parallel relationship. In one embodiment, top portion ( 1 ), middle portion ( 2 ), and first lower portion ( 3 ) are disposed relative to each other in a generally parallel relationship. In one embodiment, portions ( 1 ), ( 2 ), and ( 3 ) are disposed relative to portions ( 11 ) and ( 12 ) in a generally orthogonal relationship. For example, in the embodiment of FIGS. 1A-B , portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), and ( 12 ) are disposed in a generally orthogonal or parallel relationship relative to a grounding plane ( 6 ). It is understood, however, that the present invention is not limited to the described embodiments, as in other embodiments portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), and ( 12 ) may be disposed relative to each other in other geometrical relationships and with other geometries. For example, top portion ( 1 ) may be coupled to first lower portion ( 3 ), and first lower portion ( 3 ) may be coupled to middle portion ( 2 ), by respective coupling portions ( 11 ) and ( 12 ) such that one or more of the portions are disposed relative to each other in generally non-parallel and/or non-orthogonal relationships. In one embodiment, portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), and ( 12 ) comprise are shaped to comprise flat plate structures, wherein a flat geometry of each portion ( 1 ), ( 2 ), ( 3 ) is disposed in a plane generally parallel to the grounding plane ( 6 ), and wherein a flat geometry of each portion ( 11 ) and ( 12 ) is disposed in a plane generally perpendicular to grounding plane ( 6 ). In one embodiment, portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), and ( 12 ) may comprise conductors. The conductors may be flexible or rigid.
In one embodiment, first lower portion ( 3 ) is disposed above and electrically isolated from grounding plane ( 6 ). First lower portion ( 3 ) is coupled to grounding plane ( 6 ) at a grounding point ( 7 ). It is identified that antenna ( 99 ) may be modeled as a radiative resonant LC circuit with a capacitance (C) that corresponds to a fringing capacitance that exists across a first gap bounded generally by top portion ( 1 ) and middle portion ( 2 ), indicated generally as area ( 4 ), and with an inductance (L) that corresponds to an inductance that exists in a second gap bounded by the middle portion ( 2 ) and first lower portion ( 3 ), indicated generally as area ( 5 ).
The geometrical relationship between portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ) and the gaps formed thereby may be used to effectuate an operating frequency about which the antenna ( 99 ) resonates and radiates a signal.
FIG. 2A illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna ( 98 ). In one embodiment, antenna ( 98 ) includes one or more portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), and ( 12 ) as is referenced by FIGS. 1A-B , and further comprises a first bottom portion ( 20 ). In one embodiment, the first bottom portion ( 20 ) is coupled to first lower portion ( 3 ) by a third coupling portion ( 21 ). In one embodiment, the third coupling portion ( 21 ) and the first coupling portion ( 11 ) are disposed relative to each other in a generally parallel relationship, and the first bottom portion ( 20 ) and the first lower portion ( 3 ) are disposed relative to each other in a generally parallel relationship. In one embodiment, first bottom portion ( 20 ) is disposed in a generally orthogonal relationship relative to third coupling portion ( 21 ). It is understood, however, that the present invention is not limited to the described embodiments, as in other embodiments the portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ) and ( 21 ) may be disposed and coupled relative to each other in other geometrical relationships to comprise other geometries. For example, first bottom portion ( 20 ) may be coupled by third coupling portion ( 21 ) to first lower portion ( 3 ) such that one or more of the portions are disposed in a generally non-parallel and/or non-orthogonal relationship relative to each other. In one embodiment, portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), and ( 21 ) comprise conductors. The conductors may comprise rigid or flexible structures. In other embodiments, portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), and ( 21 ) may comprise cylindrical, curved, or other geometries. In one embodiment, portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), and ( 21 ) may comprise flat surfaces. In one embodiment, flat surface portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), and ( 21 ) are disposed relative to each other generally in the same plane plane. In one embodiment, flat surfaces of portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), and ( 21 ) are disposed relative to each other in planes that are generally parallel to each other. In one embodiment, flat surfaces of portions ( 11 ), ( 12 ), ( 21 ) are disposed generally orthogonal to flat surfaces of portions ( 1 ), ( 2 ), ( 3 ), ( 20 ).
It is identified that antenna ( 98 ) may be modeled as a radiative resonant LC circuit with a capacitance (C) that corresponds to a fringing capacitance that exists across a first gap bounded generally by top portion ( 1 ) and middle portion ( 2 ), indicated generally as area ( 4 ), and with an inductance (L) that corresponds to an inductance that exists in a second gap bounded by the middle portion ( 2 ) and first lower portion ( 3 ), indicated generally as area ( 5 ). Thus, it is identified that a particular geometrical relationship between the portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), and the gaps formed thereby, may be used to effectuate a particular operating frequency at which antenna ( 98 ) radiates a signal. It is further identified that the selection of the particular geometrical relationship is within the scope of those skilled in the art.
In one embodiment, bottom portion ( 20 ) and first lower portion ( 3 ) bound a third gap indicated generally as area ( 22 ). It is identified that a particular geometrical relationship between portions ( 3 ), ( 20 ), and ( 21 ), and the gap formed thereby, may be used to effectuate a particular antenna ( 98 ) impedance, it is further identified that the selection of the particular geometrical relationship is within the scope of those skilled in the art.
FIG. 2B illustrates two top view representations of embodiments of a differential mode capacitively loaded magnetic dipole antenna, wherein as seen in a top view of one embodiment, portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), and ( 21 ) are coupled to define a geometrically flat antenna ( 61 ), and wherein as seen in a top view of a second embodiment, portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), and ( 21 ) are coupled to define a geometrically curved antenna ( 60 ). Thus, it is understood that the portions of antenna ( 98 ), as well as the portions of other antennas described herein, may be coupled to comprise other geometries and other geometric structures and yet remain within the scope of the present invention.
FIG. 3 illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna ( 97 ). It is identified that antenna ( 97 ) may be used in a differential mode, wherein one differential connection is made to a radiative portion of antenna ( 97 ), and wherein a second differential connection is made to an impedance matching portion of antenna ( 97 ). In one embodiment, one differential connection is made to first lower portion ( 3 ) and a second differential connection is made to bottom portion ( 20 ). In one embodiment, one differential connection is made in a fourth area ( 13 ) that generally bounds first lower portion ( 3 ) and a second differential connection is made in a fifth area ( 14 ) that generally bounds bottom portion ( 20 ). In one embodiment, antenna ( 97 ) includes previously referenced portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ) and ( 21 ), and further comprises a first device portion ( 30 ). In one embodiment, first device portion ( 30 ) is coupled at one end to first bottom portion ( 20 ) in the fifth area ( 14 ) and at another end to first lower portion ( 3 ) in the fourth area ( 13 ).
It is identified that when antenna ( 97 ) is placed in a radiative field ( 71 ) comprising a particular frequency that is in the resonant operating frequency band of antenna ( 97 ), the antenna may begin to radiate a signal ( 72 ) centered about at its resonant frequency. In one embodiment, first device portion ( 30 ) may comprise a rectifier circuit. In one embodiment, first device portion ( 30 ) may comprise a transmission circuit, wherein a current flow created in the antenna ( 97 ) at its resonant frequency may be used by the rectifier circuit to energize the transmission circuit. In one embodiment, first device portion ( 30 ) may comprise a first code emission circuit, the first code emission circuit for providing a code. In one embodiment, the code may comprise information superimposed onto signal ( 72 ). In one embodiment the code is a simple binary code, although it is understood that other codes and other code protocols are within the scope of the invention. The code may represent identification information or other information, for example, information received by a transducer circuit coupled to first device portion ( 30 ). It is identified that information may be thus provided by signal ( 72 ) to identify the presence of the radiative ( 71 ) field in the vicinity of the antenna ( 97 ), the presence of the antenna ( 97 ) within the radiative field, or the code or other information provided by first device portion ( 30 ). It is further identified that design and implementation of a transmission, rectifier, and code circuit, as identified herein, may be effectuated by those skilled in the art.
In one embodiment, multiple antennas ( 97 ) may be provided, each comprising a first device portion ( 30 ) and code emission circuit, each code emission circuit comprising a unique code. For example, a,first antenna may comprise a code emission circuit with a code “101” and second antenna may comprise a code “111”. It is identified that the presence of the first or second antenna within an appropriate radiative field ( 71 ) may be thus identified by detection of a respective code “101” or “111”.
FIG. 4 illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna ( 96 ). In one embodiment, antenna ( 96 ) includes previously referenced portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), ( 21 ), ( 30 ), and further comprises a second bottom portion ( 32 ), a fourth coupling portion ( 33 ), and a second device portion ( 31 ), all coupled and geometrically disposed in accordance with previously disclosed principles. In one embodiment, second device portion ( 30 ) is coupled at one end to the third bottom portion ( 32 ) and at another end to the second portion ( 20 ).
It is identified that when antenna ( 96 ) is placed in a radiative field ( 71 ) comprising a particular frequency that is in the resonant operating frequency band of antenna ( 96 ), the antenna may begin to radiate a signal ( 72 ) at its resonant frequency. In one embodiment, first device portion ( 30 ) and second device portion ( 31 ) may each comprise a rectifier circuit. In one embodiment, first device portion ( 30 ) and second device portion ( 31 ) may each comprise a transmission circuit, wherein a current flow created in the antenna ( 96 ) at its resonant frequency may be used by the rectifier circuits to energize the transmission circuits. In one embodiment, first device portion ( 30 ) and second device portion ( 31 ) may comprise a respective first and second code emission circuit, each providing a code. In one embodiment, the code may comprise information superimposed onto signal ( 72 ). In one embodiment the code is a simple binary code, although it is understood that other codes and other code protocols are within the scope of the invention. The code may represent identification information or other information.
In one embodiment, first device portion ( 30 ) may comprise a first unique code “101” and a second device portion ( 31 ) may comprise a second unique code “111”. It is identified that the presence of an antenna and/or an item coupled to the antenna within an appropriate radiative field may be identified by detection of the first or second code, which would be useful for detecting the presence of an antenna ( 96 ) by different code detection apparatus capable of detecting only a code “101” or “111”.
It is identified that for efficient transmission of signal ( 72 ), a particular antenna impedance may be desired so as to match the antenna impedance to the impedance of a particular environment. An embodiment wherein multiple device portions are used, for example ( 30 ) and ( 31 ) as described herein, may be used to effectuate impedance matching in different environments. Multiple particular antenna impedances may be effectuated by providing a particular geometrical relationship between portions ( 3 ), ( 20 ), ( 21 ), ( 32 ), and ( 33 ). It is identified that changes to the geometrical relationship between portions ( 3 ), ( 20 ), ( 21 ), ( 32 ), and ( 33 ) may be made without affecting the resonant frequency of antenna ( 96 ). Providing a particular geometrical relationship between portions ( 3 ), ( 20 ), ( 21 ), ( 32 ), and ( 33 ) is within the scope of those skilled in the art.
FIG. 5 illustrates an embodiment wherein additional portions ( 32 ), ( 53 ), and ( 54 ) are coupled to an antenna to provide additional antenna impedance matching flexibility in accordance with principles described herein.
FIG. 6 illustrates a side view of an embodiment of a differential mode capacitively loaded magnetic dipole antenna ( 93 ). In one embodiment, antenna ( 93 ) includes previously referenced portions ( 1 ), ( 2 ), ( 3 ), ( 11 ), ( 12 ), ( 20 ), ( 21 ), ( 30 ), and further comprises one or more lower portion disposed between middle portion ( 2 ) and first lower portion ( 3 ). In one embodiment, antenna ( 93 ) comprises a second lower portion ( 41 ) and a third tower portion ( 42 ), both coupled and geometrically disposed in accordance with principles disclosed herein previously. In one embodiment, second lower portion ( 41 ) and middle portion ( 2 ) bound an area ( 43 ) to define a sixth gap, second lower portion ( 41 ) and third lower portion ( 42 ) bound an area ( 44 ) to define a seventh gap, and third lower portion ( 42 ) and first lower portion ( 3 ) define an eighth gap. It is identified that by coupling one or more additional portion within a radiative part of a capacitively loaded magnetic dipole, the geometrical relationships between the portions, and the additional gaps thus formed, may be used to effectuate creation of multiple antenna resonant frequencies. It is identified that in an embodiment, wherein an antenna ( 93 ) comprises multiple resonant frequencies, a particular signal ( 71 ) may be used to excite the antenna to radiate a signal ( 72 ) at a particular one of its resonant frequencies.
In one embodiment, first device portion ( 30 ) may comprise a rectifier circuit. In one embodiment, first device portion ( 30 ) may comprise a transmission circuit, wherein a current flow created in the antenna ( 93 ) at its resonant frequency may be used by the rectifier circuit to energize the transmission circuit. In one embodiment, first device portion ( 30 ) may comprise a first code emission circuit, the first code emission circuit for providing a code. In one embodiment, the code may comprise information superimposed onto signal ( 72 ). In one embodiment the code is a simple binary code, although it is understood that other codes and other code protocols are within the scope of the invention. The code may represent identification information or other information, for example, information received by a transducer circuit coupled to first device portion ( 30 ). It is identified that information may be thus provided by signal ( 72 ) to identify the presence of the radiative ( 71 ) field in the vicinity of the antenna ( 97 ), the presence of the antenna ( 93 ) within the radiative field, or the code or other information provided by first device portion ( 30 ). It is further identified that design and implementation of additional portions, a transmission, rectifier, and code circuit, as identified herein, may be effectuated by those skilled in the art.
FIGS. 7 and 8 illustrate views of embodiments wherein the presence of a differential mode capacitively loaded magnetic dipole antenna is detected within a radiative field.
In one embodiment, illustrated in FIG. 8 , an antenna ( 92 ) may be embedded in, coupled to, or placed in the vicinity of an article or portions thereof, for example, a paper roll ( 59 ), or some part thereof, manufactured during a paper manufacturing process. Antenna ( 92 ) may be coupled to the roll of paper, before, at the beginning, in the middle, at the end, or after the end of the manufacturing process. In accordance with the previous descriptions provided herein, by immersing the roll of paper ( 59 ) within an external radiative field ( 72 ) corresponding to a resonant frequency of the antenna ( 92 ), the antenna may be made to radiate a signal and/or code to enable tracking of the roll of paper during its manufacturing process. It is identified that for efficient radiation of a signal by antenna ( 92 ) at a particular frequency with different paper rolls, for example, paper rolls that exhibit different geometries, antenna ( 92 ) may need to be provided with different antenna impedances. It is identified that, for each roll of paper, one or more embodiment described herein may be utilized to effectuate a proper impedance match and, thus efficient transmission of a signal ( 72 ).
In one embodiment illustrated in FIG. 8 , one or more antenna ( 91 ) in accordance with the descriptions previously provided herein may be embedded or coupled to articles of airport baggage to effectuate tracking of the baggage during one or more baggage processing stages. It is identified that for each bag, one or more embodiment described herein may be utilized to effectuate a proper impedance match and, thus efficient transmission of a signal ( 72 ).
Thus, it wilt be recognized that the preceding description embodies one or more invention that may be practiced in other specific forms without departing from the spirit and essential characteristics of the disclosure and that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.
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Differential mode capacitively loaded magnetic dipole designs are provided for usage in various applications. Impedance matching may be accomplished with changes to antenna structures without concomitant changes in resonant frequency.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of U.S. application Ser. No. 12/097,983, filed Oct. 18, 2008, which claims priority to the benefit of Great Britain Patent Application No. 0526331.4, filed Dec. 23, 2005. This application was also filed as International Patent Application PCT/GB2006/004915 with an International Filing Date on Dec. 22, 2006, with subsequent publication as International Publication Number WO 2007/072054 on Jun. 28, 2007. The disclosures of each of the aforementioned patent documents are incorporated herein by reference in their entirety.
Not Applicable
BACKGROUND
The invention in a first aspect relates to mixer taps, also referred to herein as faucets, having separate controls for hot and cold water. The invention in a second aspect relates to thermostatic mixing valve, usable to provide thermostatic regulation of temperature integrated within the tap body or in a separate unit. The two aspects can be combined or used separately.
Mixer taps of various types are known, both for domestic use and for use in institutions such as hospitals, care homes and the like, where safety and ease of maintenance become important. A mixer tap generally comprises hot and cold inlets and a common outlet (spout, nozzle, shower head) for delivering a desired mixture of cold and hot water. Different forms of control are available to regulate the flow and the mix. Separate hot and cold regulating controls are simplest to provide, but can be difficult to adjust before the correct temperature and flow rate is reached. Each control may be a rotary knob or a lever, for example, and may move through a quarter turn or several turns, according to the type of head works. Single-lever mixer tap controls are another option. In one type, similar to a joystick, movement about a first axis regulates the flow and movement about a second axis controls the mix. Another form of control having a single lever is the so-called sequential control in which movement of a single lever about a single axis first enables the flow and then progressively alters the mix (usually starting from cold and progressing toward hot). Yet another form of control popular with thermostatic mixing taps is one in which a first control regulates the flow and a second control regulates the temperature via a thermostatic mixing valve.
For intuitive operation by persons unfamiliar with a particular installation, the applicant believes the simple dual control with one control on the hot water supply and a separate control on the cold water supply is to be preferred. Moreover, the simple dual control permits the user to be sure that a “cold” output contains water purely from the cold supply. Such an assurance is generally required before water can be used for drinking (“potable water”), or even brushing teeth, for example. With the other types of mixer control, there is no certainty that a small proportion of water from the hot supply is not included in the output. This might arise either from failure to set the control lever fully to the cold position, from poor design or from wear and tear of the valve components or from a deterioration in the performance of the thermostat element, due to wear and tear, in a thermostatic tap. In either case, a separate tap for drinking water must be provided, and inconvenience for the user, together with increased installation costs.
In safety-sensitive installations, the “hot” water output is typically a mix of hot water from the domestic hot water services (DHWS) at a temperature which is typically above 50° Celsius and cold water at ambient temperature, provided by a thermostatic mixer to ensure that water above, say, 40 or 42 degrees Celsius cannot be emitted even at the hottest setting. If a variable temperature thermostat is part of the mixing tap, as in a shower installation, then the thermostatic valve is naturally included in the tap body. Where a simple hot/cold mixer tap is required, for example over a basin for washing hands or dishes, the usual solution is to provide a thermostatic mixing valve separately from the tap fitting, for example beneath the sink or behind a wall panel. The same thermostat might provide a supply of such “mixed hot” water for more than one basin, using the DHWS hot and cold water service (CWS) supplies of the building, but only for a few and only in one location.
Thermostatic and other valves require regular maintenance to continue safe operation, and require strainers at their inlets to guard against ingress of particles to the intricate mechanism. All these different parts make the plumbing installation complex and costly to install. Regular maintenance is hampered by the awkward location of the valves under basins and behind panels, and frequently does not take place as it should. To simplify these installations, there have recently been brought to market some mixer taps for institutional applications in which the thermostat for providing a supply of “safe” (mixed) hot water is incorporated within the body of the tap itself. The temperature of mixing may or may not be variable, depending on the design. These new taps still leave a lot to be desired, however, when it comes to ease of maintenance of the thermostat, strainers and the like. The body of the integrated tap may need to be dismantled in several steps and even removed entirely from the wall in some cases, before access is obtained to the thermostat or other parts. Given the bulk of brass (typically) involved in accommodating the mechanism, these bodies may weigh 6 kg or more, and are not trivial to handle safely. Even where the TMV is mounted separately from the tap, servicing can be difficult.
The invention in its various aspects aims to enable the provision of safe hot water while avoiding or reducing one or more of the problems identified above.
SUMMARY
The invention in a first aspect provides a mixer tap comprising in a single housing:
first and second inlets for receiving water from hot and cold water supplies respectively; a common outlet for emitting mixed water to a user; manually operable control means whereby a user can regulate the flow of water from the inlets to the common outlet including varying the proportion of hot and cold water emitted; and a thermostatic mixing device within the single housing arranged to receive and mix hot and cold water from said inlets and supply mixed water to the common outlet under control of said control means, thereby to prevent water above a certain temperature being emitted from the common outlet,
wherein said control means includes a dedicated cold water control operable by the user to open a fluid path from the cold inlet to the common outlet bypassing said thermostatic mixing device.
By this step, the benefits of an integrated tap are combined with the facility to obtain a pure cold water supply. Depending on the detailed construction and of course the supplies themselves, this output may or may not strictly be potable, but at least it is known not to include water from the hot supply.
The control means may comprise separate first and second controls nominally for regulating the hot and cold water independently, the first control in fact regulating flow of mixed water from the thermostatic mixing device to the common outlet, while the second control is said dedicated cold water control. In such an embodiment, the simplicity of operation and low cost of the most conventional mixer tap is combined with the integrated thermostatic safety function in a manner transparent to the user.
The thermostatic mixing device may include means for adjusting its output temperature. The adjusting means may be arranged to be manually operable by the user, or hidden for operation by service personnel only.
The thermostatic mixing device may comprise a cartridge located in a chamber accessible by removing part of the single housing, in accordance with the second aspect of the invention defined below.
The single housing may also provide chambers accommodating first and second strainer cartridges for blocking the passage of debris from the first or second inlet to the mixing device.
The second strainer cartridge may serve also to block the passage of debris from the second inlet to the dedicated cold water control as well as to the mixing device.
The housing may further accommodate first and second check valves for blocking the passage of water out through said inlets. The first and second check valves may be integrated in the first and second strainer cartridges respectively with the check valves preferably downstream from the strainers so that the strainers protect the check valves from damage due to debris.
The first and second strainer cartridges and thermostatic mixing device may all be accessible for servicing by removal of a single cover part of the housing.
The housing may comprise a monolithic inner body housing said thermostatic mixing device and being located within an outer casing, wherein a sealed space within the outer casing serves as a duct to pass water from a port formed in the inner body to said outlet.
Said inner body may comprise first and second ports for emitting mixed and cold water respectively into the outer casing, the control means engaging with said ports to regulate the flow from each to the outlet.
In an embodiment with strainer cartridges, these may also be located within the monolithic inner body.
The tap may further comprise integrated isolating valves for isolating serviceable components including the mixing device from said inlets. Said isolating valves may be located within a spigot adapted for interfacing the single body to a supporting panel (wall, sink surround, worktop or the like), access for operating the isolating valves being provided without requiring access behind said panel.
The invention in the second aspect provides a thermostatic mixing device comprising in a single housing:
first and second inlets for receiving water from hot and cold water supplies respectively; an outlet for emitting mixed water to a user; and a thermostatic mixing device within the single housing arranged to receive and mix hot and cold water from said inlets and supply mixed water to the common outlet,
wherein said thermostatic mixing device is made accessible for servicing after installation of the device without demounting any major part of said housing.
The device in one embodiment is a thermostatic mixer tap with integrated thermostatic mixing valve, the outlet being adapted for emitting said mixed water to a user, the device further comprising within said single housing:
manually operable control means whereby a user can regulate the flow of water from the inlet ports to the outlet.
A “major part” in this context might be defined as any part or combination of parts comprising more than 30% of the weight of the complete device contained within and including said single housing.
The thermostatic mixing device may be in the form of a cartridge removable from the housing for servicing or replacement.
The thermostatic mixing device may be accessible through an opening in said single housing. The tap may further comprise a cover for hiding said opening in normal use, the cover preferably being independent of any functional component of the tap and preferably comprising less than 10%, preferably less than 7.5% and even less than 5% by weight of the complete tap as contained within and including said single housing. Even if a cover must be removed, this will be a far simpler and safer operation than in known integrated thermostatic mixer taps. In one known example from a major manufacturer, to access the thermostatic cartridge, first the temperature adjusting knob is removed, then the flow control lever (both brass die-castings), then the shower hose and connector are removed; then a light plastic cover is removed. Following this a large gear assembly and large ceramic disc are removed with five 5 no. M6 bolts, giving access to the thermostatic cartridge. The cover part may be located on an underside of the tap when installed.
The thermostatic mixing device may include means for adjusting its output temperature. The adjusting means may be arranged to be manually operable by the user, or hidden for operation by service personnel only.
The single housing may also accommodate first and second strainers for blocking the passage of debris from the first or second inlet to the mixing device, said strainers also being made accessible for servicing after installation of the tap without dismantling said control and without demounting said single housing.
The housing may further accommodate first and second check valves for blocking the passage of water out through said inlets, said check valves also being made accessible for servicing after installation of the tap without dismantling said control and without demounting said single housing.
The first and second check valves may be integrated in cartridges with the first and second strainers respectively with the check valves preferably downstream from the strainers so that the strainers protect the check valves from damage due to debris.
The first and second strainers/cartridges and thermostatic mixing device may all be accessible for servicing by removal of a single cover of the housing. The cover part may comprise less than 10%, preferably less than 5% by weight of the complete tap as contained within and including said single housing. In the known example mentioned above, the main casting of the tap weighing over 5 kg must be removed from the permanently mounted piece weighing only 1 kg, in order to service the strainers and check valves (although check valves rarely require attention).
The housing may comprise a monolithic inner body housing said thermostatic mixing device and being located within an outer casing, wherein a sealed space within the outer casing serves as a duct to pass water from a port formed in the inner body to said outlet.
In an embodiment with strainer cartridges, these may also be located within the monolithic inner body.
The tap may further comprise integrated isolating valves for isolating serviceable components including the mixing device from said inlets. Said isolating valves may be located within a spigot adapted for interfacing the single body to a supporting panel (wall, worktop or the like), access for operating the isolating valves being provided without requiring access behind said panel.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, by way of example only, by reference to the accompanying drawings, in which:
FIGS. 1 to 3 are external perspective views of a mixing tap including a thermostatic mixing device in accordance with one embodiment of the present invention in both first and second aspects;
FIG. 4 shows a main internal body of the tap receiving three serviceable parts from below;
FIG. 5 shows (a) side elevation and (b) plan view of the internal body with section lines A-A, D-D, F-F, G-G, C-C, H-H and M-M;
FIGS. 6 to 12 are sectional views on the lines A-A, D-D, F-F, G-G, C-C, H-H and M-M, respectively; And
FIG. 13 shows schematically another application of the serviceable mixing device, embodying the second aspect of the invention as set forth above.
NOTE: The legends C, H and M are used at various points in the description and drawings to indicate ports and spaces provided for the flow of cold, hot and mixed water, respectively. Unless the context requires otherwise, “M” and “mixed” in this case refer to the “safe hot” water emitted by the thermostatic mixing device, prior to any mixing with cold water that occurs under user control on the way to the common outlet.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 is a front perspective view of a thermostatic bib tap having an upper casing portion 10 housing a spout and a lower casing portion 12 housing operating parts to be described below. Portions 10 and 12 in this example are formed in a single piece although that is not essential. A spigot 14 is provided for attaching the tap to a wall. An on/off control 16 for hot water is located on the left-hand side of the body (as viewed by the user) and an on/off control 18 for cold water is provided on the right hand side of the body. Each control is of the quarter turn type, with a short lever moving from an upright (off) position as shown at the left to a forward (on) position as shown at the right. Off/on positions may equally be reversed, depending on the type of lever and ergonomic considerations. Spindle controls may equally be used, requiring more than a complete revolution to move from fully on to fully off.
In the rear view of FIG. 2 , more detail of the spigot 14 can be seen, including a flange where it mounts to the wall. Within the spigot are entrance ports for connection to the water supply, including a hot water supply port 20 and cold water supply port 22 . The construction is modular so that different lengths of spigot can be provided according to the setting. Different forms of spigot can be provided, adapted for example for supporting the tap on a horizontal worktop panel instead of a wall panel, or for mounting directly onto exposed pipe-work.
The underside view of FIG. 3 shows the outlet port (spout) 24 which emits a flow of water which may be a mixture between cold and hot, according to the positions of the controls 16 and 18 . The tap in this particular example includes a thermostatic device for mixing hot and cold supply water to a “safe hot” temperature, so that hot water from the entrance port 22 is never supplied directly from the DHWS to the outlet 24 . The thermostat may deliver “hot” water at 40° C., for example, while the DHWS supply itself is at a more dangerous 60°, 70° or (for example in the event of a failure of the temperature control at the DHWS calorifier, hot water generator or hot water boiler) 80° C.
The thermostatic device is housed with other components in the lower housing portion 12 , and a screw cap 26 is provided which can be removed to permit access for servicing and/or replacement of these parts. To facilitate the servicing operations, ball valves are integrated into the spigot 14 and accessed through small ports 28 (hot) and 30 (cold), for example using a screwdriver. In this way, a thermostatic safety device is included within the body of the tap itself, with integrated isolating valves, but in such a way as to allow easy access for servicing. Compared with other known designs, there is no need to remove or disassemble heavy parts of the tap, nor access isolating and/or thermostatic valves behind the wall panel to which the tap is affixed. These features are of tremendous benefit in hospital and other institutional environments, where there may be hundreds of such fittings which require to be serviced in an economic and safe manner on a regular basis.
FIG. 4 shows an internal body 40 which may be a forging of solid brass, for example, and is housed within the lower body portion 12 of the tap. Although shown with the housing removed, internal body 40 is intended to be permanently secured and sealed within the body 10 / 12 before installation, and not removed for routine servicing.
As will be described in more detail with reference to FIGS. 5 to 12 , the internal body 40 provides various ports, ducts and chambers. Visible in FIG. 4 , there is a hot water outlet 42 which co-operates with control 16 to allow hot (mixed hot) water into the upper part 10 of the housing, and hence to the spout 24 . A similar port 44 (at the rear as seen in FIG. 4 ) provides the outlet for cold water in co-operation with control 18 .
As can be seen in the underside of body 40 there is a large opening for receiving a thermostatic mixing cartridge into a large mixing chamber 46 within the body 40 . Further chambers 50 and 52 are provided to receive strainer and check valve cartridges 54 and 56 for the hot water and cold water supplies respectively. It will seen that these three items are readily accessible for servicing as soon as the cover 26 is removed from the tap housing, even though the housing and internal body part 40 remain undisturbed in relation to each other and the wall mounting. Needless to say, the isolating valves 28 and 30 in the spigot are to be closed before any of the cartridges is removed for servicing.
FIG. 5( a ) is a side view of the internal body 40 . A threaded portion 58 provides for mounting of the cap 26 , while seats 60 for O-rings facilitate a watertight seal within housing part 12 . FIG. 5( b ) is a plan view of the internal body 40 , in which the axes of the mixing chamber 46 , the hot water strainer and check valve cartridge chamber 50 and the cold water strainer and check valve cartridge chamber 52 are marked at 46 ′, 50 ′ and 52 ′ respectively. The various plan sectional views are FIGS. 6 to 9 and vertical sectional views are FIGS. 10 to 12 will now be described, with different features of the internal structure of the main internal body 40 being visible in each section.
In FIG. 6 (section A-A) we see inner ports 62 and 64 receiving the supplies of hot and cold water from the external ports 20 and 22 respectively. An upper portion of the mixing chamber 46 can be seen.
FIG. 7 shows the section on plane D-D, which is at the level of the outlet ports 42 (mixed hot water) and 44 (cold water). The thermostatic cartridge 48 can be seen in outline within mixing chamber 46 . The internal form of the mixing cartridge is not relevant to an understanding to the present invention. It may for example be of the form described in our European patent EP0448315B1. Strainer cartridge 56 can be seen within the cold strainer/check valve chamber 52 . It will be seen immediately that the mixed hot outlet port 42 leads from the mixing chamber out to the hot water control 16 , whereas the cold water outlet port 44 leads directly from the cold water inlet strainer chamber 52 to the outlet 44 and out through cold control 18 .
FIG. 8 on section F-F shows the transfer port 66 by which supply hot water enters a hot gallery space 68 surrounding the mixer cartridge 48 from chamber 50 . Similarly, FIG. 9 on section G-G shows a cold water transfer port 70 leading from the chamber 52 into a cold water gallery 72 surrounding the mixing cartridge 48 .
FIG. 10 is a section in the vertical plane C-C of FIG. 5( b ), showing further detail of the components and pathways related to the cold water. Cold water inlet 64 is seen at the top left, which leads into the cold water strainer/check valve chamber 52 . Strainer/check valve cartridge 56 houses in its upper portion a straining mesh 74 and in its lower portion a check valve 76 , which is to prevent contamination by the reverse flow of water from inside the valve towards inlet 64 . At the back side of chamber 52 the direct cold water outlet 44 can be seen, while the cold transfer port 70 allows passage of cold water from the check valve 76 into cold water gallery 72 . Again, internal details of the mixing cartridge 48 are not shown, but it can be seen that O-rings and bridge formations within mixing chamber 46 isolate the galleries 68 and 72 from one another, and from the upper space into which the cartridge 48 dispenses mixed water at a controlled temperature. Cartridge 48 is mounted on a cap 80 , which can be screwed out of the opening in body 40 to replace or service the thermostatic control. Hexagonal recesses 82 and 84 are provided for removing the mixing cartridge and cold strainer cartridge respectively using a standard hexagonal key. A temperature adjusting screw at the centre of the cap can be accessed to adjust the mixed water temperature without removing the cartridge. It will be understood that these can be accessed once the cap 26 ( FIG. 3) is removed from the housing.
FIG. 11 is a similar cross-section but on line H-H, showing the parts relating primarily to the hot water. The hot water inlet 62 can be seen at the top left, leading into space 50 where the hot water strainer cartridge 54 includes straining mesh 86 and check valve 88 . Hot water is led from the check valve outlet through hot water transfer port 66 into hot water gallery 68 surrounding the mixing cartridge 48 .
Finally, FIG. 12 shows in section M-M the outlet 42 for mixed water, which flows if permitted by control 16 , into a final mixing space and duct within the outer housing 10 and hence to the spout 24 .
Distinctive features of the tap described relate to the ease of servicing of the tap components and also its basic functionality, comprising to the provision of a “pure” cold water outlet.
Concerning ease of servicing, conventional plumbing installations for hospitals and similar institutions which include thermostatic mixers for the provision of “safe” hot water use conventional hot and cold taps or mixer taps, with thermostatic valves located beneath the wash basin or behind a wall panel, where they can be difficult to access. Isolating valves and strainers are likewise difficult to access. Although before the present priority date there have been shown examples of integrated thermostatic mixer taps of the general type described herein, these do not necessarily integrate all the components (thermostatic cartridge, strainers, check valves and isolating valves), so that demounting of the tap and/or access behind or beneath panels is still required for many servicing operations. Moreover, access to the thermostatic elements, check valves etc. in all the known examples requires demounting and/or disassembly of the tap to some degree or another, whereas all of said parts are accessible in the present design by simply unscrewing the cap 26 from under the housing. Not only is the time and money spent in servicing operations reduced by this measure, but the likelihood that proper maintenance will be performed at all is greatly increased. Moreover, the dismantling and moving of body components which can weigh several kilograms in practice is avoided, reducing the risk of injury to service personnel and damage to the basin and surrounding décor.
Concerning the second advantage, conventional mixing taps, particularly those with thermostats, cannot be guaranteed to provide and output of cold water directly from the cold water supply, even when apparently set to their coldest setting. This renders them unsuitable for the supply of drinking water, or even water for brushing teeth etc. In the model illustrated, provided the hot control 16 is shut off, operation of the cold control 80 can provide pure water through spout 24 . Depending on the ducting within the upper portion 10 of the housing, mixing of water from the outlets 42 and 44 may occur between the controls 16 , 18 and the spout 24 , in which case a short flushing period may be required to displace residual mixed water. In other embodiments, the paths from the outlets 42 and 44 to the spout 24 can be entirely separated by suitable barriers and seals, so as to provide a true potable water supply by operation of the cold control 18 . The user has no need then to be concerned with the difference between the mixing tap and drinking water supplies.
These and other modifications can be made without departing from the spirit and scope of the invention as defined in the appended claims. It will be appreciated that different forms of body may be provided, different spout arrangements, mounting arrangements and control arrangements can be substituted for those shown in this example. Additional components such as flow restrictors can be included as desired.
As one illustration, the lever action of either control may be reversed and/or replaced with a spindle or other type of flow regulation mechanism.
As another illustration, FIG. 13 illustrates a thermostatic mixing device having easy servicing features similar to the mixer tap with integrated TMV described above, but in a slightly different application. Here, water is to be supplied to a wash hand basin 100 , mounted on a wall 102 . The tap is of a no-touch (electronic) type, delivering water from a spout 104 , under control of an infra-red or similar proximity sensor 106 . These elements are part of an electronic valve assembly, whose functional parts are mounted in a body 108 behind the wall panel. In order to regulate the outlet temperature, a thermostatic mixing device 110 of the type seen in FIGS. 4-12 is mounted behind the wall 102 in housing 112 . Hot and cold supply pipes 114 and 116 enter the housing 112 and are coupled to inlets 62 and 64 of the device, while outlet pipe 116 leads safe hot water from the mixed water outlet of the device 110 to the electronic valve 108 .
Device 110 includes an internal body and serviceable cartridges substantially the same as body 40 and cartridges 48 , 54 , 56 of FIGS. 4-12 . It is a simple matter for the person skilled in the art to provide a housing 112 which leads water from the mixed water outlet 42 of the internal body 40 to a pipe connection, rather than directly to the control valves and mixing space of the integrated mixer tap. Housing 112 projects through the wall 102 , where cap 118 (similar to cap 26 in FIGS. 1-3 ) is accessible and readily removable for servicing of the thermostatic mixing cartridge, check valves and strainers. Of course the housing 112 need not be mounted in a wall panel. Where it is, the housing and/or wall 102 can be adapted also to provide screwdriver access to isolating valves (not shown in FIG. 13 ) at the inlets, just as in the integrated version of FIGS. 1-3 .
It will be appreciated that housings 112 and 108 can be integrated if desired, providing the tap and servicing cover 118 in one place. Similarly, the thermostatic mixing device can be used with a mixing tap to mix both cold and safe hot water in varying proportions, with the user controls and outlet in a separate housing from the thermostatic mixing device, rather than integrated as in FIGS. 1-3 . Compared with the illustration of FIG. 13 , in that case, both cold and mixed outlet pipes would be used to transfer water from device 110 to the tap body 108 . Housing 112 could be adapted to lead the ‘pure cold’ water outlet 44 to a second outlet pipe connection. Alternatively, since the housings for the mixer and tap are now separate, a ‘pure cold’ connection can be made simply enough by pipework direct to the tap body.
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There is described a mixer tap with integrated thermostatic mixing valve (TMV). The tap comprises in a single housing: hot and cold water inlets; an outlet for mixed water; hot and cold lever controls and a thermostatic mixing device within the single housing to prevent water above a certain temperature being emitted from the common outlet. The cold water control opens a fluid path from the cold inlet to the common outlet, bypassing said thermostatic mixing device, allowing better assurance of purity. The thermostatic mixing device and strainer/check valve cartridges are housed in an internal body so as to be readily accessible for servicing after installation of the device by removing only a cap part of the housing.
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BACKGROUND OF THE INVENTION
The present invention relates to water purification and filtration systems and, in particular, to a system including an iodine resin purification bed.
Along with expanding populations and industrialization has come an ever expanding problem of water pollution, either by way of chemical or microbial contaminants (i.e. bacterial, viral or parasitic). Natural sources of potable drinkable water are proportionately decreasing, thus requiring various processing treatments to make the water consumable.
Varieties of techniques have been developed in the latter regard at the bulk treatment levels for large populations, as well as for small volumes for an individual or household. These methodologies may include varieties of mechanical treatment systems and/or chemical treatments, but which systems suffer from various shortcomings. For example, distillation systems, while producing substantially contaminant free re-constituted water, does so at the loss of naturally occurring minerals. These systems are also slow and require large amounts of energy. Chemical treatment systems, similarly, are costly and/or leave residual tastes in the treated water.
Filtration systems and, in particular, granulated active carbon (GAC) systems, otherwise, economically remove a wide variety of relatively small contaminants. The beds do not however remove various viral and bacterial contaminants which can collect and grow within the carbon beds, thus necessitating the re-charging of the beds or costly treatment thereof to remove the undesired contaminants. Agencies responsible for large installations, as well as approval regulators for smaller installations, have accordingly begun to withhold approval for such systems.
One approach in the small volume treatment market has been to interject, upstream of the GAC, a purification element for devitalizing (e.g. sterilizing or killing) specific viruses and bacteria, prior to entering the bed. Such purification elements may also be mounted downstream of the bed to prevent reverse contamination. One cartridge system known to Applicants utilizing an iodine resin purification bed is sold by Water Technologies, Inc., Plymouth, Minn.
The cartridges of this system particularly includes a GAC bed and a co-axially aligned resin bed of equal cross-sectional flow area containing polystyrene beads to which are bonded iodine molecules. This resin is described in U.S. Pat. No. 4,238,477 and has proven effective in destroying the viral, bacterial and parasitic contaminants, when deposited to a bed depth sufficient to provide proper contact time between the resin and water.
Although effective in practice, the foregoing cartridges have proven to be economically rather expensive to produce, due to the use of excessive amounts of resin. That is, the resin bed portion of the cartridges have been constructed oversize relative to the life of the GAC bed, in lieu of adjusting the cartridge housing configuration. Although, too, a certain contact time is required between the water and purification bed to assure removal of undesired contaminants, presently available cartridges only provide a bed depth of approximately 3/4 inches.
Applicants have determined, however, that smaller volumes of purification media can be used without effecting the cartridge properties. In particular, the cross-sectional flow area of the purification bed need not be the same as the adjacent GAC bed. The length of the purification bed can also be increased without constricting throughout flow, among other improvements which better match the effective resin life and volume to that of the GAC bed.
In appreciation of the foregoing, Applicants have developed various systems, and purification/filtration cartridges and assemblies which are more economical to manufacture via a lengthening and downsizing of the volume of iodine purification resin material, while still maintaining proper contact time between the resin and water and without effecting the throughput rate.
SUMMARY OF THE INVENTION
It is accordingly a primary object of the present invention to provide a volumetrically downsized resin bed of increased length which is co-axially aligned upstream of a bed of GAC particulate media.
It is a further object of the invention to provide a flow directing containment chamber which facilitates sufficient resin contact time between the resin and water without effecting throughput rate.
It is a further object of the invention to provide improved disposable cartridges and housings which are useable with installed systems.
It is a further object of the invention to provide cartridges with replaceable sediment filters which surround a purification bed portion of a housing and in combination with the GAC bed provide a cylindrical housing shape.
It is a further object of the invention to provide a portable, personal assembly for use when traveling with available water faucets.
It is a yet further object of the invention to provide a replaceable purification bed compatible with renewable GAC bed systems.
It is a still further object of the invention to provide a pressurizable canteen filling system including a disposable cartridge and squeeze bag.
Various of the foregoing objects, advantages and distinctions of the invention are particularly achieved in variously considered constructions which are described below. In various of these constructions, a GAC containing cartridge includes a co-axial iodine resin purification chamber exhibiting a cross sectional flow area less than that of the GAC chamber, yet providing a lengthened resin bed depth sufficient to provide proper contact time with the water. The purification chamber can mount ahead of or extend into the GAC chamber. A replaceable, torroidal sediment filter can also surround the purification chamber.
In a personal, transportable construction, means are provided for coupling a housing containing cylindrically concentric purification and GAC beds to an available water supply. The purification chamber for this assembly cylindrically projects from an inlet endcap into the GAC bed chamber and includes integral filters. A nozzle extends from an outlet endcap.
In a refillable or disposable GAC bed cartridge construction, a housing manifold is formed to support a purification chamber including a pointed, multi-apertured endcap. Sediment filters mount interiorly and in concentric external relation to the purification chamber.
In canteen filling construction, a pressurizable collection reservoir (e.g. a squeeze bag or bottle) couples to a purification cartridge which, in turn, is securable to a canteen. Contaminated water can thereby be gravity fed or forced through the cartridge.
Still other objects, advantages, distinctions and constructions of the invention will become more apparent hereinafter upon reference to the following detailed description with respect to the appended drawings. Before referring thereto, it is to be appreciated the description is made by way only of presently preferred constructions and considered alternative improvements and modifications thereto. The description should therefore not be interpreted in limitation of the invention. Rather, the invention should be interpreted within the spirit of the following appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross sectional view through a prior art cartridge.
FIG. 2 shows an isometric drawing of an improved cartridge construction including a replaceable sediment filter.
FIG. 3 shows a partially sectioned view through the cartridge of FIG. 2.
FIG. 4 shows a partially sectioned elevation view though a personal, transportable filtration system.
FIG. 5 shows a partially sectioned elevation view though a cartridge system including a rechargeable GAC.
FIG. 6 shows a partially sectioned assembly drawing of a canteen filling/purification system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With attention to FIG. 1, a cross section elevation view is shown though a prior art cartridge filter 2 including a purification bed 3 of packed iodine bonded resin beads 4. The latter resin beads are more particularly described in U.S. Pat. No. 4,238,477. Such a cartridge 2 is mountable within a variety of molded housings which find application for household drinking water. These systems typically provide a usable cartridge life of 1,000 to 1,500 gallons between cartridge changes. An example of the configuration of one housing 6 which is useable with cartridges or with a refillable carbon particulate is shown in FIG. 5. Such housings 6 are typically formed of a high density molded plastic or fiberglass composite and are configured with longitudinal ribs 7 to withstand water pressures on the order of 150 psi.
The cartridge 2 otherwise provides a cylindrical construction and mounts within the housing 6 in sealed flow relation to an end mounted inlet/outlet manifold 8 and the housing bottom via a pair of rubber annular washers 10. The washers 10 are sealed to the housing 6 and manifold 8 via annular V-shaped ridges 9 (only one of which is shown) which project from the manifold 8 and bottom of the housing 6.
Water flow (shown at the darkened arrows) is directed into the cartridge 2 via a plurality of ports 12 formed within an inlet endcap 13 and through a foam sediment filter 14 (shown in partial cutaway) to the purification bed. A relatively high density annular, disk-like filter or screen 16, which exhibits an approximate 150 micron pore size, is positioned at the downstream end of the purification bed 3 to contain the resin beads 4. The resin beads 4 are filled to an approximate depth of 3/4 inches which relative to an equal diameter, carbon bed 18 provides sufficient contact time to kill parasitic, bacterial and viral contaminants within the water.
The water otherwise flows from the iodine purification bed 3 through the granulated active carbon (GAC) bed 18 (shown in partial cutaway), which contains granules of carbon 20, and exits the cartridge 2 at an end cap 21 and fibrous post-filter assembly 22 where carbon particulate is filtered from the water. The post-filter assembly comprises an end support 24, cylindrical filter 26 and internal bore ring 28. The GAC bed 18 in addition to filtering contaminants also filters iodine molecules from the water, which might otherwise cause a corresponding taste.
Although the cartridge 2 has proven to be functional for its intended purpose, it is relatively expensive to produce in view of the volume of resin required to provide the necessary purification bed depth and contact time relative to the interior diameter of the cartridge 2. Appreciating however that the resin 4 has an effective life greater than the GAC material (i.e. on the order of four times that necessary). Applicants have developed a number of improved cartridge constructions which provide an iodine resin purification chamber of reduced cross sectional area and volume relative to the GAC bed 18. These constructions also provide increased bed depths to promote sufficient contact time between the water and iodine and without restricting the flow rate.
In this regard, attention is directed to FIGS. 2 and 3 and wherein a disposable GAC cartridge 30, similar to that of FIG. 1 but with some exceptions, is shown. Dimensionally the cartridge 30 is constructed to fit housings 6 of the type which receive cartridges 2 like those shown in FIG. 1. In lieu however of the internal purification chamber 3, a reduced radius purification chamber 32 projects from the inlet side of the GAC chamber and wherein a resin bed 34 containing the resin beads 4 is supported. A plurality of apertures 35 and spacer ribs 37 to flow access to the bed 34.
A replaceable torroidal shaped filter 36 mounts about the purification chamber 32 and spacer ribs 37. It is formed of a relatively solid, porous material and filters particulates less than 10 microns. By making the sediment filter 36 separately replaceable, the overall life of the cartridge 30 is extended. The throughput capabilities are also improved, since the water flow over time does not experience partial filter plugging, such as with the cartridge 2 and wherein the foam sediment filter 14 typically becomes plugged. The end of the filter 36 is compressively sealed to an annular V-shaped ring 39 which protrudes from the forward wall of the GAC chamber 38.
More of the details of the construction of the purification chamber 32 and the mounting of the sediment filter 36 thereto can be seen in FIG. 3. It is to be appreciated that the construction of the GAC chamber 38 is substantially the same as that shown in FIG. 1, although of a larger volume, and includes the GAC bed material 20, post-filter assembly 22 (not shown) and endcap 21.
The replaceable sediment filter 36 otherwise exhibits an external diameter approximating that of the GAC chamber 38. An internal, stepped bore 40 having a ledge 42 mounts about the purification chamber 32 and spacer ribs 37 and is sized to extend forward of the purification chamber to create a space or gap 41. The aft end abuts the seal 39 and GAC chamber 38.
The purification chamber 32 otherwise exhibits a length of approximately 11/2 to 2 inches. The volume of contained resin 4 (which is shown in partial cutaway) is otherwise reduced and is approximately thirty percent of that used for the same overall sized cartridge of FIG. 1. This reduced volume provides a cost saving and better matches the useful life of the GAC particulate 20, which has been increased in volume, to that of the iodine resin 4. Comparative tests have further corroborated that the water purity and useful cartridge life for similarly sized cartridges has improved with the reduction in resin volume. In particular the cartridge 30 provides a purity of 2.5×10 9 ppm for the cartridge 2.
Separately bonded to the resin chamber 32 interiorly of the inlet port 44 is a porous filter or screen disc 46 which is sonically bonded to the chamber end at an annular projection 48. A downstream porous disk 50 is similarly bonded to an annular projection 48 at the interior forward face of the GAC chamber 38. In lieu of a sonic bond, it is to be appreciated a variety of other adhesives and plastic bonding techniques can be utilized to bond the disks 48, 50 to the cartridge chambers 32, 38. The resin 4 is otherwise contained between the impermeable outer chamber walls and the porous disks 48, 50 to the desired depth and reduced volume.
Appreciating that the resin chamber 32 might also extend interiorly of the GAC chamber 38, attention is directed to FIG. 4 which discloses an assembly 59 that finds particular advantage, such as when traveling, for individuals who desire a private filtration system. Such a system is usable with conventional water supplies, similar to those found in hotels, motels and the like. Thus, the assembly 59 is readily mountable to a faucet and not only filters macro sized contaminants from the water, but also purifies the water of any viral or bacterial contaminants.
The assembly 59 includes a cylindrical housing 60 containing inlet and outlet endcaps 62, 64 and relative to which the inlet endcap 62 and purification chamber 74 are shown in partial cross section. A formed or bent nozzle 66 extends from the outlet endcap 64. Secured to the inlet endcap 62 is a length of tubing or hose 68 which is coupled to the inlet endcap 62 via a threaded, draw-type connector assembly 70. The opposite tube end is coupled to another connector assembly 70 and a flexibly resilient faucet coupler 72. The faucet coupler 72 is formed of an elastomer material and provides an inwardly tapered orifice (not shown) which fits over most available faucets that might be encountered in a person's travels. Although a friction fit coupler 72 is shown, it is to be understood that a coupler assembly using a band fastener or threaded faucet coupler could also be used to advantage.
Upon fitting the coupler 72 over a faucet, the water is directed to the iodine resin purification chamber 74 which extends interiorly from the inlet endcap 62 and into the GAC chamber 76. A pair of porous disks 78 contain the iodine resin material 4 within the chamber 74. These disks 78 are sonically or adhesively bonded to the chamber 74 to withstand the typical pressures encountered relative to water entering a flared inlet port 80.
A further example of an iodine resin purifier which finds application with filtration housings 6 including a replaceable GAC bed is shown in FIG. 5. For the disclosed mounting, a replaceable GAC particulate 20 is used in conjunction with an inlet/outlet manifold 8 that screw couples to the GAC housing 6 in a reverse flow fashion. That is, the normal inlet, when used with replaceable cartridges 2, becomes the outlet for purposes of the inventive arrangement of FIG. 5. Thus, the inlet channelway 82 channels water to a center port 84 and an elongated replaceable candle-like purification chamber 86 which contains the iodine resin 4. The purification chamber 86 is suspended from the manifold 8 at a slipfit connector 88 and is secured thereto via a setscrew 90.
Shown in cutaway and contained within the chamber 86 between a pair of porous annular disks 92, 94 is the resin material 4. a bed length on the order of four inches is provided. Otherwise, a separate pointed, endcap 96 is secured via a second setscrew 98 to the outflow end of the purification chamber 86. The endcap 96 exhibits a conically pointed profile and includes a plurality of flow apertures 100. Other pointed profiles may be used with equal efficacy.
The pointed profile particularly facilitates mounting of the purification chamber 86 within the GAC particulate 20. That is, when the GAC particulate 20 is periodically changed, it is necessary to unscrew or remove the outer housing 6, dispose or clean the old particulate and insert new particulate. The rejuvenated particulate 20 and housing 6 is then brought to bear against the purification chamber 86 and the purification chamber is slowly inserted into the GAC particulate 20, prior to the housing 6 being screwed onto the manifold 8. A porous end washer 102 otherwise separates the GAC material 20 from the outlet port 104 and the outlet channelway 106 of the manifold 8. The annular V-shaped ring 9 seals to the washer 102.
Still another construction of the invention is disclosed in FIG. 6 and wherein an assembly 110 is shown in partial cutaway which finds application for military or recreational use. Specifically, a modular canteen filtration system is disclosed which comprises a squeeze bottle or bag 112, a purification/filtration cartridge 114 and a conventional canteen 116.
For this assembly, a relatively sturdy, flexible bag 112 or polyethylene type bottle is used to collect water which may be contaminated. This water can be collected at the individual's convenience for subsequent or immediate purification. A threaded nozzle portion of the bottle mounts to a mating coupler 120 of the purification/filtration cartridge 114. The cartridge 120, in turn, threadably couples at a collar seal 122 to the spout 124 of a canteen or other personal water storage device 116.
Referring to the cutaway portion of the purification chamber 114, it is generally constructed in the shape of a cylindrical housing 126 and provides for a suitable porous pre-filter 128 which mounts adjacent the coupler 122 and typically comprises a relatively rigid disk-like wafer. An appropriate volume of iodine containing resin bed material 4 is next provided and contained between the pre-filter 128 and a down stream porous divider filter 130. An appropriate volume of GAC material 20 and a suitable disk post filter 132 complete the interior construction of the cartridge 114.
Otherwise, a nozzle portion 134 provides a smooth walled, blunt outlet port which is insertable into the spout of the canteen 116. The surrounding, threaded collar 122, which is secured in water tight relation to the cartridge 114 via sealing arrangement (not shown), is securable to the canteen 116.
Purification and filtration are achievable via a gravity flow of the water through the cartridge, which flow may be augmented via a vent hole (not shown) in the canteen coupler 122. Otherwise, upon squeezing the water bag 112, external pressure may be developed to facilitate flow through the cartridge 114. Where a bag type collector chamber is used, the bag may be rolled as it is evacuated and whereby a sustainable pressure may be maintained relative to the cartridge. Depending upon a desired useful cartridge life, the dimensions of the cartridge 114 can be suitably tailored to accommodate corresponding amounts of purification resin 4 and GAC bed material 20.
While the present invention has been described with respect to variously considered constructions, along with various improvements and modifications thereto, it is to be appreciated that still other constructions may suggest themselves to those of skill in the art. Accordingly, it is contemplated the following claims should be interpreted to include all those equivalent embodiments within the spirit scope thereof.
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Water treatment apparatus including an iodine resin purification bed suppported in a walled structure and mounted upstream of an active carbon filtration bed. In one disposable cartridge construction, a replacable, toroidal sediment filter surrounds the purification chamber which concentrically projects from the upstream end of a larger diameter active carbon bed. In another construction, the purification bed includes a directionally permeable, replaceable, pointed housing which insertably mounts within the carbon bed. In another construction a portable housing contains a purification bed within a surrounding carbon bed, and receives water from faucet coupling means and includes a nozzle. In still another personal construction, a purification cartridge mounts between a pressurizable collector and canteen.
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BACKGROUND OF THE INVENTION
The conventional plunger which consists of a vacuum cup at one end of a handle is known. The cup is inserted into a toilet bowl and is alternately pushed and pulled to develop surge pulses on a column of water and thus dislodge the plug in the stack.
The limitations of this tool are apparent in that it is useful only in unplugging or dislodging light plugs. For more difficult situations other tools are used such as snakes or routers. These tools re normally not stocked by the home owner who then calls a plumber at great expense.
SUMMARY OF THE INVENTION
This invention is directed to a novel plumbing tool which in addition to the conventional vacuum cup provides a reversible pump for surging the fluids in a plugged stack back and forth at high pressures which create a trubulence at the plug to loosen the particles of its mass and thus release it so that it will readily flush out.
A primary object of the invention is to provide a novel pump which incorporates a vacuum cup within which is mounted a reversible pump unit for alternately pumping the fluids in opposite directions through the cup which also serves as a seal.
The invention contemplates a novel arrangement of pump and suction cup such that the parts of the mechanism may be juxtaposed in one position so that it may operate as a suction cup and in another position as a pump.
Another object of the invention is to provide a novel pump which may be reversed quickly to alternately pres-urize the fluid column between the pump and the plug and then to depressurize the column to thus loosen the plug.
The invention comprehends a novel pump comprising a pump head which is insertable into a standard toilet and which may be manipulated as a vacuum cup or operated as a pump.
These and other objects and advantages inherent in and encompassed by the invention will become more apparent from the specification and the drawings, wherein:
FIG. 1 is a side elevational view of the invention shown partly in axial section;
FIG. 2 is an enlarged cross-sectional view taken substantially on line 2--2 of FIG. 1;
FIG. 3 is an enlarged defined cross-sectional view on line 3--3 of FIG. 1 showing the parts in valve-open pump operating position, and
FIG. 3a is an illustration of FIG. 3 showing the parts in valve-closed position.
DESCRIPTION OF THE INVENTION
Refering to the drawings, the novel pump generally designated 2 comprises a longitudinal body or housing 3 preferably formed of plastic material in two halves and welded or glued together to form a handhold portion. The body encases a drive shaft 5 which is mounted in bearings 7,8 at opposite end of the housing 3.
The upper end of the shaft is connected to a shaft 10 of a reversible electric motor 12 which is confined within a cavity 14 in the upper end of the housing. A reversing switch is connected through a appropriate circuit to a power line 15, by switch 15a.
The lower end of the shaft 5 is connected to an impeller rotor 16 which is encased in a housing 18 formed as part of the lower end 20 of the body 3 and comprises an enlarged cylindrical rotor case 22 having a plurality of circumferentially spaced, curved passages 24,24 each having radial open ends 25 and axial open ends 26.
The ends 25 communicate externally of the pump in a location to be immersed in the water in the toilet bowl and the ends 26 communicate with the top side 28 of the pump rotor 16, which has vanes 30 rotatable in the cylindrical portion 32 of the casing 22.
The lower end 34 of rotor 16 opposes the top of a control plate 38 which may be integral with closure annulus 40 having collar 42 secured in bore 43 in casing 22.
The plate 38 has a plurality of axial apertures 44,44 which communicate at their upper ends with the rotor chamber 46. A valve closure plate 50 is below plate 38 and has apertures 52 which are axially alignable with the apertures 44 in plate 38. Plate 50 is adapted to be rotated to a closed position as shown in FIG. 3a wherein the holes 44,52 are misaligned or to open position as in FIG. 3 wherein the apertures or openings or ports 44,52 are in alignment.
The mounting ring member 40 has a peripheral groove 54 into which there is fitted the upper end of a vacuum cup 55, the cup 55 being made of elastomer material, such as rubber or neoprene, and has a spincteral grip on the rim 56 of the ring 40 and is preferably bonded thereto with suitable adhesive. The vacuum cup is of typical design and has a thich lower lip 60, which controls flexing and obtains a good seal.
As is well known the cup is adapted to function as a typical plunger such that upon the tool being grasped by the handle 62 and the body portion 3 and reciprocated within the fluid in a plugged toilet bowl, the cup develops a vacuum and thus pulls on the column of fluid which acts as a hydraulic hammer against the plug to cause it to dislodge and break apart. The plates 38, 50 would be in a closed mode when the tool is used solely as a plunger.
When the tool is used as a pressure or surge pump, the plates are places in the open mode as in FIG. 3. The motor is run in one direction and then switched to the other direction attendant to alternately pressing the switch which reverses the motor rotation and consequently the direction of fluid flow. Fast changes of rotor rotation direction alternately pressurizes the column of fluid and rleases the pressure on the plug. The fluid flows through the opening 44,52.
The plates 38,52 are secured to each other by a bolt 65 which has a shank 66, extending through central openings 67,68 om tje plates, shank 66 being threaded in opening 67 and having a head engaging the bottom side of the plate 50.
A locking ring 70 is expanded into a groove 72 within the rim of the ring member and seats against the peripheral edge of the lower plate 50 which, at its upper edge, bears against a shoulder 74 in the closure ring.
OPERATION OF THE DEVICE
The tool may be conditioned to operate as a plunger by closing the ports 44,52 and the cup is place into the toilet bowland moved back and forth by the handle portion cousing the cup to develop a vacuum. If this does not dislodge the plug then the tool is withdrawn from the bowl and the plates set in open or pumping mode seen in FIGS. 1 and 3. The electric motor would be plugged in and the pump actuated to force the fluid into or out of the stack. The motor could be reversed to alternate the flow of the fluid.
Thus a novel combination plunger and pump has been described in which the parts are positionable to cause the unit to function in either of a plurality of ways in an effective manner.
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This invention appertains to plumber's tools for unplugging stoppages in pipes or stacks and comprises a vacuum cup at one end of a handle and a reversible selectively operable pump which is mounted to operate through the cup.
The parts of the mechanism are positionable so that the tool operates as a plunger with a vacuum cup or as a pump.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to methods and apparatus for assembling frames and particularly to the assembly of furniture drawers.
2. Description of the Background Art
A wide variety of machines are well known in the art for assembling generally rectangular wooden frames. These machines usually require the user to assemble the frame with the machine subsequently securing the various assembled frame portions together. For example, some machines require the user to insert a pair of perpendicularly related side portions of the wooden frame into the machine. The machine then butts the two portions together in the proper arrangement and subsequently secures them by stapling or nailing. The user then positions another pair of portions of the frame together to form another corner of the wooden frame and then the various portions are assembled into a completed rectangular frame. Devices of this general type are shown in U.S Pat. Nos. 3,734,381, 3,791,017, and 4,127,226.
In the assembly of drawers for furniture, such as cabinets, dressers and the like, the assembly of the various side, back and front portions into the original unsecured assembly is somewhat more difficult and time consuming than other frame forming operations due to the interfitting relationship of the various pieces. Once the pieces are assembled, manual securement, by stapling or the like, is often as practical as automated stapling machinery.
Many manufacturers of low cost furniture have found, surprisingly, that the assembly of drawers is the most time consuming operation in the assembly of vanities and dressers. Thus, it would be highly desirable to provide an automated drawer assembly apparatus capable of continuous drawer assembly.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a method and apparatus for rapid, automated frame assembly.
It is also an object of the present invention to provide an apparatus capable of assembling the sides, back and front of a drawer into an unsecured assembly and thereafter driving fasteners to fix the various pieces together.
It is still another object of the present invention to provide a method and apparatus for assembling drawers with dovetailed side portions.
It is another object of the present invention to provide an apparatus for assembling drawers capable of manufacturing drawers of different widths, heights and thicknesses.
It is yet another object of the present invention to provide an apparatus with a plurality of storage bins that automatically feed drawer side and back portions one at a time into assembly positions within the apparatus.
It is still another object of the present invention to provide such a machine capable of automatically refilling the side portion storage bins.
It is also an object of the present invention to not only automatically secure the various drawer portions together by fasteners such as nails or staples but also to automatically pre-glue the appropriate drawer portions before securement with fasteners.
These and many other objects of the present invention are achieved by an apparatus for automated drawer assembly including means for supplying the drawer end portions one at a time as well as means for supplying the drawer side portions one at a time. A reciprocating means slides the end portions one at a time into engagement with the side portions and slides the engaged side and end portions into engagement with another end portion. Means are provided for driving fasteners to fix the side portions to the end portions.
In accordance with another embodiment of the present invention a method for automated drawer assembly includes the steps of supplying drawer end portions on a generally continuous basis one at a time and further supplying drawer side portions on a generally continuous basis, one at a time to opposite sides of the end portion. The end portions are slid into engagement with the side portions and the engaged end and side portions are then slid into engagement with another end portion. Thereafter fasteners are driven to secure the side portions to the end portions.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partial, perspective view of one embodiment of the present invention;
FIG. 2 is a partial, simplified perspective view showing the arrangement of the various drawer portions during assembly in the apparatus shown in FIG. 1; and
FIG. 3 is a partial, top plan view of the movable drawer assembly section shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing wherein like reference characters are used for like parts throughout the several views, an automated frame assembly apparatus, shown in FIG. 1, is generally designated by the reference numeral 10. While the apparatus and method are described herein with respect to the manufacture of drawers, it will be obvious to those skilled in the art that the method and apparatus disclosed are also applicable to other frame assembly operations including the formation of window or door frames, and the like. The apparatus 10 is mounted atop a frame 12 on a plurality of legs 14 such that the operator's station 16, located generally centrally along the length of the frame 12, is arranged at waist height. The frame 12 includes a forward edge 13 connected by side edges 15 to a rearward edge 17. A pair of opposed drawer assembly sections 18 are mounted on the frame 12, the section 18a being fixed to the frame 12 while the section 18b is mounted for sliding movement with respect to the frame 12 on a set of parallel, spaced apart tracks 20.
Control over the position of the movable section 18b is provided by a drive mechanism 22 including a rotatable wheel 23 with a handle 24. Rotation of the wheel 23 threads or unthreads the threaded bars 26 with respect to their threaded receivers 28 resulting in movement of the section 18b along the tracks 20. The rotation supplied by the handle 24 is communicated to the threaded bar 26b by the chain drive 30. While a screw mechanism has been illustrated as the drive mechanism 22, those skilled in the art will realize that a wide variety of other mechanisms can be used for this purpose, including a rack and pinion drive mechanism. The section 18b is retained within the track 20 by a plurality of truncated triangular sliders 32, retained under the opposed flanges 33 of the track 20 but capable of smooth sliding movement with respect thereto.
Each section 18 includes a fastener driving station 34, a side portion storage bin 36 and a U-shaped back portion support 38, the supports 38 of the sections 18a and 18b together defining a back portion storage bin 40. In addition each section 18 includes a reciprocating slider 42 mounted for movement across the width of the frame 12 from the rearward edge 17 toward the forward edge 13. Each slider 42 is operated by an extendable cylinder 44, conveniently an air cylinder controlled for constant speed movement by a hydraulic cylinder 46 in a conventional manner.
The back portion storage bin 40 supports a plurality of drawer back portions 48 arranged in a generally serially aligned, face-to-face, vertical stack. The lower front portion of the bin 40 defines a slot 50 which allows only the lowermost portion 48a to be slid forwardly out of the bin 40 on the L-shaped rack 52 located intermediately between the sections 18. The rack 52 forms the bottom supporting surface of the back portion storage bin 40 and includes a pair of parallel, spaced apart members 54, each member connected to a different one of the sections 18. Thus, the back portion storage bin 40 enables one by one gravity feeding of the back portions 48 onto the rack 52.
The side portion storage bin 36 on each section 18 includes a pair of chambers 56 and 58, each arranged to hold a plurality of drawer side portions 60 in an upstanding configuration supported on edge, in a generally side by side, serially aligned, vertical configuration. The drawer side portions 60 contained in the chamber 56 are arranged generally parallel to those in the chamber 58; however, the portions 60 in the chamber 58 are situated slightly rearwardly with respect to those in the chamber 56. The portions 60 in each chamber 56 are biased towards the region 62 between the sections 18 by an extendable cylinder 64, conveniently an air actuated cylinder, whose piston arm 66 bears, with constant force, against the last portion 60a in the stack of portions 60 in each chamber 56. The cylinder 64b used with the movable section 18b is mounted on a track 20 for sliding movement with respect to the frame 12. The portions 60 are prevented from flowing inwardly into the region 62 by an upstanding barrier 68 bearing against the first portion 60b in the chamber 56.
Each chamber 58 includes a pair of spaced apart sidewalls 70 and a floor 72 that also forms the lower surface of the chamber 56. An extendable cylinder 74, conveniently an air actuated cylinder, is located along the rearward open side of the chamber 58 and is arranged to push the drawer side portions 60 located therein, inwardly into the chamber 56 through the forward open side of the chamber 58 while the cylinder 64 is retracted. More specifically, as shown in FIG. 3 with respect to the section 18b, each cylinder 74 includes an elongated head 76 which spans from one sidewall 70 to the other, arranged, upon extension of the cylinder 74, to slide the portions 60 into the chamber 56. While the cylinder 74a used with the section 18a is fixed to the frame 12, the cylinder 74b used with the section 18b is mounted on a track 20 for movement with respect to the frame 12 with the rest of the section 18b.
A pair of sensors 78 and 80 are located on two different sides of each chamber 56. The sensor 78 is located along the forward side of the chamber 56, generally aligned with the side 70a of the chamber 58 closest to the region 62. The sensor 78 includes a spring mounted, rotatable, cam 82 arranged to be deflected when side portions 60 are present in the adjacent region of the chamber 56. A cam operated, four-way valve 83 is operable from two directions to control the cylinders 74 and 64 in response to the actuation of the cam 82. Thus, when no portions 60 are located immediately adjacent the sensor 78, the sensor cam 82 rotates, under the influence of spring biasing, operating the valve 83 to retract the cylinder 64.
The withdrawal of the cylinder 64 from the chamber 56 is sensed by the sensor 80 located along the side of the chamber 56 farthest from the region 62. The sensor 80 is actuated by the enlarged head 84 of the piston arm 66, signalling the complete retraction of the piston arm 66. Conveniently the sensor 80 includes a conventional flow control valve 85 with a spring biased rotatable cam 86. When the cylinder 64 is retracted sufficiently to operate the sensor 80, the sensor 80 in turn operates the cylinder 74 to slide a plurality of drawer side portions 60 from the chamber 58 into the chamber 56. When these portions 60 are appropriately positioned within the chamber 56, the sensor 78 is again actuated, retracting the cylinder 74 and extending the cylinder 64 until the enlarged head 84 again operates against the rearwardmost drawer side portion 60a. The cylinder 64 advantageously operates at a faster speed during withdrawal or retraction than it operates on return to the chamber 56.
Each fastener driving station 34, located on opposite sides of the region 62, includes two banks of fastener drivers 88 and 90, the bank 90 being elevated with respect to the bank 88. The banks 88 and 90 are each conveniently composed of three side by side air actuated nailing or stapling guns 91, typically devices of the kind described in U.S. Pat. No. 3,673,922, to Doyle, assigned to the assignee of the present invention, with extended fastener magazines 92. The guns 91 in the banks 90 are arranged to project nails or staples (not shown) through their mouths 94 in a generally horizontal direction. The fastener drivers 91 forming the banks 88, are arranged to project fasteners such as staples or nails at a 45° angle, and include mouths 96 arranged in a generally downwardly canted orientation. Preferably the openings in the mouths 94 and 96 of one station 34, through which the fasteners exit, are contained in the same vertical plane. Each bank 88 or 90 is vertically adjustable through the slidably adjustable mounting of these banks between the vertical supports 89.
Each fastener driving station 34 also includes a drawer front portion support platform 98. Each platform 98 includes a handle 100 for adjusting the vertical position of the upper surface of the platform 98 with respect to the rest of the apparatus 10 and another means (not shown) for fine adjusting the spacing between the two platforms 98. Preferably the upper surface 102 of each platform 98 is formed of a low friction material such as polyurethane plastic.
As shown in FIG. 2, each slider 42 includes a lower, inverted T-shaped track engaging portion 104, a vertically extending frame 106 with a drawer side sliding forward edge 108 and an uppermost generally horizontally disposed drawer back forwarding member 110 secured to the inside of the frame 106. Each member 110 defines an offset 112 extending from the forward edge 108 rearwardly to the vertical forward edge 113 of the member 110. In addition a portion 114 extends rearwardly with respect to the remainder of the slider 42, arranged to maintain the drawer back portions 48 in an upwardly shifted position within the back portion storage bin 40 after the slider 42 has moved forwardly with respect to the storage bin 40. Each track engaging portion 104 includes an offset 115 extending rearwardly from the forward edge 108.
As indicated in FIG. 3, each slider 42 is movable from a rearward position to a forward position adjacent the fastener driving station 34 along a track 116 engaged by the lower track engaging portion 104 of each slider 42. Each track 116 extends along an upstanding barrier 68, adjacent the side of the barrier facing away from the region 62. More importantly, the track 116 is arranged to intersect the forwardmost drawer side portion 60b in each chamber 56. Since the forwardmost side portion 60b is retained only by compression between its neighboring side portion 60 and the upstanding barrier 68, a gap 118 being defined over the track 116, the slider 42 may contact the rearwardly facing edge of a forwardmost drawer side portion 60b and push it forwardly from the chamber 56. In addition the track 116 leads beneath the back portion storage bin 40 such that edge 113 of the horizontally disposed back forwarding member 110 may impact against the lowermost drawer back portion 48a located within the bin 40, sliding that portion 48 forwardly along the rack 52. The apparatus 10 is amenable to use with drawer portions of a variety of thicknesses, limited only by the width of the gaps 118 and slot 50.
A side portion gluing station 120 is located over each track 116 between the platform 98 of the station 34 and the portion of the track 116 adjacent the chamber 56. Each gluing station 120 includes a slot 122 adapted to conform loosely to the lower edge 124 of each side portion 60. Thus, in the illustrated embodiment wherein the drawer side portions 60 have dovetailed lower edges 124, the slots 122 also have a dovetailed configuration. Glue is applied using an air actuated apparatus (not shown) through openings on two sides of the slot 122 to the lower edge 124 of each side portion 60 slid through the gluing station 120.
A back portion gluing station 126 is located on each section 18 between the back portion supports 38 and the adjacent chambers 56 in a position elevated but generally aligned over each track 116. Each station 126 includes an inwardly facing slot 128 arranged to receive a lateral edge region 130 of a back portion 48. When a back portion 48 is slid along the rack 52 through the gluing station 126, glue is applied to the lateral edge region 130 of the portion 48 before the portion is slid into engagement with the side portions 60. Thus, using side portions 60 with dadoed slots 132 for receiving the back portions 48, the slots 128 in the gluing stations 126 are also of a dadoed configuration. This permits glue to be provided on the back portion 48 only as needed to secure the back portion 48 within each of the dadoed slots 132 in the side portions 60. The offsets formed on the sliders 42 by the attachment of the portions 110 to the inside surfaces of the frames 106 enable the sliders 42 to move along the track 116 past the gluing stations 126 while aligned to intercept both the side portions 60 and the back portions 48.
An apparatus control panel 134 is positioned adjacent the operator's station 16, conveniently on the face of one fastener driving station support 89. The panel 134 includes a kill switch 136 and a fastener driver operating switch 138. Thus, the operator can depress the switch 138 firing the various fastener drivers 91 in each bank 88 or 90 in unison. In case of an emergency, the kill switch 136 can be operated to disable all fastener drivers 91 and piston cylinders 44, 64, 74 associated with the apparatus 10. Where the fastener drivers and cylinders are air actuated, the disable function can be accomplished by a valve that opens the air supply line.
Control over the operation of the sliders 42 is provided by a foot actuated switch 140 positioned on the surface upon which the apparatus 10 is supported. Operation of the foot switch 140 moves the sliders 42 forwardly, in unison, at constant speed, to a position adjacent each platform 98 and thereafter automatically retracts them to a position wherein the forward edge 113 of the member 110 is located just rearwardly of the back portion storage bin 40.
The apparatus 10 may be operated in the following manner. Initially a plurality of side portions 60 are arranged in the chambers 56 and 58 with the faces having the dadoed slot 132 facing inwardly toward the region 62, the cylinders 64 being retracted. Thereafter, the position of the movable section 18b with respect to the fixed section 18a is set by operating the drive mechanism 22 to define the width of the region 62 in accordance with the width of the drawers to be manufactured. After the desired spacing has been set, the appropriately sized back portions 48 are loaded into the back portion storage bin 40, aligned within each support 38 and supported on the rack 52.
The operator then turns the apparatus 10 "on", operating a source of compressed air (not shown) causing the cylinders 64, of conventional form, to expand until the heads 84 contact the side portions 60a. It is entirely permissible to insert within the chambers 56 side portions 60 having a width, measured along the line from the front edge 13 to the rear edge 17, less than the width of the bin 36 measured along the same line. This is because the pressure supplied by the cylinders 64 maintains the portions 60 in alignment. Therefore, side portions 60 of varying widths can be used in the apparatus 10 to produce drawers of a desired height.
A drawer front portion 142, shown in FIG. 2, is positioned by the operator atop the platforms 98 butted against the forward edges of the gluing stations 120. By operating the handle 100 the elevation of each platform 98 can be adjusted to accomodate portions 142 of a desired thickness, the upper surface of the portion 142 being flush with the top surface of the stations 120. The drawer front portions 142 include a pair of spaced apart grooves 144 alignable with the slots 122 in the side portion gluing stations 120 and having a dovetailed configuration when using dovetailed side portions 60. The downward facing side (not shown) of the portion 142 normally forms the exposed surface of the drawer, and is protected from scratching by the upper surfaces 102 of the platforms 98. The operator actuates the foot pedal switch 140 causing the sliders 42 to advance along the track 116 from their rearward position forwardly towards the operator to a forward position adjacent the edge 146 of the drawer front portion 142.
In the course of this movement, the horizontally disposed back forwarding member 110 on each slider 42 contacts the lowermost back portion 48a within the storage bin 40 and slides that portion forwardly towards the gluing station 126. More specifically, the forward edge 113 of the member 110 contacts the rearward edge of the lowermost back portion 48a sliding it forwardly along the rack 52. The air actuated gluing stations 126 automatically begin to feed glue at the time when a back portion 48 begins to enter the slots 128 and cease to apply glue at the point when the back portion 48 has slid beyond the glue applying station 126. Conveniently the glue application is controlled by trip valves (not shown) located near the rearward edge of each station 126, actuable by the portion 48 to start and stop the glue flow in accordance with the position of the portion 48 with respect to the station 126.
Initially an extra back portion 48 is positioned by the operator on the rack 52, in engagement with the side portions 60. The side portions 60b are contacted by the forward edge 108 while the initial back portion 48 is forwarded by the back portion 48a being pushed by the leading edge 113 of the member 110. The initial back portion normally must be manually glued since it is inserted in a position forward of the glue stations 126. The portions 60b are slid along the tracks 116 guided by the upstanding barriers 68 located along the tracks 116. The dovetailed lower edge 124 of each side portion 60 mates eventually with the dovetailed slot 122 in each gluing station 120 and glue application is automatically initiated as the side portion 60 enters the gluing station 120 and automatically terminated as the side portion 60 extends past the gluing station 120. Again the glue application is controlled by trip valves (not shown) arranged to be actuated by the side portions 60 as they enter and leave the glue stations 120.
A pair of side portions 60, connected by a back portion 48, are slid into the portion 142, the lower edges 124 sliding into the grooves 144 in the front portion 142 in the same motion of each slider 42. This is accomplished by allowing each slider 42 to extend over each gluing station 120, due to the offset 115 in the track engaging portion 104, until the side sliding forward edge 108 is adjacent the rearward edge 146 of the front portion 142. The operator holds the portion 142 against the glue stations 120 during this process. At this point the drawer has been assembled with the exception of the bottom portion (not shown) and the sliders 42 are automatically retracted to their original positions. The assembled drawer is positioned atop the platforms 98 in a configuration rotated 90° from the horizontal arrangement in which the drawer operates in use.
The operator at this time actuates the fastener driver operating switch 138 and 12 nails or staples, in the illustrated embodiment, are automatically driven into the assembled drawer. More specifically, the fastener drivers 91 in the bank 70 project nails or staples in a generally horizontal direction through the side portion 60 at the location of the dadoed slot 132 and into the lateral edges 130 of the back portion 48. At the same time a plurality of fasteners are driven at a 45° angle into the front portion 142, extending inwardly through the dovetailed lower edge 124 of each side portion 60. In this way the drawers are automatically assembled in the desired arrangement and glued and fastened in the same process. The operator then removes the drawer assembly and places it on an appropriate conveyor to proceed to a station (not shown) where the bottoms (not shown) of the drawers are positioned within the bottom engaging slots 148 in conventional fashion.
As soon as the sliders 42 have reached their forwardmost position they automatically retract to their rearwardmost position. When the forwardmost edge 108 has moved past the chamber 56, the next set of side portions 60 snap into the positions formerly occupied by the portions 60b and immediately engage within their dadoed slots 132 the back portion 48a which was positioned between the chambers 56 in the same motion of the sliders 42 that pushed the side portions 60b into the front portion 142. At the end of the rearward movement of the sliders 42, the forward edge 113 passes rearwardly of back portion bin 40 and the lowermost back portion 48 is allowed to drop into position on the rack 52. Therefore when the sliders 42 again move forwardly the process repeats automatically, it no longer being necessary to manually feed and glue an initial back portion 48.
Preferably the width of the back portions 48 is less than the width of the side portions 60 to enable the drawer bottoms to be easily inserted into the slots 148 from the rear of the assembled drawer. The portions 48 are positioned between the slots 148 in each side portion 60 and the side portion forward edges 150. This arrangement is achieved by defining the length of the offset 112 such that a leading back portion 48 is positioned by the following back portion 48, in turn forwarded by the sliders 42, within the dadoed slot 132 between the side portion forward edges 150 and the bottom engaging slots 148 in the side portions 60. When the slider forward edges 108 contact the side portions 60, the engaged side portions 60 and leading back portion 48 are pushed toward the front portion 142 while the following back portion 48 moves into the position between the chambers 56 formerly occupied by the leading back portion 48.
While the present invention has been described with respect to a single preferred embodiment, it will be obvious to those skilled in the art that a variety of modifications can be made in the present invention, and it is intended within the appended claims to cover all such modifications as are within the true spirit and scope of the present invention.
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A method and apparatus for automated frame assembly, particularly advantageous for use in forming furniture drawers, includes a first bin for storing drawer back portions, situated generally in an elevated position with respect to the rest of the machine, and a pair of opposed bins for storing drawer side portions in serially arranged fashion. A pushing mechanism feeds the drawer back portions one at a time into engagement with one of the serially aligned drawer side portions of each bin. The pushing mechanism, in the same motion, pushes the engaged back and side portions into engagement with a drawer front portion where the side portions are fastened to the drawer front and back portions. Glue is applied to the drawer back portions before they engage the drawer side portions and glue is applied to the drawer side portions before they engage the drawer front portion. The drawer side portion storage bins are automatically refilled when a shortage is detected, by a mechanism which slides a plurality of serially aligned face to face drawer portions into the drawer side portion storage bins. The apparatus is adjustable to produce drawers of different widths and heights and to accept drawer portions of different thicknesses.
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FIELD OF THE INVENTION
[0001] The invention is generally related to electronic data files. More particularly, the invention is related to selecting elements from an electronic document.
BACKGROUND OF THE INVENTION
[0002] Electronic documents may be created using a variety of techniques. Thus, it may be desirable to store data from an electronic file in a format that is independent of the process used to create it, so the electronic document may be accessible to a range of users. One format that allows such access is the portable document format (“pdf”). Pdf is a file format for representing documents in a manner independent of the application software, hardware, and operating system used to create the documents and independent of the output device on which they are displayed or printed.
[0003] A pdf workflow assumes a one-way production process where the pdf document contains a rendition of document elements that are laid out for final presentation, i.e., no logical structural information is typically preserved for the document elements. Consequently, one problem with storing documents in a pdf format is that it is difficult to reuse parts of documents, because elements with semantic affinity are not stored as one logical group of elements. Therefore, it is difficult to select related elements of a pdf document that are desired by the user to be reused.
[0004] For example, it may be desirable for a user to insert a graph or chart from a pdf document into a document of the user's own creation or make a slide presentation with the graph or chart. However, most pdf documents do not generally support sharing or repurposing the content of the document, and it is generally difficult to select for reuse all the elements for a figure, an illustration or a paragraph as an integrated object from PDF.
[0005] There are a few techniques available for reusing pdf document content. However, the available techniques are complicated and may require extensive user interaction. For example, one complicated technique may extract a raster rendition of a selected document portion from a display bitmap. However, all the original document structure and attribute information is lost, as well as resolution, which is usually limited to the 72 dpi screen resolution. Therefore, the selected portion may not be readily assembled on a new document.
SUMMARY OF THE INVENTION
[0006] According to an embodiment of the invention, a method of selecting elements from an electronic document comprises identifying a largest graphics element in a page of the electronic document; creating a graphics region in the page, the graphics region including an expandable area in the page including at least the largest graphics element; determining whether at least one bounding box for at least one other graphics element is in a vicinity of the graphics region; and growing the graphics region to further include the at least one other graphics element in response to the at least one bounding box being in the vicinity of the graphics region.
[0007] According to yet another embodiment of the invention, an apparatus configured to select elements from an electronic document comprises means for identifying a largest graphics element in a page of the electronic document; means for creating a graphics region that includes the largest graphics element; means for determining whether at least one bounding box for at least one other graphics element is in a vicinity of the graphics region; and means for growing the graphics region to include the at least one other graphics element in response to the at least one bounding box being in the vicinity of the graphics region.
[0008] According to yet another embodiment of the invention, a computing device comprises a processor operable to select a plurality of related graphics elements for extraction from an electronic document. Selecting the plurality of related graphics elements includes creating a graphics region in the electronic document. The graphics region includes an expandable area in the document including the plurality of related graphics elements. The computing device also comprises a memory storing the electronic document.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention is illustrated by way of example and not limitation in the accompanying figures in which like numeral references refer to like elements, and wherein:
[0010] [0010]FIG. 1 is a block diagram of an extraction tool, according to an embodiment of the invention;
[0011] FIGS. 2 A-D illustrate growing a graphics region for selecting elements from an electronic document, according to an embodiment of the invention;
[0012] [0012]FIG. 3 illustrates a flow diagram of a method for creating and growing a graphics region, according to an embodiment of the invention;
[0013] [0013]FIG. 4 illustrates a flow diagram of a method for identifying graphic elements in the vicinity of graphics region, according to an embodiment of the invention;
[0014] FIGS. 5 A-D illustrate a flow diagram of methods for growing the graphics region to include non-graphics elements, according to embodiments of the invention;
[0015] FIGS. 6 A-B illustrate flow diagrams of methods for growing the graphics region to include related elements, according to embodiments of the invention;
[0016] [0016]FIG. 7 is a flow diagram of a method for extracting elements of one or more additional graphics groups, according to an embodiment of the invention; and
[0017] [0017]FIG. 8 is a block diagram of a computing platform, according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that these specific details need not be used to practice the invention. In other instances, well known structures, interfaces, and processes have not been shown in detail in order not to unnecessarily obscure the invention.
[0019] [0019]FIG. 1 is a block diagram illustrating one embodiment of a graphics extraction tool 100 . The graphics extraction tool 100 includes modules 110 - 160 for extracting logically related graphics elements from an electronic document (e.g., a pdf document). The graphics extraction tool 100 , when invoked, may automatically select a group of graphics elements (i.e., a graphics group) that are related, such as a group of independent graphics elements that collectively form a table, graph, figure, etc., in a pdf document. After a graphics group is identified, the group may be extracted and used in other documents.
[0020] The graphics extraction tool 100 may include an input/output module 110 , a preprocessing module 115 , a section determination module 120 , a memory module 130 , a document generation module 140 , a verification module 150 and a processing module 160 . The modules 110 - 160 are shown to be located within the graphics extraction tool 100 for conceptual purposes only. In other embodiments, one or more of the modules 110 - 160 may reside outside of the extraction tool 100 and may be called upon by the graphics extraction tool 100 as needed.
[0021] The input/output module 110 may receive instructions from a user or software (e.g., an application, a software tool, a software module, etc.) to invoke the graphics extraction tool 100 to extract graphics from a pdf document. For example, a user may select a button on a pdf reader to invoke the graphics extraction tool 100 or the graphics extraction tool may be invoked by software.
[0022] The preprocessing module 115 may remove all invisible graphics elements (e.g., graphics elements without stroke and fill, graphics elements without stroke and with white fill, graphics elements completely covered by other elements, graphics elements mostly outside of a page, etc.). The preprocessing module 115 may also remove headers, footers, and stylistic patterns (e.g., background water mark).
[0023] The section determination module (SDM) 120 may determine what graphics elements of the pdf document should be extracted. For example, the SDM 120 may apply rules of inclusion to determine if graphics elements in the pdf document are logically related. The SDM 120 may form a graphics group including all the elements to be extracted. The graphics group, for example, is a list of all the elements (e.g., graphics elements, text elements, image elements, etc.) to be extracted.
[0024] The memory module 130 may be used to store image information, data, instructions or any other information usable for extracting a graphics group from a pdf document. For example, the memory may be used to store graphics elements in a graphics group while the SDM 120 determines what graphics elements will be included in the extraction region.
[0025] The document generation module 140 may generate a new document by extracting the elements in the region determined by the SDM 120 into the new document. In one embodiment, the document generation module 140 may extract a graphics group into a new pdf document.
[0026] The verification module 150 may verify the accuracy of the extracted region in the new document generated by document generation module 140 . In one embodiment, the verification module 150 may convert the original document and the new document generated by the document generation module 140 into bitmap images for comparison.
[0027] The processing module 160 may execute the processes for extracting graphics elements and other elements using instructions received from modules 110 , 120 , 140 and 150 . For example, the processing module 160 may increase the size of a graphics region containing graphics elements based on instructions or inclusion rules from the SDM 120 . An example of an inclusion rule is to encompass all graphics elements that intersect an expanded graphics region.
[0028] A pdf document may include, for example, text elements, graphics elements and image elements. FIGS. 2 A-D illustrate growing a graphics region 220 on an exemplary pdf page 200 to select a plurality of related graphics elements, which may be extracted. As shown in FIG. 2A, the page 200 includes graphics elements surrounded by respective bounding boxes 201 - 205 and text elements surrounded by respective bounding boxes 210 - 214 . Although a single page 200 is illustrated, a pdf document may include one or more pdf pages having elements that may be selected by the graphics tool 100 . The text elements include text runs, which are characters having similar attribute(s) (e.g., same font, same font size, all bold, all normal, etc.). The graphics elements, also known as path elements or graphic primitives, may include arbitrary shapes comprised of a sequence of straight lines, rectangles and/or cubic Bezier curves.
[0029] Bounding boxes (e.g., 201 - 205 and 210 - 214 ) are rectangles which surround objects in a document, and may refer to a rectangle which entirely encloses the object on a page. The bounding box location and size for each element may be obtained, for example, through ADOBE ACROBAT Software Development Tool Kit Application Programmer Interface, where a bounding box is guaranteed to encompass the element, but is not necessarily the smallest box that contains the element. To achieve higher accuracy for selecting and extracting the desired elements, a bounding box may be modified to be the smallest bounding box containing the element. For example, for a rectangular shaped graphics element, the bounding box may be modified to be the outline of the rectangle itself. Bounding boxes are typically invisible to a viewer of a pdf document.
[0030] The SDM 120 may determine what graphics elements of the pdf document 200 are selected using rules of inclusion. For example, the SDM 120 may apply rules of inclusion to determine if graphics elements in the pdf document are logically related.
[0031] A graphics region may include a rectangular area generated by the SDM 120 that includes all elements of the page 200 that are logically related. Graphics elements and other related elements in the graphics region are eventually extracted by the graphics tool 100 . In the page 200 , the graphics region 220 (shown in FIGS. 2 B-D) includes all the elements including and logically related to the Growth Rate Table.
[0032] As shown in FIG. 2B, in order to identify all the elements that are logically related, the SDM 120 may start the graphics region 220 with the bounding box of the largest graphics element in the page 200 , such as the graphics element surrounded by the bounding box 203 . Then, as shown in FIG. 2C, the SDM 120 may grow the graphics region 220 to include graphics elements intersecting the graphics region 220 shown in FIG. 2B. As shown in FIG. 2C, the graphics region is grown to include graphics elements 205 . As shown in FIG. 2D, the graphics region 220 is grown again to include graphic elements 201 , 202 , 204 , text elements 210 and other elements in the vicinity and intersecting the graphics region 220 shown in FIG. 2C. The result of growing again is the graphics region 220 includes all the elements shown in FIG. 2D, which are logically related to the Growth Rate Table. The process of re-growing the graphics regions 220 may be repeated until all the elements logically related to the graphics elements are included in the graphics region, which may be determined by the rules of inclusion described below with respect to the methods.
[0033] After a determination is made that the graphics region 220 includes all logically related elements, the elements within the graphics region 220 may be extracted for storage in a memory and/or for incorporation into a new document.
[0034] [0034]FIG. 3 illustrates a flow chart of an exemplary method 300 for selecting elements of an electronic document, according to an embodiment of the invention. In step 305 , the preprocessing module 105 excludes invisible elements (e.g., graphics elements without stroke and fill, graphics elements without stroke and with white fill, graphics elements completely covered by other elements, graphics elements mostly outside of a page, etc.) from being selected. These elements may not be useful to a user that needs particular graphics and logically related elements extracted from a page in the document. In step 310 , the SDM 120 identifies the graphics elements in the page of, for example, a pdf document. In step 315 , the SDM 120 identifies the largest graphics element from the identified graphics elements. The size of the graphics elements may be determined using coordinate information provided with each bounding box for each graphics element. Coordinate information is an attribute typically provided in pdf documents. The graphics elements may be sorted by size in a list, and the largest graphics element (e.g., the graphics element on top of the sorted list) is selected.
[0035] In step 320 , a graphics region is created that includes the largest graphics element. The size of the graphics region may be equal to the bounding box for the largest graphics element. The SDM 120 may instruct the processing module 160 to create and expand the graphics region to include the largest graphics element.
[0036] In step 325 , the SDM 120 determines whether a bounding box for a graphics element intersects or is in the vicinity of the graphics region created in step 320 . For example, each bounding box in the sorted list is analyzed to determine whether each bounding box intersects the graphics region. An intersecting bounding box includes bounding boxes that overlap or share a common boundary. An illustration of a common boundary is shown in FIG. 2A. For example, the bottom of the bounding box 201 and the bottom of the bounding box 205 share a common boundary. These bounding boxes also happen to overlap, but intersecting bounding boxes may not overlap. Sub-steps for identifying graphics elements within the vicinity of the graphics region are illustrated in FIG. 4 and described in detail below. Generally, the graphics region is expanded to identify elements intersecting and/or in the vicinity of the graphics region. Then, the graphics region is grown (see step 330 ).
[0037] In step 330 , the graphics region is grown to include the elements identified in step 325 . The elements included within the graphics region are added to the graphics group (step 335 ). Steps 330 and 335 may be performed repeatedly until no more new elements can be identified.
[0038] In step 340 , if no graphics elements are intersecting and/or in the vicinity of the graphics region, as determined in step 325 , the SDM 120 determines whether the number of graphics elements in the graphics region is greater than one. If the number of graphics elements is not greater than one, graphics elements are not selected and are not extracted (step 345 ). If no bounding boxes for graphics elements intersect the graphics region, then the graphics region likely includes a single graphics element. A pdf document may include a special graphics element, such as a line before the footer and all text elements. This special graphics element may not be of use to a user if extracted. If the number of graphics elements is greater than one, a small area (e.g., twice a font size in width and height) is added to the graphics region (step 350 ). Step 350 is optional and may be performed to include small elements related to a graphics element in the graphics region in subsequent steps. After step 350 , steps shown in FIGS. 5 A-D may be performed.
[0039] [0039]FIG. 4 illustrates a flow diagram of an exemplary method 400 , according to an embodiment of the invention, for identifying graphics elements within a vicinity of the graphics region. The steps for the method 400 may be performed when step 325 in the method 300 (shown in FIG. 3) is invoked.
[0040] In step 405 , the SDM 120 identifies a text element having the largest bounding box or having the largest number of characters on the page of the pdf document. In step 410 , the SDM 120 identifies the most common font size among text run elements within the text element identified in step 405 . A large text element may include multiple text runs. Although a text element may include multiple text runs, each having a different font size, a text run typically has only one font size. The most common font size among text runs may be used. Alternatively, a text run with the largest number of characters or a font size for a text run in the middle of the text element may be selected. Font size information may be retrieved from attributes associated with the text run.
[0041] In step 415 , the graphics region is expanded by twice the size of the font identified in step 410 . The height and/or the width may be expanded by twice the font size. In step 420 , the SDM 120 determines whether any bounding boxes for graphics elements intersect the expanded graphics region. If any graphics elements intersect the graphics region, as determined in step 420 , the graphics region is expanded to include those elements. Step 420 may be repeated with step 330 in the method 300 such that the graphics region is expanded until no graphics elements intersecting the expanded graphics region can be identified.
[0042] The graphics region may be further expanded to include related elements as described with respect to FIGS. 5 A-D. The related elements may include non-graphics elements logically related to the graphics elements in the graphics region. FIGS. 5 A-D illustrate steps that may be performed after step 350 , shown in FIG. 3.
[0043] [0043]FIG. 5A illustrates a method 500 , according to an embodiment of the invention. In step 505 , the SDM 120 determines whether any bounding boxes for non-graphic elements are inside the graphics region. If any non-graphics elements are inside the graphics region, these elements are added to the graphics group (step 510 ) and may subsequently be extracted. If no non-graphics elements are inside the graphics region, elements are not added to the graphics group in this method (step 515 ).
[0044] [0044]FIG. 5B illustrates a method 525 , according to an embodiment of the invention. In step 530 , the SDM 120 determines whether any bounding boxes for small elements intersect the graphics region. A small element, for example, may be an element having a bounding box area approximately less than or equal to 0.8 of the area of the graphics region. The 0.8 threshold, however, is an example, and the threshold can vary as defined. Also, the threshold may be defined by the software for the graphics extraction tool 100 .
[0045] In step 535 , small elements having bounding boxes intersecting the graphics region may be added to the graphics group, and the graphics region is grown to include these elements (step 540 ). Therefore, small elements logically related to the elements in the graphics group and in close proximity on the page to those elements may be extracted. In step 545 , if no small elements are identified in step 530 , the graphics region is not grown in this method.
[0046] [0046]FIG. 5C illustrates a method 550 , according to another embodiment of the invention, for adding text elements to the graphics region. In step 555 , the SDM 120 determines whether any bounding boxes for large elements intersect the graphics region. A large element, for example, may include an element with a bounding box area greater than a percentage (e.g., 75%, 80%, etc.) of the graphics region. If a large element intersects the graphics region (as determined in step 555 ), the SDM 120 determines whether the large element is a text element (step 565 ). If a large element does not intersect the graphics region (as determined in step 555 ), the graphics region is not expanded in this method (step 560 ). Also, if a large element intersects the graphics region and the large element is not a text element, the graphics region is not expanded in this method (step 560 ).
[0047] If the large element is a text element, a new text element is created (step 575 ). Then, the text runs in the text element identified in step 565 that intersect the graphics bounding box are added to the text element created in step 575 . Therefore, captions, titles, etc, that are associated with, for example, a figure may be extracted from the pdf page along with the figure.
[0048] In step 585 , the elements in the new text element are added to the graphics group, and the graphics region is grown to include these elements (step 590 ).
[0049] [0049]FIG. 5D illustrates a flow diagram 591 , according to an embodiment of the invention, for further expanding the graphics region to include text elements that are related to graphics elements to be extracted. In step 592 , the SDM 120 determines whether the pdf page includes one or more predetermined character strings. For example, the page is searched for the predetermined character strings. Character strings may include “Fig.”, “Figure”, “Table”, “Chart”, etc. These character strings may include characters typically used in the description of related graphics elements. In step 593 , if any of the predetermined character stings are found in the page, the SDM 120 determines whether the bounding box for the text element including the character string is within the vicinity of the graphics region. Vicinity may be based upon a font size (e.g., twice a font size in a text run).
[0050] In step 594 , the text element having the predetermined character string is added to the graphics group if the that text element is within the vicinity of the graphics region. The graphics region may then be grown to include the text element.
[0051] If none of the predetermined character strings are found (as determined in step 592 ), then the graphics region is not grown (step 595 ). If a predetermined character string identified in step 592 is not within the vicinity of the graphics region (as determined in step 593 ), then the graphics region is not grown (step 595 ).
[0052] It will be apparent to one of ordinary skill in the art that the methods 500 , 525 , 550 and 591 may be performed in any order and one or more of the steps in these methods may be combined into one or more methods to eliminate redundant steps.
[0053] [0053]FIG. 6A illustrates a method 600 , according to an embodiment of the invention, which may be used to add very small elements associated with the graphics elements in the graphics region to the graphics region. In step 605 , the SDM 120 sorts the elements in the graphics group according to their index. For example, the SDM 120 compiles an index based on an order all the elements are laid on the page. Elements that are logically related to each other on the page tend to be close in the index. For example, graphics elements for a table on a page tend to be placed on the page in succession, and thus have index values close to each other. The SDM then sorts the elements in the graphics group based on their value in the index. For example, a list is created including the elements sorted by their index value. In step 610 , the SDM 120 identifies the largest and smallest index values (i.e., Gmax and Gmin) that the elements in the graphics group have.
[0054] In step 615 , the SDM 120 determines whether very small elements in the page have an index value between Gmax and Gmin. A very small element, for example, may be an element having a bounding box area approximately less than or equal to 0.1 of the graphics region. The 0.1 threshold, however, is an example, and the threshold can vary as defined. The very small elements may generally be smaller than the small elements described in FIG. 5B. Also, the very small elements may be defined by the software. If no very small elements have index values between Gmax and Gmin, no elements are added to the graphics group in this method. Then, step 665 in a method 650 , shown in FIG. 6B, may be performed.
[0055] If one or more very small graphics elements are identified in step 615 , the SDM 120 determines whether the very small graphics elements are within a general vicinity of the graphics region (step 625 ). The general vicinity may be based on a predetermined value. In one example, the vicinity may include an area approximately equal to the graphics region being expanded by ten times the common font size of the page. The general vicinity may not necessarily be based on font size and can include any predetermined value. Note that the size of the general vicinity may be larger than the size of the vicinity (e.g., twice the most common font size) described previously.
[0056] If the very small graphics element(s) are within the general vicinity of the graphics region, they are added to the graphics group and the graphics region is grown to encompass them (step 630 ). After step 630 , steps 680 and 685 , shown in FIG. 6B and described below, are performed. If the very small graphics element(s) are not in the general vicinity, as determined in step 625 , step 665 , shown in FIG. 6B, may be performed.
[0057] [0057]FIG. 6B illustrates a method 650 , according to yet an embodiment of the invention, which may be used to add very small elements associated with the graphics elements in the graphics region to the graphics region.
[0058] In step 665 , the SDM 120 determines whether one or more very small elements have index values outside Gmax and Gmin, but next to Gmax and Gmin (e.g., Gmax +1 and Gmin −1). For example, if Gmax is 10 and Gmin is 2, then very small elements having index values of 11 or 1 are identified. If the SDM 120 determines that no very small elements have index values outside and next to Gmax and Gmin, then step 680 is performed. In step 670 , the SDM 120 determines whether any very small elements identified in step 665 are in the general vicinity of the graphics region. If the very small elements are in the general vicinity, the very small elements are added to the graphics group (step 675 ). Also, Gmax and/or Gmin are modified to include the index value of the very small element(s) (step 675 ). Steps 665 - 675 may be repeated if very small elements are initially identified in step 665 . If no very small elements are in the general vicinity of the graphics group, as determined in step 670 , step 680 is performed.
[0059] At the completion of step 630 shown in FIG. 6A or at the completion of one of steps 665 - 675 , step 680 is performed. In step 680 , the SDM 120 identifies all the elements in the graphics group. These elements may include elements added to the graphics groups in one or more of the previous methods illustrated in FIGS. 3 - 5 and the methods 600 and 650 illustrated in FIGS. 6 A-B. In step 685 , a new document is created, and all the elements in the graphics group are extracted. Extraction may include cutting or copying the elements in the graphics group, such as performed by conventional software applications. The extracted elements may be laid on a page in the new document according to an index.
[0060] Steps 615 - 630 in the method 600 and steps 665 - 675 in the method 650 may be performed in different orders or substantially simultaneously. For example, steps 665 - 675 may be performed after steps 605 and 610 , instead of steps 615 - 630 . Alternatively, after steps 605 and 610 , steps 615 - 630 and steps 665 - 675 may be performed substantially simultaneously.
[0061] The methods 600 and 650 may be used to grow the graphics region to include elements consecutively placed on the pdf page and within the vicinity of the elements within the graphics group. Elements that meet these criteria may likely be associated with the graphics elements to be extracted and accordingly are included in the graphics group.
[0062] [0062]FIG. 7 illustrates a method 700 according to an embodiment of the invention. The method 700 may be performed after the methods illustrated in FIGS. 3 - 6 . In step 705 , the graphics extraction tool 100 identifies the graphics elements in the previous graphics groups, which includes graphics elements added to the graphics group from the methods illustrated in FIGS. 3 - 6 . In step 710 , the SDM 120 filters out the graphics elements identified in step 705 from the graphics elements in the page. In step 715 , one or more of the methods illustrated in FIGS. 2 - 7 are performed on the remaining graphics elements. These steps may be repeated until no elements can be identified that belong in the graphics group. This method allows multiple figures, charts, etc., included in a single page to be extracted.
[0063] [0063]FIG. 8 illustrates a computing platform 800 operable to perform the methods in FIGS. 3 - 7 . The computing platform 800 includes one or more processors, such as processor 802 , configured to provide an execution platform for a computing device. Commands and data from the processor 802 may be communicated over a communication bus 804 .
[0064] The computing platform 800 also includes a main memory 806 , preferably Random Access Memory (RAM), where the software (e.g., the graphics extraction tool 100 shown in FIG. 1, which may perform the methods shown in FIGS. 3 - 7 ) for the computing device 32 may be executed during runtime. In addition, electronic documents (e.g., pdf documents) may be stored in the memory 806 . The software may automatically extract graphics elements and related text elements from one electronic document and incorporate them in another electronic document. These documents may be stored in the memory 806 and/or a secondary memory 808 .
[0065] The secondary memory 808 may also be included in the computing platform 800 . The secondary memory 808 includes, for example, a hard disk drive 810 and/or a removable storage drive 812 , representing a floppy diskette drive, a magnetic tape drive, a compact disk drive, and the like. The removable storage drive 812 may store a copy of the software for the computing device 32 . In addition, the removable storage drive 812 may read from and/or write to a removable storage unit 814 , e.g., floppy disk, compact disc, etc.
[0066] A user may interface with the computing platform 800 through a keyboard 816 , a mouse 818 , and a display 820 . A display adapter 822 may be interfaced between the communication bus 804 and the display 820 to receive display data from the processor 802 and to convert the display data into display commands visible on the display 820 .
[0067] The steps described above and illustrated in FIGS. 3 - 7 may be compiled into computer programs. These computer programs can exist in a variety of forms both active and inactive. For example, the computer program can exist as software comprised of program instructions or statements in source code, object code, executable code or other formats. Any of the above can be embodied on a computer readable medium, which include storage devices and signals, in compressed or uncompressed form. Exemplary computer readable storage devices include conventional computer system RAM (random access memory), ROM (read only memory), EPROM (erasable, programmable ROM), EEPROM (electrically erasable, programmable ROM), and magnetic or optical or magneto-optical disks or tapes. Exemplary computer readable signals, whether modulated using a carrier or not, are signals that a computer system hosting or running the computer program can be configured to access, including signals downloaded through the Internet or other networks. Concrete examples of the foregoing include distribution of executable software program(s) of the computer program on a CD ROM or via Internet download. In a sense, the Internet itself, as an abstract entity, is a computer readable medium. The same is true of computer networks in general.
[0068] While this invention has been described in conjunction with the specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. These changes and others may be made without departing from the spirit and scope of the invention.
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A computing device comprises a processor and a memory. The processor operable to select a plurality of related graphics elements for extraction from an electronic document. The selection of the plurality of related graphics elements includes creating a graphics region in the electronic document, and the graphics region includes an expandable area in the document encompassing the plurality of related graphics elements. The memory stores the electronic document from which the plurality of related graphics elements are extracted.
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This application is a continuation-in-part of Ser. No. 390,332, filed Aug. 22, 1973, now U.S. Pat. No. 3,884,747.
FIELD OF THE INVENTION
The field is that of tabling and processing fabric material, particularly drapery material, especially in the area of applying stiffening means to an edge part of the material.
BACKGROUND OF THE INVENTION
The machine is an improvement in the processing of drapery material with a greatly reduced amount of hand labor and space requirements which have been characteristic of the prior art up to date.
The prior art is best exemplified in this inventors U.S. Pat. Nos. 3,795,565 and 3,884,747, which are hereby incorporated herein by reference.
Known other prior art includes U.S. Pat. Nos. 1,507,342; 2,501,873; 2,529,859; 2,937,689; 3,012,603; 3,044,534; 3,058,634; 3,068,137; 3,012,603; 3,102,305; 3,143,456, 3,184,798; 3,463,482; 3,534,954; 3,654,015; 3,631,826; 2,737,750; and 3,795,565.
SUMMARY OF THE INVENTION
The invention is a machine for processing fabric material, particularly drapery material from which drapes are made. Basically, the machine provides a relatively wide tabling surface over which the material is passed and on which it is held down by pressure rollers. The tabling surface embodies a rotary drum providing a moving surface for transporting, i.e., tumbling the fabric. The machine is provided at one end of said surface with mechanism for processing the edge of a drapery material which is the edge which becomes the top of the finished drape. This mechanism is a power driven sewing machine which stitches a strip of stiffening material, preferably buckram to the drapery material.
A primary object is to realize simplified but extremely effective and easy to use apparatus for applying the stiffening material.
Another object is to simplify and make possible the continuous processing of the top of the drape, including applying of the stiffening material, simply by means of a power driven sewing machine.
Another object is to speed up the processing of the drapery material using simplified apparatus while at the same time reducing the number of personnel required and the amount of space required.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and additional advantages of the invention will become apparent from the following detailed description and annexed drawings, wherein:
FIG. 1 is a front elevational view of the machine of the invention;
FIG. 2 is a partial isometric view of the end of the machine at which the stiffener is applied.
FIG. 3 is an end view of the machine.
FIG. 4 is a sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 3;
FIG. 6 is a partial sectional view taken along the line 6--6 of FIG. 1;
DESCRIPTION OF THE PREFERRED EMBODIMENT
The general organization fo the machine will best be appreciated from FIGS. 1, 2 and 3, FIG. 1 being a front view of the machine, FIG. 3 being an end view and FIG. 2 being a partial isometric view. The operator occupies a position at the front of the machine for applying the edge or border stiffener at the right end of the machine as seen in FIG. 1. In operation, as will be explained presently, the drapery fabric is tumbled, that is, passed or carried from one basket or fabric holder over the platform or table and the rotating drum into another basket or holder on the other side of the tabling surface. The table or platform surface over which the fabric passes is designated by numeral 10. Fabric passes over the tabling surface from left to right as seen in FIGS. 2 and 3. The drapery material is designated at 12 and moves from a holder or basket 14 on the entrance side to a holder or basket on the other side.
Basket 14 is made from fabric material, the edges or ends of which are suspended underneath the frame structure of the machine by suspension members. The rear basket is of similar construction and is similarly suspended.
On the entering side, the tabling surface includes an inclined part 20. This surface may be formed of any suitable material which can be formed into the desired contour, such as plastic or otherwise. On the other side of the tabling surface beyond the processing mechanism is an inclined surface 26 which may be formed of any suitable material. There is a gap 30 shown in FIG. 2, between inclined surfaces 20 and 26.
Numeral 32 designates an elongated cylindrical drum mounted on shaft 34, the drum being in a position such that its upper part extends into gap 30. As may be seen, drapery fabric 12 leads up over the contoured inlet surface, over the upper part of rotating drum 32, and on to inclined surface at the back of the machine. It will be understood that by reason of the contact between the periphery of drum 32 and fabric 12, the drapery material will be continually moved or caused to traverse (tumbled) from left to right as will be described more in detail presently. Rotating drum 32 is exemplary of a preferred means for moving the drapery material, that is to cause it to traverse the tabling surface, although other alternative means may be employed.
Shaft 34 is journalled in bearing 38 and in a similar bearing at the other end as may be seen in FIG. 1. A supporting frame structure is provided underneath the tabling structure which is supported by four supporting legs, one of them being shown at 39.
Drum 32 is driven by motor 50 suitably supported on platform 52 supported by way of bracket structure 54. Motor 50 drives a shaft 56 which drives shaft 34 of drum 32 by way of sprocket wheels and sprocket chain 62. Shaft 34 is journalled at the opposite end of the machine. It extends beyond housing 40 and carries sprocket wheel 63 which will be referred to again presently.
The drapery material is accurately measured and formed (sized) and guided as it is passed (tumbled) over the tabling surface. It is held down during its passage. The sizing and guiding mechanism is best shown in FIG. 1. Supported over the tabling surface and substantially over drum 32 is an assembly designated generally at 110 including rail 111. Carried by rail 111 of the assembly 110 are rollers 126, 127 and 128 which may be made of rubber or composition material. These rollers are journalled on suitable shafts carried by rider members 116, 117 and 118. Member 110 is supported from the frame of the machine including bracket 130 at one end, the riders 116-118 can slide along rail 111.
The tabling surface 10 comprises a smooth surface material which may be metal or plastic or comparable material. Numeral 134 designates a metal bracket plate having a flange at the upper edge which hooks over the upper edge of the table surface adjacent to the gap 30 in it. Numeral 136 designates a small plate which is hinged to the plate 134 as shown, which provides a guide stop at the left end of the fabric material the edge of this plate being adjacent to graduated scale 137. Numeral 138 designates another bracket plate having a flange 139 which clips over the lower edge 140 of the tabling surface. Plates 134 and 138 are urged together by tension springs 141 and 142, thereby making it easy to adjust these plates along the tabling surface, the stop and measuring plate 136 being adjusted at the same time. The details of this structure are shown in FIG. 6.
The mechanism at the right end of the machine for applying the strip of stiffening material is best shown in FIGS. 1, 2 and 3, FIGS. 4 and 5 being sectional detail views. At the right end of the machine there is a stand as designated generally by the numeral 150, having side members 151 and 152. The side member 152 has a configuration as shown in FIG. 3 having legs 153 and 154 and having openings 155 and 156. The side members have upper parts 160 and 161 which include forwardly extending portions as shown in FIG. 2. The side member 151 has inclined slanted upper surface 164 and downwardly slanted surface 165. The side member 152 has a similar slanted upper surface 168 and an upper surface 169. Between the surface parts 165 and 168 is a platform 170. Beneath this platform is the roll 172 of stiffening material that is, the buckram being on a shaft 173 as shown. As may be seen in the figures, the strip of a buckram comes off the roll underneath the platform 170, as will be described. The edge part of the fabric material is over the platform 170 as may be seen in FIG. 2 so that it overlies the strip of stiffening material. Mounted between the side members 151 and 152 is a sewing machine 180 which is of a commercial type preferably being a three-spool overlock type or it may be any type that produces an overlock type of stitch. It has sewing foot 181 and foot plate 179. Beyond the foot, there is a cutting mechanism that cuts off extra material. The machine is driven by a motor 182 having a pulley 183 and driving belt 184 that drives the machine. The motor 182 is supported on a platform 186 between the side members 151 and 152. Numeral 190 designates a control lever for the sewing machine which is pivoted as shown at 191 and which may be actuated by a control cable 192 connected to a control lever 194 pivoted on a pivot 196 between the side members 151 and 152. The lever has an end foot pedal 200 which may be actuated by the operator's foot.
Numeral 210 designates a platform mounted transversely on the surfaces 165 and 169 of the side members and over which the fabric material passes after the stiffening strip has been sewn to it. This surface has rectangular openings as designated at 212 and 214. Numerals 216 and 218 designate rollers on shafts 217 and 219, the ends of which are journalled in the side members 151 and 152. See FIG. 4. On the shaft 219 is a sprocket wheel 222 driven by a sprocket chain 223 which passes over sprocket wheel 224 on the shaft 34. On the shafts 217 and 219 are sprocket wheels 226 and 227 and passing over these sprocket wheels is a sprocket chain 230 so that both of these rollers are driven.
Directly overlying the roller 216 is a roller 236 on a shaft 237 journalled in journal bearings 238 and 239 extended from a platform 242 by stems 243 and 244. See FIG. 5. Similarly supported from the platform 242 is a further roller 246 which directly overlies the roller 218 as may be seen in FIG. 3.
Numeral 250 designates a rectangular frame having side members and end members as shown, the side members being supported between the upper portions 160 and 161 of the side members 152 and 151. At the rear of the platform member 242 there are upright members secured thereto as designated at 256 and 257 which cooperate with guide slides 258 and 259 positioned perpendicularly to the frame 250 and held by brackets as designated at 260 in FIG. 3. Springs are provided as shown at 262 and 263 between platform 242 and the side members of frame 250.
As explained, the platform 242 supports the rollers 236 and 246 which can be moved in a direction normal to the surface of platform 210, that is away from the edge part of the fabric material.
Numeral 270 designates a transverse member mounted on top of the upperparts of the side members 151 and 152. Supported on the member 270 are three spindles supporting conical thread spools 271, 272 and 273. Threads from these spools extend through guide members 274, 275 and 276 down to the three spool overlap sewing machine 180 as may be seen in FIGS. 1 and 3.
Numeral 282 designates a transverse shaft underneath the platform 270 having on it two double pulleys 283 and 284. Passing over pulley 283 are two cords 285 and 286 which attach to a transverse block 290 and passing over the pulley 284 are two other cords or cables 291 and 292 which attach to the other end of the block 290. The two cords passing over pulley 283 then pass over pulleys 294 and 295 on side member 248 of frame 250 and then are attached to the platform 242 as may be seen in FIG. 2. The two cords passing over pulley 284 pass over similar pulleys 200 and 301 carried by side member 249 of frame 250 as may be seen in FIG. 3 and are secured to the other end of platform 242.
Block 290 is attached by a cable 304 which passes over a pulley 306 on a shaft 307 extending between wide members 151 and 152 and attaches to the end of lever member 310, the end of which extends forwardly to a position between side members 151 and 152 where it may be actuated by the operator's foot. When the end of the lever is pushed down, it tensions the cable 304 thus exerting a pull on all of the cables 285, 286, 291 and 292, so that the platform 242 is moved towards the frame 250 against the springs like the one designated 262 so that the rollers 236 and 246 are moved away from the rollers 216 and 218. This movement of the rollers allows initial positioning of the fabric or threading it through for the beginning of an operation. During operation both the lower rollers are being driven to assist in causing the fabric with the stiffening material sewn to it to travel through the machine.
The excess fabric material beyond the stitched line is is cut off by a driven cutter disc positioned to operate beyond the sewing machine.
OPERATION
From the foregoing, those skilled in the art will readily understand the nature of the operation of the machine and the effectiveness and simplicity with which it accomplishes its intended purpose.
The motors 50 and 182 are energized for operation. The fabric material is tabled on the tabling surface with the left edge positioned against the member 136 for the correct width as indicated on the scale. The right edge overlies the platform 170 over the stiffening material as described with the edge of the material and the stiffening material then passing the motor driven sewing machine which makes the seam along the edge of the materials. The edge of the fabric with the stiffening material attached passes over the platform 210 between the tangent rollers which serve to guide the edge and to assist in causing it to traverse through the machine. The upper tangent rollers are readily lifted away for positioning the edge of the materials initially merely by actuation of the lever 310. Operation of the sewing machine is initiated simply by actuation of the lever 200, the three threads automatically coming off the spools. Thus, it is to be seen that the operation is very simple but effective.
The foregoing disclosure is representative of a preferred form of the invention and is to be interpreted in an illustrative rather than a limiting sense, the invention to be accorded the full scope of the claims appended hereto.
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A measured length of drapery material is carried through the machine and through a processing appliance at one end of the machine. The machine has a tabling surface with a moving portion provided by a rotary drum which moves the fabric. The material passing through the machine comprises several widths seamed together. At the end of the machine, a strip of stiffening material is aligned with the edge of the material which will be the top edge of the drape and the materials are then stitched together by a sewing machine, the excess material being continuously cut off by a cutter.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2016-0079862, filed on Jun. 27, 2016 in the Korean Intellectual Property Office, the disclosure of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a fingertip toothbrush for a pet, and more particularly, to a fingertip toothbrush for a pet that is configured to allow bristles to vibrate and reciprocally slide up and down, so that toothbrushing can be carefully and precisely achieved, which is effective in improving the teeth health of the pet.
BACKGROUND OF THE DISCLOSURE
[0003] A large family in a modern society has been transformed to a nuclear family, and further, the number of one-person households has been recently increased. Under such a social atmosphere, households of the owners who care for pets have been expanded.
[0004] A lot of cares for pets such as periodical washing, vaccination, and so on should be needed, but the cares for their teeth are not actually taken well.
[0005] If their teeth are not brushed, serious mouth odor and periodontitis may be easily generated. If the periodontitis is left untreated for a long period of time, it is developed to a gum disease, which undesirably causes decayed teeth, gum bleeding, and even teeth losing.
[0006] If bacteria living on the teeth enter their body, further, they have bad influences on their heart, lung, kidney and so on, which undesirably causes other diseases.
[0007] So as to solve such problems, recently, toothbrushes only for pet animals, especially, pet dogs have been proposed and purchased easily by users.
[0008] In a similar manner to toothbrushes for people, the toothbrushes for pets are provided with bristles formed on the end portion of a stick, but in case of small dogs, their mouth is small so that it is hard to brush their teeth carefully and precisely and damages on their gum may be further caused.
[0009] So as to avoid such problems, accordingly, a fingertip toothbrush for a pet has been proposed wherein the fingertip toothbrush is fitted to a user's finger to brush the pet's teeth, and in this case, the fingertip toothbrush has a cylindrical body made of a soft silicone material and a plurality of bristles formed on the end portion of the cylindrical body.
[0010] As the conventional fingertip toothbrush for the pet is fitted to the user's finger, the pet's teeth can be more perfectly brushed than the stick type toothbrush as mentioned above, but while the pet's teeth is being brushed, the user's finger should be kept carefully moving, thereby making it inconvenient to use.
SUMMARY OF THE INVENTION
[0011] Accordingly, the present invention has been made in view of the above-mentioned problems occurring in the prior art, and it is an object of the present invention to provide a fingertip toothbrush for a pet that is configured to allow bristles to reciprocally slide up and down or vibrate while the fingertip toothbrush is being used in the state of being fitted to a user's finger, so that the pet's teeth can be carefully and accurately brushed and since there is no need to move his or her finger during toothbrushing, it is very convenient to use.
[0012] To accomplish the above-mentioned object, according to the present invention, there is provided a fingertip toothbrush for a pet including: a cylindrical body open on one side thereof and having a slide groove formed on the outer peripheral surface thereof; a motion panel seated on the slide groove and having bristles formed on top thereof and a cam insertion groove formed on underside thereof; a motor having a shaft and fixed to the slide groove formed on the body; and a cam fastened to the shaft of the motor in such a manner as to be inserted into the cam insertion groove of the motion panel seated on the slide groove, wherein as the cam rotates by means of the driving of the motor, the motion panel reciprocally slides along the slide groove.
[0013] According to the present invention, desirably, water resistant films made of a soft material are formed on the edges of the slide groove and on the edges of the motion panel, thereby preventing the pet's saliva or water from being permeated into the slide groove and the motion panel.
[0014] According to the present invention, desirably, a vibrator is disposed at the interior of the motion panel to generate vibrations so that the motion panel slides up and down and vibrates.
[0015] According to the present invention, desirably, a switch is disposed at the end portion of the interior of the body, so that if a user's finger is fitted to the body, the finger touches the switch to automatically drive the motion panel.
[0016] According to the present invention, desirably, a control knob is disposed on the body to turn on/off the reciprocating sliding motion and vibrations of the motion panel, so that any one of the reciprocating sliding motion of the motion panel, the vibrations of the motion panel, and the vibrations and reciprocating sliding motion of the motion panel is selected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the invention in conjunction with the accompanying drawings, in which:
[0018] FIG. 1 is a perspective view showing a fingertip toothbrush for a pet according to the present invention;
[0019] FIG. 2 is a sectional view showing a structure of a motion panel of the fingertip toothbrush for a pet according to the present invention;
[0020] FIG. 3 is a view showing a location of a cam before power is supplied to a motor in the fingertip toothbrush for a pet according to the present invention;
[0021] FIGS. 4 and 5 are views showing the up-and-down reciprocating sliding motions of the motion panel of the fingertip toothbrush for a pet according to the present invention through the rotation of the cam after the power is supplied to the motor;
[0022] FIG. 6 is a side view showing a driving switch disposed at the interior of the fingertip toothbrush for a pet according to the present invention; and
[0023] FIG. 7 is a perspective view showing a state wherein the fingertip toothbrush for a pet according to the present invention is worn on a user's finger.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Hereinafter, the present invention is disclosed with reference to the attached drawings wherein the corresponding parts in the embodiments of the present invention are indicated by corresponding reference numerals and the repeated explanation on the corresponding parts will be avoided.
[0025] In the description or claims, terms, such as “comprise”, “include”, or ‘have”, are intended to designate those characteristics, numbers, steps, operations, elements, or parts which are described in the specification, or any combination of them that exist, and it should be understood that they do not preclude the possibility of the existence or possible addition of one or more additional characteristics, numbers, steps, operations, elements, or parts, or combinations thereof.
[0026] As shown in FIG. 1 , a fingertip toothbrush for a pet according to the present invention includes a motion panel 110 disposed on the outer peripheral surface of one side of a cylindrical body 101 and having a plurality of bristles 111 formed thereon and an insertion hole formed on the other side of the cylindrical body 101 to insert a user's finger thereinto.
[0027] The fingertip toothbrush for a pet according to the present invention is configured wherein the motion panel 110 on which the bristles 111 are formed reciprocally slides up and down with respect to the body 101 or generates vibrations therefrom, thereby carefully brushing the pet's teeth and making the pet's gum healthy through gum massage.
[0028] The motion panel 110 is molded to a shape of a flat plate on which the bristles 111 are formed, and as shown in FIG. 2 , the motion panel 110 is seated on a slide groove 102 formed on top of the body 101 .
[0029] A cam 116 is disposed on the slide groove 102 in such a manner as to be rotated by means of the driving of a motor 115 , and further, a cam insertion groove 113 is formed on the underside of the motion panel 110 so that when the motion panel 110 is seated on the slide groove 102 , the cam 116 is inserted into the cam insertion groove 113 of the motion panel 110 .
[0030] The motion panel 110 thus reciprocally slides up and down by means of the cam 116 rotating through the driving of the motor 105 fastened to the slide groove 102 of the body 101 .
[0031] As shown in FIG. 3 , the cam insertion groove 113 is formed on the underside of the motion panel 110 in such a manner as to be extended in a longitudinal (axial) direction of the body 101 , and in FIG. 4 , hereinafter, the inner wall of the cam insertion groove 113 with which the cam 116 comes into contact is called ‘upper inner wall’, the inner wall of the cam insertion groove 113 facing the upper inner wall is called ‘lower inner wall’, and the inner walls of the cam insertion groove 113 formed on both sides of the cam 116 are called ‘side inner walls’.
[0032] In the state where power is supplied to the motor 115 , as shown in FIG. 3 , the end portion of the cam 116 is located toward the side inner wall of the cam insertion groove 113 formed to the shape of the long hole, and at this time, the end portion of the cam 116 does not come into contact with one side inner wall.
[0033] If power is supplied to the motor 115 fixedly fastened to the body 101 , on the other hand, the cam 116 fastened to the shaft of the motor 115 rotates, and as the cam 116 rotates, the end portion of the cam 116 comes into contact with the upper inner wall of the cam insertion groove 113 . In this state, the cam 116 rotates, and as shown in FIG. 4 , the cam 116 moves up the motion panel 110 up to the top portion of the slide groove 102 .
[0034] If the cam 116 is kept rotating, further, the end portion of the cam 116 comes into contact with the lower inner wall of the cam insertion groove 113 . In this state, the cam 116 rotates, and as shown in FIG. 5 , the cam 116 moves down the motion panel 110 up to the bottom portion of the slide groove 102 .
[0035] As the above-mentioned processes are repeatedly carried out through the driving of the motor 115 , the motion panel 110 reciprocally slides up and down along the slide groove 102 of the body 101 .
[0036] Accordingly, as shown in FIG. 7 , if the bristles 111 just come into contact with the pet's teeth in the state where the fingertip toothbrush according to the present invention is fitted to the user's finger, the motion panel 110 reciprocally slides up and down to allow the bristles 111 formed thereon to carefully brush the pet's teeth.
[0037] Further, as shown in FIGS. 2 to 5 , a vibrator 114 is located at the interior of the motion panel 110 to generate vibrations through the supply of power.
[0038] The vibrator 114 is fixedly fastened to the interior of the motion panel 110 , and if the vibrator 114 is driven through the supply of power, the vibrations generated from the vibrator 114 are transferred to the bristles 111 formed on the motion panel 110 .
[0039] If the bristles 111 are vibrated, the pet's teeth can be finely and carefully brushed, and further, vibration stimulations can be applied to the pet's gum, thereby making the gum healthy.
[0040] The vibrator 114 can be operated at the same time when the motion panel 110 reciprocally slides up and down, and otherwise, it can be operated solely even when the motion panel 110 does not reciprocally slide up and down.
[0041] The vibrator 114 is a well known technology, and therefore, a detailed explanation on the internal structure of the vibrator 114 will be avoided for the brevity of the description.
[0042] The motor 115 adapted to allow the motion panel 110 to reciprocally slide up and down and a switch adapted to turn the vibrator 114 on/off may be configured to a variety of forms. According to the present invention, as shown in FIG. 1 , a control knob 103 is disposed at the insertion hole of the fingertip toothbrush, and as shown in FIG. 6 , a switch 106 and a battery 105 supplying power to the switch 106 are disposed at the interior of the fingertip toothbrush.
[0043] According to the present invention, the reciprocating sliding motions and vibrations of the motion panel 110 can be turned on/off through the control knob 103 and the switch 106 .
[0044] If the user's finger is inserted into the fingertip toothbrush according to the present invention, his or her finger comes into contact with the switch 106 disposed at the interior of the body 101 to allow the motion panel 110 to reciprocally slide in an automatic manner, so that the fingertip toothbrush according to the present invention can be conveniently used, without any separate switching manipulation.
[0045] As the control knob 103 as shown in FIG. 1 is turned, the vibrator 114 disposed at the interior of the motion panel 110 is turned on/off, and the reciprocating sliding motion of the motion panel 110 is turned on/off so as to drive the vibrator 114 solely.
[0046] According to the present invention, the control knob 103 is configured to the form of a three-stage switch comprising three modes such as ‘vibrator OFF’, ‘vibrator ON’, and ‘motion panel reciprocating motion OFF and vibrator ON’. In the ‘vibrator OFF’ mode of the control knob 103 , only the reciprocating sliding motion of the motion panel 110 is generated, in the ‘vibrator ON’ mode of the control knob 103 , the reciprocating sliding motion of the motion panel 110 and the vibrations of the vibrator 114 are at the same time generated, and in the ‘motion panel reciprocating motion OFF and vibrator ON’ mode of the control knob 103 , the reciprocating sliding motion of the motion panel 110 stops and only the vibrator 114 is driven even if the user's finger comes into contact with the switch 106 disposed at the interior of the body 101 .
[0047] At this time, the manipulation of the control knob 103 is desirably carried out only when the fingertip toothbrush is worn on the user's finger, that is, when his or her finger comes into contact with the switch 106 disposed at the interior of the body 101 .
[0048] While the fingertip toothbrush is being used, further, the internal electric parts like the motor 115 may be malfunctioned by the pet's saliva or water introduced into the fingertip toothbrush, and so as to prevent such malfunction from occurring, as shown in FIG. 2 , water resistant films 112 are formed on the edges of the motion panel 110 and on the edges of the slide groove 102 of the body 101 to seal them, so that no water cannot be desirably permeated into them.
[0049] The water resistant films 112 are made of a tough material having excellent softness like silicone, so that while the motion panel 110 reciprocally slides, the water resistant films 112 are not folded or extended at all, thereby preventing their damage or breakage.
[0050] As mentioned above, if the fingertip toothbrush for a pet according to the present invention is fitted to the user's finger, the motion panel 110 reciprocally slides up and down in the automatic manner or generates vibrations, so that the pet's teeth can be carefully and accurately brushed, and since there is no need to move his or her finger during toothbrushing, further, just the position of the toothbrushing is fixed, so that it is very convenient to use.
[0051] The technical idea of the present invention has been explained with reference to the above-mentioned embodiment of the present invention.
[0052] The present invention may be modified in various ways and may have several exemplary embodiments. Specific exemplary embodiments of the present invention are illustrated in the drawings and described in detail in the detailed description. However, this does not limit the invention within specific embodiments and it should be understood that the invention covers all the modifications, equivalents, and replacements within the idea and technical scope of the invention.
[0053] While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.
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The present invention relates to a fingertip toothbrush for a pet, and more particularly, to a fingertip toothbrush for a pet that is configured to allow bristles to vibrate and reciprocally slide up and down, so that toothbrushing can be carefully and precisely achieved, which is effective in improving the teeth health of the pet.
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The present invention relates to a system for growing and cultivating plants, comprising a plant table, plant boxes arranged in the table as well as a drainage system for surplus water and condensing water from the plant boxes.
BACKGROUND OF THE INVENTION
In many situations it is not possible or not suitable to grow plants at ground level. Many older and disabled people, and particularly those bound to their wheelchair, are not able to manage a planting efficiently at ground level.
When plants are cultivated and grown indoors to be planted outdoors later on, various types of boxes and the like are used, which are placed on tables, benches or the like. Frequent problems with the watering, the runoff of surplus water as well as the soil cultivation occur.
In, e.g., public buildings it is often difficult and expensive to make alterations in a flower or plant arrangement with flower boxes.
The object of the present invention is to suggest a plant growing system of the type mentioned above, which is versatile and allows growing indoors as well as outdoors, and which allows working in a sitting position at the table e.g. in a wheel chair and which allows fast alterations or exchanges of flower arrangements and the like depending on the wishes.
SUMMARY OF THE INVENTION
This is attained by means of the system according to the present invention, which is characterized in that the table is constructed with mutually connected profiles, provided with bearing supports for soil-carrying plates or boxes, mounted in the table, which bearing supports include elements, which form channels, and in that the soil-carrying boxes or plates are provided with drainage holes, designed to be placed above said channels.
An additional object of the invention is to suggest a table, which can be built with modules, designed to be placed against a wall or in a corner or around a corner. Said modules suitably are mainly piece of pie-shaped sectors. Thus, a preferred embodiment of the table is characterized in that the table is subdivided into sectors by means of partitions, which form a first bearing support, and which partitions extend like a fan from a table corner or from the center of a long side or like spokes from the center of the table. Further, borer elements, which form second bearing supports, connect the outer ends of the partitions in order to make them jointly form the border of the table. Each sector suitably has a central angle of 45°, the table preferably comprising two such sectors in order to constitute a table in a corner, or four sectors in order to constitute a table in a corner, or four sectors to constitute a table which can be attached to a wall, or six sectors to constitute a table which extends around a corner or eight sectors to constitute a table having an outer regular octangonal shape.
In case the external shape of the table is a regular polygon, possibly rounded to form a circle, the table preferably is rotatably mounted on a central support with a hub rotatably mounted on the support. Said first bearing supports are elements on partitions comprising spoke profiles, which extend radially outwards from the hub in such a way that they subdivide the table into said sectors, said second bearing supports comprising elements on border profiles which connect the outer ends of the spoke profiles in order to jointly constitute the border of the table on all sides.
The above-mentioned channels primarily comprise said first bearing supports and at least one drainage opening or passage is disposed in or in connection with each such channel adjacent the center of the table, or adjacent the staring point for said fan-shaped outwardly directed partitions, respectively. Each such channel has a sufficient volume to be able to drain off surplus water from said drainage holes in the boxes or plates towards said drainage opening or passage.
Said second bearing supports, which are elements on the border of the table, preferably also constitute channels, which are able to collect surplus water from said drainage holes in said plates or boxes. These channels in said second outer bearing supports communicating with those channels, which constitute the first bearing supports, in such a way that water which has been collected adjacent the border of the table also will be drained off towards the center of the table or a corresponding point via the channels in the radial or fan-shaped bearing supports.
From what has been stated above one can draw the conclusion that the sectors suitably are triangle-shaped and that the central angle of the sector preferably is 45°. In each triangular sector one or several plant boxes can be placed, which preferably are complimentary to the sector triangle. By giving the plant boxes such a shape that four triangular plant boxes can be disposed in each sector, and by providing each plant box with a bottom hole in each corner, each such hole can be placed above a channel in any of said first and second bearing supports.
The table suitably is open below the plant boxes in such a way, that air can pass through the table in passages between the plant boxes. This is particularly advantageous in case the table is covered with a light-penetrable superstructure in order to obtain a mini-greenhouse. Since the bottom of the greenhouse obtained in this way is provided with air passages, a satisfactory change of air can be achieved without loosing the desirable greenhouse-effect.
Provided it is desirable, in said plant boxes several small plant containers, e.g, four small containers in each large container, can be placed. Thus, in case the table comprises eight sections, each containing 32 plant boxes, a total number of 128 small boxes can be housed, with four small boxes being placed in each one of the large plant boxes.
Thus, in its preferred embodiment the system according to the invention includes a table, which is subdivided into sectors by means of spoke profiles, designed with bearing supports as well as a border on all sides, which also is designed with bearing supports for plant boxes. The bearing supports also are used as drainage channels, which end against a central pole or the like, where the water either can flow along the central pole (for use outdoors) or be collected (for use indoors). Since the system has loose plant boxes and drainage channels, this means that no floor, i.e. means of which the boxes can be supported, is needed, which results in an excellent ventilation effect, i.e. fresh air all the time penetrating from below.
According to the preferred embodiment the boxes are supported by the bearing supports, designed as drainage channels, having three corners and two complete sides The system is built in such a way, that all the boxes lock each other and that the boxes cannot fall out from their bearing supports even if one box is removed from the system, despite the fact that there is no covering bottom between the bearing supports.
In case the plant table, in accordance with a preferred embodiment, is provided with a central axis, the plant table can be rotatably mounted about its axis. This is important to old people and/or handicapped persons, who can push their wheel chair into a position below the table and reach all of the plant boxes, when they start revolving the table.
Additional characterizing features and aspects as well as advantages of the present invention will be set forth in the following patent claims and the following description of a few preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following description reference will be made to the accompanying drawings, in which:
FIG. 1 is a perspective view of a preferred embodiment of a self-supporting table having a central support and a roof made of a transparent material, illustrating how the plant table is to be used;
FIG. 2 shows the same plant table from above without any roof and with empty plant boxes;
FIG. 3 shows the plant table according to FIG. 2 in a perspective view from below, the plant boxes being removed;
FIG. 4 is a partial view from above of the attachment between spoke profiles and two border profiles as well as the attachment of spoke, profiles in a hub, rotatably disposed about the central support of the table;
FIG. 5 shows a cross-section of a spoke profile along line V--V in FIG. 4;
FIG. 6 shows a cross-section of a border profile along line VI--VI in FIG. 4;
FIG. 7 shows a cross-section of the hub of the plant table along line VII--VII in FIG. 4;
FIG. 8 is a perspective view of a second embodiment of a plant table according to the invention, designed to be mounted on a wall; and
FIG. 9 snows a third embodiment of a plant table according to the invention, designed to be mounted in a corner.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of the plant growing system according to the present invention, designed as a table 1, mounted on a central support 2 and having a roof 3 of a transparent plastic cloth. The shown embodiment of the table is polygonal and particularly has a regular octogonal shape.
Table 1 is by means of radial partitions 4, see FIG. 3--called spoke profiles supra and infra--and a border 5 on all sides subdivided into sectors 7 substantially having a triangular shape. The triangles of this embodiment are equally sided and their central angle is 45°.
Roof 3 is stretched on top of lateral poles 6, which are placed in each corner of the polygon, i.e. on top of eight lateral poles 6 according to the shown embodiment Roof 3 then resembles a circus tent. The roof, which is made of transparent plastic cloth, is subdivided into the same number of sections as the number of sectors 7 of table 1, and each section covers an adjacent section by a few centimeters. Each roof section can separately be opened up or all of them simultaneously and be fastened in a single manipulation by means of a suitable attachment element, e.g. hooks and crooks, Velcron tape, snap fasteners, magnetic couplings or the like, i.e. gadgets which do not have to be described in detail in this text. Suitably said attachment elements are designed in such a manner that, e.g., all plastic sections can be attached above one single sector 7 of the table and a maximum accessibility to all parts of the plant table be attained.
Each sector 7 forms a frame for, according to the shown embodiment, four triangular plant boxes 8,8a. Plant boxes 8,8a have such a size that four of them will fill the frame in a sector completely. Plant containers 8a, which are disposed adjacent the center of table 1, preferably have a blunt point. The rest of the containers 8,8a have the same size, and the three outer plant containers 8 are completely identical. In the corner of containers 8 and in their bottom is provided a drainage hole 9. Containers 8a are also provided with a drainage hole 9 in two of their corners and preferably with two drainage holes 9 in that corner which faces the center of the table, see FIG. 2.
FIGS. 4 and 5 show how spoke profiles/partitions 4 are designed. Spoke profiles 4 are, made of an aluminum profile, which is stamped as a single and comprises a vertical web 12 and at the top a double flange 13 having an planar top surface as well as a screw holder 14 between said flange 13 and web 12. Also, in its lower portion spoke profile 4 on each one of its sides has a bearing support, generally designated 15. Each bearing support 15 also forms a channel 16, which is defined by an planar horizontal bottom 17, a vertical lateral wall 18 as well as the lower portion of web 12. A lower screw holder is designated 19.
In FIG. 6 a cross-section is shown of an embodiment of border profiles 5, which like spoke profiles 4 in their lower portion have a bearing support 21, which also, forms a channel 22, which faces the center of the table. The bearing support 21 comprises an upright flange, which constitutes one of the walls of channel 22. Border profile 5, which also comprises an aluminum profile, has been extruded as a single piece and has a vertical planar web 23, which faces the center of the table, as well as outer portions, which include a lower bent portion 24, an upper planar portion 25 and outside the latter a bent upper portion 26, which forms a gripping handle to be used when table 1 is to be revolved. A connecting element, designed for an assembly of spoke profiles 4 and border profiles 5, is designated 28, see FIG. 4. Each connecting element 28 includes a vertical hole 29 for the mounting of lateral poles 6 for roof 3.
A hub is generally designated 30, see FIGS. 4 and 7. In the shown embodiment hub 30 comprises an inner sliding sleeve 31 having a folded upper edge 31a and on which an attachment sleeve 32 has been mounted, which is retained on sliding sleeve 31 by means of a cover 33. Attachment elements 34 are mounted on attachment sleeve 32 and designed for the mounting of the inner ends of spoke profiles 4 by means of screws 35, see FIG. 4, extend into screw holders 14,19, see FIG. 5.
Border profiles 5 are, by means of said connecting elements 28, connected to spoke profiles 4 at the outer ends of the latter. The mounting can also in this case be done by means of a screw fitting, using screws 37, which extend into screw holders 14,19, and screws 38, which connect border profiles 5 with legs 39 of connecting elements 28 respectively.
The system works as follows. Plant containers 8,8a having bottom holes 9,9a are positioned on bearing supports 15,21 of spoke profiles 4 and border profiles 5, holes 9,9a being arranged in such a way, that they are placed above channels 16 or 22. Water, which is not absorbed by the soil but flows through holes 9,9a, is collected in channels 16,22, channels 22 communicating with channels 16. Also, channels 16 and 22 have such a large volume that they can accumulate a sufficient amount of water, that the water, without any overflowing, is guided along channels 16 towards the center of table 1. According to one embodiment the water is allowed to drop or flow towards the central support 2 and pass along its external side downwards into the ground or the like support. In an alternative embodiment a collecting vessel can be mounted on central support 2, e.g. in case the system is to be used indoors.
FIG. 8 shows an alternative embodiment of the invention. The table in this case comprises four sectors of the same type as the ones in the embodiment described supra, the table being mounted against e.g. a wall. The central support is in this case replaced by half a cylinder, provided with stationary mounting elements of the same type as shown in FIG. 4.
FIG. 9 shows an additional embodiment, which comprises only two sectors 7, which are designed for a mounting of the plant table in a corner.
The present invention can of course be modified within the scope defined by the following patent claims, and the description above is merely one example of a preferred embodiment. Thus, the roof can, e.g., be designed in a plurality of ways. Instead of lateral poles, which support the plastic roof, e.g., a round or polygonal ring can be used, which by means of a cross or the like is attached to the center pole, which in turn is screwed into the cover. In this way a completely open space below the roof, available for work, can be obtained. Roofs of plexiglass in sections can also be used.
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The present invention relates to a plant growing and cultivation system, comprising a plant growing table (1), plant growing containers (8) mounted in said table as well as a drainage system for surplus water and condensing water from said plant containers. The table is built with profiles (4,5), connected to each other and forming bearing supports (15,21) for soil-carrying plates or plant containers mounted in the table, which bearing supports include elements, which form channels (16,22).
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BACKGROUND OF INVENTION:
[0001] Several issues exist with previously designed portable decks. Some are strictly to raise one to door level of a trailer or RV with room enough to turn around (Greenwood, Aug. 4, 1972 U.S. Pat. No. 3,808,757; Weaver, Sep. 7, 1982, U.S. Pat. No. 4,347,638; Anstead, May 31, 1988 U.S. Pat. No. 4,747,243) and require guardrails (Wyse, Jul. 26, 1988, U.S. Pat. No. 4,759,162; Carson, Apr. 8, 2008, U.S. Pat. No. 7,353,639 B2) or stairs to reach the deck level (Wagner, III, Jul. 8, 1986 U.S. Pat. No. 4,598,510). Others are just plain difficult to assemble (Cauceglia et al, Dec. 9, 1975, U.S. Pat. No. 3,924,370; Rebentisch et al, Jul. 14, 1981, U.S. Pat. No. 4,277,923), requiring tools, brawn, and multiple persons. Other designs (Weaver, Mar. 16, 1993, U.S. Pat. No. 5,193,878; Baumgartner et al, May 23, 1995, U.S. Pat. No. 5,417,468; Johnson, May 18, 2004 U.S. Pat. No. 6,736,446 B1) have been physically mounted to a vehicle which, although technically portable, makes the deck usable only when the vehicle can access the area where the deck is needed. A majority of the decks are not light-weight enough for a single individual to carry. Nor are they transportable in a vehicle (with the exception of the mounted deck) where limited storage space and added towing weight must be considered.
[0002] Some of these previous designs have not accounted for variation in terrain, use in multiple locations and have restricted themselves to a specific size.
[0003] Therefore, the principal objectives of the present invention is to provide a deck system which is sturdy, light-weight, small enough to be transportable yet large enough to be practically functional, easily assembled and disassembled, high enough to rise above rain levels yet not so high as to require stairs or a ramp system to use, and flexible enough to adjust to fluctuations in topography while providing a sturdy, even walking surface.
BRIEF SUMMARY OF INVENTION
[0004] The submitted invention is for a devise where a flat, constant walking surface is desired without restrictions of permanency. This invention allows flexibility in location, overall deck size while allowing for variance in height. It is light-weight and compact enough to be portable, easily stored and packed for travel.
BRIEF DESCRIPTION OF DRAWINGS
[0005] FIG A illustrates the top perspective of the deck in disassembled form.
[0006] FIG B illustrates the top view of the assembled deck panel with the cross beam shadowed.
[0007] FIG C illustrates the underneath perspective of the deck in disassembled form
[0008] FIG D illustrates the assembled view of the underneath of the deck panel.
[0009] FIG E illustrates the side perspective of the foot portion of the foot/leg bracket assembly.
[0010] FIG F illustrates the top view of the foot/leg bracket assembly
[0011] FIG G illustrates the one completely assembled decking section.
[0012] FIG H illustrates an expanded deck of three sections and the connection points.
DETAILED DESCRIPTION OF INVENTION
[0013] Beginning with FIG A, the top perspective of the decking section in disassembled form, item
[0014] is 4″×8″×1½″ expandable iron or aluminum that is welded to the top of the deck frame making a sturdy deck top. [ 2 ] is a L-angle iron or aluminum 1″×1″×⅛″, welded into the form of a 2′×4′ rectangular deck frame. For increased stability, a support bar is added. The support bar [3] is another L-angle beam of the 1″×1″×⅛″ size welded length wise to the middle points of the 2′ frame sides.
[0015] FIG B depicts the assembled deck section. Again, [ 1 ] is the 4″×8″×1½″ expanded metal deck top and [ 2 ] is the 1″×1″×⅛″ frame with the dashed detail of [ 3 ] indicating the 1″×1″×⅛″ support beam.
[0016] FIG C shows the bottom side of the unassembled deck section. [ 1 ] Is the 4″×8″×1½″ expanded metal or aluminum mesh deck top. [ 2 ] Is the L-angle iron or aluminum 1″×1″×⅛″ deck frame. [ 3 ] Is the added support crossbeam made of 1″×1″×⅛″ angle iron or aluminum. While [4] indicates the position of the 1¼″ square leg receptacles.
[0017] FIG D represents the underneath view of the assembled decking plane. [ 1 ] Are the 1¼″ leg receptacles, [ 2 ] is the 1″×1″×⅛″ angle iron or aluminum decking frame, [ 3 ] is 4″×8″×1½″ expandable iron or aluminum decking mesh and [4] is the location of the 1″×1″×⅛″ support beam.
[0018] FIG E shows the foot/leg bracket assembly. [ 1 ] Indicates the individual leg that inserts into the 1¼″ receptacles located underneath the deck. There are four (4) separate legs per foot/leg bracket. Each leg is 1″ square making for a snuck fit into the 1¼″ leg receptacles found underneath the deck corners. These four legs on the assembly enable up to four separate decking sections to be joined together securely and without unevenness or gaps between deck sections. If deck expansion is not desired or only two or three additional decking sections are preferred the foot can be rotated to safely hide the other leg to avoid possibility of injury. Item [ 2 ] is the stabilizing foot and [ 3 ] is the adjustment bolt allowing for a variation of decking height. This height adjustment can be executed by either turning manually or by the adjustment nut (shown in FIG) which is accessible through the top of the decking unit.
[0019] FIG F shows the top view of the foot/leg bracket assembly. Item [ 1 ] depicts the top view looking down upon the individual leg units with Item [ 2 ] highlighting the top-side adjustment nut.
[0020] FIG G illustrates the assembled decking unit [ 1 ] being the complete deck section and [ 2 ] indicating the position of the foot/leg assembly when installed and [ 3 ] highlighting the crossbeam running length wise underneath the deck top.
[0021] FIG H represents the foot/leg bracket position when connecting two or more deck sections together. [ 1 ] are the deck sections already positioned with leg assembly attached. [ 2 ] indicates the position of the foot/leg bracket when adding a section. Notice that the assembly is rotated so that half the leg assembly protrudes away from the first deck section allowing access to a connecting leg for decking section [ 4 ]. Item [ 3 ] depicts the position of the foot assembly when not being used as a connector and, therefore, is turned in to hide under the deck top. [ 4 ] is a deck top being lowered onto the awaiting leg connectors already in place under the outside positioned deck sections.
[0022] Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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This invention is intended for use in outdoor activities where a firm, continuous, strong, and maintenance free walking surface that overcomes obstacles such as wetness, mud, rocks, and uneven terrains with simple-to-expand, light-weight, and easily transported attributes is desired.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2005-060816, filed on Mar. 4, 2005 the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The disclosure relates to a sewing machine control device and a multi-needle sewing machine that execute a sewing operation by selectively using a plurality of sewing needles in accordance with sewing data including needle drop point data and thread color data.
BACKGROUND
[0003] Conventionally, a multi-needle sewing machine has been used which is capable of consecutively sewing embroidery patterns that require the use of a plurality of thread colors. Such multi-needle sewing machine is provided with sewing data and a plurality of sewing needles. The sewing data includes thread color data that specifies a thread color and needle drop point data that specifies a needle drop point position for each stitch. A plurality of sewing needles is respectively attached to needle bars which are each set with a thread of different color. The multi-needle sewing machine loads the sewing data upon starting a sewing operation. Then a switch is made to the sewing needle set with a thread having a thread color that matches with the loaded thread color data, and sewing operation is executed based on the loaded needle drop point data. Such sewing needle switching is carried out when replacing the thread color to be used for a sewing process. At this point, in case a sewing needle set with a thread that matches with the thread color specified in the thread color data does not exist, the user makes the replacement to the thread having a matching thread color.
[0004] A multi-needle sewing machine disclosed in JP-A-6-15072 is provided with a storage medium that stores thread type (thread color) data of the thread set to the sewing needle. The multi-needle sewing machine loads the sewing data upon embroidery sewing. Then, in case the sewing needle set with the thread having the thread color matching the thread color data specified in the sewing data does not exist, sewing operation is stopped to enable the replacement of the thread spool by the user.
[0005] Similarly, a sewing machine control device disclosed in JP-A-2004-33538 stops the sewing operation when a sewing needle set with a thread having a thread color matching the thread color data specified in the sewing data does not exist. Then, in the subsequent sewing operation, the sewing needle set with the least frequently used thread color is determined. Then the user is informed of a specific thread spool to be replaced so that highest replacement efficiency can be attained.
[0006] The thread replacement described above requires the user to set the sewing needle with the thread in addition to the replacement of the thread spool itself, which is a troublesome work for the user. Performing such operation upon every absence of matching thread color imposes considerable burden on the part of the user.
SUMMARY
[0007] Therefore an object of the present disclosure is to provide a sewing machine control device and a multi-needle sewing machine capable of reducing the user's burden upon thread replacement work in case a sewing needle set with a thread having a thread color matching with the thread color specified in thread color data of sewing data does not exist, or in case a sewing needle set with a thread having a thread type matching the thread type specified in thread specification data of the sewing data does not exist.
[0008] The sewing machine control device of the present disclosure is provided with a control unit that controls the sewing machine so as to execute a sewing operation by selectively using a plurality of sewing needles respectively set with a thread of different color based on the sewing data which at least includes needle drop point data and thread color data of the thread to be used for a sewing process; and a sewing needle-thread color storage medium that stores sewing needle-thread color mapping data capable of specifying a correspondence between the plurality of sewing needles and the thread color of the thread respectively set to each sewing needle. The control device of the sewing machine is further provided with a similarity evaluation unit that evaluates the similarity between the thread color specified by the thread color data and the thread color of the thread set to each sewing needle based on the thread color data and the sewing needle-thread color mapping data; and a sewing needle selection unit that selects, based on the evaluation result rendered by the similarity evaluation unit, the sewing needle to be used for the sewing process performed in accordance with the sewing data.
[0009] According to such construction, among the plurality of sewing needles set with threads of different thread colors, a sewing needle set with a thread which is similar to the thread color specified by the thread color data is determined as the sewing needle to be used for the sewing process. As a result, sewing can be performed with a similar thread color without thread replacement, thereby reducing the user's burden of thread replacement.
[0010] Also, the multi-sewing needle machine of the present disclosure is provided with a plurality of sewing needles respectively set with a thread of different type; a control unit that controls the sewing machine so as to execute a sewing operation by selectively using the plurality of sewing needles based on the sewing data which at least includes needle drop point data and thread specification data that specifies the type of thread to be used for a sewing process; and a sewing needle-thread type storage medium that stores sewing needle-thread type mapping data capable of specifying a correspondence between the plurality of sewing needles and the thread type of the thread respectively set to each sewing needle. The multi-needle sewing machine is further provided with a similarity evaluation unit that evaluates the similarity between the thread type specified by the thread specification data and the thread type of the thread set to each sewing needle based on the thread specification data and the sewing needle-thread type mapping data; and a sewing needle selection unit that selects the sewing needle to be used in the sewing process in accordance with the sewing data based on the evaluation result rendered by the similarity evaluation unit.
[0011] According to such construction, among the plurality of sewing needles set with threads of different thread types, the sewing needle set with the thread which is similar to the thread type specified by the thread specification data is determined as the sewing needle to be used for the sewing process. As a result, sewing can be performed with a similar thread type without having to replace the thread, thereby reducing the user's burden of thread replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other objects, features and advantages of the present disclosure will become clear upon reviewing the following description of the illustrative aspects with reference to the accompanying drawings, in which,
[0013] FIG. 1 is a perspective view of the disclosure, wherein a multi-needle sewing machine provided with a sewing machine control device is shown;
[0014] FIG. 2 is a block diagram of control systems of the multi-needle sewing machine;
[0015] FIG. 3 is a data structure of sewing data including thread color data and needle drop point data;
[0016] FIG. 4 shows data contained in a table storing sewing needle-thread color mapping data;
[0017] FIG. 5 shows data contained in a table storing RGB value preset for each thread color for identifying a thread color;
[0018] FIG. 6A is the first half of a flow chart for sewing needle selection control;
[0019] FIG. 6B is the second half of the flow chart for sewing needle selection control;
[0020] FIG. 7 is an example of screen display of sewing needle determination result; and
[0021] FIG. 8 shows data contained in a table storing sewing needle thread type mapping data in an alternative illustrative aspect.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] An embodiment of the present invention will be described hereinafter with reference to the drawings.
[0023] As shown in FIG. 1 , a multi-needle sewing machine M is constructed by a foot 1 supporting the entire sewing machine, a pillar 2 standing on the rear end of the foot 1 , and an arm 3 extending to the front from the upper portion of the pillar 2 .
[0024] A movable case 4 is provided on the upper side of the foot 1 . A frame mounting base 5 is provided on the front side of the movable case 4 . A lateral drive mechanism equipped with an x-direction drive motor 33 (refer to FIG. 2 ) is provided inside the movable case 4 . The frame mounting base 5 is laterally driven by the x-direction drive motor 33 (refer to FIG. 2 ). A longitudinal drive mechanism equipped with a y-direction drive motor 34 (refer to FIG. 2 ) is provided inside the foot 1 . The movable case 4 is longitudinally driven by the y-direction drive motor 34 . An embroidery frame 6 retaining a workpiece cloth to be sewn in a stretched manner is mounted on the frame mounting base 5 . The frame mounting base 5 is moved in the lateral direction by the lateral drive mechanism and the movable case 4 is moved in the longitudinal direction by the longitudinal drive mechanism. Thus, the workpiece cloth mounted on the frame mounting frame 5 via the embroidery frame 6 is fed in longitudinal and lateral directions.
[0025] A needle bar case 7 mounted with a synthetic resin cover is attached on the front side of the arm 3 . A cylindrical bed 8 extending to the underside of the needle bar case 7 which is disposed in the front side of the multi-needle sewing machine is provided in the pillar 2 . In the needle bar case 7 , six needle bars 9 are stored in a single lateral row. A sewing needle 10 is attached on the lower end of each needle bar 9 . Also, six thread take-ups 11 in a single lateral row are mounted in the needle bar case 7 . Each thread take-up 11 has a corresponding needle bar 9 . A thread tension frame 12 made of synthetic resin and which is slightly inclined in the upper rear direction is fixed on the upper end of the needle bar case 7 . Six thread tension regulators 13 are provided on the thread tension frame 12 . Each thread tension regulator 13 is associated with needle thread T used by each sewing needle 10 .
[0026] Six spool pin bases 14 are provided on the upper side of the arm 3 . Thread spools 15 serving as thread supply are attached on such spool pin bases 14 . The needle thread T drawn from each thread spool 15 is hooked on the corresponding thread tension regulator 13 , thread take-up 11 , and the like and supplied to the sewing needle 10 .
[0027] A needle bar switching mechanism (not shown) having a needle bar switching motor 32 (refer to FIG. 2 ) is provided inside the arm 3 . The needle bar case 7 is moved in the lateral direction integrally with the thread tension frame 12 by the needle bar switching mechanism. Thus, one of the six needle bars 9 and the thread take-ups 11 are selectively switched to the active position. When the sewing machine motor 31 (refer to FIG. 2 ) is driven, the sewing needle 10 is vertically driven via the needle bar 9 and the thread take-up 11 . The sewing needle 10 , in cooperation with a rotary hook (not shown) provided inside the cylinder bed 8 , forms stitches on the workpiece cloth set on the upper side of the cylinder bed 8 by the needle thread T and a bobbin thread. An operation panel 16 of a touch-panel type is provided on the right side of the arm 3 . The operation panel 16 is mounted on the arm 3 via a connection arm 17 . The operation panel 16 is slidable in the axial direction of the connection arm 17 , and can also be folded toward the rear end of the arm 3 along with the connection arm 17 .
[0028] Next, an electronic configuration of the multi-needle sewing machine M will be described.
[0029] As shown in FIG. 2 , a sewing machine control device 20 is configured by a microcomputer including a CPU 21 , a ROM 22 , and a RAM 23 ; an input interface 25 ; an output interface 26 ; and the operation panel 16 . The input and output interfaces 25 and 26 are connected to the microcomputer via a bus 24 such as a data bus.
[0030] The operation panel 16 is connected to the input interface 25 . The operation panel 16 , drive circuits 27 , 28 , 29 and 30 respectively provided for the sewing machine motor 31 , needle bar switching motor 32 , x-direction driving motor 33 , and the y-direction drive motor 34 are connected to the output interface 26 .
[0031] A control program, a sewing needle selection control program, sewing data, and the like are stored in the ROM 22 . The control program controls the multi-needle sewing machine M. The sewing needle selection control program, as shown in FIGS. 6A and 6B , selects a sewing needle 10 set with a needle thread T similar to the thread color specified by a later described thread color data from the plurality of sewing needles 10 set with needle threads T of different thread colors. The sewing data is provided for performing embroidery sewing. The sewing data stored in the ROM 22 , as shown in FIG. 3 , includes the thread color data indicating the thread color of needle thread T to be used for the sewing process and the needle drop point data indicating the needle drop point for the sewing process. The thread color data and the needle drop point data are set in each sewing area (A 1 to A 7 in FIG. 3 ) within a sewing pattern. The sewing area contains one or more consecutive stitches formed by the same color of needle thread T. The sewing data is used by the multi-needle sewing machine M by being loaded into the RAM 23 upon sewing process or pattern editing process. The sewing data may be stored not only in the built-in ROM 22 storage but also be in an external storage medium such as a flexible disk or a ROM cartridge and loaded into the RAM 23 from such external storage medium.
[0032] As shown FIG.4 , a sewing needle-thread color mapping data specifying a correspondence between the six sewing needles 10 and the thread colors of the needle threads T respectively set to each sewing needle 10 is stored in the RAM 23 . Also, as shown in FIG. 5 , a table containing preset RGB values for each thread color is stored in the RAM 23 . The RGB value is used to identify a thread color.
[0033] The sewing needle-thread color mapping data can be set by user input from the operation panel 16 . Upon initial use of the multi-needle sewing machine M, the sewing needle-thread color mapping data is stored in the RAM 23 by the user's input of the thread color of the needle thread T set on each sewing needle 10 . Thereafter, in case the user changes the needle thread T set for each sewing needle 10 , such change can be updated to the sewing needle-thread color mapping data by user input via the operation panel 16 . Also, the sewing needle-thread color mapping data stored in the RAM 23 may be stored in a nonvolatile memory such as an EEPROM (not shown) provided in the multi-needle sewing machine. In such case, the sewing needle-thread color mapping data can be used by loading the same to the RAM 23 upon turning on the power supply to restart the embroidery sewing process.
[0034] The operation panel 16 is controlled by the microcomputer. As shown in FIG. 7 , a selection result screen is displayed on a display portion 16 a of the operation panel 16 . When replacing the thread color, in case a sewing needle 10 set with a needle thread T that matches with the thread color specified by the thread color data does not exist, a sewing needle number of the sewing needle 10 set with needle thread T having a thread color which is similar to the thread color specified in the thread color data is displayed on the selection result screen. Also, whether to use the selected sewing needle 10 or to replace the thread spool 15 can be selected by a touch operation of the operation panel 16 .
[0035] In case the user chooses to use the selected sewing needle 10 , the sewing machine control device 20 activates the needle bar switching motor 32 by the drive circuit 28 and switches the needle bar 9 set with the selected sewing needle 10 to the active position. Then the sewing machine motor 31 is driven by the drive circuit 27 and the sewing process is executed by the selected sewing needle 10 . On the other hand, in case the user chooses to replace the thread spool 15 and selects one of the sewing needles 10 identified by the sewing needle numbers 1 to 6, the sewing machine control device 20 switches the needle bar 9 set with the selected sewing needle 10 to the active position. Then by driving the sewing machine motor 31 by the drive circuit 27 , sewing is executed by the selected sewing needle 10 .
[0036] Next, a flow chart depicting the sewing needle selection control executed by the sewing machine control device 20 will be described based on FIGS. 6A and 6B . The symbols Si (i=1,2,3, . . . ) in the figure indicate each step number.
[0037] When the user sets the embroidery frame 6 holding the workpiece cloth to the frame mounting base 5 and starts the sewing operation by the multi-sewing needle sewing machine M, the sewing machine control device 20 loads the sewing data from the RAM 23 (S 1 ). Then, the process proceeds to step S 2 and determination is made whether the loaded sewing data is a thread color data or not. In case the loaded sewing data is a thread color data, the sewing machine control device 20 makes a yes decision and proceeds to step S 3 where the sewing needle-thread color mapping data is loaded from the RAM 23 . Next, the sewing machine control device 20 proceeds to step S 4 . In step S 4 , the similarity D of the thread color specified in the thread color data and thread color of needle thread T set to each sewing needle 10 is calculated based on the RGB value of the thread color data and the thread color-sewing needle mapping data. At this point, the RGB value of the thread color specified in the thread color data and the sewing needle-thread color mapping data can be obtained by referring the table shown in FIG. 5 . The sewing machine control device 20 calculates the similarity D from the following formula by using the RGB value (R 1 , G 1 , B 1 ) of the thread color data in the sewing data and the RGB value (R 2 , G 2 , B 2 ) of the thread color of the thread color-sewing needle mapping data.
D =( R 2 −R 1) 2 +( G 2 −G 1) 2 +( B 2 −B 1) 2
It needs to be noted that the smaller the value of similarity D, the higher the similarity of the two colors.
[0038] The sewing machine control device 20 , after calculating the similarity D, proceeds to step S 5 . In step S 5 , a judgment is made whether the calculated similarity D is zero or not; that is, whether or not the sewing needle 10 is set with needle thread T having a thread color matching the thread color specified in the thread color data or not. In case the similarity D calculated is 0, the sewing machine control device 20 , after making a Yes decision, proceeds to step S 10 where the needle bar switching control for switching the needle bar 9 set with the relevant sewing needle 10 is executed, and the control is returned.
[0039] In the above mentioned step S 2 , in case the loaded sewing data is not a thread color data, the sewing machine control device 20 makes a No decision and proceeds to step S 7 where a judgment is made whether the loaded sewing data is a needle drop point data or not. In case the loaded sewing data is a needle drop point data, the sewing machine control device 20 , after making a Yes decision, moves on to step S 8 where the sewing operation by the sewing needle 10 is executed and the process is returned. On the other hand, in the above step S 7 , in case the loaded sewing data is not a needle drop point data, that is, in case of data indicating a stop or a termination of sewing operation, the sewing machine control device 20 , after making a No decision, proceeds to step S 9 . In step 9 , a process in accordance with the given data is executed and the control is returned.
[0040] In the above step S 5 , in case the similarity D calculated by the aforementioned formula is not 0; that is, in case a sewing needle 10 set with a needle thread T matching the thread color specified by the thread color data is not detected, the sewing machine control device 20 makes a No decision and proceeds to step S 6 . In step S 6 , a judgment is made whether the loading of the thread color-sewing needle mapping data is completed or not. In case loading is not completed, the sewing machine control device 20 makes a No decision and proceeds to step S 3 . Thereafter, the process in steps S 3 to S 6 are executed until the similarity D in step S 5 amounts to 0, or loading of the sewing needle-thread color mapping data for each sewing needle 10 in step S 6 is completed.
[0041] Then, in the above step S 6 , in case the loading of the sewing needle-thread color mapping data for all the sewing needles 10 is completed; that is, in case the sewing needle 10 set with the needle thread T matching the thread color specified in the thread color data is not detected, the sewing machine control device 20 makes a Yes decision. Then, the process proceeds to step S 11 (refer to FIG. 6B ) and stops the sewing operation of the multi-needle sewing machine M.
[0042] Next, the sewing machine control device 20 proceeds to step S 12 and judges the sewing needles 10 having the lowest similarity D among the six sewing needles 10 . The sewing needle 10 set with the thread color which is most similar to the thread color specified in the thread color data is selected as the sewing needle 10 to be used for the sewing process. Then the sewing machine control device 20 proceeds to step S 13 and as shown in FIG.7 , displays the selection result to the display portion 16 a of the operation panel 16 . Next, the sewing machine control device 20 proceeds to step S 14 and judges whether the selected sewing needle 10 has been chosen or not; that is, whether the sewing needle 10 set with the similar thread color has been chosen or not. In case the user chooses the selected sewing needle 10 by touching the screen displayed on the display portion 16 a , the relevant sewing needle 10 is determined as the sewing needle 10 to be used for the sewing process. Then the sewing machine control device 20 , after making a Yes decision, proceeds to step S 15 . In step S 15 , the needle bar switching control is executed in order to perform the sewing operation with the selected sewing needle 10 and the control is returned.
[0043] On the other hand, in the above step S 14 , in case “replace thread spool” is selected on the screen displayed on the display portion 16 a , the sewing machine control device 20 makes a No decision and proceeds to step S 16 where the sewing needle number of the selected sewing needle 10 is identified. Then, in case the sewing needle 10 to be replaced has been selected, the sewing machine control device 20 , after making a Yes decision, proceeds to step S 17 and executes the needle bar switching control. In the needle bar switching control, the sewing machine control device 20 switches the needle bar 9 set with the relevant sewing needle 10 to the active position in order to enable the user to perform the sewing operation with the sewing needle 10 set with the new needle thread T drawn from the replaced thread spool 15 . Also, upon processing step S 17 , among the sewing needle-thread color mapping data stored in the RAM 23 , the sewing machine control device 20 updates the thread color corresponding to the replaced sewing needle 10 with the thread color of the newly set needle thread T.
[0044] In the above step S 16 , in case the sewing needle 10 to be replaced is not selected, the sewing machine control device 20 makes a No decision. Then the sewing machine control device 20 displays a warning message to the display portion 16 a indicating that the sewing needle 10 to be replaced has not been selected. Then, the process is returned to step S 14 .
[0045] According to the present embodiment described above, among the plurality of sewing needles 10 set with needle threads T of different thread colors, the sewing needle 10 set with the needle thread T similar to the thread color specified by the thread color data is determined as the sewing needle 10 to be used for the sewing process. As a result, sewing can be performed with the similar thread color without replacement of the needle thread T, thereby reducing the user's burden of having to replace the thread spool.
[0046] In case the sewing needle 10 set with the needle thread T matching the thread color specified in the thread color data is detected, the detected sewing needle 10 can be used for the sewing process. On the other hand, in case the sewing needle 10 set with the matching thread color is not detected, the sewing operation of the multi-needle sewing machine M is stopped and the sewing needle 10 set with the needle thread T having the similar thread color can be used for the sewing process.
[0047] Furthermore, the selected sewing needle 10 is displayed to the operation panel 16 enabling the user to decide whether to use the selected sewing needle 10 for the sewing process or not via the operation panel 16 . Thus, the sewing needle 10 set with the needle thread T having the similar thread color need not be searched by the user, thereby reducing the user's burden.
[0048] Also, by allowing the user him/herself to decide whether to use the similar thread or replace the thread spool 15 , the freedom of thread selection is increased. Additionally, according to the present embodiment, the frequency of thread spool replacement can be reduced as compared to what has been conventionally required.
[0049] Yet, furthermore, the sewing operation by the selected sewing needle 10 can be easily restarted by the touch operation of the operation panel 16 , thereby reducing the user's burden.
[0050] Also, since the detection of consistency between the thread color specified in the thread color data and the thread color of the needle thread T set to each sewing needle 10 , as well as the selection of similarity is performed based on the RGB value that specifies the thread color. Therefore a complex construction for determining the thread color is not required. This allows for a provision of a simply configured sewing machine control device 20 , which also yields cost advantage.
[0051] The present invention is not limited to the embodiment described above and illustrated in the drawings but can be transformed or expanded as follows.
[0052] Alternative to the sewing needle-thread color mapping data, as shown in FIG. 8 , sewing needle-thread type mapping data may be used which is capable of specifying the correspondence between the six sewing needles 10 and the type of needle thread T set to each sewing needle 10 . Also, thread specification data capable of specifying the thread type can be used instead of the thread color data. The type of needle thread T in this context includes data such as the thread color, manufacturer (corresponding to thread supplier), thread thickness, and thread material or the like. In this case, the sewing needle-thread type mapping data is stored in a sewing needle-thread type storage medium. According to such construction, even if a plurality of sewing needles is set with a thread color having the highest similarity with the thread color specified by the thread specification data, the similarity can be further determined by other data such as the manufacturer, thread thickness and thread material.
[0053] Thus, the similarity D can be determined based on not only by the thread color but also by the thread thickness, manufacturer and thread material, thereby further improving the accuracy in sewing needle selection. Similarity D can also be determined based on a thread number assigned by the manufacturer.
[0054] In the above described embodiment, the calculation process of similarity D based on the thread color data in the sewing data and sewing needle-thread color mapping data; and the detection process that determines whether the sewing needle 10 set with the thread having the matching thread color exists or not is performed upon every execution of the sewing process by each sewing needle 10 . Alternatively, such calculation and detection process can be performed in prior to the sewing process. For instance, in prior to the start of sewing operation by the multi-needle sewing machine M, a predetermined number (for example, the first six colors) of thread color data can be loaded from the sewing data. Then, the aforementioned calculation process of similarity D and the detection process of the sewing needle 10 can be performed for such predetermined number of thread color data.
[0055] Furthermore, the above described determination process in steps S 14 and thread spool replacement process in step S 16 can be performed in prior to the start of the sewing process.
[0056] In the above described embodiment, upon calculating similarity D, the thread color specified by the thread color data and the thread color in the sewing needle-thread color mapping data are associated with an RGB value by referring FIG. 5 . Alternatively, the thread color specified in the thread color data and the thread color in the sewing needle-thread color mapping data can be stored in the form of RGB value in advance.
[0057] In the above described embodiment, the operation panel 16 of a touch-panel type is provided which integrally assumes the functions of the informing unit and the operation unit. Alternatively, a display serving as the informing unit and operation keys serving as the operation unit can be provided separately.
[0058] Also, the informing unit may be provided as a light-emitting device composed of a plurality of light-emitting diodes or a buzzer, or the like. In such case, the sewing needle 10 to be switched can be informed to the user by changing the color of the light emitted by the light-emitting device or by changing the sound of the buzzer.
[0059] The foregoing description and drawings are merely illustrative of the principles of the present invention and are not to be construed in a limited sense. Various changes and modifications will become apparent to those of ordinary skill in the art. All such changes and modifications are seen to fall within the scope of the invention as defined by the appended claims.
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A sewing machine control device includes a control unit for controlling the execution of a sewing operation based on sewing data including at least needle drop point data and thread color data of a sewing thread by selectively using a plurality of sewing needles respectively set with different color thread; a sewing needle-thread color storage medium storing sewing needle-thread color mapping data specifying the relation between sewing needles and thread color of thread respectively set thereto; a similarity evaluation unit for evaluating the similarity between the thread color specified by the thread color data and the thread color set to each sewing needle based on the thread color data and the sewing needle-thread color mapping data; and a sewing needle selection unit for selecting the sewing needle used for sewing in accordance with the sewing data based on evaluation result rendered by the similarity evaluation unit.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein 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
The present invention relates to a computer aided tool for analyzing a computer program and more particularly, to a method for extracting, converting and displaying complex software data structures located within existing computer programs.
2. Description of the Prior Art
As those skilled in the art well know, computer or software programs are rarely created in a single session. Often, many rewrites of a program are needed to get it to operate as desired. Additionally, complex or large scale programs are often written by more than one author and contain millions of lines of source code. This source code represents the complete architecture and functionality of the program.
After a software program has been certified or approved, it is deployed as a component part of a system. Thereafter, it needs to be maintained and upgraded during the life of the system. Life cycle deployments of both a program and a system can exceed twenty years.
Computer programmers that are tasked with the maintenance and upgrading of these systems often must rely on paper documentation that is in some cases decades old. Given the extremely large size of deployed software systems, documentation limitations can place great demands on the resources of a software maintenance organization. More specifically, current maintenance programming environments typically face the following problems. There are instances where the documentation for the software system is non-existent or misleading. Programmers must locate language constructs, such as data structures, from literally millions of lines of code, before they can debug and perform program maintenance. These problems force programmers to have years of direct experience with the particular software system being maintained to exhibit any appreciable efficiency.
A variety of tools have been developed to assist programmers in finding and debugging errors in computer programs and in understanding the structure of such programs. U.S. Pat. No. 5,029,170 to Hansen, for example, illustrates a tool for identifying potential Assembly language source code errors resulting from incorrectly used symbolic and literal address constructs. The tool comprises a debugging program which has an awareness of the specific machine interfaces, conventions and symbol sets. By essentially stepping through the Assembly language statements, the debugging program is able to identify, in the Assembly language program under study, specific instances of the use of statements containing possibly incorrect symbolic or literal address constructs and to run closely related additional tests. The programmer can then examine the denoted Assembly language code to determine if a genuine error exists. Use of this debugging program however requires execution of the computer program during analysis.
U.S. Pat. No. 4,730,315 to Saito et al. illustrates a tool for testing a program in a data processing system equipped with a display terminal for interactive operations. Program specification inputs are given in a diagrammatic form through interactive operations and are edited into diagrammatic specifications. The diagrammatic specifications are then translated into a source program in which are interspersed comment statements, each of which indicates a diagrammatic specification corresponding to the associated statement of the source program. In the course of the test, the diagrammatic specification corresponding to a process under execution is retrieved and displayed according to a comment statement and the portions corresponding to executed operations are displayed while the resultant values of variables are also displayed. One of the limitations to this test program is that it requires modification or enhancement of the original computer program and recompilation prior to its use. Other limitations are that this tool does not provide a graphical representation of the data structures as they are stored in memory and that it requires operation of the program under test.
U.S. Pat. No. 5,034,899 to Schult illustrates a software process for automatically generating a functional diagram graphic which can be used for automatically generating functional diagrams from a control program for a stored-program control system on a graphical display device, particularly a programming device for such a control system. The functional diagrams generated have a high information density. They contain signal branchings and signal crossings and function blocks with several outputs further connected to other function blocks.
Still another tool available to programmers is illustrated in U.S. Pat. No. 4,937,740 to Agarwal et al. This tool comprises a software analysis system for acquiring, storing, and analyzing certain predetermined characteristics of a computer program and includes a method for acquiring certain lines of high-level language instruction code without the need for statistical sampling. Each line of instruction code generates at least one address in assembly language which is encoded with a tag and stored in a first-in, first-out memory. The memory output is asynchronous with its output such that tagged addresses are stored in real time but extracted from memory at a predetermined rate. This allows the system to acquire all software events of interest. Each tagged address is also marked with a time stamp so that the time between acquisition of each of the software events of interest may be analyzed to determined the length of time spent in a particular subroutine. Typically, this system is used to evaluate the frequency of computer memory accesses made and to assess the performance of the software article under evaluation. One of the limitations of this tool is that it requires execution of the program under analysis on the target host computer.
Recently issued U.S. Pat. No. 5,185,867 to Ito illustrates an information processing system for generating software specifications to facilitate software maintenance work. The method involved in this system comprises the steps of reading information described in at least one software product obtained by particularizing a high rank specification, extracting information taken over from the high rank specification to the low rank specifications out of the information thus read, dividing the extracted information into common items and items single existing and relating to the common items, putting together singly existing items for every common item, arranging respective items on the basis of the information put together for every common item in a network form, generating network information, converting representation format of each item of the network information, and generating a high rank specification.
SUMMARY OF THE INVENTION
Despite the existence of these software tools, there still remains a need for a tool that provides powerful data structure extraction, conversion and analysis capability. Accordingly, it is an object of the present invention to provide a tool that provides powerful data structure extraction, conversion and analysis capability.
It is a further object of the present invention to provide a tool as above which allows data structure information and conversion status information to be stored in random-access files for subsequent display processing.
It is yet a further object of the present invention to provide a tool as above which eliminates the labor intensive process of manually searching for data structure information, interpreting the information and sketching the architecture of the data storage provided in the operational computer.
It is yet another object of the present invention to provide a tool as above that can process very large quantities of computer software.
Still further objects and advantages of the present invention will become apparent from the following description and accompanying drawings wherein like reference numerals depict like elements.
The foregoing objects and advantages are attained by the present invention which comprises a computer aided tool for the extraction, conversion and display of complex software data structures located within existing programs. The engineering analysis tool of the present invention has particular utility with large programs used in military applications.
The computer aided tool of the present invention comprises a computer program for analyzing another computer program. Typically, the program to be analyzed will be in the form of one or more source code files. The method for analyzing a computer program using the tool of the present invention broadly comprises: inputting a computer program to be analyzed, extracting and converting information about at least one data structure from the program and storing the information in at least one random access file. The method further comprises displaying the information stored in said at least one random access file in a desired format.
In a preferred embodiment of the present invention, the program to be analyzed is inputted in the form of one or more source code files. The source code files are read and parsed to find variable and table data structures taking into account compiler switches (C-switches). Information about variable structures in the program are extracted and converted to a desired form and then stored in a random access variable file. Information about table structures in the program and the field structure of the table(s) are extracted and converted to a desired form and then stored in random access table and field files. Still further, inline comments about the variable and table structures are identified and stored in a random access comments file. Additionally, a random access status file is maintained which contains information about the number of extracted variables, tables, fields and comments.
The information contained in the aforesaid random access files may be retrieved by a programmer as desired and displayed either in graphical or textual form or subsequent operator analysis.
Other details of the analysis tool of the present invention are set out in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of the architecture of the software program forming the computer aided tool of the present invention;
FIG. 2 is a flow-chart illustrating the processing in the extraction and conversion segment of the program of the present invention;
FIG. 3 is an illustration of a table display in text mode generated by the display segment of the program of the present invention;
FIG. 4 is an illustration of a table display in text mode with subfield description generated by the display segment of the program of the present invention; and
FIG. 5 is an illustration of a graphic display generated by the display segment of the program of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The software tool to be described hereinafter provides a powerful data structure extraction, conversion and analysis capability for programmers. The software tool comprises a program which can be written in any desired programming language such as "C" programming language. Additionally, the software tool can be run on any properly configured computer. The tool is comprised of a single executable program coupled with a text file used for the built-in context sensitive help feature. The software can run on any IBM/PC compatible that has an Enhanced Graphics Adapter (EGA) and monitor.
Illustrative of the type of source code for which the present invention has special utility is military standard programming language CMS-2Y (Compiler Monitor System Version 2Y) which is characterized by fixed syntax of language constructs, and which employs so-called "compiler switches" (C-switches) to effect conditional compilations.
At the top level, the architecture of the program of the present invention is partitioned into three functional areas as illustrated in FIG. 1. The first is the extraction and conversion segment 10, which is the portion responsible for the parsing of the input source code and the conversion and storage of data structure information into a relational database 12. The second segment is a display segment 14 which provides for data structure selection and display. The third segment is a menu-driven, windowed interface 16 for the display and control of the program.
The extraction and conversion segment 10 performs a one-time processing of the source code file(s) 18. It is executed once for each source code file to be analyzed, preferably prior to visualizing the data structures within the display segment 14. Once a source file 18 has been processed by the extraction and conversion segment, the display segment 14 can be used as often as desired.
FIG. 2 outlines the top level processing in the extraction and conversion segment 10. It illustrates that the program of the present invention first reads and parses (interprets) a source code file 18 and determines if a parsed token (each separable word) is a recognized keyword. If a keyword is recognized, the program switches to a processing section 20, comprising process variable 22 and process table 24, that performs subsequent extraction and conversion of the appropriate data. Each of the extraction routines shown in blocks 22 and 24 takes advantage of the fixed syntax of the language constructs required by the compiler associated with the program under analysis and extracts the pertinent information defining the data structure of a variable or a table. An additional routine 26 is provided that accounts for compiler switches (C-switches). The C-switches are used by the or concomitantly with such analysis and extraction monitors states of the compiler switches for operational status of the source code file sections, compiler to effect conditional compilation of the source code and alternately switch on or off identified source code file sections. They must be accounted for in order to provide accurate representation of the data structures.
For illustrative purposes, it can be assumed that the source code under analysis is CMS-2Y and that the code utilizes the keyword "VRBL" in conjunction with certain variable data structures. Once this keyword is identified, the process variable function in block 22 is executed. This portion of the extraction and conversion process reads the name, data type, size, and sign attributes of the variable defined in the source code. Additionally, if there are any inline comments for the defined variable, that information is extracted as well. Examples of some variable definitions that can be found in a typical source code file are shown below in Table I:
TABLE I__________________________________________________________________________VRBL NAVFLAGA I 32 S P O "NAVSAT FLAG "$VRBL SCRUDANG A 32 S 31 P O "RUDDER ANGLE IN BAMS "$VRBL SCSTNPLN A 32 S 31 P O "STERN PLANE ANGLE IN BAMS '$VRBL SCSFTRPM A 32 S 6 P O "SHAFT RPM (REV/MIN) "$__________________________________________________________________________
The interpretation of the input code for variables is based upon the fixed syntax of the language of the compiler. As shown in Table I, the variable definitions include a number of tokens. Preferably, only the following formal constructs or tokens are interpreted:
(a) The syntax of the compiler is such that the first token after the keyword VRBL is a character string identifying the variable name e.g. NAVFLAGA;
(b) The next token is a single character identifying the data type of the structure to be created (I=integer or A=real);
(c) The next token is an integer that represents the size of the variable in bits;
(d) The next token is a single character that identifies the sign of the variable (U=unsigned, S=signed); and
(e) The interpretation of the next token depends on whether the second identified token identified the type of the variable as integer or real. For variables of type real, the next recognized token is an integer representing the size of the fractional portion of the variable in bits; and
(f) The next recognized token is a word beginning with two quote characters (ASCII character 0039) in a row, or the End Of Line (EOL) character "$". The quote character sequence identifies the beginning of a character string representing an inline comment. If the End of Line character is the next token, the definition of VRBL is complete. If the beginning of an inline comment was identified during the parsing of the VRBL declaration in the program, then all subsequent tokens are parsed and lexically added together (concatenated) until a token is found that ends with two quote characters in a row. This construct identifies the end of the definition of the inline comment and that the definition of the VRBL is complete.
Once the complete variable definition and inline comment has been extracted, the information is stored in the relational database 12 for subsequent use by the display functions.
For illustrative purposes, it can be assumed that the source code under analysis also uses the keyword "TABLE" to identify a complex data structure for processing. When the keyword "TABLE" is recognized, the program invokes the Process Table function 24 which in turn invokes a Process Field function. This portion of the extraction and conversion process reads the name and table top level data structure defined in the source code.
The process table function extracts the table name, type (horizontal or vertical), the number of items in the table, and the number of 32-bit words of memory to be allocated for the table. Additionally, if there is an inline comment on the table keyword, it is extracted as well.
Once the top level structure of the table has been extracted, the process table function invokes the process field function in order to extract the constituent field data structures used in the table. The data structure information extracted for each field includes field name, data type, size, sign, and position in the table (both word position and bit position).
An example table definition, complete with field definitions and inline comments is outlined below in Table II:
TABLE II__________________________________________________________________________CSTSEX H 7 MAXNTGSS "CSTS EXTENSION "$FIELD RNGRATE A 16 S 8 0 31 "RANGE RATE OF TGT IN YARDS/SECOND "$FIELD TURNAMT A 16 S 15 0 15 "TURN AMOUNT IN HAMS "$FIELD TURNAMTB A 16 U 16 0 15 "TURN AMT IN BAMS "$FIELD EUA A 16 S 15 1 31 "D/E ANGLE IN HAMS "$FIELD DE A 16 U 16 1 31 "D/E ANGLE IN BAMS "$FIELD UCRR A 16 S 8 1 15 "UNCORRECTED RNG-RATE "$FIELD DISPHIST B 2 0 "WHEN SET, THIS TARGET HAS "$ " TRACK HISTORY DISPLAYED "$FIELD OPTURN B 2 1 "OPERATOR SELECTED TURNRATE 1 - YES 0 - NO (TRAINER ONLY) "$FIELD ZIGZAG B 2 2 "TGT ZIGZAG MANEUVER IN EFFECT 1 - YES 0 - NO (TRAINER ONLY) "$FIELD PIDEQUL B 2 3 "TGT IS PI/DE QUALIFIED 1 - YES 0 - NO "$FIELD ASSB64 B 2 4 "TGT IS ASSIGNED TO B64 1 - YES 0 - NO "$FIELD PU B 2 6 " TGT IS A PARTICIPATING UNIT 1 = YES 0 = NO "$ 1 - YES 0 - NO "$FIELD SODL B 2 8 " TGT IS A SODL TRACK 1 = YES 0 = NO "$FIELD OTH B 2 5 "TGT IS OTH OR HAS GTE "$FIELD OTBITS I 4 U 2 8 "OVERLAY FOR OTH BITS "$FIELD SNORKEL B 2 9 "TGT SNORKEL STATUS (0) OFF, (1) ON "$FIELD ACTAMP B 2 10 "TGT ACTIVE SONAR LEVEL(0) LOW, (1) HIGH "$FIELD ACTSONAR I 2 U 2 12 "TGT ACTIVE SONAR MODE "$FIELD B64INX I 8 U 2 31 "B64INTF1 TABLE INDEX FOR 21B64 INTERFACE "$FIELD ORDCRS A 32 S 31 3 31 "ORDERED CRS HAMS "$FIELD ORDCRSB A 31 U 31 3 31 "ORDERED CRS BAMS "$FIELD ORDDEPTH A 16 U 3 4 15 "ORDERED DEPTH "$FIELD ORDSPD A 16 S 4 4 31 "ORDERED SPEED "$FIELD CRUMY I 16 S "Y POSITION CRUMBS "$FIELD CRUMX I 16 S "X POSITION CRUMBS "$FIELD TRNRATE A 32 S 31 6 31 "TURNRATE IN HAMS/SEC "$FIELD TRNRATEB A 31 U 31 6 31 "TURNRATE IN BAMS/SEC "$TABLE CSTSEX $__________________________________________________________________________
The interpretation of the input computer code for tables is also based upon the fixed syntax of the language of the compiler. Preferably, the following constructs for tables are interpreted in this invention:
(a) The syntax of the compiler is such that the first token after the keyword "TABLE" is a character string identifying the table name (e.g. CSTSEX);
(b) The next token is a single character identifying the table type of the structure to be created (H=horizontal, V=vertical);
(c) The next token is a variable name or an integer that represents the table size of the data structure (in 32-bit words);
(d) The next token is a variable name or an integer that identifies the number of items in the table;
(e) The next recognized token is a word beginning with two quote characters (ASCII 0039) in a row, or the End Of Line (EOL) character "$". The quote character sequence identifies the beginning of a character string representing an inline comment. If the End of Line character is the next token, the definition of the table name and size is complete and the detailed description of the internal structure of the TABLE begins. If the beginning of an inline comments was identified during the parsing of the TABLE declaration in the program, then all subsequent tokens are parsed and lexically added together (concatenated) until a token is found that ends with two quote characters in a row. This construct identifies the end of the definition of the inline comment; and
(f) The definition of the internal structure of the TABLE includes the definition of any number of fields within the table. The definition of the structure of each field is sequentially defined until the keyword "END-TABLE" is encountered. The "END-TABLE" keyword signifies the completion of the definition of the TABLE data structure.
The definition of the language syntax interpreted by the present invention for the constituent fields within a TABLE data structure may be specified as follows:
(1) The syntax of the compiler is such that the first token after the keyword FIELD is a character string identifying the field name (e.g. RNGRATE);
(2) The next token is a single character identifying the data type of the structure to be created (I=integer, A=real, B=boolean);
(3) The interpretation of the next token depends on whether the second identified token identified the variable as an integer, a real or a boolean data type.
(A) For integer and real data types;
(i) the next token is an integer that represents the field size of the structure in bits;
(ii) the next token is a single character that identifies the sign of the field (U=unsigned, S=signed);
(iii) the interpretation of the next token depends on whether the identified field is of the type integer or real. For fields of type real, the next recognized token is an integer representing the size of the fractional portion of the field in bits;
(iv) the next recognized token is an integer specifying the word position of the field within the table;
(v) the next recognized token is the bit position of the field within the previously identified word in the table;
(vi) the next recognized token is a word beginning with two quote characters (ASCII character 0039) in a row, or the End of Line (EOL) character "$". The quote character sequence identifies the beginning of a character string representing an inline comment. If the End of Line character is the next token, the definition of the field is complete. If the beginning of an inline comment was identified during the parsing of the FIELD declaration, then all subsequent tokens are parsed and lexically added together (concatenated) until a token is found that ends with two quote characters in a row. This construct identifies the end of the definition of the inline comment and that the definition of the field is complete.
(B) For boolean data types,
(i) the next token is an integer representing the word position within the TABLE data structure of the boolean field;
(ii) the next token is an integer representing the bit position of the boolean field within the previously identified word in the TABLE data structure;
(iii) the next recognized token is a word beginning with two quote characters in a row (ASCII character 0039). This sequence identifies the beginning of a character string representing an inline comment;
(iv) the next recognized token is a word beginning with two quote characters (ASCII 0039) in a row, or the End Of Line (EOL) character "$". The quote character sequence identifies the beginning of a character string representing an inline comment. If the End Of Line character is the next token, the definition of the field is complete. If the beginning of an inline comment was identified during the parsing of the FIELD declaration in the program, then all subsequent tokens are parsed and lexically added together (concatenated) until a token is found that ends with two quote characters in a row. This construct identifies the end of the definition of the inline comment and that the definition of the field is complete.
The information produced during this extracting and converting step is then stored in a series of random access files in the relational database 12 for subsequent access by the display functions. Each file in the database can be kept on an individual disk if desired.
The C-Switch Processing Block may be used to identify structures containing the keywords "CSWITCH", "CSWITCH-ON", "CSWITCH-OFF", and "END-CSWITCH" or any other keywords used to identify sections of the source code to be switched on or off for conditional compilation. The four keywords mentioned above, when found in the source code, invoke process-cswitch, process-cswitchon, process-cswitchoff and process-cswitchend functions. These functions can be invoked at any time (even in the middle of a table definition) in response to encountering switches in the compiler. The functions add to the description of individual data structure records stored during the conversion process, the definition of the existence of cswitches and their status (ON or OFF).
As can be seen from the foregoing, the processing sections discussed above extract data structure information about variables, tables, fields in the tables, and comments about the foregoing located in the source code. The data structure information, as well as conversion status information, is stored during the extraction process in one or more random access files 12 for subsequent display processing. Preferably, the information is stored on off-line storage devices such as hard disks, floppy disks, tapes, and the like. This off-line storage approach represents a relational database. It has been found that this approach is desirable because it allows for the processing of very large source files (limited only by available disk space, not by available computer memory). This approach also eliminates the need to extract data structure information each time an analysis session is initiated.
In the database, a separate status file is maintained that identifies complete status information logged during the file extraction and conversion process. The detailed data structure information extracted by the process-variable, process-table and process-cswitch functions are preferably stored in four random access data files. They are the variables file, the tables file, the fields file and the comments file.
The status file is produced at the end of the conversion process and contains information concerning the number of extracted variables, tables, fields and comments. It contains the sizes of the files used and created, their file creation dates, and a list of the CSWITCHES found.
The variables file contains a number of fixed length records, each defining the content of the data extracted for the VRBL data type. Information stored in each record includes the variable name, data type, size, sign, data position, and cswitch status. Each of these records also contains pointer information to index into the comments file for any inline comments extracted for the variable.
The tables file contains a number of fixed length records, each defining the content of the data extracted for the TABLE data type. Information stored in each record includes the table name, type (horizontal or vertical), number of items, and length in 32-bit words. Each of these records also contains pointer information to index into the comments and fields files. The pointers for the comments file provides access to any inline comments extracted from the table definition. The pointers for the fields file allow for the access to the field data that comprise the table definition.
The fields file contains a number of fixed length records, each defining the content of the data extracted for the FIELD data subtype for the TABLE data structure. Information stored in each record includes the field name, data type, size, sign, data location (word and bit positions) and cswitch status. Each of these records also contains pointer information to index into the comments file for any inline comments extracted for the field.
The comments file contains a number of fixed length records, each defining the comment information extracted during variable, table and field processing. Access to the comments records is performed once the file indexing pointers have been obtained from the appropriate variable, table or field file record.
The software tool of the present invention also includes a display segment which provides textual and graphic displays of the extracted data structures. The display segment has a simple printing function embedded therein that provides printouts of the higher level information managed by the software. If desired, the display segment may also include an embedded function that provides visual display of a desired set of information on a monitor associated with the computer on which the analysis tool of the present invention is being run.
The textual display mode provides the capability to display the content of a selected data structure stored in the aforementioned files in text format. For table data structures, the individual fields within the table may also be shown (see FIGS. 3 and 4).
The graphic display mode of the display segment may be used to provide a schematic representation of a selected data structure as it would be stored in the computer when the program is executed. As shown in FIG. 5, it provides for the display of the content, data type and location of each data structure and its constituent parts. The legend at the bottom of FIG. 5 illustrates the various types of information being displayed. With respect to "bit" information, the following code is applicable with respect to the CMS-2Y source code.
______________________________________WORD 2 (BIT FIELDS):BIT POSITION FIELD NAME______________________________________0 DISPHIST1 OPTURN2 ZIGZAG3 PIDEQUL4 ASSB645 (BLANK)6 PU7 STDL8 SODL9 SNORKEL10 ACTAMP______________________________________
The menu system 16 provides the man-machine interface and acts as the binder for the other constituent functions. It may contain memubars, pop-up menus, pop-up windows and context sensitive help. It also includes a pop-up list feature which provides for display of lists of data and for user selection from the displayed lists.
The present invention is most advantageous in that it provides a data structure extraction, conversion and display capability that eliminates the labor intensive process of manually searching for data structure information, interpreting the information, and sketching the architecture of the data storage provided in the operational computer. The present invention facilitates the processing of very large quantities of computer software and the filtering out of data not pertinent to the data structure analysis task. The present invention also provides rapid viewing of data structures, reducing the time required to perform analyses. Still further, the graphic display of the data structures enabled by the present invention provides visualization of many software architecture attributes (table packing efficiency, multiple data references, etc.). The present invention also avoids documentation errors due to the extraction of data from the source code itself.
It is apparent that there has been provided in accordance with this invention a data, structure extraction, conversion and display tool which fully satisfies the objects, means, and advantages set forth hereinbefore. While the invention has been described in combination with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the appended claims.
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The present invention relates to a tool, in the form of a computer program, for analyzing computer programs by extracting and converting information about data structures in the program, storing the information about the extracted data structures in a series of random access files forming a relational database, and displaying the stored information as desired. The method for analyzing the computer program using the tool of the present invention includes the steps of inputting a computer program to be analyzed, extracting and converting at least one data structure such as a variable or a table from the program, storing information about the data structure(s) in one or more random access files, and displaying the stored information in either a textual or graphical mode. The program to be analyzed is preferably inputted into the program of the present invention in the form of one or more source code files. It has been found to be successfully applied to the analysis of source code files written in programming language Compiler Monitor System Version 2Y (CMS-2Y), which is commonly used in military application.
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BACKGROUND
[0001] 1. Field
[0002] The present invention relates generally to the inspection of nuclear fuel rods and, more particularly, to the inspection of a nuclear fuel pellet stack within a hermetically sealed fuel rod cladding to detect missing pellet surfaces and pellet-to-pellet gaps.
[0003] 2. Related Art
[0004] The large nuclear reactors utilized for power generation employ an array of a large number fuel rods containing nuclear fuel. Each rod comprises a metal tube or a sheath which may be from 8 to 15 feet (2.4-4.6 m) long and up to one-half inch (1.27 cm) in diameter, and which contains a stack of cylindrical fuel pellets of suitable fissionable material such as uranium oxide. The upper end of the tube is empty of fuel pellets and forms a plenum for a gas or other fluid under substantial pressure which fills the top of the rod and also a small clearance space around the fuel pellets. The fuel rods are supported in parallel groups in fuel assemblies which may typically contain upwards of 300 fuel rods, and the complete nuclear reactor is made up of a large number of these fuel assemblies arranged in a suitable configuration in an active core.
[0005] The metal tubes of the fuel rods, also known as cladding, constitute the primary containment boundary for the radioactive nuclear fuel, and inspection of the internal components of the rod that can affect the rod's integrity is of primary importance. In the manufacture of the fuel rods, the tubing itself and the end cap welds are carefully inspected and helium leak tested. Since a nuclear reactor may contain upwards of 40,000 fuel rods, a probability exists that some number of defective rods will be present even with a highly effective manufacturing quality control program. It is also desirable to inspect the fully loaded fuel pellet stack for defects such as missing pellet surfaces and pellet-to-pellet gaps which can ultimately compromise the cladding's integrity or affect core performance. The temperature differences on the outer cladding surface of an assembled fuel rod can result from differences in the radial thermal resistance between the cladding inside diameter and the fuel pellet outer surface due to a missing pellet surface or a pellet-to-pellet gap. It is important to detect conditions such as this that might ultimately result in breaches of the cladding which could lead to fission products leaking into the reactor coolant and can result in many conditions that increase operating costs. These conditions include: (1) high radiation readings in the primary cooling system; (2) increased volume of liquid radioactive waste; (3) increased volume of solid radioactive waste due to more frequent demineralizer bed replacement; (4) increased costs for disposal of spent fuel assemblies due to special handling and additional decontamination; and (5) increased exposure to personnel. These increased costs outweigh the costs incurred by testing assemblies. Once identified, a leaking fuel rod may be extracted from the fuel assembly and replaced with a dummy rod to allow the eventual reload of the assembly in the core. To the extent failure mechanisms can be located in advance of placing the fuel assemblies in the core, the costs of replacing defective rods can be minimized.
[0006] Accordingly, it is an object of this invention to provide a means of nondestructively inspecting a fuel pellet stack sealed within the cladding of a nuclear fuel rod.
[0007] Further, it is an object of this invention to provide such an inspection method that can be performed efficiently, with minimal effort and expense.
SUMMARY
[0008] These and other objects are achieved by the inventions claimed hereafter which provide a method of detecting defects in nuclear fuel within a fuel rod cladding which include the step of heating at least a portion of the fuel rod to a temperature substantially above the ambient temperature, preferably in a range of between 80 to 120 degrees centigrade. The temperature over the surface of the cladding is then measured as the cladding is cooled, preferably in an ambient environment. Variations are then noted in the temperature measured over the surface of the cladding to determine defects in the fuel stack.
[0009] In one embodiment, the heating step is performed in a soaking chamber that covers at least a portion of the fuel rod and preferably, the temperature is measured with an infrared receiver such as an infrared camera. Preferably, the fuel rod is rotated as it passes in front of the infrared camera.
[0010] In another embodiment, the method includes a second heating step after the initial heating step wherein the second heating step heats the surface of the rod for a time period substantially shorter than the initial heating step and before the measuring step. The second heating step may be performed by a radiant heat source, and desirably the rod is moved past the radiant heat source.
[0011] In still another embodiment, the measuring step is performed in a reduced pressure environment, i.e., below atmospheric pressure and desirably, the noting step occurs at approximately between 60 and 180 seconds after the heating step is completed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A further understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
[0013] FIG. 1 is a sectional view of a typical nuclear fuel rod;
[0014] FIG. 2 is a schematic block diagram of a system which can be used to carry out the steps of the embodiments described hereafter;
[0015] FIG. 3 is a graphical representation of the thermal image inspection duration;
[0016] FIGS. 4A through 4F are graphical representations of the fuel rod temperature distribution of fuel rods exhibiting no missing pellet surface and two different missing pellet surface conditions measured 60 seconds and 180 seconds after the heating step described hereafter;
[0017] FIGS. 5A and 5B are graphical representations of the three missing pellet surface conditions illustrated in FIG. 4A through 4F taken at 60 seconds ( FIG. 5A ) and 180 seconds ( FIG. 5B ) from the end of the heating cycle; and
[0018] FIG. 6 is graphical representation of the fuel rod clad outer temperature differences relative to the no missing pellet surface fuel rod clad temperature noted during an inspection cycle for two different conditions of missing pellet surfaces.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] A typical nuclear fuel rod is shown by way of example in FIG. 1 . The fuel rod 10 comprises a metal tubular cladding 12 of a suitable alloy such as Zircaloy capable of withstanding the severe conditions to which it is subjected during operation, and is usually of considerable length, such as from 8 to 15 feet (2.4-4.6 m) and a relatively small diameter which may be in the order of ½ inch (12.7 mm). The tube 12 is filled for most its length with nuclear fuel pellets 14 which may be made of uranium oxide or other suitable nuclear fuel, and which are of a diameter to fit closely within the tube 12 with a very small radial clearance. The tube 12 is closed at top and bottom by upper and lower end caps 18 and 16 , respectively, which are welded in place to form a leak-tight closure. The fuel pellets 14 are disposed in a vertical column extending through most of the length of the tube 12 but with an empty space or plenum 22 at the top. A spring 20 is disposed in this plenum to hold the column of fuel pellets in position. The plenum in the top of the tube 12 , and the small clearance between the pellets 14 and the tube 12 , are filled with a fluid which is usually gas, and which usually will contain fission products during and after operation within the reactor. This fluid in the tube 12 is normally maintained under substantial pressure typically in the order of 100 to 300 psi (7-21 kg/cm 2 ) at the beginning of fuel assembly life (prior to operation within a reactor core) and further increases during operation as fission products are generated in the fuel.
[0020] As the fuel pellets 14 are loaded into the cladding 12 , there may develop increased gaps between the pellets or missing pellet surfaces such as chips or scars which can affect the temperature distribution over the cladding and detract from the optimum performance of the fuel rod. Therefore, it is desirable to be able to inspect for such defects after the pellets have been loaded into the cladding and, preferably after the cladding has been sealed and pressurized. The embodiments set forth hereafter provide such an inspection technique that is performed by thermal imaging the outer cladding surface with an infrared camera and utilizes the temperature differences over the cladding to identify fuel stack defects. The temperature differences are set up as a result of the differences in the radial thermal resistance between the cladding inside diameter surface and the fuel pellet outer surface due to the missing pellet surfaces or pellet-to-pellet gaps.
[0021] FIG. 2 is a schematic illustration of some apparatus which may be employed in carrying out the steps of the methods claimed hereafter. In accordance with one embodiment, the fuel rod 10 is soaked at a given temperature preferably at or between 80 to 120° C. in a soaking chamber 24 , preferably covering at least a portion of the fuel rod over which the fuel pellets extend or which is expected of having a defect. Then the fuel rod 10 is extracted from the soaking chamber 24 and the cladding surface 12 is heated for a short period of time of approximately 60 sec., while moving past a radiant heat source 26 . Then the rod is moved while rotating past an infrared camera 28 . Though not required, preferably the latter steps are conducted in a reduced pressure environment, i.e., below atmospheric pressure, to reduce the convective heat transfer. However, the clad temperature difference should be detectable for at least 2 min. at natural convection in air. The output of the infrared camera 28 can be operated upon by a processor 32 controlled by a computer 36 to establish a comparison of the temperature differences, and recorded by a recorder 34 . The variable radial thermal resistance will affect heat transfer from the fuel pellets 14 to the cladding 12 resulting in cladding temperature differences on the outside surface of the cladding. The thermal image will be evaluated by the software in the computer 36 to account for pellet eccentric positioning and pellet missing surfaces within the cladding. Finite element analysis is used to provide the optimal soaking temperature as well inputs for software evaluation of the temperature data.
[0022] In an alternate embodiment, the fuel rod 10 may be soaked at a higher temperature up to 120° C. and then extracted from the soaking chamber and them moved while rotating past the infrared camera 28 . Preferably, this is also done in a reduced pressure environment to reduce convective heat transfer.
[0023] A proof of principle was conducted for the thermal image inspection method claimed hereafter using a transient finite element analysis of the fuel rod with a heat up time of 60 seconds and a cool down time of 120 seconds as figuratively illustrated in the graphical representation shown in FIG. 3 . The power source is able to increase the fuel rod outer surface temperature by approximately 100° C. during the 60-second heat up time. Natural convection in air is used for the cool down part of the cycle. The fuel rod temperature distributions for a fuel rod with no defects, ( FIGS. 4A and 4D ), a fuel rod with a missing pellet surface length of 60 mils and a depth of 10 mils ( FIGS. 4B and 4E ) and a fuel rod with a missing pellet surface length of 60 mils and a depth of 20 mils ( FIGS. 4C and 4F ) at 60 seconds ( FIGS. 4A-4C ) and 180 seconds ( FIG. 4D-4F ) are graphically illustrated in FIGS. 4A-4F . The fuel rod surface temperature distributions at 60 seconds and 180 seconds are graphically illustrated in FIGS. 5A and 5B , respectively.
[0024] The clad outer surface temperature differences relative to a fuel rod with no missing pellet surface and a fuel rod with a pellet stack defect are shown in FIG. 6 . FIG. 6 shows the method's sensitivity to defect depth. The graph in FIG. 6 shows two areas along the cladding surrounding pellet defects of different depths relative to adjacent areas that surround not pellet defect. One defect is approximately 10 mils and results in and approximately 1.5° C. difference relative to the adjacent cladding area covering no defect. The second defect has a depth of approximately 20 mils and produces approximately a 1° C. difference. This difference can be easily detected by a modern thermal image device. Thus, the methods claimed herein provide a practical means of inspecting a nuclear fuel pellet stack in a sealed fuel rod for missing pellet surfaces and pellet-to-pellet gaps.
[0025] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. For example, it should be appreciated that this process could be performed continuously with the fuel rods passing through a heating zone with a velocity of, for example, approximately 10″/min and moving to a temperature detection zone where the temperature is monitored by one or more temperature detection devices such as cameras surrounding the rod. Accordingly, the particular embodiments disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
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A method of detecting defects in nuclear fuel within a fuel rod that first heats the fuel rod to a temperature substantially above the ambient temperature. The surface temperature of the fuel rod cladding is then monitored as the fuel rod is allowed to cool. Variations in the temperature measured over the surface is then noted as an indication of defects.
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RELATED APPLICATION
[0001] This application is a continuation of application Ser. No. 09/927,045 filed Aug. 9, 2001 which is a division of application Ser. No. 09/655,942 filed Sep. 6, 2000 which claims the benefit of provisional patent application Serial No. 60/152,559 filed Sep. 7, 1999.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is broadly concerned with magnetic induction heating systems and methods wherein an induction heatable object not physically connected to a magnetic induction heater can be heated and temperature regulated using Radio Frequency Identification (RFID) technology. More particularly, the invention is concerned with such systems, as well as the individual components thereof, wherein objects to be heated are equipped with RFID tags and the induction heaters include RFID readers; when a tagged object such as servingware is placed on a heater, the tag transmits information such as the class of object being heated, and the heater control circuitry uses the information to initiate and carry out an appropriate heating cycle for heating and temperature-regulating the object. In preferred forms, two-way transmissions between the tag and a reader/writer is established, with each having electronic memory to store relevant heating information. More precise temperature regulation is achieved using an RFID tag having an associated switch responsive to an external condition such as temperature experienced by the switch. The invention is applicable to virtually any type of induction heatable object such as food servingware.
[0004] 2. Description of the Prior Art
[0005] U.S. Pat. Nos. 5,951,900 to Smrke, 4,587,406 to Andre, and 3,742,178 to Harnden, Jr. describe non-contact temperature regulation methods and devices employing magnetic induction heating. In these prior devices, radio frequency transmissions between an object to be heated and the induction appliance are employed in an attempt to control the induction heating process.
[0006] In Smrke, Andre, and Harnden a temperature sensor of some kind is attached to the object to be heated to provide feedback information which is transmitted to the induction appliance. In each case, aside from manual inputs by the user, changes to the power output from the induction appliance made by its controller are based solely upon information gathered and transmitted by the temperature sensor. Inasmuch as most objects to be temperature regulated are not homogeneous, this sole dependence upon feedback from the temperature sensor often leads to unwanted temperatures within certain portions of the object. For instance, when a sauce pan filled with dense food is placed upon an induction cooktop and the power is maintained at a constant level, the pan surface temperature quickly rises, whereas the food layer furthest away from the pan is still at ambient temperature. If a temperature sensor is placed upon the surface of the pan, the temperature measured at this point may have a unknown or variable relationship to the temperature of remote food layers. Thus, when the sensor reaches a pre-set temperature that the induction appliance's control unit attempts to maintain, much of the food may still be cold. Conversely, it the temperature sensor is placed adjacent the top layer of food, the pan surface may get excessively hot prior to this food layer reaching the desired temperature, resulting in scorched food near the pan surface.
[0007] Smrke attempts to solve this problem by requiring that the temperature sensor be placed upon the lid of a pot. Harnden teaches placing a temperature sensor in direct thermal contact with the ferromagnetic inner wall of a vessel. However, regardless of sensor location, the problems associated with heating a non-homogeneous object remain. Furthermore, neither proposed solution can prevent a temperature sensor from making imperfect thermal contact with its intended surface, a likely condition that leads to gross inaccuracies in temperature control. It is often difficult to manufacture a device so as to place one or more temperature sensors in perfect thermal contact. Also, over time, the thermal expansions and contractions that the sensor/object interface experience leads to imperfect thermal contact.
[0008] In addition to the requirement for a temperature sensor on or adjacent the object to be heated, the prior art devices also require periodic or continuous temperature measurement of the object, and thus periodic or continuous transmissions from the object to a receiver connected to the induction appliance. Neither Harnden, Andre, nor Smrke teach any practical means of preventing interference between these periodic or continuous RF transmissions and the main magnetic field produced by the induction appliance, so as to ensure proper receipt of feedback information.
[0009] In Harnden, a temperature sensor such as a thermistor provides a continuous variable voltage signal, corresponding to the temperature sensed, to a voltage control oscillator located within the object. The voltage control oscillator produces a variable frequency signal that corresponds to the sensed temperature. This variable radio frequency signal is transmitted to a receiving unit that is connected to the induction cooking range. In Andre, temperature measurements of the object are periodically transmitted to a receiving/controlling unit at constant intervals of time. Each temperature value is stored in the controlling unit's memory. A differentiating circuit then calculates the temperature difference and uses this information to control a heating element.
[0010] In order to the ensure proper reception of such temperature-based radio frequency feedback information, Harnden teaches that the output frequency of the feedback signal should be at least a megahertz or multiples thereof. This is not a practical solution for an emissions-regulated production appliance. In Andre and Smrke no consideration is given to any way of preventing interference between the RF temperature signal and the main magnetic field.
[0011] Furthermore, although temperature information from the object is important, it is often not sufficient to execute a proper heating operation to a desired regulation temperature within a desired period of time. For instance, it is well known that the power applied to an object placed upon an induction cooktop depends greatly upon the distance between the object's ferromagnetic material and the work coil of the cooktop. Should an object require a particular graduated power application to prevent overheating of some parts of the object while reaching the desired regulation temperature throughout the object, as in the earlier sauce pan example, it is essential that the proper power be coupled to the object during each graduation. Furthermore, most practical heating operations required that the prescribed regulation temperature be reached within a maximum prescribed time. This restraint makes it even more important that proper power be applied during each temperature gradation. A means to correct for inconsistent power coupling that is based upon comparisons between power measurements and stored power coupling data is essential to achieve consistent heating operations and accurate temperature regulation. Neither Smrke, Andre, nor Harnden address the transmission or use of other than temperature information.
[0012] Finally, although Smrke and Andre attempt to provide for multiple induction appliance operation with like-type objects, neither teaches how a single induction appliance may automatically differentiate between different types of objects placed upon it so as to apply a unique heating operation to each type. Andre employs differential temperature measurement to prevent overheating an object that is placed upon a different, unintended heating element. In Smrke, when more than one induction appliance exists, a central electronic unit that is connected to all induction appliances can accept signals from each transmitter attached to its respective pot and use them to determine which induction appliance the pot is atop. In neither case can a single induction appliance differentiate among various types of objects prior to commencement of heating of each object type.
[0013] RFID is an automatic identification technology similar in application to bar code technology, but uses radio frequency instead of optical signals. RFID systems can be either read-only or read/write. For a read-only system such as Motorola's OMR-705+reader and IT-254E tag, an RFID system consists of two major components—a reader and a special “tag”. The reader performs several functions, one of which is to produce a low-level radio frequency magnetic field, typically either at 125 kHz or at 13.56 MHz. The RF magnetic field emanates from the reader by means of a transmitting antenna, typically in the form of a coil. A reader may be sold in two separate parts: an RFID coupler, including a radio processing unit and a digital processing unit, and a detachable antenna. An RFID tag also contains an antenna, also typically in the form of a coil, and an integrated circuit (IC). Read/write systems permit two-way communication between the tag and reader/writer, and both of these components typically include electronic memory for the storing of received information.
SUMMARY OF THE INVENTION
[0014] The present invention provides a greatly improved method and apparatus for the magnetic induction heating of objects, especially for the temperature regulation of such objects at and approximate to predetermined temperatures. Broadly speaking, the invention contemplates a combination of an induction heating device and an induction heatable object wherein the object is equipped with an RFID tag and the heating device has apparatus for receiving information from the RFID tag. In use, the object is placed adjacent the heating device and the RFID tag is caused to transmit information (typically about a heating characteristic of the object) to the information-receiving apparatus associated with the heating device; this information is used in the control of the magnetic field generator forming a part of the heating device.
[0015] In preferred forms, the induction heating device includes a component (e.g., an ultrasonic frequency inverter) for generating a magnetic field in order to inductively heat the object, together with microprocessor-based control circuitry coupled with the generating component for selectively initiating and terminating magnetic field generation. The information-receiving apparatus is operably coupled with the control circuitry, and normally includes an RFID signal reader (preferably a reader/writer) and an RFID power transmission antenna. The RFID tag associated with the object to be heated includes a transmission circuit and an antenna. In the preferred two-way systems of the invention, both the reader/writer and the RFID tag have electronic memory for storing information. The control circuitry of the heating device also advantageously includes a sensor operable to measure a circuit parameter related to the impedance of the load experienced by the device; such a sensor periodically or continuously determines such a parameter (such as current) in order to determine if the object to be heated is placed within the magnetic field.
[0016] A particular feature of the invention is that the RFID tags associated with respective classes of objects to be heated permit the use of different induction heating devices, so long as the latter are equipped with RFID readers and associated circuitry. Moreover, a given induction heating device may store multiple heating algorithms designed for heating of different classes of objects; when an object of a given class is placed on the device, the object tag transmits to the reader the identity of the class, thus initiating the heating algorithm for that class. Additionally, in the preferred systems of the invention the object tag contains stored information which is periodically updated by transmissions from the reader/writer, thereby storing on the tag the relevant induction heating history of the particular object. In this way, if a particular object is removed from the induction heater for a short period of time and then replaced, the updated RFID tag information can be communicated to the induction heater so as to resume the appropriate heating algorithm.
[0017] In order to assure high integrity, interference-free transmissions between the RFID tag and the reader/writer, the induction heating device is designed so that these transmissions occur during intermittent cessations of operation of the primary magnetic field generator of the heater.
[0018] In order to provide better temperature regulation, the RFID tags associated with objects to be heated include a switch which is switchable between circuit make and circuit break orientations in response to an external condition experienced by the switch, thereby altering the operation of the RFID tag. For example, one or more thermal switches may be operably coupled with the tag (usually the antenna or EEPROM of the tag) so that when the thermal switch experiences a predetermined temperature condition, the switch(es) responsively operate to prevent or alter transmission of information from the tag.
[0019] Induction heatable objects equipped with the RFID tags of the invention, as well as induction heaters having appropriate control circuitry and apparatus for receiving RFID tag information, corresponding methods, and RFID tag-switch composites are also separate, individual aspects of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a schematic view of an induction heating device in accordance with the invention, supporting servingware designed to be heated using the device;
[0021] [0021]FIG. 2 is a schematic cross-sectional view of a china plate body equipped with a metallic coating on its bottom surface and a centrally located RFID tag adhered to the metallic coating;
[0022] [0022]FIG. 3 is a schematic vertical sectional view of a china body espresso cup with a metallic coating on its bottom surface and a centrally located RFID tag adhered to the bottom surface;
[0023] [0023]FIG. 4 is a perspective view with parts broken away illustrating a heat-retentive pellet having an RFID tag centrally secured to the upper surface thereof;
[0024] [0024]FIG. 5 is a graph of cooktop power versus time illustrating the sequence of ideal power steps comprising a portion of the heating algorithm for the servingware illustrated in FIG. 1, and with a graph overlay of the average surface temperature of the servingware plotted on the same time scale;
[0025] [0025]FIG. 6 is a graph of the average surface temperature of the FIG. 1 servingware versus time, illustrating an ideal cooling behavior;
[0026] [0026]FIG. 7 is a flow chart of a preferred overall software algorithm for the heating device of the invention;
[0027] [0027]FIG. 8 is a flow chart of a specific software heating algorithm relative to the servingware depicted in FIG. 1;
[0028] [0028]FIG. 9 is a schematic representation of an RFID antenna with one thermal switch attached;
[0029] [0029]FIG. 10 is a schematic representation similar to that of FIG. 9 but illustrating an RFID antenna with two series-attached thermal switches; and
[0030] [0030]FIG. 11 is a list of exemplary instructions illustrating the heating operation for an object employing an RFID tag with one or more thermal switches attached thereto, and wherein the temperature information is used to define regulation temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] Embodiment of FIG. 1
[0032] Broadly speaking, the heating apparatus of the invention includes a specialized magnetic induction heating device together with an induction heatable object to be temperature-regulated which has a RFID read/write tag. To this end, the heating device is preferably capable of reading the digital information stored on the RFID tag, and also may periodically write new digital information onto the tag. Appropriate software algorithms are provided for microprocessor control of the heating device, and can be modified based upon information read from the RFID tag and/or from measured induction heating device circuit parameters.
[0033] The preferred embodiments of the present invention relating to cookware and controlled induction heating thereof incorporate some of the features described in U.S. Pat. No. 5,954,984 and pending application for U.S. patent Ser. No. 09/314,824 filed Feb. 19, 1999 which are incorporated by reference herein.
[0034] [0034]FIG. 1 depicts a preferred induction heating device in the form of a cooktop 20 , with exemplary, induction-heatable servingware 22 thereon, in this case a so-called “sizzle plate” used in restaurants. The device 20 comprises a rectifier 24 coupled with commercially available alternating current from an outlet 26 , in order to convert the alternating current to direct current. The rectifier is coupled with a solid state inverter 28 in order to convert the direct current into ultrasonic frequency current (preferably from about 20-100 kHz) directed through induction work coil 30 . A microprocessor-based control circuit including microprocessor 32 is operably coupled with and controls the inverter 28 ; this circuitry may also control various other of the cooktop's internal and user-interface functions. The control circuitry also includes a circuit parameter sensor 31 coupled with microprocessor 32 to measure a parameter related to or dependent upon the load experienced by device 20 during use; in practice, this may be a current sensor within inverter 28 which measures current through one of the inverter's switching transistors. The device 20 also includes an object support 34 above the coil 30 . Items 24 , 28 , 30 , 32 , and 34 comprise the major components of many commercially available induction cooktops. One particularly preferred induction cooktop useful in the context of this invention is CookTek Model CD-1800, although a variety of other commercially available appliances may also be used.
[0035] The device 20 also includes a RFID reader/writer coupler 36 which is connected with the microprocessor 32 ; this connection preferably allows RS-232 protocol communications. The preferred coupler 36 is Gemplus' GemWave™ Medio SO13. This coupler has RS-232, RS485, and TTL communication protocols and can transmit data at up to 26 kb/s. In addition, an RFID antenna 38 forms a part of the device 20 , and is connected to coupler 36 via coaxial cable 40 . Gemplus' Model 1″ antenna is preferably used because of its small size, lack of a ground plane, and a read/write range of approximately two inches; Gemplus' Model Medio A-SA also works satisfactorily.
[0036] The device 20 normally also includes a real time clock 42 which can maintain accurate time over long periods. The clock is microprocessor-compatible and preferably contains a back-up power supply that can operate for prolonged periods if the induction heating device 20 is unplugged. Compatible clocks include National Semiconductor Model MM58274C or Dallas Semiconductor Model DS-1286.
[0037] The device 20 also preferably has additional memory 44 that can be accessed by the microprocessor 32 . The memory device 44 should be capable of being either written to easily or replaced easily so as to allow the user to add software algorithms whenever a new type of object, not previously programmed, is to be heated using the device 20 . One preferred memory unit is a flash memory card such as Micron's CompactFlash card; another is an EEPROM device or a flash memory device equipped with a modem connection so as to allow reprogramming from a remote site over a telephone line.
[0038] The exemplary servingware 22 in the form of a “sizzle plate” includes a metallic (e.g., cast iron) pan 46 that is set into a base 48 typically formed of wood, plastic or ceramic materials. A RFID tag 50 is operably coupled to the servingware 22 in a recess formed in base 48 , and is secured via adhesive 51 or some other suitable connection medium. One preferred RFID tag is Gemplus' GemWave Ario 40-SL Stamp having dimensions of 17×17×1.6 mm and designed to withstand extreme temperature, humidity and pressure conditions. This tag has a factory embedded 8 byte code in block zero, page zero of its memory, and has two kb EEPROM memory arranged in four blocks, each block containing four pages of data. Each page of 8 bytes can be written to separately by the reader. Other suitable RFID tags include Gemplus' Ario 40-SL Module, and the ultra-small Gemplus' Ario 40-SDM.
[0039] As shown, the RFID tag 50 need not be in direct thermal contact with the portion of the object in which current is being induced, such as the metallic plate 46 of the servingware 22 . In fact, due to the limited operating temperatures of most RFID tags (the Motorola IT-254E tag can withstand continuous operating temperatures up to 200° C., the Gemplus Ario-40 SL Stamp tag can withstand temperatures up to 350° F.), it is preferred that the tag be somewhat thermally isolated from any such metallic heating element. The important point is that the tag 50 will carry information about the object's identity and its induction heating history. Furthermore, the tag will transmit that information to any RFID reader/writer that interrogates it. When the tag receives the magnetic field energy of the reader, it transmits programmed memory information in the IC to the reader, which then validates the signal, decodes the data, and transmits the data to a desired output device in a desired format. This programmed memory information typically includes a digital code that uniquely identifies an object. The RFID tag may be several inches away from the RFID reader's antenna and still communicate with the reader.
[0040] The servingware 22 depicted in FIG. 2 also illustrates the use of an optional thermal switch 52 . Such a switch is not required, but is often preferred. The specific design and use of a thermal switch in this context is described in greater detail.
[0041] In the following discussion, the hardware construction and software control of the exemplary induction heating device 20 and the sizzle plate servingware 22 will be described in detail. It should be understood, of course, that this discussion is equally applicable (with appropriate changes based upon desired end uses) to all types of other servingware such as illustrated in FIGS. 2 and 3, and also to a wide variety of other induction heatable objects such as the heating pellet depicted in FIG. 4. Therefore, this description should be taken in a broad sense as merely one possible utilization of the invention.
Hardware Integration—RFID Reader/Writer
[0042] As noted previously, the RFID reader/writer 36 is operably coupled with the microprocessor-based control circuit of the induction heating device 20 . The antenna 38 of the RFID reader/writer 36 should be placed such that the servingware 22 is within reading/writing distance from the RFID reader/writer 36 when the servingware 22 object is to be heated. In one preferred antenna configuration, a flat spiral antenna coil of the RFID antenna is situated in planar relationship and within the central opening of the work coil 30 . Referring to FIG. 1, tests have shown that the RFID antenna may also be placed between plane of the induction work coil 30 and the cooktop support surface 34 without inducing detrimental currents in the RFID antenna during cooktop operation.
[0043] Regardless of the precise antenna orientation, it is preferred that the antenna 38 be placed in the center of the work coil 30 . In order to heat various types of objects evenly on the same work coil 30 , it is desirable to center each item over the work coil 30 . Furthermore, a single RFID antenna 38 should preferably couple with a tag 50 placed upon one of as many different types of induction-compatible objects as possible.
[0044] The RFID reader/writer and tag system made up of the reader/writer 36 , antenna 38 and RFID tag 50 should transmit and receive at least the following types of information: 1) the type or class of object (hereafter referred to as COB); 2) the object's last known power step of the heating algorithm (hereafter referred to as LKPS); and 3) the last known time of application of the last known power step of the heating algorithm (hereafter referred to as t(LKPS)). This information should be transmitted by the RFID tag 50 and read by the RFID reader/writer 36 upon placement of an object such as the servingware 22 atop the device 20 . Furthermore, this information (with the exception of COB), and possibly other information, is preferably rewritten to the RFID tag 50 once every chosen time interval, Δt between transmit , during the entire time the servingware 22 is being brought to the selected regulation temperature by the device 20 . The duration of time that is required for the read/write operation to take place is referred to as Δt transmit . Using a read/write system such as Gemplus' GemWave Medio™ SO13 reader/writer and Ario 40-SL read/write tag, Δt transmit for pre-production prototypes has been found to be approximately 150 milliseconds.
[0045] Preferably, the communication between the reader/writer 36 and tag 50 occurs during interruptions in magnetic field production by the device 20 . That is, it is desirable to interrupt the production of the main magnetic field just prior to the transmission of information between the RFID reader/writer 36 and tag 50 , and to resume production of the main magnetic field after cessation of RFID transmission. This interruption can be triggered by using a 5 volt output signal emanating from one of the three built-in output ports on the Gemplus Medio SO-13 coupler to trigger the inverter of the cooktop. Alternatively, due to the microprocessor control of most cooktops and available communication between the RFID coupler and said microprocessor, the interruption may be synchronized through the microprocessor 32 .
[0046] For instance, even during normal operation, a CookTek Model C-1800 cooktop's inverter is “on” (current is flowing through the switching elements to the work coil so as to replenish energy transferred to the load) for only 59 of 60 power supply (line) cycles even when the highest power output level is used. For lower output levels during normal operation, fewer than 59 “on” cycles of the inverter are used.
[0047] During the “off” times of the inverter no rectified current is allowed to flow from the AC power source through the switching elements to the work coil 30 . During these “off” times, the near-zero intensity of the emanating magnetic field produces no interference with transmissions between RFID tag 50 and reader/writer 36 . The microprocessor 32 can thus control the number and timing of “on” and “off” cycles of the inverter and also control the time at which the RFID reader/writer 36 transmits and receives information from the RFID tag 50 . Thus, it is possible to successfully read and write information from RFID reader/writer 36 to RFID tag 50 during the “off” times of the inverter when magnetic field interference is at a minimum, even without modifying the “normal operations” power level duty cycles.
[0048] Furthermore, because of the flexibility and ease of programming of the microprocessor 32 , the “normal operations” power level duty cycles can be modified to cause the inverter to remain “off” for any number of cycles during a chosen 60 cycle period or during some other time interval. These “off” cycles may be timed to occur periodically beginning at any desired time interval. For instance, at consecutive time intervals hereafter referred to as “elapsed time between commencement of transmittals”, or Δt between transmit , the microprocessor can ensure that current flowing through the switching transistors to the work coil 30 is interrupted for a duration of time, Δt transmit . In this example, the maximum possible effective percentage of “on” time of the inverter is {(Δt between transmit −Δt transmit )/(Δt between transmit )}. It should be noted that, because Δt between transmit is consistent, Δt between transmit is also the elapsed time between termination of transmittals. Regardless of the periodicity chosen, a sufficient interference-free transmit/receive period can be achieved by synchronizing the transmit/receive period of the RFID reader/writer/tag system 36 , 38 , 50 with the times of near-zero magnetic field production of the work coil 30 .
[0049] Inasmuch as the RFID reader/writer 36 may be chosen to have an output frequency (either 125 kHz, 13.56 MHz, or other frequencies) far different from that of the induction cooktop (typically 20-60 kHz), its associated antenna 38 may transmit and receive data from the RFID tag reliably during these inverter “off” times. Furthermore, since the watt density of the field produced by the magnetic induction cooktop is sufficiently low, the antennas of the reader/writer 36 and tag 50 do not develop damaging currents from exposure to said field during the inverter on times.
Software Integration
[0050] The principal purpose of software integration is to implement a software algorithm to be followed by the magnetic induction heating, device 20 that allows it to heat an object that may begin a heating cycle at any given temperature to the desired regulation temperature and maintain it there over an indefinite period of time. “Software integration”, refers to the fact that the software algorithm should preferably allow the microprocessor 32 to use the following three sources of information to tailor a pre-programmed heating algorithm to the specific initial conditions that exist when heating begins: 1) information retrieved from the RFID tag 50 ; 2) information from the circuit sensors of the device 20 which monitor circuit parameters such as current and voltage; and 3) information stored in a memory accessible to the microprocessor 32 .
[0051] Another purpose of the software algorithm is to allow many different types of objects, each with a different regulation temperature and heating requirement, to be temperature regulated using the same device 20 . This can be easily accomplished if the RFID tag 50 of each respective object stores identity information that, once read by the RFID reader/writer 36 , is used by this software algorithm to access and modify the proper pre-programmed heating algorithm that has been designed for that specific type of object.
[0052] In summary, the microprocessor 32 of the device 20 has an overriding software algorithm that, based upon a particular RFID tag's identity information, accesses one of many pre-programmed heating algorithms. A pre-programmed heating algorithm, hereafter referred to as a “heating algorithm for a specific class of object”, or HA(COB), is a specific set of data, formulas for calculating necessary variables, and instructions stored in memory that is used by the cooktop to heat and temperature regulate a specific “class of object”, (COB). The basic tasks of the HA(COB) are to:
[0053] Task 1: Estimate the Present Temperature of the Object, EPT.
[0054] Task 2: Using the calculated value of EPT, begin heating the object using “corrected” power levels for specific elapsed times (beginning at the proper “corrected” power level and for the proper elapsed time at the power level) so as to bring the object from its EPT to the desired regulation temperature and maintain it there.
[0055] Task 3: Update the RFID tag 50 attached to the object with the object's last known power step of the heating algorithm, LKPS, and the time of application of this step of the heating algorithm, t(LKPS), once every time interval Δt between transmit until reaching the desired regulation temperature.
[0056] To accomplish these basic tasks, an HA(COB) maybe developed and implemented in the manner described below. For purposes of example, the software required to properly heat the “sizzle platter” depicted in FIG. 1 using the device 20 will be described, wherein the food-contacting surface of the cast iron pan 46 should have a desired regulation temperature of 250° F. plus or minus 20° F.
Heating Algorithm
[0057] In order to accomplish Tasks 1 and 2, “permanent memory” data that is required to temperature regulate the object under “ideal” operating conditions should first be gathered. This data includes both heating and cooling information gathered under “ideal” operating conditions. Permanent memory data is not updated periodically, but is permanently stored in a memory location corresponding to, or easily accessible to, HA(sizzle plate). Although it is preferred that the permanent memory data be stored in a memory device that is part of the induction heating device (such as the additional memory device 44 of FIG. 1), it is also possible for this information to be stored within the RFID tag's EEPROM memory. In this case, the EEPROM memory locations corresponding to this permanent memory data need not be re-written to once the RFID tag is put into service. Regardless of the physical location of the permanent memory data, it must be available to the microprocessor 32 prior to and during the heating operation.
[0058] Then knowing that ideal operating conditions will almost never occur, “altering” instructions and formulas to be used within the heating algorithm are developed to allow the system to operate under “actual” operating conditions. Finally, for these “altering” instructions and formulas to be used within the heating algorithm, information is periodically gathered by the RFID reader/writer 36 and by the cooktop circuit sensors. This gathered information is stored in “temporary memory” and is updated periodically throughout the heating operation.
[0059] The resultant set of “altering” instructions and formulas, stored “permanent memory” information, and “temporary memory” information comprise the “building blocks” of the heating algorithm that is programmed for use by the integrated microprocessor 32 . An actual software algorithm and the HA(sizzle plate) algorithm will be described line-by-line once these “building blocks” have been described below.
[0060] “Building Block” 1: “Permanent Memory” Data under “Ideal” Conditions
[0061] Assumed “ideal” operating conditions for a sizzle plate are that the sizzle plate: 1) is never heated from an initial plate temperature lower than room temperature, 2) is always heated with no food on its upper surface, 3) is always placed on the device 20 so as to magnetically couple at peak efficiency, and 4) is always removed from the cooktop only when it has reached the desired regulation temperature. With these ideal conditions controlled, a representative sizzle plate is heated on a representative magnetic induction cooktop. Thermocouples are attached to the sizzle plate and their measurements are used as feedback by the cooktop's microprocessor so as to bring the object to the desired regulation temperature in the desired period of time. The same feedback is used to maintain the desired regulation temperature for a period of time until equilibrium exists and a distinct pattern of required cooktop warming operations emerges. Once the cooktop is operating to heat and warm the sizzle plate within specifications, measurements are taken of all significant object temperature and cooktop circuit parameters while the sizzle plate is being heated to its regulation temperature and held there.
[0062] The following information is gathered and stored in “permanent memory” which is accessible to the cooktop's microprocessor for use within HA(sizzle plate).
TABLE 1 Information Code Identifier 1) Time period between start of read/write Δt between transit transmissions from/to RFID tag 2) Ideal Power Level #1 (93% Inverter “on” time) IPL 1 Command 111 “on” cycles, 9 “off” cycles, repeat 3) Ideal Power Level #2 (83% Inverter “on” time) IPL 2 Command 100 “on” cycles, 20 “off” cycles, repeat 4) Ideal Power Level #3 (74% Inverter “on” time) IPL 3 Command 89 “on” cycles, 31 “off” cycles, repeat 5) Ideal Power Level #4 (65% Inverter “on” time) IPL 4 Command 78 “on” cycles, 42 “off” cycles, repeat 6) Ideal Power Level #5 (55% Inverter “on” time) IPL 5 Command 66 “on” cycles, 54 “off” cycles, repeat 7) Lowest expected operating temperature (72 F.) T(0) 8) Temperature after Ideal Power Step 1 T(1) 9) Temperature after Ideal Power Step 2 T(2) 10) Temperature after Ideal Power Step 3 T(3) 11) Temperature after Ideal Power Step 4 T(4) 12) Temperature after Ideal Power Step 5 T(5) 13) Temperature after Ideal Power Step 6 T(6) 14) Temperature after Ideal Power Step 7 T(7) 15) Temperature after Ideal Power Step 8 T(8) 16) Temperature after Ideal Power Step 9 T(9) 17) Regulation Temperature (250 F.) T(10) 18) Linear Cooling rate #1 (from T(10) to T(6)) CR 1 19) Linear Cooling rate #2 (from T(6) to T(2)) CR 2 20) Linear Cooling rate #3 (from T(2) to T(0)) CR 3 21) Magnitude of the current that flows through I transistor max ideal the cooktop's switching transistor during inverter “on” times with the load ideally coupled 22) Maximum delay time (120 seconds) MXDT
[0063] The time scale for the heating process, which is what Δt between transmit effectively is, is chosen dependent upon customer demands. It is assumed that the customer has required that the sizzle plate be heated from room temperature to its upper food contacting surface temperature of 250° F.±20° F. within 25 seconds after being placed upon the cooktop. Through calculation and experimentation, it has been determined that a 5.0 kW induction cooktop employing the power control method of the CookTek Model CD-1800 cooktop can accomplish this task. It should be noted that the value of δt between transmit It will determine the accuracy and precision of a given temperature regulation operation for this preferred regulation method wherein no temperature sensor is employed. The smaller the effective heating time scale chosen, the more accurate the regulation temperature will be and the smaller the variations in temperature about said regulation temperature will be. However, the smaller the time scale chosen, the fewer number of complete heating cycles an RFID tag will endure before needing to be replaced. A typical RFID tag is designed to operate for at least 100,000 read/write operations before failure. Since the time required to heat the sizzle plate of FIG. 1 from room temperature to an average upper surface temperature of 250° F. requires at fewest 10 read/write operations, the RFID tag attached to the sizzle plate cannot be guaranteed to last more than 10,000 heating cycles.
[0064] Based upon the assumed customer requirements and a selected balance between accuracy, precision, and system longevity, Δt between transmit for the sizzle plate application is selected as 2.0 seconds. This value is stored in permanent memory which is accessible to the cooktop's microprocessor for use within the HA(sizzle plate).
[0065] It would appear that the simplest way to induction heat the sizzle plate such that the upper food-contacting surface reaches a uniform 250° F. temperature would be to apply all available coupled power from the cooktop for the entire heating time period. However, for many objects, including this sizzle plate, the skin effect, combined with the finite thermal conductivity of the object itself, causes a delay in temperature equilibration between the temperature of the food-contacting surface and the surface closest to the induction work coil. Thus, in this case, it is found that the best way to achieve a uniform 250° F. food-contacting surface at the end of the heating cycle without grossly overshooting it or without causing the surface nearest the work coil to reach temperatures much higher than 250° F. is to “step down” the level of the power levels applied to the sizzle plate as the temperature of the food-contacting surface increases.
[0066] [0066]FIG. 5 graphically depicts the desired sequence of “ideal” power levels to be applied to the sizzle plate at room temperature to achieve a uniform 250° F. food-contacting surface within 25 seconds. Each ideal power level application for a unit of time equal to one time interval Δt between transmit will be hereafter referred to as an “Ideal Power Step.” There are ten Ideal Power Steps in this example required to bring the sizzle plate from room temperature to a uniform surface temperature of 250° F. It should be noted that the average food-contacting surface temperature sizzle plate actually reaches only 250° F. at the end of Ideal Power Step 10 , but it continues to climb thereafter. Table 2 is a written list of the sequence of Ideal Power Steps as shown in FIG. 5. This sequence of Ideal Power Steps is used as the blueprint to command the cooktop's operation during a heating operation of the sizzle plate except that “ideal” power levels will be replaced within each Ideal Power Step by “corrected” power levels.
TABLE 2 Step Number Command to Cooktop Ideal Power Step 1 Apply IPL1 for 2 sec* Ideal Power Step 2 Apply IPL1 for 2 sec* Ideal Power Step 3 Apply IPL1 for 2 sec* Ideal Power Step 4 Apply IPL1 for 2 sec* Ideal Power Step 5 Apply IPL 2 for 2 sec* Ideal Power Step 6 Apply IPL 2 for 2 sec* Ideal Power Step 7 Apply IPL 3 for 2 sec* Ideal Power Step 8 Apply IPL 3 for 2 sec* Ideal Power Step 9 Apply IPL 4 for 2 sec* Ideal Power Step 10 Apply IPL 4 for 2 sec* Time Period MXDT Command CookTop into Standby Mode where 1 cycle test pulses check for load within impedance limits** Ideal Power Step 11 Apply IPL 5 for 2 sec** Time Period (0.50)(MXDT) Command CookTop into Standby Mode where 1 cycle test pulses check for load within impedance limits** Ideal Power Step 11 Apply IPL 5 for 2 sec** Time Period (0.50)(MXDT) Command CookTop into Standby Mode where 1 cycle test pulses check for load within impedance limits** Repeat Previous Two Steps Indefinitely**
[0067] The magnitude of each ideal power level within the sequence of Ideal Power Steps is “ideal” because it is based upon a desired (“ideal”) power coupling efficiency between the object and the work coil of the induction cooktop, i.e., it is based upon the cast iron portion of the sizzle plate being centered over the work coil, the cast iron portion of the sizzle plate being the standard height above the work coil, and the line voltage of the commercial power supply being at a value chosen as standard. Although the power level of a cooktop such as the CookTek Model CD-1800 cooktop, or its 5 kW counterpart, may be 59 “on” cycles of 60 line cycles, the actual power coupled to the sizzle plate may be less for a sizzle plate not centered over the work coil than for sizzle plate with ideal coupling efficiency on the same cooktop employing only 40 “on” cycles of 60 available cycles. Thus, it is important that a distinction be made between a “power level” and the actual power coupled to the load (sizzle plate). Therefore, for this example wherein the cooktop's power output is controlled by the percentage of inverter “on” time, a “power level” will hereafter be expressed in terms of percentage of inverter “on” time. The actual power coupled to the sizzle plate for a given “power level” can be deduced (and will be expressed hereafter) by measuring one or more of various cooktop circuit parameters.
[0068] The highest ideal power level used during final modeling (Ideal Power Level 1, hereafter referred to as IPL1) to determine this sequence of Ideal Power Steps is the highest that will be available to the heating algorithm under ideal conditions. Therefore, it is the power level for which the effective percentage of “on” time of the inverter is {(Δt between transmit −Δt transmit)/(Δt between transmit)}. All subsequently applied lower ideal power levels (Ideal Power Level 2 (IPL2), Ideal Power Level 3 (IPL3), Ideal Power Level 4 (IPL4), and Ideal Power Level 5 (IPL5)) are also described in terms of percentage of inverter “on” time. These percentages for the sizzle plate example are described later in this disclosure.
[0069] [0069]FIG. 5 also shows the first of a sequence of Ideal Power Steps to be applied to the sizzle plate once it reaches 250° F. so as to maintain it at that temperature (within 20 F.) indefinitely. Ideal Power Step 11 is a short burst of energy applied to the object over one time interval Δt between transmit that adds enough energy to overcome losses to the environment while the object is awaiting usage. For the sizzle plate, Ideal Power Step 11 is applied at an ideal power level of 55% inverter “on” time and for a duration of one time period Δt between transmit . It should be noted that after Ideal Power Step 10 is completed, transmissions between RFID reader/writer and RFID tag to update t(LKPS) but not the actual value of LKPS are still made. Thus the value LKPS remains at 10 during Ideal Power Step 11 applications but the value of t(10) is updated to reflect the completion time of the latest Ideal Power Step 11.
[0070] Ideal Power Step 11 is repeated indefinitely until the object is removed from the cooktop. However, Ideal Power Step 11 is not necessarily repeated at equal intervals of time between applications. The interval of time between consecutive applications of Ideal Power Step 11 is hereafter referred to as the delay time, or DT. Although the delay time may be variable, a maximum delay time, hereafter referred to as MXDT, is determined and is stored in permanent memory. For the sizzle plate of this example, MXDT is determined to be 2 minutes. For the sizzle plate, Ideal Power Step 11 is first applied a delay time of MXDT after the conclusion of Ideal Power Step 10. Thereafter, an identical Power Step 11 is applied to the sizzle plate at consecutive delay times equal to (50% MXDT), or 1 minute.
[0071] To summarize the results of applying the above sequence of Ideal Power Steps applied to the sizzle plate under ideal conditions to bring it from room temperature to an average surface temperature of 250° F.±20° F. and maintain it there, the following occurs:
[0072] Ideal Power Step 1 is applied at IPL1. During Ideal Power Step 1, the sizzle plate's average food contacting surface temp rises from room temperature (designated as T(0)) to temperature T1=100° F. Ideal Power Step 2 is then immediately applied at IPL1. During Power Step 2 the sizzle plates surface temp rises from temperature T(1)=100° F. to temperature T(2)=130° F. Ideal Power Step 3 is then immediately applied at IPL1. During Ideal Power Step 3 the sizzle plates surface temp rises from temperature T(2)=130° F. to temperature T(3)=160° F. Ideal Power Step 4 is then immediately applied at IPL1. During Ideal Power Step 4 the sizzle plates surface temp rises from temperature T(3 )=160° F. to temperature T(4)=190° F. Ideal Power Step 5 is then immediately applied at IPL2. During Ideal Power Step 5 the sizzle plates surface temp rises from temperature T(4)=190° F. to temperature T(5)=210° F. Ideal Power Step 6 is then immediately applied at IPL2. During Ideal Power Step 6 the sizzle plates surface temp rises from temperature T(5)=210° F. to temperature T(6)=224° F. Ideal Power Step 7 is then immediately applied at IPL3. During Ideal Power Step 7 the sizzle plates surface temp rises from temperature T(6)=224° F. to temperature T(7)=232° F. Ideal Power Step 8 is then immediately applied at IPL3. During Ideal Power Step 8 the sizzle plates surface temp rises from temperature T(7)=232° F. to temperature T(8)=240° F. Ideal Power Step 9 is then immediately applied at IPL4. During Ideal Power Step 9 the sizzle plates surface temp rises from temperature T(8)=240° F. to temperature T(9)=246° F. Ideal Power Step 10 is then immediately applied at IPL4. During Ideal Power Step 10 the sizzle plates surface temp rises from temperature T(9)=246° F. to temperature T(10)=250° F.
[0073] At this point the inverter is maintained in the off condition except for short duty cycle test pulses of the magnetic field to search for a proper load for a time period of MXDT. These short duty cycle (usually one cycle per 60 available) test pulses used to search for a suitable load atop the cooktop are implemented during the “standby” mode of operation and are standard operating procedure for most cooktops. Approximately 1 minute into MXDT the average surface temperature of the sizzle plate creeps up to 255° F. as the temperatures within the thickness of the cast iron walls of the sizzle plate equilibrate. After MXDT, the first in a sequence of Ideal Power Steps 11 is then immediately applied at IPL5. During Ideal Power Step 11 the sizzle plate's surface temperature rises from approximately 245° F. to 255° F. Immediately after the first application of Ideal Power Step 11, the inverter is again maintained in the “off” condition until a DT of (0.5)(MXDT), at which time Ideal Power Step 11 is again applied. Thereafter, as long as the sizzle plate remains upon the cooktop, Ideal Power Step 11 will be applied after a DT of (0.5)(MXDT). Should the sizzle plate be removed, the cooktop reverts to the standby mode and periodic low duty cycle test pulse production where it will await an object with a suitable load impedance and a suitable RFID tag prior to leaving the standby mode and beginning another heating operation.
[0074] As illustrated in FIG. 5, the read/write transmissions between the RFID reader/writer and the RFID tag attached to the object occur during the time interval Δt transmit which occurs at the end of, but within, each time interval Δt between transmit . Furthermore, a time period equal to Δt between transmit comprises the full time period of each Ideal Power Step. Any decrease in the number of “on” cycles of the inverter due to implementation of IPL2, IPL3, IPL4, or IPL5 will not reduce the existing inverter “off” period Δt transmit , but can only add more “off” period.
[0075] The sequence of Ideal Power Steps described above is used as the blueprint to command the cooktop's operation during a heating operation of the sizzle plate, except that “ideal” power levels will be replaced within each Ideal Power Step by “corrected” power levels. However, to calculate the proper “corrected” power levels, the “ideal” power levels are stored in permanent memory for use in the calculations.
[0076] For the present sizzle plate example, there are 5 ideal power levels used under ideal operating conditions: IPL1 being the highest through IPL5 being the lowest. IPL1 is the power level for which the effective percentage of “on” time of the inverter is {(Δt between transmit −Δt transmit )/(Δt between transmit )}, while the actual power magnetically coupled to the sizzle plate depends upon the factors discussed above. In this sizzle plate example, Δt between transmit equals 2.0 seconds, while Δt transmit equals 0.150 seconds. Thus, the effective percentage of inverter “on” time for IPL1 is 93%. To implement IPL1, the cooktop microprocessor (or the output port of the RFID coupler) will command the inverter to remain “on” (current is allowed to flow through the switching transistor(s) to the work coil) for 111 cycles out of 120, then maintains an “off” condition for the remaining 9 cycles. It is during those 9 “off” cycles that the transmit and receive operation of the RFID system occurs.
[0077] IPL 2 is a power level with an effective percentage of inverter “on” time of 83%. Thus, to implement IPL2, the cooktop microprocessor (or the output port of the RFID coupler) will command the inverter to remain “on” (current is allowed to flow through the switching transistor(s) to the work coil) for 100 cycles out of 120, then maintains an “off” condition for the remaining 20 cycles. It is during the last 9 “off” cycles of those 20 “off” cycles that the transmit and receive operation of the RFID system occurs.
[0078] IPL 3 is a power level with an effective percentage of inverter “on” time of 74%. Thus, to implement IPL3, the cooktop microprocessor (or the output port of the RFID coupler) will command the inverter to remain “on” (current is allowed to flow through the switching transistor(s) to the work coil) for 89 cycles out of 120, then maintains an “off” condition for the remaining 31 cycles. It is during the last 9 “off” cycles of those 3 “off” cycles that the transmit and receive operation of the RFID system occurs.
[0079] IPL 4 is a power level with an effective percentage of inverter “on” time of 65%. Thus, to implement IPL2, the cooktop microprocessor (or the output port of the RFID coupler) will command the inverter to remain “on” (current is allowed to flow through the switching transistor(s) to the work coil) for 78 cycles out of 120, then maintains an “off” condition for the remaining 42 cycles. It is during the last 9 “off” cycles of those 42 “off” cycles that the transmit and receive operation of the RFID system occurs.
[0080] IPL 5 is a power level with an effective percentage of inverter “on” time of 55%. Thus, to implement IPL5, the cooktop microprocessor (or the output port of the RFID coupler) will command the inverter to remain “on” (current is allowed to flow through the switching transistor(s) to the work coil) for 66 cycles out of 120, then maintains an “off” condition for the remaining 54 cycles. It is during the last 9 “off” cycles of those 54 “off” cycles that the transmit and receive operation of the RFID system occurs.
[0081] In order to implement “altering” formulas and instructions that will allow the HA(sizzle plate) to compensate for non-ideal power coupling, a cooktop circuit parameter representative of the actual power magnetically coupled to the sizzle plate under ideal coupling conditions is stored in permanent memory. The preferred storage location for this memory item is the RFID tag, but the cooktop's microprocessor memory or the additional memory device may be used.
[0082] The circuit parameter representative of the power coupled to the sizzle plate under IPL1 and ideal conditions may be chosen from many possibilities: the magnitude of the current that flows through the cooktop's switching transistor during inverter on times with the load coupled (hereafter referred to as I transistor ideal ), the magnitude of the resonant current during inverter on times with the load coupled (hereafter referred to as I resonant ), the magnitude of the rectified line current that flows from the commercial power supply to the switching transistors with the load coupled (hereafter referred to as I line ), or others. The cooktop circuit parameter representative of IPL1is referred to as I transister max ideal , although it should be understood that any other cooktop circuit parameter that is indicative of the coupled power at IPL1 will suffice for this invention. Thus, the value of I transistor max ideal may be measured via a transformer through whose primary runs the current passing through one of the switching transistors during an average “on” cycle of the inverter and through whose secondary runs the induced current. This induced current is then rectified and fed to the cooktop's microprocessor control unit. The magnitude of this induced, rectified secondary current that corresponds the power coupled to the sizzle plate under IPL1 and ideal conditions will be stored in permanent memory location shown in Table 1 to be labeled as the value I transistor max ideal .
[0083] Referring to FIG. 5, the average temperature of the food contacting surface of the sizzle plate versus time is superimposed on the graph depicting the sequence of Ideal Power Steps. At the end of each Ideal Power Step, the average temperature of the food contacting surface of the sizzle plate is measured and is stored in permanent memory. The value T(0) corresponds to the lowest normal operating temperature, which in the case of the sizzle plate is room temperature, 72° F. T(1), the temperature after Ideal Power Step 1, is 100° F. T(2), the temperature after Ideal Power Step 2, is 130° F. T(3), the temperature after Ideal Power Step 3, is 160° F. T(4), the temperature after Ideal Power Step 4, is 190° F. T(5), the temperature after Ideal Power Step 5, is 210° F. T(6), the temperature after Ideal Power Step 6, is 224° F. T(7), the temperature after Ideal Power Step 7, is 232° F. T(8), the temperature after Ideal Power Step 8, is 240° F. T(9), the temperature after Ideal Power Step 9, is 246° F. T(10), the temperature after Ideal Power Step 10, is the desired regulation temperature of 250° F.
[0084] The maximum delay time between identical power applications, referred to as MXDT, is the time between the conclusion of Ideal Power Step 10 and the beginning of the first application of Ideal Power Step 11. For the sizzle plate example, MXDT equals 120 seconds.
[0085] In order to estimate the present temperature of the sizzle plate, the cooling behavior of the sizzle plate under ideal conditions is determined. Information from the resultant temperature/time curve is then later used in an “altering” step. FIG. 6 is a graph of the temperature/time profile of an average sizzle plate that has been removed from the cooktop after a successful charge to 250° F. and has been allowed to cool down under ideal conditions. This data plotted in this graph is gathered by simply using a sizzle plate with thermocouples attached to several locations on its food contact surface that has been heated to its desired regulation temperature and is subjected to “ideal” conditions during its cool down. Ideal conditions for the sizzle plate are those that most commonly occur during normal operations. In this instance: no food load for the first few minutes, a decreasing food load for the next 20 minutes, and then no food load for the next 40 minutes until the sizzle plate's average food contact surface temperature is again at room temperature. The sizzle plate has such a large surface area, high thermal conductivity, and high emissivity that an external food load may vary greatly without significantly affecting its temperature/time profile on cool down.
[0086] Once the data has been gathered and plotted, the times required for the sizzle plate to cool from temperature T(10) to temperatures T(9), T(8), T(0) are recorded. These times are shown in FIG. 6. Next, the cooling curve is modeled by three lines that intersect the actual cooling curve at temperatures among the group T(0) through T(9). In this example, the first linear segment, whose slope is designated as “cooling rate 1”, CR 1 , intersects the cooling curve at T(10) and at T(6). The second linear segment, whose slope is designated CR 2 , intersects the cooling curve at T(6) and T(2). Finally, the third linear segment, whose slope is designated CR 3 , intersects the cooling curve at T(2) and at T(0).
[0087] The more realistic the modeled cooling curve, the more accurate the deduced estimated present temperature, EPT, of the sizzle plate will be. Furthermore, the more deviation from an ideal thermal loading during cool down, the less accurate the deduced EPT. As will be seen, the proposed “altering” step designed to determine the sizzle plate's EPT is very conservative.
“Building Block” 2: “Altering Steps” Allowing HA(sizzle plate) to Operate under Non-Ideal Conditions
[0088] Inasmuch as a given sizzle plate will almost never operate under ideal conditions as described above, formulas and instructions, referred to as “altering steps”, to be used within ideal algorithm are designed so that each sizzle plate heating operation will achieve its goal of arriving at 250° F. plus or minus 20° F. within 25 seconds of cooktop heating regardless of the initial conditions or working conditions of the sizzle plate. A myriad of non-ideal conditions may be encountered in day-to-day operations. However, in any system the non-ideal conditions that make the most impact upon the outcome of the heating operation can normally be identified. In the sizzle plate example, “altering steps” are provided that attempt to correct for the following two non-ideal conditions:
[0089] 1) non-ideal power coupling between cooktop and sizzle plate, and 2) starting the heating operation with the sizzle plate at a temperature different than room temperature.
[0090] In order to compensate for non-ideal power coupling, a cooktop circuit parameter representative of the actual power magnetically coupled to the sizzle plate under IPL1 and ideal coupling conditions is stored in permanent memory. This circuit parameter is I transistor max ideal , having previously been determined through testing under ideal conditions.
[0091] Another value representative of the magnitude of the current flowing through the cooktop's switching transistor is measured at the beginning of each heating operation of the sizzle plate and is stored in “temporary memory” storage. This value will hereafter be referred to as I transistor max actual . I transistor max actual is measured in the same manner as I transistor max ideal except that I transistor max actual is measured during a test pulse of magnetic field at the end of each standby mode of the cooktop and consequently, at the beginning of each heating operation.
[0092] The “beginning of each heating operation” means that the cooktop, having been previously in the standby mode of operation (where it was sending test pulses of magnetic field looking for a proper impedance load), has an object placed upon it which not only possesses a load impedance that causes a value of I transistor max actual within prescribed limits to be sensed, but also possesses an RFID tag that sends a proper identification signal to the RFID reader that is integrated into the cooktop's control circuitry. Both a proper load impedance and a proper RFID identity signal from the object are sensed by the cooktop prior to commencing induction heating of the object. A given sizzle plate may be removed and replaced from/upon the cooktop many times prior to reaching it's 250° F. temperature and yet, each time it is replaced, a new value of I transistor max actual will be stored in memory.
[0093] With this value of I transistor max actual available to the cooktop's microprocessor, a set of corrected power levels that use the ideal power levels as their baseline are calculated in real time at the very beginning of the heating operation. In this sizzle plate example, five corrected power levels are calculated in real time: corrected power level 1, CPL1,: corrected power level 2, CPL2, corrected power level 3, CPL3, corrected power level 4, CPL4, and corrected power level 5, CPL5. The following Table 3 illustrates the formulas used to calculate the percentage of inverter “on” time for each of these corrected power levels.
TABLE 3 Corrected Power Level Formula as Expressed in Percentage of Power Level Inverter “On” Time CPL1 CPL1 = {(Δt between transmit − Δt transmit)/(Δt between transit )} = 93% CPL2 CPL2 = (IPL2) * [(I transistor max ideal ) 2 /(I transistor max actual ) 2 ] CPL3 CPL3 = (IPL3) * [(I transistor max ideal ) 2 /(I transistor max actual ) 2 ] CPL4 CPL4 = (IPL4) * [(I transistor max ideal ) 2 /(I transistor max actual ) 2 ] CPL5 CPL5 = (IPL5) * [(I transistor max ideal 2 /(I transistor max actual ) 2 ]
[0094] CPL1is equal to IPL1 because all available coupled power is desired to begin the heating operation. Any formula to correct IPL1 could never provide for more coupled power than is available by using a 93% “on” time of the inverter. While CPL1 equals IPL1, each of the remaining CPL's may be either corrected to a higher percent “on” time or a lower percent “on” time than their respective IPL's.
[0095] The number of “on” cycles per Δt between transmit is then calculated in the manner described previously. Once calculated, the power level values and instructions to implement each power level of the cooktop are stored in temporary memory.
[0096] Once the values of CPL1 through CPL5 have been calculated at the beginning of each heating operation and these values are stored in temporary memory, they are used to implement the actual sequence of power steps, hereafter referred to as “Actual Power Steps”. The sequence of Actual Power Steps is shown in Table 4 below.
TABLE 4 Step Number Command to CookTop Actual Power Step 1 Apply CPL1 for 2 sec* Actual Power Step 2 Apply CPL1 for 2 sec* Actual Power Step 3 Apply CPL1 for 2 sec* Actual Power Step 4 Apply CPL1 for 2 sec* Actual Power Step 5 Apply CPL 2 for 2 sec* Actual Power Step 6 Apply CPL 2 for 2 sec* Actual Power Step 7 Apply CPL 3 for 2 sec* Actual Power Step 8 Apply CPL 3 for 2 sec* Actual Power Step 9 Apply CPL 4 for 2 sec* Actual Power Step 10 Apply CPL 4 for 2 sec* Time Period MXDT Command CookTop into Standby Mode where 1 cycle test pulses check for load within impedance limits** Actual Power Step 11 Apply CPL 5 for 2 sec** Time Period (0.50)(MXDT) Command CookTop into Standby Mode where 1 cycle test pulses check for load within impedance limits** Actual Power Step 11 Apply CPL 5 for 2 sec** Time Period (0.50)(MXDT) Command CookTop into Standby Mode where 1 cycle test pulses check for load within impedance limits** Repeat Previous Two Steps Indefinitely**
[0097] Therefore, all aspects of the sequence of Ideal Power Steps (duration of power steps, number of power steps, delay times, etc.) except the use of IPL's are followed. The goal of employing a sequence of Ideal Power Steps with CPL's inserted instead of IPL's is to ensure that virtually the same temperature/time curve that was shown superimposed in FIG. 5 will be achieved when the sequence of Actual Power Steps is followed under all other ideal operating conditions except ideal power coupling. Although the actual temperatures reached at the end of each Actual Power Step applied under otherwise ideal operating conditions may be unequal to T(1) through T(10) due to the inability to correct IPL1 for a lower power coupling efficiency, the respective temperatures reached would should never be higher and will be very close.
[0098] The procedures outlined above also correct for non-ideal line voltage of the commercial power supply, since I transistor max actual will also differ from I transistor max actual due to this factor.
[0099] In order to enable the HA(sizzle plate) to bring the sizzle plate to the desired regulation temperature despite its actual temperature upon beginning the heating operation, first the present temperature is estimated and then the cooktop must begin the sequence of Actual Power Steps at the proper Actual Power Step. It is also assumed that the sizzle plate will never be cooled below room temperature. Should the sizzle plate be below room temperature when it is placed upon the cooktop, HA(sizzle plate) will bring it to a temperature lower than the desired 250° F., which is a safe outcome. It is also assumed that the sizzle plate will never be subjected to a heat source (other than food placed upon its upper surface) other than a cooktop of this invention.
[0100] The temperatures T(1) through T(10) that are assumed to be achieved after the completion of Actual Power Steps 1 through 10 are the same temperatures that are shown on FIG. 6 at various positions along the Ideal Cooling Curve. Corresponding to each of these temperatures T(0) through T(10) on the cooling curve is a time in seconds that was required for the fully heated sizzle plate to cool to the respective temperature. The first step in this portion of the heating algorithm HA(sizzle plate) designed to determine EPT is to assign a value to the temporary memory location designated as “n” that corresponds to the number of seconds required for the sizzle plate to cool from T(10) (the same temperature assumed to occur after Actual Power Step 11) to a given temperature among T(LKPS).
[0101] Table 5 below describes the means to assign values to “n” . The value of “n” is assigned to variable memory immediately after the sizzle plate has been placed upon the cooktop and the first RFID tag transmission has transferred the values LKPS and t(LKPS) to the RFID reader/writer and thus to their respective temporary memory sites. Thus, based upon the value of LKPS retrieved from the RFID tag (remembering that a value higher than 10 is not allows to be stored as LKPS in the RFID tag's memory), the number of seconds required to cool from T(10) to the temperature T(LKPS), under ideal conditions, will be stored as “n”.
TABLE 5 If RFID Tag Value of Then, assign value “n” = LKPS at Beginning of Heating Operation Is If LKPS = 10 then n = 0 If LKPS = 9 then n = 120 If LKPS = 8 then n = 360 If LKPS = 7 then n = 720 If LKPS = 6 then n = 1200 If LKPS = 5 then n = 1440 If LKPS = 4 then n = 1800 If LKPS = 3 then n = 2100 If LKPS = 2 then n = 2400 If LKPS = 1 then n = 3000 If LKPS = 0 then n = 3600
[0102] The second step in this portion of the heating algorithm HA(sizzle plate) designed to determine EPT is to determine the elapsed cooling time, ELCLT, and store its value in seconds into its temporary memory site. ELCLT is simply equal to the present time, Pt, as determined by the real-time clock or as reflected in the cooktop microprocessor's time clock, minus the time of completion of the Last Known Power Step applied, t(LKPS).
[0103] The final step in this portion of the heating algorithm HA(sizzle plate) designed to determine EPT is to follow the “if, then” statements as described in Table 6.
TABLE 6 If 6 ≦ LKPS ≦ 10, then: If 0 ≦ ELCLT ≦ (1200 − n), then EPT = T(LKS) − [(CR 1 ) * (ELCLT)], and If (1200 − n) ≦ ELCLT ≦ (2400 − n), then EPT=T(LKS) − {[(CR 1 )*(1200 − n)] + [CR 2 )*([ELCLT−(1200 − n)])}, and If (2400 − n) <ELCLT ≦ (3600 − n), then EPT=T(LKS) − {[(CR 1 )*(1200 − n)] + [(CR 2 )*(1200)] + [(CR 3 )*([ELCLT − (2400 − n)]}, and If (3600 − n) < ELCLT, then EPT = T(0). If 2 ≦ LKPS < 6, then: If 0 ≦ ELCLT ≦ (2400 − n), then EPT = T(LKS) − [(CR 2 ) * (ELCLT)], and If (2400 − n) < ELCLT ≦ (3600 − n), then EPT=T(LKS) − {[(CR 2 )*(2400 − n)] + [(CR 3 )*([ELCLT−(2400 − n)])}, and If (3600 − n) < ELCLT, then EPT = T(0). If 0 ≦ LKPS < 2, then: If 0 ≦ ELCLT ≦ (3600 - n), then EPT = T(LKS) − [(CR 3 ) * (ELCLT)], and and If (3600 − n) < ELCLT, then EPT = T(0).
[0104] The formula to determine EPT therefore requires the values ELCLT, n, T(LKPS), and the linear cooling rates CR 1 , CR 2 , and CR 3 . For example, for a LKPS value of 8 that is retrieved from the RFID tag attached to the sizzle plate, the corresponding value of EPT would be equal to { T(8)−[(CR 1 )(Pt−t(8))]}.
[0105] Once EPT has been determined using the portion of the heating algorithm shown in Table 6, instructions are programmed into the cooktop's microprocessor that use this value of EPT to begin heating operations at the proper Actual Power Step of the sequence shown in Table 4. Table 7 below shows the instructions programmed into the cooktop's microprocessor so as to allow the beginning of the heating operation at an Actual Power Step commensurate with EPT. Should a value of EPT be calculated at the beginning of a given heating operation less than a given T(LKPS), the cooktop will begin the heating operation at an Actual Power Step corresponding to the assumption that the sizzle plate may actually be very close to said T(LKPS). In this way, any the sizzle plate's actual regulation temperature should always less than or equal to the desired regulation temperature, which is the safest approach. For instance, should EPT be calculated to be a temperature greater than T(3) but less than T(4), the heating algorithm, HA(sizzle plate), will begin the heating operation at Actual Power Step 5.
TABLE 7 If EPT = T(0), Then GO to Actual Power Step 1 and Complete the Remaining Sequence of Actual Power Steps; If T(0) < EPT ≦ T(1), Then GO to Actual Power Step 2 and Complete the Remaining Sequence of Actual Power Steps; If T(1) < EPT ≦ T(2), Then GO to Actual Power Step 3 and Complete the Remaining Sequence of Actual Power Steps; If T(2) < EPT ≦ T(3), Then GO to Actual Power Step 4 and Complete the Remaining Sequence of Actual Power Steps; If T(3) < EPT ≦ T(4), Then GO to Actual Power Step 5 and Complete the Remaining Sequence of Actual Power Steps; If T(4) < EPT ≦ T(5), Then GO to Actual Power Step 6 and Complete the Remaining Sequence of Actual Power Steps; If T(5) < EPT ≦ T(6), Then GO to Actual Power Step 7 and Complete the Remaining Sequence of Actual Power Steps; If T(6) < EPT ≦ T(7), Then GO to Actual Power Step 8 and Complete the Remaining Sequence of Actual Power Steps; If T(7) < EPT ≦ T(8), Then GO to Actual Power Step 9 and Complete the Remaining Sequence of Actual Power Steps; If T(8) < EPT ≦ T(9), Then GO to Actual Power Step 10 and Complete the Remaining Sequence of Actual Power Steps; If T(9) < EPT ≦ T(10), Then GO to Actual Power Step 11 and Complete the Remaining Sequence of Actual Power Steps;
“Building Block 3: “Temporary Memory” Data Sites and the Means To Input Current Information into Each Site
[0106] As noted above, several pieces of information are either retrieved from the RFID tag attached to the sizzle plate or determined from measurements made by the cooktop's circuit sensors to allow the HA(sizzle plate) to operate correctly. Most of these required pieces of information, the means to determine them, and the names given them have been described. Table 8 lists each of these required data items that must be stored in a temporary memory site accessible to the cooktop's microprocessor.
TABLE 8 Information Code Identifier 1) Last Known Power Step of Heating Algorithm LKPS Applied 2) Time at end of Last Known Power Step t (LKPS) of the Heating Algorithm Applied 3) Temperature at end of Last Known Power Step T (LKPS) 4) Elapsed cooling time = (Pt − t (LKPS) ) ELCLT 5) Estimated present temperature EPT 6) Delay time between repeats of Actual Power Step 11 DT 7) Corrected power level 1 (% inverter “on” time) CPL 1 8) Corrected power level 2 (% inverter “on” time) CPL 2 9) Corrected power level 3 (% inverter “on” time) CPL 3 10) Corrected power level 4 (% inverter “on” time) CPL 4 11) Corrected power level 5 (% inverter “on” time) CPL 5 12) Magnitude of the current that flows through I transistor max actual the cooktop's switching transistor during a test pulse with inverter“on” during the cooktop's stand by mode of operation 13) Present time (as determined from real time clock Pt or from cooktop's microprocessor clock) 14) Number of seconds required to cool from T(10) to a n Temperature corresponding to the conclusion of a given Actual Power Step
Implementing the Overall Software Algorithm and HA(Sizzle Plate)
[0107] [0107]FIG. 7 is a flow chart showing the preferred overall software algorithm, which operates to direct the cooktop to access HA(sizzle plate), assuming that at least the three mandatory items of information set forth in Table 9 below are stored in the RFID tag's memory.
TABLE 9 Bytes Required on Information Code Initials Ario 40-SL Tag MANDATORY INFORMATION 1) Class of Object COB 1 2) Last Known Power Step of LKPS 1 Heating Algorithm 3) Time of Last Known Power t(LKPS) 4 Step of Algorithm Information Code Initials OPTIONAL INFORMATION 13) Any of the “Permanent Memory” Same as in FIG. 10 variables 14) 1-22 as described in FIG. 10 15) 16) Total Number of Full Heating Cycles this #CYCLES 17) RFID tag has completed 18) 13) 19) 3) Actual Temperature that a first TS1 Temperature Switch 20) Connected to RFID tag actuates during temp rise 21) 22) 4) Actual Temperature that a second TS2 Temperature Switch 23) Connected to RFID tag actuates during temp rise 24) 25) 5) Elapsed time between TS1 and TS2 for an TS1/TS2_time 26) ideal cooling load 27) 28) 13) 29) NOTE: These items are preferred for the alternative embodiments wherein one or more temperature switches are connected to the RFID tag. 30)
[0108] The first of the three needed items of information is “Class of Object, or COB. This item of information is permanently stored in the RFID tag's microprocessor memory and will never be rewritten over with information from the cooktop's RFID reader/writer. For a RFID tag affixed to a sizzle plate, the COB digital code will be unique to the class of sizzle plates. For a different class of object, say for instance a dinner plate, a different digital code will exist on its RFID tag. The COB may or may not also include a portion of code that further identifies its attached sizzle plate uniquely from all other sizzle plates.
[0109] The other two items of needed information, Last Known Power Step of Heating Algorithm, LKPS, and Time of Last Known Power Step of Algorithm, t(LKPS), have corresponding memory sites in temporary memory of HA(sizzle plate) (and, for other classes of objects, in corresponding temporary memory sites of those HA(COB)'s). LKPS and t(LKPS) will be programmed as 0's on a newly manufactured RFID tag attached to a brand new sizzle plate. Thereafter, these values will be re-written to periodically by the RFID reader/writer.
[0110] Table 9 also sets forth optional information that may be stored on the RFID tag. For instance, any of the “Permanent Memory” variables maybe stored on the RFID tag. Furthermore, the total number of full heating cycles that the RFID tag has completed may be stored. This information could be employed to allow the user to be notified when it is time to replace the tag.
[0111] Referring to FIG. 7, the overall control algorithm operates as follows, assuming that the power to the cooktop is “on”, Step 54 . First, the cooktop reverts to standby mode, Step 56 , and a test pulse is sent every second in order to determine whether an object is placed on the cooktop; for this purpose, I transistor is measured at each pulse using the sensor 31 for this purpose. Next, in Step 58 , it is determined whether I transistor is greater than or equal to I 1 and less than or equal to I 2 (these current values are pre-set for the particular cooktop, based upon it's efficiency at low and high transistor currents). Also, all temporary memory items in microprocessor memory as set forth in Table 8 are given zero values, except for Pt (present time) which always contains the current time registered on the real time clock or the microprocessor's time base. If the answer to query 58 is “no”, meaning that no suitable induction heatable object is on the cooktop, the program reverts back to Step 56 . If the answer in Step 58 is “yes”, the program proceeds to Step 60 where the RFID reader/writer sends a signal to search for a reply from a compatible RFID tag. In the following Step 62 , a determination is made whether the RFID reader/writer receives a valid COB code from an RFID tag. If the answer to this question is “no” (which may occur, e.g., when a cast iron plate without an RFID tag is placed on the cooktop), the program reverts back to Step 56 and the cooktop remains in its standby mode. Thus, no unwanted object will ever be heated to any significant extent.
[0112] If a valid COB code is received, the answer in Step 62 is “yes”, and the program then proceeds to Step 64 whereupon the reader/writer sends the appropriate COB code to the cooktop microprocessor; this directs the software algorithm to the proper HA(COB), in this case HA(sizzle plate). During the course of execution of HA(sizzle plate), Step 66 , the cooktop continues to periodically measure the load impedance and ensure that it is within limits, as reflected in Step 68 . As long as the value of I transistor is within the boundary limits, the algorithm steps of HA(sizzle plate) will continue in order. However, should the value of I transistor fall outside these limits (such as would occur when the sizzle plate is removed from the cooktop), the algorithm will exit HA(sizzle plate) and the overall algorithm of FIG. 7 will return to Step 56 where the cooktop is in standby mode.
[0113] Attention is next directed to FIG. 8 which illustrates the important algorithm instructions for HA(COB), and in particular HA(sizzle plate). In this discussion, it is assumed that Step 64 of FIG. 7 has initiated the FIG. 8 algorithm, and further that a new sizzle plate at room temperature is placed upon the heating device, and is maintained there through 2 Actual Power Steps 11. Therefore, in Step 70 , when the reader/writer interrogates the RFID tag on the sizzle plate, LKPS and t(LKPS) will have zero values, and the temporary memory locations corresponding to LKPS and t(LKPS) within HA(sizzle plate) will receive zero values. Next, in Step 72 , the value I transistor is measured and stored in the HA(sizzle plate) temporary memory location of I transistor max actual (at this time the cooktop is still in its standby mode). Using the formulas set forth in Table 3, the CPL's for the heating operation are calculated, Step 74 . If the user placed the sizzle plate in its proper location on the cooktop, these CPL values should be nearly equal to their corresponding IPL values. At Step 76 , a value of 3600 is assigned to n, since LKPS is equal to zero. In Step 78 , the value of ELCLT is calculated to be much greater than 3600 seconds and is stored in temporary memory. Next, in Step 80 , EPT is calculated as equal to T(0) or 72° F. This value of EPT is also stored in temporary memory. In Step 82 , using this stored EPT value, the cooktop microprocessor will follow the instructions set forth in Table 7 and will start the sequence of Actual Power Steps as described in Table 4, at Actual Power Step 1.
[0114] In Step 84 , the cooktop is instructed to complete all remaining Actual Power Steps (1-10 and the two 11's). At the end of each Actual Power Step, the RFID reader/writer will transmit the value of LKPS just completed (up to the value 10). For example, at the end of Actual Power Step 1, during the time interval Δt transmit , the RFID reader/writer will transmit the value 1 as LKPS and the RFID tag will store that value in its memory location dedicated to LKPS. Simultaneously, the RFID reader/writer will also transmit the time of transmission, preferably in UTC format. This information is stored in the RFID tag's memory location set aside for t(LKPS). At the end of each successive Actual Power Step, the RFID tag's memory locations set aside for LKPS and t(LKPS) will receive two new values.
[0115] It will also be seen that in Step 84 the query of step 68 (FIG. 7) is repeated, assuring that I transistor is between I 1 and I 2 ; so long as this obtains, Step 84 continues and the remaining Actual Power Steps are carried out. However, if the answer to the Step 68 query is “no”, the temporary memory values are set to zero (Step 86 ) and the software reverts to the standby (i.e., inverter off except for test pulses) mode of Step 56 , FIG. 7.
[0116] In this scenario, the sizzle plate is not removed from the cooktop until it has completed two applications of Actual Power Step 11, and therefore the plate will have achieved its desired regulation temperature of 250° F.±20° F. Once removed, the plate's RFID tag will have the following information stored in its memory: LKPS=10, t(LKPS)=the time at which the second application of Actual Power Step 11 was completed, COB=sizzle plate. Inasmuch as the highest value of LKPS allowed is 10, while the RFID tag's memory is updated with t(LKPS) to reflect the time of the last application of an Actual Power Step 11, the sizzle plate is armed with information concerning its past charging history.
[0117] It is next assumed that the sizzle plate is served to a customer, is thereafter washed and shelved, and is again placed on the cooktop after a time period of 60 minutes, but is removed after 6 seconds. As noted above, the plate's RFID tag memory will have a value of 10 for LKPS and a value of t(LKPS) that corresponds to the end of the application of the second Actual Power Step 11 an hour prior to the time that the RFID reader/writer interrogates the RFID tag in Step 70 , FIG. 8.
[0118] Therefore, the temporary memory location corresponding to LKPS and t(LKPS) within HA(sizzle plate) and accessible to the cooktop's microprocessor will receive those values of 10 and the value of t(LKPS) just described. Next, at Step 72 , at the time of the next test pulse of the magnetic field from the cooktop (at this time the cooktop is still in it's standby operating mode), the value of I transistor will be measured and stored in the HA(sizzle plate) temporary memory location of I transistor max actual . Using the formulas found in Table 3, the CPL's for this heating operation will be calculated at Step 74 . Should the user have placed the sizzle plate in its proper location atop the cooktop, these values of CPL should be nearly equal to their corresponding IPL values. At Step 76 the value of 0 will be assigned to n, since LKPS is equal to 10. At Step 78 , the value of ELCLT will be calculated to be equal to 3600 seconds and will be stored in temporary memory. Thus, at Step 80 , the value of EPT will be calculated (via the instructions of Table 6) to be equal to T(0) or 72° F. This value of EPT will be stored in temporary memory. Using this stored value of EPT, the cooktop's microprocessor will follow the instructions as described in Table 7 and will start the sequence of Actual Power Steps, as described in Table 4, at Actual Power Step 1.
[0119] Step 84 instructs the cooktop to complete all remaining Actual Power Steps (1 through 10 and 11's). At the end of each Actual Power Step, the RFID reader/writer will transmit the value of LKPS that it just completed (not to exceed the value 10). For instance, at the end of Actual Power Step 4, during the time interval Δt transmit , the RFID reader/writer will transmit the value 4 as LKPS and the RFID tag will store that value in its memory location dedicated to LKPS. Simultaneously, the RFID reader/writer will also transmit the time of day of the transmission. This information will be stored in the RFID tag's memory location set aside for t(LKPS). At the end of each successive Actual Power Step, the RFID tag's memory will receive two new values for LKPS (Up to the value 10) and t(LKPS).
[0120] In view of the fact that the sizzle plate is removed from the cooktop after 6 seconds, it will have just completed the application of Actual Power Step 3. Thus, it will have reached a temperature of approximately T(3). Furthermore, it's RFID tag will now have the following information stored in its memory when removed from the cooktop: LKPS=3, t(LKPS)=the time at which the application of Actual Power Step 3 was just completed, COB=sizzle plate. Thus, the sizzle plate will be armed with information concerning its past charging history and will be ready to be placed upon the charger again.
[0121] If it is next assumed that the sizzle plate at approximately temperature T(3) is immediately placed again upon the cooktop, the sizzle plate will have the value 3 for LKPS and a value of t(LKPS) that corresponds to the end of the application of the second Actual Power Step 3. Assuming that the value of t(LKPS) matches that of the microprocessor once it is replaced upon the cooktop, at Step 70 the temporary memory location corresponding to LKPS and t(LKPS) within HA(sizzle plate) and accessible to the cooktop's microprocessor will receive those values of 3 and the value of t(3) just described. Next, at Step 72 , at the time of the next test pulse of the magnetic field from the cooktop (at this time the cooktop is still in it's standby operating mode), the value of I transistor will be measured and stored in the HA(sizzle plate) temporary memory location of I transistor max actual . Using the formulas found in Table 3, the CPL's for this heating operation will be calculated at Step 74 . Should the user have placed the sizzle plate in its proper location atop the cooktop, these values of CPL should be nearly equal to their corresponding IPL values. At Step 76 , the value of 2100 will be assigned to n, since LKPS is equal to 3. At Step 78 , the value of ELCLT will be calculated to be equal to 1 second or so and will be stored in temporary memory. Thus, at instruction Step 80 , the value of EPT will be calculated (via the instructions of Table 6) to be equal to a temperature slightly less than T(3) but more than T(2). This value of EPT will be stored in temporary memory. Using this stored value of EPT, the cooktop's microprocessor will follow the instructions as described in Table 7 and will start the sequence of Actual Power Steps, as described in Table 4, at Actual Power Step 4.
[0122] Step 84 instructs the cooktop to complete all remaining Actual Power Steps (Step 4 through 10 and into 11's). At the end of each Actual Power Step, the RFID reader/writer will transmit the value of LKPS that it just completed (up until it reaches the value 10). For instance, at the end of Actual Power Step 4, during the time interval Δt transmit , the RFID reader/writer will transmit the value 4 as LKPS and the RFID tag will store that value in its memory location dedicated to LKPS. Simultaneously, the RFID reader/writer will also transmit the time of day of the transmission. This information will be stored in the RFID tag's memory location set aside for t(LKPS). At the end of each successive Actual Power Step, the RFID tag's memory will receive two new values for LKPS (not to exceed 10) and t(LKPS).
[0123] In this scenario the cooktop will maintain the sizzle plate at approximately 250° F. indefinitely. The value of LKPS in the RFID memory will continue to remain at 10 and the value of t(LKPS) will continually be updated at the end of each Actual Power Step 11.
[0124] As previously described, the servingware sizzle plate 22 depicted in FIG. 1 may include, as all additional feature, a thermal switch 52 . In addition, FIGS. 9 and 10 illustrate RFID tags with one and two thermal switches, respectively. In the case of the FIG. 1 embodiment, the thermal switch 52 is preferably in contact with the undersurface of the cast iron plate 46 .
[0125] The purpose of a thermal switch in this context is to alter the transmission of data from the tag in some fashion at the specific temperature wherein the thermal switch activates so that the RFID reader will receive different information from the tag after the thermal switch has activated than was received prior to such activation. In essence, the combination of one or more thermal switches and a RFID tag becomes a switch itself that can transmit a radio frequency reply signal to the RFID reader/writer whereby the RFID reader/writer knows that the switching action has occurred. However, this new combination switch is “intelligent” because it can also store all of the digital information as described in the preferred embodiment, information that can be read and updated by the RFID reader/writer.
[0126] Turning next to FIG. 9, a combined RFID tag/thermal switch composite 88 is illustrated.
[0127] In this instance, the RFID tag 90 is a Gemplus ARIO 40-SL Stamp, made up of an epoxy base 92 with an engraved copper antenna 94 thereon. The antenna 94 is connected to an integrated circuit (not shown in FIG. 9 owing to the fact that it is on the reverse face of the tag). The copper antenna 94 terminates at two “termination plates” 96 and 98 , which are rectangular pieces of copper much larger in dimension than the rest of the antenna lines. This ARIO 40-SL Stamp architecture, the same as that of the ARIO 40-SM Module and the smaller ARIO 40-SMD, makes connecting a thermal switch a simple task. However, any RFID tag is suitable for making a composite in accordance with the invention, because all such tags contain both an antenna and integrated circuit.
[0128] The other component of the RFID tag/thermal switch composite or “intelligent switch” is the thermal switch 100 itself. Any prior art switch that changes from open contacts to closed, or from closed contacts to open at a pre-set or variable temperature will be suitable. Appropriate switches have the following characteristics: small size, moldability, high operating temperature, ability to operate in magnetic fields, small tolerance of pre-set switching temperature, and narrow differential. A thermal switch that is factory set to go from open contact to closed at a temperature of 150° F. with a tolerance of ±5° F. will go to closed contacts somewhere between 145° F. and 155° F. However, after switching closed, it will remain in closed contact for some finite time, and thus finite temperature range, until it cools down to a temperature at which the switch re-opens. This finite temperature range is termed the differential. For instance, a perfect 150° F. (normally open) switch as described above with a 40° F.±20° F. differential will re-open no earlier than 130° F. and could cool as low as 90° F. before re-opening.
[0129] The preferred thermal switch 100 for use in this invention is a miniature bi-metal thermostat, sometimes often called a thermal protector. These are commonly used for either control purposes or for temperature limiting purposes. They may be purchased in either of two configurations: 1) (normally open) close on rise, or 2) (normally closed) open on rise. The preferred switch model for this invention is the 5003 series miniature bi-metal thermostat manufactured by Airpax® Thermal Sensing Products. This thermostat has a 15° F. differential for the switching temperature ranges of interest for this invention. Other suitable thermal switches include the Klixon® line of bi-metal snap action thermostats manufactured by Texas Instruments, the Airpax series 6600 miniature bi-metal snap action thermostat, and the OP6 and UP7 series bi-metal thermal protectors manufactured by UCHIYA and sold by Selco Products Company of California. These latter mentioned switches, though smaller than the 5003 series, typically have a 50° F. differential.
[0130] It has been found experimentally that the simplest method to turn an RFID tag into an intelligent radio frequency switch or composite is to connect each end of thermal switch to a respective end of the antenna at termination plates 96 and 98 . A simple solder joint is sufficient. Of course, this connection may be done as a post-production process by the user, or by the RFID tag manufacturer.
[0131] When a single thermal switch 100 is connected in this fashion, it should be a (normally open) close on rise switch. This allows the RFID tag to communicate normally with the RFID reader at temperatures below the switching temperature (hereafter referred to as TS1) because the antenna 94 maintains its original impedance characteristics. At temperatures above TS1 the thermal switch 100 is closed. This short circuits the antenna 94 , changing its impedance characteristics, and prevents it from communicating with the RFID reader/writer. Of course, during the “differential” temperature range that exists during cool-down for a bi-metal thermostat (for instance, 15° F. below TS1 for an Airpax 5003 series thermostat) the RFID antenna 94 configured as shown in FIG. 9 will be unable to communicate with the RFD reader/writer. For a thermal switch 100 with a small differential, this fact does not detract greatly from the accuracy and precision of the alternative temperature regulation method described below. However, for a higher differential thermal switch, the much greater temperature range of “muteness” is a detriment.
[0132] [0132]FIG. 10 depicts a RFID tag/thermal switch composite 102 which overcomes the “muteness” problem which may be caused by a single bi-metallic switch with a large differential. The composite 102 includes an identical RFID tag 90 having base 92 , antenna 94 and plates 96 , 98 . However, in this instance two series-related thermal switches 104 , 106 are connected as shown to the termination plates. The switch 106 is a normally open, close on rise switch, while the other switch 104 is a normally closed open on rise switch. The switch 106 should have a switching temperature TS1, lower than the switching temperature TS2 of the normally closed switch 104 . Thus, during heat-up, prior to TS1, the RFID tag can communicate normally with the RFID reader. Between TS1 and TS2, the RFID tag cannot communicate with the RFID reader. Above, TS2 communications are normal again. During cool-down, the “muteness” temperature period is no longer the differential of a single bi-metal thermostat, but is now the difference in temperature between TS1 and TS2. This temperature interval may be chosen by the designer to be small if the value of TS2 is chosen as the regulation temperature. However, a larger temperature interval between TS1 and TS2 can also be chosen and used to compensate for non-ideal cooling loads, if TS1 is chosen as a calibration temperature and not as the regulation temperature.
[0133] Despite the fact that the simplest way to connect one or more thermal switches to an RFID tag so as to provide an “intelligent” switch or composite is to connect them so as to short out the antenna, it is also possible to connect one or more thermal switches to the RFID tag so as to short out only the EEPROM section of the tag. In this connection mode, the RFID tag would have full communication ability, i.e. the ability to read and write, with the RFID reader/writer below the switch temperature TS1 (or above TS2 for the dual switch configuration). However, above TS1 (or between TS1 and TS2 for the dual switch configuration) the tag would behave as a read-only tag. Thus the RFID reader/writer, and therefore the induction heating device of this invention, would be able to read information from the object such as its COB at all times that the tag is in the reader/writer's field. Other connection methods can also be used. Regardless of the means or location of connection of the thermal switch(es), the RFID reader/writer will be able to detect a difference between a tag whose switch or switches are in one condition versus the other.
[0134] In the following discussion, use of a composite 88 as shown in FIG. 9 or a dual-switch composite 102 as depicted in FIG. 10 will be explained. Thus, the RFID tag/thermal switch combination will appear to the RFID reader/writer as if no tag is present in the field during it's “altered” state (when one or more thermal switches shorts the RFID antenna as in FIGS. 9 and 10) but appears as a normal read/write RFID tag otherwise. During the “altered state” of the RFID tag/thermal switch composites, no communications between the tag and reader will be possible. However, the alternative methods described below will work for other RFID tag/thermal switch composites wherein the RFID tag is still communicative during an altered state as well.
Temperature Regulation Employing Information Transmitted from an RFID Tag Coupled with One or More Temperature Switches, Wherein the Temperature Switch or Switches Define the Regulation Temperature
[0135] Considering first the apparatus shown in FIG. 1, with the servingware 22 having a single thermal switch 52 , an exemplary switching temperature of the switch 52 (TS1) is selected to be equal to T(10), the pre-programmed regulation temperature shown in FIG. 5. The overall software algorithm of FIG. 7 also allows the use of such a construction without change. However, changes are made in the software HA(COB), in this case HA(sizzle plate). Therefore, upon power up of the induction heating device, all steps in FIG. 7 will be followed as previously described. It is only within Step 66 , where the HA(COB) is executed, that the microprocessor follows a different algorithm.
[0136] The class of object (COB) code on the RFID tag that has one thermal switch attached will direct the induction heating device's microprocessor controller to follow the HA(COB with 1 Thermal Switch Defining the Regulation Temperature) that is shown schematically in FIG. 11. This FIG. 11 flow chart has only one difference from that of FIG. 8, namely in Step 84 a. The difference is simply this: if, during any read/write operation made during the last 0.15 seconds of a power step, an “altered state” RFID tag is detected, then the program reverts to the Standby Mode of Operation through Steps 86 and 56 for a period of time equal to (0.5)(MXDT) whereupon the program then moves to Actual Power Step 11.
[0137] In order to make this difference clear, assume that the sizzle plate with the attached RFID tag/thermal switch composite (whose switch temperature, TS1, coincides with T(10)) is placed upon the induction heating device 20 . Assume that the RFID tag is new. Referring to FIG. 7, the cooktop microprocessor will begin implementing; HA(sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) at Step 66 . Referring, to FIG. 11, the sizzle plate will have zero values for LKPS and t(LKPS) when the RFID reader/writer interrogates the RFID tag in Step 70 . Therefore, the temporary memory location corresponding to LKPS and t(LKPS) within HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) and accessible to the cooktop's microprocessor will receive zero values. Next, at Step 72 , at the time of the next test pulse of the magnetic field from the cooktop (at this time the cooktop is still in it's standby operating mode), the value of I transistor will be measured and stored in the HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) temporary memory location of I transistor max actual . Using the formulas found in Table 3 the CPL's for this heating operation will be calculated at Step 74 . Should the user have placed the sizzle plate in its proper location atop the cooktop, these values of CPL should be nearly equal to their corresponding IPL values. At Step 76 , the value of 3600 will be assigned to n, since LKPS is equal to 0. At Step 78 , the value of ELCLT will be calculated to be much greater than 3600 seconds and will be stored in temporary memory. Thus, at Step 80 , the value of EPT will be calculated (via the last two lines of Table 6) to be equal to T(0) or 72° F. This value of EPT will be stored in temporary memory. Using this stored value of EPT, the cooktop's microprocessor will follow the instructions as described in Table 7, and will start the sequence of Actual Power Steps, as described in Table 4, at Actual Power Step 1.
[0138] Step 84 a (FIG. 11) instructs the cooktop to complete all remaining Actual Power Steps (1 through 10 and 11's). At the end of each Actual Power Step, the RFID reader/writer will transmit the value of LKPS that it just completed (up to the value 10). However, there is one possible difference between mode of operation and that described previously in connection with FIG. 8. As the sizzle plate reaches the end of Actual Power Step 10 and attempts to write a new value of LKPS and t(LKPS) to the RFID tag, it may find that the RFID tag does not communicate back because it is in an altered state. This would be the case if the thermal switch reached TS1 prior to the end of Actual Power Step 10 (in the case that the end of Actual Power Step 10 is reached prior to TS1, the cooktop would behave exactly as if the RFID tag had no thermal switch attached to it at all). Assuming that this occurs, then the RFID reader/writer would know that the sizzle plate is still on the charger because the answer the question in Step 68 is still “yes”. Therefore, the cooktop microprocessor will follow the instructions of Step 84 a and will cause the cooktop to revert to Standby mode for a period of time equal to (0.5)(MXDT). At that time the cooktop would apply Actual Power Step 11, whereby, according to Table 4, it would apply CPL5 for 2 seconds. However, during the last 0.15 seconds of CPL5, the reader/writer would again determine the RFID tag to be in an altered state, and would thus repeat the (0.5)(MXDT) period and application of Actual Power Step 11 for the second time.
[0139] Since, in this case the sizzle plate will not be removed from the cooktop until it has completed two applications of Actual Power Step 11, it will have achieved its desired regulation temperature of 250° F.±20° F. However, unlike in the FIG. 8 method, it's RFID tag will have the following information stored in its memory: LKPS=9, t(LKPS)=the time at which Actual Power Step 9 was last completed, COB=sizzle plate with 1 Thermal Switch Defining the Regulation Temperature. Thus, the sizzle plate will be armed with information concerning its past charging history and will be ready to be placed upon the charger again.
[0140] Assume next that the sizzle plate is used for customer service and is then washed and shelved, and is thereupon placed again on the cooktop for a time period of 60 minutes and is removed after 6 seconds. In this case the sizzle plate will have the value 9 for LKPS and a value of t(LKPS) that corresponds to the end of the application of Actual Power Step 9. This value of t(LKPS) is a little over an hour prior to the time that the RFID reader/writer interrogates the RFID tag in Step 70 . Therefore, the temporary memory location corresponding to LKPS and t(LKPS) within HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) and accessible to the cooktop's microprocessor will receive those values of 9 and the value of t(LKPS)just described. Next, at Step 72 , at the time of the next test pulse of the magnetic field from the cooktop (at this time the cooktop is still in it's standby operating mode), the value of I transistor will be measured and stored in the HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) temporary memory location of I transistor max actual . Using the formulas found in Table 3, the CPL's for this heating operation will be calculated at Step 74 . Should the user have placed the sizzle plate in its proper location atop the cooktop, these values of CPL should be nearly equal to their corresponding IPL values.
[0141] At Step 76 the value of 120 will be assigned to n, since LKPS is equal to 9. At Step 78 the value of ELCLT will be calculated to be equal to, say, 3700 seconds and will be stored in temporary memory. Thus, at Step 80 , the value of EPT will be calculated (via the instructions of Table 6) to be equal to T(0) or 72° F. This value of EPT will be stored in temporary memory. Using this stored value of EPT, the cooktop's microprocessor will follow the instructions as described in Table 7 and will start the sequence of Actual Power Steps, as described in Table 4, at Actual Power Step 1.
[0142] Step 84 a instructs the cooktop to complete all remaining Actual Power Steps (1 through 10 and 11's). At the end of each Actual Power Step, the RFID reader/writer will transmit the value of LKPS that it just completed (not to exceed the value 10). For instance, at the end of Actual Power Step 1, during the time interval Δt transmit , the RFID reader/writer will transmit the value 1 as LKPS and the RFID tag will store that value in its memory location dedicated to LKPS. Simultaneously, the RFID reader/writer will also transmit the time of day of the transmission. This information will be stored in the RFID tag's memory location set aside for t(LKPS). At the end of each successive Actual Power Step, the RFID tag's memory will receive two new values for LKPS (up to the value 10) and t(LKPS).
[0143] Inasmuch as the sizzle plate is removed from the cooktop after 6 seconds, it will have just completed the application of Actual Power Step 3. Thus, it will have reached a temperature of approximately T(3). Furthermore, it's RFID tag will now have the following information stored in its memory when removed from the cooktop: LKPS=3, t(LKPS)=the time at which the application of Actual Power Step 3 was just completed, COB=Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature. Thus, the sizzle plate will be armed with information concerning its past charging history and will be ready to be placed upon the charger again.
[0144] Assume next that the sizzle plate is immediately placed back on the cooktop and is allowed to remain there indefinitely. Since the sizzle plate has just reached approximately temperature T(3), the sizzle plate will have the value 3 for LKPS and a value of t(LKPS) that corresponds to the end of the application of the second Actual Power Step 3 just seconds prior to this time. If the value of t(LKPS) matches that of the computer once it is replaced upon the cooktop, at Step 70 , the temporary memory location corresponding to LKPS and t(LKPS) within HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) and accessible to the cooktop's microprocessor will receive those values of 3 and the value of T(3) just described. Next, at Step 72 , at the time of the next test pulse of the magnetic field from the cooktop (at this time the cooktop is still in it's standby operating mode), the value of I transistor will be measured and stored in the HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) temporary memory location of I transistor max actual . Using, the formulas found in Table 3, the CPL's for this heating operation will be calculated at Step 74 . Should the user have placed the sizzle plate in its proper location atop the cooktop, these values of CPL should be nearly equal to their corresponding IPL values. At Step 76 , the value of 2100 will be assigned to n, since LKPS is equal to 3. At Step 78 , the value of ELCLT will be calculated to be equal to 1 second or so and will be stored in temporary memory. Thus, at Step 80 , the value of EPT will be calculated (via the instructions of Table 6) to be equal to a temperature slightly less than T(3) but more than T(2). This value of EPT will be stored in temporary memory. Using this stored value of EPT, the cooktop's microprocessor will follow the instructions as described in Table 7 and will start the sequence of Actual Power Steps, as described in Table 4, at Actual Power Step 4.
[0145] Step 84 a instructs the cooktop to complete all remaining Actual Power Steps (Step 4 through 10 and into 11's). At the end of each Actual Power Step, the RFID reader/writer will transmit the value of LKPS that it just completed (up until it reaches the value 10). For instance, at the end of Actual Power Step 4, during the time interval Δt transmit , the RFID reader/writer will transmit the value 4 as LKPS and the RFID tag will store that value in its memory location dedicated to LKPS. Simultaneously, the RFID reader/writer will also transmit the time of day of the transmission. This information will be stored in the RFID tag's memory location set aside for t(LKPS). At the end of each successive Actual Power Step, the RFID tag's memory will receive two new values for LKPS (not to exceed 10) and t(LKPS).
[0146] It is likely that all Actual Power Steps up to number 11 will be completed. It is also likely that the thermal switch will not cause the RFID tag to enter an altered state. Thus, the preferred method sequence of Power Step 11 activations will be followed exactly as is shown in Table 4. The cooktop will maintain the sizzle plate at approximately 250° F. indefinitely. The value of LKPS in the RFID memory will continue to remain at 10 and the value of t(LKPS) will continually be updated at the end of each Actual Power Step 11.
[0147] Next assume that the same sizzle plate is removed from the cooktop, washed, heated in an oven to 150° F., and then placed back upon the cooktop after a time period of 60 minutes and is allowed to remain there indefinitely
[0148] In this case, the safety feature added by the thermal switch comes into play. The sizzle plate will have the value 10 for LKPS and a value of t(LKPS) that corresponds to the last of Actual Power Step 11. The value of t(LKPS) will be approximately 1 hour prior to the time that the RFID reader/writer interrogates the RFID tag in Step 70 . Therefore, the temporary memory location corresponding to LKPS and t(LKPS) within HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) and accessible to the cooktop's microprocessor will receive those values of 10 and the value of t(LKPS) just described. Next, at Step 72 , at the time of the next test pulse of the magnetic field from the cooktop (at this time the cooktop is still in it's standby operating mode), the value of I transistor will be measured and stored in the HA(Sizzle Plate with 1 Thermal Switch Defining the Regulation Temperature) temporary memory location of I transistor max actual . Using the formulas found in Table 3, the CPL's for this heating operation will be calculated at Step 74 . Should the user have placed the sizzle plate in its proper location atop the cooktop, these values of CPL should be nearly equal to their corresponding IPL values. At Step 76 , the value of 0 will be assigned to n, since LKPS is equal to 10. At Step 78 , the value of ELCLT will be calculated to be equal to 3600 seconds and will be stored in temporary memory. Thus, at Step 80 , the value of EPT will be calculated (via the instructions of Table 6) to be equal to T(0) or 72° F. This value of EPT will be stored in temporary memory.
[0149] Because of the unauthorized heating of the sizzle plate in an oven to a temperature of 150° F., this value of EPT is incorrect. However, the instructions found in Table 7 will be followed nonetheless. Thus, using this stored value of EPT, the cooktop's microprocessor will follow the instructions as described in Table 7 and will start the sequence of Actual Power Steps, as described in Table 4, at Actual Power Step 1.
[0150] Step 84 a instructs the cooktop to complete all remaining Actual Power Steps (1 through 10 and 11's). However, the thermal switch will reach TSI well prior to Actual Power Step 10. Thus, during the last 0.15 seconds of some Actual Power Step, the RFID tag will not communicate back to the RFID reader because it is in an altered state. The RFID reader will still know that the sizzle plate is on the charger because the answer the question in Step 68 is still “yes”. Therefore, the cooktop microprocessor will follow the instructions of Step 84 a and will cause the cooktop to revert to Standby mode for a period of time equal to (0.5)(MXDT). At that time the cooktop would apply Actual Power Step 11, whereby, according to Table 4, it would apply CPL5 for 2 seconds. However, during the last 0.15 seconds of CPL5, the reader would again determine the RFID tag to be in an altered state, and would thus repeat the (0.5)(MXDT) period and application of Actual Power Step 11 for the second time.
[0151] It should be evident that the thermal switch attached to the RFID tag prevents overheating of the sizzle plate should the sizzle plate be inadvertently heated by a device other than the induction heating device of this invention prior to placing it upon said induction heating device. It should also be evident that an RFID tag with two thermal switches, as shown in FIG. 10, could be used with only slight modifications to achieve the same ends. The altered state of the RFID tag with two thermal switches, when detected by the RFID reader, would be used to define the regulation temperature. Thus the regulation temperature would some temperature between TS1 and TS2.
[0152] In detail, the following is another temperature regulation scheme using a dual switch RFID tag composite such as shown in FIG. 10. This scheme accomplishes two goals: 1) it measures an intermediate temperature of an object during heat-up so as send the Heating Algorithm to the proper heating step—to essentially “calibrate” the Heating Algorithm, and 2) it measures the time between TS1 and TS2, compare it to an ideal time stored in memory, and accordingly adjust the remaining CPL's so as to more accurately reach the desired regulation temperature.
[0153] The object to be temperature regulated must have an attached RFID tag with two or more thermal switches connected, as described above. To simplify the following discussion, the sizzle plate of FIG. 1 is employed, but with an RFID tag/dual switch composite in accordance with FIG. 10 in lieu of the single thermal switch 52 . The switching temperature of thermal switch 106 (TS1) is selected to be the same as T(2), while the switching temperature of thermal switch 104 (TS2) is selected to be T(4). These two temperatures lie within the region over which CPL1, which equals IPL1, is applied.
[0154] Preferably, the induction heating device 20 is able to automatically differentiate between objects with no temperature sensors, and therefore employ the preferred temperature regulation method, and those that employ thermal switch(es), and automatically implement the appropriate temperature regulation method.
[0155] Thus, the overall software algorithm of FIG. 7 allows the alternative regulation schemes to be employed and accordingly all changes relative to the preferred embodiment are found only in the HA(COB) itself (within Step 66 of the overall algorithm, FIG. 7). Therefore, upon power up of the induction heating device, all steps in FIG. 7 will be followed identically. It is only within Step 66 , where the HA(COB) is executed, that the microprocessor follows a different algorithm. The class of object (COB) code on the RFID tag that has two thermal switches attached will direct the induction heating device's microprocessor controller to follow the HA(Sizzle Plate with 2 Thermal Switches Defining Intermediate Temperatures).
[0156] In this case, three new permanent memory items are added to the RFID tag's memory list. Referring to Table 9, these memory items are TS1, TS2, and TS1/TS2_time. TS1 is the temperature at which thermal switch #1 switches, causing an altered state of transmission from the attached RFID tag. TS2 is the temperature at which thermal switch #2 switches, causing the RFID tag to move from the altered state back into the normal communication mode. TS1/TS2_time is the elapsed time between TS1 and TS2 for the sizzle plate under ideal operating conditions. These items must be stored in the RFID tag memory because they are specific to the sizzle plate itself and, thus, should be readable by any individual induction heating device.
[0157] The value of TS2, which in this example is equal to T(4), is used as the calibration temperature such that the cooktop's microprocessor will initiate Actual Power Step #5 whenever the RFID reader/writer determines that the thermal switch #2 is activating during heat-up. For example, should a brand new sizzle plate that has inadvertently been placed in a warming oven to reach 125° F. be placed upon the induction heating device, the HA(Sizzle Plate with 2 Thermal Switches Defining Intermediate Temperatures) will calculate the Estimated Present Temperature (EPT) to be 72° F. and will thus start the Heating Algorithm at Actual Power Step #1. As soon as the RFID reader determines that TS2 has occurred (at 190° F.), the cooktop's microprocessor will bypass any intermediate Actual Power Steps and will automatically initiate Actual Power Step 5. This feature of alternative method #2 thus “calibrates” the heating algorithm to the true initial conditions of the sizzle plate.
[0158] In order to achieve the first goal (measurement of an intermediate temperature during heat-up so as to send the Heating Algorithm to the proper heating step), only the ability to determine when the REID tag passes from an altered state to a normal state of communication, which occurs at TS2, is necessary. However, to achieve the second goal (measurement of time between TS1 and TS2 and comparison of this time to an ideal time stored in memory), it is necessary to determine the elapsed time, as measured by the real time clock, that it takes for the sizzle plate to pass from TS1 to TS2 for both an experimental heat-up under ideal conditions, said elapsed time hereafter defined as TS1/TS2_time, and for each actual heating operation, said elapsed times hereafter defined as TS1/TS2_time_actual.
[0159] The value of TS1/TS2_time stored in a specific sizzle plate's RFID memory is determined experimentally, as described above for permanent memory information, under ideal operating conditions. Those ideal operating conditions include a reference standard induction heating device operating at nominal line voltage. Furthermore, the cooktop must be applying CPL1, which equals IPL1, throughout the experimental determination. TS1/TS2_time is thus an ideal time.
[0160] A corresponding temporary memory location must be provided for that is labeled TS1/TS2_time_actual. This value will be measured by the cooktop microprocessor during each heating operation and stored in temporary memory within HA(Sizzle Plate with 2 Thermal Switches Defining Intermediate Temperatures). Furthermore, two other temporary memory locations must be provided for: TS1_time (the time, as measured by the real time clock, when the RFID reader first detects the RFID tag passing from a normal state of communication into an altered state of communication), and TS2_time (the time, as measured by the real time clock, when the RFID reader first detects the RFID tag passing from an altered state of communication into a normal state of communication). Each of these three additional temporary memory locations must be accessible to the cooktop's microprocessor during a heating operation.
[0161] Finally, the cooktop's microprocessor will be programmed with an altering step that uses the values of TS1/TS2_time and TS1/TS2_time_actual to attempt to correct for improper thermal loads during heat-up. This new altering step's commands are applied within HA(Sizzle Plate with) 2 Thermal Switches Defining Intermediate Temperatures) at a new Step 48 b, where Step 48 b is identical to Step 84 of FIG. 8 except for the addition of the altering step commands. This new altering step's commands serve to alter the values of CPL2, CPL3, CPL4, and CPL5 based upon a comparison of the measured value of TS1/TS2_time_actual to the ideal value TS1/TS2time. Note that the alteration will be made to the Corrected Power Levels 2 through 5 because the Heating Algorithms already corrected the Ideal Power Level's prior to beginning the heating operation, as was previously described in connection with the preferred embodiment. This new correction to CPL2, CPL3, CPL4, and CPL5 is made at the time the cooktop's microprocessor is initiating Actual Power Step #5.
[0162] The purpose of this new altering step is to correct the applied power levels for non-ideal food loads encountered during heat-up. For instance, for the sizzle plate preferred Heating Algorithm, the Corrected Power Levels are based upon heating a sizzle plate with no food on its surface. Should the sizzle plate inadvertently be heated with a sizable food load on its surface, the preferred Heating Algorithm would cause the sizzle plate to reach an average surface temperature significantly below 250° F., the target regulation temperature. By comparing the actual time to traverse temperatures T(2) to T(4) to the ideal time to traverse the same temperature range, it can be approximately determined if the cooling load of the sizzle plate is ideal or not. For instance, if the value of TS1/TS2_time_actual is much greater than TS1/TS2_time, then there is food or some other heat sink in thermal contact with the sizzle plate. Therefore, to reach the desired surface temperature, CPL2 through CPL5 must be increased in power. The converse would be true if TS1/TS2_time_actual is found to be much less than TS1/TS2_time.
[0163] To achieve this power correction, the preferred altering step formula for the sizzle plate example, referred to as Equation 1, is as follows:
CPL ( n )= CPL ( n )*{1+(0.1*((TS1/TS2_time_actual)−(TS1/TS2_time)))}, where n=2, 3, 4, and 5 in our sizzle plate example.
[0164] Of course, for other objects a different altering step equation may be more suitable, but will still involve the same compared values.
[0165] The following example heating operation illustrates the present embodiment wherein two thermal switches define intermediate temperatures. Consider a new same sizzle plate, after being heated in a warming oven to 125° F. and having food placed upon it, that is positioned upon the cooktop and is allowed to remain there indefinitely. For the following discussion, refer to FIG. 8, remembering that a new Step 84 b that employs all of the instructions within Step 84 but adds the above described altering step replaces the Step 84 of FIG. 8.
[0166] In this case the sizzle plate will have zero values for LKPS and t(LKPS) when the RFID reader/writer interrogates the RFID tag in Step 70 . Furthermore, the RFID reader will read a value for TS1/TS2_time that has been stored in the RFID tag. Therefore, the temporary memory location corresponding to LKPS and t(LKPS) within HA(Sizzle plate with 2 Thermal Switches Defining Intermediate Temperatures) and accessible to the cooktop's microprocessor will receive zero values. Furthermore, the temporary memory location corresponding to TS1/TS2_time accessible to the cooktop's microprocessor will receive the value stored on the chip. For our sizzle plate example, this value is 4 seconds. Next, at Step 72 , at the time of the next test pulse of the magnetic field from the cooktop (at this time the cooktop is still in it's standby operating mode), the value of I transistor will be measured and stored in HA(Sizzle Plate with 2 Thermal Switches Defining Intermediate Temperatures) temporary memory location of I transistor max actual . Using the formulas found in Table 3, the CPL's for this heating operation will be calculated at Step 74 . Should the user have placed the sizzle plate in its proper location atop the cooktop, these values of CPL should be nearly equal to their corresponding IPL values. At Step 76 , the value of 3600 will be assigned to n, since LKPS is equal to 0. At Step 78 , the value of ELCLT will be calculated to be much greater than 3600 seconds and will be stored in temporary memory. Thus, at Step 80 , the value of EPT will be calculated (via the last two lines of Table 6) to be equal to T(0) or 72° F. This value of EPT will be stored in temporary memory. Using this stored value of EPT, the cooktop's microprocessor will follow the instructions as described in Table 7 and will start the sequence of Actual Power Steps, as described in Table 4, at Actual Power Step 1. Unfortunately, the sizzle plate's upper surface is actually at 125° F. with food upon it.
[0167] Fortunately, Step 84 b instructs the cooktop to complete all remaining Actual Power Steps (1 through 10 and 11's) unless the RFID reader detects that the RFID tag is passing from an altered state to a normal one at TS2, at which time the cooktop's microprocessor will initiate Actual Power Step #5. Furthermore, Step 84 b instructs the cooktop's microprocessor and RFID reader to read and store the times TS1_time and TS2_time, and then use them to calculate TS1/TS2_time_actual if both TS1_time and TS2_time are recorded during the same heating operation. Finally, Step 84 b instructs the cooktop's microprocessor to apply Equation 1 to modify the CPL's 2, 3, 4, and 5 should a value of TS1/TS2_time_actual be successfully calculated.
[0168] Thus, shortly after applying Actual Power Step #1, the sizzle plate will reach 130° F., at which time thermal switch #1 will close and cause an altered state of communication between the RFID tag and reader when the reader attempts to write the new values of LKPS and t(LKPS). Thus, the cooktop's microprocessor will know that TS1 has been reached and will store the current time as TS1_time. Actual Power Step #2 will be applied, followed by Actual Power Step #3. At the end of Actual Power Step #3, the sizzle plate's surface will probably have reached approximately 180° F., a temperature still short of TS2. Thus, Actual Power Step #4 will be applied. During the last 0.15 seconds of Actual Power Step #4, the RFID reader/writer will attempt to transmit a new value of LKPS and t(LKPS). However, the RFID reader/writer will determine that the RFID tag has now passed from the altered state into the normal state of communications. Thus, the cooktop's microprocessor will know that TS2 has been reached and will store the current time as TS2_time. Therefore, the cooktop's microprocessor will calculate TS1/TS2_time_actual, and will proceed to apply altering Equation 1. Equation #1 will multiply each of current CPL's 2, 3, 4, and 5 by (1.2) and store these new values of CPL2, 3, 4, and 5. Finally, the cooktop's microprocessor will initiate Actual Power Step #5 and apply this new value of CPL2.
[0169] The cooktop will now proceed to apply Actual Power Steps #5 through 10 and then apply an indefinite number of Actual Power Steps #11, just as described above. At the end of each Actual Power Step, the RFID reader/writer will transmit the value of LKPS that it just completed (up to the value 10) and will transmit each corresponding value of t(LKPS).
[0170] Embodiments of FIGS. 2 - 4
[0171] While the foregoing discussion has for exemplary purposes described the construction and operation of the servingware sizzle plate 22 , the invention is not limited to any particular type of servingware or other object to be heated. For example, FIG. 2 depicts a plate 108 of conventional design, save for the provision of a metallic layer 110 on the underside thereof along with an RFID tag 112 , the latter being encapsulated within a suitable epoxy or other synthetic resin body 114 . Similarly, FIG. 3 illustrates an espresso cup 116 having on its base a metallic layer 118 and RFID tag 120 ; the latter is maintained in place with a synthetic resin matrix 122 . Finally, FIG. 4 illustrates a warming pellet 124 designed to be inductively heated and used in connection with food delivery bags or the like (such as pizza bags). The pellet 124 includes an induction heatable core 126 and a surrounding synthetic resin body 128 . The pellet also has a centrally disposed RFID tag 130 . It will be appreciated that these devices, as well as a myriad of other types of induction heatable objects, can be used in the context of the present invention.
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A temperature-regulating induction heating system is provided which comprises an induction heater ( 20 ) having apparatus ( 36, 38, 40 ) for receiving RFID transmissions and an induction heatable object ( 22 ) with an RFID tag ( 50 ). The heater ( 20 ) includes a component ( 28 ) for generating a magnetic field, control circuitry including a microprocessor ( 32 ) coupled with the component ( 28 ) for selectively initiating and terminating generation of a magnetic field; the receiving apparatus ( 36, 38, 40 ) provides information to the microprocessor ( 32 ) causing initiation of a heating algorithm for the object ( 22 ). In preferred forms, the tag ( 50 ) and apparatus ( 36, 38, 40 ) are designed for two-way information transfer, thereby permitting continuous updating of the information carried by tag ( 50 ). In this way, if induction heating of the object ( 20 ) is interrupted, it may be resumed to nevertheless achieve a desired regulation temperature. Advantageously, the RFID tag ( 50 ) and apparatus ( 36, 38, 40 ) operate during intermittent interruption of the primary magnetic field of the heater ( 20 ) to eliminate transmission interference. The tag ( 50 ) may be equipped with one or more thermal switches ( 100, 104, 106 ) to provide better temperature control.
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FIELD
The invention relates to the field of natural product chemistry, in particular the chemistry of macrolides.
The invention concerns a compound of formula I ##STR2## wherein either
R 1 is hydroxy,
R 2 is allyl or n-propyl and there is a single bond between the carbon atoms numbered 14 and 15
or
R 1 is missing,
R 2 is allyl and
there is a double bond between the carbon atoms numbered 14 and 15.
Formula I is meant to cover the compounds in free form and, where such forms may exist, in salt form.
BACKGROUND ART
Fujisawa EP 184162 discloses a group of compounds represented by formula A ##STR3## wherein R 1 is hydroxy or protected hydroxy,
R 2 is hydrogen, hydroxy or protected hydroxy,
R 3 is methyl, ethyl, propyl or allyl,
n is an integer of 1 or 2 and the symbol of a line and dotted line is a single bond or a double bond,
and salts thereof.
As is evident from the above formula, there are many asymmetry centers and therefore, a large number of possible stereoisomers exist for any given meaning of the substituents.
On the other hand, although on page 4 in EP 184 162 it is mentioned that there may be one or more coniormer(s) or stereoisomeric pairs such as optical and geometrical isomers due to asymmetric carbon atom(s) and double bond(s), for none of the compounds specifically disclosed in EP 184 162 is there any indication of the exact stereochemical configuration.
This is so in particular for the compound named FK 900506 (FK 506), which is the object of Examples 1 to 3 therein, its derivative hydrogenated at the allyl group to an n-propyl group, which is the object of Example 21 therein, and its derivative dehydrated between positions 14 and 15, which is disclosed in Example 17 therein. From the formula and the names indicated on page 32, 95 and 98 of EP 184 162 it is not apparent what confiuration FK 506 and these two derivatives have.
The configuration of FK 506 has however been published in the scientific literature, e.g. in H. Tanaka et al., J. Am. Chem. Soc. 109 (1987) 5031-5033, T. Kino et al., J. Antibiotics 40 (1987) 1249-1255 and T. Taga et al., Acta Cryst. C43 (1987) 751-753.
It appears therefrom that FK 506 and, by implication, the two derivatives thereof mentioned above, have the configuration indicated above for formula I of the present invention, except that at the carbon atom numbered I7 the configuration is reversed, i.e. it is the R configuration, whereas in formula I above the S configuration is shown.
SUMMARY
It has now been found that, surprisingly, the compounds of formula I, which are novel and are the stereoisomers of FK 506, its dihydrogenated derivative and its dehydrated derivative, but with the opposite configuration at the carbon atom in position 17, have an excellent immunosuppressant and antiinflammatory, e.g. antipsoriatic activity.
DETAILED DESCRIPTION
The compounds of formula I are novel. They may be prepared in accordance with standard procedures.
The compounds of formula I wherein R 1 is hydroxy and R 2 is allyl (Compound No. 1; "17-epi-FK506") or wherein R 2 is missing and R 2 is allyl (Compound No. 3; "dehydro-17-epi-FK506") may be isolated in known manner from e.g. Streptomyces tsukubaensis No. 9993 using the general procedures described in EP 184 162 and in the Examples hereafter. Thus, an appropriate Streptomyces strain such as Streptomyces tsukubaensis No. 9993 may be cultivated in an appropriate culture medium and the above two compounds isolated from the resultant culture. Cultivation is effected by incubation, e.g. as described in EP 184 162 or in Example 1 hereunder. The pH is kept between about 6 and about 8, preferably at about 6.8. The temperature may vary between about 18° C. and about 35° C., it preierably is kept at around 27° C.
The compound of formula I wherein R 1 is hydroxy and R 2 is n-propyl (Compound No. 2; "dihydro-17-epi-FK506") may e.g. be prepared in known manner by hydrogenation of Compound No. 1, e.g. by catalytic reduction using palladium on charcoal as a catalyst. The temperature may e.g. vary from about 5° C. to about 30 ° C., preferably about room temperature is used. The reaction is preferably effected in the presence of.an inert organic solvent such as an alcohol, e.g. ethanol.
Compound No. 3 may e.g. also be prepared in known manner by dehydration of Compound No. 1, e.g. by catalytic dehydration in an acidic solution. Preferably an inert organic solvent such as an ester, e.g. acetic acid ethyl ester, is used. The temperature may vary between about 5° C. and about 30° C., the reaction preferably is effected at about room temperature.
The compounds of the invention may be isolated and purified from the reaction or isolation mixture in known manner.
The producing strain, Streptomyces tsukubaensis No. 9993, is disclosed in Fujisawa EP 184162. Samples are available from the Fermentation Research Institute, Tsukuba, Ibaraki 305, Japan under the provisions of the Budapest Treaty, under deposit No. FERM BP-927. This strain has been redeposited on April 27, 1989 with the Agricultural Research Culture Collection InternatIonaI Depository, Peoria, Ill. 61604, USA under the provisions of the Budapest Treaty, under deposit No. NRRL 18488.
Compound No. 1 may e.g. also be produced by total synthesis according to the procedure published for the total synthesis of FK 506 (T. K. Jones et al., J. Am. Chem. Soc. 111 [1989]1157-1159) using corresponding epimeric starting materials.
The invention thus concerns the compounds of formula I as defined above.
It also concerns a process for the preparation of a compound of formula I as defined above which comprises
(a) for the preparation of the compounds of formula I wherein
R 1 is hydroxy or missing and R 2 is allyl,
cultivating an appropriate Streptomyces strain such as
Streptomyces tsukubaensis No. 9993 and isolating the compounds from the resultant mixture,
(b) for the preparation of the compound of formula I wherein
R 1 is missing and R 2 is allyl,
dehydrating the corresponding compound of formula I wherein
R 1 is hydroxy or
(c) for the preparation of the compound of formula I wherein
R 1 is hydroxy and R 2 is n-propyl,
hydrogenating the corresponding compound of formula I wherein
R 2 is allyl.
The invention also concerns a pharmaceutical composition containing a compound of formula I as defined above together with a pharmaceutically acceptable carrier or diluent.
It also concerns a compound of formula I as defined above for use as a pharmaceutical.
It also concerns the use of a compound of formula I as defined above in the preparation of a pharmaceutical composition, comprising mixing a compound of formula I with a pharmaceutically acceptable carrier or diluent.
It further concerns a process for the preparation of a pharmaceutical composition comprising mixing a compound of formula I as defined above with a pharmaceutically acceptable carrier or diluent.
It further concerns a method for the prevention or treatment of conditions requiring immunosuppression or of inflammatory conditions, comprising administering a therapeutically effective amount of a compound of formula I as defined above together with a pharmaceutically acceptable carrier or diluent to a subject in need of such treatment, e.g. a method of treatment of immune-mediated conditions of the eye comprising topically administering to the eye surface a therapeutically effective amount of a compound of formula I as defined above in a pharmaceutically acceptable ophthalmic vehicle. DR
EXPLANATION OF THE FIGURES
FIG. 1: IR-spectrum of Compound No. 1.
FIG. 2: NMR-spectrum of Compound No. 1.
FIG. 3: IR-spectrum of Compound No. 2.
FIG. 4: NMR-spectrum of Compound No. 2.
The following Examples illustrate the invention and are not limitative.
EXAMPLE 1
Fermentation
process variant (a), cultivation
(A) Starting culture on agar
An agar culture of strain Streptomyces tsukubaensis No. 9993 is grown for 14 days at 27° C. on the following medium:
______________________________________Yeast extract (Bacto) 4.0 gMalt extract (Bacto) 10.0 gDextrose (Bacto) 4.0 gAgar (Bacto) 20.0 gdemineralised water ad 1000 ml______________________________________
The pH value is set to 6.6 with NaOH/H 2 SO 4 prior to sterilization. Sterilization is effected for 20 minutes at 120° C.
(B) Preculture
The spores and mycelium from 6 starting cultures are suspended in 90 ml of a 0.9 % solution of sodium chloride. erlenmeyer flasks containing each 1 liter of preculture medium are inoculated with 7 ml of this suspension. The preculture medium has the following composition:
______________________________________Glycerine 10.0 gStarch 10.0 gGlucose 5.0 gCotton seed extract 10.0 g(Pharmamedia)Yeast extract (Gistex) 5.0 gCaCO.sub.3 2.0 gdemineralised water ad 1000 ml______________________________________
The pH value is set to 6.8 prior to sterilization, which takes place for 20 minutes at 120° C.
The propagation of this preculture is effected for 96 hours at 27° C. at 200 rpm on an agitator with an excentricity of 50 mm.
(C) Intermediate culture
Two 500 1 aliquots of preculture medium are inoculated in a 750 1 steel fermentor with 5 liters each of preculture and incubated for 48 hours at 27° C. Rotation speed is 100 rpm and aeration is 0.5 1 per minute per liter of medium.
(D) Main culture
6000 1 of main culture medium are inoculated in two 4500 1 steel fermentors with 600 1 of intermediate culture. The main culture medium has the following composition:
______________________________________Soluble starch 45.0 gCorn steep (Roquette) 10.0 gYeast extract (Gistex) 10.0 gCaCO.sub.3 1.0 gdemineralised water ad 1000 ml______________________________________
The pH is set to 6.8 with NaOH prior to sterilization. The corn steep is presterilized for 20 minutes at 120° C. Sterilization of the whole medium is effected at 120° C. for 20 minutes.
Incubation is effected for 96 hours at 27° C, 50 rpm, 0.5 bar and an aeration rate of 0.5 1 per minute per liter of medium. Foam formation is reduced using a silicone antifoam agent.
EXAMPLE 2
17β-Allyl-1β,14α-dihydroxy-12-[2'-(4"(R)-hydroxy -3"(R)-methoxycyclohex-1"(R)-yl)-1'-methyl-trans-vinyl]-23α25β-dimethoxy-13α,19,21α,27β-tetramethyl11,28-dioxa-4-azatricyclo [22.3.1.0 4 ,9 ]octacos-18-trans-ene-2,3,10,16-tetraone
[32 Compound No. 1; "17-epi-FK506"
[Formula I: R 1 =OH; R 2 =allyl; single bond in 14,15-position
[process variant (a), isolation ]
6200 1 of fermentation medium are stirred for 6 hours at room temperature with 6000 1 of ethyl acetate and thereafter the two phases are separated in a separator. The ethyl acetate phase is evaporated to dryness under reduced pressure. The extract is then defatted by separation with thrice 70 1 of methanol/water 9:1 and thrice 70 1 of hexane.The methanol/water phase is then evaporated to dryness under reduced pressure and the residue is chromatographed on a column containing 25 kg Sephadex LH20 in methanol and then on a column containing 20 kg silicagel Merck (0.04 to 0.063 mm) using tert-butylmethylether as an eluent. After 50 1 of elution, fractions of 6.2 1 are collected. Fractions 11 to 13 contain mainly FK506. Fractions 14 to 16 are collected and brought to crystallization by dissolution in 150 ml of ether and addition of 100 ml of hexane. The product is recrystallized from acetonitrile. The titIe compound (Compound No. 1 ) is obtained. It has the following characteristics:
M.P. 180°-184° C. (dec.) (from methanol, ether or acetonitrile),
colorless crystals,
[α] D 22 =-4.0° (c=0.72 in methanol),
elementary analysis:
found C 65.6, H 8.7, N 1.8, 0 24.0%;
calc. C 65.7, H 8.7, N 1.7, 0 23.9%.
elementary formula: C 44 H 69 NO 12 (804.0),
mass spectrum FAB 804.5=(MH + ),
786.5 (MH 30 -8),
768.5 (MH 30 -36),
576.3 (MH 30 -228,
100%
UV-spectrum in methanoI: λ max =end absorption (MeOH),
IR-spectrum in KBr: see FIG. 1,
1 H-NMR-spectrum in CDCL 3 , 360 MHz with tetramethylsilane as internal standard: see FIG. 2.
The structure of this compound has also been analyzed by X-ray diffraction analysis and compared with that for FK 506. The structure was refined to an R factor of 0.046 using 3200 observed reflections. The main insight gained thereby is that the conformation of the 21-membered ring is stabilised by an intramolecular hydrogen bond (010 . . . 022) and is significantly different from the ring conformation found in the published crystal structure of FK 506.
EXAMPLE 3
1β,14 α-Dihydroxy-12-[2'-(4"(R)-hydroxy-341 (R)-methoxycyclohex-1"(R)-yl)-1,-methyl-trans-vinyl]-23α,25β-dimethoxy-13α,19,21α27β-tetramethyl-17β17β-propyl-11,28-dioxa-4-azatricyclo[22.3.1.0 4 ,9 ]octacos-18-trans-ene-2,3,10,16-tetraone
[=Compound No. 2; "dihydro-17-epi-FK506"]
[Formula I: R 1 =OH; R 2 =n-propyl; single bond in 14,15-position]
[process variant c), hydrogenation]
1.6 g of the Compound No. 1 is dissolved in 80 ml of ethanol, mixed with 80 mg of 10 % palladium on charcoal and hydrogenated for 10 minutes at normal pressure and room temperature. The catalyst is then filtered off, the filtrate evaporated to dryness, and the residue chromatographed with tert-butylmethylether on 180 g silicagel. The fractions are checked by high pressure liquid chromatography and the fractions containing the hydrogenation product are collected and crystallized from diethylether/hexane. The title compound (Compound No. 2) is obtained. It has the following characteristics:
M.P 154-156° C. (dec.):
[α] D 22 : -19.1° (c=1.10 in methanol,
Elementary analysis: found: C 65., H 9.0, N 1.8, 0 24.0 %; calc. C 65.6, H 8.9, N 1.7, 0 23.8 %;
Elementary formula: C 44 H 71 NO 12 (806.0),
Mass spectrum: FAB 806.9=(MH + ), 788.9 (MH + -18), 770.9 (MH + -36), 578.6 (MH + -228), 100 %.
UV-spectrum in methanol: λ max =end absorption (MeOH).
IR-spectrum in KBr: see FIG. 3.
1 H-NMR-spectrum in CDCl 3 , 360 MHz with tetramethylsilane as internal standard: see FIG. 4.
EXAMPLE 4
17β-Allyl-1β-hydroxy-12-[2'-(4"(R)-hydroxy-3"(R)- methoxycyclohex-1"(R)-yl)-1'-methyl-trans-vinyl]23α,25β-dimethoxy-13α, 19,21α,27β-tetramethyl-11,28-dioxa-4-azatricyclo [22.3.1.0 4 ,9 ]soctacos-14-trans,18-trans-diene-2,3,10,16-tetraone
Compound No. 3; "dehydro-17-epi-FK506"]
[Formula I: R 1 missing; R 2 =allyl; double bond in 14,15-position]
(a) Synthetically [process variant (b), dehydration] :
1 g Compound No. 1 is dissolved in 1 1 of ethyl acetate and 10 ml 1N HCl are added. Agitation is maintained for 5 days. Then the reaction mixture is neutralized with 10 ml of IN NaOH and washed with 500 ml of water. The organic phase is dried over sodium sulfate and evaporated to dryness. The residue is subjected to chromatographic separation over silicagel H using methyl tert-butylether as an eluent. The fractions are checked by HPLC. The product is recrystallized from ether. The title compound (Compound No. 3) is obtained. It has the following characteristics:
M.P. 189°-191° C. (from ether).
colourless crystals.
[α] D 22 =131.9° (c=0.84 in CHCl 3 ).
elementary formula: C 44 H 67 NO 11 (786.0).
UV-spectrum in methanol: λ max 230 log ε'=1.2115; 323 log ε'=0.2138.
retention time upon high pressure liquid chromatography (HPLC)
in gradient 1 (in 20 min from 50:50 to 10:90): 16.64 min.
in gradient 2 (in 20 min from 90:10 to 10:90): 22.48 min.
HPLC system: column: Lichrosorb RP18 Merck (250×4 mm); flow rate: 2 ml/min; detection UV 220 nm/0.1;
solvents: buffer triethylamine-phosphate pH 3.5 0.05 M 10 % acetonitrile / acetonitrile
(b) By fermentation (process variant a), isolation]
After crystallization of FK506 from fractions 11 to 13 (see Example 2) the supernatant is chromatographed over silicagel using hexane/methyl tert-butylether/methanol 5:4:1 as an eluent. The fractions are checked by HPLC and the fraction having a retention time of 17.25 min is rechromatographed over silicagel H with methyl tert-butyIether. Upon recrystallization from ether the title compound is obtained (M.P. 189°-193° C.).
The compounds of the invention possess pharmacological activity. They are, therefore, useful as pharmaceuticals.
In particular, they possess immunosuppressant and anti-inflammatory activity.
As regards immunosuppressant activity, in the mixed lymphocyte reaction [T. Meo, Immunological Methods, L. Lefkovits and B. Permis, Eds., Academic Press, N.Y. (1979) p. 227-239], they elicit suppression of mixed lymphocytes at a dosage of from about 0.15 nM to about 10 nM. They are further active at a concentration of from about 0.5 nM to about 10 nM in the test of the primary humoral immune response on sheep red blood cells in vitro (R.I. Mishell and R. W. Dutton, Science 153 [1966]1004-1006; R. I. Mishell and R. W. Dutton, J. Exp. Med. 126 [1967]423-442).
As regards anti-inflammatory activity, in the oxazolone allergy test (mouse) (described in EP 315978) the compounds elicit an activity between 20% and 70% upon topical administration at a concentration of 0.01 %.
The compounds of formula I are therefore useful as immunosuppressant and antiinflammatory agents in the prevention and treatment of conditions requiring immunosuppression and of inflammatory conditions, such as
(a) the prevention and treatment of
resistance in situations of organ or tissue transplantation, e.g. of heart, kidney, liver, bone marrow and skin,
graft-versus-host disease, such as foIIowin bone marrow grafts,
autoimmune diseases such as rheumatoid arthritis, systemic Lupus erythematosus, Hashimoto's thyroidis, multiple sclerosis, Myasthenia gravis, diabetes type I and uveitis,
cutaneous manifestations of immunologically-mediated illnesses, such as Alopecia areata, and
(b) treatment of inflammatory and hyperproliferative skin diseases, such as psoriasis, atopical dermatitis, contact dermatitis and further eczematous dermatitises, seborrhoeic dermatitis, Lichen planus, Pemphigus, bullous Pemphigoid, Epidermolysis bullosa, urticaria, angioedemas, vasculitides, erythemas, cutaneous eosinophilias, Lupus erythematosus and acne.
The compounds may be administered systemically or topically.
For these indications the appropriate dosage will, of course, vary depending upon, for example, the host, the mode of administration and the nature and severity of the condition being treated. However, in general, satisfactory results are indicated to be obtained systemically at daily dosages of from about 0.15 mg/kg to about 1.5 mg/kg animal body weight. For the larger mammal an indicated daily dosage is in the range from about 0.01 mg to about 100 mg of a compound of formula I, conveniently administered, for example, in divided doses up to four times a day.
For topical use satisfactory results are obtained with local administration of a 1-3 % concentration of active substance several times daily, e.g. 2 to 5 times daily. Examples of indicated galenical forms are lotions, gels and creams.
The compound of the invention may be administered by any conventional route, in particular enterally, e.g. orally, e.g. in the form of tabIets or capsules, or topically, e.g. in the form of lotions, gels or creams.
Pharmaceutical compositions comprising a compound of formula I as defined above in association with at least one pharmaceutical acceptable carrier or diluent may be manufactured in conventional manner by mixing with a pharmaceutically acceptable carrier or diluent. Unit dosage forms contain, for example, from about 0.0025 mg to about 50 mg of a compound of formula I.
Topical administration is e.g. to the skin. A further form of topical administration is to the eye, for the treatment of immune-mediated conditions of the eye, such as: auto-immune diseases, e.g. uveitis, keratoplasty and chronic keratitis; allergic conditions, e.g. vernal conjunctivitis; inflammatory conditions and corneal transplants, by the topical administration to the eye surface of a compound of formula I as defined above in a pharmaceutically acceptable ophthalmic vehicle.
The ophthalmic vehicle is such that the compound of formula I is maintained in contact with the ocular surface for a sufficient time period to allow the compound to penetrate the corneal and internal regions of the eye, e.g. the anterior chamber, posterior chamber, vitreous body, aqueous humor, vitreous humor, cornea, iris/ciliary, lens, choroid/retina and sclera.
The pharmaceutically acceptable ophthalmic vehicle may be e.g. an ointment, vegetable oil, or an encapsulating material.
Compound No. 1 is preferred for the above systemic and topical indications.
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The compounds of formula I ##STR1## wherein either
R 1 is hydroxy,
R 2 is allyl or n-propyl and
there is a single bond between the carbon atoms numbered 14 and 15
or
R 1 is missing,
R 2 is allyl and
there is a double bond between the carbon atoms numbered 14 and 15,
have interesting immunosuppressant and anti-inflammatory properties.
They are obtained by fermentation or synthesis, e.g. by hydrogenation or dehydration.
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BACKGROUND OF THE INVENTION
The present invention relates generally to cotton harvesters and more specifically to a low profile row unit for a cotton harvester.
Cotton harvesters, particularly cotton strippers of the type shown, for example, in U.S. Pat. Nos. 3,714,767, 3,716,976, 3,734,563 and 4,125,988, include row units that define a harvesting compartment. Cotton plants enter a forwardly opening plant passage in the row unit as the harvester moves forwardly through the field, and counter-rotating brush rolls strip the cotton from the plants. Row unit augers move the stripped cotton rearwardly from the harvesting compartment to a cross auger on the harvester. Heretofore, it has been necessary to provide the row units with a relatively high front wall structure such as shown at 31 in the aforementioned U.S. Pat. No. 4,125,988. The front wall structure had to be approximately as high as the tallest cotton plants so that the mouth of the plant passage could receive the plants into the harvesting compartment. The front wall structure together with a closed overhead panel structure was part of a structural arch affording stability to the entire row unit and maintaining the desired spacing between the brush rows on either side of the plant passage. The high front and closed panel structure has provided necessary strength to the stripping units and together with the use of chains or vertical rows of brushes to close the mouth of the passage, as described in the aforementioned U.S. Pat. No. 4,125,988, have provided a harvesting compartment which satisfactorily confines detached and vigorously agitated cotton until it is removed by the row unit augers.
However, several problems exist with the above-described cotton stripper row units. The high arch construction necessary for support and for preventing cotton from being thrown out of the unit significantly reduces visibility and prevents the operator from seeing the portions of the rows of plants directly ahead of the row units. With his vision in front of the row unit impeded, the operator often has difficulty maintaining the plant passage aligned with the row, particularly when there is, in addition, a heavy amount of dust and debris boiling from the row unit as a result of the vigorous action of the stripper rolls. If the row units move slightly off of the rows, the cotton plants will be pulled under the units rather than being stripped thereby, and productivity will be reduced. Often the field will have to be stripped a second time.
A further problem is that the row units which utilize the high arch construction are relatively hevay and are bulky to handle. As the row handling capacity of harvesters increases, the weight of additional row units can adversely shift the center of gravity of the harvester.
Another problem with the above-described structure is that the harvesting compartment is relatively inaccessible, and removing blockages, rocks or debris, or replacing or repairing brush rolls and unit augers is difficult and time consuming. Although top panels can be removed, the height of the unit makes access, particularly to the lower front of the unit, very difficult. In many units, there are structural members directly over the brush rolls and augers that limit access into the lower portion of the harvesting compartment. It is not uncommon for an operator, after removing the panels and clearing out an obstruction, to find that the primary cause of the problem was overlooked because of limited visibility into the unit. Locating and cleaning obstructions or detecting areas in need of repair within the compartment can therefore be very time consuming as well as frustrating for the operator.
Still another problem with previously available row units is that they typically utilize a head sheet at the rear of the unit auger housing which prevents cotton plants from moving rearwardly beyond the end of the brush rolls. The head sheet often traps stalks and debris and is a primary source of blockage in a row unit. The brush rolls tend to wear more quickly in the area of the sheet than elsewhere along their length. In addition, the sheet adds to the weight of the row unit.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an improved row unit for a cotton harvester.
It is another object of the invention to provide a cotton harvester row unit with a low profile for increased visibility and a more compact appearance as compared with previously available row units. It is a further object to provide such a row unit which is lighter in weight and much easier to handle than previously available row units.
It is still another object of the invention to provide a cotton harvester row unit with a removable top panel structure for convenient access to the cotton harvesting and conveying mechanisms in the harvesting compartment. It is a further object to provide such a row unit which permits problem areas to be located faster and easier than with previously available row units.
It is yet another object of the invention to provide a row unit which has reduced forward height compared to previously available row units but which permits the cotton plants to be directed into the harvesting compartment without loss of cotton even when the plants are taller than the top of the forward portion of the row unit. It is a further object to provide such a row unit with an opening in the top panel structure which is closed by horizontal rows of bristles extending from front to rear which permit the cotton plants to be directed into the harvesting compartment but prevent the removed cotton from being thrown upwardly through the opening.
It is another object of the invention to provide a cotton harvester row unit with a lower shell structure which maintains row unit stability and proper brush roll spacing on opposite sides of the plant passage and eliminates the need for an upper structural arch or similar structure.
It is a further object of the invention to provide a cotton harvester row unit which has less parts and is lighter than conventional row units. It is yet another object to provide such a row unit which is easier and less expensive to construct than most other types of cotton harvester row units.
It is another object of the invention to provide an improved cotton harvester row unit of the brush roll type which reduces blockages near the rear of the brush rolls. It is a further object to provide such a row unit wherein the rear portions of the brush rolls wear more slowly than with previously available row units, to thereby permit the brushes and flaps to be reversed for extended life and wherein the cotton from the unit augers is power discharged into the cross auger.
In accordance with the above objects, a row unit is provided having a rear support structure from which is supported a pair of transversely spaced downwardly and forwardly directed side structures between which is defined a plant passage. Reinforcing members are provided to afford both vertical and lateral stability to the side structures to thereby eliminate need for an upper supporting arch or closed upper structure. A pair of removable upper panel structures are each releasably secured above a corresponding side structure. The panel structures include forward gathering structure and upper horizontal panel structure which, when attached to the side structures define therebetween an upright opening at the mouth of the plant passage and a fore-and-aft upper opening extending rearwardly from the mouth directly above the plant passage. The upright opening is closed by horizontal bristles mounted in columns on the gathering structure. The upper opening is closed by horizontal bristles attached to the upper panel structure in rows extending from the front to the rear along the opening. A low profile row unit is provided which is light in weight and slopes downwardly in the forward direction to provide increased visibility directly ahead of the unit. The upper panel structures are quickly and easily removed to provide convenient access to the brush rolls and row unit augers. The upper opening closed by the bristles permits even the tallest cotton plants to enter the harvesting compartment while preventing removed and agitated cotton from being thrown from the compartment. Single wall construction behind the lower opening to the cross auger eliminates need for a head sheet and reduces the number of blockages at the rear of the unit. The brush rolls and cross auger extend rearwardly over the opening to keep the area free of stick and trash build-up and reduce brush and flap wear at the rear end of the brush roll. Extending the unit augers rearwardly over the opening provides an advantageous power discharge of cotton from the units into the cross auger.
These and other objects, features and advantages will become apparent from the detailed description which follows in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an entire cotton harvester.
FIG. 2 is an enlarged side view of the rear portion of the row unit of the present invention supported on the cross auger frame of the cotton harvester.
FIG. 3 is a top view of the shell assembly for the row unit.
FIG. 4 is a side view of the shell assembly shown in FIG. 3.
FIG. 5 is a rear view of the shell assembly shown in FIGS. 3 and 4.
FIG. 6 is a perspective view of the row unit with the overhead panel structure removed to expose the cotton harvesting and conveying mechanisms in the harvesting compartment.
FIG. 7 is a perspective view of the right-hand panel of the structure shown in FIG. 6 with the parts disassembled to show panel construction details.
FIG. 8 is an enlarged view of the releasable latch which retains each overhead panel in position.
FIG. 9 is a top view of the rear portion of the row unit showing the discharge area which opens downwardly into the cross auger.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A cotton harvester utilizing the row unit of the present invention may be generally of the type shown in the aforementioned U.S. patents, incorporated herein by reference. The harvester (FIG. 1) includes a tractor or frame 10 having front traction wheels 12 and a rear steerable wheel 14. A cross auger frame 16 is supported on the forward end of the frame 10 and supports a plurality of transversely spaced row units 18 above the ground. An operator's station or cab 20 is carried on the forward portion of the frame 10, and a cotton receptacle 22 is supported behind the cab. A power source or engine 24 provides drive through conventional drive assemblies to the traction wheels 12 and row units 18, and to a conventional cotton conveying system 25 for moving the cotton from the row units to the receptacle 22. Although the row units 18 of the present invention are shown mounted on a self-propelled cotton harvester of the type shown in the aforementioned U.S. patents, it is to be understood that they be mounted on other types, such as a tractor mounted harvester of the type shown in co-pending application Ser. No. 266,876 , entitled "TRACTOR MOUNTED COTTON HARVESTER" filed concurrently herewith.
The row units 18 may be mounted in any suitable conventional manner on the cross auger frame 16. However, in the preferred embodiment, as best understood by reference to FIGS. 2 and 6, each row unit 18 is connected to and transversely adjustable on the cross auger frame 16 by a unit support bracket 26. The bracket 26 includes upright side plates 28 spaced by a lower connecting plate 30. Holes 32 are provided in the connecting plate 30.
A downwardly opening channel-shaped member 34 (FIG. 2) is welded at rear lip 36 to a square tubular transverse beam 38 which forms part of the cross auger frame 16. Transversely spaced support members 40 are connected between the beam 38 and front lip 42 of the member 34. A plurality of transversely spaced sets of holes 44 are located in the top of the member 34. The bracket 26 is supported on the member 34 with the connecting plate 30 resting on the member. Bolts 46 are inserted through the holes 32 in the bracket 26 and through a set of holes 44. The set of holes 44 is selected in accordance with the desired transverse location of the row unit 18 with respect to the cross auger frame 16. The row unit 18 is pivotally connected to the bracket 26 between the side plates 28 by a pivot assembly including pivot pins 48 or other suitable pivot means and spacers 50 located at the lower rear portion of the row unit. The row unit 18 is rockable up and down about the axis of the pins 48.
A hydraulic cylinder 54 is pinned at its rod end to a lower bracket 56 which is slidably mounted on a square tubular beam 57 which forms the lower front portion of the cross auger frame 16. The anchor end of the cylinder 54 is pinned to a bracket 58 (FIG. 4) on row unit lower shell or frame assembly 60 forwardly adjacent the cross auger frame 16. Extending and retracting the cylinder 54 pivots the row unit 18 about the axis of the pins 48 to raise and lower the forward portion of the unit with respect to the cross auger frame 16.
Referring now to FIGS. 3-6, the row unit shell or frame assembly 60 includes a rear wall or mounting structure indicated generally at 62. The unit frame also includes substantially parallel and spaced apart left- and right-hand side structures or harvesting mechanism supports 64 and 66, respectively, extending forwardly from the rear mounting structure 62. A fore-and-aft extending plant passage 68 is defined between the supports 64 and 66 which are substantially cantilevered from the rear mounting structure 62 and terminate at the mouth or fore end of the passage in free non-connected ends. One of the supports 64 and 66, however, is braced by the hydraulic cylinder 54 slightly forwardly of the rear mounting structure.
The rear mounting structure 62 includes transversely spaced sidewalls 70 connected by an upright rear wall or panel 72. An angle member 74 is welded to the upper extremity of the rear wall 72 and extends transversely between the sidewalls 70. The walls are flanged at locations 76 to provide strength and rigidity to the rear mounting structure 62.
The side structures 64 and 66 include outer upright sidewalls 80 which extend rearwardly to the rear wall or panel 72. Each sidewall 80 is positioned against the inside of the corresponding rear mounting structure sidewall 70 and is connected thereto by welding or other suitable attaching means. The top of the sidewall 80 terminates in an inwardly directed flange 82. Each sidewall 80 is curved inwardly at location 84 to form an upwardly opening auger trough 86 of a substantially semicircular cross-section which terminates at an inner edge 88. Extending inwardly from the edge 88 and welded thereto is a channel-shaped brush roll support 90 which is inclined upwardly toward the rear at an angle of about five degrees with respect to the axis of the auger trough 86.
The rear of the auger trough 86 and the brush roll support 90 are welded or otherwise connected to a transverse structural member indicated generally at 92 which includes a tubular beam 94 and an angle 96 welded to the bottom of the beam 94. The tubular beam 94 extends transversely between outer upright sidewalls 97 (FIG. 5) of the brush roll support 90. The ends of the beam 94, as well as the edges 88 of the troughs 86, are connected such as by welding to the outer sidewalls 97. The sidewalls 97, along with inner upright sidewalls 98, provide a generally downwardly opening channel-shaped configuration to the brush roll supports 90 for strengthening the side structures 64 and 66. Each brush roll support 90 is angled upwardly and outwardly from a fore-and-aft extending bend location 100, and the outer sidewalls 97 cooperate with the auger troughs 86 to maintain removed cotton in the desired path. Rear edge 104 of the generally horizontally disposed portion of the roll support 90 inside the bend location 100 is welded to the top of the tubular beam 94. The cylinder bracket 58 is welded to the front face of the beam 94 and to the bottom of the horizontally disposed portion of the roll support 90 adjacent the bend location 100.
A front plate or forward wall structure 110 is welded to the forward end of each of the harvesting mechanism supports 64 and 66. The wall structure 110 includes an upright front wall 112 and a lower downwardly and rearwardly projecting portion 114 having a rear face welded to the front edge of the auger trough 86. The rear face of the portion 114 is also welded to the front edge of the brush roll support 90. Upper edge 118 of the wall structure 110 is generally horizontal and extends inwardly from near the upper edge of the front of the adjacent sidewall 80. Plant gatherer attaching brackets 120 and a height-sensing pivot bracket 122 are welded to the front wall 112. Panel locating and support pegs 124 are welded or bolted to the front wall structure and extend rearwardly therefrom.
A plant gatherer 126 (FIG. 6) is pivotally connected near its lower rear portion by pins 129 to the attaching brackets 120 so that the nose of the gatherer is free to rock up and down to follow the ground contour. A shoe 129 (FIG. 1) on the bottom of the gatherer 126 is connected to a shoe rod 130. The upper end of the rod 130 is connected to the front of a height-sensing pivot 132 rockably mounted on the pivot bracket 122. The rear of the pivot 132 is connected to a height-sensing rod 134 which extends rearwardly through the harvesting compartment adjacent the sidewall 80 to a control valve (not shown). The control valve is connected between a source of pressurized hydraulic fluid on the harvester and the hydraulic cylinder 54 to automatically control the height of row unit 18 in response to the movement of the shoe 129. Automatic height-sensing controls for cotton harvester row units are well known and commercially available, and therefore will not be described in detail here.
Each of the harvesting mechanism supports or side structures 64 and 66 carries a conventional brush roll unit 140 and unit auger 142. Each brush roll unit 140 is journalled in a conventional manner for rotation about an axis generally parallel to the brush roll support 90 by a rear bearing 143 mounted on the rear wall 72 and by a transversely adjustable forward bearing (not shown) carried by the corresponding support. Each brush roll unit 140 includes a flexible stripper roll 144 having fore-and-aft extending retainers 145 supporting alternate rubber flaps 147 and nylon brushes 149. The distance between the rolls 144 is adjusted for cotton plant stalk size and field conditions by moving the forward bearings, for example, by turning eyebolts connected at one end to the forward bearings and at the other end to the unit frame. One of the brush roll units 140 is connected by a universal joint 150 (FIG. 2) to a unit drive shaft 152 connected to a conventional drive arrangement on the cross auger frame 16. A drive gear 154 rotates with the first brush roll 140 and meshes with an identical gear (not shown) operably connected to the second brush roll 140 to drive the rolls in counter-rotating fashion. The brushes 149 and flaps 147 may be reversed in each brush roll unit 140 for extended life.
Each row unit auger 142 is journalled for rotation about the axis of the corresponding trough 86 by a forward bearing (not shown) carried by the forward wall structure 110, and by a rear bearing 162 carried by the rear wall 72. A drive gear 164 is mounted for rotation with the auger 142 about its axis, and is drivingly connected to the roll unit drive gear 154 by an idler gear 166. A top sheet 260 (FIG. 6) is bolted to flanges 262 to cover the portion of the structure 62 above the drive gears.
As best seen in FIGS. 2 and 9, a lower opening indicated generally at 168 is defined in a discharge area 169 which extends transversely between the sidewalls 70 and which is bounded at the rear by the wall 72 and at the front by the rear end of auger troughs 86 and the structural member 92. The brushes 149 and flaps 147 of the brush rolls 144 extend into the discharge area 169 above the opening 168. The unit augers 142 terminate in rear paddle structure 171, also located in the discharge area 159 above the opening 168. The paddle structure 171 actively directs the cotton exiting the troughs 86 downwardly through the opening 168. The retainers 145 releasably secure the brushes 149 and flaps 147 in position and permit them to be reversed for extended life.
The counter-rotating brush rolls 144 sweep the cotton from the cotton plants which are directed into the plant passage 68 as the harvester moves forwardly through the field. The cotton removed from the plants is directed into the unit auger troughs 86 where it is carried rearwardly by the augers 142 and is directed by the paddle structure 171 into the cross auger frame 16 through the opening 158. A transverse auger or conveyor 170 moves the cotton inwardly to a central location from which the air duct system 25 conveys the cotton to the receptacle 22.
The above-described construction of the shell assembly 60 defines a lower harvesting compartment, indicated generally at 180, between the sidewalls 80 and forwardly of the rear wall 72. The compartment 180 opens upwardly and forwardly and is virtually unencumbered with any support structure or the like which would impede access to the harvesting mechanisms including the brush roll units 140 and the unit augers 142.
Removable overhead panel structure 182 (FIG. 6) is provided to selectively close the area above the lower harvesting compartment 180 and prevent the cotton removed and agitated by the brush rolls 144 from being thrown upwardly or forwardly out of the unit 18. The panel structure 182 includes individual left- and right-hand panels 184 and 186 formed from sheet metal and having outer sidewalls 188 which, when the structure is attached, form upward extensions of the sidewalls 80 for the supports 64 and 66, respectively. Each outer sidewall 188 terminates at the lower edge in a fore-and-aft extending flange 190 (FIG. 7) which angles downwardly from a rear upright edge 192 to a forward upright edge 194. A substantially horizontal and planar top surface 196 extends inwardly from the outer sidewall 188 and terminates in a flange or edge portion 198 which is angled downwardly several degrees with respect to the surface 196. An upright front panel 200 includes a rearwardly directed side flange 202 which is bolted to the forward edge 194 of the outer sidewall 188. The front panel 200 extends upwardly from the flange 190 to the top surface 196 and terminates at an inner flange 204. An upper plant gatherer 206 is bolted at rear outside edge 208 to the flange 202 and forward edge 194. The bottom of the upper plant gatherer 206 fits within the upper opening of the lower gatherer 126 (FIG. 6) to permit the latter to pivot about the pins 128. The opposite rear edge 210 of the gatherer 206 is bolted to the inner flange 204 along with an upright column of horizontally disposed bristles 212 with ends which extend inwardly and slightly rearwardly. A fore-and-aft extending row of bristles 214 with ends that extend inwardly and slightly downwardly is clamped to the flange 198 by a retaining bracket 216 bolted to the top surface 196.
The front panel 200 includes a downwardly and rearwardly extending flange 218 having apertures 220 positioned for receiving the panel locating and supporting pegs 124 when the panel structure 182 is attached to the shell assembly 60. The pegs 124 support the front of each of the panels 184 and 186 with the panel sidewall flange 190 abutted against the downwardly and forwardly sloping flange 82 of the shell assembly sidewall 80.
Locating pegs 222 are connected to the top of the member 74. Apertures 224 in the rear of the top surface 196 are positioned to receive the pegs 222 as the panel structure is placed over the shell assembly 60.
A releasable latch assembly 230 (FIGS. 2, 7 and 8) is connected to the top surface 196 for locking each of the panels 184 and 186 over the shell assembly 60 after it is properly positioned by the locating pegs 124 and 222. The latch assembly 230 includes an apertured reinforcing plate 232 and a slotted latch member 234 carried under the rear of the top surface 196 by a securing bolt 236 and spacer 237. A carriage bolt 238 extends upwardly through slots 240 and 242 in the plate 232 and the top surface 196, respectively. A wing nut 244 threaded over the end of the bolt 238 is tightened to draw the latch member 234 upwardly against the bottom of a flange 245 which extends forwardly above the angle member 74 (FIGS. 2 and 8). Loosening the wing nut 244 permits the latch member 234 to be slid forwardly beyond the flange 245 so that the panel can be lifted from the locating pins 222. Once the rear of the panel is lifted, the entire panel can be moved rearwardly until the apertured front flange 218 (FIG. 7) is clear of the locating pegs 124. Thereafter, the panel can be lifted off the lower shell assembly to provide convenient access to the unit augers 142 and brush rolls 144.
When the overhead panel structure 182 (FIG. 6) is in position over the lower shell assembly 60, the inner edges of the panels 184 and 186 define an upper fore-and-aft extending opening indicated generally at 250 which is directly above the plant passage 68. The inside edges of the plant gatherers 126 and 206 define an upright forward opening 252 at the mouth of the plant passage 68. The upright columns of generally horizontal bristles 212 have closely adjacent free ends to close the forward opening 252. Since each set of bristles 212 is angled slightly rearwardly, the cotton plants can pass into the harvesting compartment through the bristles relatively easily while removed cotton agitated by the brush rolls will bounce off the bristles or attach themselves to the ends of the bristles. Any cotton attached to the ends of the bristles 212 will be removed by the combing action of the plants passing between the sets of bristles and through the opening 252.
The upper rows of generally horizontal bristles 214 have closely adjacent ends directed slightly downwardly to effectively close the upper opening 250 to removed and agitated cotton within the harvesting compartment while permitting cotton plants to be pulled downwardly between the two rows of bristles into the compartment. The upper opening 250 and the rows of bristles 214 permit the top 196 of the overhead panel structure 182 to slope downwardly so that the front of the row unit 18 is substantially lower than the rear when the unit is in the field-working position (FIG. 1). As the row unit 18 moves forwardly, any cotton plants which extend above the upright opening 252 will be pulled through the upper opening 250, which increases in distance above the ground in the rearward direction, and through the rows of bristles 214 without loss of or injury to the cotton. The front bristles of the rows of bristles 214 contact the top bristles of the column of bristles 212 to provide a continuous barrier between the panels 184 and 186. When the overhead panel structure 182 is attached, a substantially closed harvesting compartment is defined which extends in the fore-and-aft direction between the rear wall 72 and the front panel 200 of the plant gatherers 206, and laterally generally between the plane of the sidewalls 80. The top of the panel structure angles downwardly in the forward direction for better visibility.
The lower shell assembly structure 60 maintains the preselected spacing between the brush roll units 140 without an upper arch or other structural connection between the forward portions of the row unit side structures 64 and 66. The panels 184 and 186, which are preferably formed from sheet metal, are relatively light in weight and can be removed or attached independently of each other so that they are less cumbersome for the operator to handle.
When attached, the panels 184 and 186 provide some torsional strength to the side structures 64 and 66, respectively. A limited amount of vertical flexibility of the side structures 64 and 66 results from the elimination of a forward structural connection. Such flexibility lessens shock loading of the unit when obstacles or rough ground surfaces are encountered during harvesting. The flexibility is, however, limited by the structure of the lower shell assembly 60 to prevent a change in brush roll alignment that would appreciably decrease the harvesting efficiency of the rolls 144.
Having described the preferred embodiment, it will be apparent that modifications can be made without departing from the scope of the invention as defined in the accompanying claims.
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For a cotton harvester, a low profile row unit which is light in weight and which has a removable top panel structure for easy access to the brush rolls and augers. Rows of horizontal bristles mounted on the panel structure close the top of the row unit to prevent detached cotton from being thrown out of the harvesting compartment. A reinforced lower shell assembly maintains sufficient transverse and vertical stability in the row unit structure and together with the top panel structure eliminate need for an upper supporting arch.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 07/634,794 filed Dec. 27, 1990, now abandoned.
FIELD OF THE INVENTION
The present invention relates to polyamide textile substrates treated with stain-resistant compositions comprising water-soluble or water-dispersible maleic anhydride/vinyl ether or maleic anhydride/allyl ether polymers, and processes for their synthesis. The substrates of this invention possess stain-resistance but do not suffer from yellowing to the extent that some previously known materials do.
BACKGROUND OF THE INVENTION
Polyamide substrates, such as nylon carpeting, upholstery fabric and the like, are subject to staining by a variety of agents, e.g., foods and beverages. An especially troublesome staining agent is FD&C Red Dye No. 40, commonly found in soft drink preparations. Different types of treatments have been proposed to deal with staining problems. One approach is to apply a highly fluorinated polymer to the substrate. Another is to use a composition containing a sulfonated phenol-formaldehyde condensation product.
For example, Liss et al., in U.S. Pat. No. 4,963,409, disclose stain-resistant synthetic polyamide textile substrates having deposited on them sulfonated phenol-formaldehyde polymeric condensation products. However, sulfonated phenol-formaldehyde condensation products are themselves subject to discoloration; commonly they turn yellow. Yellowing problems are described by W. H. Hemmpel in a Mar. 19, 1982 article in America's Textiles, entitled Reversible Yellowing Not Finisher's Fault. Hemmpel attributes yellowing to exposure of a phenol-based finish to nitrogen oxides and/or ultraviolet radiation. To deal with the yellowing problem, the condensation products were modified by Liss et al. by acylation or etherification of some of the phenolic hydroxyls. In a preferred embodiment disclosed by Liss et al., the modified condensation products were dissolved in a hydroxy-containing solvent, such as ethylene glycol prior to there being applied to the textile substrate.
Allen et al., in U.S. Pat. No. 3,835,071, disclose rug shampoo compositions which upon drying leave very brittle, non-tacky residues which are easily removed when dry. The compositions comprise water-soluble metal, ammonium or amine salt of a styrene-maleic anhydride copolymer, or its half ester, and a detergent. Water-soluble metal salts of Group II and the alkali metals (particularly magnesium and sodium) are preferred and ammonium salts are most preferred by Allen et al.
On the other hand, Fitzgerald et al., in U.S. patent application Ser. No. 07/502,819, filed Apr. 2, 1990, now U.S. Pat. No. 5,001,004 disclose the usefulness of aqueous solutions of hydrolyzed vinylaromatic/maleic anhydride copolymers in the treatment of textiles to render them resistant to staining. The preferred copolymer of Fitzgerald et al. is a hydrolyzed styrene/maleic anhydride copolymer. Fitzgerald et al. disclose that the monoalkyl ester of their maleic anhydride/vinyl aromatic polymer was ineffective as a stain-resist. Moreover, hydrolyzed maleic anhydride/alpha-olefin polymer stain-resists (a hydrolyzed maleic anhydride/isobutylene polymer being preferred) are disclosed in my copending U.S. patent application Ser. No. 07/809,843 filed Dec. 18, 1991 which is a continuation-in-part of application Ser. No. 07/626,885 filed Dec. 13, 1990.
Polymers formed from maleic anhydride vinyl- or allyl-ethers are known. See for example: Ind. & Eng. Chem. 41, 1509 (1949) Seymour et.al. "Copolymers of vinyl compounds and maleic anhydride"; J. Phys. Chem. 74, 2842 (1970) Dubin et.al. "Hydrophobic bonding in alternating copolymers of maleic acid and alkyl vinyl ethers"; Europ. Polym. J., 6, 247-58 (1970), Wojtczak et.al., "Etude de la morphologie de copolymers . . . "; Polym. Prepr., ACS, Div. Polym. Chem., 12(1), 445-8 (1971), Wasley et.al., "Copolymers of fluoroalkyl ethers and maleic anhydride"; Charged React. Polym., 2 (Polyelectrolytes their Appl.), 3-13(1975), Dubin et.al., "Hypercoiling in hydrophobic polyacids"; J. Natl. Sci. Counc. Sri Lanka, 7(1), 45-55 (1979), Fujimori et.al., "The alternating copolymerization of n-butyl vinyl ether with maleic anhydride"; Brit. Pat. 1,117,515 "Maleic anhydride-alkyl vinyl ether copolymers"; DE Pat. 2208020 " Fluoroalkyl ether/maleic anhydride copolymers for finishing textiles." (The anhydride copolymer is claimed as soil release agent for wool, cotton and/or polyester textiles from solution in organic solvents); U.S. Pat. No. 4,029,867 "Terpolymers of fluoroalkyl ethers and maleic anhydride".
BRIEF SUMMARY OF THE INVENTION
The present invention provides polyamide fibrous substrates treated with one or more water-soluble or water-dispersible maleic anhydride/vinyl ether polymers and/or allyl ether polymers so as to impart stain-resistance to the substrates, and methods for preparing the same. Commonly, prior art materials known to be useful as stain-blockers were sulfonated phenol-formaldehyde condensates (excepting those of Fitzgerald et al. and those disclosed in my copending application, both cited above). Finding a non-sulfonated material, such as the water-soluble or water-dispersible maleic anhydride/allyl ether or maleic anhydride/vinyl ether polymers of this invention, to be useful for this purpose was unexpected.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the use of water-soluble or water-dispersible vinyl ether/maleic anhydride polymers or allyl ether/maleic anhydride polymers, or mixtures of the same, as stain-resists for fibrous polyamides. A variety of allyl ethers and vinyl ethers can be used for the purposes of this invention. Particularly useful ethers include those which can be represented by the formula:
CH.sub.2 ═CH--(CH.sub.2).sub.k --O--(CH.sub.2).sub.m --(A).sub.n --R
wherein
R is hydrogen or
an alkyl radical containing 4 to 8 carbon atoms, or
2,3-epoxypropyl, or
an alicyclic hydrocarbon radical containing 6 to 12 carbon atoms or
an aromatic hydrocarbon radical containing 6 to 12 carbon atoms or
a perfluoroalkyl radical containing 3 to 16 carbon atoms, preferably 6 to 12, and which may contain a terminal --CF 2 H group;
A is a divalent radical --SO2R 1 -- or --CONR 1 -- in which R 1 is hydrogen or an alkyl radical containing 1 to 6 carbon atoms;
k is 0 or 1;
m is 0 or 2; and
n is 0 or 1;
provided that when R is aromatic, K is 1.
Particular examples include, n-butyl vinyl ether, isobutyl vinyl ether, iso-octyl vinyl ether, 2-perfluorohexylethyl vinyl ether, allyl n-butyl ether, allyl phenyl ether, allyl glycidyl ether, and the like.
The polymers suitable for the purposes of this invention contain between about 0.7 and 1.3 polymer units derived from one or more allyl or vinyl ether monomers per polymer unit derived from maleic anhydride. Polymers containing about one polymer unit derived from one or more such ether monomers per polymer unit derived from maleic anhydride are most effective in imparting stain-resistance to polyamide textile substrates.
The maleic anhydride polymers useful in the present invention can be prepared according to methods well-known in the art. The maleic anhydride polymers thus obtained can be hydrolyzed to the free acid or their salts by reaction with water or alkali. Generally, the hydrolyzed maleic anhydride polymer, should be sufficiently water-soluble that uniform application to a fibrous polyamide surface can be achieved at an appropriate acidity. However, applications using water dispersions of the polymer mixed with a suitable surfactant may be used to impart stain-resistance.
It is known that the polymerization of vinyl or allyl ethers with maleic anhydride produces alternating copolymers. To make terpolymers for the purposes of this invention, a part of the vinyl or allyl ethers can be replaced by one or more other monomers; i.e. up to 90 wt % of alpha-olefins or an ethylenically unsaturated aromatic compound, such as styrene or one or more styrene derivatives, e.g. dienes containing 4 to 18 carbon atoms, such as butadiene, chloroprene, isoprene, and 2-methyl-1,5-hexadiene; 1-alkenes containing 3 to 18 carbon atoms, preferably C 4-18 , such as isobutylene, 1-butene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-octadecene, and the like, with isobutylene being most preferred, or styrene, alpha-methyl styrene, 4-methyl styrene, stilbene, 4-acetoxystilbene, or the like; up to 50 wt % with alkyl(C 1-4 ) methacrylates, alkyl(C 1-4 ) acrylates, vinyl acetate, vinyl chloride, vinylidine chloride, vinyl sulfides, acrylonitrile, acrylamide, N-vinyl pyrrolidone, as well as mixtures of the same. A part (1-75%) of the maleic anhydride can be replaced by maleimide, N-alkyl(C 1-4 ) maleimides, N-phenylmaleimide, fumaric acid, itaconic acid, citraconic acid, aconitic acid, crotonic acid, cinnamic acid, alkyl(C 1-18 ) esters of the foregoing acids, cycloalkyl(C 3-8 ) esters of the foregoing acids, sulfated castor oil, or the like.
At least 95 wt % of the maleic anhydride co- or terpolymers have a number average molecular weight of in the range between about 700 and 100,000, preferrably between about 1000 and 50,000.
The hydrolyzed maleic anhydride polymers, of this invention are applied to polyamide textile substrates in the form of aqueous solutions or aqueous dispersions. They can be effectively applied to polyamide fibrous substrates by a wide variety of methods known to those skilled in the art, such as:
padding,
spraying,
foaming in conjunction with foaming agents,
batch exhaust in beck dyeing equipment, or
continuous exhaust during a continuous
dyeing operation.
They can be applied by such methods to dyed or undyed polyamide textile substrates. In addition, they can be applied to such substrates in the absence or presence of a polyfluoroorganic oil-, water-, and/or soil-repellent materials. In the alternative, such a polyfluoroorganic material can be applied to the textile substrate before or after application of the polymers of this invention thereto.
The quantities of the polymers of this invention which are applied to the textile substrate are amounts effective in imparting stain-resistance to the substrate. Those amounts can be varied widely; in general, one can use between 1 and 5% by weight of them based on the weight of the textile substrate, usually 2.5% by weight or less. The aqueous solutions or dispersions of the polymers can be applied to polyamide substrate by methods known in the art. It is necessary that the aqueous solutions or dispersions of the polymers of this invention have a pH of 3 or less; otherwise stain-resistance will not be imparted to the polyamide substrates. However, more effective exhaust deposition can be obtained at a pH as low as 2.0. When the latter low pH is used, the preferred level of application to the textile substrate is about 2.5% by weight, based on the weight of the textile substrate. In an embodiment, a pH between about 2 and 3 is used. More effective stainblocking is obtained if the polymers are applied to the textile substrate at either 20 ° C. followed by heat treatment at a temperature in the range between about 50° and 150° C. for about 1 to 60 minutes, or applied at temperatures in the range between about 40° and 95° C. for about 1 to 60 minutes. For example, at a pH between about 2 and 3, a temperature between about 70° and 90° C. is preferred. However, stain-blocking can be obtained when application is effected even at that of cold tap water (10°-15° C.).
The polymers of this invention can also be applied in-place to polyamide carpeting which has already been installed in a dwelling place, office or other locale. They can be applied as a simple aqueous preparation or in the form of aqueous shampoo preparation, with or without one or more polyfluoroorganic oil-, water-, and/or soil-repellent materials. They may be applied as described above.
One can blend the stain-resists of the present invention with other known stain-resists, such as phenol-formaldehyde condensation products as disclosed in U.S. Pat. Nos. 4,833,009 and 4,965,325; methacrylic acid polymers disclosed in U.S. Pat. No. 4,937,123; or hydrolized polymers of maleic anhydride and one or more ethylenically unsaturated aromatic compounds described by Fitzgerald et al., or the olefin/maleic anhydride polymers disclosed in my copending application, both cited above.
The following Examples are illustrative of the invention. Unless otherwise indicated in the Examples and Evaluation Method given below, all parts and percentages are by weight and temperatures are in degrees Celsius.
EXAMPLE 1
A solution of 9.8 g of maleic anhydride (0.1 mol) and 10 g of n-butyl vinyl ether (0.1 mol) in 90 g of cumene was heated to 70° C. under agitation and nitrogen. A solution of 0.3 g of Vazo 67 initiator [2,2'-azobis-(2-methylbutyronitrile)] in 10 g of cumene was injected into the reaction vessel within half hour via a syringe pump. During this time period the exotherm reached 77° C. The reactants were agitated for another 2 hours at 70° C. before cooling to room temperature. A white solid product (12.5 g) was obtained by precipitation from a methanol/petroleum ether solution. Melting point range 155°-192° C. Number average molecular weight by vapor pressure osmometry (VPO): 9,370. Ten grams of the solid product was hydrolyzed at 80°-90° C. in the presence of 82.5 g of deionized water, 6.7 g of 30 wt % sodium hydroxide and 2 drops of a 1 wt % solution of benzyltriethylammonium chloride resulting after 1 to 2 hours in a clear yellowish solution containing 10% active ingredients.
EXAMPLE 2
A solution of 9.8 g of maleic anhydride (0.1 mol), 10 g of n-butyl vinyl ether (0.1 mol), 0.5 g of N,N-dimethylaniline and 0.3 g of Vazo 67® initiator [2,2'-azobis-(2-methylbutyronitrile)] in 20 g of methyl isobutyl ketone was added under stirring and nitrogen within one-half hour to 80 g of methyl isobutyl ketone held at 75° C. The reactants were agitated for another 3 hours at 75° C. before being poured into methanol at room temperature. A white solid formed (14.5 g) which was separated by filtration and air dried. The product had a melting point range between 155° and 206° C. and a number average molecular weight by gas phase chromatography (GPC) of 3,280. Hydrolysis was carried out as described in EXAMPLE 1.
EXAMPLE 3
The procedure was similar to that of EXAMPLE 1 using:
9.8 g maleic anhydride (0.1 mol)
10.0 g isobutyl vinyl ether (0.1 mol)
Hydrolysis was carried out as described in EXAMPLE 1.
EXAMPLE 4
The procedure was similar to that of EXAMPLE 1 using:
9.8 g maleic anhydride (0.1 mol)
15.6 g iso-octyl vinyl ether (0.1 mol)
Product: White powder (17.9 g)
Hydrolysis was carried out as described in EXAMPLE 1.
EXAMPLE 5
A solution of 9.8 g of maleic anhydride (0.1 mol), 7.5 g of n-butyl vinyl ether (0.075 mol) and 2.6 g of styrene (0.025 mol) in 90 g of cumene was heated to 70° C. under agitation and nitrogen. A solution of 0.3 g of Vazo 67® initiator [2,2'-azobis-(2-methylbutyronitrile)] in 10 g of cumene was added within one-half hour via a syringe pump. The reactants were held for another 4 hours at 70° C. at which time the reaction mass had become milky-white. The product was then cooled to room temperature and the solids separated by filtration giving 15.5 g of a white powder. The product had a melting point range between 177° and 255° C. and a number average molecular weight by gas phase chromatography (GPC) of 1500. Hydrolysis was carried out as described in EXAMPLE 1.
EXAMPLE 6
The procedure was similar to that of EXAMPLE 5 using:
9.8 g maleic anhydride (0.1 mol)
5.0 g n-butyl vinyl ether (0.05 mol)
5.2 g styrene (0.05 mol)
Product: White powder (18.8 g); melting range 195°-260° C.; number average molecular weight (VPO): 5,780; approximate terpolymer ratio by 13 C NMR:
n-Butyl Vinyl Ether/Styrene/Maleic Anhydride 0.35/0.53/1.00
Hydrolysis was carried out as described in EXAMPLE 1.
EXAMPLE 7
The procedure was similar to that of EXAMPLE 5 using:
9.8 g maleic anhydride (0.1 mol)
2.5 g n-butyl vinyl ether (0.025 mol)
7.8 g styrene (0. 075 mol)
Product: White powder (19.8 g); melting point range 205°-275° C.; number average molecular weight (GPC): 1,600
Hydrolysis was carried out as described in EXAMPLE 1.
EXAMPLE 8
A solution of 9.8 g of maleic anhydride (0.1 mol), 5.6 g of 1-octene (0.05 mol) and 5.0 g of n-butyl vinyl ether (0.05 mol) in 30 g of propylene glycol methyl ether acetate was heated under agitation and nitrogen to 95° C. A solution of 2 g of t-butyl peroxy-2-ethylhexanoate in 6 g of propylene glycol methyl ether acetate was then injected into the reaction vessel within half hour via a syringe pump. The reactants were agitated for another 2 hours at 95° C. before being cooled to room temperature. The product was then poured into methanol which caused precipitation of a white solid which was filtered and air-dried(15.5 g). Approximate terpolymer ratio by 13 C NMR:
1-octene/n-butyl vinyl ether/maleic anhydride 0.28/0.50/1.00.
Hydrolysis was carried out as described in EXAMPLE 1.
EXAMPLE 9
The procedure was similar to that of EXAMPLE 8 using:
9.8 g maleic anhydride (0.1 mol) 3.7 g
1-octene (0.033 mol) 3.3 g n-butyl vinyl
ether (0.033 mol) 3.5 g styrene (0.033 mol)
Product: White solid (18.1 g); Number average molecular weight (NMR): 3000 Approximate terpolymer ratio by 13 C NMR: 1-octene/n-butyl vinyl ether/styrene/maleic anhydride=0.15/0.24/0.44/1.00
EXAMPLE 10
The procedure was similar to that of EXAMPLE 5 using:
9.8 g maleic anhydride (0.1 mol) 3.9 g
2-perfluorohexylethyl vinyl ether (0.01 mol)
9.4 g styrene (0.09 mol)
Product: White solid (20.3 g) Fluorine: 2.3 wt. %
EVALUATION METHOD
Nylon fiber was treated with 1.2 wt % of the stain-resists of EXAMPLEs 1-11 at a goods-to-liquor ratio of 1:32 at a pH of 2.35 for 45 minutes at 80° or 95° C. The fiber was then washed, air-dried and exposed at room temperature to a dye solution consisting of 0.2 g of FD&C Red Dye No. 40 and 3.2 g of citric acid in 1 liter of deionized water at a goods-to-liquor ratio of 1:40. After approximately 65 hours, the dye adsorbed onto the fiber was determined at a wavelength of 498-502 nm by comparing the absorbance with that of the Control. Thus a number of 90 means 90% of the dye is adsorbed, indicating little stain resistance to the dye. The lower the number, the better is the resistance to stain. The results of the evaluation are set forth in TABLE I.
TABLE I______________________________________ PERCENT DYE ADSORBEDEXAMPLE At 80° C./pH 2.35 At 95° C./pH 2.35______________________________________1 9 22 3 --3 3 34 9 245 l 36 2 27 3 28 2 29 2 210 4 3*______________________________________ *Fluorine content of treated fiber was 300 ppm.
EXAMPLE 11
A solution of 9.8 g of maleic anhydride (0.1 mol), 12.7 g of 90% allyl n-butyl ether (0.1 mol) and 1.0 g of benzoyl peroxide in 60 g of cumene was heated under agitation and nitrogen to 70° C. After 4 hours another portion of benzoyl peroxide was added and the reaction mass was held for additional 17 hours at 70° C. under agitation and nitrogen. The volatiles were then removed from the resulting clear, pale yellow liquid by evaporation at reduced pressure (70°-85° C./10-20 mm Hg) giving 21.8 g of an amber solid. Hydrolysis was carried out as described in Example 1.
EXAMPLE 12
The procedure was similar to that of Example 11 using:
7.7 g maleic anhydride (0.078 mol)
10.5 g allyl phenyl ether (0.078 mol)
1.2 g benzoyl peroxide
50.0 g cumene
Product: 18.1 g of an amber solid. Hydrolysis was carried out as described in Example 1.
The polymers of EXAMPLEs 11 and 12were evaluated by the EVALUATION METHOD at 1.2 wt. % and 2.4 wt. % to give the results set for in TABLE II.
TABLE II______________________________________ PERCENT DYE ADSORBED AT 80° C./pH 2.35 AT 95° C./pH 2.35EXAMPLE 1.2% 2.4% 1.2% 2.4%______________________________________11 27 2 75 712 21 0 71 9______________________________________
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A polyamide fibrous substrate having deposited on it an amount of a composition effective to impart stain-resistance comprising a water-soluble or water-dispersible maleic anhydride/allyl ether or vinyl ether polymer or a mixture of said polymers, and processes for preparing the substates. The maleic anhydride polymer is used either in hydrolyzed form.
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[0001] This application is a divisional application claiming priority to U.S. Non-provisional application Ser. No. 11/875,805, filed Oct. 19, 2007, which is hereby incorporated by reference in its entirety.
[0002] This application claims priority of my prior, co-pending provisional patent application, Ser. 60/853,068, filed on Oct. 19, 2006, entitled “Forced Ion Migration for Chalcogenide Phase Change Memory Device,” which is incorporated herein by reference.
[0003] This work was partially supported by a NASA Idaho EPSCoR grant, NASA grant NCC5-577.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates generally to electronic memory devices, and more particularly to a method of inducing a non-phase-change stack structure into a phase-change stack memory structure.
[0006] 2. Related Art
[0007] Research into new random access electronic memory technologies has grown significantly in the past 10 years due to the near realization of the scaling limits of DRAM and the low cycle lifetime, high power requirements, and radiation sensitivity of Flash. At the forefront of this research is the phase-change random access memory (PCRAM) [see Bez, R.; Pirovano, A. “Non-volatile memory technologies: emerging concepts and new materials” Materials Science in Semiconductor Processing 7 (2004) 349-355; and Lacaita, A. L. “Phase-change memories: state-of-the-art, challenges and perspectives” Solid-State Electronics 50 (2006) 24-31]. Phase-change memory is a non-volatile, resistance variable memory technology whereby the state of the memory bit is defined by the memory material's resistance. Typically, in a two state device, a high resistance defines a logic ‘0’ (or ‘OFF’ state) and corresponds to an amorphous phase of the material. The logic ‘1’ (‘ON’ state) corresponds to the low resistance of a crystalline phase of the material. The ‘high’ and ‘low’ resistances actually correspond to non-overlapping resistance distributions, rather than single, well-defined resistance values ( FIG. 1 ).
[0008] The phase-change material is switched from high resistance to a low resistance state when a voltage higher than a ‘threshold’ voltage, V t , is applied to the amorphous material [see Adler, D.; Henisch, H. K.; Mott, N. “The Mechanism of Threshold Switching in Amorphous Alloys” Reviews of Modern Physics 50 (1978) 209-220; and Adler, D. “Switching Phenomena in Thin Films” J. Vac. Sci. Technol. 10 (1973) 728-738] causing the resistance to significantly decrease ( FIG. 2 ). The resultant increased current flow causes Joule heating of the material to a temperature above the material glass transition temperature. When a temperature above the glass transition temperature, but below the melting temperature, has been reached, the current is removed slowly enough to allow the material to cool and crystallize into a low resistance state (write 1 ′ current region, FIG. 2 ). The device can be returned to an amorphous state by allowing more current through the device, thus heating the material above the melting temperature, and then quickly removing the current to quench the material into an amorphous, high resistance state (write 0 ′ current region, FIG. 2 ).
[0009] Chalcogenide materials, those containing S, Se, or Te, have been the most widely investigated materials for electronic resistance variable memory applications since the discovery of the electronic resistance switching effect in a chalcogenide material (As 30 Te 48 Si 12 Ge 10 ) by Ovshinsky almost 40 years ago [see Ovshinsky, S. R. “Reversible Electrical Switching Phenomena in Disordered Structures” Phys. Rev. Lett. 21(1968), 1450-1453]. Chalcogenide materials are desirable for use in electronic memories due to the wide range of glasses they can form and the corresponding wide variety of glass transition and melting temperatures. One of the most well studied resistance switching chalcogenide materials is the Ge 2 Sb 2 Te s (GST) alloy [see Bez, R.; Pirovano, A. “Non-volatile memory technologies: emerging concepts and new materials” Materials Science in Semiconductor Processing 7 (2004) 349-355; and Hudgens, S.; Johnson, B. “Overview of Phase-Change Chalcogenide Nonvolatile memory Technology” MRS Bulletin, November 2004, 829-832]. GST has been used successfully in phase-change memory arrays [see Storey, T.; Hunt, K. K.; Graziano, M.; Li, B.; Bumgarner, A.; Rodgers, J.; Burcin, L. “Characterization of the 4 Mb Chalcogenide-Random Access Memory” IEEE Non-Volatile Memory Technology Symposium (2005) 97-104; and Cho, W. Y.; Cho, B.-H.; Choi, B.-G.; Oh, H.-R.; Kang, S.; Kim, K.-S.; Kim. K.-H.; Kim, E-E.; Kwak, C.-K.; Byun, H.-G.; Hwang, Y.; Ahn, S.; Koh, G.-H.; Jeong, G.; Jeong, H.; Kim, K. “A 0.18-um 3.0-V 64-Mb nonvolatile phase-transition random access memory (PRAM)” IEEE J. Solid-State Circuits 40 (2005) 293-300] but there have been many challenges to the implementation of a phase-change memory product such as the high programming current requirements, variation in switching voltages and ON/OFF resistance ratios, thermal stresses on the materials, and their adhesion to the electrodes. See also U.S. Patent Publication 2007/0029537 A1.
SUMMARY OF THE INVENTION
[0010] Our work has focused on exploring alternative materials and device structures suitable for phase-change memory operation. Recently we have investigated devices consisting of two chalcogenide layers ( FIG. 3 ) instead of a single layer alloy of chalcogenide material (such as GST). By using two chalcogenide layers, one a Ge-chalcogenide (the memory layer), and the other a Sn-chalcogenide (the metal chalcogenide layer), we hoped to reduce the voltages, currents, and switching speeds needed for phase-change memory operation without the need for a complicated physical device structure [see Cho, W. Y.; Cho, B.-H.; Choi, B.-G.; Oh, H.-R.; Kang, S.; Kim, K.-S.; Kim. K.-H.; Kim, E-E.; Kwak, C.-K.; Byun, H.-G.; Hwang, Y.; Ahn, S.; Koh, G.-H.; Jeong, G.; Jeong, H.; Kim, K. “A 0.18-um 3.0-V 64-Mb nonvolatile phase-transition random access memory (PRAM)” IEEE J. Solid-State Circuits 40 (2005) 293-300; Lankhorst, M. H. R.; Ketelaars, Bas W. S. M. M.; Wolters, R. A. M. “Low-cost and nanoscale non-volatile memory concept for future silicon chips” Nature Materials 4 (2005) 347-352; and Hamann, H. F.; O'Boyle, M.; Martin, Y. C.; Rooks, M.; Wickramasinghe, H. K. “Ultra-high-density phase-change storage and memory” Nature Materials 5 (2006) 383-387].
[0011] Devices with three types of material stacks were fabricated for this study: GeTe/SnTe; Ge 2 Se 3 /SnTe; and Ge 2 Se 3 /SnSe. While Te-based chalcogenides are well studied for use in phase-change memory applications [see Bez, R.; Pirovano, A. “Non-volatile memory technologies: emerging concepts and new materials” Materials Science in Semiconductor Processing 7 (2004) 349-355; Lacaita, A. L. “Phase-change memories: state-of-the-art, challenges and perspectives” Solid-State Electronics 50 (2006) 24-31; and Chen, M.; Rubin, K. A.; Barton, R. W. “Compound materials for reversible, phase-change optical data storage” Appl. Phys. Lett. 49 (1986) 502-504], we know of no reports of phase-change memory operation with GeSe-based binary glasses. In this work, we have explored the possibility of inducing a phase-change response in the Ge 2 Se 3 /Sn chalcogenide stack structures. We selected the Ge 2 Se 3 glass since, like the GeTe glass, it contains homopolar Ge—Ge bonds which we believe may provide nucleation sites for crystallization during the phase-change operation, thus improving the phase-change memory response [see An, S.-H.; Kim, D.; Kim, S. Y. “New crystallization kinetics of phase-change of Ge 2 S 2 Te 5 at moderately elevated temperature” Jpn. J. Appl. Phys. 41(2002) 7400-7401]. Additionally, the Ge 2 Se 3 glass offers the advantage of higher glass transition temperatures (Ge 2 Se 3 : Tg>613 K [see Feltz, A. Amorphous Inorganic Materials and Glasses, VCH Publishers Inc., New York, 1993, pg. 234]) over the Te-based glasses (GeTe: Tg=423 K [see Chen, M.; Rubin, K. A. “Progress of erasable phase-change materials” SPIE Vol. 1078 Optical Data Storage Topical Meeting (1989) 150-156]; GST: Tg=473 K [see Hamann, H. F.; O'Boyle, M.; Martin, Y. C.; Rooks, M.; Wickramasinghe, H. K. “Ultra-high-density phase-change storage and memory” Nature Materials 5 (2006) 383-387]), thus providing more temperature tolerance during manufacturing.
[0012] One possible benefit of the metal-chalcogenide layer is the potential for formation of an Ohmic contact between the electrode and the memory layer due to the presence of a low bandgap material like SnTe (Eg=0.18 eV at 300K [see Esaki, L.; Stiles, P. J. “New Type of Negative Resistance in Barrier Tunneling” Phys. Rev. Lett. 16 (1966) 1108-1111]) between the electrode and the chalcogenide switching layer. An Ohmic contact will allow a lower voltage to be applied to the memory cell since a Schottky barrier does not need to be overcome in order to achieve the current necessary for phase-change switching. Another potential benefit of the Sn-chalcogenide layer is better adhesion of the memory layer to the electrode. The better adhesion provided by the SnTe layer may help prevent delamination of the electrode from the chalcogenide memory layer, as can occur after repeated thermal cycles [see Hudgens, S.; Johnson, B. “Overview of Phase-Change Chalcogenide Nonvolatile memory Technology” MRS Bulletin, November 2004, 829-832]. In addition to these potential benefits, the Sn-chalcogenide may provide a region with ‘graded’ chalcogenide concentration between the Sn-chalcogenide and the Ge-chalcogenide memory switching layer due to the ability of the chalcogenide to form bridging bonds between the Sn and Ge atoms in the Sn-chalcogenide and Ge-chalcogenide layers, respectively. Lastly, as we show in this work, the Sn-chalcogenide material may assist in phase-change memory switching by donating Sn-ions to the Ge-chalcogenide layer during operation, thus allowing chalcogenide materials which normally do not exhibit phase-change memory switching to be chemically altered post processing into an alloy capable of phase-change response.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a graph depicting an example distribution of low and high resistance values defining a logic ‘1’ and ‘0’ state, respectively, of a resistance variable memory.
[0014] FIG. 2 is a graph depicting the relationship between current through the memory cell material and the formation of a low (write ‘1’) or high (write ‘0’) resistance state.
[0015] FIG. 3 is a top perspective schematic view of the device structures according to the present invention as tested. The notation Ge—Ch/Sn—Ch indicates a device with this structure with the films listed in the order nearest the bottom electrode to nearest the top electrode.
[0016] FIG. 4 is a graph depicting XRD spectra of SnTe and SnSe evaporated films.
[0017] FIG. 5 is a TEM image of a GeTe/SnTe device according to the present invention.
[0018] FIG. 6 is a set of IV-curves for three unique GeTe/SnTe devices according to the present invention, showing the device-to-device variation typically observed in these devices. A positive potential was applied to the top electrode in each case.
[0019] FIG. 7 is a representative IV-curve for a GeTe/SnTe device according to the present invention, with a negative potential applied to the top electrode. A positive potential has never been applied to the device top electrode prior to this measurement.
[0020] FIG. 8 is a representative IV-curve for a Ge 2 Se 3 /SnTe device according to the present invention, with a positive potential applied to the top electrode.
[0021] FIG. 9 is a representative IV-curve for a Ge 2 Se 3 /SnTe device according to the present invention, with a negative potential applied to the top electrode. A positive potential has never been applied to the device top electrode prior to this measurement.
[0022] FIG. 10 is a representative IV-curve for a Ge 2 Se 3 /SnSe device according to the present invention, with a positive potential applied to the top electrode.
[0023] FIG. 11 is an IV-curve of a Ge 2 Se 3 /SnSe device according to the present invention, with the top electrode at a negative potential. A positive potential has never been applied to the device top electrode prior to this measurement.
[0024] FIG. 12 is an IV-curve of a Ge 2 Se 3 /SnSe device according to the present invention, obtained with a negative potential applied to the top electrode after the application of a positive potential ‘conditioning’ signal consisting of a DC current sweep limited to 30 nA.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to the Figures, there are shown some, but not the only, embodiments of the invention.
[0026] FIG. 3 shows a top perspective view of a device structure, according to the present invention, used in this study. The device structure consists of a via through a nitride layer to a W bottom electrode deposited on 200 mm p-type Si wafers. The chalcogenide material layers were deposited with the Ge-chalcogenide layer first, followed by the Sn-chalcogenide layer. Prior to deposition of the first chalcogenide layer, the wafers received an Ar + sputter etch to remove residual material and any oxide layer that may have formed on the W electrode. The Ge 2 Se 3 layer was deposited by sputtering with an Ulvac ZX-1000 from a target composed of pressed Ge 2 Se 3 powder. The GeTe, SnTe, and SnSe layers were prepared by thermal evaporation of GeTe, SnTe, and SnSe (all from Alfa Aesar, 99.999% purity) using a CHA Industries SE-600-RAP thermal evaporator equipped with three 200 mm wafer planetary rotation. The rate of material deposition was monitored using an Inficon IC 6000 with a single crystal sensor head. The base system pressure was 1×10 −7 Torr prior to evaporation.
[0027] Using the planetary rotator, evaporated films were deposited on two types of wafers simultaneously in each experiment: (1) a film characterization wafer consisting of a p-type Si wafer substrate with the layers 350 Å W/800 Å Si 3 N 4 and, (2) two wafers processed for device fabrication consisting of vias etched through a Si 3 N 4 layer to a W electrode for bottom electrode contact ( FIG. 3 ). The film characterization wafer present in each evaporation step was used to characterize the actual thin-film material stoichiometry post evaporation since thermally evaporated films often have a stoichiometry different than the starting material. The evaporation chamber was opened to the ambient atmosphere between the GeTe, SnTe, and SnSe film depositions in order to expose the GeTe films to similar ambient atmospheric conditions as the sputtered Ge 2 Se 3 films which had to get exposed to the atmosphere during transfer from the sputtering tool to the evaporator for the Sn-chalcogenide film deposition. After the evaporation step(s) were complete, the device fabrication wafers continued processing through top electrode deposition (350 Å sputtered W), photo steps, and dry etch to form fully functional devices consisting of a bottom electrode, chalcogenide material layers, and top electrode. Dry etch was performed by ion-milling with a Veeco ion-mill containing a quadrupole mass spectrometer for end-point detection.
[0028] The films were characterized with ICP to determine the variation in composition of the film compared to the starting material. ICP data provided film stoichiometry with an accuracy of +/−0.8% using a Varian Vista-PRO radial ICP. The chalcogenide films were removed from the wafer prior to ICP analysis with an etching solution of 1:1 HCl:HNO 3 . XRD, performed with a Siemen's DS5000, was used to qualitatively identify amorphous or polycrystalline films. TEM measurements were made with a Phillips Model CM300.
[0029] Electrical measurements were made using a Micromanipulator 6200 microprobe station equipped with temperature controllable wafer chuck, a Hewlett-Packard 4145B Parameter Analyzer, and Micromanipulator probes with W tips (Micromanipulator size 7A). The tested devices were 0.25 um in diameter with 80 um×80 um pads for electrical contact to the top and bottom electrodes.
[0030] Results and Discussion
[0031] The GeTe and Ge 2 Se 3 films were amorphous as deposited with no observable XRD peaks. The SnTe and SnSe films were polycrystalline, as indicated by their XRD spectra ( FIG. 4 ). Due to the nature of the evaporation process, and the relatively high pressure of the evaporation chamber prior to film deposition (1E-7 Torr), oxygen is most likely incorporated into the SnTe, SnSe, and GeTe films during deposition. Our previous X-ray photoelectron spectroscopy measurements on evaporated films have shown that the percentage of oxygen in an evaporated film can be as high as 10%.
[0032] Table 1 provides the ICP results for the film characterization wafers that were included in the evaporation step with the device wafers in this study, as well as for a sputtered Ge 2 Se 3 film wafer. Note that the only elements measured by ICP analysis were Ge, Se, Sn, and Te. The presence of oxygen is not detected with ICP and is not factored into the overall film composition. The evaporated SnTe and SnSe layers are almost stoichiometric, whereas the GeTe layer was deposited slightly Te-rich (53% compared to 50%). The sputtered Ge 2 Se 3 films are stoichiometric.
[0000]
TABLE 1
Device types fabricated for this study and their actual thin film
compositions measured with ICP (within +/−0.8%).
Layer 1
Layer 2
Device Stack
Composition
Composition
GeTe/SnTe
Ge 47 Te 53
Sn 49 Te 51
Ge 2 Se 3 /SnTe
Ge 40 Se 60
Sn 49 Te 51
Ge 2 Se 3 /SnSe
Ge 40 Se 60
Sn 49 Se 51
Note that ICP analysis does not measure oxygen in the film, therefore the concentrations of the elements indicate only relative concentrations of Ge, Se, Sn, or Te in the film.
[0033] (a) GeTe/SnTe device—A TEM cross section image of a GeTe/SnTe device is shown in FIG. 5 . The evaporated material has reduced step coverage over the sidewalls of the via, leading to thinner films in this region of the devices. The pre-sputter etch clean etches into the W bottom electrode by roughly 300 Å. Thus, the device structure consists of not only a via through Si 3 N 4 , but also an indented bottom electrode which subsequently allows the chalcogenide phase-change material to be in contact at the sides and bottom of the layer near the metal electrode.
[0034] Typical DC IV-curves for devices with the GeTe/SnTe stack structure are shown in FIG. 6 . These curves were collected by forcing the current thru the devices from 10 pA to 100 μA and measuring the corresponding voltage across the devices with the positive potential on the electrode adjacent to the SnTe layer (the top electrode). The IV-curves, showing a ‘snap-back’, i.e. negative resistance, at the threshold voltage as well as a reduction in device resistance after sweeping the current, are characteristic of a phase-change memory device. There is slight device-to-device variation observed in IV-curves of unique devices ( FIG. 6 a - c ). However, in each case the threshold voltage is less than 1.8 V and there are at least two ‘snap-back’ regions in the IV-curves. The additional ‘snap-back’ responses indicate that our devices may exhibit multi-state behavior. However, the stability of each resistance state is as yet unclear. Additionally, the cycling endurance and switching properties of each state have not been explored. Similar results, though not as well defined as those in FIG. 6 , have been obtained on stacked Chalcogenide layers of GST/Si-doped GST [see Lai, Y. F.; Feng, J.; Qiao, B. W.; Cai, Y. F.; Lin, Y. Y.; tang, T. A.; Cai, B. C.; Chen, B. “Stacked chalcogenide layers used as multi-state storage medium for phase-change memory” Appl. Phys. A 84 (2006) 21-25] and are being explored as multi-state phase-change memories.
[0035] When the electrodes are reversed and a negative potential is placed on the device top electrode, the DC IV-curve is altered, as shown in FIG. 7 , but the device still exhibits phase-change behavior. In this electrical configuration the threshold voltage has increased above 2V. In either potential polarity configuration, the threshold voltage and programming currents that we observe for the GeTe/SnTe stack structure are lower than those reported for recent single devices comprised of GST [see Lv, H.; Zhou, P.; Lin, Y.; Tang, T.; Qiao, B.; Lai, Y.; Feng, J.; Cai, B.; Chen, B. “Electronic Properties of GST for Non-Volatile Memory” Microelectronics Journal, in press].
[0036] Table 2 provides a comparison of the typical initial resistance of a device prior to switching and the programmed resistance after switching, as well as the measured threshold voltage for both the positive and negative current sweep cases. The resistances were measured at +20 mV in each case, a potential too low to perturb the state of the bit. Included in Table 2 are the typical programmed resistances when the current is swept to 1 mA (for both the positive and negative potential cases). Of note is the programmed resistance when the current is swept to a −1 mA (top electrode at a negative potential) compared to the case when the current is swept to +1 mA. There is almost an order of magnitude decrease in the programmed resistance when +1 mA is forced at the top electrode compared to the bottom electrode. However, our results indicate that it is not necessary to use a current as high as 1 mA in order to program the bits (see the 100 uA results in Table 2).
[0000]
TABLE 2
Typical initial and programmed resistances and threshold voltages for devices
programmed with +/−100 uA and +/−1 mA of current.
Programmed
Programmed
Threshold
Initial
Resistance (Ohms)
Resistance (Ohms)
Voltage
Device Stack
Resistance (Ohms)
+100 uA/−100 uA
+1 mA/−1 mA
+sweep/−sweep
GeTe/SnTe
>5 × 10 6
1 × 10 4 /2 × 10 4
5 × 10 2 /3 × 10 3
1.6 V/2.5 V
Ge 2 Se 3 /SnTe
>6 × 10 6
2 × 10 3 /3 × 10 5
7 × 10 2 /7 × 10 2
3.7 V/3.7 V
Ge 2 Se 3 /SnSe
>6 × 10 6
1 × 10 3 /—
5 × 10 2 /—
3.7 V/—
Ge 2 Se 3 /SnSe
>6 × 10 6
2 × 10 8 (+30 nA limit)/
No data
—/2.5 V
(low current test)
1 × 10 5 (−2 uA limit)
A ‘—’ indicates no measurable response. Resistance was measured at 20 mV.
[0037] (b) Ge 2 Se 3 /SnTe device—When the GeTe glass is replaced with a Ge 2 Se 3 glass, the resultant Ge 2 Se 3 /SnTe devices exhibit resistance variable memory switching, FIG. 8 . However, there are two distinct differences in the DC IV-curve compared to the GeTe/SnTe case. First, the threshold voltage, when the top electrode is at a positive potential, is higher in the Ge 2 Se 3 case (greater than 3.5 V compared to less than 1.8 V for the GeTe/SnTe case). Second, the threshold voltage occurs at a current which is an order of magnitude lower than in the GeTe devices. Additionally, the Ge 2 Se 3 /SnTe devices exhibit better device-to-device consistency in their IV-curves than the evaporated GeTe/SnTe devices, most likely due to the better via sidewall film step-coverage inherent in the sputtered Ge 2 Se 3 film, as well as a reduction in film impurities (such as oxygen).
[0038] FIG. 9 shows the corresponding current sweep IV-curves for the Ge 2 Se 3 /SnTe structure with a negative potential on the top electrode. The IV-curves for this negative current sweep show a much less well-defined threshold voltage than the positive current sweep case. In addition, the current at the threshold voltage is much higher than the positive current sweep case ( FIG. 8 ). However, the negative potential Ge 2 Se 3 /SnTe IVcurve ( FIG. 9 ) shows similar threshold voltages and currents to the negative potential GeTe/SnTe IV-curve ( FIG. 7 ).
[0039] (c) Ge 2 Se 3 /SnSe device—When the SnTe layer is replaced with a SnSe layer in the Ge 2 Se 3 stack, resistance switching is observed ( FIG. 10 ) when a positive voltage is applied to the top electrode. The DC IV-curves for the Ge 2 Se 3 /SnSe device ( FIG. 10 ) and the Ge 2 Se 3 /SnTe device ( FIG. 8 ) show no differences due to the SnSe layer. However, when a negative potential is applied to a device that has not previously seen a positive potential, no threshold voltage is observed in the IV-curve ( FIG. 11 ). This is in contrast to the case of the negative potential applied to a Ge 2 Se 3 /SnTe device ( FIG. 9 ) where phase-change switching is observed with a threshold voltage less than 3 V.
[0040] The absence of a threshold voltage in the negative current sweep IV-curve ( FIG. 11 ), but its presence in the positive current sweep IV-curve ( FIG. 10 ) of the Ge 2 Se 3 /SnSe device implies that during the application of a positive potential there may be Sn-ion migration from the SnSe layer into the Ge 2 Se 3 layer which chemically alters the Ge 2 Se 3 layer to a (Ge 2 Se 3 ) x Sn y alloy capable of phase-change operation. The migration of Sn ions into the lower glass layer may also explain the switching observed in the Ge 2 Se 3 /SnTe device when a positive potential is applied to the top electrode. However, unlike the Ge 2 Se 3 /SnSe device, switching is observed in the Ge 2 Se 3 /SnTe device when a negative potential is applied to the top electrode. A possible explanation for the observed negative potential switching in the Ge 2 Se 3 /SnTe device ( FIG. 9 ) is that Te 2− -ions from the SnTe layer may be electrically driven by the negative potential into the underlying Ge 2 Se 3 glass layer, thus creating (Ge 2 Se 3 ) x Te y regions capable of phase-change switching.
[0041] To explore the possibility that the phase-change switching in the Ge 2 Se 3 /SnSe device is facilitated by Sn-ion migration into the Ge 2 Se 3 layer, the Ge 2 Se 3 /SnSe device, was initially tested by applying a positive potential ‘conditioning’ signal to the top electrode. This ‘conditioning’ signal was a DC current sweep limited to 30 nA in order to prevent any phase-change from occurring, but with enough potential (˜3 V) to drive Sn-ions into the Ge 2 Se 3 layer. After this ‘conditioning’ signal was applied to the Ge 2 Se 3 /SnSe device, a negative potential was applied to the top electrode and the IV curve was measured ( FIG. 12 ). A voltage ‘snap-back’ is observable at two separate current values, 60 nA and 100 nA. This double ‘snap-back’ is representative of the IV curves of the devices measured with this conditioning technique. Device resistances after application of the negative potential (post conditioning) were in the range of 30 kOhms to 200 kOhms.
[0042] The Ge 2 Se 3 /SnTe and GeTe/SnTe stacks were also subjected to this ‘conditioning’ signal test. However, their negative current DC IV-curves were not appreciably altered after application of the positive ‘conditioning’ voltage.
CONCLUSIONS
[0043] Phase-change memory switching was observed in devices consisting of two stacked layers of chalcogenide material: a Ge-based layer (GeTe or Ge 2 Se 3 ), and a tin chalcogenide layer (SnTe or SnSe). The observed switching is dependent upon the polarity of potential applied to the electrode adjacent to the SnTe or SnSe layer. When a positive potential is applied to this electrode, the formation of Sn-ions and their migration into the adjacent GeTe or Ge 2 Se 3 layer most likely contributes to the phase-change response of the material.
[0044] We attribute the switching of the Ge 2 Se 3 /SnTe device under negative applied potential, with no previously applied positive ‘conditioning’ voltage, to the migration of Te anions into the Ge 2 Se 3 layer during application of the negative potential. The possible Te anion migration may alter the Ge 2 Se 3 glass layer into a (Ge 2 Se 3 ) x Te y alloy capable of phase-change memory operation.
[0045] In the case of the Ge 2 Se 3 /SnSe device, no Te anions are available to migrate into the Ge 2 Se 3 glass layer when a negative potential is applied to the top electrode, and no phase-change behavior is observed in the IV-curve. If it were possible for Se anions to be forced into the Ge 2 Se 3 glass from the SnSe layer (analogous to the Te anions from the SnTe layer), they would succeed only in making the Ge 2 Se 3 glass Se-rich and thus still incapable of phase-change switching. Alternatively, if a positive potential is initially applied across the Ge 2 Se 3 /SnSe device and the current is limited to a low enough value to prohibit Joule heating, but still allow a high enough potential across the device for Sn-ion migration, Sn-ions may migrate into the Ge 2 Se 3 layer, creating a (Ge 2 Se 3 ) x Sn y alloy which is capable of phase-change switching when a negative potential is applied to the top electrode.
[0046] The addition of metal ions, forced into the chalcogenide switching layer during the first ‘forming’ electrical pulse, not only facilitates electrical switching, but it also may allow for more than one ON resistance state. This phase-change memory alloy, formed in-situ, may exhibit more than one crystallization temperature. Each crystallization temperature corresponds to a unique phase of the material, and thus a unique resistance. This means that by proper selection of the metal that is allowed to migrate into the chalcogenide glass, the alloy can be tuned to have more than one crystalline phase.
[0047] We further investigated this concept by synthesizing materials using the Ge x Se y chalcogenide glass and adding small concentrations (1 and 3%) of various metals, and measuring the thermal properties of these materials. Metals we have tested include, Sn, Zn, In, and Sb. The Sn and In addition showed the presence of two crystallization regions whereas the Zn showed three crystallizations regions. Thus the Ge x Se y Zn z alloy has the potential to have four logic states. This alloy can be formed in-situ, for example, by using a device comprising the layers of Ge 2 Se 3 /ZnSe.
[0048] GeTeSn materials have been well studied for their application as optical phase-change materials [see Chen, M.; Rubin, K. A. “Progress of erasable phase-change materials” SPIE Vol. 1078 Optical Data Storage Topical Meeting (1989) 150-156]. GeTe exhibits fast crystallization under optically induced phase-change operation (<30 ns) and it crystallizes in a single phase (no phase separation) making it attractive for phase-change operation. However, the number of optically induced write/erase cycles that could be achieved was quite low (<500) [see Chen, M.; Rubin, K. A. “Progress of erasable phase-change materials” SPIE Vol. 1078 Optical Data Storage Topical Meeting (1989) 150-156]. Our initial electrical cycling endurance tests on the GeTe/SnTe and Ge 2 Se 3 /SnTe devices and have shown endurance greater than 2 million cycles. Due to the potential for parasitic capacitances during the endurance cycling measurements, care must be taken in the measurement experimental setup [see Ielmini, D.; Mantegazza, D.; Lacaita, A. L. “Parasitic reset in the programming transient of PCMs” IEEE Electron Device Letters 26 (2005) 799-801]; with this in mind, better cycling measurements are currently in progress [see Campbell, K. A.; Anderson, C. M., Microelectronics Journal 38 (2007) 52-59].
[0049] Future studies will investigate the temperature dependence, AC switching and lifetime cycling endurance of each of these device types. Additionally, we will investigate the phase-change switching response of stack structure devices that use a metal-chalcogenide layer with a metal different than tin, such as zinc, which is expected to have much different mobility in an applied field as well as a much different chemical incorporation into the Ge-chalcogenide glass layer. It is possible that the presence of Ge—Ge bonds in the Ge-based layer assist in the incorporation of the metal ions or of the Te anions into the glass by providing an energetically feasible pathway (that of the Ge—Ge bonds) for Te- or metal-ion incorporation [see Narayanan, R. A.; Asokan, S.; Kumar, A. “Influence of Chemical Disorder on Electrical Switching in Chalcogenide Glasses” Phys. Rev. B 63 (2001) 092203-1-092203-4; and Asokan, S. “Electrical switching in chalcogenide glasses—some newer insights” J. Optoelectronics and Advanced Materials 3 (2001) 753-756]. Ge—Ge bonds are known to be thermodynamically unstable [see Feltz, A. Amorphous Inorganic Materials and Glasses, VCH Publishers Inc., New York, 1993, pg. 234], and in the presence of other ions, will easily break and allow formation of a new bond (e.g. GeTe or GeSn). Future work will investigate the role of the Ge—Ge bond by testing the electrical performance of devices made with Ge-chalcogenide stoichiometries that provide no Ge—Ge bonds, such as Ge 25 Se 75 .
[0050] Although this invention has been described above with reference to particular means, materials, and embodiments, it is to be understood that the invention is not limited to these disclosed particulars, but extends instead to all equivalents within the scope of the following claims.
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Non-volatile memory devices with two stacked layers of chalcogenide materials comprising the active memory device have been investigated for their potential as phase-change memories. The devices tested included GeTe/SnTe, Ge 2 Se 3 /SnTe, and Ge 2 Se 3 /SnSe stacks. All devices exhibited resistance switching behavior. The polarity of the applied voltage with respect to the SnTe or SnSe layer was critical to the memory switching properties, due to the electric field induced movement of either Sn or Te into the Ge-chalcogenide layer. One embodiment of the invention is a device comprising a stack of chalcogenide-containing layers which exhibit phase-change switching only after a reverse polarity voltage potential is applied across the stack causing ion movement into an adjacent layer and thus “activating” the device to act as a phase-change random access memory device or a reconfigurable electronics device when the applied voltage potential is returned to the normal polarity. Another embodiment of the invention is a device that is capable of exhibiting more than two data states.
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CLAIM OF BENEFIT TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of the United States non-provisional patent application Ser. No. 11/473,745, entitled “System and Method to Obtain Oligo-Peptides with Specific High Affinity to Query Proteins”, filed Jun. 23, 2006 and having been published on Jan. 18, 2007 with publication number 2007/0015189; application Ser. No. 11/473,745 claims the benefit of the U.S. provisional patent application Ser. No. 60/694,055, entitled “System and Method to Obtain Oligo-Peptides with Specific High Affinity to Query Proteins”, filed Jun. 24, 2005. The contents of the non-provisional patent application Ser. No. 11/473,745 and the provisional patent application 60/694,055 are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates to protein-protein binding, and more particularly, to a method of determining and constructing oligo-peptides with high binding affinity for a query protein.
BACKGROUND
[0003] Specific, high affinity interactions between proteins are very important in biology for processing of molecular information. The most important kinds of these specific, high-affinity protein-protein (P—P) interactions are present in: a) metabolic pathways (MP); b) regulatory pathways (RP); c) protein-receptor-protein-ligand interactions (R-L); and d) antigen-antibody (Ag-Ab) interactions.
[0004] It is necessary to understand the fundamental nature of the P—P interactions to understand and predict pathways, design artificial protein-ligands (agonists or antagonists), and/or design antibodies to known antigens. Specific High Affinity Protein Design (SHAPD) has application potential in medicine/pharmacology for the design of proteins or protein-like molecules which interact with metabolic, regulatory pathways (including stimulating or inhibiting of a protein receptor) and/or prevent or treat medical conditions which are known to be effected by antibody binding.
[0005] Current understanding of specific, high affinity protein-protein interactions are based on two main principles:
[0006] 1. All information necessary to specific and unique protein folding (3D structure forming) is present in the amino acid sequence. Existing approaches are commonly classified as: (1) comparative modeling; (2) fold recognition; and (3) ab initio methods. The first two methods are knowledge based (database-driven), i.e., some template sequence, which is reliably similar to the target sequence, already exists and the sequence-structure connection is already known. True ab initio approaches rely on Anfinsen's thermodynamic principle which states that protein folding is thermodynamically determined. Thus, it is theorized that amino acid sequences contain all the necessary information to make up the correct three-dimensional structure; namely, given a proper environment, a protein would fold up spontaneously into a conformation that minimizes the total free energy of the system. However, the problem is to predict the native three-dimensional structure of a protein from its amino acid sequence.
[0007] 2. The specifically interacting protein interfaces are formed by a large number of amino acids that are in a complex short-, medium-, long range cooperative interactions with each other. However, forces acting on short distances (at residue level) provide for completely different structures than forces acting on long distances and their interaction might involve many neighboring residues (cumulative effects).
[0008] Thus, none of the protein structure predicting methods perform satisfactorily, which is very frustrating because genome sequencing projects are producing numerous novel coding sequences and understanding the structure is likely required in order to understand the function. Accordingly, it would be advantageous to determine a novel method to design and produce proteins that will specifically and with high affinity interact with a query protein.
SUMMARY OF THE INVENTION
[0009] In one aspect, the present invention relates to a method for designing and isolating oligo-peptides (targets) that will specifically and with high affinity interact with a known peptide (query).
[0010] In another aspect, the present invention relates to a method for determining and producing a binding amino acid sequence having binding affinity for a known amino acid sequence, the method comprising:
[0011] determining a query nucleotide sequence for the known amino acid sequence to provide a series of codons, wherein each codon has a 1st, 2nd, and 3rd nucleotide and the nucleotide sequence has a 5′ and 3′ end;
[0012] creating a nucleotide sequence which is complement to the query nucleotide sequence wherein the 2nd nucleotide in each codon is an undefined nucleotide;
[0013] reversing the complemented sequence;
[0014] preparing a pool of target nucleotide sequences wherein the undefined 2nd nucleotide of each codon comprises equal amounts of four relevant nucleotides and the number of nucleotide sequences in the pool is 4.sup.n wherein n is the number of amino acid residues in the known amino acid sequence;
[0015] cloning of the target nucleotide sequence pool;
[0016] preparing a target protein pool expression library from the target nucleotide sequence pool;
[0017] contacting prepared target proteins pool with known amino acid sequence; and
[0018] identifying binding complexes between the known amino acid sequence and target proteins.
[0019] In yet another aspect, the present invention relates to a method for determining and producing a binding amino acid sequence (target protein) having binding affinity for a known amino acid sequence (query protein), the method comprising:
[0020] determining a query nucleotide sequence for the known amino acid sequence to provide a series of codons, wherein each codon has a 1st, 2nd, and 3rd nucleotide and the nucleotide sequence has a 5′ and 3′ end;
[0021] creating a nucleotide sequence which is complement to the query nucleotide sequence wherein the 2nd nucleotide in each codon is an undefined nucleotide;
[0022] reversing the complemented sequence and changing any T nucleotides to a U nucleotide;
[0023] preparing a pool of target RNA nucleotide sequences wherein the undefined 2nd nucleotide of each codon comprises equal amounts of A, U, G and C;
[0024] cloning of the target nucleotide sequence pool;
[0025] preparing a target protein pool expression library from the target nucleotide pool;
[0026] contacting prepared target proteins pool with known amino acid sequence; and
[0027] identifying binding complexes between the known amino acid sequence and target proteins.
[0028] In yet another aspect, the present invention provides for a method of generating a target protein product comprising the following steps:
[0029] providing nucleic acid encoding the target protein;
[0030] transfecting a host cell with the nucleic acid or using an equivalent means for introducing the nucleic acid into the host cell; and
[0031] culturing the transformed host cell under conditions suitable for expression of the target protein.
[0032] An additional aspect of the present invention relates to a diagnostic kit and method for the detection of a query protein in a test sample, comprising:
[0033] (a) incubating a test sample, which may contain a query protein with a sufficient amount of a target protein determined by the above methods, wherein the target protein is immobilized on a solid phase and incubating conditions permit the binding of the query protein to the target protein; and
[0034] (b) recovering any bound query protein.
[0035] This embodiment further provides for introducing a detectable label wherein the label is capable of binding to the query protein after binding to the target protein, and determining the presence or absence of the label, to provide an indication of the presence or absence of the query protein in the test sample. The test sample may be a bodily fluid, including, but not limited to, blood, urine, semen, saliva, mucus, tears, vaginal secretions, and the like.
[0036] Other features and advantages of the invention will be apparent from the following detailed description, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 shows the steps required to practice the method for obtaining oligo-peptides with specific high affinity to query proteins.
[0038] FIG. 2 shows representative query amino acid sequences and preparation of reverse and complement sequences wherein the second nucleotide of each codon is replaced with a variable “n” nucleotide. Displayed sequences are sequence listed as SEQ ID NO 1, 2, 3, 4, 5, 6, 7, 8, 9.
[0039] FIG. 3 shows synthesis pattern for construction of target sequences and the progression of the permutations dependent on the number of amino acid residues. Displayed sequences are sequence listed as SEQ ID NO 10-70.
[0040] FIG. 4 shows the BacterioMatch™ Two-Hybrid System (reproduced from www.strategene.com).
[0041] FIG. 5 shows sequences, designed by the method of the invention, which were expected to produce proteins (when transcribed and translated) with the potential to specifically interact with the indicated domains of the Gal4 protein. The 1st and 3rd codon letters in these target templates are complementary to the 3rd and 1st codon letters in the Gal4 coding sequences (reverse reading direction) while the 2nd codon letter is undefined (A or T or G or C). Displayed sequences are sequence listed as SEQ ID NO 71, 72.
[0042] FIG. 6 illustrates the transcription of TOT dsDNA will result in TOT mRNA. A 45 nucleic acid long TOT will be translated into 4.sup.15 different oligopeptides, each 15 amino acid long. Some of these oligopeptides are expected to specifically interact with the respective GAL4 targets. Displayed sequences are sequence listed as SEQ ID NO 73,74.
[0043] FIG. 7 . List of Proinsilin Query Oligo-Peptides. Displayed sequences are sequence listed as SEQ ID NO 1, 75-80.
[0044] FIG. 8 . These particular designs consist of the 30-45 residue long TONTs (bold) proceeded by Cys (C) codon and followed by coding sequence of MYC tag. The sequences were ligated into cloning vectors with restrictions endonucleases. RE1 and RE2 indicate recognition sequences for these enzymes. Displayed sequences are sequence listed as SEQ ID NO 81-86.
[0045] FIG. 9 . List of PINS-TOPs. These particular oligopeptides contain the PINS-TOP itself (bold) proceeded by Cys (to bound the Oligopeptide to solid surface for surface plasmon resonance (SPR) studies and Gly-Gly (spacers), and followed by MYC_COP (internal tag used as positive control). Displayed sequences are sequence listed as SEQ ID NO 87-92.
[0046] FIG. 10 : Efficiency of isolation of the TOP containing phages. The phage display library was screened for TOP producing clones by repeated pannings In this example wells were coated with PINS3-QOP was linked and exposed to phage solution. Phages producing INS-TOP3 with strong affinity to PINS_QOP3 bound to the coated wells while the weak or no binders remained in the solution and discarded. Wells coated with MYC antibodies (MYC_MAB) and phages producing only MYC_COP (but not any TOP) served as controls. Stringency refers to the concentration of Tween-20 (right Y) in the washing solutions used after pannings (Pan.) to remove weakly binding phages.
[0047] FIG. 11 . The parameter of Query-Target bindings were determined by surface plasmon resonance (SPR) and the K d values are indicated. The binding of MYC monoclonal antibody (MAB) and bovine serum albumin (BSA) served as internal controls. N/A: non-available because K d is out of the detection limit of SPR.
DETAILED DESCRIPTION OF THE INVENTION
Definitions and Abbreviations
[0048] QOP: Query (or bait) Oligo-Peptide—is one short protein sequence that the target protein, designed and produced with the Method, will specifically interact.
[0049] QON: Query Oligo-Nucleotide—is a short nucleic acid sequence coding QOP.
[0050] TOP: Target Oligo-Peptide—is a short protein which are designed by the Method to specifically interact with the query protein sequence.
[0051] TON: Target Oligo-Nucleotide—is a short nucleic acid sequence coding TOP.
[0052] TOPP: Target Oligo-Peptide Pool—is a pool of different TOPs
[0053] TONP: Target Oligo-Nucleotide Pool—is a pool of TONs. TON sequences in the pool are identical regarding the corresponding 1st and 2nd codon residues, but may differ regarding the corresponding 2nd codon residues.
[0054] TONT: Target Oligo-Nucleotide Template—is a single sequence where the 1st and 3rd codon residues are complementary to the corresponding codon residues in the QON (in reverse orientation), while the 2nd codon residues may, but not necessarily complementary to the corresponding 2nd codon residues in the QON. (A Target Oligo-Nucleotide Template, which contains 15 undefined nucleic acid residues, will result in 4.sup.15=10.sup.9 different oligonucleotides (TON) which will be translated into the corresponding number of proteins, (TOP)).
[0055] FIG. 1 shows the steps for producing the target proteins of the present invention having a high affinity for query proteins, wherein the primary structure is known for the query proteins. There is no limitation to the size of the query, however, preferably the sequence is from about 5 amino acid residues to about 40 amino acid residues, and more preferably from about 7 to 15 amino acid residues. Preferably, the real and natural coding sequence is known for the query protein. However, it might be some special cases when the sequence is not exactly known, for example in case of designed or artificially modified proteins. Thus, it is possible to fabricate a virtual coding sequence with back translation, using Codon Usage Frequency Tables. The present method relies on the entire information carried by the naturally occurring DNA/mRNA and not only that used for coding of the protein primary sequence.
[0056] The query sequence should be a “promising” domain of the query protein and specific domains are more important, including domains that are known to be a) antigenic; b) are located on the surface of the query protein; c) are not simple (repetitive) sequences; d) those containing less frequent amino acids; and e) those containing charged amino acid residues.
[0057] Once the promising area of the known amino acid sequence is chosen and the nucleotide sequence is determined, then construction of nucleic acid sequences encoding for the target proteins is initiated. As used herein, the term “nucleotide sequence” means a sequence of nucleotides connected by phosphodiester linkages. Nucleotide sequences are presented herein in the direction from the 5′ to the 3′ direction and can be a deoxyribonucleic acid (DNA) molecule or ribonucleic acid (RNA) molecule. Relevant nucleotide bases are indicated herein by a single letter code: adenine (A), guanine (G), thymine (T), cytosine (C), inosine (I) and uracil (U). The target nucleotide (RNA or DNA) prediction should follow a simple rule, namely that the 1.sup.st and 3rd codon letters of the target nucleotide sequences should be reverse-complementary to the 1st and 3rd codon nucleotide residues of the query nucleotide sequence, but the middle, 2nd residue should be any of the four possible nucleotides. The expected number of predicted target RNAs will be 4.sup.n, where n is the number of amino acids (=number of codons, =number of 2nd codon letters).
[0058] Synthesis of the nucleotide sequences can be readily prepared by, for example, directly synthesizing the fragment by chemical means, by application of nucleic acid reproduction technology, such as the PCR or by excising selected DNA fragments from recombinant plasmids containing appropriate inserts and suitable restriction enzyme sites. However, synthesis of predicted (max. 4.sup.n) sequences on a one by one basis does not seem practical. Thus, a simple mass-production is needed which will result in a mixture, containing all possible sequences in the predicted RNA/DNA pool. Fortunately, the regular nature of the nucleotides in the pool makes it possible to synthesize the entire pool of nucleotide sequences as it would be only one single nucleotide sequence. For example, the usual step-by-step (base after base) protocol can be followed except at the positions for the synthesis of the 2nd codon residue. At those points in the synthesis process, an equal mixture of the four nucleotides should be provided instead of a single nucleotide. The result of this modified oligo-nucleotide syntheses should be a mixture of the desired potential target RNAs.
[0059] Cloning the predicted and synthesized RNAs in the pool. This step is the regular cloning procedure which involves insertion of RNA into vector (plasmid or other carrier) and multiplying the sequences in bacteria or yeast as it is described in the publicly available literature. Expression vectors of the invention may comprise polynucleotides operatively linked to an enhancer-promoter, such as a prokaryotic or eukaryotic promoter. Further, an enhancer may be included in the vector. A major function of an enhancer is to increase the level of transcription of a coding sequence in a cell that contains one or more transcription factors that bind to that enhancer. Unlike a promoter, an enhancer can function when located at variable distances from transcription start sites so long as a promoter is present.
[0060] Expression vectors of the present invention comprise polynucleotides that encode the target peptides of the pool. Where expression of recombinant polypeptide of the present invention is desired and a eukaryotic host is contemplated, it is most desirable to employ a vector, such as a plasmid, that incorporates a eukaryotic origin of replication. Additionally, for the purposes of expression in eukaryotic systems, one desires to position the peptide encoding sequence adjacent to and under the control of an effective eukaryotic promoter such as promoters used in combination with Chinese hamster ovary cells. To bring a coding sequence under control of a promoter, whether it is eukaryotic or prokaryotic, what is generally needed is to position the 5′ end of the translation initiation side of the proper translational reading frame of the polypeptide between about 1 and about 50 nucleotides 3′ of or downstream with respect to the promoter chosen. Furthermore, where eukaryotic expression is anticipated, one would typically desire to incorporate into the transcriptional unit which includes the different target peptides, an appropriate polyadenylation site.
[0061] The pRc/CMV vector (available from Invitrogen) is an exemplary vector for expressing a peptide in mammalian cells, particularly COS and CHO cells. Target polypeptides of the present invention under the control of a CMV promoter can be efficiently expressed in mammalian cells. The pCMV plasmids are a series of mammalian expression vectors of particular utility in the present invention. The vectors are designed for use in essentially all cultured cells and work extremely well in SV40-transformed simian COS cell lines. The pCMV1, 2, 3, and 5 vectors differ from each other in certain unique restriction sites in the polylinker region of each plasmid. The pCMV4 vector differs from these 4 plasmids in containing a translation enhancer in the sequence prior to the polylinker. While they are not directly derived from the pCMV1-5 series of vectors, the functionally similar pCMV6b and c vectors are available from the Chiron Corp. of Emeryville, Calif. and are identical except for the orientation of the polylinker region which is reversed in one relative to the other. The pCMV vectors have been successfully expressed in simian COS cells, mouse L cells, CHO cells, and HeLa cells.
[0062] Means of transforming or transfecting cells with exogenous polynucleotide such as nucleotide molecules of the present invention are well known in the art and include techniques such as calcium-phosphate- or DEAE-dextran-mediated transfection, protoplast fusion, electroporation, liposome mediated transfection, direct microinjection and adenovirus infection.
[0063] The most widely used method is transfection mediated by either calcium phosphate or DEAE-dextran. Although the mechanism remains obscure, it is believed that the transfected DNA enters the cytoplasm of the cell by endocytosis and is transported to the nucleus. Depending on the cell type, up to 90% of a population of cultured cells can be transfected at any one time. Because of its high efficiency, transfection mediated by calcium phosphate or DEAE-dextran is the method of choice for experiments that require transient expression of the foreign DNA in large numbers of cells. Calcium phosphate-mediated transfection is also used to establish cell lines that integrate copies of the foreign DNA, which are usually arranged in head-to-tail tandem arrays into the host cell genome.
[0064] The application of brief, high-voltage electric pulses to a variety of mammalian and plant cells leads to the formation of nanometer-sized pores in the plasma membrane. DNA is taken directly into the cell cytoplasm either through these pores or as a consequence of the redistribution of membrane components that accompanies closure of the pores. Electroporation can be extremely efficient and can be used both for transient expression of cloned genes and for establishment of cell lines that carry integrated copies of the gene of interest. Electroporation, in contrast to calcium phosphate-mediated transfection and protoplast fusion, frequently gives rise to cell lines that carry one, or at most a few, integrated copies of the foreign DNA.
[0065] Liposome transfection involves encapsulation of DNA or RNA within liposomes, followed by fusion of the liposomes with the cell membrane. The mechanism of how DNA or RNA is delivered into the cell is unclear but transfection efficiencies can be as high as 90%.
[0066] Direct microinjection of a DNA molecule into nuclei has the advantage of not exposing DNA to cellular compartments such as low-pH endosomes. Microinjection is therefore used primarily as a method to establish lines of cells that carry integrated copies of the DNA of interest. A transfected cell can be prokaryotic or eukaryotic.
[0067] In addition to prokaryotes, eukaryotic microbes, such as yeast can also be used. Saccharomyces cerevisiae or common baker's yeast is the most commonly used among eukaryotic microorganisms, although a number of other strains are commonly available. For expression in Saccharomyces , the plasmid YRp7, for example, is commonly used. This plasmid already contains the trp1 gene which provides a selection marker for a mutant strain of yeast lacking the ability to grow in tryptophan, for example ATCC No. 44076 or PEP4-1. The presence of the trp1 lesion as a characteristic of the yeast host cell genome then provides an effective environment for detecting transformation by growth in the absence of tryptophan. Suitable promoter sequences in yeast vectors include the promoters for 3-phosphoglycerate kinase or other glycolytic enzymes such as enolase, glyceraldehyde-3-phosphate dehydrogenase, hexokinase, pyruvate decarboxylase, phosphofructokinase, glucose-6-phosphate isomerase, 3-phosphoglycerate mutase, pyruvate kinase, triosephosphate isomerase, phosphoglucose isomerase, and glucokinase. In constructing suitable expression plasmids, the termination sequences associated with these genes are also introduced into the expression vector downstream from the sequences to be expressed to provide polyadenylation of the mRNA and termination. Other promoters, which have the additional advantage of transcription controlled by growth conditions are the promoter region for alcohol dehydrogenase 2, isocytochrome C, acid phosphatase, degradative enzymes associated with nitrogen metabolism, and the aforementioned glyceraldehyde-3-phosphate dehydrogenase, and enzymes responsible for maltose and galactose utilization. Any plasmid vector containing a yeast-compatible promoter, origin or replication and termination sequences is suitable.
[0068] In addition to microorganisms, cultures of cells derived from multicellular organisms can also be used as hosts. In principle, any such cell culture is workable, whether from vertebrate or invertebrate culture. However, interest has been greatest in vertebrate cells, and propagation of vertebrate cells in culture (tissue culture) has become a routine procedure in recent years. Examples of such useful host cell lines are AtT-20, VERO and HeLa cells, Chinese hamster ovary (CHO) cell lines, and W138, BHK, COSM6, COS-1, COS-7, 293 and MDCK cell lines. Expression vectors for such cells ordinarily include (if necessary) an origin of replication, a promoter located upstream of the gene to be expressed, along with any necessary ribosome binding sites, RNA splice sites, polyadenylation site, and transcriptional terminator sequences.
[0069] For use in mammalian cells, the control functions on the expression vectors are often derived from viral material. For example, commonly used promoters are derived from polyoma, Adenovirus 2, Cytomegalovirus and most frequently Simian Virus 40 (SV40). The early and late promoters of SV40 virus are particularly useful because both are obtained easily from the virus as a fragment which also contains the SV40 viral origin of replication. Smaller or larger SV40 fragments can also be used, provided there is included the approximately 250 by sequence extending from the HindIII site toward the BglI site located in the viral origin of replication. Further, it is also possible, and often desirable, to utilize promoter or control sequences normally associated with the desired gene sequence, provided such control sequences are compatible with the host cell systems.
[0070] Following transfection, the cell is maintained under culture conditions for a period of time sufficient for expression of the target proteins of the pool. Culture conditions are well known in the art and include ionic composition and concentration, temperature, pH and the like. Typically, transfected cells are maintained under culture conditions in a culture medium. Suitable medium for various cell types are well known in the art. In a preferred embodiment, temperature is from about 20.degree. C. to about 50.degree. C. pH is preferably from about a value of 6.0 to a value of about 8.0, more preferably from about a value of about 6.8 to a value of about 7.8 and, most preferably about 7.4. Other biological conditions needed for transfection and expression of an encoded protein are well known in the art.
[0071] Transfected cells are maintained for a period of time sufficient for expression of the target proteins. A suitable time depends inter alia upon the cell type used and is readily determinable by a skilled artisan. Typically, maintenance time is from about 2 to about 14 days. Recovery of the target proteins comprises isolating and purifying the recombinant polypeptides. Isolation and purification techniques for polypeptides are well known in the art and include such procedures as precipitation, filtration, chromatography, electrophoresis and the like.
[0072] The target proteins are preferably arranged in a library assay system for screening with samples of the query protein. Any method which detects specific, high affinity protein-protein interactions is theoretically useful to perform the screening.
[0073] Selecting the best clones with the most specific and highest affinity interacting proteins can be followed by repeated screenings. Thus, leading to the most desired target proteins having the highest binding affinity for the query protein. The target proteins with the highest affinity are suitable for large scale target protein production.
[0074] The foregoing aspects and embodiments of the present invention are further described in the following Example. However, the present invention is not limited by the following Example, and variations will be apparent to those skilled in the art without departing from the scope of the present invention.
Example I
General Design
[0075] FIG. 2 shows the use of the present invention to obtain a Specific High Affinity Protein having binding affinity for a section of the A-peptide in the Human Insulin.
[0076] Starting with the known protein and nucleic acid sequence of the entire Pre-pro-insulin, 1-10 residues of the A peptide are selected and the corresponding nucleic acid sequence. The selected part of the peptide, called query, will be used for screening of the target protein expression library. Therefore, this sequence should be available in pure peptide form.
[0077] Next, a sequence is created which is complement to the query nucleotide sequence at 1.sup.st and 3.sup.rd codon positions but leaves the 2.sup.nd position undefined (X). The complemented sequence is reversed and in this particular example, the bases T are changed to U. The second (central) codon position remains undefined and this undefined X position can be any of possible (A, U, G, C) nucleotides. Therefore, this prediction method defines many different target RNA sequences. In the case of a sequence including 30 nucleotide bases, the expected number of possible target sequences will be .about.4.sup.10=10.sup.6.
[0078] The predicted pool of target RNAs is synthesized by following the usual step-by-step (base after base) protocol, known to those skilled in the art, except the syntheses of X positions. At the X position, a mixture of nucleotide bases are provided (which contain equal amount of A and U and G and C). The result of this modified oligo-nucleotide syntheses is a mixture of the desired potential target RNAs as shown in FIG. 3 . The target RNAs are cloned and transfected, via an expression vector, into a cell for expression therein of the encoded protein. An expression library of the expressed target protein is created for screening for query protein/target protein affinity binding. When binding complexes are found to meet the affinity binding levels, the target protein may be cloned for large scale production.
[0079] These steps may be repeated numerous times by modify the length of the query sequence and/or using another domain area of the query protein that may be of interest.
Example 2
Using Bacteriomach Two Hybrid System
Example for Designing and Characterization of a Specific Protein-Protein Interaction
[0080] The BacterioMatch™ two-hybrid system* (Stratagene, 11011 N. Torrey Pines Road La Jolla, Calif. 92037) was used to Quickly Detect Protein-Protein Interactions designed by the recent Method. It is a simple alternative or complement to yeast two-hybrid systems for in vivo detection of protein-protein interactions. Because the two-hybrid assay is performed in bacteria, results are obtained more easily and quickly than in yeast. The system is based on transcriptional activation of a primary ampicillin-resistant reporter and a secondary .beta.-galactosidase reporter for validation. The BacterioMatch two-hybrid system is based on a methodology developed by Dove, Joung, and Hochschild of Harvard Medical School.
[0081] The BacterioMatch two-hybrid system is based on transcriptional activation ( FIG. 4 j . A protein of interest—the bait—is fused to the full-length bacteriophage repressor protein (.lamda.cI). The corresponding target protein is fused to the amino-terminal domain of the .alpha.-subunit of RNA polymerase (RNAP.alpha.). The bait is tethered to the x operator sequence upstream of the reporter promoter through the DNA-binding domain of .lamda.cI. If the bait and target interact, they recruit and stabilize the binding of RNA polymerase close to the promoter and activate the transcription of the ampicillin-resistant reporter gene in the BacterioMatch two-hybrid reporter strain. The .beta.-galactosidase reporter gene provides an additional mechanism to validate putative protein-protein interactions.
[0082] FIG. 4 : The Bacteriomatch™ Two-Hybrid System (Reproduced from www.strategene.com)
[0083] A. Bait Vector: The bait vector, pBT encodes the full-length bacterial phage cI protein under the control of the strong lacUV5 promoter. A protein of interest is fused to the bacterial phage .lamda.cI protein by inserting its gene into the multiple cloning site at the 3′ end of the .lamda.cI gene. A multiple cloning site present makes it convenient to subclone a bait gene that is already present in many yeast two-hybrid bait plasmids.
[0084] B. Target Vector: The target plasmid, pTRG is compatible with Stratagene's cDNA library construction kit. The target plasmid directs transcription of the amino-terminal domain of RNA polymerase .alpha.-subunit and linker region under the control of tandem promoters, lpp and lacUV5. The target gene is fused in-frame to the .alpha.-subunit NTD through a multiple cloning site at the 3′ end of the .alpha.-subunit gene.
[0085] C. Reporter Strain: The reporter strain is derived from XL1-Blue MRF'. The strain lacks all restriction systems in order to be compatible with current cDNA library construction methods. The lac I.sup.q gene located on the F′ episome represses synthesis of the bait and target until induction. The reporter cassette is also located on the F′ episome in the cell. The lacZ gene serves as a secondary reporter to provide a visible phenotype for identifying positive protein-protein interactions.
[0086] 2. Specification (5 Biro 050825): test of a novel Method to design specifically interacting proteins.
[0087] Target Pool is synthesized by using a Target Oligo Template (TOT) which has a Constant (C) and Variable (V) part.
[0088] The TOT-C is necessary to synthesize dsDNA of the target pool sequences and it is .about.20 nucleotides long.
[0089] The TOT-V (Target Template) is about 30-45 nucleotide long, 2/3.sup.rd of nucleotides is unambiguously defined, while 1/3.sup.rd is not (X). The X residues should be synthesized by adding a mixture of nucleotides (equal amount of A+T+G+C) to the reaction during oligo synthesis. 8. Evaluate the results (number of highly, moderately, slightly positive clones). This is done by visual inspection. 9. Save the positive clones for further experiments, which will be specified later. If there are no positive clones, it is necessary to validate the orientation and translation frame in the target mRNAs. It is possible by sequencing some target mRNAs. The sequence should show the residue pattern as under point 5. Results 1. Both TARGET TEMPLATE to ESRLERLEQLFLLIF (GAL4 09-23AA) and TARGET TEMPLATE to QLFLLIFPREDLDMI (GAL4 17-31AA) contained numerous positive bacterial clones growing on double selective medium. 2. Sequencing of DNA from the vectors in randomly selected positive clones confirmed that they contained the characteristic TOT pattern, i.e. defined 1st and 3rd codon residues the nucleic acids differed only in the 2nd codon positions, while they were the same regarding the 1st and 3rd codon positions.
[0090] The restrictions endonuclease recognition sequences were present.
[0091] The start and stop codons were present.
[0092] The sequences were inserted into the correct, sense DNA strands.
[0093] The codon frames were correct in relation to the start codon and were read in the correct frames. 3. Some positive TARGET TEMPLATE to ESRLERLEQLFLLIF (GAL4 09-23AA) clones were further processed to monoclonal colonies and proteins were extracted. Characterization of the binding properties of fluorescent labeled GAL4 peptide to the protein extract indicated the presence of saturable binding sites in the protein extracts from positive clones and the absence of saturable binding sites in the negative clones.
[0094] The experiment below is specifically designed for using BacterioMatch (Stratagene) two-hybrid system. This system uses:
[0095] A Bait Vector (pBT) and the manufacturer's standard is an insert, the dimerisation domain of 1HBW REGULATORY PROTEIN GAL4.
[0096] A Target Vector (pTRG) and the manufacturer's standard is an insert, and .about.90 aa long mutant form of Gal11.
[0097] In the experiment below the Target Oligo Pool will be used instead of Gall 1 in the pTRG vector.
[0098] The Query in this experiment is the dimerisation domain of 1HBW REGULATORY PROTEIN GAL4 inserted into pBT (as it is provided and described by Stratagene).
[0099] The Target Oligo Templates (TOT-V) are these:
[0100] Target Oligo-Template design to specifically interact with K01486_SCGAL4_DIMDOM-171/9-23 and K01486_SCGAL4_DIMDOM-171/17/31 sequences.
[0101] Sequences below are sense, ssDNA sequences which means that the TOT-V in this sequence is the same as the sequence in the expected mRNAs (except T/U conversion). The TOT-C is not indicated here, BPD can decide which TOT-C to use this purpose.
[0102] FIG. 5 .: Sequences, designed by the Method, were expected to produce proteins (when transcribed and translated) with the potential to specifically interact with the indicated domains of the Gal4 protein. The 1.sup.st and 3.sup.rd codon letters in these target templates are complementary to the 3.sup.rd and 1.sup.st codon letters in the Gal4 coding sequences (reverse reading direction) while the 2.sup.nd codon letter is undefined (A or T or G or C).
[0103] The experiment consists of the following steps:
[0104] 1. Sequence the Gal 4 DNA (provided by Stratagene) to make sure that the Query sequence is as expected.
[0105] 2. Synthesize the target pool using the Target Oligo Templates
[0106] This is a single run routine oligo synthesis. Residues X are equal amount of A+T+G+C
[0107] 3. Make dsDNAs
[0108] This is a single run PCR
[0109] 4. Make Restriction Enzyme cuts on the Target Oligo Pool sequences.
[0110] This is a single run RE reaction.
[0111] 5. Insert the oligo pool sequences into the pTRG vector . . . about.10.sup.9 different vectors are expected.
[0112] Make sure that the orientation of the Target Oligo-s is correct and the transcription will result in the following mRNA. The Target Oligo Pool insertion is a single run ligase reaction. FIG. 6 : Transcription of TOT dsDNA will result in TOT mRNA. A 45 nucleic acid long TOT will be translated into 4.sup.15 different oligopeptides, each 15 amino acid long. Some of these oligopeptides are expected to specifically interact with the respective GAL4 targets. 6. Insert the vectors into bacteria. 7. Perform the BacterioMatch two-hybrid assay accordingly to the Stratagene manual.
[0113] K.sub.d of the binding sites varied between (Kd˜100 nM-100 □M range) indicating the presence of limited number of high affinity binding sites. 4. Unlabelled GAL4 inhibited the binding of labeled GAL4 to the proteins from positive clones while other randomly chosen proteins (insulin, growth hormone, prolactin) were ineffective competitors even in much higher concentrations.
[0114] This experiments indicate that it is possible to design specifically interacting oligo-peptides (target) to any oligo-peptide (query) and detect the interaction in bacterial 2 hybrid system (like BacterioMatch™). This method is quick, it takes only some days to obtain specifically and with high affinity interacting monoclonal proteins. The designed protein-protein interaction is highly specific and has high affinity Kd˜100 nM-100 μM range.
Example 3
Using Phage Display
[0115] A routine phage display method [9] was used for identifying and producing short high affinity & specifically interacting oligopeptides to 5 distinguished domains of human pre-pro-insulin peptide ( FIG. 7 , SEQ ID NO 1, 75-80). Five target oligonucleotide templates (TONT) were designed using the native CDS of the query oligopeptides (QOP). The templates (a variable nucleic acid sequence where the 1st and 3rd codon residues are defined while the 2nd codon residue remains undefined) were completed with non-variable codons/residues to add leader sequence, recognition sites for restrictions endonuclease, start/stop codons and coding sequence for MYC protein (MYC-CON). (MYC is a well known protein with commercially available antibodies and it is widely used as positive control to monitor different cloning procedures). ( FIG. 8 , SEQ ID NO 81-86).
[0116] Care was taken to monitor the TONT-MYC sequences for potential binding sites for restrictions enzymes as well as for potential stop codons, because these sequences could truncate some of the nucleic acids in the Target Oligonucleotide Pools (TONP). The risk for truncation by restrictions enzymes was seduced when the enzyme had long (5-6 residues) recognition site.
[0117] Pools of target oligo-nucleotides (TONP) were synthesized by manual method where an equal mixture of dATP/dCTP/dGTP/dTTP were provided at every N positions (central codon residue). By this way the number of different nucleotides in the pool became, say ˜4 10 =˜10 6 (derived from a 10 codons long TONT). The oligonucleotide pools were purified on 8% non-denaturing PAGE, followed by treatment with T4 kinase to obtain dsDNAs. The sequences were treated with Acc651 (G′GTACC) and NotI (GC′GGCCGC) and inserted into M13KE vector (into the correct site and correct orientation) and electro-porated. The expressions libraries were titrated and the quality of some individual DNA sequences in the TON-MYC pools were checked by resequencing. The phages were propagating in ER2738 ( E. coli ) cells (see laboratory manuals for details of these routine laboratory procedures).
[0118] The phage display libraries were enriched by repeated pannings for particular colonies which were producing the requested affinity proteins. The 5 query oligopeptides (QOP) were chemically synthesized and bound to the surface of dishes. The affinity protein producing phages bound to these coated surfaces, while other phages were easily removed by repeated washing. The surface-bound phages were further multiplied and submitted to the subsequent, similar panning procedure. The efficiency of cloning, protein expression and pannings were monitored ( FIG. 10 ).
[0119] The selectivity and efficiency of pannings (stringency) was successfully increased by increasing the concentration of Twin-20 in the washing solution from 0.1 to 0.5%.
[0120] After the 3rd panning the plates were repeatedly washed with TBST (TBS+0.5% tween-20) which left only about 10 3 phages bound (the strongest binders to the QOPs out of ˜2×10 10 input phages). These strongest binders were amplified and 100 well isolated plaques were randomly selected for final amplification, DNA extraction and sequencing. The DNA sequences corresponding to the TONs were translated (using the universal genetic code, Table I) and the oligopeptides were chemically synthesized.
[0121] The binding kinetics between QOPs and TOPs were determined by Surface Plasmon Resonance (SPR, BIACORE). The TOPs ( FIG. 9 ). were immobilized on the chips using thiol-disulphate exchange method It showed specific (selective) binding of TOPs to their corresponding QOPs and these bindings had high affinity. ( FIG. 11 ).
[0122] Discussion
[0123] 1., Proteomic Code is not a hypotheses, this is a 30 years old concept first proposed by me in 1981 and it's original suggestion (perfect complementary coding of collocating amino acids) was tested by many and many well working examples were found [or review see ref 6]. The recent invention is based on the partial complementarity coding of co-locating amino acids,—this is the novelty in the invention.
[0124] 2., Regarding the theoretical background of the invention
[0125] a., The original hypotheses of the Proteomic Code (from 1981) suggested the perfect reverse complementarity of the codons behind co-locating amino acids, like the 5-ATG-3′/3′-TAC-5′ formula. You can find hundreds of well working examples for this from different laboratories [7, 8].
[0126] b., However there were unexpected exceptions. Therefore I revised the original hypotheses and suggested the second generation of Proteomic Codes, where the 1st and 3rd codon residues are defined, while the second codon residues remain undefined behind the co-locating amino acids, like 5′ANG-3′/3′-TNC-5′ formula.
[0127] c., By this way the original 5-ATG-3′/3′-TAC-5′-like formula became the subdivision of the recently used 5′ANG-3′/3′-TNC-5′-like formula. This later Proteomic Code permits 1:4 uncertainty (per codon) of the predictions. However please note that this is a much better prediction than the 1:20 uncertainty (per amino acid) provided by the random oligopeptide syntheses. It means that if you want to find, say, interacting decapeptides using random method you have to screen a peptide library containing 20 10 different sequences. Using the 5′ANG-3′/3′-TNC-5′ type formula you can reduce this number to 4 10 , which is 10 13 /10 6 improvement. This is the novelty and industrial application of the recent patent suggestion.
[0128] d., We found, that Nature uses the 5′ANG-3′/3′-TNC-5′ type proteomic code to define collocating amino acids. This was found by using a bioinformatical tool, called SeqX. The tool picks up co-locating amino acids which are not defined by the suggested Proteomic Code. Fortunately it is not cases any methodological problems. The specific and non-specific hits are possible to separate of each other: the number of nonspecific hits corresponds to the number of random hits, while the number of specific hits are significantly higher than the number of calculated random hits. This is thoroughly discussed in most of our publication, especially in [10].
[0129] e., We are very clear, that the recent invention is to produce specifically and with high affinity interacting oligo-peptides. This method was inspired by bioinformatical studies performed on individual peptides. It is known, that short residue-to-residue-type interactions are very frequent within protein molecules (like parallel alpha helices and beta sheets) and they provide a stable 3D structure to the peptides. It is reasonable to believe, that interactions between large peptides (like antigen-antibody, receptor-ligand) are more complex than the relatively simple oligopeptide interactions within the protein structures. The recent invention doesn't require the full understanding of macromolecular interactions. Therefore we prefer not to involve any of our observations or experiment concerning the application of Proteomic Code for interactions between large peptides.
[0130] f., the controversial statement that the unit of specific protein-protein interactions are the amino acid themselves is not at all controversial if you have a look at the parallel alpha helices and beta shifts. They are far away from the familiar “docking-type” of interactions.
[0131] g., the controversial statement that the nucleic acids contain additional information to the genetic code is not at all controversial if you consider that
The information density of nucleic acids is log 2 64=6 bits/codon The information density of proteins is log 2 20=4.3 bites/residue.
[0134] The Genetic Code doesn't explain the difference.
[0135] Predictibility of the Results
[0136] It is to emphasize, that the Proteomic Code applied in this method is not a mathematical formula which gives exactly predictable result regarding the sequence of one specifically interacting oligopeptide (TOP). (If it were this wouldn't be patentable). The proteomic code itself provide a large number of sequences (TOPs) with the potential for specific interaction with the query protein (QOP). The second codon residues are undefined in the TONTs giving a degree of randomness and uncertainty into the outcome of the process. However this randomness is limited, the number sequences in the TONPs is much smaller than the number of sequences provided by perfectly random selection of the 20 amino acids into a sequence.
[0137] Another inherent uncertainty of the method, that screening of an expression library with the QOP will provide more than one interacting proteins (strong TOP binders). In the example 3 we obtained ˜1.000 strongly binding phages after the 3 rd panning We sequenced only ˜100, each slightly different from each other. It is no way to predict which sequence represent the strongest and most specific binding oligopeptides. Only synthesizing a large number of pre-selected proteins and measuring the affinity parameters will give the correct answer. However this slight sequence diversity of TOPs provides possibility to involve additional criteria to select the “best” TOPs for industrial applications (like chemical stability, toxicity, et cetera).
[0138] Rare nucleotides such as inosine present in the nucleic acids should be treated as their structurally and functionally closest relative between frequent (canonical) nucleotides.
INDUSTRIAL APPLICATIONS
[0139] The present invention thus relates to a unique in silico method of identifying the most effective binding proteins to interact with reactive epitopes on a respective protein antigen. Epitopes of a protein antigen represent the sites that are recognized as binding sites by certain immunoglobulin molecules, as antibodies.
[0140] The benefits of the present invention are widespread and beneficial to biotechnology, and are useful, for example, in developing drugs for treatment of viral diseases such as AIDS and influenza, as well as diseases such as Alzheimer's and Mad Cow (bovine spongiform encephalopathy) diseases In addition to medical research and drug development, the present invention has applications related to environmental health and public safety, including for example the detection of bacteria, viruses, toxins, etc. in air, water, and food supplies.
[0141] By way of further specific examples, the present invention has applications in the following areas:
[0142] 1. improving health-care, by providing a new and easily implement an approach to development of diagnostic kits and therapeutic drugs;
[0143] 2. improving the environment, by providing new and economic approaches to detecting environmental pathogens;
[0144] 3. improving working conditions of workers, by providing economic and effective ways to detect environmental pathogens; and
[0145] 4. improving homeland security, by providing rapid detection of known as well as new pathogens in air, water, food, etc.
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This application is based on the concept of the Proteomic Code, PC (discovered and described by Biro, 1981-2011, for review see ref 6) and making use of the biological observation, that co-locating amino acids [in interacting proteins] are coded by partially complementary codons. A method is provided to design and produce a special and distinct set of affinity oligopeptides (AffiSeq) using the PC principle. These designed and artificially produced affinity peptides will be used in any biotechnological or pharmacological applications which benefit of the specific and high affinity protein-protein interactions.
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BACKGROUND OF THE INVENTION
The invention relates to this inventor's image projection control system in an application Ser. No. 359,135 filed Mar. 17, 1982, now U.S. Pat. No. 4,390,875--which is a continuation-in-part of an application Ser. No. 201,179 filed Oct. 27, 1980, now abandoned. In the aforesaid applications a system of first and second acousto-optic optical control means are utilized as the principal means for establishing light reflecting conditions and corresponding optical path relationships between an illuminated message character and a common optical axis of the system, and thereby providing for a viewing of an image of the character along said common optical axis.
SUMMARY OF THE INVENTION
The optical system means of this invention for making determinations of eye glass or contact lens refraction requirements include the use of an array of message characters of the type which are normally used for eye test purposes, a source of light and means for exposing characters of the array to light from said source. Optical means utilizing first and second (X & Y) acousto-optic light reflector cells are positioned along a common optical axis for establishing optical path relationships between individual ones of the message characters and the optical axis so as to provide for a viewing thereof from along this axis; an eyeball of an observer (or an eye patient) doing the viewing. In the process of establishing the required optical path relationships and conditions for such viewing along the optical axis, the light reflecting conditions within the interaction media of the pair of acousto-optic cells, in each instance, perform a simulating of the lens requirements of the observer to view the character with a desired degree of sharpness and clarity; this being an important objective of the invention. Another objective of the invention is to improve upon the accuracy of available means in the providing of such eye care needs. Still other objectives of the invention include such abilities in the detection and specifying of corrective lens needs by means of easy to operate electro-optical system means.
Embodiments of the invention illustrated and described herein exemplify the means for meeting these objectives, and when read in connection with the drawing herein the description which follows will provide a better understanding of these and still other objectives and advantages of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is to exemplify schematically optical relationships of key elements and operating circuit means of one embodiment of the invention; and
FIG. 2 represent schematically a pair of X & Y a-o cells, enlarged somewhat, to which reference will be made in discussions thereof.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, an array of message characters of what will be referred to as an eye chart 10 from which selectively high quality images thereof will be available for viewing upon an exposure to light from a source 11. Being shown as but one example, such chart can be made to contain still other formations of characters, type fonts and sizes. All reference herein to the use of the word "light" is to be understood as including radiant energy extending from infrared, through the visible spectrum, to ultraviolet. Light from the source 11 is preferably monochromatic, but the invention is not to be limited in this regard. The chart can have opaque characters and transparent or translucent field or background, in which they are located, or the reversal of this. And it should be understood that such chart 10 can be illuminated from the side thereof opposite to that indicated and, for example, in the direction of the arrow 14. Then, either the characters or the field will be made a reflector of light.
Optical system means including first and second acousto-optic optical path relationship control means, which will herein be referred to as including, respectively, an X a-o cell and a Y a-o cell, each having an ultrasonic frequency transducer 20, and an interaction medium 21 positioned along a common optical axis 15 of the system. These X & Y a-o cells are utilized in an operation of establishing images of individual characters stemming from the chart 10 along the optical axis 15. This operation includes an extending of predetermined ultrasonic frequency voltages to the transducers 20 of the cells which will hereinafter be described. Regarding a functioning of an acousto-optic cell, when responding to an extending of voltages of ultrasonic frequencies the interaction medium 21 of a cell is traversed by compression waves effecting periodic stratification of the medium and wherein the density is proportional to the applied acoustic power. The distance between two successive planes of maximum density is equal to the wavelength of the applied voltage. Each device is designed and positioned along the optical axis 15 whereby the orientation of a given strata agrees substantially with the Bragg angle relative to the O-order path for light rays through the medium 21. Under such conditions the periodic stratification of the medium allows it to take the form of, and behave like, a stacked array of planar light guides, each presenting a graded index profile and a path for a viewing of light therethrough. Such path includes a bending thereof corresponding to the wavelength of a given stratification within the medium 21.
At a second, and extreme, end of the common optical axis 15 there is shown a symbol 32 exemplification of an observer's eye. In the absence of any signal voltages to either of the a-o cells a line of sight will extend from the eye 32, along the axis 15, through the media 21 and along an optical path 33 to a stop 34. Then, under the influence of a prescribed set of signal voltages to the X & Y a-o cells the eye of the observer will be allowed to see in the direction of the chart 10; the media of the cells being made to function as a pair of cylindrical lenses, oriented perpendicularly one in relation to the other.
Although the invention is not to be limited insofar as the following voltage source detailing is concerned, the ultrasonic frequency voltage source will be described as including the use of eight individual generators 1x through 8x and 1y through 8y. Each of the generators will provide a predetermined range of frequencies and each designed to effect a linear frequency modulation and consequently a cylindrical lensing effect, selectively, in the line of sight along the axis 15. The generators and their respective range of available output frequencies are listed as follows:
______________________________________generators 1x & 1y frequency range is 100 MHz to 110 MHzgenerators 2x & 2y frequency range is 100 MHz to 120 MHzgenerators 3x & 3y frequency range is 100 MHz to 130 MHzgenerators 4x & 4y frequency range is 100 MHz to 140 MHzgenerators 5x & 5y frequency range is 100 MHz to 150 MHzgenerators 6x & 6y frequency range is 100 MHz to 160 MHzgenerators 7x & 7y frequency range is 100 MHz to 170 MHzgenerators 8x & 8y frequency range is 100 MHz to 180 MHz______________________________________
The output of the generators 1x through 8x will be connected to the transducer 20, selectively, upon the closing of a desired one of the series of switches 17a. The output of the generators 1y through 8y will be connected to the transducer 20, selectively, upon the closing of a desired one of the series of switches 17b. The transducers 20 being, respectively, of the X & Y a-o cells. The output of each generator is connected to their respective transducer through an amplifier 18.
In FIG. 2 the X & Y a-o cells are again shown, schematically, and enlarged somewhat. Regarding the media 21, the use of tellurium dioxide, TeO 2 , is preferred since it has a favorable acoustic velocity of 0.6×10 5 cm/sec. But still other related materials can be considered for use as well. To the observer's eye 32 from along the axis 15, the aperture of the a-o cells will be described as each having a dimension of 1.3 cm×1.3 cm. The acoustic velocity indicated amounts to a transit time of 0.00002 sec. through such length dimension of the medium 21 for each sinusoidal stratifying thereof. During the time period of 0.00002 sec. the interaction medium will have been filled with a series of individual cycles of the periodic stratification; each of which presenting a shorter wave length with time. This initial filling of the medium utilizing a predetermined portion of the range of frequencies stemming from a given generator represents an initiating of a cylindrical lensing effect and to the eye of the observer a focusing on a finite line along one edge of the eye chart 10. With time the remaining portion of the range of frequencies from the generator allows the cylindrical lensing effect to continue until such focusing on the chart has extended to the opposite edge thereof.
The establishing of these cylindrical lensing effects in the media 21 of the X & Y a-o cells can be programmed so as to become effective either simutaneously or one following the other. When the system is in a normal operating mode each of the generators therein will be in operation and ready to have extended a selected pair of ultrasonic frequencies to the X & Y a-o cells. The number of times per second their respective range of frequencies will be repeated will be under the control of clock circuit 35, and the number of times per second can be, for example, 100, or just enough so as to provide a flicker-free viewing of message characters by the eye 32 of the observer.
The light source 11 can take the form of a helium neon light source or such other source of light. It should also be understood that the use of a laser diode can be included in the system as a light source. The exemplification of the switch means 36 and ON-OFF circuits 37 will, of course, be high speed electrical circuit switch means, which will allow the light source to be controlled ON and OFF in accordance with the presence of cylindrical effects in the media 21, or left ON for longer periods of time. In any event the intensity can be low enough so as not to be harmful to the eyes.
In practise the observer (or eye patient) may begin the operation by a closing of a pair of x and y switches 17 to establish at least a first predeterined one of light reflecting conditions in media 21 of the X & Y a-o cells with an object of establishing an optical path relationship between message characters of the eye chart 10 and the eye 32 along the optical axis 15. An opening and closing of switches 17 can continue until it has been learned which one of a series of predetermined light reflecting conditions permit the eye 32 of the observer to view a predetermined character with the highest degree of sharpness. This will be followed by a further opening and closing of switches 17 with the object of attempting to view a most difficult character to see with the highest degree of sharpness and clarity. The more extensive the number of different ultrasonic frequencies made available in the system for use by the observer the better it will be in meeting the objectives of the invention. Therefore, the invention is not to be limited to the number of frequency voltages illustrated.
A lens 39 exemplifies the use of an auxiliary optical means which can be introduced in the system by a repositioning thereof in the direction of the arrow 40. Such lens can permit the invention as hereinbefore described to greatly extend an overall lens providing means of the invention. By first establishing an approximation of given lens requirement of a patient with the aid of a lens 39, for example, the cylindrical lens simulating procedure as herein disclosed using the X & Y a-o cells will be utilized.
It should be understood by those skilled in the arts pertaining to the construction and application possibiities of the invention herein set forth that the embodiments included herein illustrates in a very limited sense the usefulness of the invention, and that the invention includes other modifications and equivalents as they may be seen by those skilled in the arts, but still being within the scope of the appended claims.
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Message character image projection control means for establishing conditions which simulate the eye glass or contact lens needs of an individual utilizing acousto-optic light refracting principles wherein a pair of acousto-optic cells, positioned in the line of sight of an observer, are controlled in a manner necessary to permit a viewing of the characters with a desired degree of sharpness and clarity.
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FIELD OF THE INVENTION
[0001] This invention relates to pyridyl piperazines having affinity for serotonin (5HT) receptors, especially the serotonin IB receptor (5HT 1B ), and to their use in treating diseases or conditions which are caused by disorders of the serotonin system.
BACKGROUND OF THE INVENTION
[0002] Serotonin, also known as 5-hydroxytryptamine and abbreviated “5HT,” is ubiquitous in plants and animals and is implicated in a great many physiological pathways, both normal and pathological. It is an important neurotransmitter and local hormone both in the periphery, particularly the intestine, and in the central nervous system (CNS). In the periphery, 5HT contracts a number of smooth muscles, induces endothelium-dependent vasodilation through the formation of nitric oxide, mediates peristalsis, and may be involved in platelet aggregation and homeostasis. In the CNS, 5HT is believed to be involved in a wide range of functions, including the control of appetite, mood, anxiety, hallucinations, sleep, vomiting, and pain perception. (Watson, S. and Arkinstall, S. “5-Hydroxytryptamine” in The G Protein - Linked Receptor Factsbook , Academic Press, 1994, pp. 159-180.)
[0003] Serotonin plays a role in numerous psychiatric disorders, including anxiety, Alzheimer's disease, depression, nausea and vomiting, eating disorders, and migraine. (Rasmussen et al., “Chapter 1. Recent Progress in Serotonin (5HT), Receptor Modulators,” in Ann. Rep. Med. Chem., 1, 30, pp. 1-9, 1995, Academic Press). Serotonin also plays a role in both the positive and negative symptoms of schizophrenia. (Sharma et al., Psychiatric Ann., 1996, 26 (2), pp. 88-92.)
[0004] Several serotonin receptor subtypes have been classified according to their antagonist susceptibilities and their affinities for 5HT. The 5HT 1B receptor was first identified in rats, where it has a distinct pharmacological profile. In humans, however, it shares an almost identical pharmacology with the 5HT 1D receptor. In the CNS, the 5HT 1B receptor is found in the striatum, medulla, hippocampus, frontal cortex and amygdala. In the periphery, it is found in vascular smooth muscle. Therefore, in humans the receptor is often denoted the “5HT 1B /5HT 1D receptor.” The 5HT 1B /5HT 1D receptor may be the therapeutic substrate of the anti-migraine drug, sumatriptan; the 5HT 1B /5HT 1D receptor is also implicated in feeding behavior, anxiety, depression, cardiac function, and movement. (Watson, S. and Arkinstall, S. op. cit.)
[0005] The 5HT 1B receptor was the first subtype to have its gene inactivated by classical homologous recombination (Saudou F, et al., Science, 1994, 265, 1875-1878). 5HT 1B receptors are expressed in the basal ganglia, central gray, hippocampus, amygdala, and raphe nuclei. They are located predominantly at presynaptic terminals where they can inhibit release of 5HT and, as heteroceptors, of other neurotransmitters. Selective agonists and antagonists for 5HT 1B receptors have until now been lacking, but indirect pharmacological evidence suggests that 5HT 1B activation influences food intake, sexual activity, locomotion, and aggression. (Ramboz, S., et al., Behav. Brain Res. 1996 73: 305312.)
SUMMARY OF THE INVENTION
[0006] This invention relates to certain pyridyl piperazines. These compounds are antagonists of the serotonin 5HT 1B receptor. As such, they are effective for the treatment of disorders of the serotonin system, such as depression and related disorders. In particular, the invention is directed to pyridyl piperazine compounds of Formula I:
and to pharmaceutically acceptable salts and prodrugs thereof where G is
where the dashed line represents an optional double bond; where Ar 1 is phenyl, a 5- or 6-membered heteroaryl ring, or an 8- to 10-membered fused aryl or heteroaryl ring system, said heteroaryl ring, and the heteroaryl moiety of said heteroaryl ring system comprising an aromatic ring made up of carbon and from one to four other elements selected independently from the group consisting of oxygen, nitrogen, and sulfur, which Ar 1 may be singly or multiply substituted with, independently, halogen, hydroxy, nitro, cyano, R 1 , R 2 , R 3 , —OR 4 , —OC(═O)R 5 , —COOR 6 , NHR 7 , NR 8 R 9 , —NHC(═O)R 10 , N(R 11 )(C═O)R 12 , —C(═O)NHR 13 , or Ar 2 ; X is CH 2 , NH, or O; V, W, and Y are, independently, hydrogen, halogen, hydroxy, nitro, cyano or R 7 , where R 1 -R 13 are, independently, C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 1 -C 8 alkoxy, C 1 -C 8 hydroxyalkyl, C 1 -C 8 alkenoxy, said alkyl, alkenyl, alkoxy, or alkenoxy optionally substituted with one or more halogen atoms or nitro, cyano, or hydroxyl groups, said alkyl or alkenyl groups being straight-chain, branched, or cyclic, wherein an alkoxy-substituted alkyl group may form a cyclic ether, or, in the case of NR 8 R 9 , R 8 and R 9 , may be linked together to form an additional ring; Z is C 1 -C 6 alkyl or C 1 -C 6 alkylcarbonyl; Ar 2 is a 5- or 6-membered aryl or heteroaryl ring or an 8- to 10-membered fused aryl or heteroaryl ring system, which Ar 2 may be singly or multiply substituted with, independently, halogen, hydroxy, nitro, cyano, R 1 , R 2 , R 3 , OR 4 , OC(═O)R 5 , COOR 6 , NHR 7 , NR 8 R 9 , NHC(═O)R 10 , N(R 11 )(C═O)R 12 , C(═O)NHR 13 ; and n is 1 or 2.
[0009] The invention is also directed to pharmaceutical compositions comprising the compound of Formula I, or a pharmaceutically acceptable salt or prodrug thereof, and a pharmaceutically effective carrier.
[0010] The invention is further directed to a method of treating or preventing a disorder or condition that can be treated by altering serotonin-mediated neurotransmission in a mammal, including a human.
[0011] The invention is still further directed to a method of treating, in a mammal, including a human, a disorder selected from the group consisting of anxiety, depression, dysthymia, major depressive disorder, migraine, post-traumatic stress disorder, avoidant personality disorder, borderline personality disorder, and phobias comprising administering to a mammal or human in need thereof a treatment effective amount of the compound of Formula I, or a pharmaceutically acceptable salt or prodrug thereof.
[0012] The invention is also directed to any of the foregoing methods wherein the compound of Formula I, or a pharmaceutically acceptable salt thereof, is administered in combination with a serotonin reuptake inhibitor (SRI) (e.g., sertraline, fluoxetine, fenfluramine, or fluvoxamine). The term “administered in combination with,” as used herein, means that the compound of Formula I or pharmaceutically acceptable salt thereof is administered in the form of a pharmaceutical composition that also contains an SRI, or that such compound or salt is administered in a separate pharmaceutical composition from that in which the SRI is administered, but as part of a dosage regimen that calls for the administration of both active agents for treatment of a particular disorder or condition.
[0013] The terms “pharmaceutically acceptable salts” and “pharmaceutically acceptable acid salts” of compounds of the Formula I refer to those salts which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of patients without undue toxicity, irritation, allergic response, and the like, as well as zwitterionic forms, where possible of compounds of the invention. The compounds of Formula I are basic in nature and are thus capable of forming a wide variety of salts with various inorganic and organic acids. The acids that can be used to prepare pharmaceutically acceptable acid addition salts of those compounds of Formula I are those that form non-toxic acid addition salts, i.e., salts containing pharmacologically acceptable anions, such as the hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate, bisulfate, phosphate, acid phosphate, isonicotinate, acetate, lactate, salicylate, citrate, acid citrate, tartrate, pantothenate, bitartrate, ascorbate, succinate, maleate, fumarate, gluconate, glucaronate, saccharate, formate, benzoate, glutamate, methanesulfonate, ethanesulfonate, benzenesulfonate, and p-toluenesulfonate. (See, for example, Berge, S. M., et al., “Pharmaceutical Salts,” J. Pharm. Sci . (1977) vol. 66, pp. 1-19, which is incorporated herein by reference.)
[0014] The term “one or more substituents,” as used herein, includes from one to the maximum number of substituents possible based on the number of available bonding sites.
[0015] The term “disorders of the serotonin system,” as used herein, refers to disorders the treatment of which can be effected or facilitated by altering (i.e., increasing or decreasing) serotonin-mediated neurotransmission.
[0016] The term “treating,” as used herein, refers to retarding or reversing the progress of, or alleviating or preventing either the disorder or condition to which the term “treating” applies, or one or more symptoms of such disorder or condition. The term “treatment,” as used herein, refers to the act of treating a disorder or condition, as the term “treating” is defined above.
[0017] The term “treatment effective amount,” as used herein, refers to an amount sufficient to detectably treat, ameliorate, prevent or detectably retard the progression of an unwanted condition or symptom associated with disorders of the serotonin system.
[0018] The term “serotonin-mediated neurotransmission-altering effective amount,” as used herein, refers to an amount sufficient to increase or decrease neurotransmission in systems controlled by serotonin.
[0019] The term “prodrug,” as used herein, refers to a chemical compound that is converted by metabolic processes in vivo to a compound of the above formula. An example of such a metabolic process is hydrolysis in blood. Thorough discussions of prodrugs are provided in T. Higuchi and V. Stella, “Prodrugs as Novel Delivery Systems,” Vol. 14, ACS Symposium Series, and in “Bioreversible Carriers in Drug Design,” ed. Edward Roche, American Pharmaceutical Association and Pergamon Press, 1987, both of which are incorporated herein by reference.
[0020] The chemist of ordinary skill will recognize that certain combinations of substituents, included within the scope of formula I, may be chemically unstable. The skilled chemist will either avoid these combinations or protect sensitive groups with well-known protecting groups.
[0021] The term “alkyl,” as used herein, unless otherwise indicated, includes saturated monovalent hydrocarbon radicals with 1-12 carbon atoms having straight, branched or cyclic moieties or combinations thereof. The term “lower alkyl” refers to an alkyl group having one to six carbon atoms. Examples include methyl, ethyl, propyl, isopropyl, cyclopropyl, butyl, isobutyl, sec-butyl, t-butyl, pentyl, neopentyl, cyclopentylmethyl, and hexyl. It is preferred that the alkyl group is lower alkyl. The preferred cyclic alkyl groups are cyclobutyl and cyclopentyl. The preferred lower alkyl group contains 1-3 carbon atoms. The most preferred alkyl group is methyl.
[0022] The term “alkoxy,” as used herein, unless otherwise indicated, refers to radicals having the formula —O-alkyl, wherein “alkyl” is defined as above. As used herein, the term “lower alkoxy” refers to an alkoxy group having 1-6 carbon atoms. It may be straight-chain or branched or an alkoxy-substituted alkyl group may form a cyclic ether, such as tetrahydropyran or tetrahydrofuran. Examples of acyclic alkoxy groups include methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, pentoxy and the like. It is preferred that alkoxy is lower alkoxy. It is more preferred that alkoxy contains 1:3 carbon atoms. The most preferred alkoxy group is methoxy. The most preferred substituted alkoxy group is trifluoromethoxy.
[0023] The halogen atoms contemplated by the present invention are F, Cl, Br, and I. Chlorine and fluorine are preferred. Alkyl groups substituted with one or more halogen atoms include chloromethyl, 2,3-dichloropropyl, and trifluoromethyl. It is preferred that the halo groups are the same. The most preferred halogen-substituted alkyl group is trifluoromethyl.
[0024] The term “alkenyl,” as used herein, refers to a hydrocarbon radical with two to eight carbon atoms and at least one double bond. The alkenyl group may be straight-chained, branched, or cyclic, and may be in either the Z or E form. Examples include ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, isopropenyl, isobutenyl, 1-pentenyl, (Z)-2-pentenyl, (E)-2-pentenyl, (Z)-4-methyl-2-pentenyl, (E)-4-methyl-2-pentenyl, 1,3-pentadienyl, 2,4-pentadienyl, 1,3-butadienyl, cyclopentadienyl, and the like. The preferred alkenyl group is ethenyl.
[0025] The term “alkynyl, as used herein,” refers to a hydrocarbon radical with two to eight carbon atoms and at least one carbon-carbon triple bond. The alkynyl group may be straight chained or branched. Examples include 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, 1-pentynyl, 2-pentynyl, 3-methyl-1-pentynyl, 3-pentynyl, 1-hexynyl, 2-hexynyl, 3-hexynyl, and the like. The preferred alkynyl group is ethynyl.
[0026] The term “aryl,” as used herein, unless otherwise indicated, includes an organic radical derived from a C 6 -C 14 aromatic hydrocarbon by removal of one or more hydrogen(s). Examples include phenyl and naphthyl. The preferred substitution pattern of the phenyl group is para.
[0027] The term “heteroaryl,” as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic heterocyclic compound by removal of one or more hydrogen atoms. The term “heterocyclic compound” denotes a ring system made up of 5-14 ring atoms and made up of carbon and at least one other element selected from the group consisting of oxygen, nitrogen, and sulfur. Examples of heteroaryl groups include benzimidazolyl, benzofuranyl, benzofurazanyl, 2H-1-benzopyranyl, benzothiadiazine, benzothiazinyl, benzothiazolyl, benzothiophenyl, benzoxazolyl, furazanyl, furopyridinyl, furyl, imidazolyl, indazolyl, indolinyl, indolizinyl, indolyl, 3H-indolyl, isoindolyl, isoquinolinyl, isothiazolyl, isoxazolyl, naphthyridinyl, oxadiazolyl, oxazolyl, phthalazinyl, pteridinyl, purinyl, pyrazinyl, pyridazinyl, pyridinyl, pyrimidinyl, pyrazolyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, tetrazolyl, thiazolyl, thiadiazolyl, thienyl, triazinyl and triazolyl. Preferred heteroaryl groups are oxazolyl and isoxazolyl.
[0028] The compounds of Formula I contain one or more chiral centers and therefore exist in different enantiomeric and diasteriomeric forms. Formula I, as defined above, includes—and this invention relates to the use of—all optical isomers and other stereoisomers of compounds of Formula I and mixtures thereof. Where compounds of this invention exist in different tautomeric forms, this invention relates to all tautomers of Formula I.
[0029] Preferred compounds of this invention are those wherein V, W, and Y are hydrogen, Z is methyl, and the dashed line in Formula I is a single bond.
[0030] Other preferred compounds of this invention are those in which X is CH 2 or O. Most preferred are those in which X is CH 2 .
[0031] Other preferred compounds of this invention are those in which G is 4-methyl-piperazin-1-yl.
[0032] Specific preferred compounds of formula I are:
1-[4-(3,5-Dimethyl-isoxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-piperidin-2-one; 2-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-4-[4-(tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one; 1-[4-(3,5-Dimethyl-isoxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 2-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-4-[4-(tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one; 1-[4-(2-Methyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 1-[4-(2-tert-Butyl-oxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 1-[4-(2-Isopropyl-oxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)pyridin-3-ylmethyl]-piperidin-2-one; 1-[4-(2,5-Dimethyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-[4-(tetrahydro-pyran-4-yl)-phenyl]-piperidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-[4-(tetrahydro-pyran-4-yl)-phenyl]-pyrrolidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-2-yl-phenyl)-pyrrolidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-4-yl-phenyl)pyrrolidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-5-yl-phenyl)-pyrrolidin-2-one; 1-[4-(2-Methyl-oxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one; 1-[4-(1-Methoxy-cyclobutyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-trifluoromethyl-phenyl)-pyrrolidin-2-one; 1-[4-(1-Hydroxy-cyclopentyl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one; 1-[4-(1-Hydroxy-1-methyl-ethyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)pyridin-3-ylmethyl]-pyrrolidin-2-one; 1-(4-tert-Butyl-phenyl)-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one; 1-[4-(1-Hydroxy-cyclopentyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 1-(4-tert-Butyl-phenyl)-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-phenyl-piperidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-trifluoromethoxy-phenyl)-piperidin-2-one; 1-[4-(1-Hydroxy-1-methyl-ethyl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 1-[4-1-Hydroxy-cyclobutyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 1-(4-tert-Butyl-phenyl)-3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one; 1-(4-tert-Butyl-phenyl)-3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one; 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-tetrahydropyran-4-yl)-phenyl]-piperidin-2-one; 1-[4-(1-Hydroxy-1-methyl-ethyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)pyridin-3-ylmethyl]-piperidin-2-one; and 1-[4-(1-Hydroxy-1-methyl-ethyl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one.
[0063] This invention is also directed to an intermediate useful in the synthesis of a compound of Formula I, where the intermediate is selected from 3-[2-(4-Methyl-piperazin-1-yl)pyridin-3-ylmethylene]-pyrrolidin-2-one and 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-piperidin-2-one.
[0064] 5HT receptor ligands of the present invention are of clinical use in the treatment of a wide variety of disorders related to serotonin-mediated physiological pathways. Accordingly, this invention is directed to a method of treating a disorder or condition that can be treated by altering (i.e., increasing or decreasing) serotonin-mediated neuro-transmission in a mammal, including a human, comprising administering to said mammal an amount of a compound of the Formula I, as defined above, or a pharmaceutically acceptable salt thereof, that is effective in treating such disorder or condition.
[0065] This invention is also directed to a method of treating migraine, headache or cluster headache in a mammal, including a human, comprising administering to said mammal an amount of a compound of the Formula I, as defined above, or a pharmaceutically acceptable salt thereof, that is effective in treating such disorder.
[0066] This invention is also directed to a method of treating a disorder selected from, depression (i.e., dysthymia, major depressive disorder, pediatric depression, recurrent depression, single episode depression, post partum depression, depression in Parkinson's patients, cancer patients, and post myocardial infarction patients, and subsyndromal symptomatic depression) generalized anxiety disorder, panic disorder, obsessive-compulsive disorder, post-traumatic stress disorder, avoidant personality disorder, borderline personality disorder and phobias in a mammal, including a human, comprising administering to said mammal an amount of a compound of the formula I, as defined above, or a pharmaceutically acceptable salt thereof, that is effective in treating such disorder.
[0067] Formula I above includes compounds identical to those depicted but for the fact that one or more atoms (for example, hydrogen, carbon, or fluorine atoms) are replaced by radioactive isotopes thereof. Such radiolabelled compounds are useful as research and diagnostic tools in, for example, metabolism studies, pharmacokinetic studies and binding assays.
[0068] This invention is also directed to a method, such as positron emission tomography (PET), of obtaining images of a mammal, including a human, to which a radiolabelled compound of the Formula I, or pharmaceutically acceptable salt thereof, has been administered. Such imaging methods can be used for any organ or system in which the 5-HT 1B receptor is found, such as those indicated above. The utility of radioactive agents with affinity for 5HT receptors for visualizing organs of the body either directly or indirectly has been documented in the literature. For example, C.-Y. Shiue et al., Synapse, 1997, 25, 147 and S. Houle et al., Can. Nucl. Med. Commun., 1997, 18, 1130, describe the use of 5HT 1A receptor ligands to image 5HT 1A receptors in the human brain using positron emission tomography (PET). The foregoing references are incorporated herein by reference in their entireties.
[0069] The compounds of Formula I and their pharmaceutically acceptable salts can be prepared as described below.
[0070] Compounds of Formula I in which one or more atoms are radioactive can be prepared by methods known to a person of ordinary skill in the art. For example, compounds of Formula I wherein the radioactive atom is tritium can be prepared by reacting an aryl halide Ar—X, wherein the halogen is chlorine, bromine or iodine, with gaseous 3 H 2 and a noble metal catalyst, such as palladium suspended on carbon, in a suitable solvent such as a lower alcohol, preferably methanol or ethanol. Compounds of Formula I wherein the radioactive atom is 18 F can be prepared by reacting an aryl trialkyl stannane Ar—SnR 3 , wherein R is lower alkyl, preferably methyl or n-butyl, with 18 F-enriched fluorine (F 2 ), OF 2 or CF 3 COOH in a suitably inert solvent (c.f M. Namavari, et al., J. Fluorine Chem., 1995, 74, 113).
[0071] Compounds of Formula I wherein the radioactive atom is 14 C can be prepared by reacting an aryl halide Ar—X, wherein X is preferably bromine or iodine, or an aryl trifluoromethane sulfonate (Ar—OSO 2 CF 3 ) with potassium [ 14 C]cyanide or potassium [ 14 C]-cyanide and a noble metal catalyst, preferably tetrakis(triphenylphosphine)palladium, in a reaction inert solvent such water or tetrahydrofuran, and preferably a mixture of water and tetrahydrofuran. (See Y. Andersson, B. Langstrom, J. Chem. Soc. Perkin Trans. 1, 1994, 1395.)
[0072] The therapeutic compounds used in the methods of this invention can be administered orally, buccally, transdermally (e.g., through the use of a patch), parenterally or topically. Oral administration is preferred. In general, these compounds are most desirably administered in dosages ranging from about 1 mg to about 1000 mg per day, although variations may occur depending on the weight and condition of the person being treated and the particular route of administration chosen. 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 can be employed without causing any harmful side effects, provided that such larger doses are first divided into several small doses for administration throughout.
[0073] The compounds of this invention can be used in combination with a serotonin re-uptake inhibitor (SRI). When used in the same oral, parenteral or buccal pharmaceutical composition as an SRI, the daily dose of the compound of formula I or pharmaceutically acceptable salt thereof will be within the same general range as specified above for the administration of such compound or salt as a single active agent. The daily dose of the SRI in such a composition will generally be within the range of about 1 mg to about 400 mg
[0074] The therapeutic compounds used in the methods of this invention can be administered alone or in combination with pharmaceutically acceptable carriers or diluents by either of the two routes previously indicated, and such administration can be carried out in single or multiple doses. More particularly, the therapeutic compounds used in the methods of this invention can be administered in a wide variety of different dosage forms, i.e., they may be combined with various pharmaceutically acceptable inert carriers in the form of tablets, capsules, lozenges, troches, hard candies, powders, sprays, creams, salves, suppositories, jellies, gels, pastes, lotions, ointments, elixirs, syrups, and the like. Such carriers include solid diluents or fillers, sterile aqueous media and various non-toxic organic solvents, for example. Moreover, oral pharmaceutical compositions can be suitably sweetened and/or flavored.
[0075] For oral administration, tablets containing various excipients such as microcrystalline cellulose, sodium citrate, calcium carbonate, dicalcium phosphate and glycine can be employed along with various disintegrants such as starch (and preferably corn, potato or tapioca starch), alginic acid and certain complex silicates, together with granulation binders like polyvinyl pyrrolidone, sucrose, gelatin and acacia. Additionally, lubricating agents such as magnesium stearate, sodium lauryl sulfate and talc are often very useful for tabletting purposes. Solid compositions of a similar type can also be employed as fillers in gelatin capsules; preferred materials in this connection also include lactose or milk sugar as well as high molecular weight polyethylene glycols. When aqueous suspensions and/or elixirs are desired for oral administration, the active ingredient can be combined with various sweetening or flavoring agents, coloring matter or dyes, and, if so desired, emulsifying and/or suspending agents as well, together with such diluents as water, ethanol, propylene glycol, glycerin and various like combinations thereof.
[0076] For parenteral administration, solutions of a therapeutic compound used in the methods of the present invention in either sesame or peanut oil or in aqueous propylene glycol can be employed. The aqueous solutions should be suitably buffered if necessary and the liquid diluent first rendered isotonic. These aqueous solutions are suitable for intravenous injection purposes. The oily solutions are suitable for intra-articular, intramuscular and subcutaneous injection purposes. The preparation of all these solutions under sterile conditions is readily accomplished by standard pharmaceutical techniques well known to those skilled in the art.
Biological Assay
[0077] The activity of the compounds of the present invention with respect to 5HT 1B (formerly referred to as 5HT 1D ) binding ability can be determined using standard radioligand binding assays as described in the literature. The 5-HT 1A affinity can be measured using the procedure of Hoyer et al. ( Brain Res., 1986, 376, 85). The 5-HT 1D affinity can be measured using the procedure of Heuring and Peroutka ( J. Neurosci., 1987, 7, 894).
[0078] The in vitro activity of the compounds of the present invention at the 5-HT 1D binding site may be determined according to the following procedure. Bovine caudate tissue is homogenized and suspended in 20 volumes of a buffer containing 50 mM TRIS.hydrochloride (tris[hydroxymethyl]aminomethane hydrochloride) at a pH of 7.7. The homogenate is then centrifuged at 45,000 G for 10 minutes. The supernatant is then discarded and the resulting pellet resuspended in approximately 20 volumes of 50 mM TRIS-hydrochloride buffer at pH 7.7. This suspension is then pre-incubated for 15 minutes at 37° C., after which the suspension is centrifuged again at 45,000 G for 10 minutes and the supernatant discarded. The resulting pellet (approximately 1 gram) is resuspended in 150 ml of a buffer of 15 mM TRIS-hydrochloride containing 0.01 percent ascorbic acid with a final pH of 7.7 and also containing 10 μM pargyline and 4 mM calcium chloride (CaCl 2 ). The suspension is kept on ice at least 30 minutes prior to use.
[0079] The inhibitor, control or vehicle is then incubated according to the following procedure. To 50 μl of a 20 percent dimethylsulfoxide (DMSO)/80 percent distilled water solution is added 200 μl of tritiated 5-hydroxytryptamine (2 nM) in a buffer of 50 mM TRIS.hydrochloride containing 0.01 percent ascorbic acid at pH 7.7 and also containing 10 μM pargyline and 4 μM calcium chloride, plus 100 nM of 8-hydroxy-DPAT (dipropylaminotetraline) and 100 nM of mesulergine. To this mixture is added 750 μl of bovine caudate tissue, and the resulting suspension is vortexed to ensure a homogenous suspension. The suspension is then incubated in a shaking water bath for 30 minutes at 25° C. After incubation is complete, the suspension is filtered using glass fiber filters (e.g., Whatman GF/B-filters.™.). The pellet is then washed three times with 4 ml of a buffer of 50 mM TRIS.hydrochloride at pH 7.7. The pellet is then placed in a scintillation vial with 5 ml of scintillation fluid (aquasol 2™) and allowed to sit overnight. The percent inhibition can be calculated for each dose of the compound. An IC 50 value can then be calculated from the percent inhibition values.
[0080] The activity of the compounds of the present invention for 5-HT 1A binding ability can be determined according to the following procedure. Rat brain cortex tissue is homogenized and divided into samples of 1 gram lots and diluted with 10 volumes of 0.32 M sucrose solution. The suspension is then centrifuged at 900 G for 10 minutes and the supernate separated and recentrifuged at 70,000 G for 15 minutes. The supernate is discarded and the pellet re-suspended in 10 volumes of 15 mM TRIS.hydrochloride at pH 7.5. The suspension is allowed to incubate for 15 minutes at 37° C. After pre-incubation is complete, the suspension is centrifuged at 70,000 G for 15 minutes and the supernate discarded. The resulting tissue pellet is resuspended in a buffer of 50 mM TRIS.hydrochloride at pH 7.7 containing 4 mM of calcium chloride and 0.01 percent ascorbic acid. The tissue is stored at −70° C. until ready for an experiment. The tissue can be thawed immediately prior to use, diluted with 10 μm pargyline and kept on ice.
[0081] The tissue is then incubated according to the following procedure. Fifty microliters of control, inhibitor, or vehicle (1 percent DMSO final concentration) is prepared at various dosages. To this solution is added 200 μl of tritiated DPAT at a concentration of 1.5 nM in a buffer of 50 mM TRIS.hydrochloride at pH 7.7 containing 4 mM calcium chloride, 0.01 percent ascorbic acid and pargyline. To this solution is then added 750 μl of tissue and the resulting suspension is vortexed to ensure homogeneity. The suspension is then incubated in a shaking water bath for 30 minutes at 37° C. The solution is then filtered, washed twice with 4 ml of 10 mM TRIS.hydrochloride at pH 7.5 containing 154 mM of sodium chloride. The percent inhibition is calculated for each dose of the compound, control or vehicle. IC 50 values are calculated from the percent inhibition values.
[0082] The agonist and antagonist activities of the compounds of the invention at 5-HT 1A and 5-HT 1D receptors can be determined using a single saturating concentration according to the following procedure. Male Hartley guinea pigs are decapitated and 5-HT 1A receptors are dissected out of the hippocampus, while 5-HT receptors are obtained by slicing at 350 mM on a McIlwain tissue chopper and dissecting out the substantia nigra from the appropriate slices. The individual tissues are homogenized in 5 mM HEPES buffer containing 1 mM EGTA (pH 7.5) using a hand-held glass-Teflon® homogenizer and centrifuged at 35,000×g for 10 minutes at 4° C. The pellets are resuspended in 100 mM HEPES buffer containing 1 mM EGTA (pH 7.5) to a final protein concentration of 20 mg (hippocampus) or 5 mg (substantia nigra) of protein per tube. The following agents are added so that the reaction mix in each tube contained 2.0 mM MgCl 2 , 0.5 mM ATP, 1.0 mM cAMP, 0.5 mM IBMX, 10 mM phosphocreatine, 0.31 mg/mL creatine phosphokinase, 100 μM GTP and 0.5-1 microcuries of [ 32 P]-ATP (30 Ci/mmol: NEG-003—New England Nuclear). Incubation is initiated by the addition of tissue to siliconized microfuge tubes (in triplicate) at 30° C. for 15 minutes. Each tube receives 20 μL tissue, 10 μL drug or buffer (at 10× final concentration), 10 μL 32 nM agonist or buffer (at 10× final concentration), 20 μL forskolin (3 μM final concentration) and 40 μL of the preceding reaction mix. Incubation is terminated by the addition of 100 μL 2% SDS, 1.3 mM cAMP, 45 mM ATP solution containing 40,000 dpm [ 3 H]-cAMP (30 Ci/mmol: NET-275—New England Nuclear) to monitor the recovery of CAMP from the columns. The separation of [ 32 P]-ATP and [ 32 P]-cAMP is accomplished using the method of Salomon et al., Analytical Biochemistry, 1974, 58, 541-548. Radioactivity is quantified by liquid scintillation counting. Maximal inhibition is defined by 10 μM (R)-8-OH-DPAT for 5-HT 1A receptors, and 320 nM 5-HT for 5-HT 1D receptors. Percent inhibitions by the test compounds are then calculated in relation to the inhibitory effect of (R)-8-OH-DPAT for 5-HT 1A receptors or 5-HT for 5-HT 1D receptors. The reversal of agonist induced inhibition of forskolin-stimulated adenylate cyclase activity is calculated in relation to the 32 nM agonist effect.
[0083] The compounds of the invention can be tested in vivo for antagonism of 5-HT 1D agonist-induced hypothermia in guinea pigs according to the following procedure.
[0084] Male Hartley guinea pigs from Charles River, weighing 250-275 grams on arrival and 300-600 grams at testing, serve as subjects in the experiment. The guinea pigs are housed under standard laboratory conditions on a 7 a.m. to 7 p.m. lighting schedule for at least seven days prior to experimentation. Food and water are available ad libitum until the time of testing.
[0085] The compounds of the invention can be administered as solutions in a volume of 1 ml/kg. The vehicle used is varied depending on compound solubility. Test compounds are typically administered either sixty minutes orally (p.o.) or 0 minutes subcutaneously (s.c.) prior to a 5-HT 1D agonist, such as [3-(1-methylpyrrolidin-2-ylmethyl)-1H-indol-5-yl]-(3-nitropyridin-3-yl)-amine, which can be prepared as described in PCT Publication WO93/11106, published Jun. 10, 1993, the contents of which are incorporated herein by reference in its entirety, and which is administered at a dose of 5.6 mg/kg, s.c. Before a first temperature reading is taken, each guinea pig is placed in a clear plastic shoe box containing wood chips and a metal grid floor and allowed to acclimate to the surroundings for 30 minutes. Animals are then returned to the same shoe box after each temperature reading. Prior to each temperature measurement, each animal is firmly held with one hand for a 30-second period. A digital thermometer with a small animal probe is used for temperature measurements. The probe is made of semi-flexible nylon with an epoxy tip. The temperature probe is inserted 6 cm. into the rectum and held there for 30 seconds or until a stable recording is obtained. Temperatures are then recorded.
[0086] In p.o. screening experiments, a “pre-drug” baseline temperature reading is made at −90 minutes, the test compound is given at −60 minutes and an additional −30 minute reading is taken. The 5-HT 1D agonist is then administered at 0 minutes and temperatures are taken 30, 60, 120 and 240 minutes later. In subcutaneous screening experiments, a pre-drug baseline temperature reading is made at −30 minutes. The test compound and 5-HT 1D agonists are given concurrently and temperatures are taken at 30, 60, 120 and 240 minutes later.
[0087] Data are analyzed with two-way analysis of variants with repeated measures in Newman-Keuls post hoc analysis.
[0088] The active compounds of the invention can be evaluated as anti-migraine agents by testing the extent to which they mimic sumatriptan in contracting the dog isolated saphenous vein strip (P. P. A. Humphrey et al., Br. J. Pharmacol., 1988, 94, 1128). This effect can be blocked by methiothepin, a known serotonin antagonist. Sumatriptan is known to be useful in the treatment of migraine and produces a selective increase in carotid vascular resistance in the anesthetized dog. The pharmacological basis of sumatriptan efficacy has been discussed in W. Fenwick et al., Br. J. Pharmacol., 1989, 96, 83.
[0089] The serotonin 5-HT 1 agonist activity can be determined by the in vitro receptor binding assays, as described for the 5-HT 1A receptor using rat cortex as the receptor source and [ 3 H]-8-OH-DPAT as the radioligand (D. Hoyer et al., Eur. J. Pharm., 1985, 118, 13) and as described for the 5-HT 1D receptor using bovine caudate as the receptor source and [ 3 H]serotonin as the radioligand (R. E. Heuring and S. J. Peroutka, J. Neuroscience, 1987, 7, 894).
DETAILED DESCRIPTION OF THE INVENTION
[0090] Scheme 1 illustrates general methods suitable for preparing compounds of formula I wherein X is carbon.
[0091] Synthesis of aldehyde 2 from 1C involves treatment of 1C with a tertiary amine, preferably N,N′-tetramethyl ethlyenediamine or 1,4-diazabicyclo[2.2.2]-octane, with a lithium alkyl base, preferably butyl lithium, in an ether solvent, preferably diethyl ether, at a temperature from about −100° to −30° C., preferably −78° C. Quenching with dimethylformamide at reaction temperature from about −100° to −30° C., where −78° C. is preferred, affords aldehyde 2.
[0092] Pyridyl piperazinyl aldehyde 4 is produced by the reaction of compound 2,2-chloro-pyridine-3-carbaldehyde, with G1* or G2* in the presence of a base such as a trialkyl amine or an alkali metal carbonate (a base that is inert towards 2, G1 or, and the solvent) in a solvent such as water, 1,4-dioxane, n-butanol, N,N-dimethyl-formamide, or dimethyl sulfoxide, at reaction temperature from about 40° to 150° C. The preferred base is potassium carbonate, the preferred solvent is water, and the preferred temperature is from about 90° to about 120° C.
[0093] Condensation of 4 and N-substituted lactam 8, in the presence of an amine or metal hydride base affords 5. The N-substituent (R3) can be vinyl or C(═O)R, (wherein R=C 1 -C 8 alkyl-straight chain, branched or (if C 3 -C 8 ) cyclic, or aryl). R=tert-butyl is preferred (Sasaki, H. et al. J. Med. Chem., 1991, 34, 628-633). The base can be sodium hydride or sodium bis(trimethylsilylamide), where sodium bis(trimethylsilylamide) is preferred. The preferred solvent is tetrahydrofuran. The reaction temperature is from about −30° to 100° C., preferably from about −10° to about 30° C. Reduction of the carbon-carbon double bond of 5 to generate 6 can be achieved by placing 5 in a reaction inert solvent such as a lower alcohol, wherein methanol or ethanol are preferred, adding a noble metal catalyst suspended on a solid support, such as platinum or palladium, where 10% palladium on carbon is preferred, then placing the mixture under a hydrogen atmosphere, from about 1 atm to 5 atm, where about 3 to about 4 atm is preferred, at a temperature from about 10° to 100° C., where 40° to 60° C. is preferred, and then shaking the mixture. In the case where R 6 =benzyl or some other group that is labile under hydrogenation conditions, the corresponding NH derivative (R 6 =H) is formed.
[0094] The conversion of 6 to 1a, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 6, an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, a base such as potassium phosphate, potassium carbonate, sodium carbonate, thallium carbonate, cesium carbonate, potassium tert-butoxide, lithium tert-butoxide, or sodium tert-butoxide, where potassium carbonate is preferred, a diamine, such as 1,2-ethylenediamine, N,N′-dimethyl ethylenediamine, or cis-1,2-diaminocyclohexane, where N,N′-dimethylethylene-diamine is preferred, a cuprous chloride, bromide or iodide, where cuprous iodide is preferred, a small amount of water, where about 1 to 4 percent is preferred, in a reaction inert solvent such as 1,2-dimethoxyethane, diglyme, t-butyl methyl ether, tetrahydrofuran, benzene, toluene, where toluene is preferred, from about 40° to about 150° C., where about 80° to 120° C. is preferred. Alternatively, the conversion of 6 to 1a, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 6 and an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, with a base such as an alkali metal carbonate, an alkali metal amine base, an alkali metal phosphonate, or an alkali metal alkoxide, where cesium carbonate is preferred, a phosphine ligand, where 9,9-dimethyl-4,5-bis(diphenyl-phosphino)xanthene (XANTPHOS) is preferred, a palladium species, such as palladium (II) acetate or tris(dibenzylidene-acetone)dipalladium (0) or the corresponding chloroform adduct, where tris(dibenzylidene-acetone)dipalladium (0) is preferred, in an inert solvent such as 1,4-dioxane or toluene, where 1,4-dioxane is preferred, at a temperature from about 40° to about 160° C., where 80° to 120° C. is preferred. If R 6 =H, then further functionalization of the secondary amine can be carried out under standard alkylation or reductive amination conditions known to one skilled in the art.
[0095] Another route to access compounds of formula 1a and 1b is shown in Scheme 1. The conversion of 5 to 1b, wherein R 3 is Ar 1 , an optionally substituted aryl or heteroaryl group as described above, can be accomplished by treating 5, an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, a base such as potassium phosphate, potassium carbonate, sodium carbonate, thallium carbonate, cesium carbonate, potassium tert-butoxide, lithium tertbutoxide, or sodium tertbutoxide, where potassium carbonate is preferred, a diamine, such as 1,2-ethylenediamine, N,N′-dimethyl-ethylenediamine, or cis-1,2-diaminocyclohexane, where N,N′-dimethylethylenediamine is preferred, cuprous chloride, bromide or iodide, where cuprous iodide is preferred, a small amount of water, where about 1 to 4 percent is preferred, in a reaction inert solvent such as 1,2-dimethoxyethane, diglyme, t-butyl methyl ether, tetrahydrofuran, benzene, toluene, where toluene is preferred, from about 40° to 150° C., where about 80° to about 120° C. is preferred. Alternatively, the conversion of 5 to 1b, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 5 and an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, with a base such as an alkali metal carbonate, an alkali metal amine base, an alkali metal phosphonate, or an alkali metal alkoxide, where cesium carbonate is preferred, a phosphine ligand, where 9,9-dimethyl-4,5-bis(diphenylphosphino)xanthene (XANTPHOS) is preferred, a palladium species, such as palladium (II) acetate or tris(dibenzylideneacetone)dipalladium (0) or the corresponding chloroform adduct, where tris(dibenzylideneacetone)dipalladium (0) is preferred, in an inert solvent such as 1,4-dioxane or toluene, where 1,4-dioxane is preferred, at a temperature from about 40° to about 160° C., where 80° to 120° C. is preferred. Conversion of 1b to 1a can be achieved by placing 1b in a reaction inert solvent such as a lower alcohol, wherein methanol or ethanol are preferred, adding a noble metal catalyst suspended on a solid support, such as platinum or palladium, where 10% palladium on carbon is preferred, then placing the mixture under a hydrogen atmosphere, from about 1 atm to 5 atm, where about 3 to 4 atm is preferred, at a temperature from about 10° to about 100° C., where 40° to 60° C. is preferred, and then shaking the mixture. In the case where R 6 =benzyl or some other group that is labile towards hydrogenation conditions, the corresponding secondary amine derivative (R 6 =H) is formed. If R 6 =H, further functionalization of the secondary amine can be carried out under standard alkylation or reductive amination conditions known to one skilled in the art.
[0096] Another route to 1b is shown in Scheme 1. The conversion of 7 to 8, wherein R 3 is Ar 1 , an optionally substituted aryl or heteroaryl group as described above and in claim 1 , can be accomplished by treating 7, an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, with a base such as potassium phosphate, potassium carbonate, sodium carbonate, thallium carbonate, cesium carbonate, potassium tert-butoxide, lithium tert-butoxide, or sodium tertbutoxide, where potassium carbonate is preferred, a diamine, such as 1,2-ethylenediamine, N,N′-dimethyl-ethylenediamine, or cis-1,2-diaminocyclohexane, where N,N′-dimethylethylenediamine is preferred, cuprous chloride, bromide or iodide, where cuprous iodide is preferred, and a small amount of water, where about 1-4% is preferred, in a reaction inert solvent such as 1,2-dimethoxyethane, diglyme, t-butyl methyl ether, tetrahydrofuran, benzene, toluene, where toluene is preferred, from about 40° to about 150° C., where about 80° to 120° C. is preferred. Alternatively, the conversion of 7 to 8 can be accomplished by treating 7 and an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, with a base such as an alkali metal carbonate, an alkali metal amine base, an alkali metal phosphonate, or an alkali metal alkoxide, where cesium carbonate is preferred, a phosphine ligand, where 9,9-dimethyl-4,5-bis(diphenylphosphino)xanthene (XANTPHOS) is preferred, a palladium species, such, as palladium (II) acetate or tris (dibenzylideneacetone)dipalladium (0) or the corresponding chloroform adduct, where tris(dibenzylideneacetone)dipalladium (0) is preferred, in an inert solvent such as 1,4-dioxane or toluene, where 1,4-dioxane is preferred, at a temperature from about 40° to 160° C., where 80° to 120° C. is preferred.
[0097] Compound 8 can also be prepared by condensation of R 3 —NH 2 with 8a, in a solvent such as water, acetonitrile, 1,4-dioxane, or tetrahydrofuran, where tetrahydrofuran is preferred, at a temperature from about 100 to 120° C., where 50° to 80° C. is preferred, in the presence or absence of a base, such as triethylamine, diisopropylethyl amine, an alkali metal hydroxide or an alkali metal carbonate, where cesium carbonate is preferred, where the group B of 8a can be F, Cl, Br, I, OC 1 -C 4 alkyl, OH, or an activated carboxylic acid group derived from reaction of the acid with a standard carboxylic acid activating reagent such as, but not limited to, a carbodiimide (dicyclohexyl carbodiimide, commonly abbreviated “DCC,” 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydro-chloride salt) or tripropyl-phosphonic anhydride, where B=Cl is preferred, where the group A of 8a can be F, Cl, Br, I, or an alkyl or aryl sulfonate, where A=Cl is preferred. Synthesis of 1b can be accomplished by reacting 4 and 8 in a solvent such as tetrahydrofuran, tert-butyl methyl ether, or 1,4-dioxane, where tetrahydrofuran is preferred, with an alkali metal amine base, such as sodium bis(trimethylsilylamide), potassium bis(trimethylsilylamide), lithium bis(trimethyl-silylamide), or lithium diisopropylamide, or an alkali metal hydride, such as sodium hydride or potassium hydride, where sodium bis(hexamethylsilylamide) is preferred, followed by the optional addition of diethylchlorophosphonate (in which case lithium diisopropyl amide is the preferred base) from about −30° to about 100° C., preferably from −10° to 30° C. Compound 1b can then be converted to compound 1a as described above. In the case where R 6 =benzyl or some other group that is labile towards hydrogenation conditions, the corresponding NH derivative (R 6 =H) is formed. If R 6 =H, further functionalization of the secondary amine can be carried out under standard alkylation or reductive amination conditions known to one skilled in the art.
[0098] Another method to make compounds of formula 1b described in Scheme 1 starts from pyridylaldehyde 2b, where D=chloro or fluoro, where fluoro is preferred. Reacting 2b and 8 in a solvent such as tetrahydrofuran, tert-butylmethyl ether, or 1,4-dioxane, where tetrahydrofuran is preferred, with an alkali metal amine base, such as sodium bis(trimethylsilylamide), potassium bis(trimethylsilylamide), lithium bis-(trimethyl-silylamide), or lithium diisopropylamide, or an alkali metal hydride, such as sodium hydride or potassium hydride, where sodium bis(hexamethylsilylamide) is preferred, followed by the optional addition of diethylchlorophosphonate (in which case lithium diisopropyl amide is the preferred base) from about −30° to 100° C., preferably from −10° to 30° C., affords F. F can then be converted to 1b and 1b can be converted to 1a as described above.
[0099] Scheme 2 illustrates general methods suitable for preparing compounds of formula I wherein X is O (Formula 1e below).
[0100] Treatment of a mixture of 3-fluoro-pyridine-2-carbaldehyde 2 and G1* or G2* in a solvent such as water, 1,4-dioxane, n-butanol, N,N-dimethylformamide, dimethyl sulfoxide, or acetonitrile, where water is preferred, with a base that is inert toward 2, G1 or G2, and the solvent, such as a trialkyl amine or an alkali metal carbonate, wherein potassium carbonate is preferred, at reaction temperature from about 40° to about 150° C., where 90° to 120° C. is preferred, affords pyridyl piperazinyl aldehyde 4. Addition of 4 and an N-substituted morpholinone 12, where the N-substituent is vinyl or C(═O)R, (wherein R=C 1 -C 8 alkyl, straight chain or branched, C 3 -C 8 cycloalkyl, or aryl), wherein C(═O)R with R=tertbutyl is preferred (Sasaki, H. et al. J. Med. Chem., 1991, 34, 628-633), with an amine or hydride metal base such as sodium hydride or sodium bis(trimethylsilylamide), where sodium bis(trimethylsilylamide) is preferred, in an inert reaction solvent, where tetrahydrofuran is preferred, from about −30° to about 100° C., preferably from about −10° to about 30° C., affords 9. Reduction of the carbon-carbon double bond of 9 to generate 10 can be achieved by placing 9 in a reaction inert solvent such as a lower alcohol, wherein methanol or ethanol are preferred, adding a noble metal catalyst suspended on a solid support, such as platinum or palladium, where 10% palladium on carbon is preferred, then placing the mixture under a hydrogen atmosphere, from about 1 atm to 5 atm, where about 3 to 4 atm is preferred, at a temperature from about 10° to about 100° C., where 40 to 60° C. is preferred, and then shaking the mixture. In the case where R 6 =benzyl or some other group that is labile towards hydrogenation conditions, the corresponding NH derivative (R 6 =H) is formed.
[0101] The conversion of 10 to 1e, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 10, an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, a base such as potassium phosphate, potassium carbonate, sodium carbonate, thallium carbonate, cesium carbonate, potassium tert-butoxide, lithium tertbutoxide, or sodium tert-butoxide, where potassium carbonate is preferred, a diamine, such as 1,2-ethylenediamine, N,N′-dimethylethylenediamine, or cis-1,2-diaminocyclo-hexane, where N,N′-dimethylethylenediamine is preferred, a cuprous chloride, bromide or iodide, where cuprous iodide is preferred, a small amount of water, where about 1 to 4 percent is preferred, in a reaction inert solvent such as 1,2-dimethoxyethane, diglyme, t-butyl methyl ether, tetrahydrofuran, benzene, toluene, where toluene is preferred, from about 40° to 150° C., where about 80° to about 120° C. is preferred. Alternatively, the conversion of 10 to 1e, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 10 and an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, with a base such as an alkali metal carbonate, an alkali metal amine base, an alkali metal phosphonate, or an alkali metal alkoxide, where cesium carbonate is preferred, a phosphine ligand, where 9,9-dimethyl-4,5-bis(diphenylphosphino)xanthene (XANTPHOS) is preferred, a palladium species, such as palladium (II) acetate or tris(dibenzylideneacetone)dipalladium (0) or the corresponding chloroform adduct, where tris(dibenzylideneacetone)dipalladium (0) is preferred, in an inert solvent such as 1,4-dioxane or toluene, where 1,4-dioxane is preferred, at a temperature from about 40° to about 160° C., where 80° to 120° C. is preferred. If R 6 =H, then further functionalization of the secondary amine can be carried out under standard alkylation or reductive amination conditions known to one skilled in the art.
[0102] Another route to access compounds of formula 1d and 1e is shown in Scheme 2. The conversion of 9 to 1d, wherein R3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 9, an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, a base such as potassium phosphate, potassium carbonate, sodium carbonate, thallium carbonate, cesium carbonate, potassium tert-butoxide, lithium tert-butoxide, or sodium tert-butoxide, where potassium carbonate is preferred, a diamine, such as 1,2-ethylenediamine, N,N′-dimethyl-ethylenediamine, or cis-1,2-diaminocyclohexane, where N,N′-dimethylethylenediamine is preferred, cuprous chloride, bromide or iodide, where cuprous iodide is preferred, a small amount of water, where about 1 to 4 percent is preferred, in a reaction inert solvent such as 1,2-dimethoxyethane, diglyme, t-butyl methyl ether, tetrahydrofuran, benzene, toluene, where toluene is preferred, from about 40° to about 150° C., where about 80° to 120° C. is preferred. Alternatively, the conversion of 9 to 1d, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 9 and an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, with a base such as an alkali metal carbonate, an alkali metal amine base, an alkali metal phosphonate, or an alkali metal alkoxide, where cesium carbonate is preferred, a phosphine ligand, where 9,9-dimethyl-4,5-bis(diphenylphosphino)xanthene (XANTPHOS) is preferred, a palladium species, such as palladium(II)acetate or tris(dibenzylideneacetone) dipalladium(0) or the corresponding chloroform adduct, where tris(dibenzylidene-acetone)dipalladium(0) is preferred, in an inert solvent such as 1,4-dioxane or toluene, where 1,4-dioxane is preferred, at a temperature from about 40° to about 160° C., where 80° to 120° C. is preferred. Conversion of 1d to 1e can be achieved by placing 1d in a reaction inert solvent such as a lower alcohol, wherein methanol or ethanol are preferred, adding a noble metal catalyst suspended on a solid support, such as platinum or palladium, where 10% palladium on carbon is preferred, then placing the mixture under a hydrogen atmosphere, from about 1 atm to 5 atm, where about 3 to 4 atm is preferred, at a temperature from about 10° to about 100° C., where 40° to 60° C. is preferred, and then shaking the mixture. In the case where R 6 =benzyl or some other group that is labile towards hydrogenation conditions, the corresponding secondary amine derivative (R 6 =H) is formed. If R 6 =H, further functionalization of the secondary amine can be carried out under standard alkylation or reductive amination conditions known to one skilled in the art.
[0103] Another route that allows for the access to 1d is shown in Scheme 2. The conversion of 13 to 12, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 13, an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, a base such as potassium phosphate, potassium carbonate, sodium carbonate, thallium carbonate, cesium carbonate, potassium tert-butoxide, lithium tertbutoxide, or sodium tert-butoxide, where potassium carbonate is preferred, a diamine, such as 1,2-ethylenediamine, N,N′-dimethyl-ethylenediamine, or cis-1,2-diamino-cyclohexane, where N,N′-dimethylethylenediamine is preferred, cuprous chloride, bromide or iodide, where cuprous iodide is preferred, a small amount of water, where about 1 to 4 percent is preferred, in a reaction inert solvent such as 1,2-dimethoxyethane, diglyme, t-butyl methyl ether, tetrahydrofuran, benzene, toluene, where toluene is preferred, from about 40° to about 150° C., where about 80° to 120° C. is preferred affords 12. Alternatively, the conversion of 13 to 12, wherein R 3 is an optionally substituted aryl or heteroaryl group, can be accomplished by treating 13 and an aryl or heteroaryl chloride, bromide, iodide, or sulfonate, where the bromide is preferred, with a base such as an alkali metal carbonate, an alkali metal amine base, an alkali metal phosphonate, or an alkali metal alkoxide, where cesium carbonate is preferred, a phosphine ligand, where 9,9-dimethyl-4,5-bis(diphenylphosphino)xanthene (XANTPHOS) is preferred, a palladium species, such as palladium(II)acetate or tris(dibenzylideneacetone)dipalladium(0) or the corresponding chloroform adduct, where tris(dibenzylideneacetone)dipalladium(0) is preferred, in an inert solvent such as 1,4-dioxane or toluene, where 1,4-dioxane is preferred, at a temperature from about 40° to about 160° C., where 80° to 120° C. is preferred. In addition, 12 is an N-substituted morpholinone, where the R 3 group may also be defined as an N-substituent defined as vinyl or C(═O)R, (wherein R=C 1 -C 8 alkyl, straight chain or branched, C 3 -C 8 cycloalkyl, or aryl), wherein C(═O)R with R=tert-butyl is preferred is prepared by adding RCOCl (where R is defined above) to morpholinone 13 and a tertiary amine base, wherein triethylamine is preferred, in a chlorinated solvent, wherein methylene chloride is preferred at a temperature from −30° C. to 50° C. wherein 0° C. is preferred to afford morpholinone 12.
[0104] In turn, morpholinone 13 was prepared using literature methods (Pfeil, E., et al., Angew. Chem., 1967, 79, 188; Lehn, J.-M., et al., Helv. Chim. Acta, 1976, 59, 1566-1583; Sandmann, G., et al., J. Agric. Food Chem., 2001, 49, 138-141. 13 may also be prepared by condensation of 14 in a solvent such as water, acetonitrile, 1,4-dioxane, or tetrahydrofuran, where tetrahydrofuran is preferred, at a temperature from about 10° to about 120° C., where 50° to 80° C. is preferred, in the presence or absence of a base, such as triethylamine, diisopropylethyl amine, an alkali metal hydroxide or an alkali metal carbonate, where cesium carbonate is preferred, where the group D of 14 can be F, Cl, Br, I, OC1-C4 alkyl, OH, or an activated carboxylic acid group derived from reaction of the acid with a standard carboxylic acid activating reagent such as, but not limited to, a carbodiimide (dicyclohexyl carbodiimide, 1-(3-dimethylaminopropyl) 3 -ethyl-carbo-diimide hydrochloride salt) or tripropylphosphonic anhydride, where D=Cl is preferred. R 9 and/or R 10 can be hydrogen, or an appropriately designed group known in the art which may be removed prior to cyclization such as a carbamate or phthalimide in which the phthalimide is preferred and removed prior to cyclization with hydrazine. Synthesis of 1d can be accomplished by reacting 4 and 12 in a solvent such as tetrahydrofuran, tert-butyl methyl ether, or 1,4-dioxane, where tetrahydrofuran is preferred, with an alkali metal amine base, such as sodium bis(trimethylsilylamide), potassium bis(trimethyl-silylamide), lithium bis(trimethylsilylamide), or lithium diisopropylamide, or an alkali metal hydride, such as sodium hydride or potassium hydride, where sodium bis(hexamethylsilylamide) is preferred, followed by the optional addition of diethylchlorophosphonate (in which case lithium diisopropyl amide is the preferred base) from about −30° to 100° C., preferably from −10° to 30° C. 1d can then be converted to 1e as described above. In the case where R 6 =benzyl or some other group that is labile towards hydrogenation conditions, the corresponding NH derivative (R 6 =H) is formed. If R 6 =H, further functionalization of the secondary amine can be carried out under standard alkylation or reductive amination conditions known to one skilled in the art.
[0105] Alternatively, 12 can also be prepared by treatment of 11 with an appropriate oxidation reagent such as potassium permanganate and a quaternary ammonium salt where benzyltrimethylammonium chloride is preferred in a chlorinated solvent such as methylene chloride, dichloroethane, chloroform, where methylene chloride is preferred, at a temperature from about 25° to 160° C., where 30° to 60° C. is preferred. The synthesis of 11 can be accomplished by treating morpholine with an aryl or heteroaryl chloride bromide, iodide, or sulfonate, where the bromide is preferred, a base such as potassium phosphate, potassium carbonate, sodium carbonate, thallium carbonate, cesium carbonate, potassium tert-butoxide, lithium tert-butoxide, or sodium tert-butoxide, where sodium tert-butoxide is preferred, a phosphine ligand, where BINAP or triphenylphosphine is preferred, a palladium species, such as palladium(II)acetate or tris(dibenzylideneacetone)dipalladium(0) or the corresponding chloroform adduct, where tris(dibenzylideneacetone)dipalladium(0) is preferred, in an inert solvent such as 1,4-dioxane or toluene, where 1,4-dioxane is preferred, at a temperature from about 40° to about 160° C., where 80° to 120° C. is preferred.
[0106] Another method for synthesizing compounds of formula 1d described in Scheme 2 starts from pyridylaldehyde 2b, where D=chloro or fluoro, where fluoro is preferred. Reacting 2b and 12 in a solvent such as tetrahydrofuran, tert-butyl methyl ether, or 1,4-dioxane, where tetrahydrofuran is preferred, with an alkali metal amine base, such as sodium bis(trimethylsilylamide), potassium bis(trimethylsilylamide), lithium bis (trimethyl-silylamide), or lithium diisopropylamide, or an alkali metal hydride, such as sodium hydride or potassium hydride, where sodium bis(hexamethylsilylamide) is preferred, followed by the optional addition of diethylchlorophosphonate (in which case lithium diisopropyl amide is the preferred base) from about −30° to about 100° C., preferably from −10° to 30° C., affords 1d. 1d can then be converted to 1e as described above. The aryl halides used in the coupling are prepared via the general methods outlined in U.S. Pat. No. 5,612,359 (Preparations 2-9); Guay, D., et al. Biorg. Med. Chem. Lett. 2002, 12,1457-1461; Sall, D. J., et al. J. Med. Chem. 2000, 43, 649-663; Olah, G. A., et al. J. Am. Chem. Soc. 1971, 93, 6877-6887; Brown, H. C. et al. J. Am. Chem. Soc. 1957, 79, 1906-1909; Nenitzescu, C., et al., I. J. Am. Chem. Soc. 1950, 72, 3483-3486; Muci, A. R.; Buchwald, S. L. Top. Curr. Chem .; Springer-Verlag: Berlin Heidelberg, 2002; 219,131-209; DE 19650708; Howard, H. R.; EP 104860; EP 0501579A; Wang, X., et al. Tetrahedron Lett., 2000, 41, pp. 4335-4338. In cases where an alcohol was present on the aryl halide, treatment of the alcohol with an alkali metal hydride or alkali metal hydroxide, such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, or cesium hydroxide, where sodium hydride is preferred, in a solvent such as tetrahydrofuran, N,N-dimethylformamide, or dimethylsulfoxide, where tetrahydrofuran is preferred, at a temperature from about −20° to about 50° C., followed by addition of an alkyl halide or tosylate, where an alkyl iodide is preferred, affords the corresponding ether.
[0107] Examples of specific compounds of Formula 1 are the following:
EXAMPLE 1
1-[4-(3,5-Dimethyl-isoxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmeth-ylene]-piperidin-2-one
EXAMPLE 2
2-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-4-[4-(tetrahydro-pyran-4-yl)-phen-yl]-morpholin-3-one
EXAMPLE 3
1-[4-(3,5-Dimethyl-isoxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmeth-yl]-piperidin-2-one
EXAMPLE 4
2-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-4-[4-(tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one
EXAMPLE 5
1-[4-(2-Methyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
EXAMPLE 6
1-[4-(2-tert-Butyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
EXAMPLE 7
1-[4-(2-Isopropyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
EXAMPLE 8
1-[4-(2,5-Dimethyl-oxazol-4-yl)-phenyl]3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmeth-yl]-piperidin-2-one
EXAMPLE 9
3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-[4-(tetrahydro-pyran-4-yl)-phen-yl]-piperidin-2-one
EXAMPLE 10
3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-[4-(tetrahydro-pyran-4-yl)-phenyl]-pyrrolidin-2-one
EXAMPLE 11
3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-2-yl-phenyl)-pyrrolidin-2-one
EXAMPLE 12
[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-4-yl-phenyl)-pyrrolidin-2-one
EXAMPLE 13
3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-5-yl-phenyl)-pyrrolidin-2-one
EXAMPLE 14
1-[4-(2-Methyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one
EXAMPLE 15
1-[4-(1-Methoxy-cyclobutyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
EXAMPLE 16
3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-trifluoromethyl-phenyl)-pyrrolidin-2-one
EXAMPLE 17
1-[4-(1-Hydroxy-cyclopentyl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one
EXAMPLE 18
1-[4-(1-Hydroxy-1-methyl-ethyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one
EXAMPLE 19
1-(4-tert-Butyl-phenyl)-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one
EXAMPLE 20
1-[4-(1-Hydroxy-cyclopentyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
EXAMPLE 21
1-(4-tert-Butyl-phenyl)-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
EXAMPLE 22
3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-phenyl-piperidin-2-one
EXAMPLE 23
3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-trifluoromethoxy-phenyl)-piperidin-2-one
EXAMPLE 24
11-[4-(1-Hydroxy-1-methyl-ethyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-yl-methyl]-piperidin-2-one
EXAMPLE 25
1-[4-(1-Hydroxy-cyclobutyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
[0108] Preparation 1
[0109] 2-(4-Methyl-piperazin-1-yl)-pyridine-3-carbaldehyde. A mixture of 1-methylpiperazine (12.8 mL, 120 mmol), potassium carbonate (13.6 g, 99 mmol), and 2-chloro-pyridine-3-carbaldehyde (9.3 g, 66 mmol) in water (75 mL) and 1,4-dioxane (33 mL) was heated at 100° C. for 18 h. The solution was cooled to room temperature, poured into water and extracted with methylene chloride. The combined organic layers were dried (Na 2 SO 4 ) and concentrated to afford 13.2 g of an oil (98% yield). MS (AP/CI) 206.2 (M+1). 13 C NMR (100 MHz, CDCl 3 ) 46.3, 51.2, 55.2, 116.1, 119.6, 140.6, 152.7, 161.8, 190.1.
[0110] Preparation 2: General Aldol Procedure
[0111] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-pyrrolidin-2-one. A solution of 10.0 g (49 mmol) of 2-(4-methyl-piperazin-1-yl)-pyridine-3-carbaldehyde and 6.2 g (49 mmol) of N-acetylpyrrolidinone in 100 mL of tetrahydro-furan was slowly added to a 0° C. suspension of 6.45 g (161 mmol, 60% by weight) of sodium hydride in 100 mL of tetrahydrofuran over a 30 minute period. After the addition was complete, the mixture was stirred 10 min at 0° C. and then stirred at room temperature for 18 h. The reaction mixture was quenched into water and extracted with methylene chloride. The organic layer was dried with sodium sulfate and concentrated to provide a yellow solid. Recrystallization from ethyl acetate provided 4.9 g (37% yield) of the title compound as a white solid. MS (AP/CI) 273.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 26.3, 39.9, 46.3, 50.4, 55.3, 116.7, 121.7, 127.2, 130.8, 137.0, 147.7, 161.3, 172.6.
[0112] Preparation 3
[0113] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-piperidin-2-one. The title compound was prepared in a procedure analogous to that described in Preparation 2. MS (AP/CI) 287.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 23.2, 26.6, 42.5, 46.3, 50.0, 55.4, 116.1, 121.4, 129.0, 133.4, 138.4, 147.6, 161.0, 166.5.
[0114] Preparation 4
[0115] 1-[4-(3,5-Dimethyl-isoxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmeth-ylene]-piperidin-2-one. The title compound was prepared in a procedure analogous to that described in Preparation 2. MS (AP/CI) 458.2 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 11.0, 11.8, 23.6, 27.1, 46.3, 49.9, 51.5, 55.4, 116.1, 116.3, 121.6, 126.6, 128.8, 129.3, 129.8, 134.0, 138.2, 143.1, 147.6, 158.8, 161.0, 164.9, 165.5.
[0116] Preparation 5: General Aldol Procedure for Morpholinones
[0117] 2-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-4-[4-(tetrahydro-pyran-4-yl)-phen-yl]-morpholin-3-one. A solution of of 2-(4-methyl-piperazin-1-yl)pyridine-3-carbaldehyde (196 mg, 0.96 mmol) and 4-[4-(tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one (300 mg, 1.1 mmol) in 10 ml tetrahydrofuran was added to a suspension of 115 mg of NaH (2.9 mmol, 60% by weight) in 5 ml tetrahydrofuran. The resulting mixture was heated at 65° C. for 18 h. After quenching into water, the mixture was extracted three times with dichloromethane. The combined organic extracts were dried with Na 2 SO 4 and concentrated to an oil. Recrystallization from ether afforded 240 mg of the title compound as a tan solid (56% yield). MS (AP/CI) 449.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 34.1, 41.4, 46.3, 49.3, 50.6, 55.5, 64.6, 68.5, 110.1, 117.1, 120.6, 125.3, 127.8, 138.4, 140.1, 144.8, 147.0, 159.8, 161.2.
[0118] Preparation 6: General Hydrogenation Procedure
[0119] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one. To a solution of 4.4 g (16.1 mmol) of 3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-pyrrolidin-2-one in 200 mL of ethanol was added 1.1 g of 10% Pd/C. Hydrogenation at 45 psi with heating at 50° C. was complete after 24 h. The reaction was filtered over celite using ethanol and concentrated to 4.4 g (99% yield) of the title compound as an oil. MS (AP/CI) 275.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 27.4, 32.3, 40.6, 41.4, 46.4, 50.6, 55.6, 118.8, 127.4, 138.5, 146.2, 162.3, 180.2.
[0120] Preparation 7
[0121] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one. The title compound was prepared in a procedure analogous to that described in Preparation 6. MS (AP/CI) 289.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 21.3, 25.4, 32.8, 41.2, 42.3, 46.1, 50.4, 55.4, 118.8, 127.6, 138.7, 145.9, 162.2, 174.9.
[0122] Preparation 8
[0123] 1-[4-(3,5-Dimethyl-isoxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmeth-yl]-piperidin-2-one. The title compound was prepared in a procedure analogous to that described in Preparation 6. MS (AP/CI) 460.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 11.1, 11.8, 22.3, 26.2, 33.8, 42.2, 46.4, 50.6, 51.7, 55.7, 116.3, 118.8, 126.7, 127.6, 128.9, 129.9, 139.1, 142.9, 146.2, 158.9, 162.3, 165.6, 172.7.
[0124] Preparation 9: General Hydrogenation Procedure for Morpholinones
[0125] 2-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-4-[4-(tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one. To a solution of 2-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethylene]-4-[4-(tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one (140 mg, 0.31 mmol) in 40 mL of ethanol was added 140 mg of 10% Pd/C. After hydrogenation at 40 psi for 18 h, additional 10% Pd/C (140 mg) was added. Hydrogenation at 40 psi was complete after another 18 h. The mixture was filtered over Celite using ethanol and concentrated to an oil. Purification by silica gel flash column chromatography (88:12, dichloromethane: methanol) afforded 25 mg of the title compound as an oil (18% yield). MS (AP/CI) 451.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 33.9, 34.1, 41.4, 46.3, 50.5, 50.6, 55.6, 62.9, 68.5, 77.6, 118.6, 125.9, 126.1, 127.9, 139.2, 140.0, 145.1, 146.4, 162.1, 168.9.
[0126] Preparation 10
4-[4-(Tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one
[0127] Step 1: 4-[4-(Tetrahydro-pyran-4-yl)-Phenyl]-morpholine. The title compound was prepared in a procedure analogous to that described in Buchwald et al. MS (APCI) 248.2 (M+H). Diagnostic 13 C NMR (100 MHz, CDCl 3 ) 34.3, 40.8, 49.8, 67.2, 68.7, 116.1, 127.6.
[0128] Step 2: 4-[4-(Tetrahydro-pyran-4-yl)-phenyl]-morpholin-3-one. 4-[4-(Tetrahydro-pyran-4-yl)-phenyl]-morpholine (2.37 g, 9.6 mmol), potassium permanganate (4.54 g, 29 mmol) and benzyltriethylammonium chloride (6.59 g, 29 mmol) were combined in dichloromethane (60 ml). After heating 4 h at 45° C., the cooled reaction mixture was quenched with aqueous sodium bisulfite and extracted three times with dichloromethane. The combined organic extracts were dried (Na 2 SO 4 ) and concentrated to an oil. Purification by silica gel chromatography afforded the title compound as a white foam (600 mg, 24% yield). MS (APCI) 262.2 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 34.0, 41.4, 49.9, 64.3, 68.5, 68.8, 125.8, 127.9, 139.7, 145.0, 166.9.
[0129] Preparation 11
[0130] 1-[4-(3,5-Dimethyl-isoxazol-4-yl)phenyl]-Piperidin-2-one. 1-(4-Iodo-phenyl)-piperidin-2-one (1.1 g, 3.7 mmol), potassium phosphate (1.57 g, 7.4 mmol), tetrakis (triphenylphosphine)palladium (0) (214 mg, 0.19 mmol) and 3,5-dimethyloxazole-4-boronic acid (780 mg, 5.5 mmol) were combined in 25 mL dioxane. After heating at 90° C. for 18 h, the cooled reaction mixture was poured in aqueous sodium bicarbonate and extracted with dichloromethane. The combined organic extracts were dried (Na 2 SO 4 ) and concentrated to an oil. Purification by silica gel chromatography (4:96, methanol:dichloromethane) afforded 340 mg of the title compound as an oil (34% yield). 1 H NMR (400 MHz, CDCl 3 ) □1.88-1.94 (m, 4H), 2.23 (s, 3H), 2.36 (s, 3H), 2.53 (t, 2H, J=6.2 Hz), 3.62-3.65 (m, 2H), 7.22 (d, 2H, J=8.4 Hz), and 7.29 (d, 2H, J=8.4 Hz). MS (APCI) 271.2 (M+1).
[0131] Aryl Halides
[0132] In cases where an alcohol was present on the aryl halide, treatment of the alcohol with an alkali metal hydride or alkali metal hydroxide, such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, or cesium hydroxide, where sodium hydride is preferred, in a solvent such as tetrahydrofuran, N,N-dimethyl-formamide, or dimethylsulfoxide, where tetrahydrofuran is preferred, at a temperature from about −20° to about 50° C., followed by addition of an alkyl halide or tosylate, where an alkyl iodide is preferred, affords the corresponding ether.
[0133] Preparation 12
[0134] 2-(4-Bromo-phenyl)-propan-2-ol. A solution of methyl p-bromobenzoate (3 g, 13.2 mmol) in tetrahydrofuran (14 mL) cooled to −30° C. was treated dropwise with methyl magnesium bromide (1 M in diethyl ether, 105.5 mmol, 105.5 mL). Upon completion of addition, the resulting suspension was allowed to warm to room temperature and was stirred for 5 h. Saturated aqueous ammonium chloride (100 mL) was added slowly and the mixture was diluted with ethyl acetate (100 mL). The organic and aqueous layers were separated and the aqueous layer was extracted with ethyl acetate (3×50 mL). The combined organic layers were dried over magnesium sulfate, were filtered, and the solvent was removed in vacuo. Purification by silica gel chromatography (10:1 hexanes—ethyl acetate) gave 2.2 g (79% yield) of 2-(4-bromo-phenyl)-propan-2-ol. 13 C NMR (100 MHz, CDCl 3 ) d 148.4, 131.4, 126.6, 120.8, 72.5, 31.9; MS (AP/CI) 197.1, 199.1 (M+H)+.
[0135] Preparation 13
[0136] 2-(5-Bromo-pyridin-2-yl)-propan-2-ol. The title compound was prepared using ethyl-5-bromo-2-carboxypyridine, but otherwise followed the general procedure for Preparation 12. 13 C NMR (100 MHz, CDCl 3 ) d 165.1, 148.9, 139.7, 120.4, 118.9, 72.2, 30.7; MS (AP/CI) 216.0, 218.1 (M+H)+.
[0137] Preparation 14
[0138] 1-(4-Bromo-phenyl)-cyclopentanol. The title compound was prepared using the procedure detailed for Preparation 12. 1 H NMR (400 MHz, CDCl 3 ) d 7.44 (d, J=8.3 Hz, 2H), 7.35 (d, J=8.7 Hz, 2H), 1.9 (m, 6H), 1.8 (m, 2H), 1.75 (s, 1H); 13 C NMR (100 MHz, CDCl 3 ) d 146.4, 131.4, 127.2, 120.8, 83.4, 42.2, 24.1.
[0139] Preparation 15
[0140] 1-(4-Bromo-phenyl)-cyclobutanol. The title compound was prepared using the procedure detailed for Preparation 12. 13 C NMR (400 MHz, CDCl 3 ) d 145.5, 131.7, 127.1, 121.3, 76.8, 37.2, 13.2; MS (AP/CI) 209.0, 211.0 (M+H−H2O)+.
[0141] Preparation 16
[0142] 4-(4-Bromo-phenyl)-tetrahydro-pyran-4-ol. The title compound was prepared using the procedure detailed for Preparation 12. 13 C NMR (100 MHz, CDCl 3 ) d 38.8, 63.9, 70.6, 121.3, 126.6, 131.7, 147.4.
[0143] Preparation 17
4-(4-Bromophenyl)-tetrahydropyran
[0144] A solution of 4-(4-bromo-phenyl)-tetrahydro-pyran-4-ol (859 mg, 3.3 mmol) and triethylsilane (596 μL, 3.7 mmol) in 12 mL dichloromethane was chilled in an ice bath. Trifluoroacetic acid (2.54 mL, 33 mmol) was added in a dropwise manner over 20 min. After 1 h at 0° C. the reaction mixture was stirred at room temperature for 3 h. 1N aqueous NaOH was added until the aqueous pH remained basic, and the mixture was extracted three times with dichloromethane. The organic extracts were combined, dried (Na 2 SO 4 ) and concentrated to an oily solid. Purification by silica gel chromatography (5:95, ethyl acetate:hexanes) afforded the title compound as a white solid (640 mg, 80% yield). 13 CNMR (100 MHZ, CDCl 3 ) 34.0, 41.3, 68.5, 120.2, 128.7, 131.8, 145.0.
[0145] Preparation 18
[0146] 1-Bromo-4-(1-methoxy-1-methylethyl)-benzene. 2-(4-Bromo-phenyl)propan-2-ol (Preparation 17, 1.77 g, 8.2 mmol) and methyl iodide (0.5 mL, 8.2 mmol) in tetrahydrofuran (100 mL) were treated with sodium hydride (60% dispersion in mineral oil, 328 mg, 8.2 mmol). The mixture was stirred for 24 h at room temperature, was poured into 0.5 M aqueous hydrochloric acid, and the mixture was extracted with ethyl acetate. The organic layer was washed with brine, was dried over magnesium sulfate, was filtered, and the solvent was removed in vacuo. The residue was purified by silica gel chromatography (200:1 hexanes-ethyl acetate) to afford 500 mg (27% yield) of the title compound. 13 C NMR (100 MHz, CDCl 3 ) d 145.4, 131.5, 127.9, 121.0, 76.7, 50.9, 28.1; MS (AP/CI) 197.0, 199.0 (M+H−OMe)+.
[0147] Preparation 19
[0148] 1-Bromo-4-(1-methoxy-cyclobutyl)-benzene. The title compound was prepared using the procedure detailed for Preparation 17. 13 C NMR (100 MHz, CDCl 3 ) d 142.5, 131.6, 128.4, 121.4, 81.3, 50.8, 33.0, 13.1; MS (AP/CI) 209.1, 211.1 (M+H−OMe)+.
[0149] Preparation 20
[0150] 5-Bromo-2-ethoxy-pyridine. A solution of freshly prepared sodium ethoxide (sodium, 4.9 g, 210 mmol; absolute ethanol, 100 mL, room temperature) was treated with 2,5-dibromopyridine (10 g, 42 mmol) and was heated at reflux for 18 h. After cooling to room temperature, the mixture was poured into aqueous saturated sodium bicarbonate solution, was extracted with diethyl ether, and the ether layer was washed with brine, was dried over magnesium sulfate, was concentrated in vacuo. Purification by silica gel chromatography (100:1 hexanes-ethyl acetate) gave 7.5 g (88% yield) of the title compound. 13 C NMR (100 MHz, CDCl 3 ) d 162.9, 147.7, 141.2, 112.9, 111.6, 62.3, 14.7; MS (AP/CI) 202.1, 204.1 (M+H)+.
[0151] Preparation 21
[0152] 4-(4-Bromo-phenyl) 4 -methyl-tetrahydro-pyran. The title compound was prepared in a similar fashion as described in EP0501579A1 3 C NMR (100 MHz, CDCl 3 ) 29.2, 35.8, 37.7, 37.8, 64.6, 119.9, 127.7, 127.8, 131.7.
[0153] Preparation 22
3-(4-Bromo-phenyl) 3 -methyl-oxetane
[0154] Step 1: 2-(4-Bromo-phenyl)-2-methyl-malonic acid diethyl ester
[0155] Sodium methoxide (5.96 g, 110.4 mmol) was added to a 0° C. solution of 2-(4-bromo-phenyl)malonic acid diethyl ester (29 g, 92 mmol) in ethanol (200 mL). After 15 min iodomethane (6.9 ml, 110.4 mmol) was added slowly. The reaction mixture was warmed to room temperature and stirred 18 h. Additional portions of iodomethane (1.1 ml, 22 mmol) and sodium methoxide (1.0 g, 22 mmol) were added and the mixture was stirred 66 h. After quenching into water the mixture was extracted three times with ethyl acetate. The combined organic extracts were dried (MgSO 4 ) and concentrated to provide 16.8 g of the title compound as an oil (55% yield). 1 H NMR (400 MHz, CDCl 3 ) 1.23-1.25 (m, 6H), 1.83 (s, 3H), 4.19-4.25 (m, 4H), 7.25 (d, 1H, J=7.4 Hz), 7.46 (d, 1H, J=7.4 Hz).
[0156] Step 2: 2-(4-Bromo-phenyl)-2-methyl-propane-1,3-diol
[0157] A solution of 2-(4-bromo-phenyl)-2-methyl-malonic acid diethyl ester (10 g, 30.3 mmol) in 100 mL diethyl ether was added in a dropwise fashion to a 0° C. solution of 1.0 M lithium aluminium hydride (45 mL, 45 mmol) in 200 mL diethyl ether. After 30 min the reaction was warmed to 40° C. and heated for 4 h. After cooling to 0° C. and quenching with aqueous saturated sodium sulfate, the reaction mixture was filtered through Celite and concentrated to a thick oil. Purification by silica gel chromatography (1:1, ethyl acetate:hexanes) afforded 3.94 g of the title compound (53% yield). 13 C NMR (100 MHz, CDCl 3 ) 20.9, 44.3, 69.6, 120.8, 126.8, 128.8, 128.9, 131.8, 142.6.
[0158] Step 3: 3-(4-Bromo-phenyl) 3 -methyl-oxetane
[0159] Triphenylphosphine (3.6 g, 13.8 mmol) was added to a solution of 2-(4-bromo-phenyl)-2-methyl-propane-1,3-diol (1.69 g, 6.89 mmol) in 57 mL toluene. After stirring 5 min, N,N-dimethyldithiacarbonate (3.16 g, 10.34 mmol) and diethyl azodicarboxylate (2.17 mL, 13.79 mmol) were added and the resulting mixture was stirred at room temperature for 18 h. After filtering through Celite the mixture was concentrated to a solid. The crude product was purified by silica gel chromatography (1:19, ethyl acetate:hexanes) to afford 1.26 g of the title compound (81% yield). 13 C NMR (100 MHz, CDCl 3 ) 27.8, 43.3, 83.6, 120.3, 127.1, 131.8, 145.7.
[0160] Preparation 23
[0161] General Procedure for the Copper-Mediated Coupling to Afford Compounds 1 of the Invention
EXAMPLE 26
1-[4-(2-Methyl-oxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one
[0162] A mixture of 3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one (170 mg, 0.59 mmol), 4-(4-bromo-phenyl)-2-methyl-oxazole (281 mg, 1.2 mmol), copper (I) iodide (45 mg, 0.24 mmol), potassium carbonate (166 mg, 1.2 mmol), and N,N′-dimethylthylendiamine (51 μl, 0.48 mmol) in toluene (1.5 mL) was stirred at 100° C. for 24 h. Copper (I) iodide (45 mg, 0.24 mmol) and N,N′-dimethylethylendiamine (51 μl, 0.48 mmol) were added and the reaction mixture was heated at 100° C. for an additional 24 h. The mixture was cooled to room temperature, poured into water and extracted with dichloromethane. The combined organic extracts were dried (sodium sulfate) and concentrated to provide 450 mg crude product. Purification by silica gel chromatography (12:88, methanol:dichloro-ethane) afforded 107 mg (41% yield) of the title compound. MS (AP/CI) 446.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 14.2, 22.3, 26.2, 33.7, 42.3, 46.3, 50.5, 51.7, 55.6, 118.8, 126.3, 126.5, 127.8, 129.7, 133.5, 139.1, 140.3, 143.2, 146.1, 162.1, 162.3, 172.5. The enantiomers were separable by HPLC: 65/35 Heptane/Ethanol; Chiralpak AD, 5 cm×50 cm; 85 mL/min). Approximate retention times: t 1 =23 min; t 2 =33 min.
[0163] The following compounds were made using the same general procedure as for Example 26.
EXAMPLE 27
[0164] 1-[4-(2-tert-Butyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)pyridin-3-ylmethyl]-piperidin-2-one: MS (AP/CI) 488.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 22.3, 26.2, 28.8, 33.6, 34.0, 42.3, 46.4, 50.6, 51.7, 55.7, 118.8, 126.5, 127.8, 130.1, 133.1, 139.1, 139.9, 143.1, 146.1, 162.4, 171.8, 172.5. The enantiomers were separable by HPLC: 60/40 Heptane/Ethanol; Chiralpak AD, 5 cm×50 cm; 75 mL/min). Approximate retention times: t 1 =12 min; t 2 =20 min.
EXAMPLE 28
[0165] 1-[4-(2-Isopropyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)pyridin-3-ylmethyl]-piperidin-2-one: MS (AP/CI) 474.2 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 20.7, 22.3, 26.1, 28.8, 33.6, 42.3, 46.4, 50.6, 51.7, 55.7, 118.8, 126.4, 126.5, 127.8, 129.9, 133.2, 139.1, 140.0, 143.1, 146.1, 162.3, 169.5, 172.5.
EXAMPLE 29
[0166] 1-[4-(2,5-Dimethyl-oxazol-4-yl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)pyridin-3-ylmeth-yl]-piperidin-2-one: MS (AP/CI) 460.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 12.0, 14.1, 22.3, 26.2, 33.7, 42.2, 46.4, 50.6, 51.7, 55.7, 118.8, 126.4, 127.4, 127.8, 131.0, 134.0, 139.1, 142.4, 143.8, 146.1, 159.3, 162.3, 172.5. The enantiomers were separable by HPLC: 60/40 Heptane/Ethanol; Chiralpak AD, 5 cm×50 cm; 75 mL/min). Approximate retention times: t 1 =13 min; t 2 =26 min.
EXAMPLE 30
[0167] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-[4-(tetrahydro-pyran-4-yl)-phenyl]-piperidin-2-one: MS (AP/CI) 449.5 (M+H). 13 NMR (100 MHz, CDCl 3 ) 22.3, 26.2, 33.7, 34.1, 41.4, 42.2, 46.2, 50.4, 51.9, 55.5, 68.6, 118.8, 126.4, 127.7, 127.8, 139.2, 141.8, 144.5, 146.1, 162.3, 172.5. The enantiomers were separable by HPLC: Methanol; Chiralpak AD, 10 cm×50 cm; 250 mL/min). Approximate retention times: t 1 =25 min; t 2 =44 min.
EXAMPLE 31
[0168] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-[4-(tetrahydropyran-4-yl)-phenyl]-pyrrolidin-2-one: MS (AP/CI) 435.5 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.8, 32.9, 34.1, 41.2, 43.8, 46.4, 46.9, 50.6, 55.6, 68.5, 118.9, 120.1, 127.2, 127.3, 137.9, 138.7, 142.4, 146.3, 162.3, 175.4.
EXAMPLE 32
[0169] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-2-yl-phenyl)-pyrrolidin-2-one: MS (AP/CI) 418.4 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.7, 33.0, 43.9, 46.4, 46.7, 50.7, 55.6, 118.9, 119.5, 123.5, 127.1, 127.2, 128.6, 138.7, 141.4, 146.4, 161.8, 162.2, 175.8.
EXAMPLE 33
[0170] 3-[2-(4-Methyl-piperazin-1-yl)pyridin-3-ylmethyl]-1-(4-oxazol-4-yl-phenyl)-pyrrolidin-2-one: MS (AP/CI) 418.4 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.8, 33.0, 43.9, 46.4, 46.8, 50.7, 55.6, 118.9, 119.9, 126.2, 127.0, 127.2, 133.7, 138.7, 139.5, 140.1, 146.4, 151.5, 162.3, 175.6.
EXAMPLE 34
[0171] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-oxazol-5-yl-phenyl)-pyrrolidin-2-one: MS (AP/CI) 418.4 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.7, 33.0, 43.9, 46.3, 46.7, 50.6, 55.5, 118.9, 119.9, 121.3, 123.9, 125.1, 127.1, 138.7, 139.9, 146.4, 150.5, 151.3, 162.2, 175.7.
EXAMPLE 35
[0172] 1-[4-(2-Methyl-oxazol-4-yl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one: 13 C NMR (100 MHz, CDCl 3 ) 14.2, 24.8, 33.1, 43.9, 46.3, 46.8, 50.6, 55.6, 118.9, 119.9, 126.0, 127.2, 127.5, 133.2, 138.7, 139.3, 140.3, 146.4, 162.1, 162.2, 175.5. MS (AP/CI) 432.4 (M+H).
EXAMPLE 36
[0173] 1-[4-(1-Methoxy-cyclobutyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one: MS (AP/CI) 449.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 13.1, 22.3, 26.2, 33.0, 33.1, 33.8, 42.1, 46.4, 50.6, 50.8, 51.8, 55.8, 81.4, 118.7, 126.1, 127.3, 127.7, 139.1, 141.7, 142.6, 146.1, 162.3, 172.6.
[0174] Preparation 24
[0175] General Procedure for Palladium Mediated Coupling to Afford Compounds 1 of the Invention
EXAMPLE 37
[0176] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-trifluoromethyl-phenyl)-pyrrolidin-2-one. 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one (600 mg, 2.2 mmol), 4-bromobenzotriflouride (369 μL, 2.6 mmol), tris(dibenzylideneacetone)dipalladium (0) (100 mg, 0.11 mmol), 9,9-dimethyl-4,5-bis(diphenylphosphino)xanthene (191 mg, 0.33 mmol) and cesium carbonate (1.08 g, 3.3 mmol) were combined in 4 ml dioxane and heated at 100° C. for 18 h. The cooled reaction mixture was then poured into water and extracted with dichloromethane. The combined organic extracts were dried (Na 2 SO 4 ) and concentrated to an oil. Purification by silica gel chromatography (8:92, methanol: dichloromethane) afforded 500 mg (54% yield) of the title compound as an oil. MS (AP/CI) 419.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.7, 33.0, 43.8, 46.3, 46.6, 50.7, 55.6, 118.9, 119.2, 126.1, 126.2, 127.0, 138.7, 142.6, 146.5, 162.2, 176.0.
[0177] The following compounds were prepared using the same general procedure as Example 37:
EXAMPLE 38
[0178] 1-[4-(1-Hydroxy-cyclopentyl)phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one: MS (AP/CI) 435.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.0, 24.8, 33.0, 42.0, 43.8, 46.2, 46.9, 50.5, 55.5, 83.4, 118.9, 119.7, 125.9, 127.2, 138.2, 138.7, 143.6, 146.4, 162.2, 175.5.
EXAMPLE 39
[0179] 1-[4-(1-Hydroxy-1-methyl-ethyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one: MS (AP/CI) 409.3 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.8, 32.0, 32.9, 43.8, 46.3, 46.9, 50.5, 55.5, 72.2, 118.9, 119.7, 125.2, 127.2, 138.0, 138.7, 145.9, 146.3, 162.2, 175.5. 50/50 Heptane/Ethanol; Chiralpak AD, 5 cm×50 cm; 75 mL/min). Approximate retention times: t 1 =25 min; t 2 =34 min.
EXAMPLE 40
[0180] 1-(4-tert-Butyl-phenyl)-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-pyrrolidin-2-one: MS (AP/CI) 407.4 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 24.8, 31.6, 32.9, 34.6, 43.8, 46.4, 46.9, 50.7, 55.6, 118.8, 119.7, 125.9, 127.3, 137.1, 138.6, 146.3, 147.7, 162.4, 175.3. The enantiomers were separated by HPLC: 75/25 Heptane/Isopropanol; Chiralpak AD, 5 cm×50 cm; 75 mL/min). Approximate retention times: t 1 =24 min; t 2 =32 min.
EXAMPLE 41
[0181] 1-[4-(1-Hydroxy-cyclopentyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmeth-yl]-piperidin-2-one: MS (AP/CI) 449.5 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 22.3, 24.0, 26.2, 33.7, 42.1, 42.2, 46.4, 50.6, 51.9, 55.7, 83.5, 118.8, 126.1, 126.2, 127.8, 139.1, 142.3, 145.7, 146.1, 162.3, 172.6.
EXAMPLE 42
[0182] 1-(4-tert-Butyl-phenyl)-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one: MS (AP/CI) 421.5 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 22.3, 26.2, 31.6, 33.7, 34.7, 42.1, 46.4, 50.6, 51.8, 55.7, 118.7, 125.8, 126.3, 127.8, 139.1, 141.0, 146.1, 149.7, 162.3, 172.5.
EXAMPLE 43
[0183] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-phenyl-piperidin-2-one: MS (AP/CI) 365.4 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 22.3, 26.2, 33.7, 42.2, 46.3, 50.5, 51.9, 55.6, 118.8, 126.4, 126.9, 127.8, 129.4, 139.1, 143.7, 146.1, 172.5.
EXAMPLE 44
[0184] 3-[2-(4-Methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-1-(4-trifluoromethoxy-phenyl)-piperidin-2-one: MS (AP/CI) 449.4 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 22.3, 26.2, 33.7, 42.1, 46.4, 50.7, 51.8, 55.7, 118.8, 121.9, 127.6, 127.8, 139.1, 142.1, 146.2, 162.4, 172.7.
EXAMPLE 45
[0185] 1-[4-(1-Hydroxy-1-methyl-ethyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)pyridin-3-ylmethyl]-piperidin-2-one: MS (AP/CI) 423.5 (M+H). 13 C NMR (100 MHz, CDCl 3 ) 22.3, 26.1, 31.9, 33.6, 42.2, 46.3, 50.5, 51.9, 55.6, 72.4, 118.9, 125.6, 126.0, 127.9, 139.2, 142.0, 146.1, 148.0, 162.3, 172.6. The enantiomers were separated by HPLC: 70/30 Heptane/Isopropanol/0.1% Trifluoroacetic acid; Chiralpak AD, 5 cm×50 cm; 75 mL/min). Approximate retention times: t 1 =19 min; t 2 =31 min. Additional silica gel chromatography required to remove olefin: 91.5: 8: 0.5, dichloromethane: methanol: ammonium hydroxide.
EXAMPLE 46
[0186] 1-[4-(1-Hydroxy-cyclobutyl)-phenyl]-3-[2-(4-methyl-piperazin-1-yl)-pyridin-3-ylmethyl]-piperidin-2-one: MS (AP/CI) 435.5 (M+H). 1 H NMR (400 MHz, CDCl 3 ) □1.42-1.57 (m, 1H), 1.63-1.91 (m, 3H), 1.92-2.03 (m, 2H), 2.15 (br, 1H), 2.36 (s, 3H), 2.30-2.39 (m, 2H), 2.51-2.68 (m, 5H), 2.75 (dd, 1H, J=14.1 and 10.2 Hz), 2.93-3.01 (m, 1H), 3.08-3.25 (m, 4H), 3.50 (dd, 1H, J=14.2 and 3.7 Hz), 3.60-3.70 (m, 2H), 6.91 (dd, 1H, J=7.1 and 4.6 Hz), 7.26 (d, 1H, J=8.2 Hz), 7.49 (dd, 1H, J=7.5 and 1.7 Hz), 7.53 (d, 1H, J=8.3 Hz), and 8.20 (dd, 1H, J=4.9 and 1.6 Hz).
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This invention is directed to compounds of Formula I and to pharmaceutical compositions comprising the compound of Formula I.
where the dashed line represents an optional double bond; and where n is 1 or 2, and Ar 1 , Ar 2 , . . . and Z are as defined in the specification. The invention is also directed to a method of treating a disorder or condition that can be treated by altering serotonin-mediated neurotransmission, such as migraine, headache, cluster headache, anxiety, depression, etc. This invention is also directed to intermediates useful in the synthesis of compounds of Formula I.
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FIELD OF THE INVENTION
[0001] The present invention relates to a wireless communication system in which a macro cell and a small-scale cell coexist.
RELATED ART
[0002] 3GPP (3rd Generation Partnership Project) LTE (Long Term Evolution) that is an advancement of UMTS (Universal Mobile Telecommunication System) is being introduced with 3GPP release 8. In 3GPP LTE, OFDMA (orthogonal frequency division multiple access) is used for downlink, and SC-FDMA (single carrier-frequency division multiple access) is used for uplink. To understand OFDMA, OFDM should be known. OFDM may attenuate inter-symbol interference with low complexity and is in use. OFDM converts data serially input into N parallel data pieces and carries the data pieces over N orthogonal sub-carriers. The sub-carriers maintain orthogonality in view of frequency. Meanwhile, OFDMA refers to a multiple access scheme that realizes multiple access by independently providing each user with some of sub-carriers available in the system that adopts OFDM as its modulation scheme.
[0003] Recently, 3GPP LTE-Advanced (LTE-A) which is an evolution of 3GPP LTE has been discussed.
[0004] In addition, a hetero-network in which a macro cell and a small-scale cell coexist has been discussed recently. Particularly, discussions have been progressed in order to detour traffic by dispersing terminals connected to a macro cell into a small-scale cell.
[0005] However, coverage of the small-scale cell is anticipated to be very narrow and it is highly probable that a plurality of terminals is located outside of the coverage of small-scale cell. Accordingly, the effort to disperse the traffic may be useless.
SUMMARY OF THE INVENTION
[0006] The present specification introduces methods which enable a terminal located outside of coverage of a small-scale cell to access the small-scale cell in an environment in which a macro cell and a small-scale cell coexist.
[0007] In order to achieve the object, in an aspect, there is provided a method for providing information on a neighboring user equipment (UE) in a wireless communication system in which a macro cell and a small cell coexist. The method may be performed by a UE served by a small cell and comprise: performing, by the UE, a handed over from the macro cell to the small cell; overhearing a signal transmitted by the neighboring UE after the hand-over is completed; measuring a signal intensity of the neighboring UE; and transferring information on the neighboring UE to the small cell when the signal intensity meets a predetermined condition.
[0008] The hand-over may be performed when the UE is positioned at a coverage extension region of the small cell or a cell range expansion (CRE) region.
[0009] The overheard signal may be a device to device (D2D) discovery signal transmitted by the neighboring UE. The discovery signal may be a UE-specific reference signal (URS), a demodulation reference signal (DM-RS), or a sounding reference signal (SRS), or a discovery dedicated signal.
[0010] Alternatively, the overheard signal may be an uplink signal which the neighboring UE transmits to the macro cell. Here, the uplink signal may be a PUCCH or a PUSCH.
[0011] When the neighboring UE is not served by the small cell, the information on the neighboring UE may be used by the small cell in order to request the hand-over to the macro cell.
[0012] In order to achieve the object, in an aspect, there is provided a method for acquiring information on a user equipment (UE) from a UE served by a small cell in a wireless communication system in which a macro cell and the small cell coexist. The method may comprise: transferring, the small cell, a request for discovering one or more neighboring UEs to a UE handed over from the macro cell; receiving, by the small cell, information on one or more neighboring UEs from the UE; verifying whether one or more neighboring UEs are served by the small cell itself; and transferring the information on one or more neighboring UEs in order to hand over one or more neighboring UEs not served by the small cell itself from the macro cell.
[0013] The UE may be a UE which has been handed over from the macro cell at the position of a coverage extension region of the small cell or a cell range expansion (CRE) region.
[0014] The transferring of the information on one or more neighboring UEs may be performed when the neighboring UE meets a predetermined condition.
[0015] The predetermined condition may be met when the signal intensity of the neighboring UE measured by the UE is equal to or less than a predetermined value.
[0016] According to the present disclosure, a UE outside coverage of a small-scale cell may access the small-scale cell under an environment in which a macro cell and the small-scale cell coexist.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates a wireless communication system.
[0018] FIG. 2 illustrates a general multiple antenna system.
[0019] FIG. 3 illustrates the architecture of a radio frame according to FDD in 3GPP LTE.
[0020] FIG. 4 illustrates an example resource grid for one uplink or downlink slot in 3GPP LTE.
[0021] FIG. 5 illustrates the architecture of a downlink sub-frame.
[0022] FIG. 6 illustrates the architecture of an uplink sub-frame in 3GPP LTE.
[0023] FIG. 7 illustrates an example of comparison between a single carrier system and a carrier aggregation system.
[0024] FIG. 8 illustrates an example in which three DL CCs (DL CC A, DL CC B, and DL CC C) are aggregated, and DL CC A is set as a PDCCH monitoring DL CC.
[0025] FIG. 9 illustrates an example of scheduling performed when cross-carrier scheduling is configured in a cross-carrier scheduling.
[0026] FIG. 10 is a block diagram representing a structure of an UE according to 3GPP LTE as an example.
[0027] FIG. 11 illustrates a frame structure for transmitting a synchronization signal in a FDD frame defined in 3GPP LTE.
[0028] FIG. 12 illustrates an example of frame structure that transmits a synchronization signal in a TDD frame which is defined in 3GPP LTE.
[0029] FIG. 13 illustrates an example of a cell detection and a cell selection through a synchronization signal.
[0030] FIG. 14 illustrates an example of multimedia broadcast/multicast service (MBMS).
[0031] FIG. 15 illustrates a hetero-network that includes a macro cell and a small-scale cell.
[0032] FIG. 16 illustrates an example of the enhanced inter-cell interference coordination (eICIC) to solve the problem of interference between BSs.
[0033] FIG. 17 illustrates a concept of expanding coverage of a small-scale cell.
[0034] FIG. 18 illustrates the interference between signals of a macro cell and synchronization signals of a small-scale cell and the interference between reference signals.
[0035] FIG. 19 is a flowchart illustrating an operation of a UE according to an embodiment of the present invention.
[0036] FIG. 20 is a flowchart illustrating an operation of a base station of a small-scale cell according to an embodiment of the present invention.
[0037] FIG. 21 is a block diagram illustrating a wireless communication system in which the embodiment of the present invention is implemented.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0038] The technical terms used herein are used to merely describe specific embodiments and should not be construed as limiting the present invention. Further, the technical terms used herein should be, unless defined otherwise, interpreted as having meanings generally understood by those skilled in the art but not too broadly or too narrowly. Further, the technical terms used herein, which are determined not to exactly represent the spirit of the invention, should be replaced by or understood by such technical terms as being able to be exactly understood by those skilled in the art. Further, the general terms used herein should be interpreted in the context as defined in the dictionary, but not in an excessively narrowed manner.
[0039] The expression of the singular number in the specification includes the meaning of the plural number unless the meaning of the singular number is definitely different from that of the plural number in the context. In the following description, the term ‘include’ or ‘have’ may represent the existence of a feature, a number, a step, an operation, a component, a part or the combination thereof described in the specification, and may not exclude the existence or addition of another feature, another number, another step, another operation, another component, another part or the combination thereof.
[0040] The terms ‘first’ and ‘second’ are used for the purpose of explanation about various components, and the components are not limited to the terms ‘first’ and ‘second’. The terms ‘first’ and ‘second’ are only used to distinguish one component from another component. For example, a first component may be named as a second component without deviating from the scope of the present invention.
[0041] It will be understood that when an element or layer is referred to as being “connected to” or “coupled to” another element or layer, it can be directly connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly connected to” or “directly coupled to” another element or layer, there are no intervening elements or layers present.
[0042] Hereinafter, exemplary embodiments of the present invention will be described in greater detail with reference to the accompanying drawings. In describing the present invention, for ease of understanding, the same reference numerals are used to denote the same components throughout the drawings, and repetitive description on the same components will be omitted. Detailed description on well-known arts which are determined to make the gist of the invention unclear will be omitted. The accompanying drawings are provided to merely make the spirit of the invention readily understood, but not should be intended to be limiting of the invention. It should be understood that the spirit of the invention may be expanded to its modifications, replacements or equivalents in addition to what is shown in the drawings.
[0043] As used herein, ‘wireless device’ may be stationary or mobile, and may be denoted by other terms such as terminal, MT (mobile terminal), UE (user equipment), ME (mobile equipment), MS (mobile station), UT (user terminal), SS (subscriber station), handheld device, or AT (access terminal).
[0044] As used herein, ‘base station’ generally refers to a fixed station that communicates with a wireless device and may be denoted by other terms such as eNB (evolved-NodeB), BTS (base transceiver system), or access point.
[0045] Hereinafter, applications of the present invention based on 3GPP (3rd generation partnership project) LTE (long term evolution) or 3GPP LTE-A (advanced) are described. However, this is merely an example, and the present invention may apply to various wireless communication systems. Hereinafter, LTE includes LTE and/or LTE-A.
[0046] FIG. 1 shows a wireless communication system.
[0047] The wireless communication system 10 includes at least one base station (BS) 11 . Respective BSs 11 provide a communication service to particular geographical areas 15 i a, 15 b , and 15 c (which are generally called cells). Each cell may be divided into a plurality of areas (which are called sectors). A user equipment (UE) 12 may be fixed or mobile and may be referred to by other names such as mobile station (MS), mobile user equipment (MT), user user equipment (UT), subscriber station (SS), wireless device, personal digital assistant (PDA), wireless modem, handheld device. The BS 11 generally refers to a fixed station that communicates with the UE 12 and may be called by other names such as evolved-NodeB (eNB), base transceiver system (BTS), access point (AP), etc.
[0048] The terminal generally belongs to one cell and the cell to which the terminal belong is referred to as a serving cell. A base station that provides the communication service to the serving cell is referred to as a serving BS. Since the wireless communication system is a cellular system, another cell that neighbors to the serving cell is present. Another cell which neighbors to the serving cell is referred to a neighbor cell. A base station that provides the communication service to the neighbor cell is referred to as a neighbor BS. The serving cell and the neighbor cell are relatively decided based on the terminal
[0049] Hereinafter, a downlink means communication from the base station 20 to the terminal 10 and an uplink means communication from the terminal 10 to the base station 20 . In the downlink, a transmitter may be a part of the base station 20 and a receiver may be a part of the terminal 10 . In the uplink, the transmitter may be a part of the terminal 10 and the receiver may be a part of the base station 20 .
[0050] Meanwhile, the wireless communication system may be any one of a multiple-input multiple-output (MIMO) system, a multiple-input single-output (MISO) system, a single-input single-output (SISO) system, and a single-input multiple-output (SIMO) system. The MIMO system uses a plurality of transmit antennas and a plurality of receive antennas. The MISO system uses a plurality of transmit antennas and one receive antenna. The SISO system uses one transmit antenna and one receive antenna. The SIMO system uses one transmit antenna and one receive antenna. Hereinafter, the transmit antenna means a physical or logical antenna used to transmit one signal or stream and the receive antenna means a physical or logical antenna used to receive one signal or stream.
[0051] FIG. 2 illustrates a general multiple antenna system.
[0052] As shown in FIG. 2 , when increasing the number of transmission antenna to N T and increasing the number of reception antenna to N R at the same time, a transmission rate can be increased and a frequency efficiency can be dramatically increased because a theoretical channel transmission capacity is increased in proportion to the number of antenna, unlike the case of using multiple antennas only in either one of transmitter or receiver.
[0053] The transmission rate due to the increase of channel transmission capacity may be theoretically increased by multiple of a maximum transmission rate R o in case of using an antenna and a rate increase R i as shown below. That is, for example, in the MIMO communication system that uses 4 transmission antennas and 4 reception antennas, the transmission rate may be increased 4 times in comparison with the single antenna system theoretically.
[0054] After the theoretical increase of capacity in such a multiple antenna system is proved in the middle of 1990′, various technologies to induce the theoretical increase into actual increase of data transmission rate has been researched up to now, and a few of the technologies are already applied to various wireless communication standards such as third generation mobile communication and next generation wireless LAN, etc.
[0000] R =min( N T ,N R ) [Equation 1]
[0055] The research trends in relation to the multiple antenna up to now show that researches have been vigorously progressed in various aspects such as a research in the aspect of information theory in relation to communication capacity calculation of multiple antenna in various channel environment and multiple access environment, researches of wireless channel measurement and modeling process of the multiple antenna system, and a research of space-time signal processing for increasing transmission reliability and transmission rate, etc.
[0056] In a user equipment structure having general MIMO channel environment, reception signals received in each reception antenna can be expressed as follows.
[0000]
y
=
[
y
1
y
2
⋮
y
i
⋮
y
N
R
]
=
[
h
11
h
12
…
h
1
N
T
h
21
h
22
…
h
2
N
T
⋮
⋱
h
i
1
h
i
2
…
h
i
N
T
⋮
⋱
h
N
R
1
h
N
R
2
…
h
N
R
N
T
]
[
x
1
x
2
⋮
x
j
⋮
x
N
T
]
+
[
n
1
n
2
⋮
n
i
⋮
n
N
R
]
=
Hx
+
n
[
Equation
2
]
[0057] Herein, the channel between respective transmission and reception antennas may be distinguished based on transmission and reception index, and the channel passing from a transmission antenna j to a reception antenna i is represented as h ij . In case of using precoding scheme like LTE when transmitting a signal, the transmission signal x can be expressed by Equation 3.
[0000]
x
=
[
x
1
x
2
⋮
x
i
⋮
x
N
T
]
=
[
w
11
w
12
…
w
1
N
T
w
21
w
22
…
w
2
N
T
⋮
⋱
w
i
1
w
i
2
…
w
i
N
T
⋮
⋱
w
N
T
1
w
N
T
2
…
w
N
T
N
T
]
[
s
^
1
s
^
2
⋮
s
^
j
⋮
s
^
N
T
]
=
W
s
^
=
WPs
[
Equation
3
]
[0000] Herein, w ij , a precoding matrix w means a weighting between a i th transmission antenna and j th information. In this time, if the transmission power of a respective signal to be transmitted is P 1 , P 2 , . . . , P NT , a transmission information of which transmission power has been adjusted may be represented as a diagonal matrix P as follows.
[0000]
s
^
=
[
P
1
0
P
2
⋱
0
P
N
T
]
[
s
1
s
2
⋮
s
N
T
]
=
Ps
[
Equation
4
]
[0058] Meanwhile, a wireless communication system may be divided into a frequency division duplex (FDD) method and a time division duplex (TDD) method. Based on the FDD method, an uplink transmission and a downlink transmission are progressed in different frequency bands. Based on the TDD method, the uplink transmission and the downlink transmission are performed in the same frequency band at different times. A channel response of a TDD method is actually reciprocal. This means the downlink channel response and the uplink channel response are almost same in the current frequency domain. Therefore, there is an advantage in that the downlink channel response in the wireless communication system based on the TDD may be obtained from the uplink channel response. In the TDD method, as the whole frequency domain is divided into an uplink transmission and a downlink transmission by time-share, it is not available to perform the downlink transmission by a terminal and the uplink transmission by a UE at the same time. In the TDD system in which an uplink transmission and a downlink transmission are divided by a subframe unit, the uplink transmission and the downlink transmission are performed in different subframes.
[0059] Hereinafter, the LTE system is described in further detail.
[0060] FIG. 3 illustrates the architecture of a radio frame according to FDD in 3GPP LTE.
[0061] Referring to FIG. 3 , the radio frame is composed of ten subframes, and one subframe is composed of two slots. The slots in the radio frame are designated by slot numbers from 0 to 19. The time at which one subframe is transmitted is referred to as a transmission time interval (TTI). The TTI may be called as a scheduling unit for data transmission. For example, the length of one radio frame may be 10 ms, the length of one subframe may be 1 ms, and the length of one slot may be 0.5 ms.
[0062] The structure of the radio frame is merely an example, and the number of subframes included in the radio frame, the number of slots included in the subframe, etc. may be variously modified.
[0063] FIG. 4 illustrates an example resource grid for one uplink or downlink slot in 3GPP LTE.
[0064] Referring to FIG. 4 , the uplink slot includes a plurality of OFDM (orthogonal frequency division multiplexing) symbols in the time domain and NUL resource blocks (RBs) in the frequency domain. OFDM symbol is to represent one symbol period, and depending on system, may also be denoted SC-FDMA symbol, OFDM symbol, or symbol period. The resource block is a unit of resource allocation and includes a plurality of sub-carriers in the frequency domain. The number of resource blocks included in the uplink slot, i.e., NUL, is dependent upon an uplink transmission bandwidth set in a cell. Each element on the resource grid is denoted resource element.
[0065] Here, by way of example, one resource block includes 7×12 resource elements that consist of seven OFDM symbols in the time domain and 12 sub-carriers in the frequency domain. However, the number of sub-carriers in the resource block and the number of OFDM symbols are not limited thereto. The number of OFDM symbols in the resource block or the number of sub-carriers may be changed variously. In other words, the number of OFDM symbols may be varied depending on the above-described length of CP. In particular, 3GPP LTE defines one slot as having seven OFDM symbols in the case of CP and six OFDM symbols in the case of extended CP.
[0066] In 3GPP LTE, the resource grid for one uplink slot shown in FIG. 4 may also apply to the resource grid for the downlink slot.
[0067] FIG. 5 illustrates the architecture of a downlink sub-frame.
[0068] For this, 3GPP TS 36.211 V10.4.0 (2011-12) “Evolved Universal Terrestrial Radio Access (E-UTRA); Physical Channels and Modulation (Release 10)”, Ch. 4 may be referenced.
[0069] The radio frame includes 10 sub-frames indexed 0 to 9. One sub-frame includes two consecutive slots. Accordingly, the radio frame includes 20 slots. The time taken for one sub-frame to be transmitted is denoted TTI (transmission time interval). For example, the length of one sub-frame may be 1 ms, and the length of one slot may be 0.5 ms.
[0070] One slot may include a plurality of OFDM (orthogonal frequency division multiplexing) symbols in the time domain. OFDM symbol is merely to represent one symbol period in the time domain since 3GPP LTE adopts OFDMA (orthogonal frequency division multiple access) for downlink (DL), and the multiple access scheme or name is not limited thereto. For example, the OFDM symbol may be referred to as SC-FDMA (single carrier-frequency division multiple access) symbol or symbol period.
[0071] Here, one slot includes seven OFDM symbols, by way of example. However, the number of OFDM symbols included in one slot may vary depending on the length of CP (cyclic prefix). That is, as described above, according to 3GPP TS 36.211 V10.4.0, one slot includes seven OFDM symbols in the normal CP and six OFDM symbols in the extended CP.
[0072] Resource block (RB) is a unit for resource allocation and includes a plurality of sub-carriers in one slot. For example, if one slot includes seven OFDM symbols in the time domain and the resource block includes 12 sub-carriers in the frequency domain, one resource block may include 7×12 resource elements (REs).
[0073] The DL (downlink) sub-frame is split into a control region and a data region in the time domain. The control region includes up to first three OFDM symbols in the first slot of the sub-frame. However, the number of OFDM symbols included in the control region may be changed. A PDCCH (physical downlink control channel) and other control channels are assigned to the control region, and a PDSCH is assigned to the data region.
[0074] As set forth in 3GPP TS 36.211 V10.4.0, the physical channels in 3GPP LTE may be classified into data channels such as PDSCH (physical downlink shared channel) and PUSCH (physical uplink shared channel) and control channels such as PDCCH (physical downlink control channel), PCFICH (physical control format indicator channel), PHICH (physical hybrid-ARQ indicator channel) and PUCCH (physical uplink control channel).
[0075] The PCFICH transmitted in the first OFDM symbol of the sub-frame carries CIF (control format indicator) regarding the number (i.e., size of the control region) of OFDM symbols used for transmission of control channels in the sub-frame. The wireless device first receives the CIF on the PCFICH and then monitors the PDCCH.
[0076] Unlike the PDCCH, the PCFICH is transmitted through a fixed PCFICH resource in the sub-frame without using blind decoding.
[0077] The PHICH carries an ACK (positive-acknowledgement)/NACK (negative-acknowledgement) signal for a UL HARQ (hybrid automatic repeat request). The ACK/NACK signal for UL (uplink) data on the PUSCH transmitted by the wireless device is sent on the PHICH.
[0078] The PBCH (physical broadcast channel) is transmitted in the first four OFDM symbols in the second slot of the first sub-frame of the radio frame. The PBCH carries system information necessary for the wireless device to communicate with the base station, and the system information transmitted through the PBCH is denoted MIB (master information block). In comparison, system information transmitted on the PDSCH indicated by the PDCCH is denoted SIB (system information block).
[0079] The control information transmitted through the PDCCH is denoted downlink control information (DCI). The DCI may include resource allocation of PDSCH (this is also referred to as DL (downlink) grant), resource allocation of PUSCH (this is also referred to as UL (uplink) grant), a set of transmission power control commands for individual UEs in some UE group, and/or activation of VoIP (Voice over Internet Protocol).
[0080] In 3GPP LTE, blind decoding is used for detecting a PDCCH. The blind decoding is a scheme of identifying whether a PDCCH is its own control channel by demasking a desired identifier to the CRC (cyclic redundancy check) of a received PDCCH (this is referred to as candidate PDCCH) and checking a CRC error. The base station determines a PDCCH format according to the DCI to be sent to the wireless device, then adds a CRC to the DCI, and masks a unique identifier (this is referred to as RNTI (radio network temporary identifier) to the CRC depending on the owner or purpose of the PDCCH.
[0081] According to 3GPP TS 36.211 V10.4.0, the uplink channels include a PUSCH, a PUCCH, an SRS (Sounding Reference Signal), and a PRACH (physical random access channel).
[0082] FIG. 6 illustrates the architecture of an uplink sub-frame in 3GPP LTE.
[0083] Referring to FIG. 6 , the uplink sub-frame may be separated into a control region and a data region in the frequency domain. The control region is assigned a PUCCH (physical uplink control channel) for transmission of uplink control information. The data region is assigned a PUSCH (physical uplink shared channel) for transmission of data (in some cases, control information may also be transmitted).
[0084] The PUCCH for one terminal is assigned in resource block (RB) pair in the sub-frame. The resource blocks in the resource block pair take up different sub-carriers in each of the first and second slots. The frequency occupied by the resource blocks in the resource block pair assigned to the PUCCH is varied with respect to a slot boundary. This is referred to as the RB pair assigned to the PUCCH having been frequency-hopped at the slot boundary. The terminal may obtain a frequency diversity gain by transmitting uplink control information through different sub-carriers over time.
[0085] FIG. 7 illustrates an example of comparison between a single carrier system and a carrier aggregation system.
[0086] Referring to FIG. 7( a ), a typical FDD wireless communication system supports one carrier for uplink and downlink. In this case, the carrier may have various bandwidths, but only one carrier is assigned to the user equipment.
[0087] In other words, in the typical FDD wireless communication system, data transmission and reception is carried out through one downlink band and one uplink band corresponding thereto. The bit stream and the user equipment transmit and receive control information and/or data scheduled for each sub-frame. The data is transmitted/received through the data region configured in the uplink/downlink sub-frame, and the control information is transmitted/received through the control region configured in the uplink/downlink sub-frame. For this, the uplink/downlink sub-frame carries signals through various physical channels. Although the description in connection with FIG. 7 primarily focuses on the FDD scheme for ease of description, the foregoing may be applicable to the TDD scheme by separating the radio frame for uplink/downlink in the time domain.
[0088] As shown in FIG. 7( a ), data transmission/reception performed through one downlink band and one uplink band corresponding to the downlink band is referred to as a single carrier system.
[0089] Such single carrier system may correspond to an example of communication in the LTE system. Such 3GPP LTE system may have an uplink bandwidth and a downlink bandwidth that differ from each other, but supports up to 20 MHz.
[0090] Meanwhile, a high data transmission rate is demanded. The most fundamental and stable solution to this is to increase bandwidth.
[0091] However, the frequency resources are presently saturated, and various technologies are partially being in use in a wide range of frequency band. For such reason, as a method for securing a broad bandwidth to satisfy the demand for higher data transmission rate, each scattered band may be designed to meet basic requirements for being able to operate an independent system, and carrier aggregation (CA) whose concept is to bundle up multiple bands to a single system has been introduced.
[0092] That is, the carrier aggregation (CA) system means a system that constitutes a broadband by gathering one or more carriers each of which has a bandwidth narrower than the targeted broadband when supporting a broadband in the wireless communication system.
[0093] Such carrier aggregation (CA) technology is also adopted in the LTE-advanced (hereinafter, ‘LTE-A’). The carrier aggregation (CA) system may also be referred to as a multiple-carrier system or bandwidth aggregation system.
[0094] In the carrier aggregation (CA) system, a user equipment may simultaneously transmit or receive one or more carriers depending on its capabilities. That is, in the carrier aggregation (CA) system, a plurality of component carriers (CCs) may be assigned to a user equipment. As used herein, the term “component carrier” refers to a carrier used in a carrier aggregation system and may be abbreviated to a carrier. Further, the term “component carrier” may mean a frequency block for carrier aggregation or a center frequency of a frequency block in the context and they may be interchangeably used.
[0095] FIG. 7( b ) may correspond to a communication example in an LTE-A system.
[0096] Referring to FIG. 7( b ), in case, e.g., three 20 MHz component carriers are assigned to each of uplink and downlink, the user equipment may be supported with a 60 MHz bandwidth. Or, for example, if five CCs are assigned as granularity of the unit of carrier having a 20 MHz bandwidth, up to 100 MHz may be supported. FIG. 7( b ) illustrates an example in which the bandwidth of an uplink component carrier is the same as the bandwidth of a downlink component carrier for ease of description. However, the bandwidth of each component carrier may be determined independently. When aggregating one or more component carriers, a targeted component carrier may utilize the bandwidth used in the existing system for backward compatibility with the existing system. For example, in a 3GPP LTE system, bandwidths of 1.4 MHz, 3 MHz, 5 MHz, 10 MHz, 15 MHz and 20 MHz may be supported. Accordingly, the bandwidth of an uplink component carrier may be constituted like 5 MHz(UL CC0)+20 MHz(UL CC1)+20 MHz(UL CC2)+20 MHz(UL CC3)+5 MHz(UL CC4), for example. However, without consideration of backward compatibility, a new bandwidth may be defined rather the existing system bandwidth being used, to constitute a broadband.
[0097] FIG. 7( b ) illustrates an example in which the number of uplink component carriers is symmetric with the number of downlink component carriers for ease of description. As such, when the number of uplink component carriers is the same as the number of downlink component carriers is denoted symmetric aggregation, and when the number of uplink component carriers is different from the number of downlink component carriers is denoted asymmetric aggregation.
[0098] The asymmetric carrier aggregation may occur due to a restriction on available frequency bands or may be artificially created by a network configuration. As an example, even when the entire system band comprises N CCs, the frequency band where a particular user equipment may perform reception may be limited to M (<N) CCs. Various parameters for carrier aggregation may be configured cell-specifically, UE group-specifically, or UE-specifically.
[0099] Meanwhile, carrier aggregation systems may be classified into contiguous carrier aggregation systems where each carrier is contiguous with another and non-contiguous carrier aggregation systems where each carrier is spaced apart from another. A guard band may be present between the carriers in the contiguous carrier aggregation system. Hereinafter, simply referring to a multi-carrier system or carrier aggregation system should be understood as including both when component carriers are contiguous and when component carriers are non-contiguous.
[0100] Meanwhile, the concept of cell as conventionally appreciated is varied by the carrier aggregation technology. In other words, according to the carrier aggregation technology, the term “cell” may mean a pair of a downlink frequency resource and an uplink frequency resource. Or, the cell may mean a combination of one downlink frequency resource and an optional uplink frequency resource.
[0101] In other words, according to the carrier aggregation technology, one DL CC or a pair of UL CC and DL CC may correspond to one cell. Or, one cell basically includes one DL CC and optionally includes a UL CC. Accordingly, a user equipment communicating with a bit stream through a plurality of DL CCs may be said to receive services from a plurality of serving cells. In this case, although downlink is constituted of a plurality of DL CCs, uplink may be used by only one CC. In such case, the user equipment may be said to receive services from a plurality of serving cells for downlink and to receive a service from only one serving cell for uplink.
[0102] Meanwhile, in order for packet data to be transmitted/received through a cell, configuration for a particular cell should be completed. Here, the term “configuration” means the state where system information necessary for data transmission/reception on a corresponding cell is completely received. For example, the configuration may include the overall process of receiving common physical layer parameters necessary for data transmission/reception, MAC (media access control) layer parameters, or parameters necessary for a particular operation in RRC layer. The configuration-completed cell is in the state where packet transmission/reception is possible simply when information indicating that packet data may be transmitted is received.
[0103] The configuration-completed cell may be left in activation or deactivation state. Here, the term “activation” refers to data transmission or reception being performed or being ready. The UE may monitor or receive a control channel (PDCCH) or data channel (PDSCH) of an activated cell in order to identify resources (which may be frequency or time) assigned thereto.
[0104] Transmission or reception with a deactivated cell is impossible, while measurement or transmission/reception of least information is possible. The user equipment may receive system information (SI) necessary for receiving packets from a deactivated cell. In contrast, the user equipment does not monitor or receive the control channel (PDCCH) and data channel (PDSCH) of deactivated cells to identify resources (which may be frequency or time) assigned thereto.
[0105] In accordance with carrier aggregation technology, thus, activation/deactivation of a component carrier may be the same in concept as activation/deactivation of a serving cell. For example, assuming that serving cell 1 comprises DL CC1, activation of serving cell 1 means activation of DL CC1. Assuming that serving cell 2 is configured so that DL CC2 is connected with UL CC2, activation of serving cell 2 means activation of DL CC2 and UL CC2. In that regard, each component carrier may correspond to a serving cell.
[0106] On the other hand, a change in the concept of serving cell as conventionally understood by the carrier aggregation technology leads to primary cells and secondary cells being separated from each other.
[0107] The primary cell refers to a cell operating in a primary frequency and means a cell where the user equipment performs an initial connection establishment procedure or connection re-establishment procedure with a bit stream or a cell designated so during the course of handover.
[0108] The secondary cell means a cell operating in a secondary frequency, and is configured once an RRC connection is established and is used to provide additional radio resources.
[0109] The PCC (primary component carrier) means a component carrier (CC) corresponding to the primary cell. The PCC means a CC where the user equipment initially achieves connection (or RRC connection) with the base station among various CCs. The PCC is a special CC that is in charge of connection (or RRC connection) for signaling regarding multiple CCs and that manages UE context that is connection information relating to the UE. Further, the PCC, in case the PCC achieves connection with the UE so that it is in RRC connected mode, always remains in activated state. The downlink component carrier corresponding to the primary cell is referred to as a downlink primary component carrier (DL PCC), and the uplink component carrier corresponding to the primary cell is referred to as an uplink primary component carrier (UL PCC).
[0110] The SCC (secondary component carrier) means a CC corresponding to the secondary cell. That is, the SCC is a CC assigned to the user equipment, which is not the PCC, and the SCC is an extended carrier for the user equipment to assign additional resources other than the PCC. The SCC may stay in activated state or deactivated state. The downlink component carrier corresponding to the secondary cell is referred to as a downlink secondary component carrier (DL SCC), and the uplink component carrier corresponding to the secondary cell is referred to as an uplink secondary component carrier (UL SCC).
[0111] The primary cell and the secondary cell have the following features.
[0112] First, the primary cell is used for transmission of a PUCCH. Second, the primary cell always remain activated while the secondary cell switches between activation/deactivation depending on particular conditions. Third, when the primary cell experiences radio link failure (hereinafter, “RLF”), the RRC reconnection is triggered. Fourth, the primary cell may be varied by a handover procedure that comes together with security key changing or an RACH (Random Access CHannel) procedure. Fifth, NAS (non-access stratum) information is received through the primary cell. Sixth, in the case of an FDD system, the primary cell is constituted of a pair of DL PCC and UL PCC. Seventh, a different component carrier may be set as the primary cell for each user equipment. Eighth, primary cells may be exchanged only by a handover, cell selection/cell reselection process. In adding a new secondary cell, RRC signaling may be used to transmit system information of the dedicated secondary cell.
[0113] As described above, the carrier aggregation system may support a plurality of component carriers (CCs), i.e., a plurality of serving cells, unlike the single carrier system.
[0114] Such carrier aggregation system may support cross-carrier scheduling. The cross-carrier scheduling is a scheduling method that allows for resource allocation of a PDSCH transmitted through other component carrier through a PDCCH transmitted through a particular component carrier and/or resource allocation of a PUSCH transmitted through other component carrier than the component carrier basically linked with the particular component carrier. That is, a PDCCH and a PDSCH may be transmitted through different downlink CCs, and a PUSCH may be transmitted through an uplink CC other than an uplink CC linked with a downlink CC through which a PDCCH including a UL grant is transmitted. As such, the cross-carrier scheduling-supportive system requires a carrier indicator indicating a DL CC/UL CC through which a PDSCH/PUSCH through which a PDCCH provides control information is transmitted. The field containing such carrier indicator is hereinafter referred to as a carrier indication field (CIF).
[0115] The carrier aggregation system supportive of cross-carrier scheduling may include a carrier indication field (CIF) in the conventional DCI (downlink control information) format. A cross-carrier scheduling-supportive system, e.g., an LTE-A system, adds a CIF to the existing DCI format (i.e., DCI format used in LTE), so that it may be extended with three bits, and it may reuse the existing coding scheme, resource allocation scheme (i.e., CCE-based resource mapping) for the PDCCH structure.
[0116] FIG. 8 exemplifies cross-carrier scheduling in the carrier aggregation system.
[0117] Referring to FIG. 8 , the base station may configure a PDCCH monitoring DL CC (monitoring CC) set. The PDCCH monitoring DL CC set consists of some of all of the aggregated DL CCs, and if cross-carrier scheduling is configured, the user equipment performs PDCCH monitoring/decoding only on the DL CCs included in the PDCCH monitoring DL CC set. In other words, the base station transmits a PDCCH for PDSCH/PUSCH that is subject to scheduling only through the DL CCs included in the PDCCH monitoring DL CC set. The PDCCH monitoring DL CC set may be configured UE-specifically, UE group-specifically, or cell-specifically.
[0118] FIG. 8 illustrates an example in which three DL CCs (DL CC A, DL CC B, and DL CC C) are aggregated, and DL CC A is set as a PDCCH monitoring DL CC. The user equipment may receive a DL grant for the PDSCH of DL CC A, DL CC B, and DL CC C through the PDCCH of DL CC A. The DCI transmitted through the PDCCH of DL CC A contains a CIF so that it may indicate which DL CC the DCI is for.
[0119] FIG. 9 illustrates an example of scheduling performed when cross-carrier scheduling is configured in a cross-carrier scheduling.
[0120] Referring to FIG. 9 , DL CC 0, DL CC 2, and DL CC 4 belong to a PDCCH monitoring DL CC set. The user equipment searches for DL grants/UL grants for DL CC 0 and UL CC 0 (UL CC linked to DL CC 0 via SIB 2) in the CSS of DL CC 0. The user equipment searches for DL grants/UL grants for DL CC 1 and UL CC 1 in SS 1 of DL CC 0. SS 1 is an example of USS. That is, SS 1 of DL CC 0 is a space for searching for a DL grant/UL grant performing cross-carrier scheduling.
[0121] FIG. 10 is a block diagram representing a structure of an UE according to 3GPP LTE as an example.
[0122] In the long-term evolution (LTE) or LTE-A, an orthogonal frequency division multiplexing (OFDM) is used in downlink, but a single-carrier (SC)-FDMA (similar to OFDM) is used in uplink.
[0123] FDMA may be said to be DFT-s OFDM (DFT-spread OFDM). When using the SC-FDMA transmission scheme, the non-linear distortion of power amplifier may be avoided, thus allowing power consumption-limited user equipment to enjoy increased transmission power efficiency. Accordingly, user throughput may be increased.
[0124] SC-FDMA is similar to OFDM in that SC-FDMA also employs FFT (Fast Fourier Transform) and IFFT (Inverse-FFT). However, the problem with the existing OFDM transmitters is that signals over each sub-carrier on frequency axis are converted to signals on time axis by IFFT. That is, IFFT is in the form of performing the same parallel operation, thus causing an increase in PAPR (Peak to Average Power Ratio). To prevent such increase in PAPR, SC-FDMA, unlike OFDM, performs IFFT after DFT spreading. In other words, the transmission scheme of performing IFFT after DFT spreading is referred to as SC-FDMA. Thus, SC-FDMA is also called DFT spread OFDM (DFT-s-OFDM).
[0125] Such advantages of SC-FDMA led to being robust for multi-path channels thanks to similar structure to OFDM while enabling efficient use of power amplifier by fundamentally solving the problem of existing OFDM that OFDM causes increased PAPR due to IFFT operation.
[0126] Referring to FIG. 10 , a UE 100 includes a RF unit 110 . The RF unit 110 includes a transmission terminal, that is, a discrete Fourier transform (DFT) unit 111 , a subcarrier mapper 112 , an IFFT unit 113 and a CP insertion unit 114 , and a radio transmission unit 115 . The transmission terminal of the RF unit 110 further includes, for example, a scramble unit (not shown), a modulation mapper (not shown), a layer mapper (not shown) and a layer permutator (not shown), and those are arranged ahead of the DFT unit 111 . That is, as previously described, in order to prevent an increase of PAPR, the transmission terminal of the RF unit 110 has the information gone through the DFT 111 before signals mapped to a subcarrier. The signal that is spread (or precoded in the same meaning) by the DFT 111 is mapped to a subcarrier through a subcarrier mapper 112 , and after that, made into a signal on the time axis passing through an inverse fast Fourier transform (IFFT) unit again.
[0127] That is, due to the correlation among the DFT unit 111 , the subcarrier mapper 112 and the IFFT unit 113 , peak-to-average power ratio (PAPR) of later time domain signal of the IFFT unit 113 is not significantly increased in the SC-FDMA, different from the case of the OFDM, and accordingly, it is beneficial in the aspect of transmission power efficiency. That is, in the SC-FDMA, the PAPR or cubic metric (CM) may be decreased.
[0128] The DFT unit 111 outputs complex-valued symbols by performing DFT for the input symbols. For example, when N tx symbols are inputted (N tx is natural numbers), the size of DFT is N tx . The DFT unit 111 may be called a transform precoder. The subcarrier mapper 112 maps the complex-valued symbols to each subcarrier in the frequency domain. The complex-valued symbols may be mapped to the resource elements that correspond to the resource blocks allocated for data transmission. The subcarrier mapper 112 may be called a resource element mapper. The IFFT unit 113 outputs baseband signal for data which is a time domain signal by performing IFFT for the inputted symbol. The CP insertion unit 114 copies a part of a rear part of the baseband signal for data and inserts it into a front part of the baseband signal for data. The inter-symbol interference (ISI) and the inter-carrier interference (ICI) are prevented by inserting the CP, thereby orthogonality can be maintained even in multi-path channel.
[0129] Meanwhile, 3GPP is actively standardizing LTE-Advanced that is an advanced version of LTE and has adopted clustered DFT-s-OFDM scheme that permits non-contiguous resource allocation.
[0130] Clustered DFT-s OFDM transmission scheme is a modification of the conventional SC-FDMA transmission scheme, and is a method of mapping by dividing the data symbols that have passed through the precoder into a plurality of subblocks and separating them in the frequency domain. Some major features of the clustered DFT-s-OFDM scheme include enabling frequency-selective resource allocation so that the scheme may flexibly deal with a frequency selective fading environment.
[0131] In this case, the clustered DFT-s-OFDM scheme adopted as an uplink access scheme for LTE-advanced, unlike the conventional LTE uplink access scheme, i.e., SC-FDMA, permits non-contiguous resource allocation, so that uplink data transmitted may be split into several units of cluster.
[0132] In other words, while the LTE system is rendered to maintain single carrier characteristics in the case of uplink, the LTE-A system allows for non-contiguous allocation of DFT_precoded data on frequency axis or simultaneous transmission of PUSCH and PUCCH. In such case, the single carrier features are difficult to maintain.
[0133] On the other hand, the RF unit 110 may include a reception terminal, for example, a radio reception unit 116 , a CP removing unit 117 , a FFT unit 118 and an interference removing unit 119 , etc. The radio reception unit 116 , the CP removing unit 117 and the FFT unit 118 of the reception terminal perform reverse functions of the radio transmission unit 115 the CP insertion unit 114 and the IFFT unit 113 .
[0134] The interference removing unit 119 removes or alleviates the interference included in the signal received.
[0135] FIG. 11 illustrates a frame structure for transmitting a synchronization signal in a FDD frame defined in 3GPP LTE.
[0136] A slot number or a subframe number starts from zero. A UE may synchronize the time and frequency based on a synchronization signal received from a BS. The synchronization signal of 3GPP LTE-A is used for performing a cell search, and may be divided into a primary synchronization signal (PSS) and a secondary synchronization signal (SSS). For the synchronization signal of 3GPP LTE-A, section 6.11 of 3GPP TS V10.2.0 (2011-06) can be referred.
[0137] The PSS is used for acquiring OFDM symbol synchronization or slot synchronization, and is in relation to a physical-layer cell identity (PCI). And the SSS is used for acquiring frame synchronization. Also, the SSS is used for detecting a CP length and acquiring a physical-layer cell group ID.
[0138] The synchronization signal may be transmitted in subframe 0 and subframe 5 respectively in consideration of 4.6 ms, which is global system for mobile communication (GSM) frame length, in order to easily perform inter-RAT measurement, and the frame boundary may be detected through the SSS. In more detail, in the FDD system, the PSS is transmitted in the last OFDM symbol of 0 th slot and 10 th slot, and the SSS is transmitted in the OFDM symbol right ahead of the PSS.
[0139] The synchronization signal may transmit one of total 504 physical cell ID through the combination of 3 PSS and 168 SSS. A physical broadcast channel (PBCH) is transmitted in first 4 OFDM symbols of a first slot. The synchronization signal and the PBCH are transmitted within 6 RB in the middle of system bandwidth, and therefore, a UE may detect or decode regardless of the transmission bandwidth. The physical channel in which the PSS is transmitted is referred as P-SCH, and the physical channel in which the SSS is transmitted is referred to as S-SCH.
[0140] The transmission diversity scheme of synchronization signal uses only single antenna port, and is not defined separately in a standard. That is, a single antenna transmission or a transmission scheme transparent to UE (for example, precoding vector switching (PVS), time switched transmit diversity (TSTD), and cyclic delay diversity (CDD) may be used.
[0141] FIG. 12 illustrates an example of frame structure that transmits a synchronization signal in a TDD frame which is defined in 3GPP LTE.
[0142] In a TDD frame, the PSS is transmitted in a third OFDM symbol of a third slot and a 13 th slot. The SSS is transmitted in the OFDM symbol which is 3 OFDM symbols ahead of the OFDM symbol in which the PSS is transmitted. The PBCH is first 4 OFDM symbols of a second slot in a first subframe.
[0143] FIG. 13 illustrates an example of a cell detection and a cell selection through a synchronization signal.
[0144] Referring to FIG. 13( a ), it is shown that a plurality of BSs, for example, a first BS 200 a and a second BS 200 b are existed neighboring each other, and a UE 100 is existed in an overlapped region therebetween.
[0145] First, each BS 200 a and 200 b transmits the PSS and the SSS as described above.
[0146] Subsequently, the UE may receive the PSS from each BS 200 a and 200 b , and acquire cell IDs for the cells configured by each BS.
[0147] Next, each BS 200 a and 200 b also transmits a cell-specific reference signal (CRS).
[0148] Herein, as known with reference to upper part of FIG. 13( b ), as an example, the CRS may be transmitted on 0 th , 4 th , 7 th and 11 th OFDM symbols of a subframe.
[0149] In order to help understanding, what is CRS will be briefly described as follows.
[0150] In 3GPP LTE system, two sorts of downlink reference signal, the CRS (or also referred to as a common reference signal (RS)) and a dedicated RS (DRS, or also referred to as a UE-specific RS) are defined in order to facilitate unicast service.
[0151] The CRS is a reference signal that is shared by all UEs in a cell, and is used for acquiring the information of channel state and measuring handover.
[0152] A UE measures a reference signal received power (RSRP) and a reference signal received quality (RSRQ) by measuring the CRS, and notifies it to a BS. Also, the UE notifies feedback information such as channel quality information (CQI), pecoding matrix indicator (PMI) and rank indicator (RI), and the BS performs downlink frequency domain scheduling by using the feedback information received from the UE.
[0153] In order to transmit reference signals to the UE, the BS allocates resources by considering the amount of radio resource that will be allocated to reference signal, the exclusive location of a common reference signal and a dedicated reference signal, the location of a synchronization channel (SCH) and a broadcast channel (BCH) and density of a dedicated reference signal, etc.
[0154] In this time, if the more resources are allocated to the reference signal, higher channel estimation performance is obtainable, but the data transmission rate is relatively decreased. And if the less resource is allocated to the reference signal, higher data transmission rate is obtainable, but the density of reference signal becomes lower and the channel estimation performance may be deteriorated. Accordingly, it may be an important element in the system performance to allocate resources effectively for the reference signal considering the channel estimation and the data transmission rate.
[0155] Meanwhile, in 3GPP LTE system, the CRS is used for both objects of the channel information acquisition and the data decoding. Particularly, the CRS is transmitted in every subframe in wideband, and the CRS is transmitted for each antenna port of a BS. For example, if there are two transmission antennas in a BS, the CRS is transmitted through antenna ports 0 and 1, and if there are four transmission antennas, the CRS is transmitted through antenna ports 0 to 3 respectively.
[0156] Referring to FIG. 13( b ) again, a UE 100 receives the CRS from each BS 200 a and 200 b , measures the RSRP and the RSRQ, and selects the cell that has better RSRP and RSRQ values.
[0157] As such, when a cell is selected, the UE 100 may receive the PBCH from a BS that configures the selected cell, and acquire system information through the PBCH. The system information may include, for example, the MIB above described. Also, the UE 100 receive the PDSCH from the BS that configures the selected cell, and acquire the SIB through the PDSCH.
[0158] Meanwhile, the UE 100 enters the RRC connection mode through the selected cell.
[0159] In summary, after the UE 100 selects a proper cell firstly, the UE 100 establishes the RRC connection in the corresponding cell, and registers the information of UE in a core network. Later, the UE 100 is shifted to RRC rest mode and remained. As such, the UE 100 that is shifted to RRC rest mode and remained (re)selects a cell as occasion demands, and looks up system information or paging information. As such, when the UE that is remained in the RRC rest mode is required to establish the RRC connection, the UE establishes the RRC connection with the RRC layer of E-UTRAN through the RRC connection procedure again, and shifted to the RRC connection mode. Herein, there are several cases that the UE in the RRC rest mode are required to establish the RRC connection again, for example, the case of requiring uplink data transmission on the reason that a user tries to call, otherwise the case of transmitting a response message when receiving a paging message from the E-UTRAN.
[0160] Meanwhile, in the next generation mobile communication system, multimedia broadcast/multicast service (MBMS) is suggested for broadcasting service.
[0161] FIG. 14 illustrates an example of multimedia broadcast/multicast service (MBMS).
[0162] As known with reference to FIG. 14 , within a service region, MBMS single frequency network (MBSFN) is applied such that a plurality of eNodeBs 200 transmit the same date at the same time and in the same form.
[0163] The MBMS is referred to provide streaming or background broadcast service or multicast service for a plurality of UEs by using downlink dedicated MBMS bearer service. In this time, the MBMS service may be divided into a multi-cell service that provides the same service for a plurality of cells and a single cell service that provides service for only one cell.
[0164] As such, a UE receives the plurality of cell services, the UE may receive the same transmission of the plurality of cell services transmitted from several cells with being combined in the MBMS single frequency network scheme.
[0165] Meanwhile, by signaling the subframe in which the MBMS is transmitted to the MBSFN subframe, the UE may know that.
[0166] FIG. 15 illustrates a hetero-network that includes a macro cell and a small-scale cell.
[0167] In the communication standard of the next generation such as 3GPP LTE-A, there is a discussion about a hetero-network in which small-scale cells that have a low transmission power in the existing macro cell coverage, such as a pico cell, a femto cell or a micro cell is existed with being overlapped.
[0168] Referring to FIG. 15 , a macro cell may be overlapped with one or more micro cell. The service of macro cell is provided by a macro eNodeB (MeNB). In the present specification, the macro cell and the MeNB may be used with being mixed. A UE in connection with the macro cell may be referred to as a macro UE. The macro UE receives downlink signals from the MeNB and transmits uplink signals to the MeNB.
[0169] The small-scale cell is also referred to as a femto cell, a pico cell or a micro cell. The service of small-scale cell is provided by a pico eNodeB, a home eNodeB (HeNB), a relay node (RN), etc. For the convenience sake, the pico eNodeB, the home eNodeB (HeNB) and the relay node (RN) are collectively referred to as a HeNB. In this specification, the micro cell and the HeNB may be used with being mixed.
[0170] The small-scale cell may be divided into an open access (OA) cell and a closed subscriber group (CSG) cell according to accessibility. The OA cell signifies a cell in which a UE receives services anytime in case of need without separate access restriction. On the other hand, the CSG cell signifies a cell in which only a specific approved UE may receive services.
[0171] Since the macro cell and the small-scale cell are overlapped in the hetero-network, an inter-cell interference is a problem. As depicted, in case that a UE is located at a boundary between the macro cell and the small-scale cell, the downlink signal from the macro cell may act as interferences. Similarly, the downlink signal of the small-scale cell may also act as interferences.
[0172] As a detailed example, when the UE 100 that accesses the small-scale cell 300 is located at a boundary of the small-scale cell, the connection between the UE and the small-scale cell may be disconnected due to the interference from the macro cell 200 . This signifies that the coverage of small-scale cell 300 becomes smaller than anticipated.
[0173] As another example, when the UE 100 that accesses the macro cell 200 is located in an area of the small-scale cell 300 , the connection with the macro cell 200 may be disconnected due to the interference from the small-scale cell 300 . This signifies that a radio shadow area occurs in the macro cell 200 .
[0174] The most fundamental ways to solve the interference problem is to use different frequency between the hetero-networks. However, since a frequency is rare and expensive resource, the way of solution through frequency division is not welcomed by the service provider.
[0175] Accordingly, in 3GPP, it has been tried to solve the problem of inter-cell interference through the time division scheme.
[0176] According to this, in recent 3GPP, enhanced inter-cell interference coordination (eICIC) has been actively researched as a method of interference cooperation.
[0177] The time division scheme introduced in LTE Release-10 is called the enhanced inter-cell interference coordination (enhanced ICIC) as a meaning that it is an evolution in comparison with the existing frequency division scheme. In the scheme, it is defined that each cell that causes interference is referred to as an aggressor cell or a primary cell, and the cell that receives interference is referred to as a victim cell and a secondary cell. The aggressor cell or the primary cell stops data transmission in a specific subframe, thereby enabling a UE to maintain access with the victim cell or the secondary cell in the corresponding subframe. That is, in case that hetero-cells coexist, in this scheme, a cell stops transmission of signal for a while for a UE that receives significantly serious interference in a region, thereby not transmitting interference signal.
[0178] Meanwhile, the specific subframe in which the data transmission is stopped is called almost blank subframe (ABS), and in the subframe that corresponds to the ABS, any data is not transmitted except indispensible control information. The indispensible control information is, for example, a cell-specific reference signal (CRS). In current 3GPP LTE/LTE-A standard, the CRS is existed in 0 th , 4 th , 7 th and 11 th OFDM symbols in each subframe on time axis.
[0179] FIG. 16 illustrates an example of the enhanced inter-cell interference coordination (eICIC) to solve the problem of interference between BSs.
[0180] Referring to FIG. 16( a ), if the small-scale cell 300 is a pico cell, a macro cell, i.e., the eNodeB 200 and the small-scale cell 300 that corresponds to the pico cell exchange the MBSFN subframe information through X2 interface.
[0181] For example, the macro cell, i.e., the eNodeB 200 includes the information of MBSFN subframe and the information of subframe that operates as the ABS in MBSFN subframe Info information element (IE), and transmits it to the small-scale cell 300 that corresponds to the pico cell through a request message based on the X2 interface.
[0182] Meanwhile, the small-scale cell 300 that corresponds to the pico cell also includes the information of MBSFN subframe and the information of subframe that operates as the ABS in MBSFN subframe Info information element (IE), and transmits it through a request message based on the X2 interface.
[0183] In the meantime, as such, the macro cell, i.e., the eNodeB 200 and the small-scale cell 300 that corresponds to the pico cell may exchange MBSFN subframe information through the X2 interface.
[0184] However, if the small-scale cell 300 is a femto cell, the small-scale cell 300 that corresponds to the femto cell does not have X2 interface with the macro cell, i.e., the eNodeB 200 . In this case, in order for the small-scale cell 300 that corresponds to the femto cell to acquire the information of MBSFN subframe of the macro cell, i.e., the eNodeB 200 , the small-scale cell 300 that corresponds to the femto cell may acquire the MBSFN subframe information by acquiring the system information which is wirelessly broadcasted from the macro cell, i.e., the eNodeB 200 . Or, the small-scale cell 300 that corresponds to the femto cell may also acquire the MBSFN subframe information of the macro cell, i.e., the eNodeB 200 from a control station of a core network.
[0185] Or, if the information of MBSFN subframe of the macro cell, i.e., the eNodeB 200 is fixed, the information of MBSFN subframe is applied to the small-scale cell 300 that corresponds to the femto cell through operations and management (OAM).
[0186] Referring to FIG. 16( b ), a subframe is shown which the small-scale cell 300 that corresponds to the pico cell configures as the MBSFN. When the small-scale cell 300 that corresponds to the pico cell configures the corresponding subframe as the MBSFN and notifies it to the macro cell, i.e., the eNodeB 200 , the macro cell 200 operates the corresponding subframe as the ABS.
[0187] In the data region of the corresponding subframe, the small-scale cell 300 that corresponds to the pico cell performs the data transmission, and the CRS is transmitted on the 0 th , 4 th , 7 th , and 11 th symbols.
[0188] On the other hand, if the eICIC is applied, the macro cell, i.e., the eNodeB 200 does not transmit any data in the data region of the corresponding subframe, and it prevents interference. However, the macro cell, i.e., the eNodeB 200 transmits only the corresponding subframe CRS.
[0189] By using the CRS received from the macro cell, i.e., the eNodeB 200 and the small-scale cell 300 that corresponds to the pico cell respectively, the UE measures the reference signal received power (RSRP) and the reference signal received quality (RSRQ). For detailed example, if the serving cell of the UE 100 corresponds to the macro cell and the small-scale cell 300 that corresponds to the pico cell corresponds to a neighbor cell, the UE measures the RSRP and the RSRQ of the serving cell through the CRS of the macro cell 200 , and measures the RSRP and the RSRQ of the neighbor cell through the CRS of the small-scale cell 300 .
[0190] In the current 3GPP LTE/LTE-A standard, the cell-specific reference signal (CRS) is existed in the 0 th , 4 th , 7 th , and 11 th OFDM symbols in each subframe on time axis. In the eICIC of LTE-A, for the compatibility with the LTE UE, separate subframe is not used, but the almost blank subframe (ABS) that does not allocate the data of the remaining part except the minimum signal required for the operation of UE including the CRS is used. Also, in case of the MBSFN ABS subframe, by additionally eliminating the remaining CRS except the first CRS, the interference among the CRSs is removed in the 4 th , 7 th , and 11 th OFDM symbols that includes the remaining CRS except the first CRS.
[0191] FIG. 17 illustrates a concept of expanding coverage of a small-scale cell.
[0192] As depicted in FIG. 17 , within the coverage of a BS (i.e., an eNodeB) 200 of a macro cell, a BS (i.e., a pico eNodeB) 300 of several small-scale cells may be installed. And if a UE that has been received service from the eNodeB 200 of the macro cell is existed in the coverage of the eNodeB 300 of the small-scale cell, the UE may handover to the eNodeB 300 of the small-scale cell, thereby obtaining the effect of offloading traffic of the eNodeB 200 of the macro cell.
[0193] Herein, the handover from the eNodeB 200 of the macro cell that corresponds to a serving BS to the eNodeB 300 of the small-scale cell that corresponds to a target BS is performed when the strength of reference signal of the target BS exceeds a specific threshold value based on the strength (RSRP, RSRQ) of the reference signal that the UE 100 received from the serving BS.
[0194] However, by putting into a certain means additionally or by improving capability of the UE 100 , it can be implemented that the handover into the target BS may be performed even in case that the received reference signal strength of the target BS does not exceed the threshold value of the received reference signal strength of the serving BS, and consequently, such an operation gives birth to an effect of expanding the cell boundary or the cell radius of the BS (i.e., the pico eNodeB) 300 of the small-scale cell that corresponds to the target BS. In the drawing, the expanded coverage area which is wider than the basic coverage of the small-scale cell 300 is represented by deviant crease lines. Such an expanded coverage area may be referred to a cell range expansion (CRE).
[0195] Herein, when representing the threshold value used for normal handover as S th — conv , the area in which the CRE is available may be represented as an area satisfying the condition, S th — conv <=S received <=S th — CRE .
[0196] Meanwhile, the reception strength for the reference signal from the BS of the small-scale cell 300 may be represented as the RSRP/RSRQ measured in the UE 100 . However, the RSRP/RSRQ may be measured only after the UE 100 detecting, i.e., distinguishing the small-scale cell 300 .
[0197] It will be described with reference to FIG. 18 in detail.
[0198] FIG. 18 illustrates the interference between signals of a macro cell and synchronization signals of a small-scale cell and the interference between reference signals.
[0199] As known from referring to FIG. 18( a ), synchronization signals (i.e., PSS and SSS) of a macro cell and synchronization signals (i.e., PSS and SSS) of a small-scale cell act as interference mutually. Accordingly, in order for a UE 100 to properly receive the synchronization signal (i.e., PSS and SSS) of the small-scale cell, the strength of noise-interference signal in comparison with received signal should be at least lower than 6 dB.
[0200] However, in order to more increase the effect of offloading traffic into the small-scale cell 300 , if trying to forcibly handover the UE 100 in the CRE area to the small-scale cell 300 , firstly, the UE 100 in the expanded coverage area, that is, the CRE area should be able to detect the synchronization signal (PSS and SSS) of the small-scale cell.
[0201] In order to do that, the UE 100 should persistently use an interference removing unit 119 for the synchronization signal (PSS and SSS) as shown in FIG. 10 . Similarly, the UE 100 should persistently use the interference removing unit shown in FIG. 10 also for the PBCH. Herein, the interference removing unit 119 of the UE 100 may include a PSS/SSS interference removing unit, a PBCH interference removing unit, and a CRS interference removing unit.
[0202] Particularly, since the UE 100 does not know whether the UE itself is in the expanded coverage area or the CRE area, as far as the UE is provided with the corresponding information from a serving BS, the UE should operate the interference removing unit 119 always for the PSS/SSS and the PBCH, and according to this, a power consumption is increased. This is very disadvantageous in an aspect of the battery capacity of UE.
[0203] In addition, referring to FIG. 18( b ), the CRS of macro cell and the CRS of small-scale cell act as interference mutually. Accordingly, in order for the UE 100 in the expanded coverage area, i.e., the CRE area to properly receive the CRS of small-scale cell, the interference removing unit should be always operated, and according to this, the power consumption becomes increased. This is very disadvantageous in an aspect of the battery capacity of UE.
[0204] However, if the UE 100 detects that it is located in the expanded coverage area or the CRE area, and operate the PSS/SSS interference removing unit, the PBCH interference removing unit, and the CRS interference removing unit in the interference removing unit 119 only in case that the UE is located in the area (that is, the UE is located in an area in which an operation of the interference removing unit is required), the power consumption may be significantly decreased.
[0205] Accordingly, hereinafter, a method of determining when the interference removing unit is operated in order for the UE 100 to perform a cell detection and measurement for the small-scale cell 300 will be described. The method may be divided into a method by a UE and a method by a BS. First, the method by a UE will be described with reference to FIG. 19 below.
[0206] FIG. 19 is a flowchart illustrating an operation of a UE according to an embodiment of the present invention.
[0207] As known with reference to FIG. 19( a ), a first UE 100 a and a second UE 100 b are positioned at a basic coverage outside region of a small-scale cell, that is, a coverage extension region, that, a CRE region.
[0208] In this case, the first UE 100 a has been handed over to the small-scale cell 300 (S 101 ).
[0209] The first UE 100 a overhears an uplink signal of a neighboring UE to measure a signal intensity (S 102 ).
[0210] For example, the first UE 100 a overhears an uplink signal which the second UE 100 b transmits to the macro cell 200 to measure the signal intensity. As described above, the first UE 100 a 's overhearing the uplink signal of the second UE 100 b may be called overhearing by a device to device (D2D). The uplink signal may be at least one of a PUCCH, a PUSCH, a PRACH, and the like.
[0211] Alternatively, when the first UE 100 a and the second UE 100 b support a D2D function, the second UE 100 b may transmit a discovery signal for the D2D and the first UE 100 a may receive the D2D discovery signal. Here, the discovery signal for the D2D is a basic signal in which any one UE transmits a specific signal to another UE and detects the transmitted signal in order for the first UE 100 a and the second UE 100 b to perform D2D communication. The discovery signal may be signals such as a UE-specific reference signal (URS), a demodulation reference signal (DM-RS), a sounding reference signal (SRS), and the like which are reused or a new dedicated discovery signal. According to a discussion in the 3GPP standard at present, a non UE specific method and a UE specific method are provided. First, the non UE specific method is a scheme that defines a resource for the discovery signal and an allocation cycle of the resource in a network and notifies the defined resource and allocation cycle to UEs. In addition, the UE specific method is a method that designates the network to use different resources for each UE.
[0212] Meanwhile, when the measurement is completed as described above, the first UE 100 a determines whether signal intensities of the neighboring UEs meet a predetermined condition (S 103 ). For example, the first UE 100 a may determine whether the signal intensity Y is equal to or less than a predetermined value X.
[0213] When the condition is met (for example, when the signal intensity Y is equal to or less than the predetermined value X), the first UE 100 a may report information on the corresponding UE, which meets the condition to the small-scale cell (S 104 ). Then, the small-scale cell performs A as illustrated in FIG. 20 .
[0214] FIG. 20 is a flowchart illustrating an operation of the small-scale cell according to an embodiment of the present invention.
[0215] As known with reference to FIG. 20 , the first UE 100 a and the second UE 100 b are positioned at the basic coverage outside region of the small-scale cell, that is, the coverage extension region, that, the CRE region and in this case, the first UE 100 a has been handed over to the small-scale cell 300 .
[0216] Then, the small-scale cell 300 requests discoverying the neighboring UEs to the first UE 100 a (S 301 ).
[0217] The first UE 100 a overhears the uplink signal of the neighboring UE to measure the signal intensity (S 102 ).
[0218] The first UE 100 a determines whether the signal intensities of the neighboring UEs meet a predetermined condition. For example, the first UE 100 a may determine whether the signal intensity Y is equal to or less than the predetermined value X.
[0219] When the condition is met (for example, when the signal intensity Y is equal to or less than the predetermined value X), the small-scale cell 300 receives information on the UE, for example, information on the second UE 100 b from the first UE 100 a (S 302 ). The small-scale cell 300 determines whether information on the neighboring UE of the first UE 100 a , for example, the second UE 100 b is served thereby.
[0220] When the neighboring UE, for example, the second UE 100 b is served by not the small-scale cell 300 but the macro cell, the small-scale cell 300 determines whether the neighboring UE, for example, the second UE 100 b meets a predetermined condition (S 304 ).
[0221] When the neighboring UE, for example, the second UE 100 b meets the predetermined condition, the small-scale cell transfers the information to the macro cell in order to hand over the neighboring UE, for example, the second UE 100 b form the macro cell (S 305 ). Then, the macro cell may start a procedure for handing over the neighboring UE, for example, the second UE 100 b to the small-scale cell.
[0222] FIG. 21 is a block diagram illustrating a wireless communication system where an embodiment of the present invention is implemented.
[0223] The base station for macro cell or small cell 200 includes a processor 201 , a memory 202 , and an RF (radio frequency) unit 203 . The memory 202 is connected with the processor 201 and stores various pieces of information for driving the processor 201 . The RF unit 203 is connected with the processor 201 and transmits and/or receives radio signals. The processor 201 implements functions, processes, and/or methods as suggested herein. In the above-described embodiments, the operation of the base station may be implemented by the processor 201 .
[0224] The wireless device 100 such as UE includes a processor 101 , a memory 102 , and an RF unit 103 . The memory 102 is connected with the processor 101 and stores various pieces of information for driving the processor 101 . The RF unit 103 is connected with the processor 101 and transmits and/or receives radio signals. The processor 101 implements functions, processes, and/or methods as suggested herein. In the above-described embodiments, the operation of the wireless device may be implemented by the processor 101 .
[0225] The processor may include an ASIC (application-specific integrated circuit), other chipsets, a logic circuit, and/or a data processing device. The memory may include an ROM (read-only memory), an RAM (random access memory), a flash memory, a memory card, a storage medium, and/or other storage devices. The RF unit may include a baseband circuit for processing radio signals. When an embodiment is implemented in software, the above-described schemes may be realized in modules (processes, or functions) for performing the above-described functions. The modules may be stored in the memory and executed by the processor. The memory may be positioned in or outside the processor and may be connected with the processor via various well-known means.
[0226] In the above-described systems, the methods are described with the flowcharts having a series of steps or blocks, but the present invention is not limited to the steps or order. Some steps may be performed simultaneously or in a different order from other steps. It will be understood by one of ordinary skill that the steps in the flowcharts do not exclude each other, and other steps may be included in the flowcharts or some of the steps in the flowcharts may be deleted without affecting the scope of the invention. The present invention may be used in a user equipment, a base station, or other equipment of a wireless mobile communication system.
INDUSTRIAL APPLICABITY
[0227] The present invention may be used for a terminal, a base station or other equipment of wireless mobile communication systems.
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The present invention relates to a method of providing, by a UE served in a small-scale cell, information about surrounding UEs in a wireless communication system in which a macro cell and the small-scale cell coexist. The method can include the steps of: carrying out a handover from the macro cell to the small-scale cell; after completion of the handover, overhearing a signal transmitted by the UE; measuring signal intensities of the surrounding UEs; and, if the signal intensities meet predefined conditions, delivering information about the surrounding UEs to the small-scale cell.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to airflow control in heating appliances, and more specifically relates to systems and methods for improving heating efficiencies of decorative heating appliances by controlling airflow in the heating appliance.
[0003] 2. Related Art
[0004] The efficiency of a heating appliance is determined based in part on the amount of heat recovered given the amount of energy consumed. Heating appliances consume energy primarily in the generation of heat using, for example, combustion of fuel (e.g., LP, natural gas, or wood/wood pellets) or the conversion of electricity into heat. Another source of power consumption with a heating appliance relates to the way into which the generated heat is delivered for its intended purpose. Operating a blower in conjunction with a heating appliance is a common way to transfer the generated heat to a desired location (e.g., from the heating appliance into a living space). Blowers require power to operate, thus contributing to the overall efficiency of heating appliance.
[0005] The heat generated by heating appliances can be transferred in many different ways that also affect the efficiency of the appliance. Some of the generated heat escapes the appliance through the exhaust flue of the heating appliance in the case of a combustion heating appliance. Other heat is transferred into the building structure surrounding the heating appliance, into a living space in which the heating appliance is exposed, or into plenum spaces within the heating appliance. The amount of heat transferred from the heating appliance for useful purposes depends on several variables including, for example, the structure, materials, and location of heating appliance. Some types of heating appliances such as gas furnaces are not intended to provide an aesthetic function and can be designed with maximum heating efficiency as a primary objective. Furnaces typically include a relatively small combustion chamber having outer surfaces exposed to large volumes of airflow and are made of relatively thin metal materials. The combustion chamber structure as a whole retains little heat and is designed to quickly transfer all heat generated by the flame into the airflow engaging the outside surface of the combustion chamber.
[0006] Other types of heating appliances, in particular decorative heating appliances such as fireplaces, stove, and fireplace inserts, include relatively large combustion chambers configured to display an actual or simulated decorative flame. The emphasis of many decorative heating appliances is aesthetics rather than efficiency. The structure and materials of decorative heating appliances in addition to their typical mounting within or adjacent to a wall structure of a building, can results in much loss of otherwise useful heat in the heating appliance itself, out of the appliance exhaust system, or into the wall structure. Although significant advances have been made to capture this otherwise lost heat, further improvements are possible.
SUMMARY OF THE INVENTION
[0007] The present invention relates to systems and method for controlling air flow and the transfer of heat in decorative heating appliances such as fireplaces, stoves, and fireplace inserts. The disclosed embodiments illustrate example systems and methods relate to control of a blower of the heating appliance, wherein blower control results in improved control and transfer of heat generated in the heating appliance. By automatically timing when the heating appliance blower turns ON and OFF, the heat generated by the heating appliance can be more effectively transferred away from the heating appliance as desired by a user, for example, to improve heating efficiency of the heating appliance.
[0008] One aspect of the invention relates to a blower system for use with a heating appliance, wherein the heating appliance including a heat generating unit. The system includes a blower and a blower time control module. The blower timing control module monitors an ON/OFF state of the heat generating unit and controls an ON/OFF state of the blower in response to the monitored ON/OFF state of the heat generating unit. The blower timing control module turns the blower OFF after a first predetermined time period from when an OFF state of the heat generating device is detected, and turns the blower ON after a second predetermined time period from when an ON state of the heat generating unit is detected. The heat generating unit can include a gas valve, and the blower timing system is configured to monitor ON/OFF signals received by the gas valve as part of monitoring an ON/OFF state of the heating appliance.
[0009] Another aspect of the invention relates to a method of controlling air flow in a heating appliance, wherein the heating appliance includes a combustion chamber, a blower, and a heat generating device. The method includes turning ON the heat generating device, turning ON the blower, turning OFF the heat generating device, and turning OFF the blower a first predetermined time period after the heat generating device is turned OFF. The method can also include turning ON the blower after a second predetermined time period after the heat generating device is turned ON.
[0010] A further aspect of the invention relates to a fireplace that includes a heat generating device, a combustion chamber enclosure defining a combustion chamber wherein heat is generated with the heat generating device, a blower configured to create an air flow in the fireplace, and a blower control module. The blower control module is configured to monitor an ON/OFF state of the heat generating device and automatically control an ON/OFF state of the blower in response to the monitored ON/OFF state of the heat generating device. The blower control module turns OFF the blower after a first predetermined time period from when the heat generating device is turned OFF, and can turn ON the blower after a second predetermined time period from when the heat generating device is turned ON. The control module can also monitor the heat generating device during the first and second predetermined time periods to confirm the ON/OFF state of the heat generating device.
[0011] The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures and the detailed description that follow more particularly exemplify certain embodiments of the invention. While certain embodiments will be illustrated and describe embodiments of the invention, the invention is not limited to use in such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
[0013] FIG. 1 is a front view of a heating appliance including an example blower system according to principles of the present invention;
[0014] FIG. 2 is a cross-section view of the heating appliance shown in FIG. 1 taken along cross-section indicators 2 - 2 ;
[0015] FIG. 3 is a front view another example blower control module according to principles of the present invention;
[0016] FIG. 4 is a schematic diagram representing an example blower control module coupled to a valve, power source, and wall switch for a heating appliance;
[0017] FIG. 5 is a schematic diagram representing another example blower control module coupled to a valve, power source, and ignition system for a heating appliance;
[0018] FIG. 6 is a schematic circuit diagram for the circuit components of the blower control module shown in FIG. 3 ;
[0019] FIG. 7 is a side cross-sectional view of another heating appliance that includes another example blower system according to principles of the present invention, the heating appliance including multiple blowers;
[0020] FIG. 8 is a schematic flow diagram illustrating steps of an example method of controlling a heating appliance blower; and
[0021] FIG. 9 is a schematic flow diagram illustrating steps of another example method of controlling a heating appliance blower.
[0022] While the invention is amenable to various modifications and alternate forms, specifics thereof have been shown by way of example and the drawings, and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The present invention generally relates systems and methods for controlling airflow and heat transfer in a decorative heating appliance. Decorative heating appliances are different from other heat generating appliances in that they include structure that acts as a heat sink (i.e., retains heat during and after shut down of the heat generating features of the heating appliance). Typically, much of this heat is lost without a productive heating purpose. In some cases, users leave a blower of the heating appliance “ON” to capture this heat retained in the structure. Blowers sometimes remain “ON” for extended periods of time well beyond optimum times for efficient transfer of the heat retained in the structure. Efficient heat transfer in this scenario is defined as the ratio between power consumption of the blower and the amount of heat removed from the heating appliance structure for useful purpose.
[0024] One aspect of the invention relates to a system that automatically controls the ON/OFF function of a decorative heating appliance blower relative to the ON/OFF state of the heat generating features of the heating appliance. This automated control can result in optimized operation of the blower to maximize efficient heat transfer from the heating appliance. For example, the system delays turning ON the blower a predetermined time after start up of heat generation in the heating appliance. This delay allows the heating appliance structure to become heated before attempting to transfer heat with an air flow from the blower. In another example, the system delays turning OFF the blower a predetermined time after shut down of heat generating in the heating appliance. This type of delay allows the blower to continue transferring heating from the heating appliance structure that may not otherwise be effectively used, while maintaining efficient power consumption by the blower.
[0025] Some example decorative heating appliances with which the disclosed systems and methods could be used include gas, electric, or wood burning style fireplaces, stoves and fireplace inserts. Other example heating appliances include universal vent, horizontal/vertical vent, B-vent, and dual direct vented fireplaces, stoves and fireplace inserts, as well as multisided heating appliances having two or three glass panels as side panels.
[0026] Referring now to FIGS. 1 and 2 , an example fireplace 10 is shown including a blower timing system. The fireplace 10 includes an outer enclosure 12 , a combustion chamber enclosure 14 , a valve 16 , an ignition system 18 , a blower 20 and a blower control module 22 . Fireplace 10 also includes a plenum 24 , a burner 26 , a vent assembly 28 , and a power source 29 .
[0027] The combustion chamber enclosure 14 is positioned within the outer enclosure 12 and is sized smaller than the outer enclosure 12 thereby defining the plenum 24 . The combustion chamber enclosure 14 includes side panels 30 , 32 , top and bottom panels 34 , 36 , front and rear panels 38 , 40 and that together define a combustion chamber 42 . Portions of the ignition system 18 and burner 26 are positioned within the combustion chamber. The valve 16 , ignition system 18 , blower 20 , blower control module 22 and power source 29 are positioned within the plenum space 24 . The ignition system 18 is configured to generate a pilot flame that is used to ignite a main flame of the burner 26 . Operation of the ignition system 18 is coordinated with opening and closing of features of the valves 16 to provide gas flow to the ignition system and to the burner for ignition of the pilot flame and the main burner flame. Typically, the valve 16 receives electronic ON/OFF signals for operation of valve features that control fuel flow through the valve 16 .
[0028] The blower control module 22 monitors receipt of the ON/OFF control signals at the valve 16 . When the blower control module 22 identifies receipt of an ON control signal at the valve 16 , the blower control module can initiate a sequence of controls related to ON/OFF control of the blower 20 . Likewise, when the blower control module 22 identifies an OFF signal at the valve 16 , the blower control module can initiate a further sequence of ON/OFF controls for the blower 20 .
[0029] In other embodiments, one or more sensors may be used to detect the actual presence of a main burner flame at the burner or the presence of a pilot flame of the ignition system to determine the ON/OFF state of the heat generating features of the heating appliance. An example monitoring and control system that describes the use of flame sensors to determine the state of an ignition system or a main burner is described in U.S. patent application Ser. No. 11/238,640, filed on Sep. 28, 2005, and titled GAS FIREPLACE MONITORING AND CONTROL SYSTEM, which application is incorporated herein by reference.
[0030] In yet further embodiments, the one or more devices (e.g., thermocouples, thermistors, thermopiles, or thermometers) may be used to detect a temperature within the combustion chamber or other features of the fireplace. When detected temperature exceeds or drops below a predetermined value, the blower ON/Off control sequence(s) is initiated. In one example, a thermistor or thermopile may be positioned inside the combustion chamber, embedded in a panel of the combustion chamber enclosure, within an exhaust duct of the fireplace, or in the plenum defined between the combustion chamber enclosure and the outer enclosure of the fireplace. A blower ON control sequence is initiated when the temperature reaches a specific value such as, for example, about 200° F. to about 400° F. A blower OFF control sequence is initiated when the temperature drops below, for example, about 200° F. to about 300° F. The temperature measure device may be used to measure the ambient temperature of gases in, around, or adjacent to the fireplace, or may be used to measure the physical features of the fireplace.
[0031] The temperature measuring device may generate an electronic signal representative of a predefined temperature that is used to activate the blower timing sequence(s). In some embodiments, different electronic signals representative of different temperatures can be generated by the temperature measuring device. The different signals can be used to activate different types of blower sequences or different blower conditions. For example, the blower speed can be increased or decreased in response to signals from the temperature measuring device that indicate incremental increases or decreases in the measured temperature. In another example, a signal indicating a threshold temperature has been met can initiate a blower sequence in which the blower speed increases automatically at predefined time intervals (e.g., every 2 minutes increases blower speed by 10 rpm) over a predefined period (e.g., 30 minutes) or for a certain number of time intervals (e.g., 10 time intervals). A similar scenario is possible for gradually or intermittently decreasing the blower speed, for example, when the temperature signal indicates the temperature has dropped below a threshold temperature.
[0032] In another embodiment, the blower operation can be controlled in response to operation of other features of the fireplace besides the ignition assembly and burner of the fireplace. For example, blower operation can be controlled in response to ON/OFF control of backlighting, an ember bed, a simulated flame display, or an electric heat generating unit associated with the fireplace.
[0033] In another embodiment, the blower timing sequence(s) may be initiated through ON/OFF activation of the fireplace using a double pole/double throw switch. Such a switch provides starting of the blower timing ON sequence when the fireplace burner ignition sequence is activated by a user turning the switch ON. The switch also provides starting of the blower timing OFF sequence when the fireplace burner ignition sequence is deactivated by the user turning the switch OFF.
[0034] Referring now to FIG. 3 , an example blower control module 122 is shown including a housing 180 , a control knob 182 , a test button 184 , a label 185 , power wires 186 , and control wires 188 . FIGS. 4 and 5 illustrate example control modules 222 and 322 , respectively, which are coupled to a power source 229 , 329 and valves 216 , 316 , respectively. FIG. 4 further illustrates coupling of the valve 216 to a wall switch or control panel 256 . FIG. 5 illustrates the valve 316 coupled to an ignition system 318 . The control modules 222 , 322 monitor signals received from the wall panel 256 or ignition system 318 , respectively, to determine the ON/OFF control signals being sent to the valve for ON/OFF control of the valve.
[0035] FIG. 6 illustrates a circuit diagram for an example control module such as the blower control module 22 , 122 , 222 , 322 described above. The circuit components illustrated in FIG. 6 include A/D and D/A converters, power regulators, signal noise filters and the like to help monitor and interpret valve ON/OFF signals and provide control signals to the blower.
[0036] Referring now to FIG. 7 , another example fireplace 100 is shown including an outer enclosure 112 , a combustion chamber enclosure 114 , a valve 116 , ignition system 118 , first and second blowers 120 , 121 , and a blower control module 122 . The fireplace 100 also includes first, second and third plenums 123 , 124 , 125 , a burner 126 , and first and second vent assemblies 128 , 129 having ducts 160 , 161 . The combustion chamber enclosure includes side panel 130 , top and bottom panels 134 , 136 , front and rear panels 138 , 140 that define a combustion chamber 142 . An intermediate panel 144 separates the plenum spaces 123 , 125 . The fireplace 100 illustrates that a blower control module 122 can be used to control multiple blowers and ventilation systems within a fireplace. Fireplace 100 includes a first blower 120 that provides ventilation through the plenum 125 and out of the duct 160 . A second blower system including a blower 119 provides ventilation through the plenum 123 and out of the duct 161 . Still further blowers and blower assemblies may be provided, all of which may be controlled by the blower control module 122 .
[0037] In one embodiment using the fireplace 100 , the blower control module controls the ON/OFF function of the blowers 119 , 120 using different delay time periods. For example, the blower 119 can be turned ON after a delay of 5 minutes from when the main burner is ignited and the blower 120 is turned ON after a delay of 10 minutes from when the main burner is ignited. The blowers 119 may both be turned OFF at the say delay time of 10 minutes from when the main burner is turned OFF.
[0000] Example Blower Control System
[0038] In one example blower control system, a blower control module monitors a condition of a gas burner of a gas fireplace. In response to the ON/OFF status of the burner, the blower control module controls an air circulation fan or blower at a predefined speed and at specified delay times relative to the burner state. The system operates independent of the ignition controls. The system also uses an A/D sensor input to detect the ON/OFF state of the burner. The A/D sensor detects the presence of a control voltage to a main burner control valve that supplies a flow of gas to the main burner.
[0039] The A/D circuit works as a high impedance voltmeter that measures the main burner valve control voltage without adversely affecting the valve control voltage. The range and sensitivity of this voltmeter input is such that it can read the control voltage of both millivolt controls from an AC power source and low voltage dc controls from a battery backup power source. Random burst and spurious noise pulses can be falsely detected as a valve ON operation. The ignition spark noise of intermittent pilot ignition (IPI) systems could be one source of burst noise. The effect of burst noise is minimized by sampling the valve control voltage at consecutive fixed intervals. The sampling interval is of sufficient length to exclude burst noise. The burst noise would typically need to be present at each consecutive sampling window.
[0040] Low frequency noise could affect the validity of a detected valve operation. A light bulb on a dimmer circuit could be one source of low frequency noise. This noise is minimized by utilizing the averaging of multiple samples during the sample window. The sampling rate is sufficiently fast to exclude low frequency noise. Low level “white noise” could also affect the detected status of valve operation, especially at the millivolt levels of power. This type of noise is ever present at some amplitude level. To minimize the effects of such white noise, the detection decision level contains hysteresis. The ON detect level is at a predefined minimum above zero volts. This effectively ignores the low noise level at both ON and OFF signals. The use of the multiple samples over multiple intervals and requiring consecutive results is a form of “fuzzy logic” that lends integrity to the burner ON/OFF decision.
[0041] A. Power ON Reset (POR) Control Function
[0042] At power ON reset, the fan control microcontroller (PIC) initializes by performing self-calibration and setting of internal counters and variables. During a first predetermined time interval (e.g., 6 minutes) the PIC monitors the “manual test button” (TEST) for operation. If TEST is depressed (e.g., test button 184 as shown in FIG. 3 ), the PIC will check the ON/OFF status of the “burner valve” (valve).
[0043] B. TEST Control Function
[0044] When TEST is depressed, the fan will come on. This provides the installer an instant opportunity to verify operation and adjust the manual fan speed control for optimum performance. If the burner is OFF, releasing the test button will turn OFF the fan. If the burner is ON, releasing the test button will maintain the fan ON for another predetermined time (e.g., 1 minute). After the expiration of the first predetermined time (e.g. 6 minutes), pressing TEST will turn ON the fan immediately. Releasing TEST will turn OFF the fan immediately. The PIC will not go into the test sequence again and normal operation occurs.
[0045] C. VALVE Monitoring Function
[0046] The PIC determines the status of the valve at regular intervals (e.g., every minute). This ensures that the valve detection circuit (A/D) is immune to power line noise and spurious emissions of pilot ignition noise within the heating appliance. This immunity of the A/D is further enhanced by the averaging of samples within the sample period. A false ON detect would require multiple signal errors in each of the consecutive sample periods, which are spaced at, for example, 1 minute increments. The VALVE status is determined by measuring the voltage applied to the main burner valve solenoid. This system works with either an intermittent pilot ignition (IPI) or a millivolt standing pilot system. The burner ON detect circuit works independent of the fireplace burner ignition and safety controls. The detected status requires the measured A/D valve value to be above a preset minimum detected voltage to be considered as an ON signal and below that limit to be considered an OFF signal. Thus, the minimum detected voltage level is set above zero in order to provide enhanced noise immunity.
[0047] D. NORMAL Operation Function
[0048] An internal counter provides a signal at regular intervals (e.g., 1 minute). After each of these intervals (e.g., once each minute), PIC determines the status of the valve. The PIC updates the ON/OFF state of the fan based on the valve and timer values. An ON_TIMER requires that the valve be detected as ON for each interval of a predetermined time period (e.g., 7 consecutive minutes). The fan is then turned ON at a previously selected speed. An OFF_TIMER requires that the valve be detected as an OFF for each interval of a predetermined time period (e.g., 12 consecutive minutes). The fan is then turned OFF. For normal operations the PIC is in a continuous loop checking the state of the valve. On the occasion of power interruptions, brownouts, or ESD, the PIC performs a POR.
[0049] Referring now to FIG. 8 , the steps of an example method of using a blower timing control system in a heating appliance are described. The method includes a step 300 of turning ON the heat generating device of the heating appliance. A step 302 includes turning ON the blower a first predetermined time period after the heat generating device is turned ON. Step 304 includes turning OFF the heat generating device, and a step 306 includes turning OFF the blower a second predetermine time period after the heat generating device is turned OFF.
[0050] Referring to FIG. 9 , another example method of using a blower timing control system for a heating appliance is shown. The method includes a step 400 of sending a control signal to the valve to open the valve. Step 402 includes monitoring the valve to determine if an open control signal has been received at the valve. If the signal has not been received, a step 404 includes continued monitoring of the valve. If an open signal has been received, a step 406 includes waiting a first predetermined time period before turning ON the blower in a step 408 . In a step 410 , a control signal is sent to the valve to close the valve, and a step 412 includes monitoring the valve to determine if a closed control signal has been received at the valve. If the closed control signal has not been received, a step 414 includes continued blower operation. If the closed control signal has been received, a step 416 includes waiting a second predetermined time period. In a step 418 , the system continues to monitor the valve to determine if an open control signal has been received at the valve. If an open signal has been received, the system resets to step 410 and 412 . If the open control signal is not received during the second predetermined time period, a step 420 includes turning OFF the blower.
[0051] The present invention should not be considered limited to the particular examples or materials described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification.
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Systems and methods for control of a heating appliance blower that provide improved the transfer of heat generated in the heating appliance. By automatically timing when the heating appliance blower turns ON and OFF, the heat generated by the heating appliance can be more effectively transferred away from the heating appliance as desired by a user, for example, to improve heating efficiency of the heating appliance.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to commonly assigned U.S. patent application Ser. Nos. 07/862,693 (RD-21,952), 07/863,603 (RD-21,214) and 07/862,688 (RD-21,988), respectively, to R. A. Ackermann et al., E. T. Laskaris et al. and E. T. Laskaris, entitled, "Linear Compressor Dynamic Balancer", "Oil Free Linear Motor Compressor" and "A Flexible Suspension For An Oil-Free Linear Motor Compressor".
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to balanced linear motor compressors which operate without the use of oil and externally tuned resonant balancers. Such structures of this type, generally, provide a highly reliable oil-free compressor which is internally balanced for use with cryogenic refrigeration equipment so as to attain unattended, continuous operation without maintenance over extended periods of time.
2. Description of the Related Art
It is known in cryorefrigerator compressors, to employ petroleum-based oil as the lubricant. Typically, a petroleum-based oil dissolves gases such as air and hydrocarbons which come in contact with the cooling gases over time. When the oil in the compressor interacts with the cooling gases pumped by the compressor into the cold head, the oil releases the air into the cooling gases. Thus, a portion of air dissolved into the oil is carried by the cooling gases into the cold head. When the cooling gases contact the cold head, which, typically is maintained at temperatures below 77K, the air condenses and solidifies on the cold head cold surfaces. The solidification of the air can adversely affect the cold head operation because it plugs up the regenerators, reduces the piston clearances and wears out the piston seals. Ultimately, the reduced capacity of the cold head can affect the overall performance of the cryorefrigerator. Therefore, a more advantageous compressor would be presented if the oil could be eliminated.
Also, linear compressors which are not internally balanced require externally tuned resonant balancers. While these external balancers have exhibited a modicum of success in dampening out the vibration created by the linear compressors, the use of the external balancer inherently adds complexity and cost to the cryorefrigerator. Therefore, a still further advantageous compressor would be presented if the oil and the external balancers could be eliminated.
It is apparent from the above that there exists a need in the art for a compressor which is internally balanced and which, at least, equals the cooling characteristics of the known cryorefrigerator compressors, but which at the same time is oil-free so that the contamination and unreliability associated with cold heads employing oil lubricants are reduced. It is a purpose of this invention to fulfill this and other needs in the art in a manner more apparent to the skilled artisan once given the following disclosure.
SUMMARY OF THE INVENTION
Generally speaking, this invention fulfills these needs by providing an oil-free linear motor compressor, comprising a stator means, an inner core means substantially located within said stator means, an axially opposed, reciprocating driver coil means substantially located between said stator means and said inner core means such that said driver coil means includes at least two driver coils which reciprocate substantially 180° out of phase relative to each other, a compressor drive means located adjacent said inner core means and attached to said driver coil means, and a gas inlet and exhaust means substantially connected to said compressor drive means.
In certain preferred embodiments, the stator means houses a stationary epoxy-impregnated DC field coil and a reciprocating AC driver coil wound on a stainless steel coil form. Also, the driver coils are operated independent of each other and powered by the DC field in the same polarity so that the interaction of their current with a reversing radial field produced by the DC field coil produces axially opposing driver forces.
In another further preferred embodiment, unattended, continuous operation of the compressor can be attained for long periods of time while reducing contamination and vibration in the cryorefrigerator cold head and increasing the reliability of the cold head.
The preferred compressor, according to this invention, offers the following advantages: easy assembly and repair; excellent compressor characteristics; good stability; improved durability; good economy; reduced vibration; and high strength for safety. In fact, in many of the preferred embodiments, these factors of compressor characteristics, durability and vibration reduction are optimized to an extent considerably higher than heretofore achieved in prior, known compressors.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention which will become more apparent as the description proceeds are best understood by considering the following detailed description in conjunction with the accompanying drawings wherein like characters represent like parts throughout the several views and in which:
FIG. 1 is a side plan view of a balanced linear motor compressor, according to the present invention;
FIG. 2 is a detailed, side plan view of the stator assembly, according to the present invention; and
FIG. 3 is a detailed, side plan view of the gas feed and drive assemblies, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference first to FIG. 1, there is illustrated oil-free linear motor compressor 2. Compressor 2, generally, includes, stator assembly 4, gas feed assembly 50 and driver assembly 100.
As shown more clearly in FIG. 2, stator assembly 4 includes a conventional, water-cooled heat exchanger coil 6 which is secured to stator 12 by a band 8 that is located around the circumference of stator 12. Band 8 and stator 12, preferably, are constructed of steel. A conventional thermal grease is located between the contacting surfaces of heat exchanger 6 and stator 12 in order to assure proper heat exchange between stator 12 and heat exchanger 6. Preferably, stator 12 is constructed of two halves 12a and 12b. A conventional threaded fastener 14 is used to retain halves 12a and 12b together. Located within stator 12 is DC field coil 18. Coil 18, preferably, contains epoxy-impregnated copper wire which is wound by conventional winding techniques upon a stainless steel coil form (not shown). Coil 18 is rigidly retained in stator 12 by conventional fasteners 14. A conventional DC lead connection 20 is electrically connected to field coil 18.
Stator 12 is rigidly attached to bracket 22 by conventional fastener 24. Bracket 22, preferably, is constructed of stainless steel. It is to be noted that bracket 22 may include a window 23. Window 23, preferably, is constructed of any suitable transparent material and is fastened to bracket 22 by conventional fasteners (not shown). A conventional elastomeric O-ring 26 is located between bracket 22 and stator 12 in order to substantially prevent leakage of gas inside stator 12. Sawcuts 28 are cut into stator 12 by conventional cutting techniques. Sawcuts 28 are used to break up the eddy current flow paths that are created by AC driver coils 34a and 34b during operation of stator assembly 4. Typically, eddy currents create adverse electrical losses unless their flow path can be interrupted.
AC driver coils 34a and 34b are located inside stator assembly 4 coils 34a and 34b preferably, include aluminum wires wound on a stainless steel coil forms 31 by conventional winding techniques. Coil 34a reciprocates along the direction of arrow X while coil 34b reciprocates along the direction of arrow X'. Electrical air gaps 33 are the annular gaps between stator halves 12a, 12b and core 42 within which the driver coils 34 are reciprocating.
Extension 40 is part of coil form 31. A conventional electrical lead 38 is electrically attached to coil 34 and a spring lead 88 (FIG. 3). Located inside coils 34 is inner core 42. Core 42, preferably, is constructed of iron and is rigidly held in stator 12 by shaft 76. Sawcuts 44 are machined in core 42 by conventional machining techniques. Sawcuts 44 perform substantially the same function as sawcuts 28 in that sawcuts 44 break up the flow path of eddy currents created by coils 34a and 34b during their reciprocating motion inside stator assembly 4.
FIG. 3 illustrates gas feed and drive assembly 50. Assembly 50 includes, in part, a conventional gas inlet valve 52, a conventional gas exhaust valve 54, and conventional gas bearings 86. Helium, preferably, is the gas used in assembly 50 and throughout compressor 2. Inlet valve 52 is rigidly attached by conventional fasteners 70 to cylinder head 58. Cylinder head 58, preferably, is constructed of stainless steel. Cylinder head 58 is rigidly attached to bracket 22 by conventional fasteners 56. A conventional elastomeric O-ring 57 is located between bracket 22 and cylinder head 58. O-ring 57 is used to prevent gas leakage from gas feed assembly 50.
Located adjacent to cylinder head 58 is a bracket 60 which rigidly attaches by conventional fasteners (not shown) a conventional water-cooling mechanism 61 to cylinder head 58. A conventional elastomeric O-ring 62 is located between bracket 60 and cylinder head 58. O-ring 62 is used to prevent leakage of the cooling fluid from water-cooling mechanism 61. Plate 64 is rigidly attached to cylinder head 58 by conventional fasteners 66. Plate 64, preferably, is constructed of stainless steel. A conventional elastomeric O-ring 68 is located between plate 64 and cylinder head 58 in order to prevent gas leakage from cylinder head 58. A conventional fastener 70 is used to rigidly attach inlet gas valve 52 and exhaust gas valve 54 to cylinder head 58. A conventional pressure transducer (not shown) may be rigidly attached to plate 64 by conventional fasteners (not shown). The transducers would then be used to measure the compression pressure within compression chamber 85.
Cylinder head 58 is rigidly attached to central shaft 76 by a conventional fastener 78. Cylinder head 58 and shaft 76, preferably, are constructed of stainless steel. Shaft 76 is rigidly retained within core 42 by a conventional shrink fit. Shaft 76 extends the entire axial length of compressor 2. A conventional elastomeric O-ring 74 is located between cylinder head 58 and plate 64 in order to prevent gas leakage from valves 52 and 54.
Located along shaft 76 are hollow piston 80a. Piston 80b preferably, are thin-walled pistons and are constructed of stainless steel. Pistons 80a reciprocates in shaft 76 along the direction of arrow X for approximately 1 inch. Piston 80b reciprocates on shaft 76 along the direction of arrow X', also for approximately 1 inch. Coating 82 is located on the circumference of shaft 76. Coating 82, preferably, is a Teflon® non-stick coating which is placed on the circumference of shaft 76 by conventional coating techniques. The purpose of coating 82 is to substantially prevent adverse wear between pistons 80 and shaft 76 as pistons 80 reciprocates and accidentally contacts shaft 76. A conventional gas bearing 86 is located on piston 80. Bearing 86 introduces gas, preferably, helium gas, between piston 80 and shaft 76 as piston 80 reciprocates along shaft 76 so that an oil-based lubricant is not needed to allow pistons 80 to freely reciprocate along shaft 76. Located adjacent to pistons 80 are gas springs 89.
Spring lead 88 is rigidly attached to leg 84 of piston 80 by a conventional fastener 90. Fastener 90 includes a conventional AC connector 91 which is electrically connected to lead 88. Lead 88, preferably, is constructed of any suitable high strength carbon steel which is capable of withstanding high cycle fatigue. It is noted that lead 88 flexes for approximately one inch. The other end of lead 88 is rigidly attached to a conventional AC connector 92. A conventional displacement sensor 94 is rigidly attached to leg 84 by conventional fasteners (not shown).
In operation of compressor 2, gas is fed into inlet valve 52 (FIG. 3) by a conventional feed source (not shown) such that the inlet pressure is approximately 75 psi. For ease of understanding, only piston 80b and its associated parts will be used in describing the operation of compressor 2. DC field coil 18 produces a radial field in air gaps 33. The radial field powers AC driver coils 34 in the same polarity so that the interaction of the current of driver coils 34 with the reversing radial field produced by field coil 18 produces axially opposing driver forces. The axially opposing reciprocation of coils 34 along the direction of arrow X is transferred from coil 34b to spring lead 88 (FIG. 3) and piston 80b. It is to be noted that coils 34, preferably, reciprocate at a rate of approximately 60 Hz.
As piston 80b reciprocates along one direction of arrow X', gas enters compression chamber 85 through inlet valve 52. As piston 80b reciprocates towards exhaust valve 54 along the other direction of arrow X' the pressure of the gas can rise up to 300 psi and reach temperatures exceeding 500K. The high pressure, high temperature gas then is exhausted out of compression chamber 85 by exhaust valve 54. As piston 80b reaches the end of the suction stroke inside cylinder head 58, a gas spring 89 assists in the return of piston 80b. While piston 80b is reciprocating, gas bearing 86 feeds gas between piston 80b and shaft 75 to provide support for piston 80b in order to keep piston 80b from rubbing against shaft 76.
In order to detect the proper motion of coil 34, piston 80 and spring 88, windows 23 and displacer sensor 94 are used. The operator can merely look through window 23 to determine if the various elements are reciprocating or flexing. Also, the operator can shine a conventional timing instrument, such as a strobe light to accurately measure the reciprocation rate. Finally, the operator can observe measurements from sensor 94 on a conventional display (not shown) in order to determine the reciprocation rate of piston 80. The procedure is designed to be continuous for approximately 10 10 cycles or approximately 5 years of operation at 60 Hz.
Once given the above disclosure, many other features, modifications and improvements will become apparent to the skilled artisan. Such features, modifications and improvements are, therefore, considered to be a part of this invention, the scope of which is to be determined by the following claims.
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This invention relates to balanced linear motor compressors which operate without the use of oil and externally tuned resonant balancers. Such structures of this type, generally, provide a highly reliable oil-free compressor which is internally balanced for use with cryogenic refrigeration equipment so as to attain unattended, continuous operation without maintenance over extended periods of time.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/672,438 filed Jul. 17, 2012, the entire specification of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention relates generally to air conditioners. More particularly, this invention relates to a window-mounted air conditioning unit. Specifically, this invention is directed to an air conditioning unit which includes an expandable duct that enables the unit to be installed in holes or windows defined in different thickness walls, and to a method of installing the unit therein.
[0004] 2. Background Information
[0005] Window-mounted air conditioning units are known in the art. Typically, these devices are generally rectangular in overall shape and are installed in the lower part of a double hung window. When installed, a bottom wall of the unit sits on part of the sill and the bottom of the lower window engages the top wall of the unit. The unit is thus sandwiched between the sill and the lower window and is thereby held in place.
[0006] There are a number of problems with these units. Firstly, they are difficult and potentially dangerous to install, especially in instances where they are installed in windows that are on a second or higher story of a building. Even small air conditioning units weigh quite a lot and that weight is unevenly distributed within the device. Consequently, the installer may accidentally lose control of the unit during installation and it may drop some distance to the ground below, leading to damage to the unit and potential injury to passersby.
[0007] Secondly, the units take up a substantial part of the space defined by the window. This reduces the amount of light coming into a room through that window. Still further, the units do not occupy the entire width of the window and because of the overall height of the unit; fairly substantially gaps are created on either side thereof. Even though baffles or some other type of obstruction are placed on either side of the unit, there may be fairly substantial exchange of air between the interior of the room and the air outside the building. This reduces the overall efficiency and effectiveness of the air conditioning unit. Additionally, the baffles block a lot of the light that could otherwise illuminate the interior of the room.
[0008] Additionally, previously known window air-conditioning units make a substantial amount of noise during operation.
[0009] There is therefore a need in the art for an improved window-mounted air conditioning unit which addresses some of the shortcomings of presently known devices.
SUMMARY
[0010] An air conditioning unit mountable in a window on a wall of a building. The unit includes a front section configured to be disposed inside the building and on a first side of the window; and a rear section configured to be disposed outside the building and on a second side of the window. A duct extends between the front and rear sections and is positioned to be clampingly engaged between the window sill and a bottom end of the lower window. The front section of the unit hangs downwardly away from the sill and is disposed adjacent a first side of the wall. The rear section of the unit hangs downwardly away from the sill and is disposed adjacent a second side of the wall. The duct includes a first duct member which moves cooled air in a first direction towards the inside of the building; and a second duct member which moves return air in a second direction away from the inside of the building. The duct is changeable in length to alter the distance between the front and rear sections so as to accommodate the air conditioning unit's installation in different windows that are installed in walls of different thickness.
[0011] There is further disclosed a method of installing an air conditioning unit, as described above, in a window defined in a wall of a building. The method comprises the steps of:
changing the length of the duct which extends between the front section and rear section of the air conditioning unit; resting the duct on the window sill; positioning the front section inside the building and adjacent a first side of the wall beneath the window sill; positioning the rear section outside the building and adjacent a second side of the wall beneath the window sill; lowering the window so that the bottom end thereof contacts the upper surface of the duct.
[0017] The method further includes the step of moving the front and rear sections of the duct towards each other so that the wall is sandwiched therebetween.
[0018] The air conditioning unit is substantially quieter than previously known units. Previously known air conditioning units sit on the window sill, with the mechanical components thereof situated partially within the room or building and partially outside the room or building. The user can therefore readily hear those components operating. The air conditioning unit described herein is contemplated to have substantially all of its mechanical components situated outside of the building. The user will therefore not easily hear these components in operation, particularly because the window is closed, and more particularly because the mechanical components are positioned below the closed window.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] A preferred embodiment of the invention, illustrated of the best mode in which Applicant contemplates applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.
[0020] FIG. 1 is a front elevational view of a window in which is mounted a window air conditioning unit, with the unit being shown from inside a room of a building and looking through the window to a location outside the building;
[0021] FIG. 2 is a perspective view of the air conditioning unit shown removed from the window;
[0022] FIG. 3 is a cross-sectional side view of the air conditioning unit taken along line 3 - 3 of FIG. 2 ;
[0023] FIG. 3A is an enlarged cross-sectional view of the highlighted region of FIG. 3 ;
[0024] FIG. 4 is a top view of the rear end of the air conditioning unit taken along line 4 - 4 of FIG. 3 ;
[0025] FIG. 5 is a top view of the air conditioning unit taken along line 5 - 5 of FIG. 3 ;
[0026] FIG. 6 is a front view of the air conditioning unit taken along line 6 - 6 of FIG. 3 ;
[0027] FIG. 7 is a rear view of the air conditioning unit taken along line 7 - 7 of FIG. 3 ; and
[0028] FIG. 8 is a cross-sectional side view of the air conditioning unit shown in an expanded condition and installed on a wider wall and window frame than the installation shown in FIG. 3 .
[0029] Similar numbers refer to similar parts throughout the drawings.
DETAILED DESCRIPTION
[0030] FIG. 1 shows a wall 10 within which is mounted a double-hung window 12 that is surrounded by a frame 14 . Window 12 includes an upper window 12 a and a lower window 12 b. Lower window 12 b may be raised and lowered relative to a window sill 16 ( FIG. 3 ). The window 12 is shown from the perspective of a person looking from inside a room of a building toward the window 12 . If one looks through the window 12 a / 12 b one will see an area outside of the building. FIG. 3 shows that wall 10 includes a first side 10 a that is located inside the room and on a first side of window 12 ; and a second side 10 b that is located on the outside of the building and on a second side of window 12 . Siding 18 is illustrated as being installed over the second side 10 b of wall 10 .
[0031] A window-mounted air conditioning unit is installed in window 12 and is generally indicated by the reference character 20 . Air conditioning unit 20 as shown in greater detail in FIG. 2-7 , comprises a front section 22 , a rear section 24 and an air duct 26 that extends between front and rear sections 22 , 24 . As best seen in FIG. 3 , air conditioning unit 20 is generally U-shaped when viewed in cross-section taken from one side of the device; as opposed to the generally square or rectangular configuration of previously known window-mounted air conditioning units.
[0032] Air conditioning unit 20 is installed in window 12 such that front section 22 thereof is retained within the room to be air conditioned, rear section 24 is retained outside of the building, and the air duct 26 extends between the interior and exterior of the building and is the only part of air conditioning unit 20 that is contacted by the lower window 12 b. In particular, air conditioning unit 20 is secured in window 12 by duct 26 being wedged between the lower window 12 b and sill 16 . Still further, front section 22 is disposed adjacent and substantially parallel to first side 10 a of wall 10 and on a first interior side of window 12 . Rear section 24 is disposed adjacent and substantially parallel to second side 10 b of wall and on a second exterior side of window 12 . Wall 10 is substantially wedged between front and rear sections 22 , 24 .
[0033] Front section 22 preferably is a generally rectangular member that has a width “W”, a height “H 1 ” and a length “L 1 ”. Duct 26 comprises a first duct 28 and a second duct 30 which are laterally separated from each other by a gap 32 . The overall width of duct 26 is slightly less than width “W”. The height of first and second ducts 28 , 30 is substantially identical and is indicated as height “H 2 ”. The length of the first and second ducts 28 , 30 , shown in FIG. 2 , is length “L 2 ”. As will be described further herein length “L 2 ” is selectively telescopingly adjustable to change the distance between front and rear sections 22 , 24 and therefore the size of the gap 23 ( FIGS. 2 & 3 ) disposed therebetween. Rear section 24 is also a generally rectangular member that has substantially the same width “W” as front section 22 and is of a height “H 3 ” and a length “L 3 ”. As is evident from FIG. 2 , the height “H 2 ” of duct 26 is smaller than the height “H 1 ” of front section 22 , which in turn is smaller than the height “H 3 ” of rear section 24 . Thus, unlike presently known air conditioning units (not shown), the overall height of air conditioning unit 20 is not constant between its front end 22 a and rear end 24 b. Most advantageously, the height “H 1 ” and length “L 2 ” of front section 22 of air conditioning unit 20 disposed within the interior of the room to be cooled are relatively small in comparison to previously known devices. Additionally, front section 22 is not seated within the space defined by window frame 14 . Instead, a portion of front section 22 hangs downwardly from the lower part 14 a of frame 14 and sill 16 and is disposed adjacent first side 10 a of wall 10 . Still further, rear section 24 hangs downwardly from the lower part 14 a of frame 14 and sill 16 , and is disposed adjacent a second side 10 b of wall 10 . This arrangement makes it less likely that an installer will loose control of unit 20 during installation. This is because air conditioning unit 20 is generally U-shaped in cross-section and is thereby relatively easily engaged over the top of sill 16 without needing to be precariously balanced in place on top of the sill until engaged by the lower window 12 b.
[0034] Referring to FIGS. 2 and 3 , front section 22 includes a front wall 22 a, a rear wall 22 b, a top wall 22 c, a bottom wall 22 d, a first side 22 e, and a second side 22 f. Walls 22 a - 22 f bound and define an interior compartment 34 ( FIG. 6 ). Compartment 34 is divided into upper and lower chambers 34 a, 34 b ( FIG. 3 ) by an angled interior wall 36 . Front wall 22 a includes a display screen 38 and control buttons 40 and knobs 42 for activating, setting and monitoring the functioning of air conditioning unit 20 . It will be understood that any desired controls and displays may be provided on front section 22 . Front wall 22 a further includes one or more vents 44 which are in fluid communication with compartment 34 , most particularly the upper chamber 34 a thereof. Cooled air is able to exit unit 20 through vents 44 , as will be hereinafter described.
[0035] FIG. 3 shows that bottom wall 22 d is also provided with a plurality of vents 46 . Vents 46 are in fluid communication with compartment 34 , most particularly the lower chamber 34 b thereof. Vents 46 are provided for return air from the room to be drawn into air conditioning unit 20 . A filter 48 extends across lower chamber 34 b of compartment 34 adjacent vents 46 to filter the return air.
[0036] As shown in FIGS. 3 and 5 , a threaded bolt 50 , with associated washers 52 and nut 54 extends from front wall 22 a of front section 22 through to front wall 24 a of rear section 24 . This bolt 50 maintains air conditioning unit 20 at a desired overall length that is determined by setting the length of duct 26 , as will be hereinafter described. FIG. 2 shows that an electrical cord 56 extends outwardly from front section 22 of air conditioning unit 20 to connect the same to a remote outlet or other source of power (not shown).
[0037] Rear section 24 of air conditioning unit 20 includes a front wall 24 a, a rear wall 24 b, a top wall 24 c, a bottom wall 24 d, a first side wall 24 e, and a second side wall 24 f. A horizontally oriented wall 58 ( FIG. 3 ) divides the rear section into an upper compartment 60 and a lower compartment 62 . Upper compartment 60 is bounded and defined by a first portion of front wall 24 a, a first portion of rear wall 24 b, top wall 24 c, and upper portions of first and second side walls 24 e, 24 f. An angled wall 64 ( FIG. 7 ) extends between horizontal wall 58 and first side wall 24 de to create a channel 66 for directing air into first duct 28 as will be hereinafter described. A vertical wall 67 ( FIGS. 3 & 5 ) extends between top wall 24 a and horizontal wall 58 and divides upper compartment 60 into first and second chambers 60 a, 60 b. An aperture 69 ( FIGS. 5 & 7 ) is defined in wall 67 . An evaporator 68 and blower 70 are also situated in upper compartment 60 adjacent an exit to second duct 30 . Evaporator 68 is located in first chamber 60 a and blower 70 is located in second chamber 60 b. In particular, blower 60 b is positioned immediately adjacent aperture 69 in wall 67 between first and second chambers 60 a, 60 b. A first motor 72 is operatively engaged with blower 70 to rotate the same about drive shaft 74 and draw air through second duct 30 , through first chamber 60 a and move it into second chamber 60 b.
[0038] Lower compartment 62 is bounded and defined by a second portion of front wall 24 a, a second portion of rear wall 24 b, bottom wall 24 d, and lower portions of first and second side walls 24 e, 24 f. A plurality of vents 76 ( FIG. 7 ) are provided on first side wall 24 e. Vents 76 are in fluid communication with lower compartment 62 and are provided to draw air from outside of the building and into air conditioning unit 20 . A plurality of vents 78 ( FIG. 3 ) are provided in rear wall 24 b and these vents 78 are in fluid communication with lower compartment 62 . Vents 78 are provided to permit heated air to exit lower compartment 62 and be released into the environment outside of the building.
[0039] A plurality of components is housed in lower compartment 62 . A condenser 80 ( FIG. 4 ) is positioned adjacent rear wall 24 b and vents 78 . A compressor 82 is operatively connected to a first end of condenser 80 by a first tube 84 . A second tube 86 ( FIG. 3 ) extends between a second end of condenser 80 and evaporator 68 in upper compartment 60 . A third tube 88 ( FIG. 3 ) extends between compressor 82 and evaporator 68 . A fan 90 is connected by way of a drive shaft 92 to a second motor 94 . Fan 90 is positioned so that the blades 90 a thereof are spaced a distance from a first region of condenser 80 . It will be understood that instead of air conditioning unit 20 including both of the first and second motors 72 , 94 , unit 20 may alternatively be configured to include only a single motor which provides power to all of the powered components. In this latter instance, components like fan 90 and blower 70 may be operatively connected together by a drive belt (not shown). It will be understood that there are suitable electrical connections between the remote power outlet and the components within second section 24 but these have not been illustrated in the figures for the sake of clarity.
[0040] As is evident from FIGS. 4 and 7 , a vertical wall 96 extends between horizontal wall 58 and bottom wall 24 d. Wall 96 has an opening 98 therein that is substantially circular and is of generally the same diameter as fan 90 . A portion of wall 96 is cut-away in FIG. 7 to show the compressor 82 and first and third tubes 84 , 88 . Wall 96 divides lower compartment into front and rear chambers 62 a, 62 b ( FIG. 4 ). Wall 96 enables the air flow through lower compartment 62 to be redirected as illustrated by the unnumbered airflow arrows in the various figures.
[0041] As indicated previously herein duct 26 , which extends between front and rear sections 22 , 24 , is comprised of first and second ducts 28 , 30 . First duct 28 extends between upper chamber 34 a of front section 22 and second chamber 60 b of upper compartment 60 of rear section 24 . Second duct 30 extends between lower chamber 34 b of front section 22 and first chamber 60 a of upper compartment 60 of rear section 24 .
[0042] Duct 26 is a telescoping duct that is able to be adjusted to change the distance between rear wall 22 b of front section 22 and front wall 24 a of rear section 24 . Particularly, duct 26 telescopes to change the size of gap 23 between a first length “L 2 ” ( FIGS. 1-3 ) and a second length “L 4 ” ( FIG. 8 ). Duct 26 is able to move between a first collapsed position where gap 23 has a size “L 2 ” and a second expanded position where gap 23 has a size “L 4 ”.
[0043] Referring to FIG. 5 there is shown the construction of first duct 28 . First duct 28 is comprised of a first duct member 100 and a second duct member 104 that are telescopingly engaged with each other. First duct member 100 is integral with front section 22 and extends for a distance rearwardly from rear wall 22 b thereof. First duct member 100 is a tubular sleeve that is generally rectangular in cross-sectional shape and defines a first bore 102 therein. First duct member 100 terminates in an outermost edge 100 a. Second duct member 104 is integral with rear section 24 and extends for a distance forwardly from front wall 24 a thereof. Second duct member 104 is a tubular sleeve that is generally rectangular in cross-section shape and defines a second bore 106 therein. Second duct member 104 is sized so as to be receivable within the bore 102 of first duct member 100 . Second duct member 104 terminates in an outermost edge 104 a. Seals 108 are provided between the interior surface of first duct member 100 and the exterior surface of second duct member 104 . Seals 108 preferably are secured to the second duct member 104 . Air flows through bore 106 of second duct member 104 when air conditioning unit 20 is operated.
[0044] In a similar fashion, second duct 30 is constructed of a third duct member 110 and a fourth duct member 112 that are telescopingly engaged with each other. Third duct member 110 is integral with front section 22 and extends for a distance rearwardly from rear wall 22 b thereof. Third duct member 110 is a tubular sleeve that is generally rectangular in cross-sectional shape and defines a third bore 114 therein. Third duct member 110 terminates in an outermost edge 110 a. Fourth duct member 112 is integral with rear section 24 and extends for a distance forwardly from front wall 24 a thereof. Fourth duct member 112 is a tubular sleeve that is generally rectangular in cross-sectional shape and defines a second bore 116 therein. Third duct member 110 is sized so as to be receivable within the bore 116 of fourth duct member 112 . Fourth duct member 112 terminates in an outermost edge 112 a. Seals 118 are provided between the interior surface of fourth duct member 112 and the exterior surface of third duct member 110 . Seals 118 preferably are secured to third duct member 110 . Air flows through third bore 114 of third duct member 110 when air conditioning unit 20 is operated.
[0045] Air conditioning unit 20 is installed and used in the following manner. The installer will first measure the thickness of wall 10 to determine how great a length to set duct 26 at for installation. This is accomplished by measuring the distance “D 1 ” between the innermost part of window 12 or wall 10 , and the outermost part window 12 or wall 10 . FIG. 3 shows that this distance “D 1 ” is measured between an interior surface 15 of window frame member 14 a and the outermost edge 16 a of sill 16 . Duct 26 is then adjusted in length to initially be longer than distance “D 1 ” so that unit 20 may be easily positioned in the open window 12 . Duct 26 is adjusted by rotating bolt 50 in a first direction to loosen the engagement of front and rear sections 22 , 24 and this causes the length of the shaft 50 a ( FIG. 5 ) between nut 54 and bolt 50 to increase, thereby increasing the size of gap 23 . (Conversely, when bolt 50 is rotated in a second direction, the length of the shaft 50 a between nut 54 and bolt 50 is decreased and front and rear sections 22 , 24 are drawn towards each other closing the size of the gap 23 .) When bolt 50 is sufficiently loosened, the installer will pull front and rear sections 22 , 24 away from each other in the direction of arrows “A” ( FIG. 2 ) to increase length “L 2 ” so that it is greater than distance “D 1 ”. This pulling motion causes a length of second duct 104 to be pulled outwardly from within the bore of first duct 100 so that end 100 a of first duct 100 is moved a distance away from second section 24 . Simultaneously, a length of third duct 110 is pulled outwardly from within the bore of fourth duct 112 so that end 112 a of fourth duct 112 is moved a distance away from front section 22 . The arrangement ensures that substantially the same length of duct is pulled outwardly in an even, smooth motion from the bores of the first and fourth ducts 100 , 112 . Alternatively, if the movement is in the opposite direction, the arrangement ensures that the motion of pushing front and rear sections 22 , 24 toward each other is a smooth, even or non-skewed motion. The arrangement ensures that rear wall 22 b of front section 22 remains substantially parallel to front wall 24 a of second section 24 at all times.
[0046] Air conditioning unit 20 is then positioned in the space created by raising lower window 12 b away from bottom frame member 14 a. Unit 20 is positioned so that front section 22 is disposed inside the room and adjacent first side 10 a of wall 10 , and second section 24 is disposed outside of the building and adjacent second side 10 b of wall 10 . Additionally, bottom surface 26 a of duct 26 contacts and rests upon sill 16 , or upon the uppermost regions of bottom window frame 14 a. When unit 20 is resting in this position the bolt 50 is rotated in the second direction to draw front and rear sections 22 , 24 toward each other in the opposite direction of arrow “A”. This motion is continued until rear wall 22 b of front section 22 is adjacent the interior surface 15 of window frame member 14 a or first side 10 a of wall 10 ; and front wall 24 a of second section 24 is adjacent the outermost exterior surface of sill 16 or second side 10 b of wall 10 . Thus, wall 10 is sandwiched between front and rear sections 22 , 24 . Window 12 b is then lowered so that a lower end 13 thereof contacts upper surface 26 b of duct 26 . Duct 26 is therefore clampingly retained between lower end 13 of window 12 and sill 16 . At this point, gravity and window 12 b keep unit 20 in place. Any tendency of unit 20 to rotate and drop out of window 12 to the outside of the building is resisted because front section 22 somewhat counterbalances the weight of second section 24 . It should be noted that the same installation method applied to installing unit 20 into a window having a greater wall thickness “D 2 ” as illustrated in FIG. 8 .
[0047] At this point, a small gap 51 ( FIG. 1 ) is defined on either side of unit 20 and between bottom end 13 of window 12 , window frame 14 and sill 16 . Unit 20 preferably is provided with baffles 53 to block gap 51 so as to prevent mixing of air within the building with the air disposed outside the building. Alternatively, baffles 53 may be replaced with foam blocks or other similar obstructions to close off gap 51 . It should also be noted that when unit 20 is installed, a spacer foot 55 ( FIG. 3 ) mounted on rear wall 22 b of front section 22 contacts the front surface of first side 10 a of wall 10 and keeps front section 22 in an orientation where it is substantially parallel to first side 10 a of wall 10 .
[0048] Once unit 20 is safely installed in window 12 , control buttons 40 and knobs 42 are then engaged to switch unit 20 on to cool the air within the interior the room. Unit 20 substantially functions in all other ways in the same manner as known air conditioning units to cool and circulate air. The rotation of fan 90 and blower 70 is indicated by arrows “B” and “C” respectively in FIG. 7 . The airflow through air conditioning unit 20 is illustrated by way of the unlabeled arrows shown throughout the figures. Suffice to say to that return air is taken into air conditioning unit 20 from the room through vents 46 and cool air is expelled into the room through vents 44 . Furthermore, air is drawn into the second section 24 of air conditioning unit from the air outside the building, through vents 76 and is expelled from second section 24 and into the air surrounding the building through vents 78 .
[0049] A method of installing an air conditioning unit 20 in a window 12 defined in a wall 10 of a building comprises the steps of:
changing the length of duct 26 extending between front section 22 and rear section 24 of the air conditioning unit 20 ; resting duct 26 on window sill 16 ; positioning front section 22 inside the building and adjacent a first side 10 a of wall 10 beneath the window sill; positioning rear section 24 outside the building and adjacent a second side 10 b of wall 10 beneath the window sill; lowering window 12 so that bottom end 13 thereof contacts upper surface 26 b of duct 26 .
[0055] The method further includes the step of moving front and rear sections 22 , 24 of duct 26 towards each other so that wall 10 is sandwiched therebetween.
[0056] It will be understood that while the air conditioning unit has been described above as being mountable within a window of a building, it may alternatively be mounted through a hole in the wall of the building in a location free of a window. In this instance, the duct 26 will be positioned in the hole in the wall and the front and rear sections 22 , 24 will be on opposite sides of the wall. The hole in the wall would be cut to be substantially equal in size to duct 26 . The through bolt 50 could be removed and the unit would be installed in two pieces, with the front 22 being on an inside of the wall and the rear 24 being on an exterior side of the wall. Once the front and rear 22 , 24 have been matingly engaged together via duct 26 being inserted through the hole in the wall, the through bolt 50 could be reinstalled to hold front 22 and rear 24 together. The term “window” should therefore be interpreted to mean any suitably sized hole or aperture defined in a building wall, whether a window frame and sheet of glass mounted in that frame are present on not.
[0057] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
[0058] Moreover, the description and illustration of the invention are an example and the invention is not limited to the exact details shown or described.
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An air conditioning unit and method of mounting the same in a hole in a wall, particularly a hole housing a window. The unit includes a front section disposed inside the building on a first side of the hole; and a rear section disposed outside the building on a second side of the hole. A duct extends between the front and rear sections and is clampingly engaged between the sill and a bottom end of the window. The duct includes a first duct member which moves cooled air in a first direction towards the inside of the building; and a second duct member which moves return air in a second direction away from the inside of the building. The duct is changeable in length to alter the distance between the front and rear sections so as to accommodate the air conditioning unit's installation in windows in different thickness walls.
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This application is a continuation of application Ser. No. 276,767 filed June 24, 1981 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to test systems and more specifically to multi-channel test systems with each channel including a wave guide and modulator through which light is transmitted to a receiver, with the signal whose status is to be determined coupled as an input to the modulator, to modulate the input to the receiver.
2. Description of the Prior Art
Prior art test systems have typically utilized some type of direct-couple sensing device to determine the status of signals indicative of the operational status of apparatus to be tested. In determining the applicability of this type of system to a specific application it was necessary to consider the loading of the apparatus to be tested. All trends in the electronics art, particularly digital arts, clearly indicate a decrease in size of apparatus coupled with an ever-increasing operating speeds. Present data rates for digital apparatus are in the 25 megabit/second range and it is anticipated to reach 200 megabits/second in the next three to four years. Considering these requirements there is no presently available directly coupled test systems which would meet these requirements.
SUMMARY OF THE INVENTION
The test system and method, according to the present invention, substantially solves many of the problems discussed above. Each channel of a multiple channel system utilizes an electromagnetic wave guide which couples a source of elecromagnetic energy to a receiver through a modulator. The receiver includes all the circuitry necessary to determine the status of the signal coupled to the input of the modulator. The preferred modulator is an electric field-operated device providing minimum loading to the apparatus to be tested. The preferred embodiment utilizes a plurality of substantially identical channels to provide means for testing a plurality of signals with the signals being indicative of the operational status of apparatus to be tested. The preferred electromagnetic energy source is light with all the channels coupled to a common light source through a light splitting manifold. For each channel to be used to perform a test, a signal indicative of the operational status of apparatus to be tested is coupled to the input of the modulator associated with that channel to modulate the light beam transmitted through the waveguide. A light sensitive device, such as light detecting diodes is used to detect the changes in the light transmitted through the waveguide as a result of the signal coupled to the modulator input. The output signal of the detectors, in most cases will be electrical, can be processed in any convenient manner to determine the status of the apparatus.
Light sources such as light-emitting diodes operating in the range of 60 milliamps are usable as light sources. Suitable optical transmission lines include wave guides formed in lithium niobate substrates by diffusing titanium therein. Suitable modulators can be provided by affixing electrodes to the surface of the lithium niobate substrate. Utilizing this technique the multi-channel test system can be small, fast and provide minimum loading to the apparatus to be tested.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of the overall system;
FIG. 2 is a functional block diagram of one channel of the test system;
FIG. 3 is a functional block diagram illustrating how the output of the multi-channel test module can be coupled to a processor such as a general purpose digital computer; and
FIG. 4 is a drawing illustrating one embodiment of the optical wave guide including a modulator.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a functional block diagram of the preferred embodiment of the test system comprising the invention. For convenience of illustration only three channels 10, 12 and 14 of the multiple channel systems are illustrated in FIG. 1. Each of the channels 10, 12 and 14 includes a modulator 16, 18 and 20. Each of the multiple channels 10, 12 and 14 couples a receiver and processing unit 30 to a common light source 32 through a light beam splitting manifold 33. In response to status signals from the apparatus 34, (a digital computer or LSI circuit for example) whose operational status is to be determined, the modulators 16, 18 and 20 to modulate the transmitted light from the light source 32 to the processing and receiving unit 20. The processing and receiving unit 30 analyzes the light energy arriving via the various channels to determine the status of the signal coupled to the input of the associated modulator. After this analysis is complete the receiver and processing unit 20 generates signals indicative of the result of the analysis. These signals may be used to take appropriate corrective action if the apparatus 30 is operating improperly or as a monitor for the apparatus 34. If the input signals to the modulators are time dependent, the output signal of one of the modulators may be used as a strobe of a separate timing signal may be provided by the system being tested.
Timing signals to synchronize the receiver and processing unit 20 with the apparatus to be tested 34 may be required. These signals may be coupled directly from the apparatus 34 or may be derived from one or more of the test channels.
Light source 32 may be any convenient light source, such as light emitting diodes. However, the use of single mode fiber optic cables and waveguides may require a single mode light source. Suitable light beam splitting manifolds are also well known in the art. For example, it is contemplated that multiple branch optical transmission lines formed in lithium niobate substrates can be used as a light manifold. In its most useful embodiment, it is contemplated that the test system which is the subject of the disclosed invention, will be used to monitor digital systems and subsystems. Typical digital apparatus which could be monitored includes digital computers, digital memories, large scale integrated circuits, computer I/O devices and subsystems of all of these.
FIG. 2 illustrates in more detail a single channel of the system illustrated functionally in FIG. 1. In this specific example a continuous wave (CW) light source 40 generates a light signal. This light signal is coupled to an optical wave guide and modulator 42 through a path 44 preferably comprising a fiber optic bundle. The output of the optical wave guide and modulator 42 is also coupled via a second path 46, preferably consisting of a fiber optic bundle, to an optical detector 48. Optical detector 48 may be a light sensitive diode or other semiconductor device for example. The output of the optical detector 48 is generally an electrical signal which is amplified by an amplifier 56 to generate at the output of this amplifier an electrical signal having convenient characteristics. This signal is then coupled to a suitable processing and display system 58.
The optical wave guide and modulator 42 may be, for example, a substrate of lithium niobate with titanium diffused in one surface to form a wave guide. Wave guides of this type are well known in the art. The transmission characteristics of the optical wave guide 42 may be modified by placing electrodes 60 and 62 on the surface of the optical wave guide to form a modulator. Other electro-optical modulators may also be utilized.
FIG. 3 is a more detailed diagram of a system to collect and process data from a plurality of channels. In this embodiment, data processing will be done by a conventional microcomputer.
More specifically, and considering the current stage of the art, the digital output data from amplifier 56 can have a bit rate in the range of 320 MHz. This information can be conveniently coupled to the data input terminal of a serial-to-parallel shift register 70 via, for example, a single coaxial cable 72. If the system is designed such that each word of the data input signal to shift register 70 is designated as sixteen bits, data words can be transmitted from the serial-to-parallel shift register 70 at a rate of 20 million words/second. This requires that the serial-to-parallel shift register 28 be shifted by a clock generator 74 operating at a frequency of approximately 320 MHz. Frequencies in this range are most conveniently handled currently using ECL or emitter-coupled logic. This type of circuitry has a non-standard logic level prohibiting it from being used directly by most digital data processing systems. Therefore, the output of the serial-to-parallel shift register 70 is coupled through a level translator 80 to convert the logic levels to standard levels for example those compatible with commercially available TTL logic circuits.
The output signals of the level translator circuit 80 are coupled to a 16-bit parallel data bus 90. The rate of data transfer to the data bus 90 is much higher than can be conveniently handled by most standard digital data processors and memories. Therefore, a plurality of memory modules, with three typical modules being illustrated at reference numerals 96, 98 and 100, are also coupled to the data bus. Memories 96, 98 and 100 are multiplexed to provide a sufficient data rate. Addresses to the memory modules 96, 98 and 100 are provided by a high-speed address generator 102. A separate high speed address generator is required because currently available digital processors 94, such as microcomputers, cannot supply memory addresses at the required 20 mhz rate. These addresses are coupled to the memories via an address bus 104 to which the digital processor 94 also has access. After the data has been transferred to the memory modules 96, 98 and 100 it can be read by the digital processor 94 and processed in any fashion which is convenient dependent upon the application.
FIG. 4 illustrates in isometric view the preferred embodiment of the optical modulators illustrated at reference numerals 16, 18 and 20 of FIG. 1. Functionally, the modulator includes a substrate 110 of lithium niobate, for example. Titanium is diffused in the upper surface of the lithium niobate substrate 110 to form an optical wave guide 114. In a region between its two ends the optical wave guide 114 is divided into two branches, 116 and 118. A first electrode 120 is affixed to the upper surface 112 of the lithium niobate and extends along the outer edge of the first branch 118 of the wave guide. A second electrode 122 is also affixed to the upper surface 112 of the lithium niobate substrate 110 and extends between the two branches 116 and 118 of the optical wave guide. The signal whose status is to be determined is coupled between the electrodes 120 and 122 to impose an electrical field across the first branch 118 of the optical wave guide. This field causes the propagation velocity of the optical signal in the two branches 116 and 118 of the wave guide to vary causing amplitude modulation of signal at the output of the modulator due to combining two signals of differing phase. If sufficient phase shift is provided, the modulator can be operated as an on-off switch.
Coupling is provided to each end of the optical wave guide 114 by first and second fiber optic bundles 130 and 132. A shelf is provided at each end of the optical wave guide. Coupling is provided to the optical wave guide 114 through tapered matching sections 131 and 133. Matching sections 131 and 133 may be conveniently provided by tapering the cladding of the fiber optic bundles 130 and 132. The ends of the coupling sections 131 and 133 are positioned adjacent to the wave guide and fixed to the vertical edge of the shelf with adhesive or other suitable methods.
The modulator illustrated in FIG. 4 and discussed above when considered independently of the overall system is not a part of the subject matter of this application. This modulator was developed by co-workers of the inventor and is included in this application for purposes of showing the best current embodiment of the modulator for purposes of disclosure requirements of 35 U.S.C. 112.
The invention has been described above with reference to preferred embodiments and many modifications of the basic system can be made. For example, it will be recognized by those skilled in the art that generically the transmission lines and modulators illustrated are devices for selectively transmitting electromagnetic radiation. Therefore, a wide range of wavelengths could be used for the light source ranging from microwaves to ultraviolet and beyond provided that suitable wave guides and modulators are available. Many specific techniques may be used to detect the modulated signals. Also the data processing and display units illustrated can be modified so long as the modification results in a system which can handle the data output from the test system.
In its various embodiments, it is contemplated that the test circuits can be constructed as an integral part of the system. For example, in digital computer applications the test circuit can be a module mounted on a circuit board which may also include one or more of the circuits to be monitored. In other applications, such as LSI integrated circuits, the test module may be mounted external to the circuits to be monitored. External mounting may complicate the task of providing convenient means for coupling input signals to the modulators as well as coupling the output of the modulators to suitable detectors. This is especially true when the input signals to the modulators are digital and have a high pulse rate.
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A test system utilizing modulators responsive to signals to be tested positioned between a source of electromagnetic radiation and a sensor with the signal to be tested coupled to the input of the modulators. Preferably the modulators are positioned in optical wave guides with the modulators being electric-field operated devices to prevent any significant loading of the signals to be tested. Disclosed embodiments utilize light as the electromagnetic energy with lithium niobate substrates having titanium diffused therein forming the optical wave guides. Modulators are provided by planar electrodes affixed to the surface of the lithium niobate substrate to change the electric field across the optical waveguide. Coupling is conveniently provided to the wave guides through fiber optic bundles.
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FIELD OF THE INVENTION
This invention relates to the art of well services, and more particularly to a user friendly interactive computer system, to aid an engineer in selecting a proper treatment fluid for a particular situation. This interactive computer system, also called “the Advisor” in the remaining part of this specification is typically used in the art of constructing and stimulating subterranean wellbore for water or hydrocarbons production.
BACKGROUND OF THE INVENTION
In the art of wellbore services, numerous treatment fluids are pumped into the well and eventually into the formation. For instance, fracturing fluids are pumped to create a conductive flow path for the hydrocarbons trapped in the formation and thus facilitate enhanced recovery of the same. Fracturing fluids are required to initiate and propagate a fracture to its desired length, and provide necessary width and viscosity to transport, and efficiently place proppant inside the fracture.
The desired fluid properties are obtained through a combination of additives such as polymeric additives used for controlling the viscosity. However, the fluid composition may somehow be altered during the treatment. For instance, during the job execution most of the polymeric fluids have a tendency to dehydrate due to the phenomenon known as fluid loss, thus resulting in higher concentrations of polymer inside the proppant pack. This can hinder the movement of hydrocarbons inside the fracture. To ensure a proper clean up the fluid must be adequately loaded with ample amount of breakers to enable proper disintegration of polymers.
The above example is just an example showing that selection of proper treatment fluids mainly involves a delicate balance between the basic fluid requirements such as adequate viscosity, stability at higher temperatures, lower friction pressures, low fluid leak off coefficients, etc. and fluid properties that may be detrimental to the job such as tendency to form emulsions, shear degradation, high initial stresses, improper clean-up f the pack, etc. A wide range of parameters pertaining to formation and fluid characteristics need to be evaluated in order to arrive at an optimum fluid design. Some of these parameters are independent and some work in conjunction with another and can alter the affect of one another if they co-exist. This leads to several possible combinations and to carry out analysis of each in the limited decision making time is humanly impossible. This may result in a tendency to selecting or pumping the fluids that have “traditionally” enabled proper execution of job and have helped in “reasonable” recovery of the hydrocarbons after the job, thus leaving little room for improvement or allowing introduction of latest technology.
Moreover, the well services industry typically operates in relatively remote locations. Though the use of modern communications tools such as Internet has greatly enhanced the possibility of exchanging information with distant experts, it would be often beneficial to appeal to their expertise even for ordinary operations.
Therefore it would be suitable to provide a convenient tool to aid in selecting a fluid appropriate for a given situation while taking advantage of experts' knowledge. Such a tool also could be helpful for training new entrants and by providing concise statements validating a selection and/or a non-selection of other candidates.
SUMMARY OF THE INVENTION
The invention is an interactive computer system for providing help in selecting a well-services treatment fluid, the system comprising a act of fluid families, a set of relevant fluid characteristics and a set of digital ratings of each fluid family with regard to these characteristics. The Advisor further includes a set of job parameters pertaining to the treatment and qualitative ratings of said parameters estimating their relevance in the effective success of a treatment. An interface allows the user to enter the job parameters values known to him. Built in rules, associated with calculating means such as an integrated spreadsheet, match fluid characteristics and job parameters and trigger the elimination of fluids that are not compatible with some value of the job parameters and compute a confidence index for the non-eliminated fluid families, said confidence index based on the sum of the products of the fluid families digital ratings and on the rating of the known job parameter. The Advisor also includes means to display the results.
According to a preferred aspect of the invention, experts provide at least a list of fluid characteristics and a list of job parameters that affect the selection of a fluid family, as well as the ratings of the relative importance of these parameters and the matching and filtering rules. This is indeed an important aspect of the invention to ensure for instance that users will not overlook key criteria of rare occurrence. The specific fluid characteristics are preferably entered also through the control of experts but not necessarily—provided that all fluid characteristics are provided.
Fluids used in well services are suitable within a limited temperature range. Comparing that useful temperature range and the bottomhole temperature of the well is indeed the first filter of suitability of any fluid family and indeed, no recommendation can be made unless the bottomhole temperature of the well is known.
For most applications including, for instance, selecting a fluid family appropriate for a fracturing operation, all other job parameters may remain unknown, and the system will still provide a selection of suitable fluid families based on the temperature of use. However in this later case, the confidence index will be low. Moreover, according to a preferred embodiment of the present invention, where some of the unknown parameters could have triggered the elimination of certain fluid families, a warning message is displayed. With any job parameter added to the system, the confidence index will increase.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart used as a selection guide for a fracturing fluid depending on the well temperature, the formation fluid type and the water-sensitivity of the formation.
FIG. 2 illustrates the basic temperature screening;
FIG. 3 illustrates the basic of screening through a succession of filters;
FIG. 4 shows a partial copy of an input screen;
FIG. 5 shows a worksheet with final ratings for a scenario;
FIG. 6 shows a worksheet showing confidence in the results;
FIG. 7 shows an example of comparing the ranking for two fluids; and
FIG. 8 illustrates the contribution of ratings to the final ranking.
DETAILED DESCRIPTION
The invention will be further described in relation to an interactive computer system for fracturing fluid selection but it will be clear for one skilled in the art that the same principles could be use to build other systems for instance to select a fluid appropriate for an acidizing treatment or to select any fluids appropriate for any other types of treatment of subterranean formations such as gravel packing, cleaning etc.
The fluid Advisor according to the present invention requires different collection of data including a set of fluid characteristics, a set of job parameters that may enter into consideration for selecting a fluid, and a set of rules linking the fluid characteristics to the job parameters.
The main fluid characteristics should be the temperature interval in which the fluid is useful; in other words for a fracturing fluid, the temperature interval within which the fluid offers maximum stability and efficiently carries the proppants inside the fracture, along with several other requirements.
Other relevant fluid characteristics will be, for instance, the capacity to form an emulsion on contacting formation fluid, capillary effects for gas formations, reactivity with formation clay, pH, Yield stress, leak-off properties, ability to transport proppant, ability to generate early viscosity, shear sensitivity, environmental friendliness, friction factor, fluid cost, whether a fluid is a gelled oil. Some of the characteristics such as the temperature interval of stability do not require expert opinion since the ranges are set after adequate laboratory and field-testing and are typically well documented in fluids engineering manuals. Others are simply YES/NO values; again that information is usually readily available.
The second set of data to be considered include job parameters, distributed between formation properties and job details. For helping with the selection of a fracturing fluid, the formation properties to be considered may include beyond the formation temperature, formation fluid type (gas, oil or condensate), the reservoir permeability, the reservoir pressure, the Young's modulus, the Fracturing gradient, the Barrier Fracturing Gradient, the existence of natural fractures, the sensitivity to fluid pH, the presence of clay (and the consecutive sensitivity to aqueous fluid) etc. Job details that may be considered include for instance where the well is located (on-land or off-shore or anywhere where some specific environmental laws may be applicable), the desired fracture length, the desired proppant distribution in the fracture, the pumping rates, some well completion details such as tubular sizes, deviated wells, etc. and surface temperature.
An important aspect of well services is that several—if not most—of the job parameters are often unknown to the fluid engineer. It is therefore important that the Advisor allows these job parameters to remain in blank (unknown status). Where a specific value of some parameters would have triggered the elimination of some fluids—as it is the case for instance if a fluid type is not compatible with gas but the nature of the formation fluid is unknown to the fluid engineer—then a warning message is preferably displayed for the engineer to either get the needed information or to assume the worse case scenario and disregard potentially harmful selections.
The selection of a fluid is essentially a two-step process: first, some fluids are eliminated through the use of a succession of filters; then, the selected (non-eliminated) fluids are rated.
FIG. 1 is a flow chart that shows how several successive filters can be used to de-select a fluid type. To be noted that in this flowchart Y and N are respectively used for Yes and No or don't know. In that examples, the following three rules are considered:
Rule A: For a fluid to be selected, it has to pass the basic temperature range test. If the user-entered temperature is within the range of a fluid, the fluid gets selected.
Rul A 1 : If the formation is gas, the fluids of the gelled-oil type have to be excluded. Exception is made if the formation water-sensitivity is set at Yes. F r all others reservoir fluid values (oil, Heavy oil, not sure), only rule A applies.
Rule A 2 : If the formation is declared water-sensitive, only FOAM and oil-based fluid will be used. This implies that gelled oil series is in, even if it is a gas formation. No straight fluids without foam are allowed.
For a fracturing fluid system, other rules will preferably be further implemented such as:
Rule A 3 : If the formation is gas and if the formation permeability is selected as “Below 0.1”, foam fluids have to be included even if the reservoir is not depleted. Gelled oils and oil-base fluids are excluded.
Rule A 4 _ 1 : If the reservoir is not depleted, exclude all foams from the previous selection, except if the foam is included because of rule A 3 .
Rule A 4 _ 2 : If the reservoir is depleted, select all water base foams, and do not show straight (un-foamed) liquid fluids. This step includes gelled oils foams also.
Rule A 5 : If the reservoir is depleted below the gradient of oil column, then show gelled oils foams, otherwise show only gelled oils fluids.
Rule B 2 : If user chooses to provide cool down and if the formation permeability is more than 5 md and fracture length is less than 300 ft, then the situation is ideal for cool down. Now check if the entered surface temperature is outside the fluid range of temperature.
The rules are preferably treated by simply using a spreadsheet such as an Excel spreadsheet (Excel is a trademark of Microsoft Corporation, Redmond, Wash.). FIG. 2 shows how bottomhole static temperature (BHST) is used to narrow down the list of probable fluid families that can be pumped for a particular situation. The BHST is actually the only data that the user needs to be entered for getting a basic selection (an average value may be proposed by default for training purposes).
Following this initial screening, other screenings are performed as illustrated FIG. 3 for rule A 1 . Columns A and B are the result of the basic temperature test. In this example the first 3 fluids pass the test. Column C is a reading from the fluid characteristics, where YES indicates that the fluid is gelled oil. The user interface questions the user about the nature of the formation fluids. This parameter is entered through a drop down button with 4 options: unknown, oil, gas or condensate, and is repeated in cell H 2 for convenience. To be noted that in the test of rule A 1 , the value GAS is the only one that triggers the elimination of a fluid by changing the selection from TRUE to FALSE if the fluid is gelled oil (see cell F 5 ). Columns E, F, G and H correspond to the different possible scenarios. The value of H 2 determines which of these four columns is selected. To be noted that the following logical rules are used:
TRUE*TRUE=TRUE
TRUE*FALSE=FALSE
FALSE*FALSE=FALSE
In other words, a fluid that has already been sanctioned by a preceding rules can no more be qualified.
In the preferred embodiment shown in FIG. 3, a warning message may be displayed if the user does not know the nature of the formation fluids and the fluid is gelled oil.
Following the execution of all elimination rules, the selection now comprises a subset of fluid families that were not excluded. According to an important aspect of the invention, a set of possible events or scenario is attached to different ranges of value of the job parameters. For instance, the permeability of a formation will be considered as very low (below . . . ), low, medium or high. More complex scenarios include different parameters. Each scenario is rated by at least one expert, preferably by a pool of experts to evaluate its impact on the treatment. This rating is preferably under the form of a numeric value, for instance with 1 for a situation that has little impact and 5 for the utmost critical scenario.
For the selection of a fracturing fluid, Table 1 lists possible combinations of fluid characteristics and job details. Each of this combination receives a rating from 1 to 5, based on the effective relevance of that combination.
The following scenarios may be for instance considered as relevant for selecting a fracturing fluid; the column “Final Rating” providing the rating of the importance to give to that scenario if it occurs. Note that for a given fluid characteristics, some of the situations are self-excluding. For instance, in scenario #12 (environmentally friendly), it is clear that the well can either be offshore or on-land but not simultaneously both. With other scenarios, such as #11, several combinations are possible (the well may be either shallow, medium or deep) while the tubing may be of small or large size.
TABLE I
Final
Scenario#
Fluid Characteristics
Situation
Rating
#1
Frac Fluid Emulsion
1. Condensate Well
3
Tendency. Compatibility
2. Heavy Oil Well
5
with formation fluids.
3. Oil in Winter
5
#2
Gas Formation + R1tv.K
1. Tight gas reservoir
3
or capillary effect
2. High permeability
1
reservoir
#3
Clay Sensitivity
1. High content of
4
swelling clays
(high perm)
2. High content of
2
swelling clays
(low perm)
3. Low content of
2
swelling clays
(Smoctite)
#4
pH Form Compatibility
1. Client requests
5
neutral or low pH
#5
Frac Fluid Yield
1. High perm
4
Stress Effect
(internal filter cake)
2. Medium to high
3
permeability (wall bldg)
#6
Proppant Pack
1. High permeability
4
Clean Up
2. Low permeability
5
3. High reservoir
3
pressure grad
(>0.35)
4. Med. reservoir
4
pressure grad
(0.25-0.35)
5. Low reservoir
5
pressure grad
(>0.25)
#7
Frac Fluid Leak off
1. Low reservoir
1
permeability (<0.1 md)
2. Med-Low reservoir
2
permeability (0.1
to 5 md)
3. Med-High reservoir
4
permeability (5-
200 md)
4. High reservoir
5
permeability
(<200 md)
5. Natural Fracture/
5
Fissure reservoir
#8
Proppant Transport
1. Small Fracture
3
(<100 ft)
2. Medium Fracture
4
(100-300 ft)
3. Long Fracture
5
(>300 ft)
4. High Proppant
5
Density
5. Medium Proppant
4
Density
6. Low Proppant
2
Density
#9
Near Wellbore
1. Tortuosity
5
Early Viscosity
2. High Youngs Modulus
5
High Viscosity
(>6 E6 psi)
3. Low Youngs Modulus
2
(<1 E6 psi)
4. Low Frac Height/
4
High Stress Contrast
#10
Shear Sensitivity
1. Job through tubing
4
at high rate
2. Job through casing
2
or senulus
#11
Frac Fluid Friction
1. Shallow well
2
(<4000 ft)
2. Medium depth well
4
(4000-10000 ft)
3. Deep well
4
(>10000 ft)
4. Small tubing size
4
available for frac job
5. Large tubing size
3
available for frac job
#12
Enviromentally
1. Offshore
5
Friendly
2. Onland
2
#13
Frac Fluid Cost
1. Fluid cost less than
3
15% of Frac Cost
2. Fluid cost 15 to 30%
4
of Frac Cost
3. Fluid cost greater
5
than 30% of Total
frac Cost
#14
Fracture Width
1. High
5
2. Medium
4
3. Low
3
#15
Sea Water
1. Only Sea Water
4
Available
In practice, many of the parameters may be unknown at least at the time a first screening of candidate fluids is performed. This should not prevent the system from providing a rating for a candidate fluid but will essentially affect the confidence in the result such that the engineer should be aware that the proposed recommendation is likely to have been different if more data had been provided. For instance, let us assume that the inputted values are as shown in FIG. 4, a partial copy of an input screen. Based on the inputted values, a new column of the worksheet can be built that represents the importance of the scenario for the real case. This is illustrated in FIG. 5, where column D shows the type of reading and comparisons used to compute the final rating column E. In column D, the formula are written using standard BASIC language, in other words of the type IF (Logical test; value if true, value if false).
In the present example, since the user has indicated that the type of the fluid formation is “gas”, it is irrelevant that a fluid be suitable for condensate oils, heavy oils or winter oil. Therefore, the final rating for that information is null. As it can be seen, some scenari s are more complex, and combine several characteristics. See for instance #6 that converts the question “oil in winter” to “Is the type of formation fluid oil, and in that case, is the surface temperature below 60° F”.
The next step is to compute the confidence on results, taking into account if a value is known or remains uncertain. This is done as illustrated in FIG. 6 by calculating the ratio of the final ratings of each scenario to the sum of all final rating for each scenario where the relevant variables are effectively inputted. In the present example, the sum of all the final ratings (noted TotalRating) was equal to 172 (some scenarios are not shown for clarity purpose). Since the type of fluid formation is known, the contribution to the confidence index of the scenario “condensate oil” is therefore equal to 3 (final rating of said scenario) to 172, or 1.74%.
In the exemplified case, the user has entered most relevant data, meaning that the rating of the fluids will be presented with a confidence index of 97.7% (therefore, it is believed that there is more than 97% chance that the fluid rated number 1 be effectively the best option among the different fluid types available).
The final step is to rate the different available fluids, not only disregarded during the initial screening process. This rating is based on a table built through questionnaires to experts that assign a unique confidence number to each fluid type for all of the proposed scenarios. Again a rating of 1 to 5 is used, with 1 for least favorable condition and 5 stating that, particular fluid is most applicable and may be used with highest confidence. For confidence numbers designated for a range, the sensitivity is preferably checked to see if they could be varied for various values within the specified range so as to make the consultation more dynamic. Confidence numbers are preferably provided in the form of a table along with algorithm to inter/extrapolate them.
An example of ranking for 2 fluids (noted fluid A and fluid B) is provided in FIG. 7 (again, for clarity purpose, the ranking is only provided for the first scenarios). In the Fluid A has been rated 3 for condensate well, as fluid B but fluid B is rated only 2 for heavy well. Since each scenario is individually rated, no fluid is a priori a “good” or “bad” fluid.
The real case rating of each scenario, as obtained FIG. 5, indicating the importance of a particular parameter for a given combination of scenarios, is finally combined with the fluid rating as obtained FIG. 7 to obtain a final ranking of each preselected fluid. According to one embodiment of the invention, this final ranking is based on the sum of the products of the real case ratings and fluid ratings for all possible scenarios. FIG. 8 shows how the two ratings provide the individual contribution of each scenario to the final rating of Fluid A by simply multiplying the value. At the end, the sum of all individual contributions is computed and the fluids are presented in order (the highest sum corresponding to the most suitable fluid), and the confidence index is also displayed.
Other techniques, including rules and algorithms may be applied for some specific cases. Normalizing of the results may be carried out if the resultant values are too close. Apart from these, knowledge from a few other fluid selection trees available for instance from the fluid engineering manuals may be used to generate rules.
The rating of each fluid is advantageously free of any prejudice—or assumed degree of confidence—a user may have based on his/her experience in the real world and further provides a strong justification of the choice.
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The invention is an interactive computer system for help in selecting well-services treatment fluid comprising a set of fluid families, a set of relevant fluid characteristics and a set of digital ratings of each fluid family with regard to these characteristics. The system further includes a set of job parameters pertaining to the treatment and qualitative ratings of said parameters estimating their relevance in the effective success of a treatment. An interface allows the user to enter the job parameters values known to him. Built in rules, associated with calculating means including an integrated spreadsheet, match fluid characteristics and job parameters and trigger the elimination of fluids that are not compatible with some value of the job parameters and compute a confidence index for the non-eliminated fluid families, said confidence index based on the one the sum of the products of the fluid families digital ratings and on the rating of the known job parameter. The system also includes means to display the results.
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This is a divisional application of Ser. No. 340,377, filed on Nov. 14, 1994, now U.S. Pat. No. 5,486,617.
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The invention relates to a novel process for preparing 2-substituted 5-chloroimidazole-4-carbaldehydes of the general formula: ##STR3## wherein R is hydrogen, an alkyl group, an alkenyl group, a cycloalkyl group, an arylalkyl group or an aryl group.
2. Background Art
Several methods for preparing 2-substituted 5-chloroimidazole-4-carbaldehydes of the general formula I are known in the art.
U.S. Pat. No. 4,355,040 discloses a process in which 2-amino-3,3-dichloroacrylonitrile is reacted both with an aldehyde to obtain the corresponding azomethine intermediate, and further with a halohydrocarbon and water to obtain the 2-substituted 5-haloimidazole-4-carbaldehyde. It should be noted that experimental details are lacking in the patent specification. And, a great disadvantage of this synthesis is that the starting 2-amino-3,3-dichloroacrylonitrile first has to be prepared by reacting dichloroacetonitrile with hydrocyanic acid/sodium cyanide. The dichloroacetonitrile and hydrocyanic acid/sodium cyanide reactants are extremely toxic reactants. The safety measures which are necessary even to prepare these starting materials make the entire process unsuitable on an industrial scale.
U.S. Pat. No. 4,355,040 also discloses a variant 3-stage process in which, in the first stage, an amidine hydrochloride is ring-closed with dihydroxyacetone at a high NH 3 pressure, and an imidazole alcohol is halogenated and then oxidized to the aldehyde. It should be noted that it has been shown that pressures of over 20 bars are necessary for the ring-closure reaction. Also, the oxidation of the alcohol works in the presence of chromium oxide. Clearly, an oxidation which uses a heavy metal oxide such as chromium oxide is no longer considered to be ecologically responsible, since heavy metal oxides usually are not recyclable.
BROAD DESCRIPTION OF THE INVENTION
An object of the invention is to provide a process which does not have the disadvantages and problems of the prior art as set out above. Other objects and advantages of the invention are set out herein or are obvious herefrom to one ordinarily skilled in the art.
The objects and advantages of the invention are achieved by the process of the invention.
The invention involves a process for preparing 2-substituted 5-chloroimidazole-4-carbaldehydes of the general formula: ##STR4## wherein R is hydrogen or is an alkyl group, an alkenyl group, a cycloalkyl group, an arylalkyl group or an aryl group. The process includes, in a first stage, reacting a glycine ester hydrohalide of the general formula: ##STR5## wherein R 1 is an alkyl group and X is a halogen atom, with an imidate ester of the general formula: ##STR6## wherein R has the above-mentioned meaning and R 2 is an alkyl group, in the presence of a base, to obtain 2-substituted 3,5-dihydroimidazole-4-one of the general formula: ##STR7## wherein R has the above-mentioned meaning. Next, in a second stage, this intermediate is converted with an N,N-substituted formamide acetal of the general formula: ##STR8## where in R 3 and R 4 are identical or different and each is an alkyl group or an arylalkyl group, and R 5 and R 6 are identical or different and each is an alkyl group or an aryl group, into an N,N-substituted aminomethyleneimidazolinone of the general formula: ##STR9## wherein R, R 5 and R 6 have the above-mentioned meanings. Next, in the third stage, this latter intermediate of general formula VI is chlorinated with phosphorus oxychloride or phosgene to obtain the the final product.
Preferably the intermediates of the general formula IV and VI are not isolated. Preferably an alkali metal hydroxide or an alkali metal alkoxide is used as the base in the first stage. Preferably the reaction temperature in the first stage is between -20° C. and 50° C. Preferably the reaction in the second stage is carried out in the presence of an inert solvent at a temperature between -50° C. and 100° C. Preferably the chlorination with phosphorus oxychloride is carried out at a temperature between 50° and 150° C. Preferably the chlorination with phosphorus oxychloride and N,N-dimethylformamide or phosgene and N,N-dimethylformamide is carried out at a temperature between 50° and 150° C.
The invention also includes N,N-substituted aminomethyleneimidazolinones of the general formula: ##STR10## wherein R is hydrogen or is an alkyl group, an alkenyl group, a cycloalkyl group, an arylalkyl group or an aryl group and R 5 and R 6 are identical or different and each is an alkyl group or an aryl group, in the form of the E- or Z-isomer.
Preferably the compound of general formula VI is (Z)-2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one wherein R is butyl, and R 5 and R 6 are each methyl.
The 2-substituted 5-chloroimidazole-4-carbaldehydes of the general formula I are important starting materials for the preparation of hypotensive pharmaceuticals (U.S. Patent No. 4,355,040) or of herbicidally active compounds (German Patent No. A 2,804,435).
DETAILED DESCRIPTION OF THE INVENTION
The general names of the groups in the substituents R, R 1 , R 2 , R 3 , R 4 , R 5 and R 6 in the general formulae I to VI have the following meaning.
An alkyl group is a straight-chain or branched (C 1 -C 6 )-alkyl group, in particular, a methyl group, an ethyl group, a n-propyl group, an i-propyl group, a n-butyl group, a sec.-butyl group, a tert.-butyl group, a pentyl group or one of its isomers, or a hexyl group or one of its isomers. A preferred alkyl group for R is the n-butyl group. A preferred alkyl group for R 1 , R 2 , R 3 , R 4 , R 5 and R 6 is a (C 1 -C 4 )-alkyl group.
An alkenyl group is a straight-chain or branched (C 2 -C 6 )-alkenyl group, such as, a 1-propenyl group, a 2-propenyl group, a 1-butenyl group, a 2-butenyl group, a 3-butenyl group, a pentenyl group or one of its isomers, and a hexenyl group or one of its isomers. A preferred alkenyl group is the 2- or 3-butenyl group.
Examples of cycloalkyl groups are the cyclopropyl group, the cyclobutyl group, the cyclopentyl group and the cyclohexyl group.
The term arylalkyl group means a phenyl-(C 1 -C 6 ) alkyl group, preferably a benzyl group.
The term aryl means phenyl.
Both the arylalkyl group and the aryl group can have one or more substitutents, for example, an alkyl group, halogen, nitro or amino, on their aromatic ring. The term halogen means chlorine, bromine or iodine; the preferred halogen is chlorine.
The first stage of the process of the invention involves reacting a glycine ester hydrohalide of the general formula: ##STR11## wherein R 1 is an alkyl group and X is a halogen atom, with an imidate ester of the general formula: ##STR12## wherein R has the above-mentioned meaning and R 2 is an alkyl group, in the presence of a base, to obtain the 2-substituted 3,5-dihydroimidazole-4-one of the general formula ##STR13## wherein R has the above-mentioned meaning.
A procedure is expediently used in which the glycine ester hydrohalide of the general formula II is reacted with the imidate ester of the general formula III in the presence of a base, expediently at a pH of 7 to 12, preferably of 9 to 11.
The glycine ester hydrohalides of the general formula II are commercially available stable compounds.
Suitable bases for use in this reaction are the alkali metal hydroxides, such as, Sodium hydroxide and potassium hydroxide, and the alkali metal alkoxides, such as, sodium and potassium methoxide, ethoxide and tert.-butoxide. Advantageously, the base is present dissolved in a suitable solvent. Solvents which are particularly suitable for this purpose are aliphatic alcohols, such as, methanol or ethanol. The imidate ester is expediently also added in the form of a solution in an inert solvent. As a rule, aromatic solvents, such as, toluene, chlorobenzene, or aliphatic solvents, such as, methanol and ethanol, are particularly and highly suitable for this purpose.
The reaction of the reactants, namely, the glycine ester hydrohalide, the imidate ester, and the base advantageously takes place in a stoichiometric ratio of 1:1:1. The reaction temperature is expediently in the range of -20° to 50° C., preferably in the range of 0° to 25° C.
After a reaction time of a few hours, the corresponding intermediate 2-substituted 3,5-dihydroimidazole-4-one of the general formula IV can be isolated in yields greater than 95 percent in a technical manner, as a rule by simple filtration.
Advantageously, however, the intermediate/imidazolinone of the general formula IV is not isolated, but rather the N,N-substituted formamide acetal of the general formula: ##STR14## wherein R 3 and R 4 are identical or different and each is an alkyl group or an arylalkyl group, and R 5 and R 6 are identical or different and each is an alkyl group, an arylalkyl group or an aryl group, is directly added to the resultant reaction mixture containing the intermediate of the general formula IV.
Suitable N,N-substituted formamide acetals of the general formula V are the N,N-dimethylformamide dialkyl acetals. N,N-Dimethylformamide dimethyl acetal, in which R 3 , R 4 , R 5 and R 6 are methyl, is particularly preferable.
The reaction in the second stage can be carried out in the presence of an inert solvent, for example, in an aliphatic alcohol, a halogenated hydrocarbon or an aromatic. Therefore, methanol, methylene chloride or toluene can be used with good results. However, it is also possible to carry out the reaction without using an additional solvent, in other words, in the presence of the acetal as a solvent.
The reaction expediently proceeds at a temperature between -50° C. and 100° C. (but preferably at room temperature).
The invention includes the resultant N,N-substituted aminomethyleneimidazolinone of the general formula: ##STR15## wherein R, R 5 and R 6 have the above-mentioned meanings. These compounds are an important intermediate in the synthesis of the instant invention and are not known in the literature. The N,N-substituted aminomethyleneimidazolinones of the general formula VI can occur as either E- or a Z-isomers. A particularly preferred imidazolinone of the general formula VI is the (Z)-2-butyl derivative wherein R is n-butyl and R 5 and R 6 each are methyl.
The N,N-substituted aminomethyleneimidazolinone of the general formula VI can be isolated from the reaction mixture in any customary technical manner.
However, without isolation of the intermediate of the general formula VI, it can be chlorinated with phosphorus oxychloride or phosgene in the third and last stage to obtain the final product. The chlorination can be carried out either in the presence of phosphorus oxychloride or in the presence of the so-called Vilsmeier reagent. The so-called Vilsmeier reagent consists of phosphorus oxychloride and N,N-dimethylformamide, or phosgene and N,N-dimethylformamide, expediently in a molar ratio of 1:1 to 4:1. The mentioned chlorinating agents are expediently employed in an excess amount and, thus, simultaneously serve as a solvent. However, the chlorination can be carried out in the presence of an additional inert solvent. The chlorination is expediently carried out at a temperature between 50° and 150° C.
After a reaction time of about 0.5 hours to 4 hours, the corresponding end product 2-substituted 5-chloroimidazole-4-carbaldehyde of the general formula I can be obtained in both good yield and good purity in any customary technical manner. The end product is expediently obtained by treatment of the reaction mixture with water, and by subsequent extraction with a suitable solvent.
EXAMPLE 1
Preparation of (Z)-2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one VI from 2-butyl-2-imidazolin-5-one IV
2.85 g (content about 92 percent, 22 mmol) of N,N-dimethylformamide dimethyl acetal was added to a solution of 2.80 g (20 mmol) of 2-butyl-2-imidazolin-5-one in 20 ml of methanol. The temperature of the solution rose from 18° to 26° C. After 45 minutes, the solution was concentrated and dried in a high vacuum. 3.88 g of 2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one, having a content of greater than 9 percent according to H-NMR, was obtained. This corresponds to a yield of about 90 percent, based on the 2-butyl-2-imidazolin-5-one. The product could be recrystallized from ethyl acetate. The product had a melting point of 114° to 116.5° C. Other data concerning the product is:
1 H-NMR (CDCl 3 , 400 MHz)
0.95 (3 H, t);
1.42 (2 H, m);
1.68 (2 H, m);
2.53 (2 H, t);
3.17 (3 H, br s);
3.55 (3 H, br s);
7.03 (1 H, s);
10.35 (1 H, br s).
EXAMPLE 2
Preparation of (Z)-2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one VI from methyl pentanimidate III
5.00 g (39.42 mmol) of glycine methyl ester hydrochloride was added in a single portion to a solution of 1.59 g (39.42 mmol) of sodium hydroxide in 13 ml of methanol at 0° C. The temperature dropped to -10° C. The mixture was then stirred for 15 minutes and during this time the temperature rose again to 0° C. 4.73 g (39.42 mmol) of methyl pentanimidate was added, and the mixture was stirred at room temperature for 3 hours. Then, during the course of 5 minutes, 5.62 g (43.39 mmol) of N,N-dimethylformamide dimethyl acetal was added, and the reaction mixture was stirred for a further 3 hours. Thereafter, solvent was removed on a Rotavapor, and the residue was treated with 40 ml of CH 2 Cl 2 and 15 ml of water. After phase separation, the organic phase was washed with 10 ml of water, and then the combined H 2 O phases were washed twice, each time with 20 ml of CH 2 Cl 2 . Then, the combined organic phases were dried (MgSO 4 ), filtered, concentrated on the Rotavapor and dried in a high vacuum. 6.70 g of 2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one was obtained, having a content of about 90 percent, according to 1 H-NMR. This corresponds to a yield of about 78 percent, based on the methyl pentanimidate.
EXAMPLE 3
Preparation of 2-butyl-5-chloroimidazole-4-carbaldehyde I from (Z)-2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one IV
A mixture of 1.00 g (5.12 mmol) of 2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one and 3.20 g (20.48 mmol) of POCl 3 was heated at 100° C. for 45 minutes. Then, 1.76 g of POCl 3 was distilled off on the Rotavapor, and the residue was treated with 6 ml of ethyl acetate. The mixture thus obtained was added to 20 ml of water, and the water was stirred at room temperature for 5 minutes. Then, the pH was adjusted from 0.34 to 7, using 30 percent strength sodium hydroxide solution. The mixture was extracted twice, using 10 ml of ethyl acetate each time. The combined organic phases were dried (MgSO 4 ), filtered and concentrated, and the residue was dried in a high vacuum. 0.89 g of 2-butyl-5-chloroimidazole-4-carbaldehyde was obtained; this product having a purity greater than 95 percent, according to H-NMR. This corresponds to a yield of 93 percent, based on the 2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one.
EXAMPLE 4
Preparation of (Z)-2-butyl-4-dimethylaminomethylene-2-imidazolin-5one VI from 2-butyl-2-imidazolin-5-one IV
A solution of 5.00 g (35.67 mmol) of 2-butyl-2-imidazolin-5-one and 7.02 g (39.24 mmol) of N,N-dimethylformamide diisopropyl acetal in 25 ml of methylene chloride was stirred at room temperature for 2.5 hours. Then, the solvent was removed on a Rotavapor, and the residue was treated with 40 ml of methylene chloride. The solution thus obtained was washed twice, each time with 10 ml of water, and dried (MgSO 4 ) and concentrated on the Rotavapor. The residue was then dried in a high vacuum. 5.37 g of 2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one was obtained; the product had a content of greater than 90 percent, according to H-NMR: This corresponds to a yield of about 71 percent, based on the 2-butyl-2-imidazolin-5-one.
EXAMPLE 5
Preparation of (Z)-2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one VI from methyl pentanimidate III
5.00 g (39.42 mmol) of glycine methyl ester hydrochloride was added in a single portion to a solution of 1.59 g (39.42 mmol) of sodium hydroxide in 13 ml of methanol, at 0° C. The temperature dropped to -10° C. Then, the mixture was stirred for 15 minutes. During this time, the temperature rose again to 0° C. 4.73 g (39.42 mmol) of methyl pentanimidate was added, and the mixture was stirred at room temperature for 3 hours. 9.00 g (43.36 mmol) of N,N-dimethylformamide dibutyl acetal then was added, during the course of 5 minutes, and the reaction mixture was stirred for a further 3 hours. Then, the solvent was removed on the Rotavapor, and the residue was treated with 40 ml of CH 2 Cl 2 and 15 ml of water. After phase separation, the organic phase was washed with 10 ml of water. The organic phase was dried (MgSO 4 ), filtered and concentrated on the Rotavapor, and the residue was dried in a high vacuum. 6.92 g of 2-butyl-4-dimethylaminomethylene-2-imidazolin-5-one was obtained; the product had a content of about 80 percent according to H-NMR. This corresponds to a yield of about 72 percent, based on the methyl pentanimidate.
EXAMPLE 6
Preparation of 2-butyl-5-chloroimidazole-4-carbaldehyde I from methyl pentanimidate III
31.72 g (250 mmol) of glycine methyl ester hydrochloride was added in a single portion to a solution of 10.13 g (250 mmol) of sodium hydroxide in 80 ml of methanol at 0° C. The temperature dropped to -10° C. The mixture was stirred for 10 minutes, during which time the temperature rose again to 0° C. 108.25 g (a 26.6 percent strength solution in toluene, 250 mmol) of methyl pentanimidate was added, and the mixture was stirred at room temperature for 3 hours. 35.64 g (about 92 percent strength, 275 mmol) of dimethylformamide dimethyl acetal then was added, during the course of 5 minutes. The reaction mixture was stirred for an additional 3 hours. 200 ml of toluene was added, and methanol and water were removed from the mixture by distillation in vacuo. Of the remaining 203.5 g, 91.68 g (corresponding to 112 mmol of methyl pentanimidate) was initially introduced at room temperature and treated with 65.09 g (416 mmol) of POCl 3 . The mixture was heated 15 100° C. for 1.5 hours and then 118.5 g of POCl 3 /toluene was distilled off and the residue was treated with 121 ml of ethyl acetate and 408 ml of water. The pH was adjusted to 1, by addition of 18 ml of 30 percent strength sodium hydroxide solution, and the phases were separated. The aqueous phase was extracted twice, each time with 200 ml of ethyl acetate, and the combined organic-phases were washed with 200 ml of water, dried (MgSO 4 ), and filtered and concentrated. The residue was dried in a high vacuum. 14.07 g of 2-butyl -5-chloroimidazole-4-carbaldehyde (HPLC content 79.9 percent) was obtained. This corresponds to a yield of 56 percent, based on the methyl pentanimidate.
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A process for preparing 2-substituted 5-chloroimidazole-4-carbaldehydes of the general formula: ##STR1## In the process, a glycine ester hydrohalide is ring-closed with an imidate ester to obtain the intermediate 2-substituted 3,5-dihydroimidazol-4-one. This intermediate is converted with an N,N-substituted formamide acetel into an N,N-substituted aminomethyleneimidazolinone. This latter intermediate is chlorinated with phosphorus oxychloride or phosgene to obtain the final product 2-substituted 5-chlorimidazole-4-carbaldehydes of the general formula I.
Also disclosed are N,N-substituted aminomethyleneimidazolinones of the general formula: ##STR2## wherein R is hydrogen or is an alkyl group, an alkenyl group, a cycloalkyl group, an arylalkyl group or an aryl group, and R 5 and R 6 are identical or different and each is an alkyl group or an aryl group, in the form of the E- or Z-isomer.
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TECHNICAL FIELD
[0001] The present invention relates to a theanine-surface-treated powder showing smooth touch and good compatibility with skin, and a cosmetic preparation obtained by using the same which shows smooth use feeling and good adhesion to skin and is excellent in uniformity of cosmetic-film and in cosmetic retentivity over time.
BACKGROUND ART
[0002] Into a cosmetic preparation, various powders such as an inorganic powder, an organic powder, and a coloring powder are incorporated for the purpose of providing a make-up effect and retentivity thereof and adjusting the touch. However, since inorganic powders are especially poor in compatibility with skin due to a nature of inorganics, a cosmetic preparation with an inorganic powder incorporated therein is poor in spreading on skin and gives strong squeaky feel, whereby physical irritation to skin is caused and smoothness during application is impaired. Furthermore, because of high aggregation property and low oil dispersibility of the particles, an inorganic powder has lowered long-term storage stability, make-up effect, UV absorption effect, and the like of the cosmetic preparation. For solving the problems, the surface of the powder has conventionally been treated with various surface treating agents. For example, a number of methods such as methods of surface treatment with an ester oil, a metal soap, lecithin, a silicone oil (see, for example, PTLs 1 and 2), a perfluoroalkyl oil (see, for example, PTLs 3 and 4), and the like are known.
[0003] However, although a powder surface-treated with an ester oil, a metal soap, a silicone oil, a perfluoroalkyl oil, and the like has smooth touch and is lowered in physical irritation to skin, such a powder is poor in affinity with a living body, and therefore has not been satisfactory in compatibility with skin. In addition, in order to achieve good touch and enhance the compatibility with skin, techniques of using an acylated amino acid (see, for example, PTLs 5 and 6) and techniques of using an acylated polypeptide obtained by acrylating a polypeptide which is a polymer of an amino acid (see, for example, PTLs 7 and 8) are known, but the effects thereof have not been satisfactory.
[0004] Although a cosmetic preparation which has good usability and touch and also shows high cosmetic retentivity has been conventionally demanded, it is not easy to satisfy both the requirements. In particular, in a powdery cosmetic preparation, when it is intended to enhance too much the adhesion to skin in pursuit of cosmetic retentivity, the powdery cosmetic preparation has a tendency to reduce smooth spreading and deteriorate usability and use feeling. In addition, uniform formation of cosmetic-film is also required, but it is difficult in practice to provide a cosmetic preparation satisfying all the requirements.
[0005] Among the demands of consumers regarding the cosmetic retentivity, there is a demand to prevent elimination of cosmetic-film due to secondary adhesion (a phenomenon that the cosmetic-film is broken up and eliminated due to a hand, handkerchief and face mask coming into contact with skin after application of the cosmetic preparation). However, in a cosmetic preparation which is enhanced merely in adhesion to skin, it has been difficult to also prevent the adhesion to hands or clothes. In order to prevent the secondary adhesion, for example, a technique of using an organic silicone resin (PTL 9), a technique of using a powder surface-treated with a specific film forming agent (PTL 10), and a technique of incorporating a boron nitride powder and a coating agent (PTL 11) are known. The techniques are however not fully satisfactory in the effect and the touch in use.
CITATION LIST
Patent Literature
[0000]
PTL 1: JP-A-5-339518
PTL 2: JP-A-2001-072527
PTL 3: JP-A-10-167931
PTL 4: JP-A-11-335227
PTL 5: JP-A-1-50202
PTL 6: JP-A-3-200879
PTL 7: JP-A-10-226626
PTL 8: JP-A-9-328413
PTL 9: JP-A-10-218725
PTL 10: JP-A-2007-302800
PTL 11: JP-A-2000-302644
SUMMARY OF INVENTION
Technical Problem
[0017] An object of the present invention is to provide a novel surface-treated powder showing smooth touch and good compatibility with skin, a cosmetic preparation which shows smooth touch during application and good compatibility with skin and is excellent in uniformity of cosmetic-film and cosmetic retentivity, and a cosmetic preparation which is further excellent in preventing elimination of cosmetic-film due to secondary adhesion.
Solution to Problem
[0018] As a result of intensive studies in view of the above situation, the present inventors have found that among amino acid derivatives, theanine has a higher affinity with keratin which is a constituent of skin, and by performing surface treatment of powder using theanine, touch during application and skin compatibility are improved; and that, by incorporating the powder surface-treated with theanine into a cosmetic preparation, a cosmetic preparation which shows smooth spreading during application, and is excellent in compatibility with skin, and also excellent in uniformity of cosmetic-film and cosmetic retentivity can be obtained. The present inventors have further found that by combining an organic powder with the inorganic powder surface-treated with theanine, a powdery cosmetic preparation which is improved in smoothness of spreading during application, uniformity of cosmetic-film, and cosmetic retentivity over time, and is also excellent in the effect of preventing elimination of cosmetic-film due to secondary adhesion can be obtained, thereby completing the present invention.
[0019] That is, the present invention relates to a powder for a cosmetic preparation, the powder being surface-treated with theanine.
[0020] The present invention also relates to a cosmetic preparation having the surface-treated powder incorporated therein.
[0021] The present invention also relates to a powdery cosmetic preparation containing an inorganic powder surface-treated with theanine and an organic powder.
[0022] The present invention further relates to a powdery cosmetic preparation containing boron nitride together with an inorganic powder surface-treated with theanine and an organic powder.
Advantageous Effects of Invention
[0023] Theanine which is used in the present invention is excellent in affinity with keratin which is a constituent of skin, and therefore enhances compatibility with skin of a powder even with a small treatment amount and gives smooth touch. Accordingly, a cosmetic preparation in which the powder surface-treated with theanine is incorporated is excellent in compatibility with skin, shows smooth spreading and has good usability, and is further excellent in uniformity of cosmetic-film and cosmetic retentivity effect. In addition, a powdery cosmetic preparation in which an inorganic powder surface-treated with theanine is combined with an organic powder is improved in smoothness of spreading during application, uniformity of cosmetic-film, and cosmetic retentivity over time, and is further excellent in the effect of preventing elimination of cosmetic-film due to secondary adhesion.
DESCRIPTION OF EMBODIMENTS
Surface Treating Agent
[0024] Theanine which is used in the present invention has a chemical name of glutamic acid-γ-monoethylamide and has a d-form and an l-form, and although the l-form generally exists, the present invention may include the d-form. When theanine was compared with various amino acid derivatives in the affinity with keratin by using a method of measuring the wavenumber shift in an ATR analysis, a shift to a lower wavenumber was observed on the hydrogen bond. Examples of commercial products of theanine include L-THEANINE (manufactured by Kurita Water Industries Co., Ltd.) and SUNTHEANINE (manufactured by Taiyo Kagaku Co., Ltd.).
(Surface-Treated Powder for Cosmetic Preparation)
[0025] The surface-treated powder of the present invention is obtained by allowing theanine as mentioned above to be supported on the surface of a powder. The powder which is surface-treated is not particularly limited in the shape such as a sphere shape, a tabular shape, and a needle shape, the particle size such as an atomized form, a fine particle form, and a pigment grade, the particle structure such as a porous structure and non-porous structure, and the like, as long as the powder is a powder generally used for a cosmetic preparation. One kind or two or more kinds of an inorganic powder, a photoluminescent powder, an organic powder, an organic coloring powder, a complex powder, and the like may be used, but an inorganic powder such as an inorganic powder, a photoluminescent inorganic powder, and a complex inorganic powder is preferred, and an inorganic tabular powder and a metal oxide pigment such as titanium oxide, zinc oxide, and iron oxide are more preferred.
[0026] As the inorganic powder, one kind or two or more kinds selected from titanium oxide, black titanium oxide, iron blue pigment, ultramarine blue, colcothar, yellow iron oxide, black iron oxide, zinc oxide, aluminum oxide, silica, magnesium oxide, zirconium oxide, magnesium carbonate, calcium carbonate, chromium oxide, chromium hydroxide, carbon black, aluminum silicate, magnesium silicate, aluminum magnesium silicate, mica, synthetic mica, sericite, talc, kaolin, silicon carbide, barium sulfate, bentonite, smectite, boron nitride, and the like may be used. Incidentally, fine particles of approximately from 10 to 80 nm prepared from the powder may be used.
[0027] As the photoluminescent inorganic powder, one kind or two or more kinds selected from bismuth oxychloride, a titanium oxide-coated mica, an iron oxide-coated mica, an iron oxide-coated mica titanium, a titanium oxide-coated glass powder, an aluminum powder, and the like may be used. The photoluminescent inorganic powder may include in a part thereof an organic compound, but a part or the whole of the surface is preferably coated with an inorganic compound.
[0028] As the organic powder, one kind or two or more kinds selected from a nylon powder, a polymethyl methacrylate powder, an (acrylonitrile/methacrylic acid) copolymer powder, a (vinylidene chloride/methacrylic acid) copolymer powder, a PET resin powder, a polyethylene powder, a polystyrene powder, an organopolysiloxane elastomer powder, a polymethylsilsesquioxane powder, a polyurethane powder, a wool powder, a silk powder, a crystalline cellulose powder, an N-acyl lysine powder, and the like may be used.
[0029] As the coloring powder, one kind or two or more kinds selected from an organic tar pigment, an organic coloring rake pigment, and the like may be used.
[0030] As the complex inorganic powder, one kind or two or more kinds selected from a fine particle titanium oxide-coated mica titanium, a fine particle zinc oxide-coated mica titanium, a barium sulfate-coated mica titanium, a titanium oxide-containing silica, a zinc oxide-containing silica, and the like may be used. The complex inorganic powder may include an organic compound in a part thereof, but a part or the whole of the surface is preferably coated with an inorganic compound.
[0031] Among them, especially suitable as the powder to be surface-treated are a tabular inorganic powder such as talc and mica and a metal oxide pigment such as titanium oxide, zinc oxide, and iron oxide. In the case of, for example, titanium oxide, in particular, of fine particles, the powder is easily aggregated in the untreated state, but when the theanine mentioned above is used as a surface treating agent, since the dispersibility of the surface-treated titanium oxide is improved, it is possible to efficiently impart a UV blocking effect which is a characteristic of titanium oxide to a cosmetic preparation.
(Method for Producing Surface-Treated Powder)
[0032] In the present invention, as the method for surface-treating powder, a known treatment method which has been conventionally used for modifying a powder used in a cosmetic preparation can be employed. For example, a wet method using a solvent, a dry method of treating powder in a gas phase, a mechanochemical method involving pulverization with mixing and shear, and the like may be used, and use of an aqueous solvent is particularly preferred since the surface treatment is then homogenously achieved. Specifically, the surface-treated powder can be obtained by dissolving theanine in water of 50° C., adding a powder in the aqueous solution, mixing the mixture uniformly with stirring using a Henschel mixer or the like mixer, and then drying and pulverizing the powder.
[0033] The surface-treated powder of the present invention may further be multiply coated before use with a generally known surface treating agent such as a silicone compound, a fluorine compound, an oil, a fat, a higher alcohol, a wax, a polymer, and a resin, for the purpose of improving dispersibility in the cosmetic preparation base, improving the touch, and the like.
[0034] The treatment amount of theanine in the surface-treated powder obtained as above is not particularly limited, but preferably 0.002 to 20% by mass (hereinafter abbreviated as “%” simply), more preferably 0.1 to 5%, in the treated powder. Within this range, a powder for a cosmetic preparation showing excellent touch and skin compatibility is obtained, and by incorporating the powder, a cosmetic preparation which spreads smoothly during application, is excellent in compatibility with skin, and also excellent in uniformity of cosmetic-film and cosmetic retentivity can be obtained.
[0035] The surface-treated powder of the present invention is obtained by allowing theanine mentioned above to be supported on the surface of a powder. The mode of the support in the present invention is not particularly limited, and theanine may be supported on the surface of a powder in a particle form or may be supported in a film form together with other components. In addition, theanine may be supported on the surface of a powder by physically adhering, or may be supported by chemical binding, and may be supported not on the whole but on a part of the surface of a powder.
(Cosmetic Preparation)
[0036] The cosmetic preparation of the present invention is produced by combining and blending one kind or two or more kinds of the surface-treated powders as described above with known components of a cosmetic preparation according to an ordinary method. The amount of the surface-treated powders incorporated in the cosmetic preparation of the present invention is not particularly limited and different depending on the formulation form and the item of the cosmetic preparation, but the amount may be 0.1 to 90%, preferably 5 to 40%.
[0037] In the cosmetic preparation, components capable of being incorporated may be incorporated appropriately as need arises. For example, an oil, a surfactant, an alcohol, water, a moisturizer, a gelling agent, and a thickener, a powder other than the surface-treated powder, a UV absorber, a preservative, a antimicrobial an antioxidant, a component for beautiful skin (a whitening agent, a cell activator, an anti-inflammatory agent, a blood circulation promoter, a skin astringent, an antiseborrheic agent, etc.), a vitamin, an amino acid, a nucleic acid, a hormone, and the like may be incorporated.
[0038] Examples of the formulation form of the cosmetic preparation of the present invention include a powder formulation, an oil-in-water emulsion formulation, a water-in-oil emulsion formulation, an oily formulation, an aqueous formulation, and a solvent formulation. Examples of the form of the cosmetic preparation include a powder form, a powdery solid form, an oily solid form, a cream form, a gel form, a liquid form, a mousse from, and a spray from. Among them, a powder formulation is particularly preferred since it can maximize the characteristics of the surface-treated powder of the present invention. The cosmetic preparation of the present invention is required only to contain the surface-treated powder of the present invention, and can be suitably used especially for a makeup cosmetic preparation such as a foundation, a concealer, a face powder, an eyeshadow, a cheek rouge, a makeup base, an eye color, a rouge, an eyebrow, a mascara, an eyeliner, and a manicure, and for a sun screen cosmetic preparation.
(Powdery Cosmetic Preparation)
[0039] A cosmetic preparation especially suitable as the cosmetic preparation of the present invention is a powdery cosmetic preparation in which an organic powder is incorporated together with inorganic powder surface-treated with theanine.
[0040] The inorganic powder surface-treated with theanine for use in the powdery cosmetic preparation of the present invention is the powder for a cosmetic preparation described above in which an inorganic powder is used as the powder to be treated.
[0041] Theanine which is used as the surface treating agent has a chemical name of glutamic acid-γ-monoethylamide and has a d-form and an l-form, and although the l-form generally exists, the present invention may include the d-form. When theanine was compared with various amino acid derivatives in the affinity with keratin by using a method of measuring the wavenumber shift in an ATR analysis, a shift to a lower wavenumber was observed on the hydrogen bond. Examples of commercial products of theanine include L-THEANINE (manufactured by Kurita Water Industries Co., Ltd.) and SUNTHEANINE (manufactured by Taiyo Kagaku Co., Ltd.).
[0042] The inorganic powder to be surface-treated is not particularly limited in the shape such as a sphere shape, a tabular shape, and a needle shape, the particle size such as an atomized form, a fine particle form, and a pigment grade, the particle structure such as a porous structure and a non-porous structure, and the like, as long as it is an inorganic powder generally used in a cosmetic preparation, and one kind or two or more kinds of an inorganic powder, a photoluminescent inorganic powder, a complex inorganic powder, and the like may be used.
[0043] As the inorganic powder, one kind or two or more kinds selected from titanium oxide, black titanium oxide, iron blue pigment, ultramarine blue, colcothar, yellow iron oxide, black iron oxide, zinc oxide, aluminum oxide, silica, magnesium oxide, zirconium oxide, magnesium carbonate, calcium carbonate, chromium oxide, chromium hydroxide, carbon black, aluminum silicate, magnesium silicate, aluminum magnesium silicate, mica, synthetic mica, sericite, talc, kaolin, silicon carbide, barium sulfate, bentonite, smectite, boron nitride, and the like may be used. Incidentally, fine particles of approximately from 10 to 80 nm prepared from the powder may be used.
[0044] Examples of the photoluminescent inorganic powder include bismuth oxychloride, a titanium oxide-coated mica, an iron oxide-coated mica, an iron oxide-coated mica titanium, a titanium oxide-coated glass powder, and an aluminum powder. The photoluminescent inorganic powder may include an organic compound in part thereof, but a part or the whole of the surface is preferably coated with an inorganic compound.
[0045] Examples of the complex inorganic powder include a fine particle titanium oxide-coated mica titanium, a fine particle zinc oxide-coated mica titanium, a barium sulfate-coated mica titanium, a titanium oxide-containing silica, and a zinc oxide-containing silica. The complex inorganic powder may include an organic compound in part thereof, but in this case, a part or the whole of the surface is preferably coated with an inorganic compound.
[0046] Among them, especially suitable as the powder to be surface-treated of the present invention are a tabular inorganic powder such as talc and mica and a metal oxide pigment such as titanium oxide, zinc oxide, and iron oxide. In the case of, for example, titanium oxide, especially of fine particles, the powder is easily aggregated in the untreated state, but when the theanine mentioned above is used as a surface treating agent, since the dispersibility of the surface-treated titanium oxide is improved, it is possible to efficiently impart a UV blocking effect which is a characteristic of titanium oxide to the cosmetic preparation.
[0047] As for the method of the surface treatment in the surface-treated powder used in the present invention, a known treatment method which has been conventionally used for modifying a powder used in a cosmetic preparation can be employed. Examples thereof include a wet method using a solvent, a dry method of treating powder in a gas phase, and a mechanochemical method involving pulverization with mixing and shear may be used, and use of an aqueous solvent is particularly preferred since the surface treatment is then homogenously achieved. Specifically, the surface-treated powder can be obtained by dissolving theanine in water of 50° C., adding a powder in the aqueous solution, mixing the mixture uniformly with stirring using a Henschel mixer or the like mixer, and then drying and pulverizing the powder.
[0048] The surface-treated powder used in the present invention is one in which the theanine described above is supported on the surface of the inorganic powder described above, and the mode of the support is not particularly limited, and, for example, theanine may be supported on the surface of a powder in a particle form or may be supported in a film form together with other components. Theanine may be supported on the surface of a powder by physically adhering, or may be supported by chemical binding, and may be supported not on the whole but on a part of the surface of a powder.
[0049] The treatment amount of theanine is not particularly limited, but preferably 0.002 to 20%, more preferably 0.1 to 5%, in the surface-treated powder. When the treatment amount is within this range, a surface-treated powder having excellent affinity with skin is obtained, and a cosmetic preparation having the powder incorporated therein is favorable in the touch.
[0050] The content of the inorganic powder surface-treated with theanine in the powdery cosmetic preparation of the present invention is not particularly limited, but preferably 0.1 to 90%, further preferably 1 to 40%. When the inorganic powder is used within the range, the affinity with skin of the surface-treated powder itself is efficiently exhibited. In the case of being combined with an organic powder to produce a powdery cosmetic preparation, the effect of preventing elimination of cosmetic-film due to secondary adhesion (hereinafter, abbreviated to “secondary adhesion-less effect”) is increased, and therefore the case is preferred.
[0051] On the other hand, the organic powder used in the powdery cosmetic preparation of the present invention is not particularly limited in the shape such as a sphere shape and a tabular shape, the particle size such as a fine particle form, the particle structure such as a porous structure and non-porous structure, and the like, as long as the powder is an organic powder generally used in a cosmetic preparation. Specifically, one kind or two or more kinds of a nylon powder, a poly(methyl methacrylate) powder, poly(alkyl acrylate) powder, an (acrylonitrile/methacrylic acid) copolymer powder, a (vinylidene chloride/methacrylic acid) copolymer powder, a PET resin powder, a polyethylene powder, a polystyrene powder, an organopolysiloxane elastomer powder, a polymethylsilsesquioxane powder, a polyurethane powder, a wool powder, a silk powder, a crystalline cellulose powder, an N-acyllysine powder, and the like may be used. Among them, a nylon powder, a poly(methyl methacrylate) powder, a crystalline cellulose powder, and an organopolysiloxane elastomer powder are preferred since these organic powders spread smoothly and are excellent in use feeling when combined with the theanine-surface-treated inorganic powder.
[0052] The content of the organic powder in the powdery cosmetic preparation of the present invention is not particularly limited, and is preferably 0.1 to 30%, and more preferably 5 to 20%. Within the range, the organic powder deposits on the outer side of the theanine-surface-treated powder layer oriented in the vicinity of the surface of the skin and exhibits a barrier effect against hands and clothes, thereby enhancing the secondary adhesion-less effect.
[0053] The powdery cosmetic preparation of the present invention preferably further contains boron nitride. The boron nitride for use in the present invention is not limited in the crystal structure as long as it is a boron nitride which is used in a common cosmetic preparation, and those having any crystal structure such as hexagonal crystal and cubic crystal may be used. The mean particle size thereof is not particularly limited, but preferably approximately from 1 to 200 μm, more preferably approximately from 5 to 20 μm. The content thereof is also not particularly limited, but preferably approximately from 0.1 to 30%, further preferably approximately from 0.5 to 5%. Within the ranges, the lubricity of the boron nitride further enhances the uniformity of the cosmetic-film, and therefore the cosmetic retentivity and the secondary adhesion-less effect are synergistically enhanced. Incidentally, the mean particle size is a value which is measured by a laser diffraction/scattering particle size distribution analyzer (HORIBA LA-950 PARTICLE ANALYZER).
[0054] Into the powdery cosmetic preparation of the present invention, in addition to the above components, components which can be incorporated in a common cosmetic preparation may be appropriately incorporated as required to the extent that does not impair the effects of the present invention.
[0055] Specifically, for example, a powder other than the surface-treated powder and the organic powder described above, an oil, a surfactant, an alcohol, water, a moisturizer, a UV absorber, a preservative, an antimicrobial agent, an antioxidant, a cosmetic component (a whitening agent, a cell activator, an anti-inflammatory agent, a blood circulation promoter, a skin astringent, an antiseborrheic agent, a vitamin, an amino acid, etc.) may be incorporated.
[0056] As the attribute of the powdery cosmetic preparation of the present invention, a powder form and a powdery solid form may be mentioned.
[0057] The production method thereof is not particularly limited, and, for example, the inorganic powder surface-treated with theanine, an organic powder, and other powders to be incorporated as required are mixed and dispersed together, and an oil or the like is added as required to uniformly disperse the mixture. The mixture is charged as it is in a container, whereby a powdery cosmetic preparation can be obtained. In the case of a powdery solid form, a method in which the mixture is charged and molded in a dish container made of a metal or a resin (dry compaction molding) and a method in which the mixture is dispersed in a solvent in advance and then charged in a container, and dried and molded (wet molding) may be exemplified.
[0058] In addition, examples of the powdery cosmetic preparation of the present invention may include a makeup cosmetic preparation such as a foundation, a concealer, a face powder, an eyeshadow, and a cheek rouge.
EXAMPLES
[0059] Next, the present invention will be described in more detail with reference to examples, but the present invention is by no means limited thereto.
(Production Examples of Surface-Treated Powder)
[0060] A surface-treated powder was prepared using theanine as a surface treating agent according to the following method.
Production Example 1
Example of Titanium Oxide
[0061] To 49.0 g of titanium oxide (TIPAQUE CR-50: manufactured by Ishihara Sangyo Kaisha, Ltd.) or fine particle titanium oxide (MT-500SA: manufactured by Tayca Corporation), a solution of 1.0 g of theanine as a surface treating agent dissolved in 70 g of water was added and mixed. The mixture was dried in air and pulverized with a pulverizer, thereby obtaining a 2.0%-treated titanium oxide.
Production Example 2
Example of Iron Oxide
[0062] As in the above, to 47.5 q of red iron oxide (TAROX R-516P: manufactured by Titan Kogyo, Ltd.), yellow iron oxide (TAROX IRON OXIDE YP1200P: manufactured by Titan Kogyo, Ltd.), or black iron oxide (TAROX BLACK BL-100P: manufactured by Titan Kogyo, Ltd.), a solution of 2.5 g of theanine as a surface treating agent dissolved in 70 g of water was added and mixed, and the mixture was dried in air and pulverized with a pulverizer, thereby obtaining a 5.0%-treated iron oxide.
Production Example 3
Example of Talc, Mica, or Sericite
[0063] As in the above, to 49.5 g of talc (TALC JA-46R: manufactured by Asada Milling, Co., Ltd.), mica (MICA POWDER TM-20: manufactured by YAMAGUCHI MICA Co., Ltd.), or sericite (SERICITE FSE: manufactured by Sanshin Ko Kogyo), a mixed liquid of 0.5 g of theanine as a surface treating agent dissolved in 70 g of water was added and mixed, and the mixture was dried in air and pulverized with a pulverizer, thereby obtaining a 1.0%-treated powder.
Production Example 4
[0064] To 49.0 g of sericite (SERICITE FSE: manufactured by Sanshin Ko Kogyo), a solution of 1.0 g of theanine as a surface treating agent dissolved in 70 g of water was added and mixed, and the mixture was dried in air and pulverized with a pulverizer, thereby obtaining a theanine (2%)-treated sericite.
Production Example 5
[0065] According to the Production Example 4, theanine was added to each of various powders in an amount to give a treatment amount (X %), thereby obtaining a theanine (X %)-treated powder.
Comparative Production Example 1
Examples of Methyl Hydrogen Polysiloxane-Treated Powder
[0066] The raw material powders of Production Examples 1 to 3 were each treated according to the Production Examples except that theanine and water were changed to methyl hydrogen polysiloxane (KF-99-P: manufactured by Shin-Etsu Chemical, Co., Ltd.), thereby obtaining powders surface-treated with methyl hydrogen polysiloxane.
Comparative Production Example 2
Examples of Stearoyl Glutamic Acid Salt-Treated Powder
[0067] The raw material powders of Production Examples 1 to 3 were each treated according to the Production Examples except that theanine was changed to disodium stearoyl glutamate, thereby obtaining powders surface-treated with disodium stearoyl glutamate.
(Method for Evaluating Surface-Treated Powder)
[0068] The theanine-treated powders obtained in Production Example 5 above were evaluated according to the following method.
[Evaluation Method]
[0069] On an inside portion of a upper arm of each of 10 panelists specializing in cosmetic evaluation, equal amounts of each untreated powder and treated powder obtained in Production Example 5 were placed, and the touch at the time of spreading the powders with a finger was evaluated. When another treated-powder was to be evaluated, the sample was once rinsed off before the next evaluation. The “smoothness” and “skin compatibility” in comparison with each untreated powder were evaluated by each panelist according to the following evaluation criteria, and in turn the average of the scores by all the panelists was used to make determination according to the following determination criteria.
(Evaluation Criteria)
(Evaluation Result): (Score)
[0070] Very good: 5
Good: 4
Normal: 3
Bad: 2
Very bad: 1
(Determination Criteria)
(Average of Scores): (Determination)
[0071] 4.5 or higher: ∘∘ Very good
4.0 or higher and lower than 4.5: ∘ Good
3.0 or higher and lower than 4.0: Δ Satisfactory
Lower than 3.0: x Bad
[0000]
TABLE 1
Treatment amount (X %)
Untreated powder
Evaluation item
20
10
5
2
1
0.5
0.1
0.002
Titanium oxide *1
Smoothness
Δ
Δ
Δ
∘
∘∘
∘∘
∘∘
Δ
Skin Compatibility
Δ
Δ
∘
∘
∘∘
∘∘
∘∘
Δ
Red iron oxide *2
Smoothness
Δ
Δ
∘
∘
∘∘
∘∘
∘∘
Δ
Skin Compatibility
Δ
Δ
∘
∘∘
∘∘
∘∘
∘∘
Δ
Sericite *3
Smoothness
Δ
∘
∘
∘∘
∘∘
∘∘
∘
Δ
Skin Compatibility
Δ
∘
∘∘
∘∘
∘∘
∘∘
∘
Δ
*1: TIPAQUE CR-50 (manufactured by Ishihara Sangyo Kaisha Ltd.)
*2: TAROX R-516P (manufactured by Titan Kogyo, Ltd.)
*3: SERICITE FSE (manufactured by Sanshin Ko Kogyo)
[0072] It was demonstrated that surface treatment with theanine allows any powder to show smoother touch during application and better skin compatibility as compared with the untreated powder, in a wide range of treatment amount.
(Formulation Examples of Cosmetic Preparation)
[0073] The surface-treated powders prepared by the above methods were used in the following formulations.
Examples 1 to 4 and Comparative Examples 1 to 3
Powder Foundation
[0074] Powder foundations of Examples 1 to 4 and Comparative Examples 1 to 3 were prepared according to the constitutions and production methods in Table 2. Each of the obtained powder foundations was evaluated for smooth use feeling, uniformity of cosmetic-film, cosmetic retentivity, and secondary adhesion-less effect, by the methods described below. The results are also shown in Table 2 together.
[0000]
TABLE 2
(%)
Comparative
Example
Example
No
Component
1
2
3
4
1
2
3
1
Talc of Production Example 3
10
3
5
—
—
—
—
2
Red iron oxide of Production Example 2
—
—
—
0.1
—
—
—
3
Titanium oxide of Production Example 1
—
—
—
10
—
—
—
4
Talc of Comparative Production Example 1
—
—
—
—
10
—
—
5
Talc of Comparative Production Example 2
—
—
—
—
—
10
—
6
Boron nitride
10
10
10
10
10
10
10
7
Talc
24.4
4.4
29.4
34.4
24.4
24.4
34.4
8
Sericite
20
20
20
20
20
20
20
9
Titanium oxide
10
10
10
—
10
10
10
10
Zinc oxide
3
3
3
3
3
3
3
11
Iron oxide
0.1
0.1
0.1
—
0.1
0.1
0.1
12
Nylon powder
3
3
3
3
3
3
3
13
Barium sulfate
5
5
5
5
5
5
5
14
Poly(methyl methacrylate) powder
5
5
5
5
5
5
5
15
(Vinyldimethicone/methicone silsesquioxane)
0.5
0.5
0.5
0.5
0.5
0.5
0.5
crosspolymer
16
Squalane
2
2
2
2
2
2
2
17
2-Ethylhexyl p-methoxycinnamate
3
3
3
3
3
3
3
18
Glyceryl tri(2-ethylhexanate)
2
2
2
2
2
2
2
19
Dimethyl polysiloxane (6 mm 2 /s: 25° C.)
2
2
2
2
2
2
2
Evaluation item and determination result
i
Smooth use feeling
∘∘
∘∘
∘∘
∘
∘
∘∘
x
ii
Uniformity of cosmetic-film
∘∘
∘∘
∘
∘
Δ
Δ
x
iii
Cosmetic retentivity
∘∘
∘∘
∘∘
∘∘
Δ
Δ
x
iv
Secondary adhesion-less effect
∘∘
∘∘
∘∘
∘∘
x
x
x
[Production Method]
[0075] A: Components 1 to 16 are mixed and dispersed.
B: Components 17 to 19 are added to A and the mixture is uniformly mixed.
C: B is pulverized with a pulverizer.
[Evaluation Method 1: Smooth Use Feeling, Uniformity of Cosmetic-Film, Cosmetic Retentivity]
[0076] The samples of Examples and Comparative Examples above were evaluated by each of 20 panelists specializing in cosmetic evaluation for each of the items “smooth use feeling”, “uniformity of cosmetic-film”, and “cosmetic retentivity” according to the following 7-level evaluation criteria, and in turn the average of the scores by all the panelists was used to make determination according to the following determination criteria. Incidentally, as for the cosmetic retentivity, each panelist applied each sample on his/her face and then performed a normal life, and the cosmetic effect after 6 hours was evaluated in comparison with that immediately after the application.
(Evaluation Criteria)
(Evaluation Result): (Score)
[0077] Very good: 6
Good: 5
Satisfactory: 4
Normal: 3
Slightly bad: 2
Bad: 1
Very bad: 0
(Determination Criteria)
(Average of Scores): (Determination)
[0078] 5.0 or higher: ∘∘ Very good
3.5 or higher and lower than 5.0: ∘ Good
1.5 or higher and lower than 3.5: Δ Bad
Lower than 1.5: x Very bad
[Evaluation 2: Secondary Adhesion-Less Effect]
[0079] Each sample of Examples and Comparative Examples above was applied on the whole face and finished, and immediately after that, a facial tissue was pushed against a forehead portion. The coloring degree by the foundation which transferred to the facial tissue at that time was evaluated according to the following criteria.
(Evaluation Criteria)
(Evaluation Result): (Score)
[0080] Very good (not colored): 6
Good (hardly colored): 5
Reasonably good: 4
Normal (colored a little): 3
Slightly bad: 2
[0081] Bad (colored): 1
Very bad: 0
(Determination Criteria)
(Average of Scores): (Determination)
[0082] 5.0 or higher: ∘∘ Very good
3.5 or higher and lower than 5.0: ∘ Good
1.5 or higher and lower than 3.5: Δ Bad
Lower than 1.5: x Very bad
[Results]
[0083] The powder foundations of Examples 1 to 4 showed smooth touch during application as well as good adhesion to skin, and were excellent in the uniformity of cosmetic-film, the cosmetic retentivity, and the secondary adhesion-less effect. On the other hand, Comparative Examples 1 and 2 in which methyl hydrogen polysiloxane-treated powder or stearoyl glutamic acid salt-treated powder was used instead of the surface-treated powder of the present invention, and Comparative Example 3 in which the surface-treated powder of the present invention was not contained were poorer in each item.
Examples 5 to 9 and Comparative Example 4
Powder Foundation (Powder Form)
[0084] Powder foundations of Examples 5 to 9 and Comparative Example 4 were prepared according to the constitutions and production method shown in Table 3. Each of the obtained powder foundations was evaluated for the “smooth use feeling”, “uniformity of cosmetic-film”, “cosmetic retentivity”, and “secondary adhesion-less effect” by the evaluation method described above. The results are also shown in Table 3 together.
[0000]
TABLE 3
(%)
Comparative
Example
Example
No
Components
5
6
7
8
9
4
1
Theanine(2%)-treated sericite of Production
5
0.1
20
5
5
—
Example 4
2
Boron nitride
3
3
3
—
3
3
3
Mica
20
24.9
5
20
32
25
4
Iron oxide
3
3
3
3
3
3
5
Talc
20
20
20
20
20
20
6
Silica
5
5
5
5
5
5
7
Titanium oxide
15
15
15
15
15
15
8
Zinc oxide
1
1
1
1
1
1
9
Barium sulfate
5
5
5
5
5
5
10
Nylon powder
5
5
5
5
—
5
11
Poly(methyl methacrylate) powder
5
5
5
5
—
5
12
(Vinyl dimethicone/methicone silsesquioxane)
2
2
2
2
—
2
crosspolymer
13
Squalane
2
2
2
2
2
2
14
2-Ethylhexyl p-methoxycinnamate
3
3
3
3
3
3
15
Glyceryl tri(2ethylhexanoate)
3
3
3
3
3
3
16
Dimethyl polysiloxane (6 mm 2 /s: 25° C.)
3
3
3
3
3
3
Evaluation item and determination result
i
Smooth use feeling
∘∘
∘∘
∘
∘
∘
∘
ii
Uniformity of cosmetic-film
∘∘
∘∘
∘
∘
∘
∘
iii
Cosmetic retentivity
∘∘
∘
∘∘
∘
∘
Δ
iv
Secondary adhesion-less effect
∘∘
∘
∘∘
∘
Δ
x
[Production Method]
[0085] A: Components 1 to 12 are mixed and dispersed.
B: Components 13 to 16 are added to A and the mixture is uniformly mixed.
C: B is pulverized with a pulverizer.
[Results]
[0086] The powder foundations of Examples 5 to 9 showed smooth touch during application as well as good compatibility with skin, and were excellent in the uniformity of cosmetic-film, the cosmetic retentivity, and the secondary adhesion-less effect. This is inferred to be attributable to good lubricity of the organic powder and high affinity of the organic powder with theanine. Meanwhile, the results showed that Comparative Example was inferior in the cosmetic retentivity and the secondary adhesion-less effect.
Example 10
W/O Liquid Foundation
[0087]
[0000]
(Components)
(%)
1.
Titanium oxide of Production Example 1
10.0
2.
Red iron oxide of Production Example 2
0.4
3.
Yellow iron oxide of Production Example 2
2.0
4.
Black iron oxide of Production Example 2
0.1
5.
Silica
3.0
6.
Lauryl PEG-9 polydimethylsiloxyethyl dimethicone
1.0
7.
Cyclomethicone
5.0
8.
PEG-9 Polydimethylsiloxyethyl dimethicone
5.0
9.
Methyl trimethicone
20.0
10.
Petrolatum
1.0
11.
2-Ethylhexyl p-methoxycinnamate
4.0
12.
Phospholipid
0.5
13.
Sorbitan sesquiisostearate
1.0
14.
(Dimethicone/vinyl dimethicone) crosspolymer
3.0
15.
Isotridecyl isononanoate
2.0
16.
Glycerol
2.0
17.
Ethanol
2.0
18.
Sodium chloride
0.5
19.
Water
Balance
20.
Preservative
q.s.
21.
Perfume
q.s.
[Production Method]
[0088] (1) Components 1 to 7 are uniformly dispersed with a roller.
(2) Components 8 to 15 and 21 are uniformly mixed.
(3) (1) is added to (2), and the mixture is uniformly mixed.
(4) Components 16 to 20 are added to (3), and the mixture is emulsified. A W/O foundation was thus obtained.
[Results]
[0089] The W/O foundation of the Example showed a smooth touch during application as well as good adhesion to skin, and was excellent in the uniformity of cosmetic-film and the cosmetic retentivity.
Example 11
W/O BB Cream
[0090]
[0000]
(Components)
(%)
1.
Titanium oxide of Production Example 1
10.0
2.
Zinc oxide of Production Example 1
3.0
3.
Red iron oxide of Production Example 2
0.4
4.
Yellow iron oxide of Production Example 2
2.0
5.
Black iron oxide of Production Example 2
0.1
6.
Lauroyl lysine
3.0
7.
Lauryl PEG-9 polydimethylsiloxyethyl dimethicone
1.0
8.
Dimethicone
5.0
9.
PEG-9 Dimethicone
5.0
10.
Liquid paraffin
20.0
11.
Inulin stearate
0.5
12.
Dextrin palmitate
0.5
13.
Cyclomethicone
4.5
14.
Dipentaerythrityl hexa(hydroxystearate/stearate/rosinate)
1.0
15.
(Dimethicone/vinyl dimethicone) crosspolymer
3.0
16.
Neopentylene glycol diethylhexanoate
2.0
17.
2-Ethylhexyl p-methoxycinnamate
2.0
18.
Hexyl diethylaminohydroxybenzoylbenzoate
2.0
19.
BG
8.0
20.
Sodium chloride
0.5
21.
Water
Balance
22.
Preservative
q.s.
23.
Perfume
q.s.
[Production Method]
[0091] (1) Components 1 to 9 are uniformly dispersed with a roller.
(2) Components 10 to 12 are dissolved with mild heat.
(3) Components 13 to 18 are added to (1) and (2) and the mixture is uniformly mixed.
(4) Components 19 to 23 are added to (3) and the mixture is emulsified. A W/O BB cream was thus obtained.
[Results]
[0092] The W/O BB cream of the Example showed smooth touch during application as well as good adhesion to skin, and was excellent in the uniformity of cosmetic-film and the cosmetic retentivity.
Example 12
Oil Foundation
[0093]
[0000]
(Components)
(%)
1.
Titanium oxide of Production Example 3
10.0
2.
Red iron oxide of Production Example 2
0.4
3.
Yellow iron oxide of Production Example 2
2.0
4.
Black iron oxide of Production Example 2
0.1
5.
Talc of Production Example 3
Balance
6.
Lauroyl lysine
1.0
7.
(Vinyl dimethicone/methicone silsesquioxane) crosspolymer
15.0
8.
PEG-9 Dimethicone
5.0
9.
Cyclomethicone
20.0
10.
Dimethicone
10.0
11.
Isododecane
1.0
12.
(Acrylates/dimethicone) copolymer
4.5
13.
Isohexadecane
1.0
14.
(Dimethicone/(PEG-10/15)) crosspolymer
3.0
15.
Triethylhexanoin
10.0
16.
2-Ethylhexyl p-methoxycinnamate
7.0
17.
Preservative
q.s.
18.
Perfume
q.s.
[Production Method]
[0094] (1) Components 1 to 10 are uniformly dispersed with a roller.
(2) Components 11 to 16 are uniformly dissolved.
(3) (1) and Components 17 and 18 are added to (3) and the mixture is uniformly mixed. An oil foundation was thus obtained.
[Results]
[0095] The oil foundation of the Example showed smooth touch during application as well as good adhesion to skin, and was excellent in the uniformity of cosmetic-film and the cosmetic retentivity.
Example 13
O/W Liquid Foundation
[0096]
[0000]
(Components)
(%)
1.
Polyoxyethylene sorbitan monooleate (20EO)
0.5
2.
Sorbitan sesquioleate
0.5
3.
1,3-Butylene glycol
10.0
4.
Titanium oxide of Production Example 1
10.0
5.
Red iron oxide of Production Example 2
0.4
6.
Yellow iron oxide of Production Example 2
2.0
7.
Black iron oxide of Production Example 2
0.1
8.
Talc of Production Example 3
5.0
9.
Xanthan gum
0.2
10.
Carboxyvinyl polymer
0.3
11.
Triethanolamine
1.0
12.
Purified water
Balance
13.
Phenylbenzimidazole sulfonic acid
2.0
14.
Ethanol
2.0
15.
Stearic acid
1.0
16.
Behenyl alcohol
0.5
17.
Liquid paraffin
2.0
18.
Glyceryl tri(2-ethylhexanoate)
2.0
19.
2-Ethylhexyl p-methoxycinnamate
2.0
20.
Petrolatum
0.5
21.
Preservative
q.s.
22.
Perfume
q.s.
[Production Method]
[0097] (1) Components 1 to 8 are uniformly dispersed with a roller.
(2) Components 9 to 14 are uniformly mixed.
(3) (1) is added to (2) and uniformly mixed.
(4) Components 15 to 21 are mixed and dissolved at 80° C.
(5) (4) is added to (3) at 80° C. and the mixture is emulsified.
(6) (5) is cooled, and component 22 is added thereto. An O/W foundation was thus obtained.
[Results]
[0098] The O/W foundation of the Example showed smooth touch during application as well as good adhesion to skin, and was excellent in the uniformity of cosmetic-film and the cosmetic retentivity.
Example 14
Oily Solid Foundation
[0099]
[0000]
(Components)
(%)
1.
Talc
15.0
2.
Mica
10.0
3.
Titanium oxide of Production Example 1
15.0
4.
Red iron oxide of Production Example 2
1.0
5.
Yellow iron oxide of Production Example 2
3.0
6.
Black iron oxide of Production Example 2
0.2
7.
Synthetic gold mica
3.0
8.
Nylon
3.0
9.
Polyethylene wax
7.0
10.
Microcrystalline wax
6.0
11.
Glyceryl tri(2-ethylhexanoate)
Balance
12.
Dimethyl polysiloxane
10.0
13.
Liquid paraffin
10.0
14.
Diisostearyl malate
5.0
15.
Lauryl PEG-9 polydimethylsiloxyethyl dimethicone
2.0
16.
Lauryl polyglyceryl-3 polydimethylsiloxyethyl dimethicone
1.0
17.
Trimethylsiloxycinnamic acid
0.5
18.
Cyclomethicone
5.0
19.
Preservative
q.s.
20.
Perfume
q.s.
[Production Method]
[0100] (1) Components 9 to 19 are dissolved under heat at 90° C.
(2) Components 1 to 8 are added to (1) and uniformly dispersed with a roller.
(3) Component 20 is added to (2) and dissolved at 80° C., and the mixture is charged into a metal dish. An oily solid foundation was thus obtained.
[Results]
[0101] The oily solid foundation of the Example showed smooth touch during application as well as good adhesion to skin, and excellent in the uniformity of cosmetic-film and the cosmetic retentivity.
Example 15
Powdery Face Powder
[0102]
[0000]
(Components)
(%)
1.
Mica of Production Example 3
20.0
2.
Talc of Production Example 3
Balance
3.
Mica titanium
10.0
4.
Red No. 226
0.5
5.
Liquid paraffin
0.5
6.
Glyceryl tri(2-ethylhexanoate)
1.0
7.
Preservative
q.s.
8.
Perfume
q.s.
[Production Method]
[0103] (1) Components 1 to 4 are uniformly mixed.
(2) Components 5 to 8 are added to (1) while stirring (1) with a Henschel mixer and the mixture is uniformly mixed.
(3) (2) is pulverized with a pulverizer. A face powder was thus obtained.
[Results]
[0104] The powdery face powder of the Example showed smooth touch during application as well as good adhesion to skin, and was excellent in the uniformity of cosmetic-film and the cosmetic retentivity.
Example 16
W/O Sunscreen Agent
[0105]
[0000]
(Components)
(%)
1.
Fine particle zinc oxide
2.0
2.
Fine particle titanium oxide of Production Example 1
5.0
3.
Glyceryl tri(caprylate/caprate)
5.0
4.
Bis-ethylhexyloxyphenol methoxyphenyl triazine
3.0
5.
Octyl palmitate
3.0
6.
2-Ethylhexyl p-methoxycinnamate
10.0
7.
Methylene bis-benzotriazoryl tetramethylbutylphenol
5.0
8.
Decamethylcyclopentasiloxane
10.0
9.
Methyl polysiloxane/cetyl methyl
1.8
polysiloxane/poly(oxyethylne/oxypropylene) methyl
polysiloxane copolymer (Note 1)
10.
Glyceryl tri(2-ethylhexanoate)
3.0
11.
Preservative
q.s.
12.
Sodium chloride
0.3
13.
Purified water
Balance
14.
Dipropylene glycol
3.0
15.
Ethanol
3.0
16.
Perfume
q.s.
(Note 1)
ABIL EM-90 (manufactured by EVONIC GOLDSCHMIDT GMBH)
[Production Method]
[0106] (1) Components 3 and 4 are dissolved with mild heat, then Components 1 and 2 are added thereto and the mixture is uniformly dispersed with a triple roller.
(2) Components 5 toll are dissolved at 70° C., then (1) is added thereto at 60° C., and the mixture is uniformly mixed and dissolved.
(3) Components 12 to 14 are mixed and dissolved, and then added to (2) at 60° C., and the mixture is emulsified.
(4) Components 15 and 16 are added to (3) and the mixture is uniformly mixed. A W/O sunscreen agent was thus obtained.
[Results]
[0107] The W/O sunscreen agent of the Example showed smooth touch during application as well as good adhesion to skin, and was excellent in the uniformity of cosmetic-film and the cosmetic retentivity.
Example 17
Solid Powdery Foundation
[0108]
[0000]
(Components)
(%)
1.
Mica
20.0
2.
Talc
15.0
3.
Theanine(5%)-treated titanium oxide of Production
15.0
Example 5
4.
Sericite
Balance
5.
Theanine(2%)-treated yellow iron oxide of Production
2.0
Example 5
6.
Theanine(2%)-treated red iron oxide of Production
0.5
Example 5
7.
Theanine(2%)-treated black iron oxide of Production
0.2
Example 5
8.
Synthetic gold mica
5.0
9.
Crosslinking silicone/network silicone block copolymer
1.0
10.
Preservative
q.s.
11.
Boron nitride
5.0
12.
Polyethylene powder
5.0
13.
PET Resin powder
3.0
14.
Poly(methyl methacrylate) powder
5.0
15.
Liquid paraffin
3.0
16.
Dimethyl polysiloxane (10 mm 2 /s: 25° C.)
3.0
17.
Cetyl 2-ethylhexanoate
3.0
18.
Perfume
q.s.
[Production Method]
[0109] (1) Components 1 to 14 are uniformly dispersed at 75° C. with a Henschel mixer (manufactured by Mitsui Miike Machinery).
(2) Components 15 to 18 are uniformly mixed and dissolved.
(3) (2) is added to (1) and uniformly dispersed while stirring (1) with a Henschel mixer.
(4) (3) is pulverized with a pulverizer.
(5) (4) is charged in a metal dish and molded with compaction. A solid powdery foundation was thus obtained.
[Results]
[0110] The solid powdery foundation of the Example showed smooth touch during application, good compatibility with skin, uniform cosmetic-film, and beautiful finishing, and was excellent in no-color transfer to a face mask.
Example 18
Solid Powdery Eyeshadow
[0111]
[0000]
(Components)
(%)
1.
Synthetic gold mica
10.0
2.
Theanine(2%)-treated talc of Production Example 5
Balance
3.
Titanium oxide-coated mica
30.0
4.
Boron nitride
5.0
5.
Polyethyleneterephthalate/aluminum/epoxy laminated
5.0
powder
6.
Ultramarine blue
2.0
7.
Red No. 202
0.5
8.
Organopolysiloxane elastomer powder
1.0
9.
Preservative
q.s.
10.
Bismuth oxychloride
5.0
11.
Barium sulfate
3.0
12.
Liquid paraffin
3.0
13.
Dimethyl polysiloxane (6 mm 2 /s: 25° C.)
5.0
14.
Diisostearyl malate
3.0
15.
Perfume
q.s.
[Production Method]
[0112] (1) Components 1 to 11 are uniformly dispersed with a Henschel mixer (manufactured by Mitsui Miike Machinery).
(2) Components 12 to 15 are uniformly mixed.
(3) (2) is added to (1) and uniformly dispersed while stirring (1) with a Henschel mixer.
(4) (3) is pulverized with a pulverizer.
(5) (4) is charged in a metal dish and molded with compaction. A solid powdery eyeshadow was thus obtained.
[Results]
[0113] The solid powdery eyeshadow of the Example showed smooth touch during application as well as good compatibility with skin, and was excellent in the uniformity of cosmetic-film, the cosmetic retentivity, and the secondary adhesion-less effect.
Example 19
Solid Powdery Face Color
[0114]
[0000]
(Components)
(%)
1.
Theanine(2%)-treated mica of Production Example 5
20.0
2.
Theanine(2%)-treated talc of Production Example 5
Balance
3.
Titanium oxide-coated mica
10.0
4.
Ultramarine blue
0.5
5.
Red No. 226
0.2
6.
Polystyrene powder
1.0
7.
Preservative
q.s.
8.
Squalane
2.0
9.
Dimethyl polysiloxane (6 mm 2 /s: 25° C.)
3.0
10.
Glyceryl 2-ethylhexanoate
3.0
11.
Perfume
q.s.
[Production Method]
[0115] (1) Components 1 to 7 are uniformly dispersed with a Henschel mixer (manufactured by Mitsui Miike Machinery).
(2) Components 8 to 10 are uniformly mixed.
(3) (2) and component 11 are added to (1) and uniformly dispersed while stirring (1) with a Henschel mixer.
(4) (3) is pulverized with a pulverizer.
(5) (4) is charged in a metal dish and molded with compaction. A solid powdery face color was thus obtained.
[Results]
[0116] The solid powdery face color of the Example showed smooth touch during application as well as good compatibility with skin, and was excellent in the uniformity of cosmetic-film, the cosmetic retentivity, and the secondary adhesion-less effect.
Example 20
Powdery Face Powder
[0117]
[0000]
(Components)
(%)
1.
Theanine(2%)-treated mica of Production Example 5
20.0
2.
Talc
Balance
3.
Theanine(2%)-treated titanium oxide mica of Production
10.0
Example 5
4.
Crystalline cellulose powder
5.0
5.
Red No. 226
0.5
6.
Liquid paraffin
0.5
7.
Glyceryl tri(2-ethylhexanoate)
1.0
8.
Preservative
q.s.
9.
Perfume
q.s.
[Production Method]
[0118] (1) Components 1 to 5 are uniformly dispersed with a Henschel mixer (manufactured by Mitsui Miike Machinery).
(2) Components 6 to 9 are uniformly mixed.
(3) (2) is added to (1) while stirring (1) with a Henschel mixer and the mixture is uniformly mixed.
(4) (3) is pulverized with a pulverizer. A face powder was thus obtained.
[Results]
[0119] The powdery face powder of the Example showed smooth touch during application as well as good compatibility with skin, and was excellent in the uniformity of cosmetic-film, the cosmetic retentivity, and the secondary adhesion-less effect.
Example 21
Foundation
[0120]
[0000]
(Components)
(%)
1.
Titanium oxide
10
2.
Sericite
Balance
3.
Theanine(2%)-treated talc of Production Example 5
10
4.
Barium sulfate
5
5.
Silicic acid anhydride
3
6.
Sphere polystyrene
3
7.
Perfluorohexylethyltriethoxysilane-treated colcothar*
0.5
8.
Perfluorohexylethyltriethoxysilane-treated yellow iron
2
oxide*
9.
Perfluorohexylethyltriethoxysilane-treated black iron oxide*
0.2
10.
Fine zinc white
2
11.
Cetyl 2-ethylhexanoate
8
12.
Petrolatum
1
13.
Liquid paraffin
3
14.
Perfume
0.1
*3%-Treated with Dynasylan F8261 (manufactured by Degussa Japan)
[Production Method]
[0121] (1) Components 11 to 14 are mildly heated to 70° C., mixed and dissolved.
(2) Components 1 to 10 are uniformly mixed with stirring.
(3) (1) is added to (2) and the mixture is uniformly mixed with stirring.
(4) 100 parts by mass of a 5% ethanol aqueous solution is added as a solvent to 100 parts by mass of (3), and the mixture is uniformly mixed with stirring to obtain a slurry.
(5) (4) is charged in a dish container, and paper for absorbing solvent is disposed between the cosmetic preparation and a compaction head, and compaction molding is performed while absorbing the solvent added.
(6) (5) is dried at room temperature for 10 hours. A foundation was thus obtained.
[Results]
[0122] The foundation of the Example showed smooth touch during application as well as good compatibility with skin, and was excellent in the uniformity of cosmetic-film, the cosmetic retentivity, and the secondary adhesion-less effect.
Example 22
Eyeshadow
[0123]
[0000]
(Components)
(%)
1.
Syntehtic gold mica
10.0
2.
Theanine(2%)-treated talc of Production Example 5
Balance
3.
Titanium oxide-coated mica
30.0
4.
Boron nitride
5.0
5.
Polyethyleneterephthalate/aluminum/epoxy laminated
5.0
powder
6.
Theanine(2%)-treated red iron oxide of Production
1.0
Example 5
7.
Red No. 202
1.5
8.
Organopolysiloxane elastomer powder
1.0
9.
Preservative
q.s.
10.
Bismuth oxychloride
5.0
11.
Barium sulfate
3.0
12.
Liquid paraffin
5.0
13.
Dimethyl polysiloxane (6 mm 2 /s: 25° C.)
5.0
14.
Perfume
q.s.
[Production Method]
[0124] (1) Components 1 to 11 are uniformly mixed with stirring.
(2) Components 12 to 14 are uniformly mixed.
(2) (2) is added to (1) and uniformly mixed with stirring.
(3) 30 parts by mass of light liquid isoparaffin is added as a solvent to 100 parts by mass of (2) and the mixture is uniformly mixed with stirring to obtain a slurry.
(5) (4) is charged in a dish container, and paper for absorbing solvent is disposed between the cosmetic preparation and a compaction head, and compaction molding is performed while absorbing the solvent added.
(6) (5) is dried at room temperature for 10 hours. An eyeshadow was thus obtained.
[Results]
[0125] The eyeshadow of the Example showed smooth touch during application as well as good compatibility with skin, and was excellent in the uniformity of cosmetic-film, the cosmetic retentivity, and the secondary adhesion-less effect.
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The present invention has an object to develop a surface-treated powder which shows both of smooth touch during application and good compatibility with skin, and to provide a cosmetic preparation which shows smooth touch during application as well as good compatibility with skin, and is excellent in cosmetic-film uniformity and in cosmetic retentivity by incorporating the treated powder into the cosmetic preparation. The powder for cosmetic preparation resolving the problem is characterized by being surface-treated with theanine.
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This is a division of application Ser. No. 535,421, filed Dec. 23, 1974, now abandoned.
BACKGROUND OF THE INVENTION
The present invention pertains to apparatus for the continuous casting of metals, particularly aluminum and its alloys, and the invention is more particularly concerned with a new and improved form of roll caster and method of operating the same.
The roll casting machine is characterized by a pair of parellel casting rolls which are spaced apart slightly to receive molten metal between them, a pouring tip fitted snugly into the converging space between said casting rolls on the entrance side thereof, and means for driving said rolls. The rolls are usually water-cooled to chill the molten metal and solidify the same. A good example of the prior roll caster described above is shown and described in U.S. Pat. No. 2,790,216, which issued Apr. 30, 1957, to J. L. Hunter.
The Hunter continuous casting machine is well known in the industry, and has enjoyed a large measure of commercial success because it produces a high quality of aluminum strip at a fairly good rate of production. The commercially available Hunter caster has 24 -inch diameter rolls and produces 0.250 inch thick strip of the softer aluminum alloys (e.g. alloy No. 1100, for example) at the rate of 40 to 45 inches per minute. In the Hunter caster, complete solidification of the molten metal takes place slightly ahead of the centerline of the rolls, and this solidified metal is then reduced in thickness by some 15 to 20% as the metal advances through the diminishing space between the rolls, until it passes through the roll centerline, where the roll spacing is at the minimum. Thus, the Hunter caster provides simultaneous casting, solidification, and a slight amount of hot rolling, which produces a crystal grain structure that is essentially "as cast" structure, except that the dendrites have been laid down somewhat, and are oriented at an acute angle to the surface, due to the rolling action.
This typical orientation of the crystal structure gave the metal produced by the Hunter caster certain advantages over that produced by other continuous strip casting machines, such as "band casters", but the metal still suffered from many of the handicaps inherent in the "as cast" structure, particularly where subsequent cold work was relatively slight. For example, deep drawing of heavy gauge metal frequently results in severe "earing" of the metal. However, for any application where cold work was sufficient, as in rolling foil, the traditional Hunter cast metal was of excellent quality, and its relatively large, dendrite crystal structure was no handicap.
Before going on to the present invention, it might be well to digress for a moment to discuss what happens to any crystalline metal structure (particularly aluminum and its alloys) during casting, hot working, cold working, and annealing. In conventional casting processes, molten metal is usually poured into or through a mold. Cooling of the molten metal and subsequent solidification is obtained primarily through the mold walls and later, by cooling the metal walls, as with water sprays or air blasts. The resulting "as cast" crystalline structure comprises a relatively thin skin of small-grain structure along the outer surface due to the violent "chill" of the mold; the said skin surrounding the main body of large, needle-shaped dendrite crystals forming the body of the casting; and there being a central inner area where the dendrites growing perpendicular to the mold surface meet. This central inner area is usually an area of heavy segregation of impurities. The grain structure obtained on a "band caster" (e.g., the Hazelett caster) is very similar to the grain structure described above, since the heat transfer and metal solidification follow the same general pattern.
The particular grain structure described above (usually referred to as "as cast" structure), is not suitable for most applications, and to obtain a grain structure suitable for commercial application, the "as cast" structure must be completely destroyed and regenerated through a cycle of deformation (hot or cold rolling), and heat treatment, which produces a phenomenon known as "recrystallization".
When a crystalline metal structure is subjected to sufficient internal stress, the original crystalline structure is fractured. If the material is heated (either instantaneously with the internal stressing or at a later time) to the recrystallization temperature (which, in the case of aluminum alloys will usually be in the range of 650° to 750° F), "centers of recrystallization" are formed along the fractured grain boundaries. The higher the internal stresses, the more centers of recrystallizaion are formed, and the finer the ultimate grain size. The higher the temperature to which the stressed metal is exposed, the quicker the recrystallization takes place. There is also a relationship between stresses required at different temperatures to trigger the recrystallization phenomenon, as heat increases the molecular and crystalline mobility. The finest grain size is achieved with heaviest internal stresses (to produce the largest number of centers of recrystallization) and heating the metal to an elevated temperature just sufficient to give enough time for the newly formed grains to "take over" the full metal volume. If the metal is exposed to the high temperature beyond the optimum time interval, there is a tendency of the larger grains to absorb the smaller grains, with the result that the grain structure becomes larger and coarser.
Recrystallization is customarily achieved by either of two processes: (1) cold rolling, followed by heat treatment; or (2) hot rolling.
In the cold rolling process, hot rolled sheet, with its given grain structure, is cold rolled at varying degrees, usually 35 to 90% total reduction, depending on the metal alloy and the product. The hot rolled grain structure is crushed, and heavy internal stresses are imparted to the metal, but no recrystallization take place (under normal circumstances) because the temperature during the cold rolling cycle is too low, and the metal is in a "frozen" state. The metal is then heat-treated, or annealed, by raising the temperature to a sufficiently high level to cause centers of recrystallization to form. New grains then start to grow around these centers, and if the exposure to high temperature is sufficiently long, the new grain will completely replace the old grain, and the metal will be completely recrystallized.
Hot rolling is usually done to transform cast metal ingots, or slabs, into a thinner sheet product, which may be the finished product, or it may be cold-rolled to finish gauge. The chief benefit of hot rolling is that there is a considerable economy due to energy savings and to reduction of equipment size. If hot rolling is performed at sufficiently high temperatures, and if the reduction ("draft") of a particular rolling pass is sufficient to impart to the metal sufficient internal stresses, then a recrystallization cycle is triggered during and immediately after the rolling cycle.
The original grain structure has a great deal of influence on the final structure, and to eliminate all of the adverse effects from the "as cast" structure (low ductility, elongation, drawability, etc.), the metal must go through an extremely heavy cycle of hot and/or cold work, and repeated recrystallization cycles, until the metal has been completely recrystallized down to the finest possible grain size.
The conventional Hunter casting machines, and all other casting machines known to me at this time, produce what is basically an "as cast" structure, with all of the disadvantages and adverse physical characteristics of "as cast" metal. Metal sheet or strip produced by these machines must be completely recrystallized by a combination of hot and/or cold rolling, together with heat treatment, all of which require expensive equipment, consumption of large amounts of energy, and high labor cost.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a new and improved casting machine which is capable of producing a completely recrystallized metal product of superior quality, having an exceedingly fine grain structure that is vastly superior to the metal product produced by any other known caster. In fact the metal produced by the present invention has a grain structure that appears to be equivalent to the grain structure obtained on hot rolled strip of similar gauge produced by conventional slab casting and hot rolling (for example, hot rolling a 16-inch thick slab down to 1/4-inch thick strip).
Another object of the invention is to provide a new and unique method of casting metal in a roll caster, which, in one step, produces a fully recrystallized product.
Still a further object of the invention is to provide a casting machine that has a faster rate of output than a conventional roll caster.
These and other objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment thereof, with reference to the accompanying drawing, which shows a fragmentary sectional view through the casting rolls at the point where the pouring tip projects into the space between the rolls.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The roll casting machine of the present invention is generally similar to the casting machine shown in the Hunter patent, except that the two casting rolls 10 and 12 are arranged one above the other, instead of side-by-side. The casting rolls 10 and 12 are parallel to one another, and are spaced apart slightly at the roll centerline A--A. The ends of the rolls are rotatably supported in bearing blocks (not shown) which are mounted on a suitable frame (not shown). The rolls 10, 12 are water cooled, and suitable means (not shown) is provided for circulating liquid coolant through the rolls.
Fitting snugly into the converging space between the casting rolls on the left-hand, or entrance side thereof, is a pouring tip 14 made of heat-resistant material having insulation properties and also non-wettable by molten metal. The top and bottom surfaces of the tip 14 are formed with a cylindrical curvature at 16 and 18 to lie snugly against the outer surfaces of the respective rolls. An internal passageway 20 is provided in the pouring tip, and this passageway opens out at the tip end 22 into the space between the rolls.
The rolls 10, 12 are driven synchronously by power transmission means (not shown) in the direction indicated by the arrows, with the top roll 10 turning in the counterclockwise direction, and the bottom roll 12 turning clockwise. With the rolls turning as shown, molten metal from the pouring tip is carried through the space between the rolls, being solidified and hot rolled in the process, and issuing from the machine on the exit side of the rolls as a solid sheet, or strip 24.
In the drawing, it will be noted that the radius of the rolls is R; the distance that the tip 22 is set back from the roll centerline A--A is L 1 ; and the roll spacing at the centerline A--A is T 1 . In the machine that has been built and tested extensively, the roll radius R is 18 inches; the tip setback L 1 has varied from 2.5 to 3 inches; and the roll spacing T 1 is 0.250 inches. These dimensions can be increased or decreased within certain limits, and will vary with different alloys of aluminum, or with different metals, such as zinc, for example. However, certain relationships must be maintained in order to practice the invention. These relationships will be given presently.
It has been learned from experience that when the rolls 10, 12 are turning at the optimum speed, molten aluminum freezes solidly across from one roll surface to the other at the vertical plane 26, shown at distance L 2 back from the roll centerline A--A. Distance L 2 has been determined by empirical means to be approximately 0.6 of L 1 for soft aluminum alloys, and therefore if L 1 is 2.5 inches, L 2 is 1.5 inches. The thickness of the metal at the point 26 is designated T 2 , and this works out to 0.376 inches.
Another dimensional ratio that may help to distinguish the present invention from prior roll casting machines is the ratio of the thickness of the finished strip (T 1 ) to the thickness of the tip end 22 of the pouring spout 14. The tip end 22 is approximately 0.563 inch across (measured vertically in the drawing) and therefore the thickness T 1 of the finished strip is slightly less than half the thickness of the spout tip 22. Stated in another way, the reduction in thickness from the tip end 22 of the spout to the finished strip (T 1 ) is greater than 2, whereas in the Hunter caster and in other workable roll casters, the ratio has been appreciably less than 2 -- more on the order of 1.5 or less. While this may appear to be a small difference, the resulting difference in the grain structure of the strip produced by the two machines is suprisingly and unexpectedly large.
As the molten metal issues from the pouring tip 14, it fills the converging space between the casting rolls 10, 12, and starts immediately to freeze at the area of contact with the roll surfaces. The thickness of the frozen metal on each roll surface increases as the rolls carry the metal toward the centerline A--A, and at point 26, the metal has solidifed across the entire space between the rolls. From point 26 to the roll centerline A--A, the frozen metal, which has already acquired the dendritic crystal structure of "as cast" metal, is reduced in thickness by hot rolling. The reduction in thickness is from 0.376 to 0.250 inches, which is approximately a 33% reduction. This is substantially greater than the 15 to 20% reduction of the Hunter caster, and exerts extremely high stress on the hot metal, causing the dentrites to fracture and creating a large multitide of recrystallization centers. The temperature of the metal between points 26 and the centerline A--A is in the neighborhood of 950°-1000° F, and the roll force required to produce the internal stresses necessary to fracture the dendrite crystals and to create the maximum number of recrystallization centers at this temperature is only a fraction of the roll force that would be required at a lower temperature. At the same time, the speed of recrystallization is at its maximum, as the temperature of the metal is close to the melting point.
Thus, the present invention realizes the perfect solution for continuously casting strip of the highest quality, and that is to simultaneously cast, solidify, heavily hot roll, and recrystallize the metal. This is accomplished by destroying the dendritic "as cast" crystal structure at the instant of its formation, and then replacing the "as cast"structure with a completely recrystallized new grain structure. The finished strip 24 has the extremely fine-grained, fully recrystallized structure that is otherwise formed only in metal that has been heavily hot-rolled after casting.
In order for the apparatus to be effective, it is necessary that certain conditions be observed. For soft aluminum alloys (e.g., 1100), the thickness T 2 of metal at point 26 should be equal to or greater than 1.5 times the dimension. I have obtained excellent results when casting 0.250 inch thick strip of this alloy, using a ratio of L 2 /T.sub. 2 approximately equal to or slightly less than 4. As mentioned earlier, L 2 in my experimental machine is 1.5 inches, and T 2 is approximately 0.376 inches. One important factor that must be observed is that the pouring tip 22 should be set well back from the roll centerline A--A in order to allow the molten metal to freeze solidly across by the time it reaches point 26. Roll speed also enters into the consideration, as too slow roll speed will allow the metal to freeze solidly across, ahead of point 26, and this would greatly increase the roll-separating force, possibly leading to breakage of the rolls. The optimum roll speed with the dimensions shown is about 0.6 rpm. At this roll speed, and with the dimensions shown, the ration of L 1 /T.sub. 1 is approximately equal to 10.
One important and characteristic feature of the invention that appears to be largely responsible for producing fine-grained, fully recrystallized structure in the finished strip, is the use of large-diameter rolls 10 and 12. In the embodiment shown and described herein, the rolls 10, 12 are 36 inches in diameter, where the Hunter caster has always been made with 24-inch diameter rolls. At first glance, the difference between 24-inch diameter rolls and 36-inch diameter rolls might seem to be almost without significance, yet the fact is that the larger diameter rolls of the present invention produce a dramatic and totally unexpected improvement in the grain structure of the finished product, in addition to providing a casting machine having the structural strength to stand up under the stresses that are produced.
It is a fact well known to designers of hot rolling mills, that small diameter rolls require less force than rolls of larger diameter to effect a given reduction. Small rolls lessen the separating force for two reasons: (1) the area of contact is less, so that, with a given pressure, the total force required is less; and (2) the pressure builds up to a lower peak because of the shorter distances through which friction acts. These principles influenced the design of the Hunter casting machine, which used the smallest diameter rolls consistent with the strength and rigidly needed, as the small-diameter rolls enabled the machine to operate with a lower power requirement. On the other hand, the larger diameter rolls of the present invention exert a considerably greater pressure on the metal, and use more power for a given reduction, as compared with the 24-inch diameter rolls of the Hunter caster. The additional power that goes into hot rolling is what causes the greatly increased internal stress within the metal that fractures and crushes the dendrite crystals and sets up the extremely large number of recrystallization centers. Thus, the large-diameter casting rolls constitutes the means by which a relatively large amount of power is expended in hot rolling the metal to effect a reduction of the order of 37 to 50%, so as to produce the high-level internal stressing necessary for complete recrystallization of the metal. At the same time, the increased diameter of the rolls gives them greater strength and rigidity to resist bending under the increased roll-separating force.
As stated earlier, the tip set-back L 1 on the machine shown and described herein is preferably about 2.50-inches. This distance has been experimentally increased to 3.00-inches or more, with the same 0.250-inch dimension for T 1 , which increased the ratio L 1 /T.sub. 1 to 12. However, when L 1 was increased to 3 inches, it was deemed advisable to increase the rotational speed of the rolls somewhat to avoid excessive roll-spreading force, due to the fact that the freezing point 26 might other-wise move back further from the roll centerline A--A, causing T 2 to increase to about 0.438-inch estimated distance. This would result in a hot-roll reduction(T 1 )/(T 2 ) 0 of 57%, which is a fairly heavy reduction, and about the maximum that can be done without going to an excessively heavy and expensive roll construction. By speeding up the rolls to approximately 0.8 rpm, the freezing point 26 was found to be approximately at the same distance from the roll centerline A--A as before (i.e., L 2 = approximately 1.5 inches) and T 2 = approximately 1.5 T 1 .
With all other parameters remaining constant, L 2 is increased by slowing down the rotational speed of the rolls, and is decreased by speeding up the rolls. The higher the roll speed, the greater the output. However, roll speed should preferably not be increased beyond the point where the metal freezes solidly across from one roll to the other at a point 26 where T 2 is appreciably less than 1.5 times T 1 .
The point 26 where the metal freezes solidly across will also be changed by increasing or decreasing the rate of heat transfer from the molten metal to the rolls, which is a function of the thermal conductivity of the metal forming the roll shell. Thus, rolls having a copper shell would produce extremely fast chilling action, and this would have to be compensated for by driving the rolls at a faster speed, or by reducing the tip set-back L 1 so that the tip end 22 is closer to the freezing point 26. In that case, L 2 might have a considerably larger value than 0.6 L 1 .
The above ratios are given to enable one skilled in the art to scale the casting machine up or down so as to produce thicker or thinner strip 24; or to drive the casting rolls 10, 12 at a higher or lower speed; or to otherwise modify the dimensions or other parameters of the machine.
While I have shown and described in considerable detail what I believe to be the preferred form of my invention, it will be understood by those skilled in the art that the invention is not limited to such details, but might take various other forms within the scope of the following claims.
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A method and apparatus for producing extremely fine-grained aluminum sheet in a casting machine having a pair of parallel casting rolls, a pouring tip on the entrance side of the rolls, and means for driving the rolls. Molten aluminum is poured through the tip into the space between the rolls, and the rolls are driven at a speed such that solidification of the metal is completed at a point ahead of the centerline of the rolls, and the frozen metal is then hot-rolled down to the thickness of the roll spacing. During this hot-rolling, the metal is heavily stressed internally by being reduced at least 33% of the thickness at the point of solidification, and this destroys the "as cast" crystal structure and causes complete recrystallization to take place. As compared with conventional roll casters, the present caster has larger-diameter casting rolls, which are driven at a faster speed, and the tip is set back further from the rolls centerline. The resultant cast product is vastly superior to anything produced by prior casters.
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CROSS REFERENCE TO RELATED INFORMATION
This application claims the benefit of U.S. Provisional Patent Application No. 62/037,479, filed Aug. 14, 2014, titled, “Distributed Wild Fire Alert System”, the contents of which are hereby incorporated herein in its entirety.
TECHNICAL FIELD
The present disclosure is directed to a fire detection system, and more specifically to a fire detection system employing mobile and distributed sensors with wireless connectivity.
BACKGROUND OF THE INVENTION
Everyone is familiar with the environmental and social costs of forest fires; in summertime, the prime fire season in the West, there are regular news stories about people losing their homes and thousands of acres ablaze. The economic costs both in lost homes and property and who pays to put the fires out are enormous and growing. As many as 90 percent of wild fires in the United States are caused by humans, according to the U.S. Department of Interior. Some human-caused fires result from campfires left unattended, the burning of debris, negligently discarded cigarettes and intentional acts of arson. The remaining 10 percent are started by lightning or lava.
Severe forest fires have increased in frequency over the past decade, resulting in substantial losses of property and human lives. In 2013, 47,579 wildfires burned over 4 million acres, with California, North Carolina, Oregon, Montana and Arizona experiencing the most wildfires, according to the National Interagency Fire Center. On June 30, 19 firefighters were killed while working to contain the Yarnell Hill Fire in Arizona. This was the deadliest event for firefighters since 9/11 and the third-highest firefighter death toll attributed to wildfires. A massive wildfire that began near Yosemite Park in California on August 17 had burned over 255,000 acres and was designated as the state's third-largest wildfire. The December 17 fire in Big Sur, Calif., burned 917 acres and more than 30 homes.
The increased severity of fires, combined with continuing development in, and near, forests, puts many more communities at risk and has substantially increased both the difficulty and cost of fire suppression. Expenditures on fire suppression by the U.S. Forest Service alone have exceeded $1 billion in five of the last seven years. And in 2009, nearly $2 billion (48 percent of the agency's budget) is to be targeted at fire management, up from $300 million (13 percent) in 1991.
While no single technology or remedy will prevent tragedies caused by wildfires, any technology or system that could provide for earlier warnings, coordinate responses by firefighters, and improve fire fighter safety would be helpful in the ongoing fight to prevent, contain and manage wildfires.
BRIEF SUMMARY OF THE INVENTION
In a preferred embodiment, a system and method for detecting and managing wildfires is described that includes a plurality of fixed sensors, each operable to detect ambient conditions in the vicinity of the fixed sensor and to relay that information to a central control center. A plurality of mobile sensors are worn by responders and are capable of detecting ambient conditions near the respective responder and conditions of the responder, the plurality of mobile sensors in communication with the central control center. The collective data from the plurality of fixed sensors and the plurality of mobile sensors can be used to determine attributes of the wildfire and to coordinate the responders in response to the wildfire.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a system diagram showing an embodiment of a fire detection system according to the concepts described herein;
FIG. 2 is a block diagram of an embodiment of a mobile sensor according to the concepts described herein;
FIG. 3 is a block diagram of an embodiment of a fixed or distributed sensor according to the concepts described herein;
FIG. 4 is a block diagram of an alternate embodiment of a fixed or distributed sensor according to the concepts described herein;
FIG. 5 is a perspective view of a an embodiment of a fixed or distributed sensor according to the concepts described herein.
FIG. 6 is a flow chart of an embodiment of a method for detecting and managing wildfires according to the concepts described herein.
DETAILED DESCRIPTION OF THE INVENTION
Wildfires present many problems for the Forest Service, Park Rangers, firefighters and the like. Among those problems are the inability in many instances to detect fires early, the difficulty managing and tracking large numbers of firefighters over large areas, understanding and tracking a fire as it progresses and detecting when a firefighter is in danger or has been injured.
A preferred embodiment of a system 100 that addresses each of these problems is shown in FIG. 1 . The system can be composed of network 101 of inexpensive sensor units that can be either fixed sensors 103 (FS) or mobile sensors 102 (MS). Each type of sensor can come in different variations depending on the application or circumstances. For example, the fixed and mobile sensors can contain combinations of multiple sensor types that collect information about the surrounding environment. As will be discussed in more detail with reference to FIGS. 2-4 , preferred embodiments of the fixed and mobile sensors might include a smoke sensor and a temperature sensor that are able to send messages using one or more of a variety of communication schemes as will be discussed below. In addition to smoke and temperature sensors, other sensors can be included that provide an important data point regarding the surrounding environment. For example, light sensors could be useful in detecting fires during the night hours, acoustic sensors could detect the acoustic signature of a wildfire, etc. Other types of sensors could include wind, humidity, and lightning sensors.
As shown in FIG. 1 , the mobile sensors 102 are preferably worn by fire fighters or other personnel or placed on equipment or vehicles. The fixed sensors 103 are preferably distributed in the terrain being monitored. The fixed sensors could be pre-placed in locations, such as in or on trees, on rock formation, or other locations by forest rangers. The fixed sensors could also be deployed from the air by dropping them from drones, helicopters or airplanes. Fixed sensors deployed by dropping them into the forest would be designed to catch in the trees or other foliage for best operation.
The fixed sensors 103 and mobile sensors 102 are designed to communicate with each other and with mobile hubs 104 deployed along with the sensors. Since the sensors would be in remote areas often without cellular service, a preferred method would be to have the sensors form a mesh network by communicating directly with each other. The mesh network 101 allows all of the sensors to send and receive data from a command and control center 109 . Given the remote nature of the devices, they could also be configured to use one or more of any usable type of network, such as cellular networks 105 , wireless networks 107 , such as wifi, or even satellite communications 106 . The data can then be sent over a provider network 108 to control center 109 . In areas where cellular networks do not exist or are not adequate, mobile wireless networks can be set up to facilitate communications with the sensors 102 , 103 and hubs 104 . These mobile networks could use temporary antennas, vehicle mounted antenna or airborne antennas using drone, blimps, planes or any other suitable carrier. These networks would then relay the sensor data and sensor location for each of the mobile sensors 102 and fixed sensors 103 . The network could be created at the time a fire is detected by bringing in mobile units that could communicate with one or more of the sensors and relay information from all the sensors using the mesh network. While a “mothership” might provide advantages, it is not required as the system could operate solely using the mesh networked devices which relay communications through the network of sensors until a sensor or hub with connectivity to the outside network is found.
The fixed sensors 103 could have their location determined at the time of installation, such as by the ranger or drone, by associating a device id with the deployment location noted by the ranger, drone or other operator. The fixed sensors 103 could also include GPS receivers for location information. The mobile sensors 102 could include location information and might also include other sensors not required in the fixed sensors. A motion, or fall detection, sensor worn by a firefighter could provide and indication that the firefighter was injured or disabled. Smoke and temperature sensors, could provide an indication of the firefighters proximity to the fire. Biometric sensors could provide an indication of the firefighter's health and status. Location sensors, such as GPS, would provide a real-time location for the firefighter and corresponding environmental data. The mobile sensors could also be equipped with RF or cellular voice communication allowing two-way voice transmissions between the firefighter and a control center 109 .
Preprogrammed voice commands could be stored in the mobile sensors 103 and triggered by a command from the control center, other authority or as a result of environmental conditions. The voice commands could give directions to the firefighter on preferred escape routes, redeployment or other instructions.
The strength of the system proposed according to the concepts described herein lies in the ability to process environmental and other data from a large number of sensors. The collective data can be used to chart the location, intensity, progress and direction of the wildfire allowing resources to be deployed more efficiently. The data can also be used to show escape routes, as well ingress and egress paths for firefighters. The mobile sensor data would show the real-time location of all of the fire fighting resources and along with the fixed sensor data can be used to make sure those resources are deployed most efficiently. In addition to live streaming data from the sensors, information could also be derived from the loss of signals from the sensors, providing information about where fixed sensors have been destroyed by the fire.
Referring now to FIG. 2 , and an embodiment of a mobile sensor device 102 from FIG. 1 is shown. The device 200 includes a microprocessor 201 and memory to store data and programming information. The device 200 also includes one or more transmitters or transceivers, such as RF transceiver/cellular transceiver/wifi transceiver 207 , a satellite transceiver 209 , or other transceiver, to allow the device to communicate in the mesh network with other sensor devices or to communicate with other wireless or cellular networks using antennal 212 and transceiver power supply 206 . The satellite transceivers 209 and satellite antenna 211 can allow data transmission and reception and for GPS location. Power can be supplied by batteries or by solar cells or other power supply, or by any combination thereof.
As described above, the devices 200 preferrably include one or more sensors, including sensors 202 and 203 that measure the ambient temperature and smoke, respectively. Motion sensors 204 or accelerometers can provide indication that the sensor device 200 has moved, such as from a firefighter involved in a fall. Any other sensor 205 that would provide useful data can also be included. The sensors can be inside the device or can be remote from the device and communicating with the device using a wired or wireless interface, such as Bluetooth or other short range protocol. The units can also include other elements such as lights 213 or sirens 214 that can be activated when fire is detected or when the wearer of a mobile unit appears incapacitated from a fall, smoke inhalation, or other event.
Referring now to FIG. 3 , an embodiment of a fixed sensor device 102 from FIG. 1 is shown. Device 300 is preferably a simpler device to mobile sensor 102 having few components and sensors that could be deactivated when not in use to conserve power. Device 300 includes microprocessor 301 and memory to store data and programming information. Sensor or sensors 302 collect data which can be stored and/or transmitted by the device. The device 300 also includes one or more transmitters or transceivers 303 to allow the device to communicate in the mesh network with other sensor devices or to communicate with other wireless or cellular networks using antennal 309 . A location circuit 304 , such as GPS or cellular location services, can be used to determine the location of device 300 or as described earlier, a device id 305 could be used to identify the device and associate it with a location determined by the deployer of the device. Power source can be batteries or by solar cells or other power supply, or by any combination thereof. In addition, fixed sensor device 300 can include a piezoelectric power circuit 307 that derives power from the motion of external “leaves” 308 on the device that vibrate with wind or other motion source. The piezoelectric power circuit 307 can be used to maintain a charge in the batteries and can allow the device to exist deployed for long periods, such as 5 or more years.
In a preferred embodiment of the present system, the sensors might come in two or more configurations optimized for their intended use. An alternate embodiment of a fixed sensor is shown in FIG. 4 . Device 400 is similar to fixed sensor device 300 shown in FIG. 3 . It can includes microprocessor 401 and memory to store data and programming information. The device 400 may also include one or more transmitters or transceivers 403 to allow the device to communicate in the mesh network with other sensor devices or to communicate with other wireless or cellular networks using antennal 409 . A location circuit 404 , such as GPS or cellular location services, may be used to determine the location of device 400 or as described earlier, a device id 405 could be used to identify the device and associate it with a location determined by the deployer of the device. Power source 406 can be batteries or by solar cells, piezoelectric generator 407 with “leaves” 408 or other power supply, or by any combination thereof. Device 400 may be configured with a fire detection sensor 402 . In this configuration, the device 400 would lie dormant until fire detection sensor 402 detects a fire. At that time the device would wake up and transmit its id or location before it is consumed by the fire. This type of device would allow the control center to monitor the direction and progress of the fire from the signals from these devices as they are consumed. The device 400 could also be powered by the heat from the fire, further reducing the internal components and cost of the device.
Other configurations of fixed sensors could be employed that would be simpler and contain fewer sensors and transceivers to allow them to better manage power consumption. They could also be programmed differently to activate only when triggered by a remote command or when a sensor has detected a data level above a certain threshold. Mobile units can have more capabilities since they would not normally have the same power constraints as the fixed units. The mobile units can carry more sensors, location detection, lights and sirens, and voice communication capabilities among other things.
Referring now to FIG. 5 , an embodiment of a fixed sensor form factor is shown. Device 500 includes case 501 holding the components. It may also include peizoelectric power “leaves” 502 that allow power to be generated from the wind. Hooks 503 , or other mechanisms, allow the device 500 to catch in trees when deployed from the air or other mechanism without having to be strapped or nailed to trees. In place of hooks 503 any other mechanism that allows device 500 to catch in the branches and leaves or needles of trees can be employed on case 501 without departing from the scope of the concepts described herein.
Many other embodiments of mobile and fixed sensors and hubs can be envisioned that would work with the system as described. Those embodiments could include sensors as part of camping gear or as part of GPS tools for hikers and campers, and embodiments incorporated into tents. Parks may buy sensors and post around edge of park and within park, while ranchers or landowners may want to place around land, especially at edges, report data back to landowner. The devices could include speakers on sensors and have multiple connectivity types. The devices could be powered by any method such as battery, solar, etc, or could be powered by movement, such as wind or connected to animal trackers. Devices could be made to be fireproof and include enough memory to record long periods of data.
Referring now to FIG. 6 , a embodiment of a method for detecting and managing wildfires is shown. Method 600 begins with deploying fixed sensors in an area of interest, as shown by step 601 . The area may be an area that is prone to wildfires, an area where a wildfire has already been detected or other areas of interest from a fire concern. The fixed sensors can be deployed in advance where they can monitor for fires for years or can be placed in an area where a fire has already been detected to help monitor the fire. The fixed sensors can both help detect new fires, monitor local conditions prone to fire, and collect data on known and existing fires.
In step 602 , mobile sensors are carried by responders, such as fire fighters, responding to the detection of a fire. In step 603 the data returned from the fixed and mobile sensors is monitored and used to determine fire conditions. Those conditions can include location, direction of spread, speed of movement and other related conditions. These fire conditions can then be used to coordinate the fire fighting response to the fire and to provide safety information to fire fighters such as warnings of advancing lines of fire and escape routes, as shown by step 604 .
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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A system and method for detecting and managing wildfires is described. The system and method deploy a plurality of fixed sensors in an area to be monitored. Each fixed sensor is operable to detect ambient conditions in the vicinity of the fixed sensor and to relay that information to a central control center. A plurality of mobile sensors are deployed with responders, where each mobile sensor is capable of detecting ambient conditions near the respective responder and conditions of the responder. The plurality of mobile sensors are in communication with the central control center. The system then determines attributes of the wildfire from the collective data from the plurality of fixed sensors and the plurality of mobile sensors and coordinates the activity of responders in response to the wildfire using the collective data.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present invention claims priority to provisional U.S. patent application Ser. No. 61/153,584 filed Feb. 18, 2009.
FIELD OF THE INVENTION
The present invention relates to electronic musical instruments.
SUMMARY
The present invention provides a system and methods for an electronic musical instrument. Through a novel combination of sensor inputs, it allows simulation of real world instruments including but not limited to a Trombone, Trumpet and Saxophone.
The device itself includes a series of sensor inputs configured to act as a user interface, and a speaker to output sound. Various sensors can be employed, including a touch screen, microphone, accelerometer, and camera or light sensor.
Sensor inputs are processed through a set of sub-processors to determine events and respond accordingly with parameters and actions for manipulating sound. Attributes that can be varied include tone, pitch, attack/accent (also known as velocity), volume, and special modes such as vibrato, growl or tonguing. Parameters and commands are sent to a playback processor which responds to the input parameters and commands by processing stored digital representations of sounds and sends them to an output buffer for playback.
Generated sounds are stored digitally as either data, or algorithms/equations. They are contained within a Tone data object which comprises a set of representations which may provide different phases and/or qualities.
Sensor inputs can be configured to trigger playback of sound and control its various attributes either alone, or in combination. For example, Tone and pitch may be determined exclusively by location of touches on a display, or by a combination of device rotation and touch location. These methods are illustrated by a variety of embodiments including a simulated Trombone, Trumpet, and Saxophone.
Further objects, advantages, and features of the invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
Presently preferred embodiments of the invention are described below in conjunction with the appended drawing figures, wherein like reference numerals refer to the like elements in the various figures, and wherein:
FIG. 1 is a block diagram of the device of one embodiment of the present invention.
FIG. 2 is a diagram of the Tone data object model.
FIG. 3 is a block diagram of the system sub-processors.
FIG. 4 is a flow diagram of the general steps performed periodically by the sensor input sub-processors.
FIG. 5 is a flow diagram of the general steps performed periodically by the audio output sub-processor, also referred to as the playback processor.
FIG. 6 is a diagram of present invention embodied as a Trombone.
FIG. 7 is a flow diagram of the steps performed by the touch sensor sub-processor for the embodiment of FIG. 6 .
FIG. 8 is a flow diagram of the steps performed by the mic sub-processor for the embodiment of FIG. 6 .
FIG. 9 is a flow diagram of the steps performed by the accelerometer sub-processor for the embodiment of FIG. 6 .
FIG. 10 is a diagram showing the embodiment of FIG. 6 configured to control volume by rotation in the XY plane.
FIG. 11-14 are diagrams of the present invention embodied as a Trumpet. FIGS. 11 and 12 are configured to control Tone and pitch exclusively by touch, whereas FIGS. 13 and 14 are configured to control Tone and pitch by a combination of touch and rotation.
FIG. 15 is a flow diagram of the steps performed by the touch sensor sub-processor for the embodiments of FIG. 11-14 .
FIG. 16 is a flow diagram of the steps performed by the mic sub-processor for the embodiment of FIG. 11-14 .
FIG. 17 is a flow diagram of the steps performed by the accelerometer sub-processor for the embodiment of FIG. 11-14 .
FIG. 18 is a diagram of the present invention embodied as a Saxophone. FIG. 18A is the front of the device. FIG. 18B is the back of the device.
FIG. 19 is a diagram of the embodiment of FIG. 18 configured to set octave and/or partial by rotation in the XY plane.
FIG. 20 is a flow diagram of the steps performed by the touch sensor sub-processor for the embodiments of FIGS. 18 and 19 .
FIG. 21 is a flow diagram of the steps performed by the mic sub-processor for the embodiments of FIGS. 18 and 19 .
FIG. 22 is a flow diagram of the steps performed by the accelerometer sub-processor for the embodiments of FIGS. 18 and 19 .
FIG. 23 is a flow diagram of the steps performed by the camera sub-processor for the embodiments of FIGS. 18 and 19 .
DETAILED DESCRIPTION
The system of the present invention comprises an electronic device with sensor inputs configured to act as a user interface and speaker output to produce sound responsive to the inputs.
FIG. 1 shows a block diagram of such a device 100 . It has a set of sensor inputs 105 including, but not limited to:
(1) a touch screen 110 which can sense location and optionally force (or touch area), (2) a microphone 120 , (3) a 1 to 3 axis accelerometer 130 , (4) a camera and/or light sensor 140 .
It has a speaker 150 for outputting sound, one or more digital sound representations, a memory 160 for storing them, and a processor 170 for executing software capable of receiving configuration parameters, maintaining state, receiving sensor input data, processing the input data, and responding. The response is done in accordance with the configuration parameters, system state, and the input events. It involves controlling playback of audio through the speaker; sounds may be started and stopped and attributes such as tone, pitch, accent, nuance, volume, and vibrato may be varied. A power source powers the device 180 , and display may be attached to the touch screen or separate 115 .
Sound Representation
Audio to be output is represented digitally within a data object called a Tone. As shown in FIG. 2 , a Tone comprises one or more digital representations, where the representation is either digital data or an equation or algorithm. The data files have an inherent pitch, which is later adjusted to produce alternative pitches. The data files may be split into different phases, including, for example, attack, loop, and decay. The attack segment is the beginning of a Tone, the loop segment is to be looped repeatedly as long as the note is intended to be sustained, and the decay segment is played once playback of the Tone is to be stopped. Alternatively to storing the phases in separate files, they may be stored in a single file and instead indicated by times from the start of the file.
One or more representations of the Tone which offer different musical nuance with the same inherent pitch may be contained within the Tone. For example, the Tone may consist of a set of attack, loop and decay files which have a strong accent and vibrato, and another set of which have a soft accent and a steady sustain. Parameters for selecting one set versus another are also stored within the Tone model and associated with each set. An example of such a parameter would be, “Volume>0.5”, which would indicate that the particular representation by played if the volume output is above 0.5.
In some embodiments, sound waveforms may also be generated by algorithmic and/or mathematical models, or some combination thereof. In this case, the algorithm or model is associated with the Tone. If no stored representations are used, the pitch may be set directly.
Event Processing and Output
As shown in FIG. 3 , three classes of sub-processors are used to provide system functionality: one, the sensor event sub-processor 300 , two, the audio output sub-processor 310 , and three, the base application sub-processors 320 . The base application sub-processors are for controlling system views, configurations, and interacting with models beyond what is performed by the two other classes of sub-processors.
As shown in FIG. 4 , sensor event sub-processors receive 400 sensor data, process 410 the data to determine 420 actionable events, and respond 430 to the events in accordance with configuration flags, and system state. The response consists of either sending (1) a command and parameters to the audio output sub-processor and/or setting (2) flags to be used by other sensor event sub-processors, which in turn send commands and parameters to the audio output sub-processor. The series of steps is executed repeatedly often at intervals less than 10 ms.
The audio output sub-processor is responsible for receiving and executing instructions on sound playback. FIG. 5 illustrates the overall process by which it operates. On receipt 502 of commands it sets 504 flags and parameters which are then acted on by a “callback” function which executes periodically at a rate determined by the audio sampling rate and audio buffer size. Assuming it is not stopped 506 , in which case it played silence 508 , it selects and sets 510 the appropriate Tone, type, pitch and volume. It then extracts 512 a segment of the appropriate data or waveform, prepares for stopping 518 , 520 or transitioning 514 , 516 to another note, transposes 522 the waveform and adjusts volume, filters 524 , and finally copies the result to the audio output buffer for playback through the system speaker 528 . If multiple simultaneous sounds are to be produced, the sounds are mixed 526 prior to copying to the buffer.
The process of FIG. 5 includes two processes for transitioning the sound to silence or another note. When transitioning 516 to silence, the sound is ramped down in volume to prevent clipping and indices tracking position with data or waveform algorithms are reset. When transitioning 520 to another note, the sound is prepared for transition to another note, as might be the case if the note were to be slurred to another note. In a simple embodiment, the sample is ramped down in volume, the indices reset, and the next note and its attributes are set for subsequent processing in the next iteration of the audio output sub-processor.
Methods of Triggering Sound and Setting Attributes
Sounds are triggered and their attributes set by the inputs, alone, or in combination. Inputs may require varying degrees of processing, for example accelerometer input can be filtered to determine angle change or vibration; mic input can be processed to determine level or pitch. Derivative methods may also be employed, for example, in the case of using touch as a trigger, duration between touch events may be used to determine whether a fast attack or a slow attack should be played. (Attack is often referred to as, or linked to note velocity).
Table 1 summarizes various methods by which sounds are triggered and attributes set.
TABLE 1
Methods by which sounds are triggered and controlled
Attribute
Input(s)
Notes and Examples
Trigger
Touch
Begin = ON, End = OFF
Mic level
Above threshold = ON,
below threshold = OFF
Accelerometer (shake)
Shake = ON, subsequent
Shake = OFF
Accelerometer (angle)
Above angle = ON, Below
angle = OFF
Camera/Light
Light = ON, Dark = OFF
Tone &
Touch location(s)
Pitch
Mic pitch or level
Accelerometer (angle or
shake)
Camera/Light
Touch location(s) +
Angle controls partial, touch
Accelerometer (angle or
location represents
shake)
pressing keys. Or, shake
toggles octave.
Touch location(s) +
As Accelerometer shake,
Camera/Light
Tone Type
Accelerometer (shake)
Shake = fast attack, no
shake = regular attack
Based on Volume
Low volume = slow attack,
High volume = fast attack
Based on duration between
Short duration = quick
Touches
attack, Long duration =
slow attack
Touch force or area
High force = Fast attack,
Low force = Slow attack
Volume
Accelerometer (angle)
High angle = High volume,
Low angle = Low volume
Touch force or area
High force = high volume,
Low force = low volume
Mode (i.e.
Touch location(s)
tonguing)
Accelerometer (angle or
shake)
Several of these methods are illustrated by embodiments representing real instruments including a Trombone, a Trumpet, and a Saxophone.
Trombone
FIG. 6 shows the present invention embodied as a Trombone. A real Trombone consists of a length of brass tubing with a mouthpiece connected at one end, and a flared bell at the other. It has a telescoping slide designed for modifying the effective length of the instrument and thus changing pitch. The slide has seven positions, each marking a semitone decrease in pitch from the 1 st , fully closed position. Sound is generated when a person “buzzes” their lips into a mouthpiece, causing the column of air inside the tubing to vibrate. Pitch is determined by both the frequency of the “buzzing” and the position of the slide.
By tightening lips (embouchure) and “buzzing” at a higher frequency, users can increase the pitch to a higher partial in the overtone series. Quality, nuance and volume are determined largely by the embouchure, and air speed and direction.
As embodied by the present invention. The device has a touch display 600 , a mic 610 , and speaker 620 , with additional sensors and processor electronics contained within the case.
The display is partitioned into 8 overtone partials 630 on the Y-axis, and 7 slide positions 640 along the X-axis, and shows a corresponding image. Sound is triggered when a user either blows into the mic, or touches the display. Pitch is determined by the location of the touch on the display. Volume is determined by mic level, force of touch (or area of touch) on the display, or angle of the device as determined by an accelerometer. Attack type, note quality and other nuance are determined by shaking the device, or may be linked directly to volume or duration of notes.
FIG. 7 shows a flow diagram of the process by which the processor handles touch events. Display sensor information is received 700 periodically, and processed to determine whether a touch has begun 702 , moved 704 , or ended 706 . If a touch has begun, the tone and pitch adjustment are determined 708 based on location of the touch.
In determining the Tone and pitch, the partial is first determined from the location along the Y-axis. A base Tone ( FIG. 2 ) comprising one or more attack, loop, and decay data files or waveforms is assigned to its corresponding partial in a designated slide position. Table 2 shows a sample of the relationship between Y-axis touch location, pitch in first position (slide closed), and assigned Tone.
TABLE 2
Sample association between Y-position,
partial, base Tone and pitch
Adjustment
Y-position [pixels]
1 st Pos. Note
Assigned Tone
Semitones
7-8 * pixels/partial
C5
Tone-Bb4
2
6-7 * pixels/partial
Bb4
Tone-Bb4
0
5-6 * pixels/partial
Ab4
Tone-Bb4
−2
4-5 * pixels/partial
F4
Tone-F3
0
3-4 * pixels/partial
D4
Tone-F3
−3
2-3 * pixels/partial
Bb3
Tone-Bb3
0
1-2 * pixels/partial
F3
Tone-Bb3
−5
0-1 * pixels/partial
Bb2
Tone-Bb2
0
Thus, for example, with a display 320 pixels high and 8 partials assigned, a touch at Y-position of 310 pixels would fall within the 8 th partial, and correspond to a base Tone of Bb4.
A pitch adjustment of the base Tone is then determined. First, the number of semitones variation due to slide extension is calculated from the X-axis touch location according to the following equation (we assume the slide is equal to the entire display width):
Slide semitones= X position pixels*(6 semitones/Display width pixels)
This value is then added to a pre-configured number of adjustment semitones for the previously determined Tone. Sample adjustment semitone values are shown in Table 2.
Total semitones=Adjustment semitones+Slide semitones
The total semitones are then used to calculate the pitch adjustment by the following formula:
Pitch adjustment=2^(Total semitones/12)
Therefore, in this particular example, assuming display dimensions of 480 pixels wide by 320 pixels high, if the user touches location (200 pixels, 310 pixels), the touch falls within the 8 th partial which corresponds to the base Tone of Bb4 and has two Adjustment semitones. The final pitch adjustment is calculated as follows:
Slide semitones=200 pixels*(6 semitones/480 pixels)=2.5 semitones
Total semitones=2+2.5=4.5 semitones
Pitch adjustment=2^(4.5/12)=1.3
TABLE 3
Sample activation parameters for Attack and Loop types
Tone Bb3
Attack 1
Vol. < 0.5
Force > 0.5
Shake < 0.5
Time since last
Tone < 1 sec
Attack 2
Vol. >= 0.5
Force >= 0.5
Shake > 0.5
Time since last
Tone > 1 sec
Loop 1
Vol. < 0.5
Force > 0.5
Shake < 0.5
Time since last
Tone < 1 sec
Loop 2
Vol. >= 0.5
Force >= 0.5
Shake > 0.5
Time since last
Tone > 1 sec
With the Tone selected, a sound type, if available may also be selected 710 . For example, if the volume, force (or touch area), and/or shake is above a certain threshold, a different attack type may be selected. Table 3 shows sample activation parameters for selecting different attack and loop types. Note that the volume may be determined from force (or area) of touch or from one of the additional sensor inputs, such as mic level, or accelerometer angle. In this case, a delay may be added to ensure that the external event is determined and flag set prior to determining the type. Attack type may also be determined from the duration between successive touches; if short, then a faster attack is used, whereas if long, a slower attack is used. In order to calculate the duration between successive touches the time of last touch must be stored and then later subtracted from the time of current touch.
With qualities of the note determined, the Tone, its type, and pitch adjustment are sent 712 to the playback processor. If 714 configured to trigger sound by touch, the playback command is sent 716 to the playback processor.
If 704 a touch is determined to have moved, a similar process is followed. The Tone and pitch adjustment are determined 718 , as previously described; however, if the partial has changed from the previous partial, such as if a player was moving from a Bb up one partial to a D, a “slur” can be assumed, and the playback processor is sent 720 a slur request with the new Tone and pitch adjustment. Otherwise, if the movement has occurred within a partial, the new pitch is requested 720 of the playback processor such that it can continue to use the same base Tone but adjust the pitch.
Finally, if 706 a touch is determined to have ended, and the system is configured to trigger by touch 722 , a stop is requested 724 of the playback processor. A decay phase may also be employed. In this case, the playback processor will playback a decay segment before ramping down and stopping playback. In a modified embodiment, the type of decay phase may first be determined (for example, fast vs. slow), and then sent to the playback processor along with the request for stop.
FIG. 8 shows a flow diagram of the process by which the mic sensor handles events assuming it has been selected by the user to trigger sound playback. The raw mic data is received 800 periodically and peak and average levels are determined 802 by a callback and/or timer function. If 804 the player is currently not playing and 806 the average volume level is above a particular threshold, a start request is sent 808 to the playback processor, with the Tone and pitch having separately been requested by the Touch event processor. If 804 the player is currently playing and 810 the average volume level is above the threshold, it should continue playing and a volume adjustment based on the average volume level is requested 812 of the playback processor. Finally, if 804 the player is currently playing, but 810 the average volume level is below the threshold, a stop is requested 814 of the playback processor. In another embodiment, toggling sound is controlled by touch, whereas volume can be controlled by mic.
FIG. 9 shows a flow diagram of the process by which the accelerometer sub-processor handles events. The raw data is received 900 and filtered 902 , 904 to determine an actionable event. In this particular embodiment the event is either a low frequency event, such as an n angle change, or a high-frequency event, such as a shake. As shown in FIG. 10 the X-Y angle of the device is configured to correspond to a volume adjustment. At an angle of approximately 30 degrees, the invention produces maximum volume, where as, at −90 degrees it produces 0 volume. It varies linearly in this range. Referring again to FIG. 9 , the X-Y angle is determined 906 and the volume adjustment is then determined. The volume adjustment is then sent 908 to the playback processor.
If 904 a shake event is detected, a flag that the event occurred and the time at which it occurred is set 910 , such that any of the event processors responsible for starting playback may refer to it to determine attack type. In a modified embodiment, the shake could be configured to start and stop the sound playback, as well. In yet another embodiment, the shake could be configured to request a special playback mode of the playback processor, such as a rapid fire tonguing mode where the notes are started and stopped rapidly rather than sustained.
Trumpet
FIG. 11 shows the present invention embodied as a Trumpet. A real Trumpet consists of a length of brass tubing with a mouthpiece connected at one end, and a flared bell at the other. It has a set of three valves which when open and closed modify the effective length of the instrument and thus change pitch. As with the Trombone, sound is generated when a person “buzzes” their lips into a mouthpiece, causing the column of air inside the tubing to vibrate. Pitch is determined both by opening and closing the valves and changing the frequency of the “buzzing”.
The valves are numbered 1 through 3, starting with the valve closest to the mouthpiece. The first valve decreases the pitch by 2 semitones, the second by a semitone, and the third by 3 semitones. Simultaneously, by tightening lips (embouchure) and “buzzing” at a higher frequency, users can increase the pitch to a higher partial in the overtone series. Quality, nuance and volume are determined largely by the embouchure, and air speed and direction.
As embodied by the present invention. The device has a touch display 1100 , a mic 1110 , and speaker 1120 , with additional sensors and processor electronics contained within the case.
Various embodiments are presented. One set of embodiments determines Tone and pitch by touch exclusively, whereas another set of embodiments determines Tone and pitch by a combination of touch location and device rotation.
FIGS. 11 and 12 show embodiments where Tone and pitch are determined by touch exclusively. In the embodiment of FIG. 11 , three areas 1130 on the display are defined, each representing a valve. An additional area 1140 is defined which represents all open valves.
In FIG. 11 , the three valve areas 1130 and open valve area 1140 stretch across the height of the display, spanning 7 overtone partials 1150 , such that touching a combination of keys at a particular partial level will generate a tone with that particular pitch.
In a variant of FIG. 11 , there is no open valve area. The open valve state is signaled by a quick tap, rather than a sustained touch in a partial area.
In FIG. 12 , the three valve areas 1230 do not correspond to a particular partial 1250 . The partial is rather determined by a touch at a particular partial in the open valve area.
FIGS. 13A and 14A show embodiments where Tone and pitch are determined by a combination of touch location and rotation of the device. The angle of rotation is used to set the partial. In FIGS. 13A and 13B the partial is set by rotating about the X axis, whereas in FIGS. 14A and 14B , the partial is set by rotating about the Y axis.
In each of the embodiments, the sound may be triggered by various methods including, but not limited to touch, and mic levels. If mic levels are used, the open valve area is not required for embodiments of FIGS. 13 and 14 which use touch and rotation to determine pitch.
FIG. 15 shows the flow of the process by which the Trumpet embodiments handle touch events.
Display sensor information is received 1500 periodically, and processed to determine whether a touch as begun 1502 , moved 1504 , or ended 1506 . If a touch has begun, the Tone and pitch adjustment are determined 1508 through one of several methods depending on embodiment
In embodiments of FIGS. 11 and 12 , Tone and pitch are determined exclusively by touch. Areas of the display are assigned to key valves or open valves. If a touch location lies within one of these regions it is considered to be pressed. As with the previously described Trombone embodiment, the partial is first determined from the touch location along the Y-axis. A base Tone and its associated Adjustment Semitones are determined from the partial. Table 4 shows sample associations between Y-position, partial, base Tone, and adjustment semitones.
TABLE 4
Sample association between Y-position,
partial, base Tone and pitch
Adjustment
Y-position [pixels]
Open Valve
Assigned Tone
Semitones
6-7 * pixels/partial
C5
Tone-Bb4
2
5-6 * pixels/partial
Bb4
Tone-Bb4
0
4-5 * pixels/partial
G4
Tone-Bb4
−3
3-4 * pixels/partial
E4
Tone-Bb4
−6
2-3 * pixels/partial
C4
Tone-C4
0
1-2 * pixels/partial
G3
Tone-C4
−6
0-1 * pixels/partial
C3
Tone-C3
0
The semitone adjustment due to the valve presses is then determined. 1 st valve closed, 2 nd valve closed, and 3 rd valve closed cause 2, 1, and 3 semitone decreases, respectively. The semitone decrease is additive, such that if 1 st and 2 nd valves are closed, there is a 3 semitone decrease; likewise, if 1 st and 3 rd valves are closed, there is a 5 semitone decrease.
With the valve semitones determined, the total semitone adjustment from base Tone pitch can be determined.
Total semitones=Adjustment semitones+Valve semitones
The total semitones are then used to calculate the pitch adjustment by the following formula:
Pitch adjustment=2^(Total semitones/12)
A similar procedure is followed for the embodiments of FIGS. 13 and 14 ; however, the partial is determined not be touch location along the Y-axis, but by rotation. In the case of FIG. 13 , rotation is within the YZ plane. And in the case of FIG. 14 , rotation is within the XZ plane.
When the touch event is received, the device angle is determined from the accelerometer data, and matched to find the associated partial, base Tone, and adjustment semitones. Table 5 shows an example of the association.
TABLE 5
Sample association between YZ angle, partial, base Tone and pitch
Adjustment
YZ angle [degree]
Open Valve
Assigned Tone
Semitones
82.5-97.5
C5
Tone-Bb4
2
67.5-82.5
Bb4
Tone-Bb4
0
52.5-67.5
G4
Tone-Bb4
−3
37.5-52.5
E4
Tone-Bb4
−6
22.5-37.5
C4
Tone-C4
0
7.5-22.5
G3
Tone-C4
−6
−7.5-7.5
C3
Tone-C3
0
Determination of the pitch adjustment proceeds as described for the other embodiments. In order to ensure that the angle is determined prior to partial being determined, a slight delay may be inserted.
With Tone and pitch determined, the type of attack or other quality of Tone is found 1510 as described in the Trombone embodiment. Finally, with Tone, pitch adjustment, and other Tone quality determined, the parameters are sent 1512 to the playback processor, and if 1514 set to trigger playback by touch, playback is requested 1516 .
A similar process is followed if a touch moved event is received 1504 . A new Tone, pitch adjustment, and note quality are determined 1518 . If the Tone or partial changes a slur may be signaled 1520 to the playback processor along with the other Tone parameters.
Finally, if a touch end event is received, and 1522 the system is configured to trigger playback by touch, a playback stop is requested 1524 of the playback processor.
As in the previously described Trombone embodiment, FIG. 16 shows a flow diagram of the process by which the mic sensor handles events if it has been selected by the user to trigger sound playback. The raw mic data is received 1600 periodically and peak and average levels are determined 1602 by a callback and/or timer function. If 1604 the player is currently not playing and 1606 the average volume level is above a particular threshold, a start request is sent 1608 to the playback processor, with the Tone and pitch having separately been requested by the Touch event processor. If 1604 the player is currently playing and 1610 the average volume level is above the threshold, it should continue playing and a volume adjustment based on the average volume level is requested 1612 of the playback processor. Finally, if 1604 the player is currently playing, but 1610 the average volume level is below the threshold, a stop is requested 1614 of the playback processor. In another embodiment, toggling sound is controlled by touch, whereas volume can be controlled by mic. In yet another embodiment, mic input can be used to determine partial. A Fourier transform is done on the mic input to determine its pitch. It is then matched to the set of partial pitches to select the closest partial.
FIG. 17 shows a flow diagram of the process by which the accelerometer handles events. The raw data is received 1700 and filtered 1702 - 1706 to determine an actionable event. In this particular embodiment the event is either an angle change, or a shake. The angle change may correspond either to a change in volume, or a change in partial, as would be the case with the embodiments of FIGS. 13 and 14 . If 1702 the angle change occurs about an axis configured to correspond to a partial, the angle itself is stored 1712 for later query by the touch event processor, or the partial is determined 1710 as described previously and in accordance with FIGS. 13 and 14 , and stored 1712 for later reference by the touch event processor.
If 1704 the angle change occurs about an axis configured to correspond to volume, the volume can be determined 1714 as previously described in accordance with FIG for the Trombone embodiment. With volume determined, it is sent 1716 to the playback processor.
If 1706 a shake event is detected, a flag that the event occurred and the time at which it occurred is set 1718 , such that any of the event processors responsible for starting playback may refer to it to determine attack type. In a modified embodiment, the shake could be configured to start and stop the sound playback, as well.
Saxophone
FIG. 18 shows the present invention embodied as a Saxophone. A real Saxophone consists of a length of brass tubing with a mouthpiece connected at one end, and a flared bell at the other. It has a series of holes which are covered and uncovered by pads which are controlled by pressing a series of keys. Keys are pressed by both left and right hands, including the left and, sometimes, right thumbs. Sound is generated when a person blows into the mouthpiece and vibrates the reed. Pitch is determined by wind and reed vibration and the combination of keys pressed.
By changing the oral cavity users can “lip up” to higher partials to play altissimo notes. However, they can reach many notes by the standard keys, which include the octave key. Quality, nuance and volume are determined largely by the shape of the oral cavity, lip position, wind speed and direction.
As embodied by the present invention. The device has a touch display 1800 , a mic 1810 , and speaker 1820 , with additional sensors and processor electronics contained within the case.
Areas for each key are defined on the display. There are the left hand main keys (B, A/C, G, front F, and Bb), palm keys (D, Eb, F), and little finger keys (G#, Low C#, Low B, Low Bb). There are also right hand main keys (F, E, D, F#), side keys (E, C, Bb, High F#), and little finger keys (Low Eb, Low C). A thumb key for changing octave may also be located on the display, or an alternate input may be used, such as the camera 1840 located on the back of the device. If sound is to be triggered by touch, an open key area is also defined to indicate that no keys are pressed, but sound is to be played. Base Tone and pitch are determined by location of touches in these regions. As with other embodiments, volume is determined by mic level, force (or area) of touch on the display, or angle of the device as determined by an accelerometer. Attack type, note quality and other nuance are determined by shaking the device, or may be linked directly to volume, or duration of notes.
FIG. 20 shows a flow diagram of the process by which the processor handles touch events. Display sensor information is received 2000 periodically, and processed to determine whether a touch has begun 2002 , moved 2004 , or ended 2006 . If 2000 a touch has begun, the Tone and pitch adjustment are determined 2008 based on location of the touch.
Similarly to the other previously described embodiments, partial or level is first determined, followed by adjustment due to key presses. The Saxophone differs from the Trumpet embodiments in that there is less reliance on partial shift, and more on key press shift. With the standard key arrangement (including thumb octave key) the instrument is capable of two and a half octaves. Altissimo registers can also be reached extending the range to 3 or even 4 octaves.
Partial, or octave shift, can be set through various methods. In one embodiment ( FIG. 18B ) the camera 1830 is used as a thumb octave key. In another embodiment, the device can be rotated in the XY plane, as shown in FIG. 19 to raise the octave and enter altissimo registers. To each partial, octave or level, a base Tone with corresponding adjustment semitones is assigned.
Locations of the touches are then used to determine key presses. As with the other embodiments, the semitone shift due to key presses is then added to the base Tone adjustment semitones to determine the final pitch shift of the base Tone.
Attack type and other qualities of the note is then determined 2010 . With Tone, pitch adjustment, note quality and any other parameters determined, they are sent 1512 to the playback processor. If 2014 configured to trigger playback by touch, playback is also requested 2016 .
A similar process is followed if 2004 a touch moved event is received. A new Tone, pitch adjustment, and note quality are determined 2018 . If the note changes a slur may be signaled 2020 to the playback processor along with the other Tone parameters.
Finally, if 2006 a touch end event is received and 2022 playback is configured to be triggered by touch, a playback stop is requested 2024 of the playback processor.
FIGS. 21 and 22 show the process by which mic events and accelerometer events are handled, respectively. These processes proceed similarly to those of the previously described Trumpet embodiments.
FIG. 23 shows the process by which camera input is handled to set the octave shift. The data is received 2300 periodically, processed 2302 to determine whether light is on or off, and the octave shift flag is set 2304 accordingly.
The invention has now been described with reference to the preferred embodiments. Alternatives and substitutions will now be apparent to persons of skill in the art.
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Methods and a system for providing electronic musical instruments are disclosed. Through novel combinations of sensor inputs and processing, they allow simulation of acoustic instruments including but not limited to a Trombone, Trumpet, and Saxophone. Sensor inputs are configured to trigger playback and transitioning of sound and control its various attributes alone, or in combination.
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FIELD OF THE DISCLOSURE
[0001] This patent generally pertains to insulated doors and curtains and, more specifically, to frost inhibiting joints for insulated panels and curtains.
BACKGROUND
[0002] Food manufacturers and distributors have a need to freeze food products quickly in order to maintain food product freshness and safety. Within a larger freezer room, a smaller area is cordoned off and is used as a blast freezer. The blast freezer performs this quick freeze using a high level of airflow at below freezing temperatures. In order to remove a stack of food products from the blast freezer and load the next stack quickly, a large sliding curtain wall or panel opens and closes by sliding on a track and trolley system. These sliding walls are insulated and can be up to 30 feet tall and 25 feet wide or larger.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a schematic top view of an example panel assembly constructed according to the teachings disclosed herein.
[0004] FIG. 2 is a schematic top view of another example panel assembly constructed according to the teachings disclosed herein.
[0005] FIG. 3 is a schematic top view of yet another example panel assembly constructed according to the teachings disclosed herein.
[0006] FIG. 4 is a front view of FIG. 3 .
[0007] FIG. 5 is a front view similar to FIG. 4 but showing the example panel assembly of FIG. 4 moved to an open position.
[0008] FIG. 6 is a back view of an example panel assembly constructed according to the teachings disclosed herein.
[0009] FIG. 7 is an exploded cross-sectional view of an example panel assembly constructed in accordance with FIGS. 6 and 8 and other teachings disclosed herein.
[0010] FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 6 .
[0011] FIG. 9 is an exploded cross-sectional view of another example panel assembly constructed according to the teachings disclosed herein.
[0012] FIG. 10 is a cross-sectional view similar to FIG. 8 but showing the example panel assembly of FIG. 9 .
DETAILED DESCRIPTION
[0013] FIGS. 1-10 show various example panel assemblies that can be used to provide a blast freezer within a larger freezer room. However, the panel assemblies may be used in other applications as well. The panel assemblies comprise at least first and second panels that, in some examples, are joined along their vertical edges to make one wider assembled panel. To reduce (e.g., prevent) frost from developing along the joint, various example seal members seal the joint. In some examples, two or more of the wider assembled panels are arranged to provide or create a blast freezer.
[0014] FIG. 1 , for instance, shows an example panel assembly 10 comprising a seal member 12 joining a first panel 14 to a second panel 16 . Similar panel structures 18 and 20 are assembled to separate a first chilled area 22 from a second chilled area 24 , thereby providing or creating a blast freezer 26 within a freezer room 28 . For example, the first chilled area 22 may have an area (e.g., a square footage area) that is less than an area of the second chilled area 24 . Air conditioning system 30 (one or more air conditioners) cools areas 22 and 24 to temperatures below freezing.
[0015] To rapidly freeze product 32 within blast freezer 26 in preparation for transferring product 32 to the freezer room's chilled area 24 , air conditioning system 30 cools the blast freezer's chilled area 22 to a first freezing temperature (e.g., −45 degrees Celsius) that is significantly lower than a second freezing temperature (e.g., −20 degrees Celsius) of the main freezer room's chilled area 24 . To further expedite freezing, in some examples, air conditioning system 30 provides greater air circulation in the blast freezer's chilled area 22 than in the freezer room's chilled area 24 . In other words, the average air velocity in area 22 is greater than the average air velocity in area 24 .
[0016] FIG. 2 shows another example panel assembly 34 comprising seal member 12 joining panels 14 and 16 . In this example, the panels 14 and 16 are arranged to provide a blast freezer 36 at alternate location within freezer room 28 .
[0017] FIGS. 3 , 4 and 5 show an example panel assembly 38 having two assembled panels 40 and 42 that are suspended from a track structure 44 and arranged to separate a first chilled area 46 from a second chilled area 48 , thereby providing or creating a blast freezer 50 within a freezer room 52 . Each of the assembled panels 40 and 42 includes a seal member 12 joining, coupling and/or attaching a first panel 54 to a second panel 56 . To provide access to products 32 within blast freezer 50 , at least one assembled panel 40 can travel along track structure 44 . FIG. 4 , for example, shows blast freezer 50 closed with panel 40 at a first travel position, and FIG. 5 shows blast freezer 50 in at least a partially open position with panel 40 at a second travel position.
[0018] Although the structural details of the panel assemblies disclosed herein may vary, an example construction is illustrated in FIGS. 6 , 7 and 8 . In this example, a panel assembly 58 includes a tubular metal frame 60 having two subframes 62 that are joined by some suitable means, e.g., via a fastener, welding, screws 64 , clips 67 , etc. In examples where frame 60 has a frame width 66 that is at least fifty percent greater than a single panel width 68 , at least a first panel 70 and a second panel 72 are mounted to frame 60 by some suitable means, e.g., via mechanical and/or chemical fasteners such as, for example, screws, snaps, clips, adhesive, clamps, etc. In some examples, a third panel 74 is also attached to frame 60 , as shown in FIG. 6 . As viewed in FIG. 6 , upper, lower and left peripheral edges of first panel 70 are fastened to frame 60 by way of screws and/or some other suitable means. Upper and lower peripheral edges of second panel 72 are fastened to frame 60 . Further, upper, lower and right peripheral edges of third panel 74 are fastened to frame 60 . Seal 12 joins, couples and/or seals the right edge of first panel 70 to the left edge of second panel 72 . Similarly, another seal 12 joins couples and/or seals the right edge of second panel 72 to the left edge of third panel 74 .
[0019] In some examples, panel assembly 58 is lightweight so that panel assembly 58 , when used for access to blast freezer 50 , can be opened and closed rapidly. In some examples, panel assembly 58 has high thermal resistance to reduce (e.g., minimize) the load on air conditioning system 30 . To achieve such benefits, in some examples, frame 60 is made of steel for rigidity but is hollow to reduce (e.g., minimize) weight. To further reduce (e.g., minimize) weight while providing sufficient thermal insulation, in some examples, each panel 70 and 72 includes a lightweight core of insulation 76 (e.g., polyester batting, polyurethane foam, etc.) sandwiched between two outer sheets 78 made of a pliable material (e.g., vinyl sheeting, vinyl fabric, coated nylon fabric, cloth fabric with vinyl coating, cloth fabric with other coating, neoprene sheeting, coated polyester fabric, etc.). The term, “pliable” as used in this patent to describe a sheet of material means the sheet is sufficiently flexible to be folded over onto itself and subsequently unfolded without appreciable permanent damage. In some examples, for each individual panel 70 and 72 , insulation 76 is contained within the panel 70 and 72 by having the panel's outer sheets 78 joined along their perimeters by some suitable means. Examples of such means include, but are not limited to, sewing, thermal bonding, gluing, chemical adhering, etc.
[0020] To provide a sealed joint (e.g., a vertical or lateral joint) between adjacent panels 70 and 72 , in some examples, seal member 12 has a sheet of material that includes a first loop 12 a sealingly touching or engaging first panel 70 and a second loop 12 b sealingly touching or engaging second panel 72 . In some examples, loops 12 a and 12 b are formed by folding a single sheet material of seal member 12 back over onto itself from either direction and sewing the resulting two loops in place. Examples materials of seal member 12 include, but are not limited to, chlorosulfonated polyethylene synthetic rubber or CSM or CSPE (also known as HYPALON, which is a registered trademark of DuPont of Wilmington, Del.); canvas duck; rubber-impregnated fabric; coated or uncoated nylon, polyester or vinyl fabric; other fabric materials, neoprene sheeting, vinyl sheeting, other flexible polymeric sheeting, etc.
[0021] In the illustrated example, a first touch-and-hold fastener 80 and a second touch-and-hold fastener 82 connect seal member 12 to first panel 70 and second panel 72 , respectively. The term, “touch-and-hold” fastener refers to means for connecting two parts together, wherein the two parts become connected upon simply forcing one part up against the other. A VELCRO hook-and-loop fastener is one example of a touch-and-hold fastener, (VELCRO is a registered trademark of Velcro USA Inc. of Manchester, N.H.). While air can pass through an unsealed VELCRO connection, loops 12 a and 12 b sealingly engaging panels 70 and 72 inhibit air from bypassing or flowing through seal member 12 . Restricting (e.g., preventing) the colder air from the first chilled area 46 of blast freezer 50 from flowing through seal member 12 to the second chilled area 48 of the less cold freezer room 52 reduces (e.g., minimizes) heat loss and helps reduce (e.g., prevent) frost from developing on the freezer room 52 side of seal member 12 .
[0022] . In some examples, panel assembly 58 includes first panel 70 having a first core of insulation 76 a sandwiched or otherwise positioned between a first warmer sheet 84 and a first cooler sheet 86 . The terms, “warmer sheet” and “cooler sheet” do not necessarily pertain to temperature but are used merely for distinguishing one sheet from the other based solely on the orientation or the direction the sheets face. For example, a warmer sheet and a cooler sheet face in opposite directions. In some examples, panel assembly 58 also includes second panel 72 having a second core of insulation 76 b sandwiched or otherwise positioned between a second warmer sheet 88 and a second cooler sheet 90 . Warmer sheets 84 and 88 face in one direction (e.g., away blast freezer 50 ), and cooler sheets 86 and 90 face in the opposite direction (e.g., toward blast freezer 50 ). In other words, warmer sheets 84 , 88 are positioned in fluid communication with the freezer room 52 and cooler sheets 86 and 90 are positioned in fluid communication with the blast freezer 50 . Seal member 12 , as shown in FIG. 8 , sealing touches or engages first cooler sheet 86 and second warmer sheet 88 .
[0023] First touch-and-hold fastener 80 has a first engaging piece 80 a and a first mating piece 80 b. The first engaging piece 80 a is attached and/or (directly or indirectly) coupled to first cooler sheet 86 , and the first mating piece 80 b is attached and/or (directly or indirectly) coupled to seal member 12 . The terms, “engaging” and “mating” refer to the two connecting pieces of a touch-and-hold fastener. In the example of a VELCRO hook-and-loop fastener, the engaging piece can refer to the hook piece or the loop piece. In examples where the engaging piece refers to the hook piece, the mating piece refers to the loop piece. In examples where the engaging piece refers to the loop piece, the mating piece refers to the hook piece.
[0024] Second touch-and-hold fastener 82 has a second engaging piece 82 a and a second mating piece 82 b. The second mating piece 82 b is attached and/or (directly or indirectly) coupled to the second warmer sheet 88 , the second engaging piece 82 a is attached and/or (directly or indirectly) coupled to seal member 12 . With such an arrangement of engaging and mating pieces, pieces 80 a and 80 b mate to fasten seal member 12 to first panel 70 , and pieces 82 a and 82 b mate to fasten seal member 12 to second panel 72 , as shown in FIG. 8 . Alternatively, in some examples, first engaging piece 80 a mates with second mating piece 82 b to fasten first panel 70 directly to second panel 72 without the intervening seal member 12 . In some examples, existing blast freezer installations originally assembled without seal members 12 can later be retrofit by adding seal members 12 .
[0025] In the example shown in FIGS. 9 and 10 , a seal member 92 is made of a material different than a sheet of material folded to provide two sealing loops. Seal member 92 is illustrated to represent any sealing structure 94 that in combination with first and second touch-and-hold fasteners 80 and 82 can join, attach, couple and/or seal panels 70 and 72 . Examples of sealing structure 94 include, but are not limited to, a vertically elongate foam pad or strip, a vertically elongate flexible strip of material (e.g., rubber, polyurethane, HYPALON, flexible PVC) and a vertically elongate rigid strip of material (e.g., rigid PVC, aluminum). In some examples, sealing contact between sealing structure 94 and panels 70 and 72 is provided in various ways, examples of which include, but are not limited to, the sealing structure's compliance to panels 70 and 72 , the panels' compliance to sealing structure 94 , and/or a sealingly contoured shape of sealing structure 94 .
[0026] Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of the coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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Example panel assemblies with frost inhibiting seal members are disclosed herein. Some example panel assemblies disclosed herein are particularly suited for creating a blast freezer (for food and other products) by using the panels in cordoning off a relatively small quick-freeze area within a larger freezer room. In some examples disclosed herein, a touch-and-hold fastener (e.g., VELCRO) connects two or more insulated flexible panels along their adjoining vertical edges to span the width of a supporting frame that is wider than a width of a single panel. To seal the joint and/or inhibit frost from developing along the joint, some example panel assemblies disclosed herein include a seal member with touch-and-hold elements plus sealing edges extending laterally in opposite directions. In some examples disclosed herein, the touch-and-hold elements couple two panels together while the sealing edges (e.g., foam strip or double looped sheet of material) block air from flowing through the touch-and-hold elements.
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BACKGROUND
1. Field of the Invention
This invention relates to tank-type toilets and, more particularly, to an apparatus and method for conserving water during the flush cycle of the toilet.
2. The Prior Art
The conventional tank-type water closet or toilet is configurated with a water reservoir or tank located above and to the rear of the pedestal. An outlet from the tank directs water into the pedestal where it flushes the wastes therein into the sewer system. A manually operable stopper occludes the outlet and serves as the mechanism for initiation of the flush cycle. A float mechanism inside the tank senses the water level to operate a water inlet valve and replenish the water in the tank after each flush cycle. The flush cycle is commenced by
(1) raising the stopper to allow the water in the tank to flush the pedestal,
(2) the lowering water level in the tank causing
(3) the float to fall and thereby
(4) opening the inlet valve to permit refilling of the tank before the stopper has again closed.
As can be readily observed, the foregoing opening of the inlet valve to refill the tank before the stopper has closed directs water from the inlet valve to the drain. However most conventional toilets are configurated such that there is a sufficient reservoir of static water available in the toilet tank to accomodate a complete suitable flushing of the toilet. The extra water contributed by the premature opening of the inlet valve is generally wasted. For example, it has been estimated that a conventional toilet tank contains a water reservoir of about 41/2 gallons. This is generally considered to be adequate for the flushing cycle. It has also been determined that opening of the inlet valve prior to the cessation of the flushing cycle results in about 11/2 gallons of additional water being used for the flushing cycle and, thereby, wasted.
When consideration is given to the millions of tank-type toilets in use both in residential and commercial buildings, the amount of water wasted during the flushing cycle represents a significant quantity of water. Additionally, since the wasted water is not required for suitably flushing the toilet, the additional water contributes to overloading of sewage treatment facilities. Various water conservancy devices have been proposed and include, for example, the placement of bricks or the like as displacement means in the toilet tank to displace an equal volume of water thereby reducing the total volume of water used in the flushing cycle.
In view of the foregoing, it would be a significant advancement in the art of conserving water, particularly during the flushing cycle of a tank-type toilet, by restraining the toilet tank float until a significant quantity of the static water in the toilet tank has been drained therefrom and thereafter allowing the toilet tank float to be lowered so as to open the inlet valve to refill the toilet tank. It would also be an advancement in the art to provide an apparatus which can be readily adapted to be placed in various commercial models of toilet tanks. An even further advancement in the art would be to provide a method for suitably controlling the lowering of the toilet tank float substantially automatically. Such an apparatus and method is disclosed and claimed in the present invention.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
The novel apparatus and method of this invention involves a pivotally mounted lever arm having a toilet tank float engagement means on one end and a water-fillable weight on the other end. The weight of the water in the water-fillable weight is sufficient to substantially support the weight of the toilet tank float engaged by the engagement means. A calibrated drain hole is provided in the water-fillable weight to accommodate draining of the water therefrom. Drainage of the water from the water-fillable weight provides a predetermined time delay to change the balance of the lever arm thereby allowing the toilet tank float to be lowered toward the end of the draining of the tank. The lowered float opens the inlet valve and the toilet tank is again refilled with water from the inlet valve. The size of the calibrated drain opening is predetermined so as to delay lowering of the toilet tank float until substantially all of the water has been drained from the toilet tank thereby conserving water by inhibiting its being wasted by going directly out the drain.
It is, therefore, a primary object of this invention to provide an apparatus for conserving water during the flush cycle of a tank-type toilet.
Another object of this invention is to provide an improved method for conserving water during the flushing cycle of a tank-type toilet.
Another object of this invention is to provide a lever arm with means for engaging a toilet tank float at one end and a variable weight counterbalance on the other end wherein the variable weight is provided by a water-fillable weight.
Another object of this invention is to provide means for releasably engaging the apparatus of this invention inside the tank of a tank-type toilet.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic perspective view of the internal mechanism of a tank-type toilet shown in the partial environment of a toilet pedestal with portions broken away for purposes of clarity;
FIG. 2 is a side elevation of the internal mechanism of the toilet tank apparatus of FIG. 1 during the initial stages of the flushing cycle with portions broken away for sake of clarity;
FIG. 3 is a side elevation of the toilet tank mechanism of FIGS. 1 and 2 near the completion of the flushing cycle with portions broken away for sake of clarity;
FIG. 4 is a perspective view of one preferred embodiment of the apparatus for releasably mounting the apparatus of this invention in a toilet tank with portions broken away for sake of clarity; and
FIG. 5 is a perspective view of a another preferred embodiment for releasably engaging the apparatus of this invention in a toilet tank with portions broken away for sake of clarity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is best understood by reference to the drawing wherein like parts are designated with like numerals throughout.
Referring now to FIGS. 1-3, the water saver apparatus of this invention is shown generally at 10 as mounted in a conventional toilet tank 12 so as to be concealed therein beneath toilet tank lid 14. Toilet tank 12 is a conventional toilet tank and is mounted in fluid communication with a toilet pedestal (shown herein broken away as toilet pedestal 11). Toilet tank 12 is interconnected to a water inlet line 16 and is supplied with water from a water shut-off valve 18 in a water supply line 20.
Toilet tank 12, lid 14, water inlet line 16, shut-off valve 18 and water supply line 20 are all conventional apparatus. Other conventional apparatus include an inlet standpipe 22, a water inlet 25, and a water inlet valve 24 which is interconnected to a toilet tank float 26 by means of float rod 28 and a bracket 30. Other conventional components include an overflow standpipe 32, drain stopper 34, lift rod 36, and drain valve seat 38. These conventional components are set forth herein so as to provide an appropriate environment to assist in understanding the novel apparatus and method of this invention. The operation of these conventional components will not be discussed in depth except as they relate to the operation of the apparatus and method of this invention. Although a particular type of toilet tank may be illustrated herein, it is to be specifically understood that the apparatus and method of this invention is not restricted to use in a toilet tank having the specific components shown but may be readily adapted to various commercial models of tank-type toilets.
With particular reference to the novel apparatus and method of this invention, the water saver 10 includes a lever arm 56 having a water-fillable weight 50 on one end and a toilet tank float engagement means 58 on the other end. Toilet tank float engagement means 58 is configurated as an upwardly turned hook in the end of an arm 57 formed on the end of lever 56. Toilet tank float engagement means 58 is specifically configurated to restrain toilet tank float 26 by being engaged beneath float rod 28.
Lever arm 56 is pivotally mounted to overflow standpipe 32 by means of a pivot pin 60 secured to a retaining ring 62. Retaining ring 62 is dimensionally configurated to be releasably mounted to overflow standpipe 32 at a position adjacent an upper level 19 (shown in broken lines, FIG. 2) of water in toilet tank 12.
Water-fillable weight 50 is configurated as an open end container secured to the end of lever arm 56 and includes a calibrated drain hole 52 in the bottom thereof. The volume of water-fillable weight 50 is coordinated with the length of lever arm 56 on each side of pivot 60 and the combined weight of toilet tank float 26 and float rod 28 so as to adequately support toilet tank float 26 above the receding water level (illustrated schematically at 21, FIG. 2) during the flushing cycle. Importantly, as stopper 34 is raised and water is allowed to flow outwardly from tank 12 as indicated by flow arrows 40, sufficient water is retained within water-fillable float 50 so as to impede the lowering of toilet tank 26. The opening of inlet valve 24 is thereby suitably delayed until a substantial quantity of water has been drained from toilet tank 12.
Since it is desirable to have toilet tank float 26 ultimately lowered thereby opening inlet valve 24, a calibrated opening 52 is provided in the bottom of water-fillable weight 50. Accordingly, as the water level 21 (FIG. 2) drops in toilet tank 12 the water level in water-fillable weight 50 also starts to lower as indicated schematically at 51 (FIG. 2).
With particular reference to FIG. 3, the toilet tank mechanism is shown at the completion of the flush cycle with the stopper 34 again seated against valve seat 38 and toilet tank float 26 in its lowered position thereby opening valve 24. The lowering of toilet tank float 26 is accommodated by drainage of water, indicated schematically herein as water 54, through drain hole 52 so that the weight of the water-fillable weight 50 is overcome by the combined weight of toilet tank float 26 and float rod 28. The size of drain hole 52 is predetermined with respect to the volume of water contained in water-fillable weight 50 so as to provide a sufficient time delay between the raising of stopper 34 and its subsequent lowering into sealing relationship with valve seat 38. In this presently preferred embodiment of the invention, drain hole 52 is configurated to slowly drain water from water-fillable weight 50 at such a rate that the toilet tank 12 is substantially drained and stopper 34 is again seated on valve seat 38 before any substantial degree of opening of valve 24 is obtained by lowering of toilet tank float 26. Clearly, however, any suitable delay can be selectively predetermined for water-fillable weight 50 by selectively determining the opening of drain aperture 52 and, therefore, the rate at which water flows therethrough.
Referring now more particularly to FIG. 4, one preferred embodiment for securing a pivot 70 for lever arm 56 in a toilet tank 13 is shown and includes a spring clip 72 formed from a strip of resilient material. Spring clip 72 is fabricated with a configuration generally representing the letter W. The distance across the W configuration of spring clip 72 is greater than the internal dimensions of toilet tank 13 to thereby advantageously utilize the outwardly pressing force of spring clip 72 when the same is inserted into toilet tank 13.
Although spring clip 72 is shown generally in the form of the letter W, it could be readily reversed in its orientation so as to generally represent the letter M. Alternatively, the two ends of spring clip 72 could be joined so as to form a continuous loop below lid 15. Importantly, regardless of the configuration chosen, spring clip 72 is configurated to pivotally support lever arm 56 in the desired location in tank 13 and to avoid interference with the movement of toilet tank float 26 and float rod 28.
Referring now more particularly to FIG. 5, another preferred embodiment for securing a pivot 87 for lever arm 56 in a toilet tank 13 is illustrated generally as a bracket 80. Bracket 80 is fabricated from a cylinder 82 with a spring-biased rod 85 extending from each end. Rod 85 is configurated with a piston 84 in engagement with a spring 83 at one end and termintes in a foot 86 at the other end. Spring 83 is configurated as a compression spring and resilently urges rod 85 and, more particularly, foot 86 against the inside walls of toilet tank 13.
Bracket 80 is mounted in toilet tank 13 by first removing lid 15 and pushing rods 85 inwardly to compress spring 83 while lowering bracket 80 into position into toilet tank 13. Pivot 87 is supported on the end of a downwardly depending shaft 81 extending from bracket 80. In this manner, pivot 87 for lever arm 56 is selectively located at the appropriate position in toilet tank 13. Preferably, bracket 80 and, more particularly, pivot 87 is suitably adjusted in toilet tank 13 so that pivot 87 is adjacent the upper level of water in toilet tank 13 as set forth with respect to pivot 60 and water level 19 of FIG. 2.
THE METHOD
The method of this invention involves placing the water saver apparatus 10 in a toilet tank by pivotally supporting lever arm 56 therein either by means of pivot 60 (FIGS. 1-3), pivot 70 (FIG. 4), or pivot 87 (FIG. 5). In each configuration, lever arm 56 is pivotally suspended in the appropriate toilet tank at a position adjacent the upper level 19 (FIG. 2) of the water therein. The water-fillable weight 50 is thereby immersed in the water to accommodate filling with water by forcing the water through the drain aperture 52.
Upon commencing the flush cycle for the toilet tank 12 (FIGS. 1-3) by raising rod 36 and, correspondingly, stopper 34, the desired water conservation sequence provided by water saver 10 is commenced. In particular, as the water level (water level 21, FIG. 2) drops away from both water-fillable weight 50 and toilet tank float 26 the level of water (water level 51, FIG. 2) in water-fillable weight 50 also lowers but at a slower rate than water level 21. Accordingly, sufficient weight is imparted to the end of lever arm 56 so as to support the weight of toilet tank float 26 and thereby suspend the same above the lowering water level 21 (FIG. 2). After sufficient water has drained from drain aperture 52, the residual weight of water-fillable weight 50 is overcome by the combined weight of toilet tank float 26 and float rod 28 thereby lowering toilet tank float 26 and opening inlet valve 24. With inlet valve 24 opened, the inrushing water 27 from inlet port 25 refills toilet tank 12 (FIG. 3), preferentially, after stopper 34 is again reseated on valve seat 38.
As the lowered water level (water level 23, FIG. 3) raises through the action of the inrushing water 27, toilet tank float 26 correspondingly rises allowing water-fillable weight 50 to be lowered into contact with the rising water level. Thereafter, the rising water level enters water-fillable weight 50 through drain aperture 52 again refilling water-fillable weight 50. Accordingly, the water saver apparatus 10 is again functionally prepared to operate on the next flush cycle of the toilet.
The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An apparatus and method for conserving water during the flush cycle of a tank-type toilet. The apparatus includes a pivotally mounted lever arm having a water-fillable weight on one end and a toilet tank float engagement means on the other end. The water-fillable weight serves as a counter balance to maintain the toilet tank float in an elevated position to thereby hold the water inlet valve closed during the initial stages of the flush cycle. The apparatus also includes means for mounting the pivot mechanism in the toilet tank. The method involves slowly draining water from the water-fillable weight during the flush cycle so as to allow the toilet tank float to be lowered toward the end of the flush cycle and thereby open the inlet valve to refill the toilet tank.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
NAMES OF PARTIES TO JOINT RESEARCH AGREEMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to rosuvastatin enantiomer compounds having (3R,5R), (3S,5R), or (3S,5S) configurations, which maximize or normalize cellular phenotypic expression and that are broadly useful in the treatment of a wide variety of human diseases, including cancer, atherosclerosis, and immune system diseases or disorders.
2. Description of Related Art
Pyrimidine derivatives, including rosuvastatin compounds with a (3R,5S) configuration, have been recognized for their ability to inhibit 3-hydroxy-3-methyl-glutaryl coenzyme A (HMG-CoA) reductase. Because HMG-CoA reductase plays a major role in the synthesis of cholesterol, these pyrimidine derivatives have been described as useful in the treatment of hypercholesterolemia, hyperlipoproteinemia, and atherosclerosis (U.S. Pat. RE 37,314). A number of other compounds have similarly been described as useful in the inhibition of HMG-CoA reductase, and thus in the treatment of atherosclerosis, including pravastatin sodium (U.S. Pat. No. 4,346,227), simvastatin (U.S. Pat. No. 4,444,784), and certain mevalonate and mevalonolactone derivatives (U.S. Pat. No. 5,849,777).
Compounds in this latter category (mevalonate and mevalonolactone derivatives) have also been recognized for their ability to modulate cell function. See U.S. Pat. No. 5,849,777, which is hereby incorporated by reference. Because abnormal cell function is associated with a number of diseases, including cancer and Acquired Immune Deficiency Syndrome (AIDS), the ability to enhance or modulate cell function is therefore of significant importance in the treatment of diseases associated with such aberrant or deficient cell function. Unfortunately, despite research efforts spanning a number of decades, modulation of cellular activity, including differentiation, is still incompletely understood, partly a result of the numerous and complex pathways by which such modulation occurs. The mevalonate and mevalonolactone derivates described in U.S. Pat. No. 5,849,777 are believed to function by modulating phenotypic expression, such as by inducing expression of unexpressed genes so as to increase cell function, and/or by normalizing cell surface membrane characteristics including the expression of oligosaccharides.
Although some compounds that inhibit HMG-CoA reductase are also useful as cell modulators, there is no apparent correlation between the inhibition of HMG-CoA reductase and cell modulation. In addition, the relevant literature has recognized the importance of distinguishing between enantiomeric forms of pharmaceutically active substances due to potential differences in pharmacologic activity as well as the difficulty in predicting the therapeutically relevant characteristics of any given enantiomeric form (Darrow, J., The Patentability of Enantiomers, Implications for the Pharmaceutical Industry, Stanford Technology Law Review, 2007, pages 2 et seq.).
BRIEF SUMMARY OF THE INVENTION
The rosuvastatin enantiomer compounds of the present invention, having a (3R,5R), (3S,5R), or (3S,5S) configuration, induce or enhance cellular differentiation, that is, they maximize or normalize cellular phenotypic expression. Unlike rosuvastatin compounds described in the literature (see, e.g., Z. Casar, Lactone Pathway to Statins Utilizing the Wittig Reaction. The Synthesis of Rosuvastatin. Journal of Organic Chemistry, 2010, vol. 75, pp. 6681-84), the compounds of the present invention operate via a different mechanism of action, owing to their particular stereoisomeric configuration, and thereby exhibit unexpectedly increased effectiveness and applicability to a much broader array of diseases. By modulating the phenotypic expression of cells with diminished or aberrant cellular function, the compounds of the present invention, among other things, maximize the function of immunocytes by facilitating immunological recognition and elimination from the body. They are therefore of therapeutic benefit in a range of diseases characterized by either (i) diminished cellular function or (ii) aberrant cellular function. Diseases in category (i) include infectious diseases such as Acquired Immune Deficiency Syndrome (AIDS) and hypogammaglobulenemia, and other diseases of bacterial, fungal, rickettsial, viral, or parasitic origin. Diseases in category (ii) include: autoimmune diseases such as diabetes, multiple sclerosis, lupus erythematosus, and rheumatoid arthritis; nervous system diseases such as Alzheimer's disease, Amyotrophic Lateral Sclerosis, and Parkinson's disease; and cancer.
BRIEF DESCRIPTION OF THE DRAWINGS
Not Applicable
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to compounds of the formula:
wherein R is any of the following:
Preparation of the Invention
The compounds of the present invention can be prepared according to the methods described in U.S. RE 37,314 E, which is hereby incorporated by reference, followed by chiral resolution (separation). Resolution of racemates or other mixtures of the enantiomers can be readily accomplished by conventional procedures, as described, for example, in U.S. Pat. No. 4,613,610, which is hereby incorporated by reference. Alternatively and preferably, the desired differentiatively-active enantiomers can be synthesized by processes that yield only or substantially only the desired enantiomers. Such processes are well known in the art. While the presence of inactive or less active stereoisomeric matter is not generally detrimental, the presence of inactive or less active enantiomers must be considered when calculating dosage levels. The invention therefore includes racemic or other mixtures of any of the enantiomers described herein.
Utility of the Invention
The rosuvastatin enantiomer compounds of the present invention are contemplated to modulate cell differentiation activity across a broad array of cell types, and thus to be useful in the treatment of a number of diseases. According to the invention, cells with aberrant or deficient function are exposed in vivo or in vitro to the compounds of the invention in order to improve cell modulation activity. As used herein, “cell modulation” refers to substantially all activities of the normal mature cell that tend to differentiate that cell from other cell types, including: the bioproduction of proteins, carbohydrates, fats, cholesterol, hormones, enzymes, sugars, and immunoproducts (such as globulins and antibodies); growth regulation functions which maintain or impose normal growth patterns; and cell structure regulation functions which provide cell structures characteristic of normal cell differentiative function, such as cell membrane composition, e.g., oligopolysaccharide structure, or cytoplasmic composition. Thus, the process of the invention provides a method for the autoregulation of cellular functions comprising virtually all functions characteristic of the mature individuated cell, i.e., those functions not peculiar to early progenitor cells having a purely proliferative capability, and further provides a method for increasing biologically adequate cell differentiative activity by inducing expression of unexpressed cell differentiative capacity, for example, to diversify expression of differentiative activity, or to induce differentiative activity in immature, substantially non-individuated cells, or in abnormally differentiated cells, e.g., transformed or aberrant cells.
The term “autoregulation” as used herein refers to the utility of the modulators in restoring cellular biochemical balance to cells exhibiting abnormal differentiative activity owing to known or unknown factors; such as toxic substances introduced into the organism from the environment; biochemical imbalance of the organism caused by metabolic disturbances, diseases, or disorders; or injury to the cell, organ, or organism. The term “autoregulation” further includes the utility of the modulators in the rectification of cell activity heretofore regarded as “normal”, such as arresting senescence of cells both in vivo and in vitro, and diversification of cell function with respect to existing cell function within accepted ranges of normal cell function.
The modulators of the invention accordingly function to stimulate phenotypic cell expression, including rectification of abnormal cell production, reassertion of normal cell function, correction of cellular incompetence, restoration of normal growth patterns, modulation of aberrant cell structures, reestablishment of normal cell growth patterns, and further, diversification and/or expansion of existing cell function within the genetic capabilities of the cell.
The term “abnormal”, as used herein to modify differentiative activity or cell function, refers to cell differentiative activity, as described above, which is outside of accepted ranges; thus, “abnormal differentiative activity” refers to pathological cell differentiative activity manifested in cell morphology and/or activity above or below accepted standards, and which in vivo tends to result in malfunction of the organism, resulting in distress, debilitation, and/or death of the organism.
Exposure of cells to the differentiators according to the invention invokes cell mechanisms which promote normal differentiative activity or which expand or diversify cell differentiative activity. In applications wherein the differentiators are employed to improve abnormal differentiative activity at least a ten percent improvement in such function is contemplated; i.e., at least a ten percent, preferably twenty percent, improvement in the parameter of interest (with reference to the conventional measurement of such parameter) is contemplated. For example, if bioproduction of a cell is abnormally low or high, at least a ten percent increase or decrease by mass, respectively, of the product of interest over a comparable time period is contemplated. Thus, if a given leukocyte biomass produces ten nanograms of immunoglobulin G (IgG) over a one-hour period under normal in vitro conditions, the same biomass will produce at least eleven nanograms of IgG over the same time period under the same culture conditions on exposure to the modulators of the invention. By the same token, the growth rate of a biomass of malignant cells exhibiting an abnormally high growth rate is decreased by at least about ten percent on exposure to the modulators of the invention. Similarly, in vivo, rectification of abnormal cell differentiative activity of at least about ten percent is established by comparing cell or organ activity before and after exposure to the modulators of the invention, according to standard measuring techniques, such as blood determinations for the product of interest, nuclear magnetic resonance (NMR) or computed axial tomography (CAT) scans for evaluation of cellular activity, weight assessments for determination of cell growth, and a variety of other biotechnical diagnostic procedures well-known in the art.
For use of differentiators according to the invention to diversify or expand cell differentiative activity, a similar, about ten percent, preferably about twenty percent, increase in cell differentiative activity, based on conventional measurements of the parameter of interest, is contemplated. For example, exposure of stimulated murine splenocytes to the differentiators promotes the production of antibody, with at least a ten percent increase in antibody diversity with respect to affinity, avidity, and/or specificity of the antibody pool produced. With respect to modification of cell structure, at least about a ten percent change in cell structure, particularly cell component biochemical characteristics, chemical characteristics, or stereochemical arrangement of cell components, is contemplated. For example, a change in the oligosaccharide content of cell-surface membranes (as measured, for example, by lectin binding) of at least about ten percent, preferably at least about twenty percent, is contemplated. Oligosaccharide cell-surface membrane characteristics have been correlated with cell growth patterns, and a modulation of abnormal cell-surface membrane oligosaccharide content with the differentiators of the invention to provide at least about a ten percent decrease in abnormally high cell reproduction rates, or at least about a ten percent increase in abnormally low cell reproduction rates, as observed in senescent cells, for example, is within the scope of the invention. In this instance, for example, improvements in cell differentiative activity are measurable in vitro by either a change in the rate of lectin binding, reflecting a change in oligosaccharide cell-surface membrane characteristics, or by a direct measurement of cell reproduction activity, typically determined by change in generation time (Tg).
Cell modulation includes the ability to promote cytostasis, and thus to inhibit tumor growth and/or tumor metastasis. As such, the rosuvastatin enantiomer compounds of the present invention are contemplated as useful in the treatment of various tumor types including leukemias, lymphomas, melanomas, and myelomas, as well as tumors of the ovary, cervix, breast, lung, colon, stomach, liver, pancreas, bladder, prostate, brain, and larynx, among others. The compounds of the present invention may also function as anti-tumor agents by enhancing the activity of natural killer cells or other cells of the immune system, as these cells are believed to play an important role in the body's defense against tumor-transformed cells.
It is postulated that the modulators described herein influence a sufficiently primitive biochemical control process which affects the regulation of cell differentiation at a sufficiently basic level, to have a substantially universal function as a modulator of cell activity to promote normal cell differentiative function over a broad spectrum of cells. It is specifically contemplated that the modulators of the invention function to rectify abnormal production of a variety of protein, glycoprotein, carbohydrate and fat cell products, such as cholesterol, as well as enzymes; hormones, such as somatostatin, MSH (melanocyte-stimulating hormone), and pituitary hormones; immunoproducts, such as lymphokines, globulins and antigens; to reassert normal cell function, such as the normal function of liver cells; to correct cell deficiencies, such as immunodeficiencies, glandular deficiencies, such as hypothalmia, and metabolic deficiencies; to restore normal growth patterns to cells exhibiting decelerated growth rates, such as senescent cells, or accelerated growth rates, such as malignant cells; to modulate aberrant cell structures to approach those of normal cells; to stimulate progenitor and/or precursor cells into full production of mature cells; and, further, to diversify and/or expand existing cell function within the genetic capabilities of the cell, such as to increase the immunoresponse of splenocytes to antigenic stimulus, with respect to both the diversity and amount of antibodies produced.
The modulators exert biochemical control over cell differentiation processes, intervening at a very early point in cellular differentiative pathways to promote cell autoregulation of differentiative function. It is accordingly believed that the modulators described herein comprise molecules which, with respect to both biologically-active functional moieties and with respect to the presentation of these biologically-active functional groups to the cell (i.e., the stereochemistry of the molecule), function to counteract cellular imbalances (resulting in abnormal differentiative function over a broad spectrum of cells and differentiative activity). Thus, in contrast to known differentiators which tend to be relatively specific in effect, with respect to either particular cells or particular differentiative activity, the modulators of the present invention are effective in restoring normal differentiative function to chemically imbalanced cells of plants, animals (especially mammals including humans), microorganisms, viruses, and insects. Further, the modulators of the invention function to increase diversity of differentiative function within the genetic potential of the cell.
Administration of the Invention
The compounds of the present invention can be administered orally or intraparenterally, such as via intravenous or intramuscular injection. For example, the compounds of the present invention may be administered: (1) orally, such as in the form of tablets, powders, capsules or granules, aqueous or oily suspensions, or syrups or elixirs; or (2) parenterally, such as in the form of injections of aqueous or oily suspensions, or in the form of nasal sprays, aerosols, powders or suspensions. These formulations can be prepared in a conventional manner by using excipients, binders, lubricants, aqueous or oily solubilizers, emulsifiers, suspending agents, and the like. In addition, preservatives, stabilizers, or adjuvants may be used.
Appropriate dosage levels may vary with the administration route, age, weight, condition, and disease type under treatment. In general, however, when the mode of administration is via intraperitoneal or subcutaneous injection or via nasal spray, optimal dosage levels are in the range of one hundred nanograms per kilogram, administered every other day, to one hundred micrograms per kilogram, administered every other day. When the mode of administration is oral, optimal dosage levels are in the range of one nanogram per kilogram, administered every other day, to one milligram per kilogram, administered every other day. Regardless of the mode of administration, equivalent dosage levels administered on a more frequent (e.g., daily or twice daily, etc.) basis, or less frequent basis (e.g., once a week) may also be used.
Dosage of the invention appears to be critical, i.e., dosages in excess of the therapeutic dosage range are typically ineffective to increase response and may actually, for example, stimulate tumor growth, while dosages below the range are substantially ineffective, for example, in inhibiting tumor burden. The differentiators have no observed toxic side effects at therapeutic dosage levels. For humans, it is recommended that administration occur via intravenous (i.v.), intraperitoneal (i.p.), or subcutaneous injection on a regimen of at least alternate days until tumor response is noted, preferably by non-invasive diagnostic techniques such as nuclear magnetic resonance imaging (NMRI). Initial positive tumor response (such as tumor deformity or presence of tumor-associated edema) is contemplated as observable as early as about two weeks from the start of the therapeutic regimen. After substantial tumor response has been achieved, dosage frequency may be decreased to, for example, a weekly basis, until the tumor has been conquered.
In an exemplary procedure, administration of a therapeutic dosage of cytostatic compound is begun on a human tumor host on Monday of week 1. One hundred ng/kg in physiological saline is administered i.v., or i.p., Monday, Wednesday, and Friday of week 1; this procedure is repeated on continuous weeks 2, 3, 4, and following weeks with NMR monitoring on a weekly basis until the desired reduction in tumor burden is achieved. While the regimen may be continued thereafter, experimental evidence indicates that tumor rebound after treatment is not significantly incident to the therapeutic process of the invention.
Stereochemistry of the Invention
Although both the mevalonate and mevalonolactone derivatives described in U.S. Pat. No. 5,849,777 and the pyrimidine derivatives described in U.S. Pat. RE 37,314 have been recognized for their ability to inhibit HMB-CoA, there is no apparent correlation between HMG-CoA reductase inhibitory activity and promotion of cell modulation activity. The ability to modulate cell activity does, however, appear to depend on the particular chiral configuration of the 3,5 carbon atoms in the heptanoic or heptenoic acid portion of the invention. In particular, the rosuvastatin enantiomer compounds of this invention in either their (3R,5R), (3S,5R), or (3S,5S) configurations, including racemates or mixtures of (3R,5R)-(3S,5S) or (3S,5R)-(3R,5S), are contemplated as having greater cell modulation activity than do related compounds having the (3R,5S) configuration. Purified rosuvastatin enantiomers of the (3R,5S) configuration, substantially free of the enantiomers having a (3R,5R), (3S,5R), or (3S,5S) configuration, are therefore not within the scope of this invention. The conventions used herein to characterize particular stereoisomeric configurations are those commonly used in the art. See, for example, U.S. Pat. No. 4,613,610.
Clinical Applications of the Invention
The rosuvastatin enantiomer compounds described in the present invention induce or enhance cellular differentiation, i.e., they maximize and/or normalize cellular phenotypic expression. Therefore, they will be of therapeutic benefit in diseases characterized by either (1) diminished cellular function or (2) aberrant cellular function. Examples of the first category include acquired immune deficiency syndrome (AIDS) and hypogammaglobulinemia. Another example of the first category is the treatment of infectious diseases caused by pathogens of bacterial, fungal, rickettsial, viral or parasitic origin. The compounds of the invention maximize the function of immunocytes by maximizing the phenotypic expression of these cells. Therefore, immunological recognition and elimination of these pathogens from the body are facilitated by treatment using the compounds described in the invention. Patients with atherosclerosis benefit by treatment with the compounds of this invention, since phenotypic expression (differentiation) of liver cells (hepatocytes) are induced and enhanced. This leads to increased levels of the LDL receptor on the surface of hepatocytes and this facilitates the removal of cholesterol from the body. Although rosuvastatin in its (3R,5S) configuration has previously been disclosed as useful in the treatment of atherosclerosis by inhibiting cholesterol biosynthesis at the rate-limiting step, i.e., HMG-CoA reductase, the rosuvastatin enantiomer compounds of the present invention do not inhibit cholesterol biosynthesis and are believed to achieve their utility via a different mechanism of action (enhancement of cellular differentiation, e.g., increased levels of the LDL receptor on the surface of liver cells (hepatocytes) and this facilitates removal of cholesterol from the body and, therefore, leads to a decrease in blood cholesterol. The different mechanism of action of the rosuvastatin enantiomers of the present invention—(3R,5R), (3S,5S), and (3S,5R)—allows for both greater efficacy and reduced toxicity as compared to rosuvastatin compounds of the (3R,5S) form. Also, it is known in the art that only the (3R,5S) enantiomer inhibits cholesterol biosynthesis, making the utility of the particular enantiomers of the present invention unexpected.
Diseases of the second category, i.e., aberrant cellular function, include cancer, as well as autoimmune diseases such as diabetes, multiple sclerosis, lupus erythematosus and rheumatoid arthritis.
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The invention discloses a method for the treatment of diseases, particularly those diseases characterized by diminished or aberrant cellular function, including AIDS, cancer, and Alzheimer's Disease. The method comprises administering a therapeutically effective amount of rosuvastatin enantiomer compounds in their (3R,5R), (3S,5R), or (3S,5S) configurations, or pharmaceutically acceptable salts thereof. Biologically-active rosuvastatin enantiomer compounds with (3R,5R), (3S,5R), and (3S,5S) stereochemistry are also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to photodegradable and thermostable compositions based on homopolymers and copolymers of vinyl or vinylidene monomers, such as polyethylene, polypropylene, polyisobutene, polystyrene, polyvinyl chloride and ethylenepropylene copolymers.
2. The Prior Art
It is quite well known that vinyl and vinylidene polymers are widely used as packaging materials in the form of films or in the form of containers of different types. It is also well known that the stability of such packagings with the passage of time is rather high, so much so as to cause serious environmental pollution problems due to the lack of an efficient system for the gathering and destruction of such materials. The environmental pollution caused by the residues of these packaging materials may be avoided by the use of degradable materials that decay under atmospheric conditions or under biological attack.
In particular, the degradability of vinyl or vinylidene polymers under the photochemical action of sunlight may usually be enhanced by mixing such polymers with photosensitizing substances. Photosensitizing substances which are in common use at present, are salts of the transition metals and compounds containing particular chromophore groups such as carbonyls or double bonds. The presence of such substances in the polymeric composition accelerates the photooxidation of the polymeric chain, with consequent degradation thereof. This degradation may in fact proceed to the point of reducing the manufactured article to a fine dust, and possibly up to the point of reducing the molecular weight of the polymeric material to values that are low enough for subsequent biological degradation.
In general, it is known that a photodegrading action will be exerted on the above-noted polymers by transition metal compounds. Specifically, such action will be exerted by all transition metal compounds that are soluble in the polymer and in which the transition metal has an atomic number between 21 and 30, 40 and 47 and 57 and 79 inclusive, wherein the binder or anion that is chemically bound to the metal, does not itself possess intrinsic photostabilizing properties. As examples of such compounds, mention may be made of the stearates, naphthenates, laurates, palmitates, oleates, sulphonates, phenolates, phosphonates, phosphites, oxides, acetyl acetonates, dibenzoylacetonates, alkylthiocarbamates, complexes with hydroxybenzophenone, cyclopentadiene, mono- and polyamines, oximes, ketones and thioketones, hydrazines, azo-compounds, etc. of copper, titanium, cobalt, iron, nickel, manganese, chromium, niobium, molybdenum, cerium, tungsten, etc. The compounds of the above-described type and their photodegrading properties with regard to vinyl and vinylidene polymers, are both quite well known in the art. They are described in, for example, German Patent Application No. 2,136,704. The majority of the above transition metal compounds which act as photodegrading agents, have, however, a deleterious action on the thermal stability of the vinyl and vinylidene polymers.
On the other hand, since the processing of these polymers and their transformation into manufactured articles take place at high temperatures, the presence of highly thermodegradable substances such as the transition metal compounds, causes degradation of the polymer in the processing stage, as a result of which there are obtained products possessing rather poor physical-mechanical properties.
It is, of course, known that one may hinder or slow down the thermal degradation of a polymer by adding to the polymer suitable substances which act as thermal stabilizers. For this purpose, there are commonly used aromatic amines, such as phenyl-1-naphthylamine and N'N'-diphenyl-p-phenylenediamine, certain aryl phosphites, such as triphenylphosphite, phenols such as 2,2'-methylenbis(4-methyl-6-t-butylphenol), 2,6-di-t-butylparacresol, 4,4'-thiobis(2-methyl-6-t-butylphenol), and other organic compounds of different types.
In general, it may happen, however, that the addition of a thermal stabilizer will reduce the photodegrading action of the transition metal compound. Thus, in most instances it becomes necessary to effect a compromise between thermal stability and photodegradability, using particular ratios between the transition metal compound and the thermal-stabilizing agent.
It is an object of the present invention to overcome these problems of the prior art, and in accordance with the invention as will be hereinafter described, this has been achieved.
BRIEF DESCRIPTION OF THE DRAWING
FIG. I is a graphical representation of the oxygen absorbing capacity of the polymeric compositions of the invention; and
FIG. II is a graphical representation of the variation with time of the carbonyl content of the polymeric compositions of the invention.
SUMMARY OF THE INVENTION
In accordance with the invention, it has now been discovered that there is a class of compounds which, when admixed with the vinyl or vinylidene polymer that has been made photodegradable by the presence of one or more of the above described transition metal compounds, are capable of having their thermal stability increased without altering to any appreciable degree their photodegradability. Consequently, it is possible to obtain polymeric compositions that possess a high thermal stability and develop a fast rate of photodegradation.
This class of compounds which is capable of thermally stabilizing the polymer without reducing the photodegrading action of the transition metal compounds are the chlorinated quinonic compounds of the formula ##STR1## wherein: X 1 is hydrogen, Cl, a C 1 -C 18 alkyl group, or a C 1 -C 21 thioalkyl, alkoxy, aryloxy, alkylcarboxy, arylcarboxy or aryl sulfonoxy group;
X 2 and X 3 each independently have the same definition as X 1 , or together constitute a bivalent radical of the formula: ##STR2## in which Z 1 , Z 2 , Z 3 and Z 4 , each independently have the same definition as X 1 .
Thus, it is an object of the invention, and the invention provides, photodegradable and thermostable polymeric compositions comprising:
a. a polymer consisting of monomeric units of the formula: ##STR3## wherein R 1 and R 2 are independently selected from the group consisting of hydrogen, C 1 -C 3 alkyl, C 6 -C 12 aryl, C 6 -C 12 cycloalkyl and chlorine;
b. at least one compound of a transition metal having an atomic number between 21 and 30, 40 and 47 and 57 and 79 inclusive, said compound being soluble in said polymer and possessing a photodegrading action on the polymer; and
c. least one compound of the formula: ##STR4## wherein X 1 X 2 and X 3 are as defined above.
Among the compounds of group (c) which are usable for the purposes of this invention, there may be mentioned tetrachloro-paraquinone (chloranil), 2-methyl-3,5,6-trichloro-paraquinone, 2-n-dodecyl-3,5,6-trichloro-paraquinone, 2-n-propyl-5,6-dichloro-paraquinone, 2,3-dichloronaphthoquinone, 2(2-benzoyl-5-octoxy-phenoxy)-3,5,6 -trichloro-paraquinone, 2-(2,5-di-t-butyl-phenoxy)-3,5 -6-trichloro-paraquinone, 2-n-pentoxy-3,5,6-trichloro-paraquinone, 2-ethoxy-3,5,6-trichloro-paraquinone, 2-(α-naphthoxy)-3,5,6-trichloro-paraquinone, 2-(pentachloro-phenoxy)-3,5,6-trichloro-paraquinone, 2-(p-toluene-sulfonoxy)-3,5,6-trichloro-paraquinone, 2-(n-dodecane-thio)-3,5,6-trichloro-paraquinone.
The preparation of the photodegradable and thermostable compositions according to the invention is carried out by adding the quinonic derivative and the transition metal compound, dissolved or dispersed in a liquid medium, to the polymer to be stabilized in the form of a powder, after which the solvent or dispersant liquid is allowed to evaporate from the homogeneous mixture thereby obtained.
Alternatively, the quinonic derivative and the transition metal compound may be added to the molten polymer, using conventional machines that are used for the preparation and processing of polymeric compositions.
There may also optionally be added to the polymer, either before or after addition of the quinonic derivatives and the transition metal compounds, one or more lubricating agents, plasticizing agents, inert fillers and pigments. In addition, conventional thermostabilizing agents may also be added, provided that they are used in such quantities as to not negatively influence the photodegrading action of the above mentioned transition metal compounds. The quinonic compounds usable for the purposes of the invention, belong substantially to the known class of derivatives of chloro-paraquinone and naphthochloro-paraquinone, the preparation of which is commonly carried out by a substitution reaction of one or more of the chlorine atoms of the quinonic or naphthoquinonic derivative, with the sodium or lithium derivative of the organic groups which are desired to be introduced into the quinonic molecule. General methods for the preparation of such compounds may also be found in "Organische Chemie", Beilstein -- Vol. VII, pages 636 and 724. The polymers that participate in the compositions of this invention, and which consist of monomeric units defined by the formula (II), include the homopolymers and copolymers of vinyl and vinylidene monomers of the formula: ##STR5## wherein R 1 and R 2 are as defined above. Examples of such polymers and copolymers are polyethylene, polypropylene, polyisobutene, polystyrene, polyvinylcyclohexane, polyvinyl chloride, and ethylenepropylene copolymers.
The polymeric compositions according to the invention may contain one or more of the above-described transition metal compounds and one or more of the above-described quinonic compounds.
The amount of transition metal compound or mixture of such compounds present in the polymeric composition, varies depending on the desired photodegrading effect and on the nature of the transition metal or metals and of the anions bound to such metals. Generally, a total amount of such transition metal compounds between 0.001 and 5% by weight, preferably between 0.01 and 0.5% by weight based on the weight of the polymer, is suitable for causing a photodegrading effect at a satisfactory rate. The chlorinated quinonic compound is also added in amounts varying according to and depending on the nature of the transition metal and of the anion bound thereto.
In general the total amount of quinonic compound is between 0.05 and 5% by weight, preferably between 0.1 and 1% by weight based on the weight of the polymer.
The polymeric compositions obtained using the above described amounts of additives exhibit, in general, a high thermal stability and a photochemical degradation rate greater than those of compositions based on vinyl or vinylidene polymers, and which are rendered photodegradable by the addition of transition metal compounds and conventional thermostabilizers.
The properties of the polymeric compositions stabilized according to the present invention, were determined on films of the composition having thicknesses of 50-100μ. The thermooxidative stability of the film was also determined at 145° C. and at an oxygen pressure of 760 mmHg, taking as the stability value the period of time necessary for inducing thermooxidation, i.e., the time after which a rapid increase in the speed of the absorption of oxygen occurs. The thermal stability was also tested on the polymer powder containing the additives in accordance with the invention. The results obtained were similar to those obtained on the film, which shows that the hot processing necessary for obtaining the films from the polymer powder does not alter to any appreciable extent the stability of the composition. FIG. (I) records the oxygen absorbing curves expressed in moles/kg. of polymer (ordinate) with time (abcissa) produced by polymeric compositions according to the invention.
The light degradation was observed by exposing the films to light in a "Xenotest 450" apparatus built by Hanau and by determining on said films the variations in concentration of carbonyl groups by means of IR spectrometry, and the variation of the mechanical properties by means of a bending at break test. The choice of the film thickness was made on the basis of using thicknesses comparable with those of films usually used as packaging materials.
With films of greater thickness it is possible to observe the degradation of the mechanical properties with a higher degree of accuracy. FIG. (II) records the curves relating to the variation with time of the content of carbonyl groups (ordinate) in (moles × 10.sup. -2 )/(liter of polymer) in polymeric compositions according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described in greater detail in the following examples, which are given merely for illustrative purposes.
EXAMPLE 1
5 grams of polyethylene of the low density type (M.I. = 2), in the form of a fine powder were admixed with 0.015 g. of chloranil and 0.005 g. of cobalt acetylacetonate. The mixing was carried out by adding to the polyethylene powder, 40 cc. of chloroform containing the chloranil and the cobalt acetylacetonate dissolved therein.
The mixture was then subjected to stirring at room temperature for 18 hours and then evaporated in vacuum under stirring in a rotating evaporation apparatus. Finally the mixture was dried for 30 minutes at 80° C. at a pressure of 0.1 mmHg.
The thus obtained powder was molded at 165° C. for 2 minutes in a press between two square steel plates (20 cm./side) and under a load of 15,000 kg. The films thereby obtained had a uniform thickness between 50 and 70μ , and were homogeneous and practically colorless.
0.2 gram of the film, cut into pieces, was introduced into a cell of about 50 cc. wherein there was subsequently introduced an oxygen atmosphere (by repeated flushing of the cell with oxygen). The cell was connected to a device for measuring the oxygen and provided with a recorder for recording the volume of absorbed oxygen. This cell was then immersed in a thermostatically controlled bath maintained at 145° C. ± 0.01° C.
The induction period was about 30 hours. The same test repeated on the powder before molding gave an induction period of 42 hours (see curve 1; FIG. I).
A few cut pieces of the film were mounted on special supports in a Xenotest 450 apparatus and exposed therein to the light of a Xenon lamp of 1600 W., filtered in such a way as to obtain an emission spectrum as close as possible to the solar spectrum of Xenon. The temperature in the exposure chamber was maintained at 50° ± 2° C., while the relative humidity was kept at 35 ± 5%. Film samples were drawn at intervals and the IR absorption at a wave length 1720 cm.sup. -1 (corresponding to the absorption of the carbonyl groups) was measured.
In order to evaluate the concentration of the carbonyl groups, there was assumed a conventional number for the molar absorption coefficient equal to 300 1/mole.cm. Curve 1 in FIG. (II) represents the index of carbonyls in the film with the passage of time. The induction period was about 60 hours.
The brittleness of the film samples was tested by simple bending. The time within which the samples became brittle was about 250 hours.
For comparative purposes, by an analogous procedure, there was prepared a composition consisting of 5 g. of the same polyethylene powder, 0.005 g. of acetylacetonate cobalt and 0.015 g. of a conventional thermal stabilizer consisting of the (3,5-di-tert-butyl-4-hydroxyphenyl)propionate of pentaerythrite.
The period of thermal induction, measured on such a composition under analoguous conditions as those used for the preceding composition, was 136 hours.
The period of photooxidation induction, measured on film cuttings of a film prepared in a press and of a comparative composition, under the above-described conditions, was about 150 hours.
The time within which such a film became brittle, measured by means of simple bending, was about 430 hours.
EXAMPLES 2-9
Proceeding as in Example 1, there was prepared a series of polyethylene films having the additives as shown in Table 1. In Table 1 are also recorded the values for the period of thermooxidization induction as well as the time required for becoming brittle under the action of light.
Curves 2 to 9 in FIG. (I) illustrate the oxygen absorption with passing time, while curves 2 to 9 in FIG. (II) show the course of the index in carbonyls in the obtained films.
TABLE 1__________________________________________________________________________ Chlora- Metal com- nil(wt. Other addi- Time necessary pound (wt. % based tives (wt.% Thermal Induc- for becomingEx- % based on on poly- based on tion period brittle underample polymer) mer) the polymer) (hrs.) light (hrs.)__________________________________________________________________________2 *Co(acac).sub.3 -- -- 0 345 0.13 Co(acac).sub.3 -- -- 0 513 0.014 Co(acac).sub.3 -- **BHT 0.02 0 240 0.15 -- -- -- 5.6 11006 -- 0.1 -- 7.5 8007 -- 0.3 -- 36.4 7508 Co(acac).sub.3 0.1 BHT 0.02 7.7 240 0.19 Co(acac).sub.3 0.3 -- 39.3 362 0.01__________________________________________________________________________ *Co(acac).sub.3 = acetylacetonate of cobalt. **BHT = 2,6-ditert-butylparacresol (thermal stabilizer).
EXAMPLES 10-15
Operating according to the procedures of Example 1, a series of films was prepared from polyethylene and containing one or more of the following additives as set forth in Table 2:
A. bis(2-benzoyl-5-octoxy-phenate)titanium dichloride;
B. ferric 2-benzoyl-5-octoxy-phenate;
C. bis(2,5-di-tert-butyl-3-hydroxybenzyl-ethylphosphate) titanium-dicyclopentadienyl;
D. ferric p-n-dodecylbenzene-sulphonate;
E. bis(2,5-di-tert-butyl-3-hydroxybenzyl-ethylphosphate) dititanile; ##STR6## 2-(2-benzoyl-5-octoxy-phenoxy)-3,5,6-trichloro-paraquinone.
The preparation of compound (F) was carried out by reacting 2-hydroxy-5-octoxy-benzophenone in methylalcohol solution with an approximately equimolar amount of tetrachloroparaquinone (chloranil) dissolved in benzene, in the presence of sodium metal and in a nitrogen atmosphere.
The tetrachloroparaquinone solution was added dropwise at about 50° C. to the solution of the benzophenone derivative, and the reaction mixture was allowed to react for about 12 hours at 75° C. At the end of the reaction period, the precipitated sodium chloride was eliminated by filtering and the 2-(2-benzoyl-5-octoxyphenoxy)-3,5,6-trichloroparaquinone was recovered by bringing the solution to dryness.
Table 2 records, for each example, the additives used, the thermal oxidation induction periods and the times required for the samples to become brittle under light.
TABLE 2__________________________________________________________________________ Metal com- pound (wt. % based on Quinone deriva- Period of ther- Time necessary toEx- the poly- tive (wt.% based mal induction become brittleample mer) on the polymer) (hrs.) under light (hrs.)__________________________________________________________________________10 (A) 0.3 Chloranil 0.1 7 48511 (B) 0.1 Chloranil 0.1 7 50012 (C) 0.1 Chloranil 0.3 15 430 + Co(acac).sub.3 0.113 (D) 0.1 Chloranil 0.3 7.3 69014 (E) 0.2 Chloranil 0.1 26.8 450 + Co(acac).sub.3 0.115 Co(acac).sub.3 (F) 0.3 15.4 400 0.1__________________________________________________________________________
EXAMPLES 16-18
To a polyethylene (low density type, M.I. = 2), loaded with 2% by weight of titanium dioxide, were added, according to the same procedures followed in Example 1, the metal compound and the chlorinated quinone derivative, as reported in Table 3.
The mixture was molded into a film with a mean thickness of 100μ by extrusion and blowing at 180° C.
The time necessary for becoming brittle under light was determined on a sample of the film. For comparison purposes, the same value was measured on a similar polyethylene having 2% by weight of titanium dioxide, but no chlorinated quinone (Example 16).
TABLE 3______________________________________ Chloranil (wt.% Period necessaryEx- TiO.sub.2 Metal compound (wt. based on for becomingam- (wt. % based on the the poly- brittle underple %) polymer) mer) light (hrs.)______________________________________16 2 -- -- 75017 2 Co(acac).sub.3 0.08 0.3 39018 2 *(A) 0.3 0.1 390______________________________________ *See Examples 10 - 15.
EXAMPLES 19-20
Operating as in Example 1, there was prepared a polypropylene film (M.I. = 3.5) having the additives indicated in Table 4. The experimental data obtained are compared in Table 4 with those of the same polypropylene without the additives.
TABLE 4______________________________________ Chloranil (wt.% Period for Time necessaryEx- Metal compound based on thermal in- for becomingam (wt.% based on the poly- duction brittle underple polymer) mer) (hrs.) light (hrs.)______________________________________19 -- -- 0 8020 Co(acac).sub.3 0.1 0.3 7 65______________________________________
EXAMPLES 21-49
The following chlorinated quinone derivatives were used:
G. chloranil (in quimolar admixture with anthracene as dispersant)
H. chloranil (in equimolar admixture with 1,2,4,5 tetramethyl-benzene as dispersant)
I. 2-n-pentoxy-3,5,6-trichloro-paraquinone
L. 2-ethoxy-3,5,6-trichloro-paraquinone
M. 2-(α-naphthoxy)-3,5,6 trichloro-paraquinone
N. 2-(pentachloro-phenoxy)-3,5,6-trichloro-paraquinone
O. 2-(p-toluene-sulfonoxy)-3,5,6-trichloro-paraquinone
P. 2-(2,5-di-t-butyl-phenoxy)-3,5,6-trichloro-paraquinone
Q. chloranil (in equimolar admixture with pyrene as dispersant)
R. 2-(n-dodecane-thio)-3,5,6-trichloro-paraquinone
The quinone derivatives from (I) to (R) were prepared in the same way in which compound (F) was prepared, using respectively n-pentanol, ethanol, α-naphtol, pentachlorophenol, p-toluen sulfonic acid, 2,5-di-t.butyl phenol and n-dodecanthiol instead of 2 -hydroxy-5-octoxy-benzophenone.
To a polyethylene (low density type, M.I. = 2), loaded with 2% by weight of titanium dioxide, were added, by mixing in a roller mill at a temperature of 120° C. for three minutes, the metal compounds and the chlorinated quinone derivatives, as reported in Table 5.
By using the mixture thus obtained and operating according to the procedures of Example 1, a series of films was prepared with a mean thickness of 70-100μ .
In Table 5 are recorded the values for the period of thermal induction as well as the time required for becoming brittle under the action of light.
TABLE 5______________________________________ Time neces-Metal com- Quinone deri- Period of sary toEx- pound (wt.% vative (wt.% thermal become brit-am- based on based on poly- induction tle underple polymer) mer) (hrs.) light (hrs.)______________________________________21 -- (G) 0.17 30.5 92022 Co(acac).sub.3 0.1 (G) 0.17 31 42523 *Co(bop) 0.3 (G)0.17 33.5 42524 **Fe(naph) 0.3 (G) 0.17 2.3 17025 Co(bop)0.3+ Fe(naph) 0.3 (G) 0.17 42 16026 ***Fe(acac).sub.3 0.2+ Fe(naph) 0.3 (G) 0.17 3.5 170+ Co(bop) 0.227 -- (H) 0.15 22 75028 Fe(naph) 0.1 (H) 0.15 4.5 40029 -- (I) 0.3 35 75030 Co(acac).sub.3 0.1 (I) 0.3 30.7 45031 Co(bop) 0.3 (L) 0.3 greater 330 than 5532 Co(bop) 0.1 (L) 0.3 greater 500 than 5533 Fe(naph) 0.1 (L) 0.3 19.5 42034 Fe(naph) 0.3 (L) 0.3 9 36035 Co(acac).sub.3 0.1 (M) 0.3 20.8 45036 Fe(naph) 0.3 (M) 0.3 6 40037 -- (N) 0.3 38.5 77038 Fe(naph) 0.3 (N) 0.3 3 40039 -- (O) 0.3 23 55040 Co(acac).sub.3 0.1 (O) 0.3 5 35041 -- (P) 0.3 greater 920 than 2642 Co(acac).sub.3 0.1 (P) 0.3 greater 615 than 1543 -- (Q) 0.17 27 75044 Co(acac).sub.3 0.1 (Q) 0.17 17.3 50045 Fe(naph) 0.3 (Q) 0.17 4.5 48046 Co(bop)0.2 + (Q) 0.17 8 500+ Fe(naph) 0.347 -- (R) 0.3 greater 920 than 7048 Fe(naph) 0.3 (R) 0.3 15 36549 Fe(acac).sub.3 0.15 ++ Fe(naph) 0.15 (R) 0.3 6.5 350______________________________________ *Co(bop) = 2-benzoyl-5-octoxy-phenate of cobalt **Fe(naph) = ferric naphthenate ***Fe(acac).sub.3 ferric acetylacetonate
Variations and modifications can, of course, be made without departing from the spirit and scope of the invention.
Having thus described our invention, what we desire to secure by Letters and hereby claim is.
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Disclosed are photodegradable and thermostable polymeric compositions based on a vinyl or vinylidene polymer such as polyethylene or polypropylene, at least one compound of a transition metal which is soluble in said polymer and which has photodegrading properties with respect to the polymer and at least one halogenated p-quinoid compound.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
Such a three-side stacker has become known from U.S. Pat. No. 4,470,750, the entire contents of which are hereby incorporated by reference in its entirety, for instance. For instance, it is used as a storage rack conveyor. A side push or guide frame is arranged on the front end, transversely to the longitudinal axis of the apparatus. Depending on the type, the side push frame is connected stationarily with the vehicle or guided in the height on a lifting mast or so. Finally, it is also possible to fix the side push frame on the front side of the cab of the vehicle, which is itself as a whole traversable in the height on the lifting mast. In this case, the three-side stacker represents an order picking apparatus. A side arm is horizontally traversable on the side push frame. The side arm consists of two portions, namely a first portion, which is guided on the side push frame, and a second portion, which is mounted to be rotatable around a vertical axis. On the second portion, there is either directly attached a holder for a load supporting means, a fork for instance, or an additional mast, for instance, on which the fork holder can be traversed in the height. With the aid of a drive, which is preferably a hydraulic one, the second portion and with this the load fork or the mast, respectively, can be pivoted around a vertical axis in an angle range of 0 to 180°. The pivoting drive has parallel hydraulic cylinders, which actuate a chain, which is turn wound around a sprocket. The sprocket is splinedly connected with a shaft portion, which is mounted in a rotational bearing of the side arm and is connected with a lifting scaffold. The hydraulic lines for the supply of the drives on the movable parts are integrated and guided in a suitable manner, such that they can follow the horizontal and rotational movement of the side arm or the lifting scaffold, respectively. Toothed racks, arranged parallel in a distance and running horizontally, are attached on the side push frame, with which sprockets or gearwheels on the side arm co-operate. The sprockets or gearwheels sit splinedly on a common torsion shaft, which is in turn driven by a suitable drive. With the aid of this drive, the side arm can be moved horizontally. The torsion shaft provides also stabilisation around an axis parallel to the longitudinal axis of the vehicle.
The rotational drive for the holder for a load receiving means or a mast on the side arm of the side push frame, respectively, requires a high expense for assembly and maintenance, as well as a big number of individual components. In addition, the drive needs a relatively large installation space.
The present invention is based on the objective to improve a three-side stacker of the type mentioned in the beginning, such that the drive for a lifting scaffold or a holder for a load receiving means on the side arm of the side push frame, respectively, needs a smaller number of individual components and requires less expense in the assembly.
BRIEF SUMMARY OF THE INVENTION
In the present invention, the casing of a hydraulic rotational drive is fixed on the first portion of the side arm. The hydraulic rotational drive has a lathe spindle, which stays outside the casing with a portion on which a holder or a lifting scaffold for the load supporting means is splinedly attached. The casing can be attached without problems on that arm of the side arm which is coupled to the side push frame. It is only required to provide the outside positioned portion of the lathe spindle of the hydraulic rotational drive with means for attaching the pivoting body thereon, which is pivotable about an angle of approximately 180°, according to the principle of the three-side reach truck. In the case that the body has a lifting scaffold and also a lifting cylinder for the actuation of the load supporting means along the lifting scaffold, care must also be taken for a hydraulic supply of the lifting cylinder.
According to an embodiment of the present invention, it is provided for this purpose that the rotational drive is realised as a rotary transmission leadthrough for the line of the hydraulic medium towards the lifting cylinder and away from the same, wherein an axial channel in the spindle is in every position of the spindle connected with a stationary hook-up on the casing for the hydraulic medium, and the axial channel is connected with the lifting cylinder. Such a supply of the hydraulic medium avoids the use of a hydraulic tube. As is known, movable tubes are a source of troubles and errors, in particular when the actuated part performs a turning or swivelling movement, respectively.
In a further embodiment of the idea pointed out before, the present invention provides that the spindle of the rotational drive is actuable by a threaded sleeve, which is in turn actuable by a plunger which is guided in the casing of the rotational drive. The channel in the spindle is connected with at least one radial channel in a flange of the spindle, which is sealingly and rotatably mounted in the casing, wherein the radial channel is aligned with an annular channel on the inner side of the casing, which is in connection with the outer hook-up for the hydraulic medium on the outer side of the casing via bore portions. A hydraulic drive of the described kind is per se known. It is only slightly modified so that it can be used as a rotational drive for the pivotable lifting scaffold of a three-side stacker, for instance.
In another embodiment of the present invention, it is provided that a bottom part for the lifting cylinder is connected with the free end of the spindle, on which the envelope of the lifting cylinder is sealingly supported.
In the drive equipment according to the invention for the load supporting means or the lifting scaffold of a three-side stacker, respectively, it is advantageous when the respective turning position can be determined. As a consequence, one embodiment of the present invention provides that a transmitter is connected with the spindle, and an angle sensor is arranged in the casing. Different mechanical or contactless arrangements of sensor and transmitter are conceivable. According to a further embodiment of the present invention, a particularly simple measure is that a gearwheel sits on the spindle, which meshes with a sprocket of a potentiometer.
Several advantages are attained by the present invention. The installation frame for the pivoting drive is extremely small and permits to place the side push frame further downward, through which the visible edge is moved towards the downside and thus it improves the sight on the fork arms. Even in the horizontal direction, a reduction of the installation space is possible. The assembly and the maintenance are improved with respect to conventional drives, not at least by the reduction of the number of the individual parts. A very important advantage is that the force which is exerted by the mast or the load supporting means is directly taken up by the spindle. Through this, the rotational drive is not only a driving means but also a force receiving means.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The present invention is explained in more detail by means of drawings below.
FIG. 1 shows a side push frame with side arm for a three-side stacker according to the invention in a perspective view.
FIG. 2 shows a final view of the representation according to FIG. 1 .
FIG. 3 shows schematically a rotational drive for the arrangement according to FIGS. 1 and 2 in a cross section.
FIG. 4 shows a perspective view of the side push frame with side arm for a three-side stacker shown in FIG. 1 .
FIG. 5 shows a perspective view of the side push frame with side arm shown in FIG. 4 with the fork rotated 90 degrees.
FIG. 6 shows a cross-sectional view of the embodiment shown in FIG. 4 .
FIG. 7 shows a cross-sectional view of the embodiment shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
While this invention may be embodied in many different forms, there are described in detail herein a specific preferred embodiment of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiment illustrated
In the FIGS. 1 and 2 , a side push frame 10 of a three-side stacker is designated with 10 . The three-side stacker is not shown for the rest. Insofar, reference is made to U.S. Pat. No. 4,470,750, for instance. The side push frame 10 is fixed horizontally on the front side of the three-side stacker, for instance on the vehicle itself or on a lifting mast or even on a cab, which is height-movably guided on the lifting mast.
The side push frame has a frame profile 12 , U-shaped in its cross section, through which a channel 14 is formed. On the upper side of the frame profile 12 , a flat rail 16 is fixed. A toothed rack 18 is fixed on the rail 16 . Rail 16 and toothed rack 18 run horizontally. A further flat rail is fixed on the lower side of the frame profile 12 . A toothed rack 22 is fixed on the rail 20 . The toothing of the toothed rack 22 does not extend completely over the width of the rack, instead a slightly retracted portion 24 is provided, which a forms a horizontally extending vertical running path 26 . On the side directed towards the toothing of the toothed rack 18 , the rail 16 forms also a running path 28 . This one too is somewhat retracted against the toothing of the toothed rack 18 . The running paths 26 , 28 extend in a common plane. However, they can also be in parallel planes. In addition, they run in parallel to the parallel toothed racks 18 , 22 .
A side arm 30 , generally extending vertically to the frame profile 12 , has an upper mounting plate 32 and a lower mounting plate 34 , which are fixed on a stable casing, which is indicated at 36 . The mounting plates 32 , 34 rotatably bear a torsion shaft 38 , on which an upper gearwheel 40 and a lower gearwheel 42 are splinedly arranged. The gearwheels 40 , 42 mesh with the toothing of the toothed racks 18 , 22 . The torsion shaft 38 is rotationally driven by a hydraulic drive 46 . On the mounting plate 32 , two guide rollers are rotatably mounted around a vertical axis on the lower side, one of which can be recognised at 50 in FIG. 2 . The guide rollers 50 co-operate with a guideway of the toothed rack 18 , which is on the rear side in FIG. 1 . On the lower mounting plate 34 , two guide rollers are also rotatably mounted, one of which is shown in FIG. 2 at 52 . They co-operate with a guideway on the backside ( FIG. 1 ) of the toothed rack 22 . The guide rollers 50 , 52 take up the weight momentum of the side arm 30 around an axis parallel to the longitudinal axis of the side push frame 10 .
In the mounting plate 32 , a further guide roller 54 is rotatably mounted around a horizontal axis. It co-operates with an upper guideway of the toothed rack 18 and takes up the weight force of the side arm. Preferably, two such rolls can also be provided.
An arm 58 is fixed on the casing 36 of the side arm 30 , extending horizontally on the lower end, on which a further mounting plate 60 is fixed, which extends transversely. The mounting plate 60 carries a hydraulic rotational drive 66 via an upper arm 62 or a lower arm 64 . Via a block 68 , its casing supports a lifting mast 70 , into which a lifting cylinder 72 is inserted, which is in turn supported on the block 68 . With the aid of the rotational drive 66 , the lifting mast 70 can be turned around a vertical axis 72 a , preferably between 0 and 180° or 0 to ±90°. On the lifting mast 70 , a sliding cradle or fork carrier 76 is guided in the height, which can be shifted in the height with the aid of a not shown chain and the lifting cylinder 72 . Such a lifting drive is commonly known in floor conveyors, and thus it will not be described in more detail. In FIG. 1 or 2 , a mounting for a sensor is indicated at 78 , by which the lifting height of the sliding cradle 76 is determined.
The supply of hydraulic energy for the drives 46 , 66 and the cylinder 72 has naturally to take place from the carrier vehicle, wherein the hydraulic lines are integrated in a corresponding manner (not shown) and are guided through the profile frame 12 . They can be guided in a loop (not shown), which is moved in the channel 14 , so that the side arm 30 can freely move along the side push frame 10 .
As can be further recognised in FIGS. 1 and 2 , an upper spacer roller 86 and a lower spacer roller 88 sit on the torsion shaft 38 . The spacer roller 86 rolls on a guideway 26 , 28 . With the aid of the spacer rollers 86 , 88 , a predetermined distance between the gearwheels 40 , 42 and the toothed racks 18 , 22 is set.
In FIG. 3 , the hydraulic rotational drive 66 is shown in some more detail. One recognises a casing 100 , which is connected via the lugs 62 , 64 with the mounting plate 60 , as has already been described. The casing mounts a spindle 101 , which consists of the portions 102 , 104 , 106 , 108 , 110 and 112 . The mentioned portions are either part of a workpiece formed in one part or splinedly connected with each other. A flange 114 is connected with the lower portion 102 , which has not shown seals which co-operate with a casing bore 116 . The portion 106 , provided with a greater radial diameter, is axially mounted in the casing 100 with the aid of an upper and a lower nail bearing 118 , 120 , so that the spindle is rotatable, but axially stationary. In the casing bore 116 , a threaded sleeve 122 is arranged, which is provided with a not shown inner and outer thread, which threads are realised as being relatively steep. The inner thread of the threaded sleeve co-operates with an outer thread (not shown) of the portion 104 , and the outer thread of the threaded sleeve 122 co-operates with a thread in the bore 116 , wherein the threads are directed contrarily on radially opposing sides of the sleeve. Further, a plunger 124 is connected with the threaded sleeve 122 , which can be pressurized with hydraulic fluid from opposing sides. The hydraulic fluid is fed via hook-ups 126 and 128 ( FIG. 2 ). The lines to the hook-ups 126 and 128 are not shown. As a consequence, the plunger 124 moves in the axial direction upon pressurization, and thus the linear motion of the plunger 124 is transformed into a rotational movement by the threaded sleeve and the spindle. Such a drive is in principle known. Through the co-operation of two pairs of threads, it is possible to produce the desired rotational movement about an angle of 180° and more with a relatively small stroke.
As can be seen from FIG. 2 , the casing of the rotational drive 66 has an additional hook-up 130 for hydraulic medium. It is connected with a first bore portion 132 in the casing 100 , which is connected with an axis parallel bore portion 134 . The vertical axis parallel bore portion 134 is in connection with an annular groove 136 on the inner side of the casing 100 . Several radially or beam-shaped, respectively, channels 138 run out into the annular groove 136 . The channels 138 run out into an axial channel 140 , which extends towards the upside through all the portions of the spindle 101 up to portion 112 inclusively. Towards the downside, the axial channel 140 is closed by a stopper 142 . Through this, a rotary transmission leadthrough is provided. The hydraulic medium reaches the rotating spindle from the stationary hook-up 130 .
The spindle portion 110 forms a bottom part for the lifting cylinder 72 , wherein the portion 112 , which is smaller in its diameter, is sealingly inserted into the envelope of the cylinder 72 . The ring 69 ( FIG. 2 ) is screwed on the outer thread of portion 110 and thus it fastens the block 68 on the conical portion 108 . The mast 70 is fixed on the block 68 . The hydraulic medium is directly introduced into the lifting cylinder 72 . The spindle portion 108 , conical in its upper region and thereafter cylindrical, carries the lifting mast 70 , which is not shown in more detail in FIG. 3 .
As a consequence, when the hydraulic rotational drive according to FIG. 3 is actuated, the spindle 101 and with it lifting mast 70 and lifting cylinder 72 are rotated about a desired amount around the vertical axis 72 a . Stops which limit the rotation are internally present in the rotational drive and therefore they have not to be provided separately.
With the lower side of the flange 114 , a gearwheel 144 is splinedly connected, which meshes with a sprocket (not shown) which drives a not shown potentiometer. Thus, the respective turning position of the lifting mast 70 or the lifting cylinder 72 can be determined with the aid of such an arrangement.
FIGS. 4 and 5 each show a perspective view of an embodiment of the invention as shown in FIG. 1 . FIG. 5 shows the fork carrier 76 rotated 90 degrees from its position in FIG. 4 . FIGS. 6 and 7 show a cross sectional view of the embodiment as shown in FIGS. 4 and 5 , respectively. Here, the actuation of mast 70 as described above can be seen. The sleeve 122 has an inner and outer thread. The outer thread engages a thread of the casing bore 116 , and the inner thread engages a thread of spindle 101 . The spindle 101 through portion 112 engages a member 68 , which in turn is rotationally fixed with respect to mast 70 . A plunger 124 is connected with sleeve 122 . If plunger 124 is moved upwardly or downwardly, the sleeve is rotated accordingly and drives spindle 101 rotationally. Thus, mast 70 is rotated as desired. This is described in the specification at pages 7-8, and no new matter has been introduced.
The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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A three-side stacker with a side push frame at one end of the stacker, on which a side arm is horizontally traversable mounted, wherein the side arm has a first traversable portion mounted on the side push frame and a second portion, which is mounted pivotally around a vertical axis on the first portion and on which a load supporting means is mounted, which is actuable by a hydraulic lifting cylinder, and a pivoting equipment for the second portion, mounted on the first portion, wherein the casing of a hydraulic rotational drive with a rotatable spindle is fixed on the first portion, wherein a portion of the spindle is splinedly connected with a holder or a lifting scaffold for the load supporting means outside the casing.
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RELATED APPLICATION
This application claims priority to Australian Application No. 2005902847, filed Jun. 2, 2005, the content of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to an alignment aid for the manual alignment of the towing hitch of a trailer, caravan, boat trailer, horse float or the like with the tow-ball of a vehicle. In particular although not exclusively the present invention relates to a trailer alignment apparatus suited to a jockey wheel assembly which temporarily supports the towing hitch of the trailer.
BACKGROUND ART
Typically trailers, caravans, boat trailers, horse floats and the like are provided with a jockey or manoeuvring wheel assembly. The wheel assembly is provided to facilitate movement of the trailer over relatively short distances. The wheel assembly typically includes a raising and lowering mechanism for both levelling of the trailer, and the engagement of and/or removal of the towing hitch from the tow-ball.
Manually manoeuvring of the trailer via the jockey wheel is relatively simple when the trailer is carrying a light load. However in instances where the trailer is carrying a large load, manual manoeuvring the trailer can be exceedingly difficult. In such situations the trailer may escape the control of a person manoeuvring the trailer and start to freewheel. This freewheeling can result in the trailer colliding into the towing vehicle, or worse still running down the person manoeuvring the trailer. Accordingly, a number of jockey wheel manufacturers have implemented several arrangements in order to aid manoeuvring and to reduce the risk of freewheeling.
One such arrangement is disclosed in WO 2004037567 entitled ‘Jockey Wheel Assembly’, which describes a jockey wheel assembly having a drive system including a crank coupled to a rotatable shaft which is inturn coupled to the wheel hub. Rotation of the crank causes rotation of the shaft, this rotation then being translated into linear movement by the wheel, in a forward or reverse direction depending on the direction of rotation of the crank. The assembly is also provided with a tiller which enables the user to control the direction the wheel is facing and thus control the direction of movement of the trailer. The problem with such an arrangement is that it utilises a number of gears and these gears under the strain of moving such large loads are prone to wear, sheering and slippage, which can lead to a momentarily loss of control over the trailer. This momentary loss of control may be all that is required to cause the trailer to freewheel.
Another example of such a jockey wheel assembly is disclosed in AU 2002100165 to Ark Engineering Pty Ltd entitled ‘Jockey Wheel’. The assembly includes a frame mountable on a trailer, a wheel frame and a lever arm. The lever includes a ratchet arm which mates with a corresponding pawl mounted on the frame. The pawls being operable upon pivotal movement of the lever to selectively move or restrain rotation of the wheel in the frame. Again such an arrangement utilises a complex mechanical arrangement which is prone wear to shearing and slippage.
Furthermore in both the above arrangements the tyre of the jockey wheel is prone to slip on the wheel hub when the hub is mechanically driven. Such a slippage again can lead to the trailer freewheeling. If the tyre is a pneumatic tyre this slippage can tear out the valve stem leading to deflation of the tyre requiring the replacement of the stem or entire inner tube.
Clearly it would be advantageous to provide an alignment apparatus which substantially ameliorates one or more of the aforementioned problems and that is relatively simple to manufacture and use.
SUMMARY OF THE INVENTION
Accordingly in one aspect of the invention there is provided an apparatus for manoeuvring a trailer having a jockey wheel assembly comprising a ground engaging wheel rotatably mounted on an axle said apparatus comprising:
a lever assembly adapted to engage the peripheral surface of said wheel, whereby movement of said lever thereby rotates said wheel.
In another aspect of the invention there is provided an apparatus for manoeuvring a trailer having a jockey wheel assembly a ground engaging wheel rotatably mounted on an axle, said apparatus comprising:
a link member pivotally mounted on the jockey wheel assembly adjacent the axle; and a lever assembly removably securable to said link and adapted to engage a peripheral surface of said wheel, whereby movement of said lever rotates said wheel.
In a further aspect of the present invention there is provided a method of manoeuvring a trailer having a jockey wheel assembly comprising a ground engaging wheel rotatably mounted on an axle, said method comprising the steps of:
positioning a lever assembly on a peripheral surface of said wheel; applying a force to said lever assembly whereby said lever assembly grips the peripheral surface of said wheel thereby causing rotation of said wheel.
In another aspect of the invention there is provided a method of manoeuvring a trailer having a jockey wheel assembly comprising a ground engaging wheel rotatably mounted on an axle, said method comprising the steps of:
pivotally mounting a link on the wheel assembly adjacent the axle; coupling a lever assembly to said link, such that said lever assembly engages a peripheral surface of said wheel; and applying a force to said lever assembly, so as to cause said lever to rotate said wheel.
In a further aspect of the present invention there is provided an alignment apparatus for manoeuvring a trailer having jockey wheel assembly comprising a ground engaging wheel rotatably mounted on a hollow axle, said apparatus comprising:
a link member coupled to a lever assembly adapted to engage a peripheral surface of said wheel, said link member adapted for insertion into said hollow axle to thereby pivotally mount the link member and lever assembly on the jockey wheel assembly; and whereby, upon insertion of the link member into said hollow axle, lateral movement of the lever assembly directs the wheel on a desired direction of travel and, upon the lever assembly engaging said wheel, rotation of the lever about the pivotal mount acts to rotate the wheel for manoeuvring the trailer in the desired direction of travel.
Preferably the lever assembly includes a handle and a wheel engagement portion disposed at one end of the handle. The lever assembly may be manufactured from high grade carbon steel, or other such suitable material capable of withstanding the shear forces generated during movement of a heavily laden trailer or the like. Suitably the handle has a plurality of apertures disposed at a predetermined distance from the pad.
The wheel engagement portion may be in the form of a pad. The pad may be any suitable closed shape such as a square, rectangle, hexagon, pentagon, triangle or circle. Most preferably the pad is substantially circular in shape. Suitably the pad may be coated with a material having a relatively high co-efficient of friction such as vulcanised rubber or the like. The pad may be provided with a formation, such as series of grooves that match the shape of the peripheral surface wheel to further increase the frictional engagement therebetween.
Alternatively the wheel engagement portion may take the form of a tooth or the like wherein said tooth is shaped for complementary engagement with the peripheral surface of the wheel. Suitably the peripheral surface of the wheel is in the form of a treaded tyre.
Suitably the link member is pivotally mounted on the outside of the wheel assembly, or on the inside wheel assembly between the wheel mount and the wheel by any suitable fastening means such as a bolt or cotter pin. Preferably the link is mounted adjacent the axle. Most preferably the link is mounted on the axle of the wheel assembly.
Preferably the link is a single elongate member. Alternatively the link may be formed from a plurality of interlinked members. The link may include one or more mounting plates secured the end of the link. In the case where the axle is hollow the link member is preferably in the form of a rigid C-shaped bar wherein one arm of the bar is coupled to the lever assembly and the remaining arm is adapted for insertion into the hollow axle.
Preferably the link extends about a portion of the wheel forming a space therebetween into which the lever can be inserted. The link may have a pin slideably mounted thereon, said pin being inserted into one of the plurality of apertures provided in the handle, to thereby secure the lever assembly to the link in a removable manner.
Alternatively the link may extend from the frame adjacent the wheel, the lever then being positioned on the wheel and adjacent the link. The link may also include a plurality of apertures through which a pin may be inserted, the pin then being passed through a corresponding aperture provided on the handle of the lever assembly, to thereby secure the lever assembly to the link in a removable manner.
The apparatus may further include a braking assembly mounted on the frame that is selectively engagable with the peripheral surface wheel. Suitably the braking assembly includes a brace and a plate. The plate may include a tail for engagement with the brace and a tip for engagement with the peripheral surface wheel. Preferably the plate is positioned within the wheel mount. The brace may include a lever coupled to a pin. Suitably the pin is U-shaped with one arm of said U passing through the wheel mount.
BRIEF DETAILS OF THE DRAWINGS
In order that this invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings, which illustrate preferred embodiments of the invention, and wherein:
FIG. 1 is a schematic diagram showing one possible arrangement of a lever and a pin of a trailer alignment apparatus according to an embodiment of the present invention;
FIG. 2 is a schematic diagram depicting the trailer alignment apparatus according to one embodiment of the present invention in position on a jockey wheel assembly;
FIG. 3 is a schematic diagram depicting the trailer alignment apparatus of FIG. 2 during the driving stroke;
FIG. 4 is a schematic diagram depicting the trailer alignment apparatus of FIGS. 2 and 3 during the return stroke upon completion of the driving stroke;
FIG. 5A is a schematic diagram depicting the alignment aid mounted on a jockey wheel assembly according to a further embodiment of the present invention;
FIGS. 5B to 5G depict the stages in operation of another arrangement of a braking mechanism for use with the trailer alignment apparatus of the present invention;
FIG. 6 is a schematic diagram depicting a still further embodiment the trailer alignment apparatus mounted on a jockey wheel assembly according to the present invention;
FIG. 7A is a perspective view of a link member according to one embodiment of the present invention;
FIG. 7B is a schematic view of a link member according to a further embodiment of the present invention;
FIG. 7C is a perspective view of a link member according to a still further embodiment of the present invention; and
FIGS. 8A to 8C illustrate stages in operation of a further embodiment of the trailer alignment apparatus of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 there is illustrated an embodiment of the lever 10 for an alignment apparatus of the present invention. The lever includes handle 11 and pad 12 and a plurality of apertures 13 a - d disposed along the handle at varying locations. Apertures 13 a - d are provided so as to allow a pin 14 to be inserted therethrough. Pin 14 is adapted to pass through an aperture 21 in link 20 (see FIGS. 2 and 7A ) thereby securing the lever 10 in a removable manner to link 20 . The amount of purchase on the tyre 39 of the wheel 33 imparted by lever 10 is proportional to the distance of the pad to the aperture 13 a - d at which the pin 14 is inserted. For example the maximum available purchase is provided when the pin 14 is inserted into the furthermost aperture 13 a.
Pad 12 may be any suitable shape such as a square, rectangular, hexagonal, pentagonal or circular. However the pad 12 is most preferably substantially circular in shape. Providing a circularly shaped pad allows the lever 10 to be utilised through a wider range of angles θ to the vertical (see FIG. 6 ). This is particularly the case as discussed below in relation to FIG. 6 when the link is in the form of a tensile cable 23 . In addition the pad may be provided with a frictional coating on its engagement face in order to increase the amount friction between the pad 12 and wheel 33 when engaged, thereby further increasing the amount of purchase on the wheel 33 during the lever's movement stroke. Alternatively the face of the pad 12 may be provided with a series of grooves that match or at least co-operate with the peripheral surface of the wheel 33 . Upon engagement the pad with the wheel 33 the pad 12 is inserted within the corresponding groove thereby further increasing the amount of purchase on the wheel 33 during the movement stroke.
FIG. 2 depicts the trailer alignment apparatus of one embodiment of the present invention positioned on a jockey wheel assembly 30 which is attached to the trailer's A frame (not shown). The wheel assembly 30 includes wheel 33 having a treaded tyre 39 supported on axle 34 within a wheel mount 32 and an extendable support 31 . Link 20 is pivotally mounted at point 22 on wheel mount 32 adjacent the axle 34 . In use lever 10 is positioned adjacent the link 20 with pad 12 engaging the periphery of wheel 33 , namely the treaded surface of tyre 39 . Pin 14 is then inserted through aperture 21 in link 20 into one of the corresponding apertures 13 a - d in handle 11 (in this instance aperture 13 b ).
In order to align the towing hitch of the trailer with the tow ball the wheel 33 is inched forward by drawing down handle 11 as shown in FIG. 3 . As handle 11 is drawn down by a user through a driving stroke in the direction of arrow 35 , pad 12 grips the tyre 39 of wheel 33 thereby forcing it against the hub. Link 20 in turn pivots with the movement of lever 10 thereby causing pad 12 to rotate wheel 33 in the desired direction 36 to draw the trailer linearly in this case the forward direction.
Upon the lever 10 reaching the apex of the driving stroke (i.e. pad 12 is brought into contact with the ground), the pressure is released form handle 11 and pad 12 is removed from the tyre see FIG. 4 . The lever 10 and link 20 are then returned to their positions prior to the commencement of the downward stroke 35 as illustrated in the dashed outline. The lever 10 may then be engaged with the wheel 33 ready for the next downward driving stroke 35 . This process is then repeated until the towing hitch is positioned above or at least adjacent to the tow ball.
With the arrangement of the alignment apparatus as discussed with reference to FIG. 1 to 4 , lever 10 may also be used to brake the wheel 33 . By applying a sufficient downward force on handle 11 , pad 12 is wedged against the tyre 39 forcing it against the hub preventing movement of wheel 33 . Applying this type of braking to the wheel 33 steadies the trailer and reduces unwanted movement until the wheels of the trailer can be chocked. Once the chocks are in position the force may be released from handle 11 thereby disengaging pad 12 from wheel 33 . The lever 10 and link 20 may then be returned to their initial position ready for the next downward stroke 35 as discussed above.
In a further embodiment the jockey wheel assembly may alternatively be fitted with braking mechanism 37 as shown in FIG. 5A . The braking mechanism is engaged with the wheel 33 prior to removal of pad 12 . Upon re-engagement of the pad 12 with wheel 33 at the top of the movement stroke (shown in dashed outline) brake 37 is released, and handle 11 drawn downward to impart movement of wheel 33 in the desired direction 36 .
FIGS. 5B to 5F illustrate another possible arrangement of the braking mechanism for use with the alignment aid of the present invention. In this instance the braking mechanism includes a brace 40 and plate 38 which in the present case is positioned within the wheel mount 32 . Brace 40 is includes a lever 41 which is coupled U-shaped pin 42 . The plate 38 as shown includes a tail 45 for engagement with the brace, a tip 44 for engagement with the surface of the tyre 29 . The tip being connected to the main body of the plate 38 via neck 43 .
In FIGS. 5B and 5C the braking mechanism is shown in the locked position with tail 45 positioned over both arms of the u-shaped pin 42 . In this position the main body of the plate 38 is free to rest upon the tyre 29 with the tip being elevated above the tyre 29 see FIG. 5C . In the locked position the breaking mechanism allows the wheel to move in the forward direction only. Any movement of the wheel in the opposing direction forces the plate 38 back toward the wheel mount 32 forcing tail 45 away from the external arm 42 a of pin 42 see FIG. 5B . This causes the neck 43 to engage the wheel mount 32 forcing tip 44 to bite down onto the surface of the tyre 29 thereby braking the wheel 33 .
FIGS. 5D to 5F illustrate the various stages of releasing the brake mechanism to enable free motion of the wheel 33 . In the initial stage of release the lever 41 of brace 40 is drawn upward forcing the external arm 42 a of pin 42 downward and away from plate 38 ( FIG. 5E ). Plate 38 may then be manually drawn forward so that the tail 45 engages the internal arm 42 b (not pictured) of the pin 42 . Lever 41 is then pushed downward to its lowest most extent positioning the external arm 42 a against the wheel mount 32 and drawing the internal arm 42 b of pin 42 into engagement with tail 45 thereby wedging the plate against the stirrup of the wheel mount 32 . This wedging action inturn raise the remainder of the plate including the neck 43 and tip 44 clear of the surface of the tyre 29 allowing wheel 33 to run free (see FIGS. 5G and 5F ).
With reference to FIG. 6 there is shown an alternative embodiment of link 20 and the manner in which it is pivotally mounted on the jockey wheel assembly 30 . In this instance link 20 is in the form of a tensile cable 23 coupled to mounting plates 22 . The plates 22 are mounted on the axle 34 between the wheel mount 32 and wheel 33 such that cable 23 extends between opposite ends of the axle 34 and is positioned about the wheel 33 creating a space 38 therebetween. Pin 14 is slidably mounted on the cable 23 . In operation lever 10 is positioned in the space 38 between the cable 23 and the wheel 33 . Pin 14 is then inserted into the desired aperture 13 a - d thereby removably securing lever 10 to link 20 . Lever 10 may then be engaged with the wheel 33 in the manner discussed above in order to move wheel 33 in the desired direction. With this arrangement the position of the lever can be varied from vertical through a range of angles θ as illustrated by the lever positions shown in broken lines. Accordingly the user need not be directly in front of the jockey wheel assembly in order to use the lever 10 but can be to one side of the jockey wheel without a losing purchase on wheel 33 .
FIGS. 7A to 7C illustrate in greater detail a number of possible configurations of the link 20 . FIG. 7A depicts a rigid link 20 in the form of a single bar 23 not unlike that discussed above in relation to FIGS. 2 to 5 . Bar 23 includes a number of apertures 21 a - c through which pin 14 can be inserted, this enables the position at which lever 10 is secured to the bar 23 to be selectively varied. Bar 23 also includes a mounting aperture 22 via which the link 20 is pivotally mounted to the wheel mount 32 or on axle 34 and is held in position by a suitable fastening means such as a bolt, cotter pin or CER-clip.
FIG. 7B shows the link 20 in this instance in the form of rigid U or C shaped bracket 23 , upon which pin 14 is slidably mounted. The bracket 23 includes mounting apertures 22 via which the link 20 is pivotally mounted to the wheel mount 32 or on the axle 34 by a suitable fastening means.
FIG. 7C depicts a flexible link 20 in the form of a tensile cable 23 . Cable 23 is attached to a pair of mounting plates 22 having apertures 24 via which the link 20 is pivotally mounted on the axle 34 of wheel 33 . The cable 23 may be attached to the mounting plates 22 via any suitable means e.g. the ends may be swagged to the plates. An alternative arrangement for mounting the cable 23 to the axle 34 is the simply for a loop at end these loops are then secured back to the main cable 23 by a swagged connector.
FIGS. 8A to 8C illustrate a further embodiment of the alignment apparatus of the present invention. In this instance the link 20 is in the form of a rigid C shaped bar with end 20 a coupled to the lever 10 at a predetermined distance from the wheel engagement portion 12 . End 20 b of the link 20 is adapted to be pivotally mounted within hollow axle 34 . Lever 10 is secured to link in such a manner so as to enable the lever 10 to be pivoted about end 20 a . The wheel engagement portion 12 in this particular case includes at least one tooth 12 a , said tooth being shaped for complementary engagement with the peripheral surface 39 of the wheel 33 . As shown in FIG. 8 a link 20 and lever 10 are designed to be removable from the jockey wheel assembly. As lever 10 can be pivoted about end 20 a the link 20 may be conveniently fold against the lever 10 for easy of storage.
FIG. 8B shows the link 20 and lever 10 mounted in situ on the jockey wheel assembly with end 20 b being mounted within hollow axle 34 . Applying a driving force 35 in the direction of arrow 35 cases the tooth 12 a of wheel engagement portion 12 to grip the tyre 39 rotating the wheel in the direction of arrow 36 .
FIG. 8C shows the reverse angle of the apparatus as shown in FIG. 8B by applying a lateral force in either of the directions indicated by arrow 82 directs the wheel in a desired direction of travel. Once the wheel is positioned in the desired direction of travel a driving force is applied in the direction of arrow 35 cases the tooth 12 a of wheel engagement portion 12 to grip the tyre 39 to rotate the wheel to thereby move the trailer in the desired direction of travel. At the base of the drive stroke a force is applied in the direction of arrow 81 causing lever 10 to pivot about end 20 a of link 20 thereby releasing tooth 12 a from tyre 39 . Upon release a user may then change the direction of the tyre if required or simply return the lever to the top of the drive stroke if further movement in the desired direction is required.
It is to be understood that the above embodiments have been provided only by way of exemplification of this invention, and that further modifications and improvements thereto, as would be apparent to persons skilled in the relevant art, are deemed to fall within the broad scope and ambit of the present invention described herein.
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An apparatus and method for maneuvering a trailer having jockey wheel assembly comprising a ground engaging wheel ( 33 ) rotatably mounted on an axle ( 34 ). The apparatus comprising a link member ( 20 ) which is adapted to be pivotally mounted on the jockey wheel assembly adjacent the axle ( 34 ) and a lever assembly ( 10 ) removably securable to said link ( 20 ) and adapted to engage a peripheral surface ( 39 ) of said wheel ( 33 ), whereby movement of said lever ( 10 ) rotates said wheel ( 33 ).
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This is a continuation of prior application Ser. No. 08/077,814, filed on 17 Jun. 1993, which is a continuation of application Ser. No. 07/874,253, filed on 24 Apr. 1992, both abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a display device having a display robe provided with a display screen and a tube neck located opposite thereto, and including a convergence correction device which comprises an arrangement of correction coils arranged around the neck, and a convergence correction circuit for applying correction currents to the correction coils.
U.S. Pat. No. 4,027,219 describes a device in which eight or twelve coils (solenoids) wound on cores of a ferromagnetic material are arranged in a row around the robe in such a way that their axes are coplanar, while they are incorporated in a circuit having controllable current sources in such a way that, upon energization, two four-pole fields and two six-pole fields are generated whose intensity and polarity are controllable for obtaining (static) convergence.
Drawbacks of the use of such a configuration of solenoids are:
the insensitivity, requiring a convergence circuit with relatively expensive amplifiers;
little freedom of design as regards the exact field shape;
a complicated electric circuit is required to generate all desired multipolar fields with a limited number of coils;
less suitable for dynamic convergence due to the large inductance of the solenoids.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a construction which does not have at least one of the above-mentioned drawbacks or which has the at least one drawback to a lesser extent.
According to the invention, the display device of the type described in the opening paragraph is therefore characterized in that each correction coil is of the planar wound type and in that the arrangement of correction coils comprises at least a first and a second system of coils each subtending an angle of 360°, each system comprising a plurality of coils which jointly produce; a magnetic 2N-pole field upon energization, with N being 2, 3, etc.
The invention is based on the use of (coreless) coils having (for example concentric) conductor turns which are present on a (cylindrical) surface. This provides the possibility of easily placing a system or a number of systems of such coils in a position close to the neck glass of the display tube (small diameter of the cylinder) so that a high sensitivity is possible. The inductance is low due to the absence of cores. For this concept particularly coils (referred to as print coils) are suitable which are arranged on a surface of a flexible support by means of a printing technique, the support surrounding the tube neck in such a way that the axes of the coils are radially directed towards the axis of the tube neck. All this provides greater freedom of design. More particularly, a separate system of coils can be used for each multipole field to be generated.
For example, two sets of four (print) coils, one for generating a four-pole x field and one for generating a four-pole y field, can be used, combined or not combined with two sets of six of six (print) coils, one for generating a six-pole x field and one for generating a six-pole y field. Each set of coils may be arranged on its own flexible support, while the two sets of coils each producing a four-pole field may be arranged on one and the same flexible support (which is folded or rolled up in such a way that the sets of coils form a winding, one surrounding the other), similarly as the two coils each producing a six-pole fields, or (and preferably) all correction coil systems may be arranged on one and the same flexible support which is wound around the tube a number of times (hereinafter also referred to as foil coil system). In this ease it is important that it should be possible for each set of coils to use the entire circumference of the annular support, in other words, one set of coils for each turn.
As will be described hereinafter, the use of a foil coil system as described above is particularly suitable to be combined with a convergence correction circuit supplying the previously fixed correction currents for a number of positions on the display screen, which currents are associated with said positions. This has, inter alia, the advantage that the correction signal is independent of the deflection frequencies used.
More particularly, such a convergence correction circuit is characterized in that it comprises means for measuring the line deflection current and the field deflection current and for supplying correction currents with reference to the measured currents.
A first, analogous, embodiment is characterized in that the convergence correction circuit includes a multiplier circuit for supplying at least the square, the cube and the fourth power of the deflection currents as output signals.
The correction circuit may include a matrix circuit for multiplying, multiplying by weighting factors and adding the output signals of the multiplier circuit.
A second embodiment is characterized in that the convergence correction circuit includes an A/D converter for digitizing the measured deflection currents, means for digitially computing the correction currents and a D/A converter for supplying the correction currents in an analog form.
A very interesting possibility is presented by incorporating a memory (for example a calibrated (E)EPROM) in the correction circuit, in which memory the corrections are stored which are necessary to correct the convergence errors at a number of measuring points (for example, 25) on the display screen. With this zero convergence option it is possible for the maximum convergence error to be at most 0.2 min.
The coils may be of the planar wound type having concentric external turns surrounding a central window. However, the coils have a greater sensitivity if, in accordance with a preferred embodiment of the invention, they are of the type having external turns surrounding an outer window and internal turns surrounding at least one inner window. The outer and inner window(s) may be concentric or not concentric.
These and other aspects of the invention will be described in greater detail with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows diagrammatically a display device including an arrangement of coils for convergence correction and
FIG. 2 shows a larger detail of FIG. 1;
FIGS. 3A and 3B show embodiments of two four-pole field correction coil systems with associated fields for the device shown in FIGS. 1 and 2,
FIG. 4 shows an embodiment of an alternative four-pole field correction coil system;
FIG. 5 is a perspective elevational view of a foil coil correction device;
FIG. 6 shows a blank in the flat plane of the foil coil system of FIG. 5;
FIG. 7 is a cross-section taken on the line VII--VII of the display tube of FIG. 1;
FIGS. 8 and 9 show diagrammatically a convergence circuit for supplying correction currents to the coils of the system of FIG. 5, and
FIGS. 10A and 10B show examples of fields generated by sixpole field correction coil systems.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The colour display tube shown diagrammatically in FIG. 1 has a cylindrical neck portion accommodating electron guns (not visible in FIG. 1) for generating three approximately coplanar electron beams, and a funnel-shaped portion 3. A deflection unit 5 which is combined with a convergence correction device 7, is arranged at the area of the interface between the two portions. As is shown in FIGS. 3A and 3B, this correction device may comprise a plurality of coils 9 formed as flat spirals surrounding respective axes which are directed radially towards the axis of the tube neck 1. The coils are arranged in a holder 11 secured to the neck in such a way that their axes are coplanar. When the coils 9 are connected to one or more current sources, magnetic fields resulting in a displacement of the three electron beams 13, 15, 17 arc, generated within the tube neck 1. Red-blue y errors (y astigmatic errors) can be corrected by means of four coils which are positioned and energized in the way as shown in the embodiment of FIG. 3A. Red-blue x errors (x astigmatic errors) can be corrected by means of four coils which are positioned and energized in the way as shown in the embodiment of FIG. 3B. In fact, a four-pole field having a horizontal axis direction produces a vertical displacement of the outer beams 13, 17 in opposite directions (see inset FIG. 3A) and a four-pole field having an axis direction at 45 degrees to the horizontal produces an opposite displacement in the horizontal direction (see inset FIG. 3B).
Green-red/blue x errors (x coma errors) (see FIG. 10A) or green-red/blue y errors (y coma errors) (see FIG. 10B) can be corrected by means of six coils which are positioned and energized in the correct way.
As is known, for example, from U.S. Pat. No. 3,725,831, a magnetic six-pole field with an axis in the plane of the three beams 13, 15, 17, i.e. horizontal, produces a simultaneous displacement of the two outer beams R(ed) and B(lue) in a direction perpendicular to the plane of the beams (FIG. 10B), while the central beam 15 is not influenced. A six-pole field, an axis of which is perpendicular to the plane of the three beams (i.e. vertical) thus produces a simultaneous displacement of the outer beams R(ed) and B(lue) towards the left or the fight.
The embodiment of FIG. 4 shows a coil configuration with four coils having a greater sensitivity. This results from the fact that the coils in question have a given winding distribution, with external turns surrounding an outer window and internal turns surrounding an inner window.
Referring to FIGS. 6A-6D, the conductors required for the correction coils are arranged on an elongate strip of synthetic material foil. The conductors are formed in this case by "multiple" wires with two parallel sub-wires having the desired distribution for four-pole ×(4px), four-pole y (4py), six-pole ×(6px) and six-pole y (6py). The strip, which is illustrated in four parts in connection with the space available for the Figure, is provided with a lead-out 20 to which the multi-pole terminals are connected. The lead-out is arranged as close as possible to the conductors for the 6-poles so as to minimize the ohmic resistance and the inductance in the 6-pole circuits. This is important because the 6-poles have a lower sensitivity than that of the 4-poles. The strip is rolled up on a ring functioning as a support. In this case the strip surrounds the ring four times. The support 7 with the coils (FIG. 5) is subsequently mounted on the deflection unit at the location reserved for this purpose (see FIG. 2) and the lead-out is fixed and provided with a connection to an electric circuit.
The arrangement 7 of correction coil systems may be arranged by means of a printing technique on one and the same flexible support which is wound around the tube neck a number of times and which is provided with a plurality of connection conductors connected to a connector (FIG. 5). For example, the ,correction coil systems may be arranged on the lower and upper sides of the flexible support, or all on the same side. The use of the flexible support with printed coils renders it easily possible to arrange the coil systems in (slightly) different axial positions, if so desired.
The coil systems of the above-mentioned convergence correction device are to be connected to an electric circuit which supplies the suitable correction signals.
The use of a foil coil system as described hereinbefore leads to a high sensitivity and a low inductance so that low current intensifies and low voltages are sufficient for correction. One can benefit from this advantage as such and make use of a conventional correction circuit. However, an alternative is to utilize the advantage for designing and using a perfected circuit.
A correction circuit which is very well applicable within the scope of the invention is a circuit supplying correction signals as a function of the instantaneous position of the beam spot on the display screen. In principle, the position of the beam/spot on the screen depends on 3 parameters, namely:
the horizontal deflection current (line deflection current)
the vertical deflection current (field deflection current)
the high voltage.
If the influence of the high-voltage variation can be eliminated or compensated for, there are only two parameters which determine the position of the beam/spot on the display screen. An alternative for determining the position on the display screen of the horizontal and vertical deflection currents is to measure the time which has elapsed after a vertical or horizontal synchronizing pulse. This determination of the position on the display screen by means of a "time measurement" instead of a "current measurement" has the drawback that this measuring method is frequency-dependent. Moreover, working with currents for obtaining the correction signals has the advantage that the supply voltage of the correction circuit may be limited to 5 V. In contrast, if the correction signals are generated on the basis of voltages, the supply voltage must be much higher to obtain a range of amplification which is large enough.
FIG. 8 shows a first embodiment of a correction circuit for correcting, for example, convergence errors on a display screen. With reference to the measured horizontal deflection current It and the measured vertical deflection current I f , the correction circuit determines the position on the screen and computes the required correction current/currents with reference to this position. The current I 1 is applied to a multiplier circuit 52 via a current transformer 51. This multiplier circuit supplies I 1 2 , I 1 3 and I 1 4 in addition to the measured horizontal deflection current I 1 . The current I f flows through a resistor 53. The voltage measured across this resistor is applied to a multiplier circuit 54. Outputs of this multiplier circuit 54 supply also I f 2 , I f 3 and I f 4 in addition to the vertical deflection current I f . The outputs of the multiplier circuits 52 and 54 are connected to a matrix circuit 55. In the matrix circuit the required correction currents are obtained by multiplying the currents I 1 , I 1 2 , I 1 3 , I.sub. 1 4 , I f , I f 2 , I f 3 and I f 4 by the desired factors and by adding them. The correction currents Ic k (with k=1 . . . n) are supplied at outputs 561 . . . 56n.
The correction current Ic k has the following shape: ##EQU1## The weighting factors a ij are determined in advance and determine the weight of each I 1 i I f j component in the sum. For each type of display tube/coil combination the factors a ij will have different values. These factors are determined by displaying a known test signal on a relevant display tube/coil combination and by measuring the occurring (convergence) errors at a fixed number of measuring points (for example, 25).
FIG. 9 shows a second embodiment of a correction circuit. In this embodiment the current I, is converted to a digital value in an A/D converter 60 and stored in a memory 62. The current I f is also converted to a digital value in an A/D converter 61 and stored in the memory 62. A microprocessor 63 reads the stored horizontal and vertical deflection currents from the memory, (with which the location on the display screen is unambiguously determined). The microprocessor receives the correction values associated with this location on the screen from an E 2 PROM and determines with reference thereto the digital values of the correction currents Ic 1 . . . Ic n and applies these values via the memory 62 at outputs to D/A converter 631 . . . 63n. Each D/A converter is connected to an amplifier 641 . . . 64n. Each output of the amplifier is connected to an output terminal 651 . . . 65n of the correction circuit. The analog correction currents are supplied at these output terminals. The output terminals 651 . . . 65n may be connected to correction coils (not shown).
The choice of taking 25 measuring points and determining, with reference thereto, the weighting factors a ij for generating the correction currents also determines the powers of the deflection currents required to determine the correction currents completely. Horizontally, there are 5 measuring points (in the case of 25 measuring points) and hence 5 comparisons. These 5 comparisons are completely determined by means of 5 variables. By taking I 1 0 , I 1 1 , I 1 2 , I 1 3 and I 1 4 , this yields the required 5 variables. Moreover, there are vertically 5 measuring points and hence 5 comparisons. Here again it holds that these 5 comparisons are completely determined by means of 5 variables for which I f 0 , I f 1 , I f 2 , I f 3 and I f 4 are now taken. If there were 36 measuring points, the terms I 1 5 and I f 5 would also be necessary, etc.
The correction circuits shown in FIGS. 8 and 9 may supply correction signals for dynamic convergence throughout the display screen. These correction circuits could also be used for other required corrections, for example, other location error corrections such as pincushion/barrel correction.
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Display tube including a convergence correction device which comprises a plurality of correction coils having coplanar axes and being arranged around the tube neck. The coils are of the planar type. More specifically, there are two sets of four coils for generating two differently oriented four-pole fields and two sets of six coils for generating two differently oriented six-pole fields, while all these coils are arranged on one flexible support which is wound around the tube neck a number of times, for example, one set of coils for each turn.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/764,111 filed Jun. 15, 2007 entitled Embolization Device Constructed From Expansile Polymer, which claims the benefit of U.S. Provisional Patent Application No. 60/814,309 filed on Jun. 15, 2006 entitled HESII: Embolization Device Constructed From Expansile Polymer, both of which are hereby incorporated herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to devices for the occlusion of body cavities, such as the embolization of vascular aneurysms and the like, and methods for making and using such devices.
BACKGROUND OF THE INVENTION
[0003] The occlusion of body cavities, blood vessels, and other lumina by embolization is desired in a number of clinical situations. For example, the occlusion of fallopian tubes for the purposes of sterilization, and the occlusive repair of cardiac defects, such as a patent foramen ovale, patent ductus arteriosis, and left atrial appendage, and atrial septal defects. The function of an occlusion device in such situations is to substantially block or inhibit the flow of bodily fluids into or through the cavity, lumen, vessel, space, or defect for the therapeutic benefit of the patient.
[0004] The embolization of blood vessels is also desired in a number of clinical situations. For example, vascular embolization has been used to control vascular bleeding, to occlude the blood supply to tumors, and to occlude vascular aneurysms, particularly intracranial aneurysms. In recent years, vascular embolization for the treatment of aneurysms has received much attention. Several different treatment modalities have been shown in the prior art. One approach that has shown promise is the use of thrombogenic microcoils. These microcoils may be made of biocompatible metal alloy(s) (typically a radio-opaque material such as platinum or tungsten) or a suitable polymer. Examples of microcoils are disclosed in the following patents: U.S. Pat. No. 4,994,069—Ritchart et al.; U.S. Pat. No. 5,133,731—Butler et al.; U.S. Pat. No. 5,226,911—Chee et al.; U.S. Pat. No. 5,312,415—Palermo; U.S. Pat. No. 5,382,259—Phelps et al.; U.S. Pat. No. 5,382,260—Dormandy, Jr. et al.; U.S. Pat. No. 5,476,472—Dormandy, Jr. et al.; U.S. Pat. No. 5,578,074—Mirigian; U.S. Pat. No. 5,582,619—Ken; U.S. Pat. No. 5,624,461—Mariant; U.S. Pat. No. 5,645,558—Horton; U.S. Pat. No. 5,658,308—Snyder; and U.S. Pat. No. 5,718,711—Berenstein et al; all of which are hereby incorporated by reference.
[0005] A specific type of microcoil that has achieved a measure of success is the Guglielmi Detachable Coil (“GDC”), described in U.S. Pat. No. 5,122,136—Guglielmi et al. The GDC employs a platinum wire coil fixed to a stainless steel delivery wire by a solder connection. After the coil is placed inside an aneurysm, an electrical current is applied to the delivery wire, which electrolytically disintegrates the solder junction, thereby detaching the coil from the delivery wire. The application of current also creates a positive electrical charge on the coil, which attracts negatively-charged blood cells, platelets, and fibrinogen, thereby increasing the thrombogenicity of the coil. Several coils of different diameters and lengths can be packed into an aneurysm until the aneurysm is completely filled. The coils thus create and hold a thrombus within the aneurysm, inhibiting its displacement and its fragmentation.
[0006] A more recent development in the field of microcoil vaso-occlusive devices is exemplified in U.S. Pat. No. 6,299,619 to Greene, Jr. et al., U.S. Pat. No. 6,602,261 to Greene, Jr. et al., and co-pending U.S. patent application Ser. No. 10/631,981 to Martinez; all assigned to the assignee of the subject invention and incorporated herein by reference. These patents disclose vaso-occlusive devices comprising a microcoil with one or more expansile elements disposed on the outer surface of the coil. The expansile elements may be formed of any of a number of expansile polymeric hydrogels, or alternatively, environmentally-sensitive polymers that expand in response to a change in an environmental parameter (e.g., temperature or pH) when exposed to a physiological environment, such as the blood stream.
[0007] This invention is a novel vaso-occlusive device, a novel expansile element, and a combination thereof.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to novel vaso-occlusive devices comprising a carrier member, novel expansile elements, and a combination thereof. Generally, the expansile element comprises an expansile polymer. The carrier member may be used to assist the delivery of the expansile element by providing a structure that, in some embodiments, allows coupling to a delivery mechanism and, in some embodiments, enhances the radiopacity of the device.
[0009] In one embodiment, the expansile polymer is an environmentally sensitive polymeric hydrogel, such as that described in U.S. Pat. No. 6,878,384, issued Apr. 12, 2005 to Cruise et al., hereby incorporated by reference. In another embodiment, the expansile polymer is a novel hydrogel comprised of sodium acrylate and a poly(ethylene glycol) derivative. In another embodiment, the expansile polymer is a hydrogel comprising a Pluronics® derivative.
[0010] In one embodiment, the expansile polymer is a novel hydrogel that has ionizable functional groups and is made from macromers. The hydrogel may be environmentally-responsive and have an unexpanded bending resistance of from about 0.1 milligrams to about 85 milligrams. The macromers may be non-ionic and/or ethylenically unsaturated.
[0011] In another embodiment, the macromers may have a molecular weight of about 400 to about 35,000, more preferably about 5,000 to about 15,000, even more preferably about 8,500 to about 12,000. In another embodiment, the hydrogel may be made of polyethers, polyurethanes, derivatives thereof, or combinations thereof. In another embodiment, the ionizable functional groups may comprise basic groups (e.g., amines, derivatives thereof, or combinations thereof) or acidic groups (e.g., carboxylic acids, derivatives thereof, or combinations thereof). If the ionizable functional groups comprise basic groups, the basic groups may be deprotonated at pHs greater than the pKa or protonated at pHs less than the pKa of the basic groups. If the ionizable functional groups comprise acidic groups, the acidic groups may be protonated at pHs less than the pKa or de-protonated at pHs greater than the pKa of the acidic groups.
[0012] In another embodiment, the macromers may comprise vinyl, acrylate, acrylamide, or methacrylate derivatives of poly(ethylene glycol), or combinations thereof. In another embodiment, the macromer may comprise poly(ethylene glycol)di-acrylamide. In another embodiment, the hydrogel is substantially free, more preferably free of unbound acrylamide.
[0013] In another embodiment, the macromers may be cross-linked with a compound that contains at least two ethylenically unsaturated moieties. Examples of ethylenically unsaturated compounds include N,N′-methylenebisacrylamide, derivatives thereof, or combinations thereof. In another embodiment, the hydrogel may be prepared using a polymerization initiator. Examples of suitable polymerization initiators comprise N,N,N′,N′-tetramethylethylenediamine, ammonium persulfate, azobisisobutyronitrile, benzoyl peroxides, derivatives thereof, or combinations thereof. The polymerization initiator may be soluble in aqueous or organic solvents. For example, azobisisobutyronitrile is not water soluble; however, water soluble derivatives of azobisisobutyronitrile, such as 2,2′-azobis(2-methylproprionamidine)dihydrochloride, are available. In another embodiment, the hydrogel may be substantially non-resorbable, non-degradable or both, at physiological conditions.
[0014] In another embodiment, the invention comprises a method for preparing an environmentally-responsive hydrogel for implantation in an animal. The method includes combining at least one, preferably non-ionic, macromer with at least one ethylenically unsaturated moiety, at least one macromer or monomer having at least one ionizable functional group and at least one ethylenically unsaturated moiety, at least one polymerization initiator, and at least one solvent to form a hydrogel. The solvent may include aqueous or organic solvents, or combinations thereof. In another embodiment, the solvent is water. Next, the hydrogel may be treated to prepare an environmentally-responsive hydrogel, preferably one that is responsive at physiological conditions. The ionizable functional group(s) may be an acidic group (e.g., a carboxylic acid, a derivative thereof, or combinations thereof) or a basic group (e.g., an amine, derivatives thereof, or combinations thereof). If the ionizable functional group comprises an acidic group, the treating step may comprise incubating the hydrogel in an acidic environment to protonate the acidic groups. If the ionizable functional group comprises a basic group, the treating step may comprise incubating the hydrogel in a basic environment to de-protonate the basic groups. In certain embodiments, it is preferable that the acidic groups are capable of being de-protonated or, conversely, the basic groups are capable of being protonated, after implantation in an animal.
[0015] In another embodiment, the ethylenically unsaturated macromer may have a vinyl, acrylate, methacrylate, or acrylamide group; including derivatives thereof or combinations thereof. In another embodiment, the ethylenically unsaturated macromer is based upon poly(ethylene glycol), derivatives thereof, or combinations thereof. In another embodiment, the ethylenically unsaturated macromer is poly(ethylene glycol)di-acrylamide, poly(ethylene glycol)di-acrylate, poly(ethylene glycol)di-methacrylate, derivatives thereof, or combinations thereof. In another embodiment, the ethylenically unsaturated macromer is poly(ethylene glycol)di-acrylamide. The ethylenically unsaturated macromer may be used at a concentration of about 5% to about 40% by weight, more preferably about 20% to about 30% by weight. The solvent may be used at a concentration of about 20% to about 80% by weight.
[0016] In another embodiment, the combining step also includes adding at least one cross-linking agent comprising an ethylenically unsaturated compound. In certain embodiments of the present invention, a cross-linker may not be necessary. In other words, the hydrogel may be prepared using a macromer with a plurality of ethylenically unsaturated moieties. In another embodiment, the polymerization initiator may be a reduction-oxidation polymerization initiator. In another embodiment, the polymerization initiator may be N,N,N′,N′-tetramethylethylenediamine, ammonium persulfate, azobisisobutyronitrile, benzoyl peroxides, 2,2′-azobis(2-methylproprionamidine)dihydrochloride, derivatives thereof, or combinations thereof. In another embodiment, the combining step further includes adding a porosigen.
[0017] In another embodiment, the ethylenically unsaturated macromer includes poly(ethylene glycol)di-acrylamide, the macromer or monomer or polymer with at least one ionizable group and at least one ethylenically unsaturated group includes sodium acrylate, the polymerization initiator includes ammonium persulfate and N,N,N,′,N′ tetramethylethylenediamine, and the solvent includes water.
[0018] In another embodiment, the ethylenically unsaturated macromer has a molecular weight of about 400 to about 35,000 grams/mole, more preferably about 2,000 to about 25,000 grams/mole, even more preferably about 5,000 to about 15,000 grams/mole, even more preferably about 8,000 to about 12,500 grams/mole, and even more preferably about 8,500 to about 12,000 grams/mole. In another embodiment, the environmentally-responsive hydrogel is substantially non-resorbable, or non-degradable or both at physiological conditions. In certain embodiments, the environmentally-responsive hydrogel may be substantially free or completely free of unbound acrylamide.
[0019] In one embodiment, the carrier member comprises a coil or microcoil made from metal, plastic, or similar materials. In another embodiment, the carrier member comprises a braid or knit made from metal, plastic, or similar materials. In another embodiment, the carrier member comprises a plastic or metal tube with multiple cuts or grooves cut into the tube.
[0020] In one embodiment, the expansile element is arranged generally co-axially within the carrier member. In another embodiment, a stretch resistant member is arranged parallel to the expansile element. In another embodiment, the stretch resistant member is wrapped, tied, or twisted around the expansile element. In another embodiment, the stretch resistant member is positioned within the expansile element.
[0021] In one embodiment, the device comprising the expansile element and carrier member are detachably coupled to a delivery system. In another embodiment, the device is configured for delivery by pushing or injecting through a conduit into a body.
[0022] In one embodiment, the expansile element is environmentally sensitive and exhibits delayed expansion when exposed to bodily fluids. In another embodiment, the expansile element expands quickly upon contact with a bodily fluid. In another embodiment, the expansile element comprises a porous or reticulated structure that may form a surface or scaffold for cellular growth.
[0023] In one embodiment, the expansile element expands to a dimension that is larger than the diameter of the carrier member in order to provide enhanced filling of the lesion. In another embodiment, the expansile element expands to a dimension equal to or smaller than the diameter of the carrier member to provide a scaffold for cellular growth, release of therapeutic agents such as pharmaceuticals, proteins, genes, biologic compounds such as fibrin, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view showing one embodiment of the present invention prior to expansion of the expansile element;
[0025] FIG. 2 is a perspective view showing a device similar to FIG. 1 in an expanded state;
[0026] FIG. 3 is a perspective view of an alternative embodiment of the present invention;
[0027] FIG. 4 is a perspective view of an alternative embodiment wherein the carrier member comprises a fenestrated tube, braid or knit;
[0028] FIG. 5 is a perspective view of an alternative embodiment incorporating a stretch resistant member running approximately parallel to the expansile element;
[0029] FIG. 6 is a perspective view of an alternative embodiment incorporating a stretch resistant member approximately intertwined with the expansile element;
[0030] FIG. 7 is a perspective view of an alternative embodiment wherein the expansile element has formed a loop or fold outside the carrier member.
[0031] FIG. 8 is a perspective view of an alternative embodiment showing a device similar to those shown in FIG. 1 and FIG. 2 wherein the expansile element is not expanded to a diameter larger than the carrier member.
DESCRIPTION OF THE INVENTION
[0032] As used herein, the term “macromer” refers to a large molecule containing at least one active polymerization site or binding site. Macromers have a larger molecular weight than monomers. For example, an acrylamide monomer has a molecular weight of about 71.08 grams/mole whereas a poly(ethylene glycol)di-acrylamide macromer may have a molecular weight of about 400 grams/mole or greater. Preferred macromers are non-ionic, i.e. they are uncharged at all pHs.
[0033] As used herein, the term “environmentally responsive” refers to a material (e.g., a hydrogel) that is sensitive to changes in environment including but not limited to pH, temperature, and pressure. Many of the expansile materials suitable for use in the present invention are environmentally responsive at physiological conditions.
[0034] As used herein, the term “non-resorbable” refers to a material (e.g., a hydrogel) that cannot be readily and/or substantially degraded and/or absorbed by bodily tissues.
[0035] As used herein, the term “unexpanded” refers to the state at which a hydrogel is substantially not hydrated and, therefore, not expanded.
[0036] As used herein, the term “ethylenically unsaturated” refers to a chemical entity (e.g., a macromer, monomer or polymer) containing at least one carbon-carbon double bond.
[0037] As used herein, the term “bending resistance” refers to the resistance exhibited by a sample (e.g., an unexpanded hydrogel) as it steadily and evenly is moved across a resistance-providing arm or vane. The maximum displacement of the resistance-providing arm or vane is measured at the point the sample bends and releases the resistance-providing arm or vane. That maximum displacement is converted to bending “resistance” or “stiffness” using conversions appropriate to the machine, its calibration, and the amount of resistance (e.g., weight), if any, associated with the resistance-providing arm or vane. Herein, the units of measure for bending resistance will be milligrams (mg) and essentially is the amount of force required to bend the sample.
[0038] Referring to FIG. 1-8 , the invention is a device comprising an expansile element 1 and a carrier member 2 . The expansile element 1 may be made from a variety of suitable biocompatible polymers. In one embodiment, the expansile element 1 is made of a bioabsorbable or biodegradable polymer, such as those described in U.S. Pat. Nos. 7,070,607 and 6,684,884, the disclosures of which are incorporated herein by reference. In another embodiment, the expansile element 1 is made of a soft conformal material, and more preferably of an expansile material such as a hydrogel.
[0039] In one embodiment, the material forming the expansile element 1 is an environmentally responsive hydrogel, such as that described in U.S. Pat. No. 6,878,384, the disclosure of which is incorporated herein by reference. Specifically, the hydrogels described in U.S. Pat. No. 6,878,384 are of a type that undergoes controlled volumetric expansion in response to changes in such environmental parameters as pH or temperature. These hydrogels are prepared by forming a liquid mixture that contains (a) at least one monomer and/or polymer, at least a portion of which is sensitive to changes in an environmental parameter; (b) a cross-linking agent; and (c) a polymerization initiator. If desired, a porosigen (e.g., NaCl, ice crystals, or sucrose) may be added to the mixture, and then removed from the resultant solid hydrogel to provide a hydrogel with sufficient porosity to permit cellular ingrowth. The controlled rate of expansion is provided through the incorporation of ethylenically unsaturated monomers with ionizable functional groups (e.g., amines, carboxylic acids). For example, if acrylic acid is incorporated into the crosslinked network, the hydrogel is incubated in a low pH solution to protonate the carboxylic acid groups. After the excess low pH solution is rinsed away and the hydrogel dried, the hydrogel can be introduced through a microcatheter filled with saline at physiological pH or with blood. The hydrogel cannot expand until the carboxylic acid groups deprotonate. Conversely, if an amine-containing monomer is incorporated into the crosslinked network, the hydrogel is incubated in a high pH solution to deprotonate amines. After the excess high pH solution is rinsed away and the hydrogel dried, the hydrogel can be introduced through a microcatheter filled with saline at physiological pH or with blood. The hydrogel cannot expand until the amine groups protonate.
[0040] In another embodiment, the material forming the expansile element 1 is may be an environmentally responsive hydrogel, similar to those described in U.S. Pat. No. 6,878,384; however, an ethylenically unsaturated, and preferably non-ionic, macromer replaces or augments at least one monomer or polymer. The Applicants surprisingly have discovered that hydrogels prepared in accordance with this embodiment can be softer and/or more flexible in their unexpanded state than those prepared in accordance with U.S. Pat. No. 6,878,384. Indeed, hydrogels prepared in accordance with this embodiment may have an unexpanded bending resistance of from about 0.1 mg to about 85 mg, about 0.1 mg to about 50 mg, about 0.1 mg to about 25 mg, about 0.5 mg to about 10 mg, or about 0.5 mg to about 5 mg. The Applicants also have discovered that ethylenically unsaturated and non-ionic macromers (e.g., poly(ethylene glycol) and derivatives thereof) may be used not only to prepare a softer unexpanded hydrogel; but, in combination with monomers or polymers containing ionizable groups, one that also may be treated to be made environmentally responsive. The surprising increase in unexpanded flexibility enables the hydrogels to be, for example, more easily deployed in an animal or deployed with reduced or no damage to bodily tissues, conduits, cavities, etceteras.
[0041] The hydrogels prepared from non-ionic macromers in combination with monomers or polymers with ionizable functional groups still are capable of undergoing controlled volumetric expansion in response to changes in environmental parameters. These hydrogels may be prepared by combining in the presence of a solvent: (a) at least one, preferably non-ionic, macromer with a plurality of ethylenically unsaturated moieties; (b) a macromer or polymer or monomer having at least one ionizable functional group and at least one ethylenically unsaturated moiety; and (c) a polymerization initiator. It is worthwhile to note that with this type of hydrogel, a cross-linking agent may not be necessary for cross-linking since, in certain embodiments, the components selected may be sufficient to form the hydrogel. As hereinbefore described, a porosigen may be added to the mixture and then removed from the resultant hydrogel to provide a hydrogel with sufficient porosity to permit cellular ingrowth.
[0042] The non-ionic macromer-containing hydrogels' controlled rate of expansion may be provided through the incorporation of at least one macromer or polymer or monomer having at least one ionizable functional group (e.g., amine, carboxylic acid). As discussed above, if the functional group is an acid, the hydrogel is incubated in a low pH solution to protonate the group. After the excess low pH solution is rinsed away and the hydrogel dried, the hydrogel can be introduced through a microcatheter, preferably filled with saline. The hydrogel cannot expand until the acid group(s) deprotonates. Conversely, if the functional group is an amine, the hydrogel is incubated in a high pH solution to deprotonate the group. After the excess high pH solution is rinsed away and the hydrogel dried, the hydrogel can be introduced through a microcatheter, preferably filled with saline. The hydrogel cannot expand until the amine(s) protonates.
[0043] More specifically, in one embodiment, the hydrogel is prepared by combining at least one non-ionic macromer having at least one unsaturated moiety, at least one macromer or monomer or polymer having at least one ionizable functional group and at least one ethylenically unsaturated moiety, at least one polymerization initiator, and a solvent. Optionally, an ethylenically unsaturated crosslinking agent and/or a porosigen also may be incorporated. Preferred concentrations of the non-ionic macromers in the solvent range from about 5% to about 40% (w/w), more preferably about 20% to about 30% (w/w). A preferred non-ionic macromer is poly(ethylene glycol), its derivatives, and combinations thereof. Derivatives include, but are not limited to, poly(ethylene glycol)di-acrylamide, poly(ethylene glycol)di-acrylate, and poly(ethylene glycol)dimethacrylate. Poly(ethylene glycol)di-acrylamide is a preferred derivative of poly(ethylene glycol) and has a molecular weight ranging from about 8,500 to about 12,000. The macromer may have less than 20 polymerization sites, more preferably less than 10 polymerization sites, more preferably about five or less polymerization sites, and more preferably from about two to about four polymerization sites. Poly(ethylene glycol)di-acrylamide has two polymerization sites.
[0044] Preferred macromers or polymers or monomers having at least one ionizable functional group include, but are not limited to compounds having carboxylic acid or amino moieties or, derivatives thereof, or combinations thereof. Sodium acrylate is a preferred ionizable functional group-containing compound and has a molecular weight of 94.04 g/mole. Preferred concentrations of the ionizable macromers or polymers or monomers in the solvent range from about 5% to about 40% (w/w), more preferably about 20% to about 30% (w/w). At least a portion, preferably about 10%-50%, and more preferably about 10%-30%, of the ionizable macromers or polymers or monomers selected should be pH sensitive. It is preferred that no free acrylamide is used in the macromer-containing hydrogels of the present invention.
[0045] When used, the crosslinking agent may be any multifunctional ethylenically unsaturated compound, preferably N, N′-methylenebisacrylamide. If biodegradation of the hydrogel material is desired, a biodegradable crosslinking agent may be selected. The concentrations of the crosslinking agent in the solvent should be less than about 1% w/w, and preferably less than about 0.1% (w/w).
[0046] As described above, if a solvent is added, it may be selected based on the solubilities of the macromer(s) or monomer(s) or polymer(s), crosslinking agent, and/or porosigen used. If a liquid macromer or monomer or polymer solution is used, a solvent may not be necessary. A preferred solvent is water, but a variety of aqueous and organic solvents may be used. Preferred concentrations of the solvent range from about 20% to about 80% (w/w), more preferably about 50% to about 80% (w/w).
[0047] Crosslink density may be manipulated through changes in the macromer or monomer or polymer concentration, macromer molecular weight, solvent concentration and, when used, crosslinking agent concentration. As described above, the hydrogel may be crosslinked via reduction-oxidation, radiation, and/or heat. A preferred type of polymerization initiator is one that acts via reduction-oxidation. Suitable polymerization initiators include, but are not limited to, N,N,N′,N′-tetramethylethylenediamine, ammonium persulfate, azobisisobutyronitrile, benzoyl peroxides, 2,2′-azobis(2-methylpropionamidine)dihydrochloride, derivatives thereof, or combinations thereof. A combination of ammonium persulfate and N,N,N′,N′-tetramethylethylenediamine is a preferred polymerization initiator for use in the macromer containing embodiments of the invention.
[0048] After polymerization is complete, the hydrogels of the present invention may be washed with water, alcohol or other suitable washing solution(s) to remove any porosigen(s), any unreacted, residual macromer(s), monomer(s), and polymer(s) and any unincorporated oligomers. Preferably this is accomplished by initially washing the hydrogel in distilled water.
[0049] The hydrogels of the present invention may be made environmentally-responsive by protonating or deprotonating the ionizable functional groups present on the hydrogel network, as discussed above. Once the hydrogel has been prepared and, if needed, washed, the hydrogel may be treated to make the hydrogel environmentally-responsive. For hydrogel networks where the ionizable functional groups are carboxylic acid groups, the hydrogel is incubated in a low pH solution. The free protons in the solution protonate the carboxylic acid groups on the hydrogel network. The duration and temperature of the incubation and the pH of the solution influence the amount of control on the expansion rate. In general, the duration and temperature of the incubation are directly proportional to the amount of expansion control, while the incubation solution pH is inversely proportional thereto.
[0050] It has been determined that incubation solution water content also affects expansion control. In this regard, higher water content enables greater hydrogel expansion and is thought to increase the number of protonation-accessible carboxylic acid groups. An optimization of water content and pH is required for maximum control on expansion rate. Expansion control, among other things, has an effect on device positioning/repositioning time. Typically, a positioning/repositioning time of about 0.1 to about 30 minutes is preferred for hydrogel devices in accordance with the present invention.
[0051] After incubation, the excess treating solution is washed away and the hydrogel material is dried. A hydrogel treated with the low pH solution has been observed to dry down to a smaller dimension than an untreated hydrogel. This effect is desirable since devices containing these hydrogels may be delivered through a microcatheter.
[0052] For hydrogel networks where the ionizable functional groups are amine groups, the hydrogel is incubated in a high pH solution. Unlike carboxylic acid functional groups, deprotonation occurs on the amine groups of the hydrogel network at high pH. Aside from incubation solution pH, the incubation is carried out similarly to that of the carboxylic acid containing hydrogels. In other words, the duration and temperature of the incubation and the pH of the solution are directly proportional to the amount of expansion control. After incubation is concluded, the excess treating solution is washed away and the hydrogel material is dried.
[0053] In a preferred embodiment, the expansile element 1 is an expansile hydrogel comprised of (a) at least one, preferably non-ionic, ethylenically unsaturated macromer or monomer or polymer having at least two crosslinkable groups; (b) at least one monomer and/or polymer which has at least one crosslinkable groups, and at least one moiety that is sensitive to changes in an environmental parameter; and (c) a polymerization initiator. In some embodiments, the monomers and polymers may be water soluble, while in other embodiments they may be non-water soluble. Suitable polymers for components (a) and (b) include poly(ethylene glycol), poly(ethylyene oxide), poly(vinyl alcohol), poly(propylene oxide), poly(propylene glycol), poly(ethylene oxide)-co-poly(propylene oxide), poly(vinyl pyrrolidinone), poly(amino acids), dextrans, poly(ethyloxazoline), polysaccharides, proteins, glycosaminoglycans, and carbohydrates, and derivatives thereof. The preferred polymer is poly(ethylene glycol) (PEG), especially for component (a). Alternatively, polymers that biodegrade partly or completely may be utilized.
[0054] One embodiment comprises combining in the presence of a solvent (a) about 5% to about 40% of a non-ionic, ethylenically unsaturated macromer or monomer or polymer; (b) about 5% to about 40% of an ethylenically unsaturated monomer or polymer with at least one ionizable functional group; and, (c) a polymerization initiator. Suitable ionizable, ethylenically unsaturated monomers include acrylic acid and methacrylic acid, as well as derivatives thereof. One suitable monomer having at least one ionizable functional group is sodium acrylate. Suitable macromers with two ethylenically unsaturated moieties include poly(ethylene glycol)di-acrylate and poly(ethylene glycol)di-acrylamide, and poly(ethylene glycol)di-acrylamide, which have molecular weights ranging between 400 and 30,000 grams/mole. The use of macromers with a plurality of ethylenically unsaturated groups permits the elimination of the crosslinker, as the crosslinker functions are performed by the multi-functional polymer. In one embodiment, the hydrogel comprises, about 5% to about 40% sodium acrylate, about 5% to about 40% poly(ethylene glycol)di-acrylamide, and the remaining amount water.
[0055] A sodium acrylate/poly(ethylene glycol)di-acrylamide hydrogel is used to enhance the mechanical properties of the previously-described environmentally responsive hydrogel. Since a sodium acrylate/poly(ethylene glycol)di-acrylamide hydrogel is softer than a sodium acrylate/acrylamide hydrogel (e.g., the one utilized in Hydrogel Embolic System (HES) made by MicroVention, Aliso Viejo, Calif.), devices incorporating it may be more flexible. Due to the relative stiffness of the HES, MicroVention recommends pre-softening the device by soaking in warm fluid or steaming the implant. In addition, devices made from acrylamide are relatively straight before pre-softening because the stiffness of the acrylamide-based hydrogel prevents the carrier member (for the HES, a microcoil) from assuming its secondary configuration. Devices made from a sodium acrylate/poly(ethylene glycol)di-acrylamide hydrogel may not require pre-softening techniques such as soaking in warm fluid such as saline or blood or exposure to steam in order to form into a secondary configuration heat-set into the carrier member 2 or a similar carrier member. Thus, in embodiments comprising, for example, sodium acrylate and poly(ethylene glycol)di-acrylamide, a substantially continuous length of hydrogel disposed either within the lumen 3 of the carrier member 2 as shown in, for example, FIG. 1 or on a carrier element such as those shown in the Martinez '981 application or Greene '261, will form into the secondary configuration pre-formed into the carrier member without pre-treatment (e.g. exposure to steam, fluid, or blood). This makes the device easier to use because it allows elimination of the pre-treatment step and the device may be safer when deployed into the patient because a softer device is less likely to cause damage to the lesion.
EXAMPLE
[0056] 3 g of acrylamide, 1.7 g of acrylic acid, 9 mg of bisacrylamide, 50 mg of N,N,N′,N′-tetramethylethylenediamine, 15 mg of ammonium persulfate, and 15.9 g water were combined and polymerized in a 0.020 inch tube. The tubularized polymer was removed from the tubing to prepare Hydrogel 1 in accordance with U.S. Pat. No. 6,878,384.
[0057] 4.6 g of poly(ethylene glycol)diacrylamide, 3.3 g of sodium acrylate, 100 mg of N,N,N′,N′-tetramethylethylenediamine, 25 mg of ammonium persulfate, and 15.9 g water were combined and polymerized in a 0.020 inch tube. The tubularized polymer was removed from the tubing to prepare Hydrogel 2, in accordance with a macromer-containing hydrogel embodiment of the present invention.
[0058] A hydrogel identical to Hydrogel 2 was prepared; however, it additionally was acid treated in accordance with the present invention to prepare Hydrogel 2-Acid.
[0059] A large platinum microcoil has a 0.014 inch outer diameter and a 0.0025 inch filar. A small platinum microcoil has a 0.010 inch outer diameter and a 0.002 inch filar.
[0060] The bending resistance of the unexpanded hydrogel samples and the bending resistance of the microcoils were obtained using a Gurley 4171 ET tubular sample stiffness tester with a 5-gram counterweight attached to its measuring vane. The sample length was 1 inch. The average measured resistance and standard deviation of five replicates each are summarized in the following table.
[0000]
MEASURED RESISTANCE,
SAMPLE
milligrams
Hydrogel 1
88 ± 13
Hydrogel 2
23 ± 1
Hydrogel 2-Acid
1 ± 0
Large Platinum Coil
5 ± 1
Small Platinum Coil
2 ± 1
[0061] The results show the large difference in relative stiffness between the first generation Hydrogel 1 (HES), the second generation macromer-containing Hydrogel 2, the second generation macromer-containing Hydrogel 2 that has been acid treated, and the microcoils. Hydrogel 1 is nearly 20 times stiffer than a large platinum microcoil whereas Hydrogel 2 is less than 5 times stiffer than a large platinum microcoil. The acid-treated Hydrogel 2 is less stiff than a large platinum microcoil and about as stiff as a small platinum microcoil. A skilled artisan will appreciate that much more flexible unexpanded macromer-containing hydrogels are provided by the methods and materials disclosed in the present invention. When used in a medical device, these hydrogels may result in a more flexible medical device as well.
[0062] In another embodiment, monomers are used to impart moieties to the expansile element 1 that are suitable for coupling bioactive compounds, for example anti-inflammatory agents such as corticosteroids (e.g. prednisone and dexamethasone); or vasodilators such as nitrous oxide or hydralazine; or anti-thrombotic agents such as aspirin and heparin; or other therapeutic compounds, proteins such as mussel adhesive proteins (MAPs), amino acids such as 3-(3,4-dihydroxyphenyl)-L-alanine (DOPA), genes, or cellular material; see U.S. Pat. No. 5,658,308, WO 99/65401, Polymer Preprints 2001, 42(2), 147 Synthesis and Characterization of Self-Assembling Block Copolymers Containing Adhesive Moieties by Kui Hwang et. al., and WO 00/27445; the disclosures of which are hereby incorporated by reference. Examples of moieties for incorporation into hydrogel materials include, but are not limited to, hydroxyl groups, amines, and carboxylic acids.
[0063] In another embodiment, the expansile element 1 may be rendered radiopaque by incorporation of monomers and/or polymers containing, for example, iodine, or the incorporation of radiopaque metals such as tantalum and platinum.
[0064] In some embodiments, the carrier member 2 is a flexible, elongate structure. Suitable configurations for the carrier member 2 include helical coils, braids, and slotted or spiral-cut tubes. The carrier member 2 may be made of any suitable biocompatible metal or polymer such as platinum, tungsten, PET, PEEK, Teflon, Nitinol, Nylon, steel, and the like. The carrier member may be formed into a secondary configuration such as helix, box, sphere, flat rings, J-shape, S-shape or other complex shape known in the art. Examples of appropriate shapes are disclosed in Horton U.S. Pat. No. 5,766,219; Schaefer applicaion Ser. No. 10/043,947; and Wallace U.S. Pat. No. 6,860,893; all hereby incorporated by reference.
[0065] As previously described, some embodiments of the instant invention may comprise polymers that are sufficiently soft and flexible that a substantially continuous length of the expansile element 1 will form into a secondary configuration similar to the configuration originally set into the carrier member 2 without pre-softening the device or exposing it to blood, fluid, or steam.
[0066] In some embodiments, the carrier member 2 incorporates at least one gap 7 that is dimensioned to allow the expansile element 1 to expand through the gap (one embodiment of this configuration is shown in FIGS. 1-2 ). In other embodiments, the carrier member 2 incorporates at least one gap 7 that allows the expansile element 1 to be exposed to bodily fluids, but the expansile element 1 does not necessarily expand through the gap (one embodiment of this configuration is shown in FIG. 8 ). In other embodiments, no substantial gap is incorporated into the carrier member 2 . Rather, fluid is allowed to infiltrate through the ends of the device or is injected through a lumen within the delivery system and the expansile element 1 expands and forces its way through the carrier member 2 .
[0067] In one embodiment shown in FIG. 1 , the expansile element 1 comprises an acrylamide or poly(ethylene glycol)-based expansile hydrogel. The carrier member 2 comprises a coil. At least one gap 7 is formed in the carrier member 2 . The expansile element 1 is disposed within the lumen 3 defined by the carrier member 2 in a generally coaxial configuration. A tip 4 is formed at the distal end of the device 11 by, for example, a laser, solder, adhesive, or melting the hydrogel material itself. The expansile element 1 may run continuously from the proximal end to the distal end, or it may run for a portion of the device then terminate before reaching the distal or proximal end, or both.
[0068] As an example, in one embodiment the device is dimensioned to treat a cerebral aneurysm. Those skilled in the art will appreciate that the dimensions used in this example could be re-scaled to treat larger or smaller lesions. In this embodiment, the expansile element 1 is about 0.001″-0.030″ before expansion and about 0.002″-0.25″ after expansion. The expansile element is, for example, approximately 5%-30% sodium acrylate, 10%-30% poly(ethylene glycol)di-acrylamide with a molecular weight ranging between 400 and 30,000 grams/mole, and the remainder water. Those skilled in the art will appreciate that the ratio of expansion could be controlled by changing the relative amounts of sodium acrylate, PEG di-acrylamide, and water. The carrier member 2 in this embodiment is a microcoil in the range of about 0.005″-0.035″ in diameter. In an alternate embodiment, the microcoil diameter has a range of 0.008′-0.016′. The microcoil may have a filar in the range of 0.0005″-0.01″. In an alternate embodiment, the filar range is 0.00075″-0.004″. The implant 11 comprises at least one gap 7 ranging from 0.5 filars (0.00025″) long to 20 filars (0.2″) long. In an alternate embodiment, the gap range is between approximately 0.00025″ to 0.005″. In one preferred embodiment, the microcoil has a diameter of 0.012″ and a 0.002″ filar, with a gap 7 of 0.0013″. A coupler 13 is placed near the proximal end to allow the implant 11 to be detachably coupled to a delivery system or pushed or injected through a catheter. Examples of delivery systems are found in co-pending application Ser. No. 11/212,830 to Fitz, U.S. Pat. No. 6,425,893 to Guglielmi, U.S. Pat. No. 4,994,069 to Ritchart, U.S. Pat. No. 6,063,100 to Diaz, and U.S. Pat. No. 5,690,666 to Berenstein; the disclosures of which are hereby incorporated by reference.
[0069] In this embodiment, the implant 11 is constructed by formulating and mixing the hydrogel material as previously described in order to form the expansile element 1 . The carrier member 2 is wound around a helical or complex form, and then heat-set by techniques known in the art to form a secondary diameter ranging from 0.5 mm to 30 mm and a length ranging from 5 mm to 100 cm. After processing, washing, and optional acid treatment, the expansile element 1 is threaded through the lumen 3 of the carrier member 2 . The distal end of the expansile element 1 is then tied, for example by forming a knot, to the distal end of the carrier member 2 . Adhesive, such as UV curable adhesive or epoxy, may be used to further enhance the bond between the expansile element 1 and the carrier member 2 and to form the distal tip 4 . Alternatively, the tip may be formed by, for example, a laser weld or solder ball.
[0070] In some embodiments, depending on the size of the gap 7 and the ratio of expansion, loops or folds 12 may form as shown in FIG. 7 as the expansile element 1 expands. Although the loop or fold 12 may not affect the functionality of the device, in some embodiments it is desirable to prevent the loop or fold 12 from forming. This can be done by stretching the expansile element 1 either before placing it within the carrier member 2 or after the distal end of the expansile element 1 is secured to the carrier member 2 . For example, once the distal end of the expansile element 1 is secured to the carrier member 2 , the expansile element 1 is stretched to a final length between 101% to 1000% of its initial length (e.g. if the initial length is 1″, the expansile element is stretched to 1.01″-10.0″) or to a length sufficient to prevent loops from forming in the expansile element 1 after expansion. For example, in the previously described cerebral aneurysm treatment embodiment, the expansile element 1 is stretched to a final length, which is approximately 125%-600% of the initial length. In an alternate embodiment, the expansile element 1 is stretched to a final length, which is approximately 125%-300% of the initial length. In one preferred embodiment the expansile element is stretched to a final length that is approximately 267% of its initial length. After stretching, the expansile element 1 may be trimmed to match the length of the carrier member 2 and then bonded near the proximal end of the carrier member 2 by, for example, tying a knot, adhesive bonding, or other techniques known in the art.
[0071] Once the implant 11 has been constructed, it is attached to a delivery system previously described by methods known in the art. The device may also be exposed to, for example, e-beam or gamma radiation to cross-link the expansile element 1 and to control its expansion. This is described in U.S. Pat. No. 6,537,569 which is assigned to the assignee of this application and hereby incorporated by reference.
[0072] Previously, the secondary dimensions of prior devices (e.g. HES) are generally sized to a dimension 1-2 mm smaller than the dimension (i.e. volume) of the treatment site due to the relative stiffness of these devices. The increased flexibility and overall design of the implant 11 of the instant invention allows the secondary shape of the implant 11 to be sized to a dimension approximately the same size as the treatment site, or even somewhat larger. This sizing further minimizes the risk of the implant moving in or slipping out of the treatment site.
[0073] Prior implant devices, such as the HES device, currently provide the user with about 5 minutes of repositioning time. However, the implant 11 of the present invention increases the length of repositioning time. In some embodiments, the repositioning time during a procedure can be increased to about 30 minutes. In this respect, the user is provided with a longer repositioning time to better achieve a desired implant configuration
[0074] FIG. 2 shows an implant 11 similar to that shown in FIG. 1 after the expansile element 1 has expanded through the gap 7 to a dimension larger than the carrier member 2 .
[0075] FIG. 3 shows an implant 11 wherein multiple expansile elements 1 run somewhat parallel to each other through the carrier member 2 . In one embodiment, this configuration is constructed by looping a single expansile element 1 around the tip 4 of the implant 11 and tying both ends of the expansile element 1 to the proximal end of the carrier member 2 . In another embodiment, multiple strands of the expansile element 1 may be bonded along the length of the carrier member 2 . The construction of these embodiments may also comprise stretching the expansile element 1 as previously described and/or forming gaps in the carrier member 2 .
[0076] FIG. 4 shows an embodiment wherein the implant 11 comprises a non-coil carrier member 2 . In one embodiment, the carrier member 2 is formed by cutting a tube or sheet of plastic such as polyimide, nylon, polyester, polyglycolic acid, polylactic acid, PEEK, Teflon, carbon fiber or pyrolytic carbon, silicone, or other polymers known in the art with, for example; a cutting blade, laser, or water jet in order to form slots, holes, or other fenestrations through which the expansile element 1 may be in contact with bodily fluids. The plastic in this embodiment may also comprise a radiopaque agent such as tungsten powder, iodine, or barium sulfate. In another embodiment, the carrier member 2 is formed by cutting a tube or sheet of metal such as platinum, steel, tungsten, Nitinol, tantalum, titanium, chromium-cobalt alloy, or the like with, for example; acid etching, laser, water jet, or other techniques known in the art. In another embodiment, the carrier member 2 is formed by braiding, knitting, or wrapping metallic or plastic fibers in order to form fenestrations.
[0077] FIG. 5 shows an implant 11 comprising a carrier member 2 , an expansile element 1 , and a stretch resistant member 10 . The stretch resistant member 10 is used to prevent the carrier member 2 from stretching or unwinding during delivery and repositioning. The stretch resistant member 10 may be made from a variety of metallic or plastic fibers such as steel, Nitinol, PET, PEEK, Nylon, Teflon, polyethylene, polyolefin, polyolefin elastomer, polypropylene, polylactic acid, polyglycolic acid, and various other suture materials known in the art. Construction of the implant 11 may be by attaching the ends of the stretch resistant member 10 to the ends of the carrier member 2 as described by U.S. Pat. No. 6,013,084 to Ken and U.S. Pat. No. 5,217,484 to Marks both hereby incorporated by reference. Alternatively, the distal end of the stretch resistant member 10 may be attached near the distal end of the carrier member 2 and the proximal end to the stretch resistant member 10 attached to the delivery system as described in co-pending application Ser. No. 11/212,830 to Fitz.
[0078] FIG. 6 is an alternative embodiment comprising a stretch resistant member 10 wrapped around, tied to, or intertwined with the expansile element 1 . This may occur over the length of the expansile element 1 , or the wrapping or tying may be in only one area to facilitate bonding the expansile element 1 to the carrier element 2 by using the stretch resistant member 10 as a bonding element.
[0079] FIG. 7 shows a loop or fold 12 of the expansile element 1 protruding outside the carrier element 2 . In some embodiments, it may be desirable to avoid this condition by, for example, stretching the expansile element 1 as previously described. This would be done, for example, in embodiments configured for delivery through a small microcatheter to prevent the implant 11 from becoming stuck in the microcatheter during delivery. In other embodiments, slack may be added to the expansile element 1 so that the loop or fold will be pre-formed into the implant 11 . This would be done in embodiments where, for example, a large amount of volumetric filling were necessary because the loops or folds would tend to increase the total length of the expansile element 1 .
[0080] FIG. 8 shows an embodiment wherein the expansile element 1 is configured to expand to a dimension larger than its initial dimension, but smaller than the outer dimension of the carrier member 2 . This may be done by adjusting the ratio of, for example, PEG di-acrylamide to sodium acrylate in embodiments wherein the expansile element 1 comprises a hydrogel. Alternatively, a relatively high dose of radiation could be used to cross-link the expansile element 1 , thus limiting its expansion. Embodiments such as shown in FIG. 8 are desirable when low volumetric filling is necessary and it is desirable to have a substrate for tissue growth and proliferation that the expansile element 1 provides. In an embodiment used to treat cerebral aneurysms, this configuration would be used as a final or “finishing” coil, or in devices dimensioned to treat small (under 10 mm diameter) aneurysms, or as a first “framing” or 3-D coil placed. In one embodiment, the expansile element 1 comprises a hydrogel incorporating a porosigen as previously described to provide a reticulated matrix to encourage cell growth and healing. Incorporating, for example, growth hormones or proteins in the expansile element 1 as previously described may further enhance the ability of the implant 11 to elicit a biological response.
[0081] In one embodiment of the invention a vaso-occlusive device comprises an expansile polymer element having an outer surface, a carrier member that covers at least a portion of the outer surface of the expansile polymer element, and wherein no carrier is disposed within the outer surface of the expansile element.
[0082] In another embodiment, a vaso-occlusive device comprises a coil having a lumen and a hydrogel polymer having an outer surface wherein the hydrogel polymer is disposed within the lumen of the coil and wherein the hydrogel polymer does not contain a coil within the outer surface of the hydrogel polymer.
[0083] In another embodiment, a vaso-occlusive device comprises a carrier member formed into a secondary configuration and an expansile element, wherein the expansile element is made from a polymer formulated to have sufficient softness that the expansile element will substantially take the shape of the secondary configuration formed into the carrier member without pre-treatment.
[0084] In another embodiment, a vaso-occlusive device comprises a carrier member formed into a secondary configuration and a substantially continuous length of hydrogel, wherein the device will substantially take the shape of the secondary configuration formed into the carrier member without pre-treatment.
[0085] In another embodiment, a vaso-occlusive device comprises a microcoil having an inner lumen and an expansile element disposed within the inner lumen. In this embodiment the expansile element comprises a hydrogel selected from the group consisting of acrylamide, poly(ethylene glycol), Pluronic, and poly(propylene oxide).
[0086] In another embodiment, a vaso-occlusive device comprises a coil and a hydrogel polymer disposed at least partially within the coil wherein the hydrogel has an initial length and wherein the hydrogel polymer has been stretched to a second length that is longer than the initial length.
[0087] In another embodiment, a vaso-occlusive device comprises an expansile element and a carrier member defining an inner lumen, wherein the expansile element is disposed within the inner lumen of the carrier member and wherein the expansile element has been stretched to a length sufficient to prevent a loop of the expansile element from protruding through the carrier member.
[0088] The invention disclosed herein also includes a method of manufacturing a medical device. The method comprises providing a carrier member having an inner lumen and an expansile element, inserting the expansile element into the inner lumen of the carrier member, and stretching the expansile element.
[0089] In another embodiment, a vaso-occlusive device comprises an expansile element encapsulated by a carrier element, wherein said expansile element is comprised substantially entirely and substantially uniformly of material having an expansile property.
[0090] In another embodiment, a vaso-occlusive device comprises a carrier element and an expansile element wherein the carrier element has a secondary shape that is different from its primary shape and wherein the expansile element is sufficiently flexible in a normal untreated state to conform with the secondary shape of the carrier.
[0091] In another embodiment, a vaso-occlusive device includes a carrier and an expansile element wherein the expansile element is fixed to the carrier in a manner such that the expansile element is in a stretched state along the carrier.
[0092] In another embodiment, a vaso-occlusive device includes a carrier having a plurality of gaps along the carrier and an expansile element positioned along an inside envelope of the carrier and wherein the expansion of the expansile element is controlled such that the expansile element expands into the gaps but not beyond the external envelope of the carrier.
[0093] In another embodiment, a vaso-occlusive device includes a carrier member and an expansile element wherein the expansile element is comprised of multiple strands extending along the carrier.
[0094] In another embodiment, a vaso-occlusive device includes a carrier and an expansile member wherein the carrier is a non-coiled cylindrically shaped structure and wherein said expansile member is disposed inside said carrier.
[0095] In another embodiment, a vaso-occlusive device includes a carrier and an expansile member and a stretch resistant member; said expansile member and said stretch resistant member being disposed in an internal region of the carrier and wherein the stretch resistant member is in tension on said carrier.
[0096] The invention disclosed herein also includes a method of treating a lesion within a body. The method comprises providing a vaso-occlusive device comprising a carrier member and an expansile element wherein the carrier member is formed into a secondary configuration that is approximately the same diameter as the lesion and inserting the vaso-occlusive device into the lesion.
[0097] Although preferred embodiments of the invention have been described in this specification and the accompanying drawings, it will be appreciated that a number of variations and modifications may suggest themselves to those skilled in the pertinent arts. Thus, the scope of the present invention is not limited to the specific embodiments and examples described herein, but should be deemed to encompass alternative embodiments and equivalents.
[0098] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0099] The terms “a,” “an,” “the” and similar referents used in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0100] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
[0101] Certain embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
[0102] Furthermore, numerous references have been made to patents and printed publications throughout this specification. Each of the above-cited references and printed publications are individually incorporated herein by reference in their entirety.
[0103] In closing, it is to be understood that the embodiments of the invention disclosed herein are illustrative of the principles of the present invention. Other modifications that may be employed are within the scope of the invention. Thus, by way of example, but not of limitation, alternative configurations of the present invention may be utilized in accordance with the teachings herein. Accordingly, the present invention is not limited to that precisely as shown and described.
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Devices for the occlusion of body cavities, such as the embolization of vascular aneurysms and the like, and methods for making and using such devices. The devices may be comprised of novel expansile materials, novel infrastructure design, or both. The devices provided are very flexible and enable deployment with reduced or no damage to bodily tissues, conduits, cavities, etceteras.
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This is a division of application Ser. No. 41,606, filed May 23, 1979 now U.S. Pat. No. 4,353,851, which is a continuation of Ser. No. 848,742 filed Nov. 4, 1977, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of this invention includes methods and machines for on-line recycling of both oriented and unoriented film produced on a film extrusion line.
2. Prior Art
Systems for on-line recycling of edge trim produced by a film extrusion line are known and work reasonably well. However, such systems have been generally unsuccessful when applied to oriented tapes produced from oriented or unoriented slit films. The reason apparently being that static charges from the oriented film results in "balling" or "bridging" (terms common to the art) that cause blockages in these systems. Such blockages cause the output of an extruder to surge (too much flow) or to starve (too little flow).
U.S. Pat. Nos. 4,014,461 (1977) and 3,797,702 (1974) both to J. D. Robertson disclose an example of a recycle or reclaim system which works well on edge trim recycled from a film extrusion line, but eventually has problems during production due to bridging when low density reclaim contains oriented film in addition to edge trim.
"Low density reclaim" means chopped film which has an apparent density of less than about 9 pounds/cubic feet (lb/cf). The apparent density is the weight of chopped film which without either induced settling thereof such by shaking of the container or pressure applied thereto just fills a 1 cubic foot container when added thereto after a loose freefall of at least 2 inches but not in excess of about 12 inches.
BRIEF DESCRIPTION OF THE INVENTION
An object of this invention is to provide an automatic reclaim system suitable for use in an on-line configuration with a film extrusion line.
Another object of this invention is to provide a method and machine capable of recycling in an on-line configuration with a film extrusion line both oriented and unoriented slit films, which avoids or substantially lessens problems of prior art systems.
Another object of this invention is to provide an on-line reclaim method and system wherein the rate of recycling is coupled to the operating speed of an in-line extruder.
Another object of this invention is to avoid most of the bridging problems that otherwise frequently interfere with extruder feeding when low density reclaim with an apparent density as low as about 6 lb/cf is recycled.
Another object of this invention is to provide an on-line reclaim method and machine for film produced on an extrusion line wherein at least 11/2, and preferably at least about 2 or 4, and more preferably at least about 5 or more parts by weight of virgin resin pellets to each part by weight of said film in the form of chopped reclaim are positively fed as a mixture into an extruder of said line.
Other objects of this invention will be clear from this Specification.
Generally, the above objects for reclaiming a portion of oriented and unoriented film produced on an extrusion line can be achieved by the process of this invention which comprises: entangling said oriented and unoriented film to form a collection thereof containing at least 25% by weight unoriented film; chopping said collection to form a chopped reclaim; transferring, as for example by means of an auger, at least 11/2 parts by weight of a virgin resin to a mixing zone while simultaneously transferring, as for example by means of a carrier stream, 1 part by weight of said chopped reclaim to said mixing zone; mixing said virgin resin and said chopped reclaim to form a mixture thereof; transferring, as for example by means of one or more augers, said mixture to a plasticization zone which is within said extrusion line; and transferring, as for example gravitationally, additional virgin resin to said plasticization zone downstream from where said mixture enters said plasticization zone. "Downstream" means throughout this Specification and Claims the direction of flow of material which is being plasticated by said means for plasticizing. An example of the mixing zone is a cyclone which is adapted both to separate chopped reclaim from a carrier stream and to mix the incoming chopped reclaim and virgin resin to form a mixture thereof.
Generally, the above objects can be achieved when the improved machine of this invention is used in an on-line configuration with a system for reclaiming a portion of oriented and unoriented film produced on an extrusion line. This system has: at least one carrier stream which can transfer a portion of said film to a means for both entangling said oriented and unoriented film to form a collection thereof containing at least 25% by weight of unoriented film and chopping said collection to form a chopped reclaim therefrom; and at least one other carrier stream which can transfer the chopped reclaim to a means for transferring both virgin resin and chopped reclaim to a means for plasticizing such materials which means is a part of said line. The improved machine of this invention is an improvement to said means for transferring both virgin resin and chopped reclaim which comprises: a first container which is adapted to receive and to store a virgin resin and to transfer both a first and a second part of said virgin resin; a second container which is adapted both to separate incoming chopped reclaim from said at least one other carrier stream and to induce mixing of any virgin resin simultaneously entering therein; a first means for transferring which is adapted to transfer the first part of said virgin resin from the first container to the second container in such a manner that virgin resin and chopped reclaim which simultaneously enters therein become intermixed so as to form a mixture therein; a second means for transferring which is adapted to transfer said mixture from said second container to said means for plasticizing; and a third means which is adapted to transfer the second part of said virgin resin from the first container to a means for plasticizing at a location downstream from where said mixture enters said means for plasticizing.
It is to be noted that preferably all rotary power both to the first and at least a part of the second means for transferring is transferred by a drive means from the screw of an in-line means for plasticization, i.e., an extruder. An example of this drive means comprises a first, second, third and fourth cog wheel, a first chain and a second chain. The first cog wheel is attached to the screw of said extruder so as to rotate as the screw rotates. The first chain is adapted to couple the first cog wheel, which is preferably torque limiting, and the second cog wheel so as to cause rotation of the second cog wheel in response to any rotary movement of the first cog wheel. The second cog wheel is attached to a first powered auger, which comprises a part of said second means for transferring, so as to cause rotation thereof in response to any rotary movement of the second cog wheel. The third cog wheel is attached to the first powered auger so as to rotate in response to rotary movement of the first powered auger. The second chain is adapted to couple the third cog wheel and the fourth cog wheel so as to cause rotary motion of the fourth cog wheel in response to any rotary movement of the third cog wheel. The fourth cog wheel is attached to the powered auger of the first means for transferring so as to cause rotation thereof.
When used in an on-line system for reclaiming a portion of oriented and unoriented film produced on an extrusion line, which has at least one carrier stream that transfers a portion of said film to a means for both entangling said oriented and unoriented film to form a collection thereof containing at least 25% by weight of unoriented film and chopping said collection to form a chopped reclaim therefrom and at least one other carrier stream that transfers said chopped reclaim to a means for transferring both virgin resin and said chopped reclaim to an in-line means for plasticizing such materials, a more specific embodiment of this invention involves an improvement to said means for transferring both virgin resin and said chopped reclaim. This more specific embodiment comprises: a first container which is adapted (i) to receive and to store virgin resin and (ii) to permit both transfer of a first portion of virgin resin to the interior of a first conduit and transfer a second portion of virgin resin gravitationally to the interior of a passageway; a cyclone which is adapted (i) to receive and to separate chopped reclaim from a carrier stream, (ii) to receive the first portion of said virgin resin from the first conduit so that such virgin resin and any chopped reclaim simultaneously being received in the cyclone become intermixed under the influence of the carrier stream so as to form a mixture thereof which collects within the cyclone, and (iii) to transfer this mixture to the interior of a second conduit; the aforesaid passageway, which is attached at one end to the first container and at the other end to the interior of the in-line means for plasticizing, is adapted to accommodate a third conduit with a third auger therein while transferring gravitationally a second portion of said virgin resin into the in-line means for plasticizing; a first conduit which is connected at one end to the first container and at the other end to the cyclone has one end adapted to receive the first portion of the virgin resin and upon rotation of a first auger therein to transfer a first portion of virgin resin to the cyclone; a second conduit which is connected at one end to the cyclone and at the other end to a third conduit, has one end adapted to receive a mixture from within the cyclone and the other end attached to the third conduit so that upon rotation of a second auger therein the mixture is transferred to the interior of the third conduit; the third conduit, which is supported within said first container, has one end disposed within the passageway so that upon rotation of the third auger the mixture is transferred to the interior of an in-line means for plasticizing; a meter which is attached to the first container is arranged to impart rotary motion to the third auger; and a drive means which causes the first and second augers to rotate. This drive means comprises a first, second, third, and fourth cog wheel, a first chain and a second chain. The first cog wheel is attached to a screw of the in-line means for plasticizing so as to cause rotation of this first cog wheel in response to any rotary movement of the screw. The first chain is adapted to couple said first cog wheel and said second cog wheel so as to cause rotation of the second cog wheel in response to any rotary movement of the first cog wheel. The second cog wheel is attached to the second auger so as to cause rotation thereof in response to any rotary movement of the second cog wheel. The third cog wheel is either attached to the second auger or to the second cog wheel so as to rotate in response to any rotary movement of the second auger. The second chain is adapted to couple the third cog wheel and the fourth cog wheel so as to cause rotation of the fourth cog wheel in response to any rotary movement of the third cog wheel. The fourth cog wheel is attached to the first auger so as to cause rotation of the first auger in response to any rotary movement of said fourth cog wheel.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of a typical film extrusion line with an on-line reclaim system which includes the means for feeding of this invention.
FIG. 2 is an enlarged perspective view of the feed system of this invention with a portion cut-a-way to reveal the interior and some walls in crosssection.
In FIG. 1, there is an extrusion line with a reclaim system of this invention comprising: an in-line extruder 10, a cooling bath 11, a slitting stand 19 which has an array of vertically oriented razor blades 23 anywhere from 1 to 10 blades/inch across the width of an extruded film, a first drive and tension control 12, an orientation oven 13, a delustering stand 14, a second drive and tension control 15, an annealing oven 16, a third drive and tension control 17, a winder stand 18, blowers 20a, 20b, 20c, and 20d and a blower 25, conduits 22, 24a, 24b, 24c, and 26, a reclaim cyclone 28, a chopper 29, a feed system 31 of this invention, a drive means or coupling 32, a virgin resin cyclone 38, a container 34, a container 35, a means for conveying 36 and 37, the former for virgin resin and the latter for a mixture of virgin resin and chopped reclaim, and motor 39.
The operation of an extruder line with an attached on-line reclaim system of this invention is as follows.
Virgin resin enters cyclone 38 through inlet port 41 and is gravitationally fed into container 35. Container 35 is adapted to feed said resin into extruder 10 as for example through an open passageway 47 shown in FIG. 2. A gravity method of feeding is preferably used to transfer the virgin resin from container 35 into extruder 10. The virgin resin in the form of pellets fed into extruder 10 is extruded into cooling bath 11 and is then slit on stand 19. Edge trim 40 is recycled by blower 20a through conduit 24a to reclaim cyclone 28, then through a chopper or grinder 29 which converts all film passing therethrough into a chopped reclaim which is transferred in conduit 26 under the influence of blower 25 into the entry port 48 of container 34. The details of how material within container 34 is transferred to extruder 10 will be explained in detail while discussing FIG. 2. The inside diameter (I.D.) of conduit 24a for edge trim 40 is 4 inches and blower 20a attached thereto has sufficient power to move 1,000 cubic feet of air/minute (cfm). The remaining film less edge trim is oriented in oven 13 then treated at delustering stand 14 and then brought into an annealing oven 16 where it is oriented further. Loose ends 42, both before and after annealing oven 16 are fed back through 4 inch I.D. conduits 24b and 24c under the influence of a carrier stream moving at a rate of 1,000 cfm provided by blowers 20b and 20c to reclaim cyclones 28. Subsequent to annealing oven 16 the slit film or ribbon yarn 27 is taken to winder stand 18 shown schematically where it is either rolled on bobbins 21 or recycled as start-up scrap 44 through conduit 22 under the influence of air blown by blower 20d.
Air bleeds 43 are between about 10 to 15 feet downstream of blowers 20a, 20b, 20c, 20d and 25 and can consist of 10 inches of random holes, which range from 1/2 inch to 3/8 inch. The number and density of holes is varied depending upon the amount of bleed found necessary in order to have the system function smoothly, i.e., provide enough suction to carry the loose ends, edge trim, start-up scrap, etc. back to the reclaim cyclone without too much turbulence.
There are some limitations to the reclaim system of this invention is that if the apparent density of the chopped reclaim falls much below about 2 lb/cf then bridging problems occur. However, an apparent density of about 6 lb/cf can be easily handled in the reclaim system of this invention.
It is to be noted that a conventional reclaim cyclone such as disclosed in U.S. Pat. Nos. 4,014,462 (1977) and 3,797,702 (1974) can be used provided the reclaim contains at least about 25% or more edge trim, which is entangled with oriented film before being fed to chopping means 29 preferably employing a scissor-like cut. If much less than 25% of edge is present, then there occur bridging and balling problems from static charge buildup.
The extruder line disclosed in FIG. 1 without the on-line reclaim system is typical of extrusion lines for producing slit film fibers. The use of delustering stand 14 is optional as well as the number of blades/inch across the width. The locations of some of the elements of the line are optional and can be shifted. The edge trim 40, loose ends 42 and start-up scrap 44 ordinarily are collected separately and pelletized after being extruded from an off-line extruder.
In FIG. 2, there is a feed system 31 of this invention which comprises: two containers 34 and 35 connected by two augers 36 and 37, a vertical auger 46, an extruder 10, a drive coupling 32 for coordinating the speeds of the auger 36 and 37 with the screw rate of extruder 10, and motor 39 which drives vertical auger 46.
Container 34, a cyclone, has attached thereto: a chopped reclaim port 48 and two augers 36 and 37. The first auger 36, which connects container 35 and container 34, is adapted to transfer virgin resin from container 35 into container 34 through a wall thereof. Due to flow caused by the carrier stream which is indicated by an arrow in container 34, virgin resin upon entering container 34 is swirled around and intermixed with incoming chopped reclaim. This intermixing aids the settling of chopped reclaim in the form of mixture 50. Auger 37 transfers mixture 50 to vertical auger 46.
Container 35 has attached thereto: a virgin resin cyclone 38 with inlet port 41, a vertical auger 46 powered by a motor 39, and augers 36 and 37. Virgin resin entering port 41 of cyclone 38 is separated from its carrier stream and gravitationally fed into container 35. It is important to maintain the level of virgin resin so as to keep auger 36 completely filled. The location of vertical auger 46 in opening 47 is very important to efficient feeding of extruder 10. Vertical auger 46 transfers mixture 50 into extruder 10 preferably upstream from gravitationally fed virgin resin 49. Location of feeding of virgin resin 49 is indicated by arrow 45. In the event that excess mixture 50 is transferred by auger 37 over that which is being transferred to extruder 10, there is a relief tube 52 which permits such excess to escape. Optionally, a declogging port can be made near opening 47 to insure uniform gravitational feeding of virgin resin 49 by periodic probing therethrough.
It is important that the operating rate of each of the augers 36, 37 and 46 is controlled or coordinated to the rate of extruder 10 so as to insure proper transfer of both virgin resin 49 and mixture 50. The chains 54 and 56 interact with the sprockets on cog wheels 60, 62, 64, and 66 and thereby coordinate to the relative rates of augers 36 and 37 in relation to the operating rate of extruder 10. Cog wheel 60 on the shaft of the screw 51 of extruder 10 is the driving cog and is preferably torque limiting to avoid damage that might otherwise occur in the event augers 36 or 37 freeze.
The size, pitch and rate of turning of the screw of an auger determines the amount of material transferred by that auger. In general, the rates a which the various augers 36 and 37 operate relative to each other and to extruder 10 are such that for each 100 parts by weight (pbw) extruded by extruder 10, there are: between about 40 to about 90 and preferably, as for example in the case of polypropylene, between about 50 and about 80 pbw of virgin resin 49 transferred by auger 36; and between about 45 to about 100 and preferably, as for example in the case of polypropylene, between about 50 and about 90 pbw of mixture 50 transferred to augers 37 and 46. The case of polypropylene involves the extrusion of polypropylene films having a finished thickness after orientation in the range of between about 0.25 mil and about 100 mils. Alternatively, the operating rates of augers 36 and 37 are coordinated so that mixture 50 has for each part by weight of chopped reclaim at least about 11/2 and preferably at least 2 or 4, and more preferably at least 5 or more parts by weight of virgin resin. It is to be noted that in general the higher the parts by weight of virgin resin to chopped reclaim the better. If the parts by weight of virgin resin is not high enough, i.e., falls more and more below about 11/2 parts by weight for each part by weight of chopped reclaim, then bridging in container 34 occurs more and more frequently. The consequences of this bridging are eventual overflow of container 34 and a stopping of the flow of material through auger 37. It is to be noted, however, that the effect upon extruder 10 will be minor because of the alternate feeding possible at 47 of virgin resin 49 from container 35.
The virgin resin used in the reclaim system of this invention can be in the form of hot-cut cylindrical pellets having a diameter in the range of between about 2 millimeters (mm) and about 7 mm and preferably in the range of between about 3 mm and about 4 mm and a length in the range of between about 1 mm and about 7 mm and preferably in the range of between about 2 mm to about 5 mm. As is known, the hot-cut process for forming cylindrical pellets involves chopping an extruded strand while still semi-molten which causes a rounding of all edges. Examples of such virgin resins are extrudable thermoplastics such as polyolefins, polyamides, polyesters, polycarbonates, and the like.
It is to be noted that within opening 47, vertical auger 46 is upstream relative to virgin resin which is gravitationally being fed where indicated by arrow 45. This is important because it is desirable to have the upstream portion of the extruder screw 51 filled by mixture 50 rather than virgin resin 49. If the virgin resin 49 were to feed first, there would be little or no room in screw 51 for mixture 50. Further, it has been found empirically that extruder surging or extruder starving is much less frequent, if at all, with this feeding scheme. Auger screw 59 extends 0 to 6 inches and preferably 1 to 3 inches beyond housing 58 and is about 1/16 inch to about 4 inches and preferably 1/2 to about 1 inch from the top of the extruder screw 51. This arrangement permits some mixing to occur between virgin resin 49 and mixture 50 just prior to its entering extruder 51, but without indriducing so much turbulence as to interfere with uniform feeding of extruder 10.
EXAMPLE
An example of the extrusion line of FIG. 1 in operation is: Polypropylene having a melt flow of between 21/2 to 4 grams/10 minutes at 250° C. is used. This polypropylene initially in the form of hot-cut cylinders 3-4 mm in diameter by 2-5 mm in length is extruded at a melt temperature of between 235°-250° C. into a water bath. The thickness determined immediately after the water bath is 5-6 mils. After orientation the thickness is between 1.8 and 2.2 mils. The water bath is at 30° C. The extruded film is moved through the system by drive means 12, 15, and 17 set at the following speeds, respectively, 130 ft/min., and 775 ft/min. The oven 13 is set at 190°-200° C. and the oven 16 is set at 175°-195° C. Blowers 20a, 20b, 20c, and 20d each of 71/2 horsepower move 1,000 cfm of air and blower 25 of 21/2 horsepower moves 1,000 cfm of air. The chopper means is a granulator Model #1526 sold by Polymer Machinery, Inc. with a screen size of 1/2 inch. The low density reclaim has an apparent density of about 6 lb/cf, auger 36 transfers 60 pbw, and auger 46 transfers 80 pbw.
The above example is intended to be illustrative only. Variations thereon are readily apparent to one skilled in the art and are intended to be within the scope of the invention.
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An improved method and machine for reclaiming in an on-line configuration both oriented and unoriented film produced on an extrusion line, in general, and an improved means within an on-line reclaim system for transferring both virgin resin and chopped reclaim to an in-line extruder, in particular, are disclosed.
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BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to piston rings for reciprocating engines or compressors and to methods of their manufacture.
It will be appreciated that when a piston ring, particularly (but not exclusively) a compression ring having a single gap, of either a plain rectangular cross-section or any other known or convenient cross-section, is installed in an engine, the outer periphery of the ring should be circular and should have an outward resilient load so that it maintains sealing contact with the cylinder bore around the entire periphery. When the ring and bore are new the gap should be small or substantially closed. It is also desirable that as the cylinder bore and/or piston ring wear during operation, the resilient sealing contact between the ring and the bore should be maintained around the entire periphery (although it will be obvious that as the diameter of the piston ring increases by say 0.5% of the diameter, the gap will increase correspondingly). Moreover, to promote good sealing and minimise friction, it is desirable for the outward resilient load to be as uniform as possible around the periphery.
In the following specification and claims, the term `diameter` is used in relation to the inner and outer peripheries of a ring blank even though these peripheries of the ring blank may be precisely circular but may, prior to machining, be slightly oval or elliptical. Nevertheless these peripheries of the ring blank will be approximately circular and so the term `diameter` will, for convenience, be used. Thus, references in the specification and claims to the `diameter` of the ring blank are to be construed accordingly.
The term `closed` as used herein in relation to the condition of a ring blank having a gap cut therein is defined as a condition of the ring blank in which the gap is reduced, as compared with a position of the ring blank when the ring blank is unstressed by external forces, or in which the free ends are lightly in abutment with one another. In most cases, however, there is still a small gap between the free ends in the `closed` condition. The finished ring when contracted to fit into a cylinder bore may be in a `closed` condition, as defined.
The term `circular` as used herein in relation to the machining of a clamped ring blank or blanks is to be construed as meaning circular within the tolerances of which the means used for machining are capable.
DISCUSSION OF THE PRIOR ART
Hitherto, in order to solve this problem, pison rings have been made by one of two methods, which may be outlined as follows:
In the first method the piston ring is machined to have both its inner and outer diameters circular before cutting the gap; the gap is then cut and the piston ring is heat formed by placing it on a mandrel and subjecting it to a high temperature so that the ring is expanded within its elastic limit to have a "permanent set." The extent of this is that on assembly of the piston ring in an engine with the gap closed, the outer diameter is circular and the ring has an inherent resilient load which maintains it in contact with the cylinder bore.
The second known method is to turn the piston ring before cutting the gap so that its inner and outer diameters have a predetermined non-circular form, usually determined by the shape of a cam on a machine of which the cutting tool follows the movement of the cam follower. A predetermined gap is then cut, so arranged that on assembly, when the gap is closed, the external periphery of the ring is circular and has an outward resilient load.
The latter method has the disadvantage that the calculations of the non-circular form assume that the material is homogeneous, and in practice this is not always so.
It has been proposed in British Patent Specification No. 709,246 to provide a machine for forming a piston ring, comprising a device having a plurality of rollers adapted to be spaced round the outer periphery of the ring blank for constricting and holding the ring blank, and a grinding wheel for grinding the outer perpheral surface of the ring blank. This machine has many serious disadvantages. Firstly, the free ends are not maintained at the same predetermined distance apart throughout the machining step. Secondly, instead of the ring blank between its free ends being allowed to take its natural form, allowing for internal stresses and non-homogeneity of the material, it is constricted by a number of, e.g. twelve, spaced rollers, so that the periphery will have a small but significant waviness, with a smaller radius at the point of contact of the rollers and a larger radius between the rollers. Thirdly, the ring blank is not clamped between clamping members against its parallel faces, to prevent it from moving while being machined. Fourthly, the ring blank in this prior art is ground to size progressively around the periphery; therefore the part of the ring which has been ground, and which therefore has a smaller radius than the part not yet ground, must move in an outward direction to maintain contact with the rollers. This implies that the centre of the ring blank moves progressively, as the ring blank is moved round to bring successive positions of its circumference into position to be ground; but unless the centre of the ring blank remains in the same portion, the grinding of the periphery will not result in a ring of which the outer surface is a true circle.
It is an object of the invention to mitigate or overcome these disadvantages.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided a method of manufacture of a piston ring, including the steps of making a ring blank of which the diameter over the outer periphery is greater, and the diameter within the inner periphery is less than that required in the finished ring, cutting a gap in the ring blank to afford two free ends, holding the ring blank in a closed position by the application of a force only to each of the free ends of the ring blank, clamping one or more of said ring blanks in a closed position, and then machining the inner and outer peripheries to be circular.
According to a second aspect of the invention there is provided a method comprising drilling a hole simultaneously and then extending the two pins simultaneously.
According to a third aspect of the invention there is provided a method of manufacture of a piston ring, including the steps of making a ring blank of which the diameter over the outer periphery is greater, and the diameter within the inner periphery is less than that required in the finished ring, cutting a gap in the ring blank to afford two free ends, holding the ring blank in a closed position by the application of a force only to each of the free ends of the ring blank, clamping one or more ring blanks in a closed position between the stationary clamping member and an annular clamping member forming part of a machining head, the machining head being movable towards the ring blank or blanks to bring the annular clamping member into engagement with the or a ring blank to clamp the ring blank or blanks, and then machining simultaneously the interior and exterior peripheries of the clamped ring blank or blanks to be circular, by respective boring and turning tools carried on respective inner and outer parts of the machining head, said inner and outer parts of the machining head being coaxial with, and arranged respectively within and outside the annular clamping member, being movable axially relative to said annular clamping member, after the annular clamping member has engaged the ring blank or blanks and being rotatable relative to the annular clamping member to perform said machining step.
According to a fourth aspect of the invention there is provided apparatus for the manufacture of a piston ring, including means for holding a ring blank having two free ends formed by the cutting of a gap in the ring blank, the ring blank having a diameter over the outer periphery which is greater than, and a diameter within the inner periphery which is less than that required in the finished ring, the holding means applying a force only to each of the free ends of the ring blank to hold the ring blank in a closed position, means for clamping one or more of said ring blanks and means for machining the clamped ring blank or blanks so that the inner and outer peripheries of the ring blank or blanks are circular.
According to a fifth aspect of the invention there is provided apparatus for the manufacture of a piston ring from a ring blank having a diameter over the outer periphery which is greater than, and a diameter within the inner periphery which is less than that required in the finished ring blank having two free ends formed by the cutting of a gap in the ring blank, the apparatus comprising means for holding the two free ends of the ring blank in a closed position by the application of a force only to each of the free ends of the ring blank, a machining head having an annular clamping member and being for movement towards the ring blank to bring the annular clamping member into engagement with the side face of the ring blank to clamp the side faces of the ring blank between said annular member and a stationary clamping member to clamp the ring blank in a closed position, the machining head also including inner and outer parts carrying respective boring and turning tools, said inner and outer parts being coaxial with, and arranged respectively within and outside, the annular clamping member, being movable axially relatively to said annular clamping member, after the annular clamping member has clamped the ring blank, to respective positions for commencement of machining and being rotatable relatively to the annular clamping member for perform said machining step.
According to a sixth aspect of the invention there is provided apparatus wherein the annular clamping member includes a first annular portion having, at one free end, a face for engagement with a ring blank and having at an end opposite said one end a generally annular convexly pat-spherical surface whose centre lies in the plane of the face, and a second annular portion having at one end a concavely part-spherical surface with the same or substantially the same centre and radius of curvature as said convexly part-spherical surface and in engagement with said convexly part-spherical surface to provide a seating therefor which allows rational movement of the first cylindrical portion relatively to the second cylindrical portion.
According to a seventh aspect of the invention there is provided a piston ring for an internal combustion engine, the piston ring having a gap cut therein to afford two free ends and there being a hole in each free end and extending parallel to the axis of the piston ring.
BRIEF DESCRIPTION OF THE DRAWINGS
Some embodiments of the invention will now be specifically described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is an elevation of a piston ring blank;
FIG. 2 is an elevation of the piston ring blank of FIG. 1 showing holes drilled in the ring and a gap being cut in the piston ring blank;
FIG. 3 is an elevation of a part of the piston ring blank of FIGS. 1 and 2 and of a manual tool for closing the piston ring blank;
FIG. 4 is a section on the line IV--IV of FIG. 3;
FIG. 5 is a similar view to FIG. 3 but showing the manual tool in engagement with the piston ring blank and the piston ring blank in a closed position;
FIG. 6 is a section on the line VI--VI of FIG. 5;
FIG. 7 is an elevation, partly in section, of one part of a first apparatus for machining a piston ring blank, a portion of said part being shown in greater detail in an inset;
FIG. 8 is a section on the line VIII--VIII of FIG. 7;
FIG. 9 is an elevation, partly in section, of a second part of the apparatus of FIGS. 7 and 8;
FIG. 10 is an elevation, partly cut away, of part of a second apparatus for machining piston ring blanks;
FIG. 11 is a simplified view of two slides of the apparatus of FIG. 10 and in one position;
FIG. 12 is a similar view to FIG. 11 but with the two slides in another position;
FIG. 13 is an elevation, partly cut away, of part of a third apparatus for machining piston ring blanks;
FIG. 14 is a cross-sectional view of the apparatus of FIG. 13 showing a drilling unit of the apparatus;
FIG. 15 is a similar view to FIG. 13 but showing the piston ring blank with a gap cut therein;
FIG. 16 is a cross-sectional view of the apparatus in the condition shown in FIG. 15 and showing a sawing unit;
FIG. 17 is a similar view to FIGS. 13 and 15 but showing the piston ring blank in a position to be clamped and machined and a pair of arms for centering the ring;
FIG. 18 is a side elevation, partly in cross-section, of a portion of the apparatus of FIGS. 13 to 17 and showing clamping means and a machining head of the apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In piston ring practice it is conventional to refer to the radial dimension of the ring as the thickness and the axial dimension of the ring as the width.
The ratio of diameter to thickness of a piston ring typically varies from 20:1 to 30:1 depending on the material.
Referring first to FIG. 1, a typical piston ring 10 has, when finish machined, an outside diameter of 60 mm, a thickness of 2.5 mm and a width of 2 mm. It is shown and described as a compression ring of plain rectangular cross-section, though it may be of any of a large number of known or convenient cross-sections. The piston ring may be a compression or scraper ring, though it may also be, in suitable cases, an oil control ring, for example, a plain ring of a multi-piece oil control ring.
The ring blank may be cast, or produced by any known or convenient method and preferably has a small degree of ovality, though in certain cases--e.g. where the required gap is small--may be truly circular; the ring blanks thus produced will have a machining tolerance, the reason for which will become apparent; thus the outer diameter will be larger and the inner diameter smaller than the finished dimensions, each by, say, 1 mm. The ring blank may be formed with a notch or projection 12 at a point on its circumference, for the purpose of correctly orientating the ring blank for machining. The side faces 11 are then ground parallel to one another and to the required width.
In a first method of finishing a piston blank of this kind, the piston ring blank 10 (FIG. 1) is formed with two holes of 1 mm diameter through the entire width of the ring, for example by drilling; the holes 13 being at a predetermined distance apart. The holes 13 are drilled close to where the free ends of the ring will be, after a gap has been cut in the ring blank. Preferably, the two holes 13 are drilled before the gap is cut, so that the correct spacing of the holes 13 on the ring blank can readily be achieved. The holes 13 are on respective sides of the position where the gap is to be. This position is where the locating notch or similar feature 12 is formed on the blank.
The gap is then cut, preferably by two circular saw blades 14 (FIG. 2), so as to leave the holes 13 symmetrically disposed in relation to free ends 15 and on the neutral axis of the ring. A plain gap is shown, though, as is well known, this may have different forms. Any notch or projection 12 is removed by this operation. However, if desired, the gap may be cut before drilling the holes.
A manual tool 16 (FIGS. 3 & 4), resembling a pair of pliers with two projecting parallel pins 17 extending from respective ends of jaws 18, has the pins 17 sized to fit in the 1 mm holes 13. The pins 17 are inserted in the holes 13 and the jaws 18 of the tool 16 are then closed to bring the free ends 15 of the ring blank 10 into the closed position (FIGS. 5 & 6). The distance apart of the two holes 13 in this position will be determined by means of co-operating stops 19 on the tool 16. It will be appreciated that both the forces applied to move the free ends 15 of the ring blank 10 to the closed position and the forces holding these ends in the closed position have no or substantially no radially directed components.
The ring 10 is then transferred from the manual tool 16 by sliding the ring 10 so that the holes 13 in the ring engage with two pins 20 on a plane face 21 of a part 22 of a lathe or equivalent machine, the pins 20 being spaced at the same predetermined distance apart as the spacing of the holes 13 when the ring is in the closed position (FIG. 8) so that the ring 10 is maintained in the closed position. The ring 10 is then centralised, by means of a male conical or part-conical member 23 (FIG. 7) engaging against one edge formed between one side face 11 and the inner periphery 24 of the ring 10. The ring 10 is then clamped in this predetermined position against the plane face 21 by a member 25 which is screwed onto a rod 27 and which has a plane face 26 engaging the other side face of the ring. The clamping force is provided by applying a tension through the rod 27 to member 25 by any convenient means, such as a piston and cylinder device. The conical member 23 is loaded against the ring by a spring 28 abutting the central part of member 25. The outer periphery 29 may then be turned to true circular form by rotation of ring 10 clamped between lathe parts 22, 25, relative to a cutting tool 30. The latter is traversed parallel to the axis of rotation by an amount at least equal to the width of the ring 10.
Following this, the ring 10 is unclamped and then centralised (FIG. 9) by a female conical member 31 engaging one edge formed between the outer periphery 29 machined in the previous operation and one side face 11; the ring 10 having its holes 13 either engaged on the same pins 20, or transferred by means of the manual tool described above with reference to FIGS. 3 to 6 to an identical pair of pins 20 formed on a part similar to part 22. As these parts may be identical, the same reference numerals will be used. The ring 10 is then clamped in this predetermined position against the plain face 21 by a member 32 having a plane face 33 engaging the other side face 11 of the ring.
The clamping force is provided by applying a tension through an annular sleeve 34 and links 35 to member 32 by any convenient means, such as a piston and cylinder device. The links 35 are disengageable from the sleeve 34 to allow loading of the ring 10. The conical member 31 is loaded against the ring by springs 36 abutting pockets 37 in member 32.
Next the inner periphery 24 is turned to true circular form by rotation of the ring 10, clamped between parts 22, 32, relative to cutting tool 38. The tool 38 is traversed in a direction parallel to the axis of rotation for a distance at least equal to the width of the ring.
It will be clear that by mounting part 22 to rotate in good quality bearings, and by mounting the cutting tools 30, 38 on rigid supports, an accurately circular ring 10 should be produced. The absence of any substantial radially directed forces on the ring blank 10 before clamping ensures that there is no radial deformation of the ring blank 10 produced by such forces and tending to prevent true circularity being achieved. Moreover, since the outer periphery 29 is machined to be accurately circular in the first turning operation (FIG. 7 and 8) and since the member 31 is also accurately circular, the concentricity of the inner periphery 24 with the outer periphery 29 should be good after the second turning operation (FIG. 9).
However, because in the first turning operation the male conical member 23 contacts the inner periphery 24 in its unmachined state (i.e. its as-cast state when the blank is made by casing, or the as-sintered state when the blank is made by sintering), which is unlikely to be accurately circular, it is preferred to repeat the two operations of clamping the ring between parts 22, 25 and turning the outer periphery 29 as described with reference to FIG. 7 and then unclamping the ring, centering it within member 31, clamping it between members 22, 32, and then turning the inner periphery 24 in the manner described above; it is found that after the turning operations have been repeated the accuracy of the curvature of the ring is even better.
The inside periphery 29 may, of course, be machined before the outside periphery 24. Moreover, any so-called "features", that is grooves, steps, bevels, or other non-rectangular profiles in cross section of the ring will now be machined, preferably with the ring still mounted on the pins 20 and centralised and clamped in one of the two ways described above, as appropriate.
It will be evident that when the ring is freed from the machine, its free ends will move apart, increasing the gap, as a result of the resilience of the material.
Moreover, it will also be evident that, when the ring is installed in the engine, with the gap closed to the predetermined position, the outer diameter will be truly circular and of the correct dimension to fit in the cylinder bore.
Referring next to FIGS. 10 to 12, instead of using a manual tool, the apparatus for the manufacture of the rings may include a pair of slides 40, each having a projecting pin 41 fixed to it, the slides being mounted to move in converging slideways 42.
In one position of the slides (see FIG. 11) the distance apart of the two pins 41 may be such that the ring blank 10, after the formation of the holes 13 and the gap in the manner described above with reference to the drawings, readily engages with the slides 40, by the two holes 13 engaging over the projecting pins 41. In this position, the ring 10 is unstressed by any external forces. The two slides 40 are then moved simultaneously in the converging slideways 42 by equal amounts to their second position (see FIG. 12), so that the free ends 15 of the ring blank 10 are still opposite one another and at equal radial from the centre, but have moved towards one another to a closed position in which the gap is reduced (or the free ends 15 are lightly in abutment with one another). As before, the pins 41 close the free ends 15 of the ring blank 10 and maintain the ring blank 10 in the closed position by applying forces to the ring blank which have no or substantially no radially-directed components.
The ring blank 10 may then be centralised, clamped and machined as described above.
With the slideways 42 symmetrically disposed on each side of a vertical plane, the motion of the two slides 40 may be synchronised by means of a horizontal bar 45 engaging in a corresponding groove 44 in the slides 40, a vertical arm 46 attached to the horizontal bar being raised or lowered by means of a suitable pneumatic ram 47. The bar 45 is trapped between the rear face of the casing in which the slideways 42 are formed and a cover plate, the front of the slides 40 being flush with the front of the bar 45.
In another embodiment illustrated in FIGS. 13 to 18, the ring blank 10 in full annular form (i.e. with no gap) may be loaded into a unit where it is initially located by resting on a projecting rod 48 (which may if desired engage with a notch 12 in the ring blank) and centralised by means of two symmetrically-disposed ways or guides 49. The unit may also comprise a pair of slides 50 in converging slideways 52, substantially as described above with reference to FIGS. 10 to 12, apart from one important difference. The difference is that, instead of the slides having fixed pins 41, the pins 51 can be retracted and extended through guide bore 53 in the slides 50. For this purpose, the pins 51 are attached to pivoted end portions 54 of pivoted levers 55. The latter are loaded by springs 56 to the position in which the pins 51 ar retracted, and may be moved by means of further levers 57 and pins 58 to the position in which the pins 51 are extended. Extension of the pins 51 is effected by means of an actuator 59 acting on the levers 57.
The unit has a base 60 which is substantially annular, and has the same mean radius and slightly smaller thickness than the required finished dimensions of the ring, but has a cut-out portion 61 at the top (see FIG. 13). The surface of the base 60 is co-planar with the surface of the ends of the slides 50 in which the guide bores 53 are formed.
The axes of rotation of two drills 62 are aligned with the axes of the guide bores 53. The drills 62 are driven in any convenient manner, and the drilling unit 63 incorporates a ring blank clamping plate 64 and an associated actuator 65, which clamps the ring blank 10 against the surface of the base 60 and of the ends of the slides 50, before drilling. The drilling uint 63 is then advanced and operated, to drill two holes 13 in the ring blank 10 at a predetermined spacing, such that the holes 13 will be close to the free ends of the ring after a gap is cut, and approximately midway between its inner and outer peripheries. As the drills 62 are retracted, the actuator 59 is operated to cause the two pins 51 to extend, engaging one in each hole 13. To facilitate this, the pins 51 may be of slightly smaller diameter than that of the drills 62.
In this way, the problems of manually positioning the holes 13 of the ring blank over pins (e.g. 20, 41) are overcome.
The drilling unit 63 is then retracted, and a sawing unit 66 is next employed (see FIGS. 15 and 16). A ring blank clamping plate 67 and actuator 68 clamp the ring blank 10 against the surface of the base 60 and of the ends of the slides 50, as described above with reference to FIGS. 13 and 14. The orientation rod 48 is then withdrawn by operation of an actuator, and ways 49 are also withdrawn. The gap is then cut, for example, by two circular saws 69 (see FIG. 16), positioned one on each side of the axis of symmetry, so that the portion of the blank 10 containing the notch or projection 12 is removed. The clamping plate 67 is then released.
The two slides 50 are then moved on their converging slideways 52, until their opposed faces 71, which serve as stops, come into contact with one another. Thus, by means of the projecting pins 51, the ring blank is brought to the closed position, in which the gap is reduced (or the free ends 15 are lightly in abutment with one another). Moreover, the ring blank 10 is, by this movement of the slides 50, brought to a position in which it is substantially in register with the base 60 (though the radial thickness of the base 60 will be less than that of the ring blank, to allow for machining). The ends of the slides 50 substantially fill the cut-out portion 61 (and the radial thickness of these ends will also be less than that of the ring blank). The movement of the slides may be snychronised as described for the previous embodiment or in any convenient way.
With the ring blank 10 in its closed position, supported against base 60 by pins 51, it is centralised by means of a centralising unit shown in FIG. 17 which consists of a pair of meshing gears 74 mounted to rotate in bearings (not shown) and carrying respective arms 73. An actuator 75 is connected to one of the gears 74 to cause the arms 73 to move symmetrically, by virtue of the meshing teeth of the gears 74, on either side of a plane in which lies the desired position of the centre of the ring blank 10, said plane being normal to the plane of the base 60. The free ends 76 of the arms are arranged to contact the ring blank 10 at positions angularly spaced by approximately 120 degrees from the free ends 15 supported on pins 51, so as to centralise the blank 10.
Referring next to FIG. 18, a turning and boring unit 78 is next aligned with the central axis of the ring blank 10. The unit 78 as a whole is movable towards and away from the ring blank 10, for example on slides. The machining head of this unit has three concentric parts. The inner part 79 and the outer part 81 are secured together, and are mounted in a sliding member 82 by means of bearings 83. The outer part 81 carries a sleeve 84 slidable within it against a coil spring 85.
An intermediate annular clamping part 80 is journalled within the outer part 81, is rotatable relative to the inner and outer parts, and has a thrust bearing 86 between itself and the sleeve 84. The intermediate part 80 has a first annular portion 80a including an annular clamping face 87 of substantially the same mean radius and thickness as the base 60. The portion 80a has a convex part-spherical face 88 engaging with a concave part-spherical face 89 on a second annular portion 90 of the intermediate part 80; the common center of these faces lying in the plane of the clamping face 87.
The inner part 79 has a boring tool 91 and the outer part 81 has a turning tool 92 at their ends near the annular clamping face of the intermediate part 80.
In operation, the unit 78 is advanced towards the ring blank 10 and the face 87 engages the ring blank 10 to press and clamp the ring blank 10 against the base 60 and the surfaces of the lower ends of the slides 50. The arms 73 are withdrawn either before this engagement or as the engagement occurs. Continued movement of the unit 78 clamps the side faces 11 of the ring blank 10 between the clamping face 87 and the base 60, which forms a stationary clamping member. The clamping force is partly supplied by the spring 85.
The inner and outer parts 79, 81, including sleeve 84 and coil spring 85, are rotated by any convenient form of drive, and, as the unit 78 is advanced further, the boring tool 91 machines the inner periphery and the turning tool 92 machines the outer periphery of the ring blank 10 traversing across the width of the ring blank. The advance of the unit 78 compresses the spring 85 within sleeve 84, and thus causes an increased clamping force to be exerted through the thrust bearing 86 and the intermediate part 80 on the ring blank 10.
The part-spherical mating faces 88, 89 allow the face 87 to bear evenly on the ring blank 10 around its whole circumference even if the axis of the face 60 is not exactly in alignment with the axis of the intermediate part 80. The boring tool 91 and the turning tool 92 cut at respective points on the surfaces of the ring blank, the points lying on a common radius of the ring blank as they rotate around the ring blank. This ensures that the tools apply no net radial forces to the ring blank.
If desired, there may be provided a rough turning and boring unit, followed by a fine turning and boring unit; as a result of the retraction of part 80, the ring blank 10 will be unclamped between the operation of the former and of the latter unit. Any "features" such as grooves, steps, bevels, etc., may also be machined by means of a suitable tool in a similar way.
It will, however, be seen that in comparison with machines in which the internal and external peripheries are located by means of cones while the external and internal peripheries are machined consecutively, the number of operations is halved and the machining time greatly reduced. In addition, using the apparatus just described, a better approximation to true circular form may be obtained with one machining operation, than is obtained after machining the inside and outside peripheries consecutively.
Piston rings with a circularity of better than three microns have been produced.
It has been found that with rings manufactured as described above with reference to the drawings, the resilient action of the ring against the cylinder bore is maintained around the entire periphery for a longer time, in terms of the wear of the cylinder bore, than with a conventional ring. For example, with a 60 mm diameter rings, as described, a conventional ring may maintain good sealing contact for an increase in cylinder bore size of 0.15 mm on diameter. It has been found that rings made in accordance with the present invention retain good sealing characteristics until about double this amount of wear has taken place.
In addition, the fact that the rings may be machined by normal turning to circular form, rather than on a special machine designed to give a particular non-circular form, tends to reduce the cost of machining.
Instead of the holes being drilled wholly through the axial width of the ring, where the ring is of sufficient width, the holes may be drilled part way only through the width. The criterion is that the pins, whether mounted on a hand tool or on a face of a machine tool, when inserted in the holes, should have sufficient bearing area to enable the gap to be maintained at the predetermined closed dimension. Moreover where the holes are drilled through the entire width of the ring, pins may be inserted in the holes with an interference fit, the projecting portion of the pins enabling the gap to be closed by a suitable tool or slides, and the projecting portion then being ground off.
It will be appreciated that before the ring blank 10 is clamped, it is free from distortions caused by radially directed forces and it may be clamped in this state, as described above. Alternatively, the ring blank may be radially deformed by predetermined radially directed forces before being clamped; the radial deformation being held by the clamping. The radial deformations are chosen so that, after the inner and outer peripheries have been machined to be circular and the ring blank unclamped to release the radial deformations, the peripheries of the ring have a required shape for the insertion of the finished ring in a cylinder bore. For example, finished rings may be produced in this way in which the free ends of the ring depart from true circular form either inwardly, e.g. diesel engines, or outwardly, e.g. petrol engines.
Alternatively, rings having such inwardly and outwardly extending ends may be made by machining a ring blank without radial deformations to be circular but of greater or lesser diameter respectively than the diameter of the cylinder bore.
Other variations within the scope of the invention will be apparent to those skilled in the art.
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The manufacture of piston rings for internal combustion engines comprises making a ring blank of which the diameter over the outer periphery is greater, and the diameter within the inner periphery is less than that required in the finished ring. A gap is cut in the ring blank to afford two free ends and the ring blank is held in a closed position by the application of a force only to each of the free ends of the ring blank. One or more ring blanks are then clamped in a closed position and machined so that the inner and outer peripheries are circular. This enables a ring to be produced which conforms very closely to a required shape and which thus, in use, provides a good seal between a piston and the associated cylinder of an internal combustion engine.
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BACKGROUND OF THE INVENTION
The present invention relates to a method for displaying a battle situation under consideration and indication of the movement and position of friendly forces and with the position and motion behavior of targets being recorded from angular and distance information, as well as to apparatus for practicing the method.
For such a battle situation display, it is necessary to free the measured values obtained by sensors from irrelevant information and to concentrate the measured values for a display on which an observer can observe his own and the enemy's movements, and make decisions regarding tactical consequences.
U.S. Pat. No. 3,981,008 issued Sept. 14th, 1976 discloses a target evaluation device for use with ship's radar which generates target distance information for a plurality of distance ranges. This target evaluation device forms two pulses which identify the azimuthal expanse of the target and which are stored separately in their distance ranges. This information is used to derive the speed and course of the targets which are displayed as motion vectors. The target evaluation device described in this patent, used as a ship's radar and including an active transmitting system, has the drawback that it makes active soundings and, when in operation, gives away the position of the vehicle or ship on which it is installed. Moreover, the military significance of the target cannot be recognized so that the observer requires further information to determine how to adjust the motion behavior of his own vehicle to find ways to fight the enemy targets.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a method for displaying a battle situation without requiring disclosure of the observing vehicle and wherein all target data and observing vehicle data are displayed in a particularly pleasing manner so as to enable evaluation of the battle situation and efficient weapons utilization without additional means.
The above object is accomplished by the present invention by providing a method for displaying a battle situation under consideration and indication of the movement and position of friendly forces and with the position and motion behavior of targets being recorded from angle and distance information. According to the invention: the display takes place on an electronic display device; one or a plurality of passive bearing systems and/or passive distance measuring systems are used to furnish angle and distance information of targets which radiate wave energy; the position, course and speed for every target are calculated per time interval and are displayed as motion vectors; the angle and distance information on the targets from given time intervals are used for the display of target paths; specific markers are associated with the respective targets as a result of their changes in position and/or the characteristics of associated signals received from the bearing and/or distance measuring systems, and these markers are displayed at the associated target positions; and uncertain measurement regions for each target are calculated from the measuring tolerances of the angle and distance information and displayed around the associated target position.
When a battle situation is displayed according to the method of the present invention, located targets, the observing vehicle and picture information required to clarify the battle situation, such as coordinates or legends, are identified on an electronic display by brightness signals. It is known that a vehicle has available to it combinations of instruments, i.e. transducer arrangements and associated signal processing systems, for taking bearings and determining the distance of a target which radiates wave energy, in dependence on its direction, so that angular and distance information can be furnished by such a combination of instruments. For its distance measurements, such a combination of instruments preferably utilizes the cross bearing method with offset transducer arrangement. Such a measuring method is disclosed, for example, in German Patent No. 567,322 issued Dec. 31st, 1932.
On the other hand, transducer arrangements have been provided for circular bearings which are used preferably for determining the angular information, as described, for example, in German Patent No. 1,441,482, issued Apr. 6th, 1972 for obtaining bearings of noise sources. This patent discloses a panoramic sonar system which determines the aximuth and elevation of the impinging wave energy as the angular information.
In conjunction with an angle evaluation system which considers, over a given period of time, the course and the speed of the observing vehicle, this system could also be used to determine the distance information, i.e. as a distance measuring system, as disclosed, for example, in German Patent No. 887,926 issued Aug. 27th, 1953. In that system, distance, course and speed of a noise source are passively determined by taking several bearings from stationary or moving measuring points. The time intervals between several bearings are measured and the distance from the noise source is determined therefrom with the speed being known or estimated. This measuring method employs the principle of doubling-the-angle-of-the-bow bearings.
Angle and distance information are obtained as data with reference to the vehicle. To be able to calculate positions, courses and speeds of targets, the movement of the observing vehicle is included in the calculations. On the display, the direction and speed of each target is displayed by a respective motion vector which is plotted at the position of the target and whose length and direction correspond to the speed and course, respectively, of the associated target.
The positions of the targets determined in given time intervals from angle and distance information are stored in a picture memory. The positions of preceding time intervals or precalculated positions for future time intervals can be stored and utilized for generation and display of target paths, as proposed, for example, in German Patent Application P 29 24 176.7, filed June 15th, 1979.
The target position is displayed by a target specific marker. The particular type of marker used for a specific target is obtained from evaluation of information known about the target. Such known information can be typical changes in position of the target, as for example characteristic maneuvers or travel behavior which also includes vertical movements of submarine vessels. Moreover, special characteristics of the received signals, such as the frequency curve or pulse behavior, as recorded by the passive sounding and/or distance measuring systems are also evaluated for the selection of a marker.
In an advantageous embodiment, the markers are displayed at the positions of the targets by symbols of a predeterminable shape which identify certain predeterminable types of targets and are displayed with an explanatory legend to the side of the display of the battle situation.
As is known, the angle and distance information from the bearing and distance measuring systems include specific measuring tolerances which are inherent in the systems. According to a feature of the present invention these measuring tolerances are used to calculate and to display uncertain measurement areas around the position of each target. If several measuring systems obtain values from the same targets with different measuring tolerances, the measuring results are evaluated differently and the uncertain measurement areas are derived therefrom.
In this regard, it is further known that passive distance measuring systems operating according to the cross-bearing principle require the largest possible distances between their sensors (see German Patent No. 567,322). Consequently, distance measurements made from the bow and from the stern exhibit large measuring tolerances as compared to distance measurements made over the side so that the uncertain measurement areas will differ considerably. Consequently, it might be necessary to turn the observing vehicle if a target in a measuring uncertainty area is of particular interest.
The battle situation may be displayed in polar coordinates, in a grid with degrees longitude and latitude or in a military grid. In a north reference polar coordinate display, the observing position of the observing vehicle together with the motion vector of its movement is displayed at the origin of the coordinate system so that the bearings of the targets with respect to the position of the observing vehicle can be recognized immediately. This display is of particular advantage, for example, for a submarine since these bearing values are available immediately for observation by means of a periscope.
In a grid display, angle and distance information for the target or targets and for the position of the observing vehicle converted to degrees longitude and latitude. This map-like display is of particular advantage if ocean map details are to be included in the battle situation display.
For evaluation of the development of a battle situation, it is necessary to obtain knowledge about the future motion behavior of the targets. For that reason, accordng to an advantageous feature of the method according to the invention, expected target position areas are displayed in addition to the uncertain measurement areas. For the display of these expected target position areas, the positions, course and speeds of the targets at given times are estimated according to known statistical calculations methods from the actually measured or determined positions, courses and speeds of the targets and from their measuring tolerances, and the associated expected target position areas are determined or calculated and displayed. These areas correspond generally to the associated uncertain measurement areas, but cover a larger area, since position, course and speed have also been estimated for this furture point in time. For an evaluation of the battle situation, the display of such expected target position areas has the advantage that the combattability of a target with a particular weapon is made particularly clear and the margin of safety of a decision to use the particular weapon is increased considerably.
If the individual targets move over almost the same or intersecting courses, it is of advantage to use different line elements, such as dots or dashes, to display target paths.
Uncertain measurement areas, expected target position areas and positions of targets can be shown in different colors. Moreover, it is of particular advantage to reduce the intensity of the expected target position areas with respect to symbols, motion vectors and line elements.
According to a further feature of the method according to the invention, the depth of a target is calculated from the angle information in elevation and from the distance information, and this depth is displayed in association with the target. A depth indication is displayed by selecting the marker for this target in the display of the battle situation and/or an alphanumeric indication of the depth in the legend.
To improve the display of the battle situation, another advantageous feature of the method according to the invention provides a passive bearing system for taking bearings and evaluation received signals from active transmitting systems in the form of a pulsed bearing system. Active transmitting systems generally transmit in a frequency range which is higher than that of panoramic sonar systems for taking bearings of noise sources, so that special transducer configurations and signal processing devices must be provided for this purpose. The result of the sounding is indicated by a specially emphasized cursor which extends from the observing vehicle to the target. Such a bearing system is known from German Patent No. 1,766,755 issued July 29th, 1976.
In a further, particularly advantageous feature of the method according to the invention, the signals for each target received from the passive bearing and/or distance measuring systems are subjected to a time and/or frequency analysis. This includes the determination of frequency spectra and their changes in time, as well as signal patterns, pulse shapes and pulse durations of the received signals, and these determined signal characteristics are compared with corresponding signal characteristics of known types of targets. Based on these signal characteristics, the target is identified, and the associated class or signal type is displayed by different markers. Moreover, particularly whenever the comparsion permits the conclusion that the signal is one which is typical for a weapon, a double target or a change in motion behavior, a warning which is noticeable by a special marking is displayed. The realizable advantage is particularly the objective comparability of frequency and signal characteristics. The automatic comparison of actual and stored target data takes place more quickly and reliably than an observer searching through tables, so that early and accurate identification is provided particularly for critical targets.
The advantages realized with the method according to the invention are mainly that a friendly vehicle does not give away itself by transmitting signals from reflected beam ranging systems, since the display of the combat situation according to the invention is composed only of received signals from passive bearing and distance measuring systems from which all further target data for a display of the battle situation, such as distance, position or classification features, are calculated. Moreover, targets are no longer measured in succession by directing all ranging systems onto but a single target to be displayed in the distance range of the battle situation display. By combining all target data in a single battle situation display, a high degree of automatization can be realized, transmission errors can be excluded and an up-to-date view of the situation, without the requirement for additional means, is always available.
The concentration of all data required for the display of the battle situation in a well-organized and easily interpreted display of uncertain measurement areas and expected target position areas gives increased security to the observer of the display in his decision regarding his own motion behavior and the combattability of targets.
The display of uncertain measurement areas is of particular advantage since they indicate that a target is disposed in the uncertain measurement area with close to certain probability. This display indicates whether the observing vehicle is at an unfavorable position with respect to a worthwhile target. The associated uncertain measurement area can then be reduced in that the observing vehicle maneuvers itself to a more favorable measuring position.
It is particularly favorable if the electronic display is a color picture tube because then it is possible, for example, to display the depth particularly clearly and pleasingly by graduations in color.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the display of a battle situation on a screen. According to the method of the invention
FIG. 2 is a block circuit diagram of an apparatus according to the invention for practicing the method according to the invention.
FIG. 3 is a block circuit diagram of a multiplexer suitable for substitute signal transmission according to the invention.
FIG. 4 is a block circuit diagram of a screen with reference to FIG. 2 suitable for coordinate transformation according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the screen 1 of a display device showing a battle situation according to the method of the invention as observed, for example, by a submarine. The display of the battle situation on the screen, is made in polar coordinates with reference to North within a compass card 2 for a selected distance range. The position of the observing vehicle 3, i.e. a submarine, is represented in the center of the display by the symbol in the form of a circle with a cross. From the center of this symbol there is plotted a motion vector 4 for the movement of the observing vehicle, with the direction of this vector 4 indicating the true course of the observing vehicle 3 and with the length of the vector 4 being a measure for the speed of the observing vehicle 3. The additional marker in the form of the letter t indicates that the observing vehicle 3 is submerged, the depth being indicated next to the letter t in a legend 60 on the display device adjacent the compass card 2.
Concentrically around the position of the observing vehicle 3 on the screen 1 there is displayed a panorama 5 of a passive bearing system. This passive bearing system measures the noise level all around the observing vehicle 3 and displays it with inwardly increasing amplitudes. Passive bearing systems of this type are particularly sensitive for indicating the direction of even more remotely disposed noise sources. This display 5 is independent of the displayed distance range of the battle situation.
The battle situation around the observing vehicle 3 is determined by the positions and motion behavior of a target A, a target B and a target C. The position of target A is symbolized by a circle 10 which has been provided with the letter A as further means of distinction. In the same way as for the movement vector 4 for the observing vehicle 3, a respective target movement vector 13 is provided to describe course and speed of each of the targets A, B and C.
Around the circle or marker 10 representing the position of target A there is entered and displayed a rectangular uncertain measurement area 16. The uncertain measurement area 16 has been determined on the basis of the measuring tolerances of the passive ranging and distance measuring system used by the observing vehicle 3 to determine the relative position of the target A. Corresponding to the larger measuring tolerances of the distance measuring system, the area 16 is larger in the radial direction than in the azimuthal direction, leading to the conclusion that the bearing system has the better discrimination. In principle, the actual position of target A, as represented by the marker 10, may be at any point in this uncertain measurement area 16.
Since the target A has been in the observation range of the passive bearing and distance measuring systems of the observing vehicle 3 for a substantial period of time, its motion behavior can be followed. From preceding positions, a target path 17, e.g. a series of dashed lines, is plotted on the display which path 17 characterizes the path of the center of gravity of the preceding uncertain measurement area. Moreover, expected target position areas 18 and 19, which were precalculated from the previous motion behavior of the target A and have a similar shape as the uncertain measurement area 16, are provided on the display. The increase in size of the expected target position areas 18 and 19 with respect to the uncertain measurement area 16, considers the uncertainties of the future motion behavior of target A, particularly the possibility that on account of maneuvering, i.e. due to changes in course or speed, target A might take on a different position in this display.
The observing vehicle 3 is prepared to fight the target A by means of a weapon 30. Based on the known behavior of the target A, a point of impact or hit 31 of the weapon 30 on the target A has been precalculated and displayed. As shown, a position or point of impact which lies in the expected target position area 19 and is identified by a symbol in the form of a propeller has been determined and displayed. The path 32 of the weapon 30 from the position of the observing vehicle 3 to the point of impact 31 is shown as a dashed line on the display. The weapon 30, which in the illustrated battle situation is a torpedo, is identified by a triangle and the letter t, which again indicates that the weapon 30 operates at a certain depth. The depth t of the weapon 30, as well as its course and speed are displayed in the legend 60.
The target B, which is at a bearing of 350° to the right, has its position symbolically identified, as does the target A, by a circle 11. The associated motion vector 13 and target path 33 indicate the actual as well as the past motion behavior of target B. In contrast to the uncertain measurement area 16 of target A, target B is associated with a significantly larger displayed uncertain measurement area 34, particularly in the radial direction. From a comparison of these two displayed areas 16 and 34, the observer of the battle situation can tell that greater measuring tolerances had to be considered in the radial direction for the calculation of the uncertain measurement area 34 for the target B which is directly in the path of the vehicle 3 as indicated by the motion vector 4. The greater measuring tolerances for the target B are the result of the inherent properties of the passive distance measuring system whose measuring accuracy is limited in the forward and backward direction of the observing vehicle 3 as compared to the distance measuring accuracy from the side of the vehicle 3. In contrast to the target B, the target A and also the target C, whose position is represented by a marker 12 in the shape of a rhomboid or diamond, are disposed to the side of the observing vehicle 3 and thus in distance measuring ranges having smaller measuring tolerances. The target B will possibly be attacked later by the observing vehicle 3 at a time when the firing position is more favorable.
As shown in FIG. 1, and as explained above, the same marker or symbol, i.e. a circle, has been used to mark target A, (circle 10) and target B (circle 11). The reason for this is that the same signal characteristics resulted when the signals received by the passive bearing and distance measuring systems from these targets were analyzed as to time and/or frequency and possibly as to their changes in time. These signal characteristics make it possible to associate the target with a class of targets, for example, surface vessel, submarine, aircraft carrier, and/or to identify it, for example a frigate of the Bremen class. In the illustrated examples, a cruiser is symbolized by a circle as shown in the legend 60.
The target A has a star or asterisk adjacent the letter A on the display to indicate, as explained in the legend 60, that a "double target" exists at this location. This results from the time and frequency analysis for the received signals from target A which has shown that noise sources are at this position which belong to several classes. This indicates, for example that the frigate or cruiser indicated by the circle 10 is dragging one or a plurality of decoys behind it.
In the illustrated example, target C has just entered into the distance range of the display of the battle situation. Its actual position is clarified to some extent in the associated uncertain measurement area 41 by a rhomboid sitting on its tip, i.e. a diamond 12. As shown in legend 60, the rhomboid or diamond 12 identifies target C as submarine chaser.
Since the target C has only just entered into the distance range of the display, a target path for the target C cannot be shown yet at the time of the display of the battle situation. The target C is shown under a bearing of 60° oriented toward the right, and travelling in a general direction toward the observer's own vehicle 3. Between the target C and the observer's own vehicle 3, a dot-dash cursor or bearing line 43 is displayed which indicates that the observing vehicle's passive bearing system for taking bearings and evaluating signals received from active transmitting systems is receiving such signals from the target C. If the target C, whose course is toward generally the position of the observing vehicle 3 as indicated by the motion vector 13 extending from the diamond 12, approaches to such a degree that the observing vehicle 3 can be detected by enemy reflected beam ranging systems, the observing vehicle 3 would be in direct danger. Consequently, an additional direct warning is displayed by means of a change in the brightness of the marker 12 for the target C. As indicated, an alarm indication may also be provided on the legend 60.
In the illustrated example the weapon 30 to be used by the vehicle 3 to fight the target A is a wire controlled torpedo. Preferably, according to a feature of the invention, the controllability and operating time of this weapon or torpedo 30 are shown graphically in the form of a bar diagram 45 adjacent and in addition to the display of the battle situation on the compass card 2. In the display 45, the reference numeral 46 represents the point or time of start of travel of the torpedo or weapon 30 while the symbol or marker 47 represents the distance or time at which the end of the wire will be reached between the points 46 and 47, i.e., until the end of the wire is reached, the torpedo can be controlled directly by the observing vehicle 3. The completely blackened area 48 adjacent the point 46 indicates the distance or time already travelled, and hence relative amount of already played out wire, for the weapon 30 to reach the position actually shown or instaneously being represented in the battle situation display. The hatched area 49 on the display 45 corresponds to the wire length, i.e. the directly guided travel time, for the torpedo 30 which is still available, while a bright region 51 following the end of the wire symbol 47 indicates the travel time remaining for the torpedo without guidance by the observing vehicle 3. Within the hatched region 49, a propeller symbol 50 indicates the precalculated point of impact 31 indicated on the battle situation display. The advantage of the additional graph 45 is that the remaining length of wire can be indicated independently of the plotted path 32 of the torpedo 30 in the display of the battle situation.
As indicated above a legend 60 is provided adjacent the compass card display 2 to show the symbols used in the display of the battle situation and explain them in alphanumeric terms. As illustrated, this explanation includes, in addition to the features identifying the targets and their association with a known class or type of target, the parameters characteristic for their motion behavior in the form of numerical values. Of course, the parameters listed in the legend 60 as illustrated are only examples and their specific selection depends on the actual targets represented in the battle situation display.
Turning now to FIG. 2 there is shown a block circuit diagram for a system for displaying a battle situation according to FIG. 1. The reference numeral 80 represents a convential passive bearing system which is equipped with a receiving arrangement 81 which receives noise over the entire azimuthal and elevation angle range. These signals, from the receiving arrangement 81 are transmitted, via preamplifiers 82, to an angle measuring system 83 in order to determine the azimuth and elevation of the angle information from the received signals. A first output of the passive bearing system 80 is connected with an angle data line 84 designed in the form of a bus bar.
A conventional passive distance measuring system 90, which includes a transducer arrangement 91 with series connected amplifiers 92 and processing unit 93, is also provided. A first output of the distance measuring system 90 is connected with a distance data line 94.
The position, course, speed and depth of the observing vehicle, i.e. the observer's own ship 3, are determined in a conventional manner in an own or observing ship data system 100 which is connected via an output with an observer's data line 101. The own ship data system 100 also has an input for receiving a control signal from a control generator 102. The passive bearing system 80 and the passive distance measurement system 90 likewise receive and are actuated by control signals from the control generator 102.
To provide the panoramic display 5 of FIG. 1, a conventional control circuit 105 for a panoramic display of the received signals over the azimuth is provided. Circuit 105 has a first signal input connected to the angle data line 84 and a control input connected with the output of the control generator 102. The output of the control circuit 105 is connected to a picture or image memory 106. With this arrangement, control pulses from the control generator 102 sent to the passive bearing system 80 cause received signals to be emitted by the bearing system 80 and transferred to the control circuit 105 for a panoramic display. In the control circuit 105 the angle and amplitude information for a complete azimuthal sweep are processed and transmitted as brightness information to the image memory 106.
In order to determine the position, course and speed of the various targets, the system is provided with a plurality of conventional signal processors, and in particular a position signal processor 110, a course or direction signal processor 111, a speed signal processor 112 and a depth signal processor 113. Each of these signal processors 110-113 has its input for the angle information connected to the angle data line 84, its input for the distance information connected to the distance data line 94, its input for the necessary data from the observing vehicle connected to the own data line 101, and its output connected to an input of the image memory 106. Each of the processors 110-113 likewise has a control input connected with an output of the control generator 102.
The signals corresponding to the actual positions of the targets, as determined by the position processor 110, are transmitted to a conventional target path computer 125, in addition to being transmitted to the memory 106. The target path computer 125 generates line elements for target paths for actual and preceding positions of the respective targets and transmits intensity signals corresponding to these line elements to the image memory 106.
In the depth processor 113 the respective depths of submerged objects, e.g. submarines, which have been found to be targets are determined from the input data to same, i.e. the data on lines 84, 94 and 101. Signals corresponding to these determined depths are transmits only to the image memory 106.
The data determined by the processors 110 to 112 regarding position, course and speed of a target are fed to a motion vector computer 126. After being enabled by the output signal from the control generator 102, the motion vector computer 126 determines the intensity signals required for displaying a motion vector from the data supplied by the signal processor 110-112 and transmits these intensity signals to the image memory 106. A computer suitable for the processing of motion vectors is well known in the art (see, for instance, the digital computer 114 of U.S. Pat. No. 3,981,008).
From their input values, the position, course and speed signal processors 110-112 calculate the associated measuring tolerances, and transmit these values, in addition to the associated data regarding position, course and speed respectively, to a target area computer 130. In the target area computer 130, future positions at given times for selected targets are precalculated with the methods of probability calculations. Based on the supplied measuring tolerance values and the previous motion curve of these targets, the expected target position areas associated with these positions are determined in the target area computer 130. Signals corresponding to the intensities for areas and outlines of the uncertain measurement areas and/or expected target position areas are transmitted by the target area computer 130 to the image store 106. Control instructions from the control generator 102 are transmitted over respective connections to the image memory 106 and to the target area computer to cause the target area computer to take over the input data at its inputs and for causing the image memory 106 to read out the intensity signals from the target area computer suitable for 130. A computer determining the target area is disclosed in U.S. Pat. No. 3,725,918 issued Apr. 3rd, 1973.
Also connected in the overall system is a passive pulse bearing system 140 including a transducer configuration 141 with a series connected pulse amplifier 142 and a series connected pulse evaluation system 143 for evaluating foreign transmitting energy with respect to its direction of impingement and its time curve. The output of the pulse evaluation system 143 is connected to a pulse data line 132 which is connected to the input of a cursor or bearing trace generating units 145. The cursor generating unit 145 evaluates the output data from the pulse bearing system 140 present on the pulse data line 132, generates intensity signals required to produce a connecting line, for example the line 43 of FIG. 1, from the observing vehicle to the particular target on the screen 1, and transmits these intensity signals to the image memory 106 under control of the control circuit 102. The cursor processing unit 145 is well known in the art; see, for instance, the German Pat. No. 17 66 755, issued July 29, 1976, where the combination of multipliers and integrators for the product signals U 20 and U 21 is suitable to provide a trace signal.
The outputs of the position signal processor 110, the course signal processor 111, the speed signal processor 112 as well as the angle data line 84, the distance data line 94 and the pulse data line 132, are each connected to respective inputs of a classifying computer 131. Control instructions from the control generator 102 are also fed to the classification computer 131 via a control input. In a known manner, the classificaton computer 131 analyzes its input signals with respect to their time and frequency behavior as well as their changes in time. Based on the knowledge to those familiar with target recognition systems that targets are able to perform only movements or changes of movement which are characteristic for their type, that vehicles emit known noises or a characteristic, variety of noises, and that active transmitting systems emit characteristic noises and/or emit characteristic pulses, these characteristic features of the received signals are determined in the classification computer 131 and compared with known signal patterns stored in same. This comparison leads to an association of the target with a known class of targets or with an accurate identification, so that the symbol agreed upon for this association can be assigned to the associated target, whose intensities are stored in the image memory 106, for later display on the screen 1.
If the received signals analyzed in the classification computer 131 contain features of targets which indicate a danger to the observing vehicle, e.g. characteristic noise spectra of a weapon or pulses from an active transmitting system, the intensities of the associated targets on the display are used as a warning signal. For example, the star or asterisk adjacent target A of FIG. 1, are provided together with an explanation in the legend or 60, are provided the brightnesses in the markings of associated targets are rhythmically changed. The signals for producing these special indications are likewise generated in the classification computer 131 and fed to the image memory 106 for subsequent control of the screen display. The classification computer 131 is well known in the art and for instance, disclosed in the U.S. Pat. No. 4,122,432, issued Oct. 24, 1978, which shows a classifier suitable and able to generate the signals for the legend symbols, if it is adequately programmed.
Finally, the outputs of the position, course and speed processors 110 to 112 respectively, are also connected to inputs of a hit computer 135. The hit computer 135 is further connected with and receives input data from data line 101 regarding the observing vehicle and from a unit 136 which provides the required characteristic data of an available weapon which wil be used to combat a selected target. From its input signals, the hit computer 135 calculates a probable point of impact between the weapon and the selected target and generates intensity signals for the display of a hit symbol (symbol or marker 31 of FIG. 1) and a path line (32 of FIG. 1) which are transmitted to the image memory 106. As with each of the other mentioned computers, operation of the hit computer is controlled by the control unit 102. The hit computer 135 is well known in the art; see, for instance, the German Pat. No. 978,063 which shows a computer unit which can be used to compute the point of impact.
The image memory 106 is connected with the control generator 102 via a control line, through which it receives instructions for storing the intensity signals in the image memory 106 and for subsequently reading out the image memory contents for a display on the screen 1.
Preferably, as shown, the operating reliability of the system for displaying the battle situation is increased in that, the output data from the passive bearing system 80, the passive distance measuring system 90 and the passive pulsed bearing system 140 are fed not only directly to the angle data line 84, the distance data line 94 and the pulse data line 132 respectively, but are additionally fed, via a ring or circulating line 150, to a data bus line 151. The passive bearing system 80, the passive distance measuring system 90 and the passive pulse bearing system 140 are connected to the ring line 150 by respective coupling units 152 and are caused, by control instructions from the control generator 102, to transfer the associated angle and distance information to the ring line 150 via the coupling units 152. For this purpose, each of the coupling units 152 is equipped with a receiver and a transmitter as well as with additional coupling and synchronizing circuits. The transfer of the data from the line 150 to the data bus line 151 takes place by means of a coupling stage 155.
The control circuit 105, the position processor 110, the course processor 111, the speed processor 112, the depth processor 113, the bearing unit 145 and the classification computer 131 are connected to the data bus line 151 by means of respective additional inputs and are activated by address bits which are associated with the angle and distance information so as to take over the angle and distance information. For purposes of control and monitoring, the ring line 150 is connected, via a control coupling stage 156, with the control generator 102.
The determination of angle and distance information is of such primary importance for the display of the battle situation that a substitute passive bearing system 160 is provided. It includes a substitute receiving device 161, a substitute amplifier 162 and a substitute measuring system 163. The substitute bearing system 160 is connected, via an input or an output, with a substitute coupling stage 165 of the ring line 150 and can be actuated by the control generator 102. The substitute measuring system 163 furnished angle information for targets radiating wave energy and additionally determines the distance information for the target according to the principle of a double the angle of the bow bearing under consideration of the data for the observing vehicle. The data about the observing vehicle necessary for this purpose are fed to the substitute measuring system 163 via further data coupling, circuit 166 which is connected to the own data line 110 and is included in the ring line 150. The ring or circulating data line 150 is well known in the art; see, for instance, the telecommunication system as disclosed in the U.S. Pat. No. 3,652,798, issued Mar. 28, 1972, including a timing station which is part of the control generator 102 and the coupling unit 156.
Not shown in the control generator 102 are test checking systems which check the operation of the bearing, substitute bearing, distance measuring and pulse bearing systems 80, 160, 90, and 140, respectively, of the processors 110 to 113, and of the computers 125 to 131 and 135. The operational reliability of the entire system can now be increased considerably in that a multiplex circuit 107 is connected between the preamplifier 82 and the angle measuring system 83 of the bearing system 80. The second input of this multiplex circuit 107 is connected with the output of the substitute amplifier 162 of the substitute bearing system 160. When there is a malfunction in the receiving device 81 or the preamplifier 82, the multiplex circuit 107 is caused to switch over and establish a connection between the input of the angle measuring device 83 and the substitute receiving arrangement 161 and its substitute amplifiers 162 of the ranging system 160. Thus the angle information can be provided to the signal processors and other circuits used to generate the display by the more powerful angle measuring device 83, which now receives the received noise via the substitute receiving arrangement 161 and the substitute amplifier 162. Thus, by utilizing essentially the same design for the angle measuring system 83 and the substitute angle measuring device 163 for forming angle information, further additional substitute operational functions may be provided. For example, by introducing additional multiplex units, it is possible to replace circuits, such as filters, integrators or processing units, by their respective identical functions in the substitute measuring system 163 and vice versa. The control generator 102 includes an error checking circuit which is well known in the art by the German Offenlegungsschrift 26 06 669, published Aug. 25, 1977. The German application discloses a method for testing digital systems, which is suitable to check the various signal processing units and to control the multiplexer 107.
FIG. 3 shows a multiplexer 107, which can be used in various processing and computing circuits of the invention. The multiplexer 107 includes an address unit 1071 having an input which is connected to the control generator 102. The address unit 1071 compares addresses from the control generator with its significant address. An output of the address unit 1071 is connected to a first AND-Gate 1072 and to an inverted input of a second AND-Gate 1073 whose outputs are combined in an OR-Gate 1074 and switched to the output 1075 of the multiplexer 107. A second input of the first AND-Gate 1072 and a second input of the second AND-Gate 1073 are the inputs 1076 and 1077 of the multiplexer 107. For normal operation the address unit 1071 has a logical HIGH-signal to open the AND-Gate 1072 and all signals at input 1076 are switched to the output 1075. In case of detecting a fault in signal processing, the control generator 102 transmits an address and an operand code which is identified in the proper address unit 1071. A logical LOW-signal is generated to stop normal signal transmitting and initiate substitute signal transmitting from input 1077 to output 1075 of the multiplexer 107. The multiplexer 107 shown in FIG. 2 is connected to the amplifier 82 with its input 1076, to the substitute amplifier 162 with its input 1077, and to the angle measuring system 83 with its output 1075. It is also possible to use this multiplexer 107 in connection with the processors 110 to 113 and 145 and with the classification computer 131 to distinguish the normal data on the lines 84 and 94 from the substitute data on line 151. In this case, the input 1076 is connected to line 84 or 94 and the input 1077 to line 151. The output 1075 is connected to the corresponding input of the processors 110 to 113, 145 and the computer 131.
FIG. 4 shows a modification of screen 1 in FIG. 2 including a screen unit 1001 and a cathode ray tube 1002. The screen unit 1001 transforms the data from the image memory in order to control the cathode ray tube 1002. The battle display is stored in the image memory in polar coordinates and the screen unit 1001 converts them into cartesian coordinates with a given origin. Such a screen unit 1001 is well known in the art, is disclosed, for example in the German Auslegeschrift 28 21 421, corresponding to U.S. patent application Ser. No. 799,064, filed May 20, 1977 (now U.S. Pat. No. 4,149,252, issued Apr. 10, 1979), and is suitable for displaying a battle situation with a military grid net.
It is to 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 for displaying a battle situation under consideration and indication of the movement and position of friendly forces and with the position and motion behavior of targets being derived from angle and distance information, wherein: the display takes place on an electronic display device; one or a plurality of passive bearing systems and/or passive distance measuring systems are provided to furnish angle and distance information of targets which radiate wave energy; position, course and speed are calculated for every target per time interval and displayed as motion vectors; angle and distance information on the targets from given time intervals are used for the display of target paths; markers are associated with the targets resulting from their changes in position and/or the characteristics of signals received from the bearing and/or distance measuring systems and these markers are displayed at the associated target positions; and uncertain measurement regions are calculated from the measuring tolerances of the angle and distance information and displayed for each target.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of International Patent Application No. PCT/EP2006/068730 filed on Nov. 21, 2006 and entitled “RADAR SYSTEM”, the contents and teachings of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a radar system, and relates specifically to scanning radar systems that are particularly, but not exclusively, suitable for detecting and monitoring ground-based targets.
BACKGROUND OF THE INVENTION
[0003] Radar systems are used to detect the presence of objects and to measure the location and movement of objects. In general, radar systems are designed for a specific application: to measure distance over a specified range of distances; over a specified scan region; within a specified level of accuracy; and in relation to a specified orientation. For radar systems that are required to scan over large distances, the antennas are required to generate powerful electromagnetic radiation, requiring the use of a correspondingly powerful source and specific types of antennas.
[0004] It is common for such radar systems to sweep across a given region, scanning the region for the presence of such objects. In order to sweep over the region the radar systems either employ mechanical devices comprising an antenna that physically moves in space, or electronic devices comprising elements that are arranged to steer radiation as it is transmitted or received. A problem with the mechanical radar systems is that their operation is reliant on physical components and associated control and moving parts. This inventory of parts is costly and can require a commensurately large power source.
[0005] One known group of electronic devices is phased antenna arrays, which apply various phase shifts to signals, thereby effectively steering the received and transmitted beams. These electronic devices are commonly used in RF sensor and communications systems because they do not involve physical motion of the antenna and are capable of moving a beam rapidly from one position to the next. Whilst radar systems incorporating such devices can provide an extremely accurate measure of the position of targets, a problem with these types of electronic devices is that adequate control of the beam requires often several arrays of electronics components; this increases the physical size, complexity and cost of the radar system.
[0006] Another group of such electronic devices is frequency scanning arrays, which, in response to input signals of varying frequencies, can steer a beam in an angular plane. Frequency scanning arrays have been combined with moving parts that rotate in another plane, as described in U.S. Pat. No. 4,868,574. However, a problem with this combination is that it incurs the size and cost shortcomings of regular mechanical scanning system and performance-wise, is less accurate than the phased antenna systems.
[0007] It will therefore be appreciated that the various known radar systems are one or several of costly, bulky and heavy, which limits their applicability to uses in which either cost or weight or size are an issue.
SUMMARY OF THE INVENTION
[0008] In accordance with a first aspect of the present invention, there is provided a scanning radar system comprising a frequency generator, a frequency scanning antenna, and a receiver arranged to process signals received from a target so as to identify a Doppler frequency associated with the target,
[0009] wherein the frequency generator is arranged to generate a plurality of sets of signals, each set having a different characteristic frequency, the frequency generator comprising a digital synthesiser arranged to modulate a continuous wave signal of a given characteristic frequency by a sequence of modulation of patterns whereby to generate a said set of signals, and
[0010] wherein the frequency scanning antenna is arranged to cooperate with the frequency generator so as to transceive radiation over a region having an angular extent dependent on the said generated frequencies.
[0011] The inventors of the present invention have focussed the design effort on low power radar systems that are capable of detecting and locating objects moving along the ground, and to this end have combined digital synthesiser techniques, which are capable of precise frequency generation and control, with passive frequency scanning and Doppler processing techniques. This enables accurate control of range and of scan rates, and enables optimisation of range cell size for factors such as slow and fast target detection and Signal to Noise ratio, and thus enables detection of targets located at distances considerably farther away than is possible with known systems having similar power requirements.
[0012] With scanning radar systems there is inherently a trade off between the rate at which an area is scanned and the range, or distance, over which targets can be detected during the scan. For relatively fast scan rates, a given angular region can be scanned several times as a target moves relative to the region, but the number of signals in a given set of signals will be correspondingly limited, with the result that the detectable range will be limited. For relatively slow scan rates, the number of signals in a given set of signals is relatively high, meaning that targets located further away can be detected, at the expense of tracking movement of targets within the angular region. Advantageously these parameters can be accurately and repeatably controlled by the digital synthesiser, while use of a frequency scanning radar means that the radar system can return to transmit at precisely the same angle at which signals have previously been transmitted, thereby reducing errors in range return associated with Doppler modulation that are associated with mechanical scanning radar systems.
[0013] The range R max of the scanning radar system according to embodiments of the invention can be estimated from the radar equation R max =(P t G A e σ/((4 π) 2 S min )) 1/4 , where S min is the minimum detectable signal (as a power value), P t is the transmitted power, G is the gain of the antenna, A e is the effective aperture of the antenna and σ is the cross sectional area of the target. For a target having a cross sectional area of approximately 1 m 2 , the maximum range R max is approximately 5 km; for targets such as cars, which present a cross sectional area of approx 10 m 2 , the maximum range R max is approximately 9 km while for larger targets having a cross sectional area of the order 100 m 2 , the maximum range R max is approximately 15 km. It will be appreciated that as the scanning duration in a particular direction increases, the value of S min will decrease; accordingly, for a given target size, the radar range in respect of that target in the particular direction will increase until, due to system imperfections, target motion and Doppler spread, further scanning in that direction cannot reduce S min or increase P t any further to have a material bearing on R max .
[0014] Since signal strength is proportional to distance to the fourth power from source, an advantage of designing a short range radar system is that the power required to transmit radiation within a range of tens of km requires less power than conventional radars typically require. Consequently the weight and required output of the power source components is less than that required by conventional radar systems.
[0015] The radar system might be physically located on the ground or sited upon an object that is itself grounded (such as on a floor of a building or upon a vehicle).
[0016] A further advantage of embodiments of the invention is that frequency scanning antennas are less complex, in terms of processing and control components, than phased antenna arrays or mechanical steering antennas. As a result, the size and weight of the antenna circuit components are relatively small and light, respectively. These factors together enable the radar system to be powered by for example a 12 Volt battery, a solar panel or a vehicle battery (e.g. via a convenient connection within the vehicle such as a cigarette lighter) such as a 12, 24 or 48 Volt vehicle battery.
[0017] In one arrangement the radar system is arranged to transmit data indicative of radiation received and processed thereby to a remote processing system for display, review and interpretation at the remote processing system instead of at the radar system, thereby further reducing the processing and control components required by the radar system. Advantageously, and as will be appreciated from the foregoing, since a radar system according to this aspect of this invention is neither bulky nor heavy, it readily lends itself to portability.
[0018] Having selected a frequency scanning antenna, the inventors were faced with the problem of identifying a frequency source that minimises the amount of phase noise in the signal, so as to enable discrimination between small targets that move and large stationary targets. Most known synthesisers utilise a fixed frequency source (e.g. in the form of a crystal oscillator), which, in order to generate a range of frequencies, are integrated with a circuit that includes frequency dividers and a variable frequency oscillator (conventionally referred to as Phase Locked Loop Synthesisers). Such variable frequency oscillators inherently have a certain amount of phase noise (typically referred to as dither) in the output signals, and phase locked loop synthesisers multiply up the signal received from the signal generator, including the noise. As a result, a signal with a significant amount of dither, when reflected from a stationary target, can confuse the signal processing components and appear as a moving target.
[0019] Preferably, therefore, the frequency generator is embodied as a signal generator comprising a first circuit portion and a second circuit portion,
[0020] the first circuit portion comprising a variable frequency oscillator arranged to output signals at an output frequency in dependence on control signals input thereto and tuning means arranged to generate said control signals on the basis of signals received from the second circuit portion for use in modifying operation of the variable frequency oscillator,
[0021] the second circuit portion being arranged to receive said output signals and to derive therefrom signals to be input to said tuning means, the second circuit portion comprising a frequency divider arranged to generate signals of a divided frequency, lower than said output frequency,
[0022] wherein the second circuit portion comprises means arranged to derive reduced frequency signals from said output signal, said reduced frequency signals being of a frequency which is lower than said output frequency and higher than said divided frequency.
[0023] Conveniently the frequency generator further includes a fixed frequency oscillator such as a crystal oscillator or SAW (Surface Acoustic Wave) oscillator, which provides input to the first circuit portion. In one arrangement the tuning means of the first circuit portion preferably comprises a further frequency divider and a phase comparator, and the second circuit portion comprises a static frequency multiplier and a mixer which cooperate so as to reduce the frequency of signals that are input to the frequency divider of the second circuit portion. The further frequency divider associated with the first circuit portion is employed to step-down the fixed oscillator frequency, so as to control the frequency resolution of the signal generator. In relation to the second circuit portion, the frequency divider is employed to step-down the frequency of signals output from the mixer, and the output from the first and second frequency dividers are synchronised by a phase comparator, which generates said control signals (in the form of phase-error signals) to modify the output of the voltage controlled oscillator. Conveniently the second circuit portion serves to reduce the frequency of signals that are input to the second frequency divider, which means that the amount of multiplication required by the second frequency divider is correspondingly reduced.
[0024] Since phase noise is dependent on the amount by which the frequency of a given signal is multiplied, substantially less phase noise is present in the signals generated by embodiments of the invention compared with that generated by conventional signal generators. In addition, this means that phase locked loops of signal generators embodied according to the invention are capable of operating at higher loop frequencies than is possible with conventional arrangements.
[0025] Essentially, therefore, the inventors identified a specific arrangement of components which minimises the amount by which output from the frequency source is multiplied, and thus the amount of phase noise that is transmitted.
[0026] In preferred arrangements, the scanning radar system is a Frequency Modulated Continuous Wave (FMCW) radar system, which is arranged to output a frequency modulated signal of a predetermined pattern, preferably comprising a sequence of linear frequency sweeps. In a most convenient arrangement the digital synthesiser is responsive to inputs so as to repeat the modulation pattern a predetermined number of times.
[0027] Radar systems are commonly used to identify the Doppler frequency of targets so as to identify the magnitude and direction of movement thereof. The inventors have identified a problem with FMCW radar resulting from the fact that a target's Doppler frequency is dependent on the radar's carrier frequency, namely that a radar which operates within a range of frequencies can generate Doppler frequencies for a given target which can, of themselves, indicate movement of the target. The inventors realised that by varying the period of the frequency sweeps in proportion to the carrier frequency, the normalised Doppler frequency remains substantially constant.
[0028] Accordingly in relation to this aspect of the present invention, the inventors have developed a frequency scanning radar controller for use in controlling frequency modulation of a continuous wave signal, the continuous wave signal having a characteristic frequency and being modulated by a sequence of modulation patterns, wherein the radar controller is arranged to modify a given modulation pattern in dependence on the characteristic frequency of the signal being modulated.
[0029] In preferred embodiments of the invention the radar controller is arranged to modify the duration of individual patterns in the sequence, thereby modifying the modulation pattern. In one arrangement each modulation pattern of the sequence comprises a linear ramp period and a dwell period, and the radar controller is arranged to modify the duration of dwell periods of respective modulation patterns in the sequence, thereby modifying the modulation pattern. In another arrangement each modulation pattern of the sequence comprises a linear ramp period and a descent period, and the radar controller is arranged to modify the duration of descent periods of respective modulation patterns in the sequence, thereby modifying the modulation pattern. In other arrangements the modulation pattern includes a combination of a ramp period, a descent period and a dwell period, in which case the duration of either of the descent or dwell periods can be modified.
[0030] Conveniently the frequency generator is responsive to inputs indicative of the respective durations so as to modulate the characteristic frequency.
[0031] In relation to the frequency scanning antenna, the inventors found that a particularly efficient antenna (in terms of level of complexity—relatively low—and performance—relatively good) is the travelling wave antenna. The inventors were then faced with the problem that a travelling wave antenna only radiates over a relatively narrow scan angle as the frequency is changed, this limiting the scan area over which the antenna could be used.
[0032] The inventors realised that two or more array antennas could be arranged to form an antenna structure, and that, by coordinating the feed to a respective antenna array of the antenna structure, individual scan areas can be combined to generate an increased overall scan region.
[0033] Accordingly the inventors developed a frequency scanning antenna structure for transceiving radio frequency energy and being capable of steering a radio frequency beam to a plurality of different angles about the antenna structure, the antenna structure comprising at least two array antennas and a controller for controlling input of energy to the two array antennas, wherein the array antennas are disposed within the antenna structure such that the antenna structure is capable of steering a beam to a first angle using one of said two array antennas and of steering a beam to a second angle, different to said first angle, using the other of said two array antennas.
[0034] In one arrangement the antenna structure is arranged to steer a beam across a plurality of non-contiguous angular regions, and in another to steer a beam across a contiguous angular region. Conveniently the antenna structure is capable of steering a beam across a first range of angles (a first angular region) using one of said two array antennas and of steering a beam across a second range of angles (second angular region) using the other of said two array antennas: the first and second angular regions being different, and collectively offering a scan region of an angular extent greater than that achievable with individual antenna arrays.
[0035] Conveniently each said array antenna comprises input means for inputting said energy thereto, and the controller is arranged to input energy to respective array antennas so as to steer the beam to said first and second angles. More specifically, each input means is arranged to input energy to respective array antennas so as to steer the beam across said contiguous or non-contiguous angular regions. In one arrangement the input means is connectable to ends of the antenna array and is in operative association with a frequency generator—such as that described above—so as to receive signals comprising radio frequency energy at a plurality of different frequencies in order to steer the beam.
[0036] Preferably the controller is arranged to input energy in accordance with a predetermined sequence so as to steer the beam across said first and second angles, the sequence comprising, for example, inputting energy to a first end of the first antenna array, inputting energy to a first end of the second antenna array, inputting energy to a second end of the second antenna array, and inputting energy to a second end of the second antenna array.
[0037] In relation to the configuration of the antenna structure itself, the antenna structure can conveniently be characterised in terms of a longitudinal axis and a transverse axis perpendicular to said longitudinal axis: a first of said array antennas being inclined at said first angle relative to said transverse axis and a second of said array antennas being inclined at said second angle relative to said transverse axis. Moreover, the first and second array antennas are symmetrically disposed about the longitudinal axis and each of said array antennas comprises two ends and two side portions, a side portion of said second array antenna substantially abutting a side portion of said first array antenna. The extent of the scan region is dependent on the physical relationship between the two array antennas, more specifically on the angle each respective array antenna makes to the transverse axis. In one arrangement the angular extent of the radar system is substantially 80 degrees, but other angles are possible, ranging from 60 degrees, 100 degrees, 120 degrees, consistent with various arrangements of the antenna arrays within the antenna structure. Furthermore the antenna structure can be configured so as to include more than two array antennas, thereby further increasing the angular extent of the radar system.
[0038] In one arrangement, each of the array antennas comprises a mesh structure and a dielectric base. Each mesh structure can comprise a plurality of interconnected elements embodied as a micro circuit strip (commonly called a microstrip) and can conveniently be disposed on a surface of a corresponding said dielectric base.
[0039] The mesh structure can conveniently be characterised by the lengths of respective sides and ends of the elements: each of said elements comprising two sides and two ends of respective lengths, the length of said sides being greater than the length of said ends. Typically the length of the sides is of the order of one wavelength at a mid-point between said first frequency and said second frequency and the length of the ends is of the order of one-half of one wavelength at said mid-point frequency. Each mesh element has a characteristic width, and in a preferred arrangement the mesh widths of the sides are progressively decreased from the centre of the mesh to each respective end thereof. Since impedance is inversely proportional to mesh width, it will be appreciated that this provides a convenient means of controlling the impedance of the antenna array elements and thus the resulting radiation pattern.
[0040] Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a schematic block diagram showing components of a radar system according to embodiments of the invention;
[0042] FIG. 2 is a schematic block diagram showing an arrangement of components of a frequency generator shown in FIG. 1 ;
[0043] FIG. 3 is a schematic diagram showing a modulation pattern for use by the frequency generator of FIG. 2 ;
[0044] FIG. 4 is a schematic block diagram showing an alternative arrangement of components of a frequency generator shown in FIG. 1 ;
[0045] FIG. 5 a is a schematic diagram showing an embodiment of an antenna array utilised in the antenna shown in FIG. 1 ;
[0046] FIG. 5 b is a schematic diagram showing another embodiment of an antenna array utilised in the antenna shown in FIGS. 1 and 4 ;
[0047] FIG. 6 is a schematic diagram showing components of a radar system according to an alternative embodiment of the invention;
[0048] FIG. 7 is a schematic engineering drawing showing an antenna structure comprising the antenna arrays of FIG. 5 a or 5 b for use in either of the radar systems shown in FIG. 1 or 6 ;
[0049] FIG. 8 a is a schematic diagram showing radiation emitted from the antenna structure of FIG. 7 for a given output frequency;
[0050] FIG. 8 b is a schematic block diagram showing radiation emitted from the antenna structure of FIG. 7 for two different output frequencies;
[0051] FIG. 9 is a schematic block diagram showing components of a radar system according to yet another embodiment of the invention;
[0052] FIG. 10 is a schematic engineering drawing showing an antenna structure comprising the antenna arrays of FIG. 5 a or 5 b for use in any of the radar systems shown in FIG. 1 , 6 or 9 ;
[0053] FIG. 11 is a schematic diagram showing radiation emitted from the antenna structure of FIG. 10 ;
[0054] FIG. 12 is a schematic flow diagram showing steps performed by the controller shown in FIG. 1 during scanning of the radar system of FIG. 1 ;
[0055] FIG. 13 is a schematic diagram showing processing of signals in relation to a transmitted modulation pattern;
[0056] FIG. 14 is a schematic block diagram showing components of a radar system according to yet another embodiment of the invention;
[0057] FIG. 15 is a schematic block diagram showing components of a radar system according to a yet different embodiment of the invention; and
[0058] FIG. 16 is a schematic engineering drawing showing an alternative antenna structure comprising the antenna arrays of FIG. 5 a or 5 b for use in either of the radar systems shown in FIG. 1 or 6 .
[0059] Several parts and components of the invention appear in more than one Figure; for the sake of clarity the same reference numeral will be used to refer to the same part and component in all of the Figures. In addition, certain parts are referenced by means of a number and one or more suffixes, indicating that the part comprises a sequence of elements (each suffix indicating an individual element in the sequence). For clarity, when there is a reference to the sequence per se the suffix is omitted, but when there is a reference to individual elements within the sequence the suffix is included.
DETAILED DESCRIPTION OF THE INVENTION
[0060] FIG. 1 shows a radar system 1 according to embodiments of the invention, comprising a power source 10 , a controller 12 , and a computer 14 , the power source and computer 10 , 14 being arranged to provide power to, and operational control over, the controller 12 . The controller 12 comprises a microprocessor and a set of instructions (not shown) for execution thereby, effectively generating control signals that cause the RF frequency source, or signal generator 16 , to output RF energy at a specified frequency F OUT , and this output signal, under control of switches 18 and amplifiers 20 , drives antenna 22 (whilst the Figure shows a switch component 18 , it will be appreciated that in this particular arrangement—in which there is only one antenna 22 —the switch 18 is inessential). As will be described in more detail below, the RF frequency source 16 generates signals within a range of frequencies, causing the antenna 22 to transmit beams in different angular directions, thereby scanning over a region beyond the radar system 1 .
[0061] The radar system 1 also includes a receiving antenna 32 , which receives radiated signals reflected back from objects, and passes the received radiation through switch and amplifier components 18 ′, 20 ′ to mixer 34 . The mixer 34 comprises two inputs: a first connected to the RF source 16 ; and a second connected to the receiving antenna 32 . The output of the mixer 34 is fed to an Analogue to Digital converter ADC 36 , to produce a digitised signal for input to the signal processor 38 , which performs analysis of the received signal. The signal processor 38 performs a spectral analysis on the received signals, because the range between the radar system and external (reflecting) objects is contained as frequency information in the signal. Aspects of the receiving and processing components are described in detail below, but first aspects of the RF frequency source and antenna will be described.
[0062] FIG. 2 shows components of the RF frequency generator 16 according to an embodiment of the invention, which is preferably used to generate signals having a range of frequencies. Referring to FIG. 2 , the frequency generator 16 comprises a frequency source 200 , first circuit portion 210 and a second circuit portion 220 . The first circuit portion 210 comprises a frequency divider 205 , a phase comparator 209 , a filter 211 , and a Voltage Controlled Oscillator VCO 213 , while the second circuit portion 220 comprises a frequency divider 207 , static multiplier 201 and a mixer 203 . The mixer 203 receives, as input, signals output from the VCO 213 and signals from the high grade, static multiplier 201 , and generates signals of frequency equal to the difference between the frequencies of the two inputs (f 3 ). The values R1, R2 characterising the frequency dividers 205 , 207 are selectable, and the phase comparator 209 is arranged to compare the frequency and phase of signals output from the frequency dividers 205 , 207 (f 3 /R2 and f ref ), so as to output a phase-error signal, of magnitude dependent on the difference between f 3 /R2 and f ref . The phase-error signal is input to the VCO 213 , and the first circuit portion 210 operates so as to cause the output from the VCO 213 to stabilise in dependence on the phase-error signal. Thus different values of R2 can be used to force the loop to stabilise at a frequency multiple of the input signal. In one arrangement the frequency source 200 is embodied as a crystal oscillator and in another arrangement as a SAW oscillator.
[0063] As stated above, an objective of the design of the RF frequency generator 16 is to minimise the amount of phase noise present in the output signal F OUT . As will be appreciated from earlier parts of this specification, multiplication of the phase noise of the reference oscillator and phase comparator is dependent on the magnitude of R1 and R2, so an objective of the RF frequency generator 16 is to minimise the amount of multiplication of the oscillator output 200 —in other words to keep the values of R1 and R2 as low as possible.
[0064] Accordingly the frequency generator 16 includes high-quality multiplier 201 and mixer 203 , the former ( 201 ) being arranged to increase the frequency of the signal output from oscillator 200 to as high a value as possible (e.g. the lower limit of the desired output frequency of VCO 213 ), while the mixer 203 serves to output signals of frequency equal to the difference between f 2 and f 1 , thereby effectively stepping down the output of the VCO 213 . As a result, the magnitude of the frequency input to divider 207 is relatively low, which means that for tuning of the output of VCO 213 , the value of R2 can be far lower than that possible with conventional arrangements.
[0065] The advantages of embodiments of the invention can best be seen with reference to a particular example, considering firstly how signals are processed by conventional phase-locked loop circuits and then how signals are processed by embodiments of the invention, assuming frequency source 200 outputs signals with a frequency of 100 MHz:
[0000]
VCO 213 Output
R1
R2
Conventional
5 GHz
1
50
5.1 GHz
1
51
5.11 GHz
10
511
Embodiments of
5 GHz
1
10
the Invention
5.1 GHz
1
11
n = 40
5.11 GHz
10
111
Embodiments of
5.1 GHz
1
1
the Invention
5.11 GHz
10
10
n = 50
[0066] It can be seen that by stepping up the frequency of signals input from the frequency source 200 and mixing them with the output of the VCO 213 , the amount of multiplication applied by the frequency dividers 205 , 207 , and thus amplification of phase noise in the oscillator output, is correspondingly reduced compared to conventional frequency synthesisers. It is to be noted that the circuit design shown in FIG. 2 offers a 20-30 dB reduction in noise contribution of the phase detector compared to conventional circuits operating loop frequencies of the order 200 MHz.
[0067] The signals output from the second circuit portion are then modulated by output f DDS of a third circuit portion 230 , which in one arrangement comprises a Direct Digital Synthesiser 223 , a Digital to Analogue Converter DAC 225 and a low pass filter 227 . The third circuit portion 230 is configured, under control of the controller 12 shown in FIG. 1 , to generate a repeating pattern comprising a linear frequency ramp. The ramp has a specified duration and magnitude, values of which are programmed via the controller 12 . FIG. 3 shows an example of one such frequency ramp 301 1 for a given carrier frequency f c1 , the duration of which is approximately 64 μs, the magnitude of which, in terms of range of frequencies (f DDS,max -f DDS,min ), is approximately 20 MHz, and is followed by a flyback ramp 303 1 to prepare the third circuit portion 230 for the next ramp 301 2 . The pattern repeats at a predetermined rate—in the present example a rate of 8 KHz (thus a sweep repeat period 307 of 125 μs (subject to the modifications described later in the specification)) is a convenient choice. Such a modulation pattern is entirely conventional and the foregoing details are included as illustrative; the skilled person will appreciate that any suitable values could be selected, dependent upon the use of the radar system (e.g. the nature of the targets to be detected). For each carrier frequency, the third circuit portion 230 is arranged to repeat the linear ramp pattern a specified number of times, e.g. 256 or 512 times, the number being dependent on the desired signal to noise ratio and therefore a design choice. Whilst the third circuit portion 230 shown in FIG. 2 comprises digital synthesiser components, it could alternatively be embodied using analogue components such as a sawtooth generator and VCO or similar. Preferably, and in order to save power, it is to be noted that the antenna 22 is not energised during either of the flyback ramp or dwell periods 303 , 305 .
[0068] Turning back to FIG. 2 , the output f DDS of the third circuit portion 230 is input to a fourth circuit portion 240 , which comprises a phase comparator 233 , a filter 235 , a Voltage Controlled Oscillator 237 and a mixer 231 . The mixer receives signals output from the second circuit (having frequency f 2 ) and signals output from the VCO 237 (having frequency f 5 ) and outputs a signal at a frequency equal to the difference in frequency between f 2 and f 5 . The phase comparator 233 outputs a phase-error signal, of magnitude dependent on the difference between (f 2 -f 5 ) and f DDS to the VCO 237 , and the fourth circuit portion 240 operates so as to cause the output from the VCO 237 to stabilise accordingly.
[0069] The signals output from the fourth circuit portion 240 (having frequency f 5 ) are then combined, by means of mixer 241 , with signals of a reference frequency f 4 , which are signals output from the oscillator 200 having been multiplied by a second static multiplier 251 , and the output is filtered (filter 243 ) so as to generate a signal having an output frequency F OUT . It will be appreciated from FIG. 2 that when the signal generator 16 is operable to output signals corresponding to a carrier frequency of between 15.5 GHz and 17.5 GHz, for a crystal oscillator 200 outputting signals of frequency 100 MHz, the second static multiplier 251 is of the order 130 .
[0070] Whilst the signal generator 16 could be used to generate frequencies within any selected range of frequencies, when used as a ground-based radar system, the frequency range can fall within the X band (8 GHz-12.4 GHz); the Ku band (12.4 GHz-18 GHz); the K band (18 GHz-26.5 GHz); or the Ka band (26.5 GHz-40 GHz), and most preferably within the Ku band, or a portion within one of the afore-mentioned bands. Thus for each carrier frequency the frequency generator 16 generates a repeating pattern of frequency modulated signals of various carrier frequencies.
[0071] Whilst in preferred arrangements the first and second circuit portions 210 , 220 of frequency generator 16 are embodied as shown in FIG. 2 , the frequency generator 16 could alternatively be based on an arrangement comprising a plurality of fixed frequency oscillators, as shown in FIG. 4 , one of which is selected via switch 400 so as to generate a signal at frequency f 2 . Judicial selection of an appropriate fixed frequency oscillator (e.g. a crystal oscillator) means that the frequency generator 16 can incur minimal phase noise, since the signals are taken directly from one of the oscillators. However, this advantage is accompanied by a corresponding limitation, namely that there is no means for fine-tune adjustment of the carrier frequency, which can be a disadvantage when working with antennas 22 that require fine tuning of the carrier frequency to achieve optimal beamwidth distribution (in terms of distribution of radiation within the lobes).
[0072] It will be appreciated from the foregoing that the antennas 22 , 32 transmit and receive radiation in response to input signals of varying frequencies; accordingly the antennas 22 , 32 are of the frequency scanning antenna type. In a preferred embodiment, the frequency scanning antenna is embodied as a travelling wave antenna structure comprising at least two array antennas, one such antenna array 500 being shown in FIG. 5 a . In one arrangement, the antenna array comprises a mesh structure 501 and a dielectric base 503 and has input means 507 for inputting energy to the mesh structure 501 . Preferably the antenna array 500 also includes a ground plane. The input means 507 can comprise coaxial feeds positioned orthogonal to the plane of the antenna array 500 , but the skilled person will appreciate that alternative feeds could be used.
[0073] In the arrangement shown in FIG. 5 a , each mesh structure 501 comprises a plurality of rectangular interconnected elements 509 that are disposed on a surface of the dielectric base 503 ; each rectangular element 509 comprises two sides 513 a , 513 b and two ends 511 a , 511 b , the length L of the sides 513 a , 513 b being greater than the length S of the ends 511 a , 511 b . The physics underlying the operation of the travelling wave antenna are well known, having first been investigated by John Kraus and described in U.S. Pat. No. 3,290,688. Suffice to say that the length L of the sides 513 is of the order of one wavelength of the mean carrier frequencies, and the length S of the ends 511 is of the order one half of the wavelength of the mean carrier frequencies. It will be appreciated from the teaching in U.S. Pat. No. 3,290,688 that mesh configurations other than rectangular and planar can be used.
[0074] In relation to the particular configuration adopted for embodiments of the invention, when current is fed through the mesh structure 501 via feed 507 , currents passing through the ends 511 a , 511 b are in phase with one another. The current flowing through a respective side 513 a of a given element 509 is received from an end 511 a of an adjacent element (shown as input 517 ) and splits into two current flows, each flowing in a different direction and being out of phase with one another. As is also shown in FIG. 5 a , the width of the mesh making up sides 213 a , 213 b is progressively decreased from the centre of the mesh to each respective end thereof, thereby effectively increasing the length of the sides 213 a , 213 b from the centre of the array towards its ends. In a preferred arrangement the antenna can be embodied as a micro circuit strip.
[0075] The configuration of the antenna structure 701 according to an embodiment of the invention will now be described with reference to FIGS. 6 and 7 . FIG. 6 shows a development of the radar system 1 shown in FIG. 1 , including two antennas 22 a , 22 b rather than one. Turning also to FIG. 7 , each of the antennas 22 a , 22 b is embodied in the form of antenna array 500 a , 500 b shown in FIGS. 5 a and 5 b , and the antenna structure 701 is responsive to input from the controller 12 for controlling input of energy to respective feeds I 1 , I 2 of the antenna arrays 500 a , 500 b . Referring also to FIG. 8 a , the two planar array antennas 500 a , 500 b are disposed within the structure 701 such that, for any given radio frequency, the antenna structure 701 is capable of transmitting the radio frequency energy within different angular regions 801 a , 801 b.
[0076] Referring back to FIG. 7 , the antenna structure 701 can be characterised by a longitudinal axis A 1 and a transverse axis A 2 , which provides a convenient frame of reference for describing the arrangement of the planar antenna arrays 500 a , 500 b . As can be seen from FIG. 7 , the first array antenna 500 a is inclined at an angle α relative to said transverse axis A 2 and the second planar array antenna 500 b is inclined at angle β relative to the transverse axis A 2 . As can also be seen from the Figure, a side portion of said second array antenna 500 b abuts a side portion of said first array antenna 500 a (in the Figure the side portions are located on the dot indicating axis A 1 ) such that when viewed face on, the antenna arrays 500 b are located in adjacent longitudinal planes.
[0077] It will be appreciated from the schematic shown in FIG. 8 a that the orientation of the respective antenna arrays 500 a , 500 b —that is to say angles α and β—determine the direction in which radiation is emitted from the antenna structure 701 . Thus, by varying the relative positions of the respective antenna arrays 500 a , 500 b , different portions of an angular region can be scanned for a given output frequency, f OUT,1 .
[0078] FIG. 8 b shows radiation emitted 801 a - 801 d from the antenna arrays for two different output frequencies f OUT,1 and f OUT,2 , and it can be seen that appropriate selection of the values of f OUT,1 and f OUT,2 , results in the antenna structure 701 outputting radiation so as to cover a substantially contiguous region, thereby scanning over a greater angular region than is possible with a single antenna array, or even two arrays that are positioned in the same plane, such as that described in U.S. Pat. No. 4,376,938.
[0079] The arrangements shown in FIGS. 5 a , 6 , 7 , 8 a and 8 b relate to an arrangement in which the antenna arrays 500 a , 500 b comprise a single feed I 1 , I 2 at one end of respective antenna arrays. However, and referring to FIGS. 5 b and 10 , each antenna array could comprise an additional feed at its other end (I 1,2 , I 2,2 ). Each antenna 22 a , 22 b can then be considered to be capable of emitting radiation in two directions for a given frequency f OUT , since the transceive-behaviour of the antenna array 500 a is dependent on the direction from which energy is fed into the antenna. In FIG. 9 , this is indicated by the presence of two antennas for each of antenna parts 22 a and 22 b . Turning to FIG. 11 , it can be seen that by feeding energy to two input feed points for each antenna array, the region R within which radiation can be transceived is effectively doubled.
[0080] It will be appreciated from the foregoing that the frequency f OUT of signals output from the signal generator 16 is controlled by the controller 12 . In addition to controlling the duration and rate of the ramp as described above, the controller 12 is arranged to select a different value for carrier frequency after the ramp pattern has been repeated a specified number of times for a given carrier frequency (examples of 256 and 512 were given above). In one arrangement the values for the carrier frequency can be selected from a look-up table accessible to the controller 12 (e.g. stored in local memory or on the computer 14 ), this look-up table being particular to a given antenna array 500 a , 500 b.
[0081] Operation of the radar system 1 described above will now be described with reference to FIG. 12 , which is a schematic flow diagram showing steps carried out by the controller 12 . At step S 12 . 1 the controller 12 energises one of the input feeds I k,n of the antenna structure 701 , e.g. by appropriate configuration of the switch 18 ; at S 12 . 3 the controller 12 retrieves the value of the first carrier frequency f c1 (e.g. from the look-up table mentioned above), and at step S 12 . 5 the controller 12 sets the values of R1 and R2 accordingly (to set the carrier frequency) and causes the third circuit portion 230 to generate the ramp pattern a predetermined number of times Rmp max (S 12 . 7 ), to repeatedly modulate the carrier frequency. Having reached Rmp max , the controller retrieves the value of the next carrier frequency f c2 and sets the values R1, R2. Preferably the overall duration of step S 12 . 7 —in other words the duration of any given set of repetitions of the linear ramp 301 i pattern—is the same for all values of the carrier frequency, f cj . These steps are repeated, as shown in FIG. 12 , for each feed point I 1,1 I 2,1 I 2,2 I 2,1 to the antenna structure 701 , thereby causing the antenna structure 701 to progressively scan over the angular extent R.
[0082] The description has thus far focussed on the generation and transmission of signals from the radar system 1 ; referring to FIGS. 1 , 6 , 7 , 9 and 10 , aspects of with receiving and processing of signals will now be described. As can be seen from these Figures the radar system 1 preferably also includes a separate antenna 32 embodied as structure 703 for receiving radiation, which corresponds to the transmitting antenna structure 701 described above. Referring to FIG. 6 or 9 , the signals received by antenna structure 703 are input to mixer 34 , together with the output f OUT from the RF frequency generator 16 , and, in accordance with standard homodyne operation, the output from the mixer 34 is fed through an ADC 36 to produce a digitised Intermediate Frequency (F if ) signal as input to the signal processor 38 . Energising of the receiving antenna structure 703 is performed under control of the controller 12 , via switch 18 ′, and, as for the transmitting antenna structure 703 , this occurs during the linear ramp period only 301 i .
[0083] The signal processor 38 is conveniently embodied as a programmable logic controller (PLC) and a plurality of software components, which run locally on the PLC 38 in response to signals received from a conventional PC computer 14 and which are written using the proprietary programming language associated with the PLC 38 .
[0084] As described above, the radar system 1 operates according to homodyne principles, which means that the Intermediate Frequency F if is equal to differences between the received signal frequency and the transmitted signal frequency. In embodiments of the invention, as will be appreciated from the foregoing and FIGS. 2 and 3 in particular, the output of the radar system 1 is a sequence of frequency sweeps 301 i . It is a well known principle of radar that targets located in the path of a given transmitted beam will reflect the transmitted signals; since the transmitted signal in embodiments of the present invention comprises a linear frequency sweep 301 i , the reflected signals also comprise a linear frequency sweep. Targets that are stationary will generate reflected signals that are identical to the transmitted signals (albeit somewhat attenuated), but separated therefrom at a constant frequency difference referred to herein as a tone. Referring to FIG. 13 , it will be appreciated from the Figure that different targets T 1 , T 2 —located at different distances from the radar system 1 —reflect the transmitted sweep 301 i at different delays in relation to the time of transmission, and that therefore targets T 1 , T 2 at these different locations will be associated with different tones Δf 1 , Δf 2 .
[0085] In view of the fact that the signals output from the mixer 34 contain tones, the signal processor 38 is arranged to delay the processing of signals until the ramp 301 has traveled to the extents of the detection region and back. Thus for example, if the detection region extended to 4.5 km from the radar system 1 , the signal processor 38 would start processing signals output from the mixer 34 at:
[0000]
4500
×
2
3
×
10
8
=
30
µs
from
the
start
of
transmission
of
a
given
ramp
301
i
.
[0086] Considering, for the sake of clarity, one processing period 1301 1 , the signal processor 38 essentially calculates the Doppler frequency of targets within range of the transmitted beam—and which reflect the transmitted beam. This is achieved by sampling the received tones Δf 1 , Δf 2 . . . Δf m at a predetermined sampling rate. The sampling rate is selected so as to as ensure that phase shifts of the transmitted signal, which are induced by moving targets, can be captured. The skilled person will appreciate that this is dependent on the ramp rate, since the Doppler frequency is dependent on the frequency of the transmitted signal:
[0000] Doppler Frequency=2 vf c /c [Equation 1]
[0087] Thus, the output of the ADC 36 falling within the processing period 1301 1 will be processed a predetermined number of times (corresponding to the sampling rate) by the signal processor 38 . Each sample will contain zero, one or a plurality of tones, each relating to signals reflected from targets.
[0088] As will be appreciated from the foregoing, the linear ramp 301 i is transmitted a plurality of times for each carrier frequency. Accordingly the signal processor 38 processes data received during a corresponding plurality of processing periods 1301 i , and generates, by means of a Range FFT, a set of return samples, individual members of which are assigned to a respective set of range gates for each said processing period 1301 i . Thus the output of the Range FFT, for a given Processing period 1301 1 , is frequency information distributed over so-called range gates. As is well known in the art, range gates represent successive distances from the radar system 1 , such that if return samples fall within a given range gate, this indicates the presence of a target located at a distance equal to the range gate within which the return sample falls.
[0089] Having transformed the received signals into range gates the signal processor 38 is arranged to take the FFT of the return samples assigned to each given range gate. In the current example it will be appreciated that each set of range gates corresponds to transmission of a linear ramp 301 i (for a given carrier frequency), and that the sampling rate in relation to range gates—the rate at which data falling within a given range gate are measured—is the frequency at which the pattern of transmission of linear ramps 301 i is repeated (commonly referred to as the Pulse Repetition Frequency (PRF)). In the example given above, and with reference to FIG. 3 , this is nominally 8 KHz. Accordingly, for each carrier frequency, the signal processor 38 effectively generates an array of data, each row in the array corresponding to a given processing period 1301 i , and each column in the array corresponding to a given range gate.
[0090] The FFT output comprises amplitudes and phases of various components of signal energy which fall on frequencies spaced linearly at the inverse of the duration of a complete signal sample set (in embodiments of the invention, the signal set comprises tones, not absolute frequency values). In the current example, therefore, and assuming the signal sample set for a given carrier frequency to comprise the 512 linear ramps 301 1 . . . 301 512 transmitted at a rate of 8 KHz, there are 512 FFT output bins spaced at a Doppler frequency of 8000/512=15.625 Hz; for a carrier frequency of 15 GHz, this is equivalent to 0.15625 m/s. Thus each FFT output bin represents a different velocity; stationary targets will appear in bin 0 , while moving targets will appear in a bin dependent on their velocity (a target travelling at 10 m/s will appear in bin 64 ).
[0091] As is known in the art, the signal processor 38 can be arranged to store each set of range gate samples in a “row” of a conceptually rectangularly-organised memory, referred to as a corner store, each row corresponding to range gates falling within a given processing periods 1301 and thus to a particular linear ramp 301 i . Once all 512 linear ramps 301 1 . . . 301 512 have been transmitted, each column—i.e. each range gate—is read out and input to a FFT for processing thereby in the manner described above.
[0092] From Equation 1, it will be appreciated that the Doppler frequency is directly proportional to the carrier frequency f c . Therefore when the carrier frequency varies—as is the case with frequency scanning antennas—the variation in carrier frequency will modify the derived Doppler frequencies so as to effectively scale the magnitude of the frequencies. For example, a radar system that operates between 15.5 GHz to 17.5 GHz can generate Doppler frequencies, for a given target, which vary by ±6%. This equates to a system-generated shift in Doppler frequency of more than 2 semitones, and a variation in ambiguous Doppler velocity from 70 mph to 79 mph, which can complicate the task of removing velocity ambiguity from targets moving at these speeds and above. Referring back to FIG. 11 it will be appreciated that in certain configurations of the radar system 1 the carrier frequency can jump from the maximum carrier frequency to the minimum carrier frequency, causing the signal processor 38 to output a change in tone of more than 2 semitones.
[0093] Accordingly the controller 12 is arranged to modify the sweep repeat period 307 (or sweep repetition frequency) such that the sweep repetition frequency is proportional to the carrier frequency, thereby effectively removing this systematic aberration. Turning back to FIG. 12 , this means that step S 12 . 5 performed by the controller 12 in relation to carrier frequency f cj retrieved at step S 12 . 3 is accompanied by calculation of a sweep period 307 for the particular value of this carrier frequency f cj . In preferred embodiments of the invention the linear sweep period 301 remains unchanged (so that the effect of this adjustment does not affect the signal processor 38 ), and the controller 12 adjusts the duration of the flyback and/or dwell periods 303 , 305 ; most preferably the dwell period 305 is modified. Of course all of the repetitions of the sweep repeat period 307 1 , f cj . . . 307 512 , f cj are identical for a given carrier frequency f cj (step S 12 . 7 ). In one embodiment the controller 12 has access to a look-up table, which lists sweep repeat periods 307 j for discrete carrier frequencies f cj . Conveniently such data could be stored in the look-up table that is accessed by the controller at step S 12 . 3 , when identifying a next carrier frequency f cj .
[0094] As described above in relation to FIG. 12 , the overall duration D of step S 12 . 7 is preferably maintained constant. When, as is the case with embodiments of the invention, the sweep repeat period 307 j varies in accordance with carrier frequency f cj the duration of 512 repetitions applied in respect of each different carrier frequency varies; thus, of itself, the period associated with 512 repetitions would not be of duration D for all carrier frequencies. In order to ensure that the duration is nevertheless constant, the controller 12 is configured to wait for a period equal to the time difference between the end of 512 repetitions and duration D before moving onto the next instance of steps S 12 . 3 , S 12 . 5 and S 12 . 7 (i.e. for a different carrier frequency). In the present example the value of D is preferably set to the sum of 512 sweep repeat periods 307 corresponding to the duration of the longest sweep repeat period (and thus that associated with the lowest carrier frequency f cj ).
[0095] This feature of the controller 12 is advantageous for configurations in which the linear ramp period 301 is constant (in FIG. 3 it is shown as 64 μs), incurring a fixed transmitter power dissipation: maintaining duration D for the overall duration of step S 12 . 7 means that the average transmitter dissipation is constant and independent of variations to the sweep repeat period 307 (PRF). As a result the temperature of the transmitter T x is maintained at a constant level, which, in turn, minimises the variations in parameters that are temperature dependent.
[0096] Preferably the Doppler frequencies are scaled and output as tones within the audible range and at a fixed audio sample rate. Playing back the tones at a fixed rate is a convenient approach in view of the fact that the Doppler frequencies have been normalised in relation to the variation in carrier frequency.
[0097] As an alternative to selecting sweep repeat periods 307 j as a function of carrier frequency f cj , the sweep repeat period 307 j could be varied incrementally, for example linearly, based on the approximation 1+α≈1/(1−α) for α<<1. For the example frequency range of 15.5 GHz-17.5 GHz, the sweep repeat period 307 for a carrier frequency of 15.5 GHz could be 140.65 μs, and period 307 for a carrier frequency of 17.5 GHz could be 125 μs, while the sweep repeat period 307 for carrier frequencies between the extents of this range can be selected so as to vary linearly between 125 μs and 140.65 μs. As for the first alternative—where the sweep repeat period 307 is varied discretely as the carrier frequency varies—the linear ramp 301 and thus the processing periods 1301 remain unchanged for all values of the sweep repeat period 307 . The net change in Doppler frequency is then reduced to ±0.2% and the ambiguous Doppler velocity varies from 78.7 mph to 79.0 mph.
[0098] As described above, a radar system according to embodiments of the invention can conveniently be used for transceiving radio frequency energy and processing the same so as to output an audible representation of Doppler frequencies and thus identifying moving targets. The signal processor 38 is arranged to transmit data indicative of the Doppler frequencies to the computer 14 , which comprises a suite of software components 39 arranged to convert the Doppler frequencies to audible signals and to playback the same. As described above, the Doppler Frequencies are normalised by processing the received signals at a variable rate, the rate being selected in dependence on the carrier frequency of the transceived signal, while the rate at which the audio is played back is substantially constant. Preferably the post processing software components 39 are arranged to ensure smooth transition between respective audio bursts by controlling the playback rate in relation to the rate at which, for a given range gate, data have been processed by the signal processor 38 (i.e. the frequency at which the pattern of transmission of linear ramps 301 i is repeated). If the PRF is varied between 7 KHz and 8 KHz and the audio playback rate is 8.5 KHz, then in the absence of suitable phased-audio control, there will be gaps in the audio output, which presents an interruption to any audible analysis of the Doppler data; one way of mitigating this is to recycle Doppler data during periods that would otherwise be silent, until such time as further Doppler data are made available from the signal processor 38 . In order to ensure a smooth transition between respective sets of Doppler data, the computer 14 would be arranged to fade-out previous, and fade-in and current, sets of Doppler data. As an alternative, the audio playback rate could be set at a value lower than the PRF (e.g. for the current example, 6.9 KHz) so that respective sets of Doppler data overlap; the periods of overlap can be managed using appropriately selected fade-in and fade-out functions.
[0099] In arrangements where the duration of sets of repetitions of the linear ramp period 301 i is constant (duration D), any set of Doppler data (corresponding to a given carrier frequency f cj ) will arrive at the signal processor 38 a constant rate, which means that the software components 39 can be configured to apply the same conditions in relation to overlaps and/or gaps in the Doppler data (since the amount of overlap or gap can always be calculated from duration D). An advantage of this arrangement is that it simplifies the logic associated with the post-processing software components 39 and enables more constant audio output over the varying PRF.
[0100] A particular feature of a radar system according to embodiments of the invention is that the software components 39 are arranged to transmit data output from the signal processor 38 to a remote processing system, for tracking and monitoring of targets. Most preferably the software components 39 are arranged to transmit data output from the signal processor 38 each time the carrier frequency—and thus region being scanned—changes. This means that the computer 14 acts primarily as a conduit for data, while the data intensive processes of correlating targets between successive scans, rendering of targets upon a display and prediction of target behaviour can be performed by a separate processing system. In a preferred arrangement the data are transmitted wirelessly, but it will be appreciated that any suitable transmission means could be used.
Additional Details and Alternatives
[0101] Whilst in the foregoing the linear ramp 301 is independent of variations in the sweep repeat period, the controller 12 could alternatively modify the duration and/or slope of the linear ramp. Whilst this is not a preferred method, because operation of the signal processor 38 (in particular in relation to the processing periods 1301 ) would have to be modified, modifying the slope is a convenient method when more than one radar system is being utilised in a given region, since the difference in slopes of the linear ramp can be used to distinguish between output from respective radar systems.
[0102] FIG. 14 shows an alternative configuration of the radar system 1 comprising antenna structures according to embodiments of the invention, in which the single amplifiers 20 , 20 ′ are replaced by individual amplifiers, each being associated with a respective antenna.
[0103] In the above passages the radar system 1 is assumed to comprise a separate transmit and receive antenna structure 701 , 703 . However, and turning to FIG. 15 , the radar system 1 could alternatively comprise a single antenna structure 701 and a circulator 40 , which, as is known in the art effectively combines signals that are transmitted and received from the antenna structure 701 . As an alternative to the circulator 40 , the radar system 1 could include a switch or an alternative antenna utilising a turnstile junction or orthomode junction (not shown).
[0104] FIG. 16 shows an alternative configuration of the antenna arrays 500 a , 500 b within an antenna structure 701 , in which each the antenna array 500 a , 500 b is located on a respective support structure, an outer edge 531 a of one support structure abutting a corresponding outer edge 531 b of another support structure so as to form an antenna structure having a generally isosceles shape; since the supports of respective antenna arrays abut one another the radar system can be fabricated such that receiving antenna structure 701 abuts transmitting antenna structure 703 , thereby generating a physically smaller radar system, in terms of depth occupied by the antenna structure, compared to that shown in FIG. 7 . It will be appreciated that other configurations are possible, involving two, three or several such antenna arrays mounted on suitable support structures.
[0105] Whilst in embodiments of the invention the radar system 1 preferably uses antenna structure 701 described above, which is based on travelling wave antenna technology, the radar system 1 could alternatively use a waveguide in the form of a serpentine antenna or similar as the frequency scanning antenna. A suitable antenna is described in U.S. Pat. No. 4,868,574.
[0106] Whilst the above embodiments describe use of a frequency scanning antenna for beam steering, it will be appreciated that the configurations and methods described above could be applied for the purposes of avoidance detection, and/or in the presence of other radar systems, and/or to counteract frequency jamming equipment (e.g. by hopping between operating frequencies in order to avoid detection of, interference with, or jamming of, the radar system).
[0107] The above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.
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Embodiments of the invention are concerned with a radar system, and relates specifically to scanning radar systems that are suitable for detecting and monitoring ground-based targets.
In one aspect, the radar system is embodied as a scanning radar system comprising a frequency generator, a frequency scanning antenna, and a receiver arranged to process signals received from a target so as to identify a Doppler frequency associated with the target, wherein the frequency generator is arranged to generate a plurality of sets of signals, each set having a different characteristic frequency, the frequency generator comprising a digital synthesiser arranged to modulate a continuous wave signal of a given characteristic frequency by a sequence of modulation of patterns whereby to generate a said set of signals, and wherein the frequency scanning antenna is arranged to cooperate with the frequency generator so as to transceive radiation over a region having an angular extent dependent on the said generated frequencies.
Embodiments of the invention thus combine digital synthesiser techniques, which are capable of precise frequency generation and control, with passive frequency scanning and Doppler processing techniques. This enables accurate control of range and of scan rates, and enables optimisation of range cell size for factors such as slow and fast target detection and Signal to Noise ratio, and thus enables detection of targets located at distances considerably farther away than is possible with known systems having similar power requirements.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of prior filed International Application, Serial Number PCT/US2010/023615 filed Feb. 9, 2010, which claims priority to U.S. Provisional Patent Application No. 61/150,890, filed Feb. 9, 2009; the contents of each of which are herein incorporated by reference.
GOVERNMENT INTEREST STATEMENT
[0002] This invention was made with Government support under Grant No. 1R01NS043408-01 awarded by the National Institutes of Health (NIH). The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] The lipoprotein receptor signaling system is known to play a significant role in the adult CNS such as cholesterol homeostasis, clearance of extracellular proteins, modulating memory formation, synaptic transmission, plasticity and maturation through the activation of numerous signal transduction pathways. Importantly, the lipoprotein receptor ligand apolipoprotein E (apoE) is one of the best validated risk factors for late-onset, sporadic Alzheimer's disease (AD) (Hoe H S, Harris D C, Rebeck G W. Multiple pathways of apolipoprotein E signaling in primary neurons. J Neurochem 2005; 93:145-155; Hoe H S, Freeman J, Rebeck G W. Apolipoprotein E decreases tau kinases and phospho-tau levels in primary neurons. Mol Neurodegener 2006, 1:18; Hoe H S, Pocivaysek A, Chakraborty G, et al. Apolipoprotein E receptor 2 interactions with the N-methyl-Daspartate receptor. J Biol Chem 2006, 281:3425-3431). Moreover, the extracellular matrix protein reelin can bind to both lipoprotein receptors and amyloid precursor protein (APP) and is known to be associated with Aβ plaques in a number of AD mouse models (Chin J, Massaro C M, Palop J J, et al. Reelin depletion in the entorhinal cortex of human amyloid precursor protein transgenic mice and humans with Alzheimer's disease. J Neurosci 2007, 27:2727-2733; Hoareau C, Borrell V, Soriano E, Krebs M O, Prochiantz A, Allinquant B. Amyloid precursor protein cytoplasmic domain antagonizes reelin neurite outgrowth inhibition of hippocampal neurons. Neurobiol Aging 2008, 29:542-553; Hoe H S, Tran T S, Matsuoka Y, Howell B W, Rebeck G W. DAB1 and Reelin effects on amyloid precursor protein and ApoE receptor 2 trafficking and processing. J Biol Chem 2006, 281:35176-35185; and Miettinen R, Riedel A, Kalesnykas G, et al. Reelin-immunoreactivity in the hippocampal formation of 9-month-old wildtype mouse: effects of APP/PS1 genotype and ovariectomy. J Chem Neuroanat 2005, 30:105-1180). Aβ accumulation can influence reelin signaling and lipoprotein receptor function, thereby promoting AD pathogenesis and affecting synaptic and cognitive function.
[0004] Therefore, what is needed are specific agonists that act upon the lipoprotein receptor system in a manner similar to Reelin for use as therapeutics in the improvement of cognitive function as well as the treatment of neurological disease such as AD and other age-related neurodegenerative disorders.
SUMMARY OF INVENTION
[0005] The invention relates generally to methods of influencing, and enhancing, cognitive function by increasing, and/or preventing interference with, Reelin levels as well as the cellular signal transduction initiated or maintained with Reelin or Reelin signaling.
[0006] In a first embodiment, the invention includes a method of improving cognitive function, in a subject in need thereof, by administering a therapeutically effective amount of Reelin, a Reelin-specific modulator or an agonist of a lipoprotein receptor to the subject. The lipoprotein receptor can be selected from candidates such as ApoER2 and VLDLR. As disclosed herein, agonists or antagonists of the lipoprotein receptor for use with the inventive method include, but are not limited to, APC, Sep and Fc-RAP. In addition to administering exogenous Reelin, a Reelin-specific modulator, such as a recombinant Reelin fragment, can be used to increase Reelin levels and/or signaling. In an illustrative embodiment, the therapeutically effective amount of Reelin or an agonist of a lipoprotein receptor is approximately 5 nM.
[0007] In another embodiment, the invention includes a method of treating a symptom of a disease or disorder of the nervous system by administering a therapeutically effective amount of Reelin, a Reelin-specific modulator or an agonist of a lipoprotein receptor to a subject in need thereof. As with the previous embodiment, the lipoprotein receptor is selected from the group consisting of ApoER2 and VLDLR. The agonists of the lipoprotein receptor for use with the inventive method include, but are not limited to, APC, Sep and Fc-RAP. In this embodiment, the disease or disorder of the nervous system can be selected from the group consisting of fragile X syndrome, William's syndrome, Rett syndrome, Down's syndrome, Angelman syndrome, autism, ischemia, hypoxia, Alzheimer's disease, Reelin deficiency, schizophrenia, neurodegeneration, traumatic brain injury, mental retardation, dementia, and stroke. The therapeutically effective amount of Reelin or an agonist of a lipoprotein receptor is, in one example, approximately 5 nM.
[0008] A third embodiment of the invention includes a method of increasing dendritic spine density, in a subject in need thereof, by administering a therapeutically effective amount of Reelin, a Reelin-specific modulator or an agonist of a lipoprotein receptor to the subject. The lipoprotein receptor can be selected from candidates such as ApoER2 and VLDLR. As disclosed herein, agonists of the lipoprotein receptor for use with the inventive method include, but are not limited to, APC, Sep and Fc-RAP. In addition to administering exogenous Reelin, a Reelin-specific modulator, such as a recombinant Reelin fragment, can be used to increase Reelin levels and/or signaling. In an illustrative embodiment, the therapeutically effective amount of Reelin or an agonist of a lipoprotein receptor is about 5 nM.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
[0010] FIG. 1 . Application of recombinant Reelin enhances LTP. Field recordings from acute hippocampal slices in area CAL Wild-type mice were perfused with either 5 nM reelin (n=7) or Mock (n=6).
[0011] FIG. 2 . Reelin enhances NMDAR currents through postsynaptic mechanisms. (A,B) Illustration of measurement of EPSCNMDA. The thick gray trace in B) represents the mEPSCNMDA. C) Reelin treatment significantly increased mEPSCNMDA amplitude (closed circle, before reelin; open circle, after reelin; ***p<0.001; n=18; paired t test). Treatment with mock was without effect [closed square, before mock; open square, after mock; not significant (ns), p>0.05; n=13; paired t test]. D) No correlation of 1/CV2 ratios and mean EPSCNMDA ratios (after/before reelin) was revealed based on recordings from nine cells (r=0.31; p=0.4; Spearman's test).
[0012] FIG. 3 . Reelin signaling alters surface expression and total levels of glutamate receptor subunits. A) Representative blots showing levels of both surface and total G1uR1, NR1, NR2A, and NR2B. B) Quantitative results of surface glutamate receptor subunits pooled from 4 experiments. Compared with mock groups, both surface G1uR1 and NR2A were significantly increased [G1uR1, F(2,11)=15.56, ***P<0.001; NR2A, F(2,11)=44.9, ***P<0.001], and the level of surface NR2B was significantly reduced [F(2,11)=22.6, ***P<0.001] after chronic Reelin treatment. C) Reelin treatment significantly increased levels of total G1uR1 [F(2,11)=11.2, **P<0.01], NR2A [F(2,14)=9.75, **P<0.01], and decreased level of total NR2B [F(2,11)=4.1, *P<0.05]. In contrast, neither total nor surface (in B) levels of NR1 was observed.
[0013] FIG. 4 . Reelin supplementation can improve associative learning and spatial learning. A) Wild type mice were given either 5 nM RAP or 5 nM Reelin by bilateral injection into the ventricles 3 hours prior to receiving fear conditioning. 24 hrs after training, mice were placed into the context and freezing measured. RAP was found to inhibit learning and memory while Reelin led to an enhancement (RAP n=9, no shock n=5, no treatment n=7, Reelin n=5; p>0.05). B) Wild type mice were trained to find a hidden platform through the Morris Water maze. Mice were given a single injection of either 5 nM Reelin (red circle, n=4) or Vehicle (open circle, n=6). On day 5, a probe trial was given then the mice were trained to find a new platform location on day 6. C) Examination of latencies from individual trials on day 1. (*=p>0.05). D) Wild type mice were trained to find a hidden platform through the Morris Water maze. Mice were given a single injection of either 5 nM Reelin (n=4) or Vehicle (n=6).
[0014] FIG. 5 . Reelin signaling is altered in AD mouse models. A.) Isolated cortices from 14-month old wild type, Tg2576 (SweAPP), PS1-FAD (M146L), and 2× (SweAPP×M146L) were subjected to western analysis (n=4). No significant differences were detected in Reelin 450, 190 and 180 kDa products in Tg2576 versus wild type, but unidentified N-terminal species recognized by G10 were significantly elevated in Tg2576 and 2× mice. In contrast, Reelin 450 and 180 kDa products were significantly elevated in PS1-FAD and 2× mice (p<0.05). B.) There were significant reductions in Dab1-pTyr220 in Tg2576 mice, and significant elevations in both PS1-FAD and 2× mice. C.) Application of Reelin (5 nM) prior to stimulation was able to rescue deficits in HFS-stimulated LTP in area CA1 of Tg2576 mice. D.) The 3-epitope strategy for mapping Reelin processing in vivo was employed on 14-month old Tg2576 horizontal sections. Reelin-CT (G20) and -MT (AF3820) detected Reelin fragments containing R7-8 and R3-6, respectively, sequestered at the core of a dense-core plaque detected with 6E10 (anti-A13). E.) Reelin-NT fragments (N-R2) surrounded the plaque core in the tg2576 mouse model. Scale bar=15 μm.
[0015] FIG. 6 . LTP induction using a standard 2-train, 100 Hz HFS was given to hippocampal slices from 12 month-old Tg2576 mice. A set of slices were perfused with 5 nM reelin. Reelin treated slices showed an increase of LTP induction to that of wild-type levels.
[0016] FIG. 7 . Targeted deletion of the Selenoprotein P gene results in LTP deficit. Field recordings of acute hippocampal slices show no LTP after 100 Hz stimulation is given (blue arrow) SeP (−/−) n=12, SeP (+/+) n=8. Peters et at 2006
[0017] FIG. 8 . Addition of Selenoprotein P rescues the LTP deficit in mice lacking the Selenoprotein P gene. Field recordings of acute hippocampal slices in SeP (−/−). Slices treated with 2 nM SeP for 20 min (red line) then given 100 Hz stimulation. SeP (−/−)+2 nM SeP n=16, SeP (−/−) no SeP n=28.
[0018] FIG. 9 . Perfusion with Fc-RAP enhances hippocampal LTP induction. Hippocampal slices were perfused with Fc-RAP (10 μg/ml), Fc (10 μg/ml), or control medium. Baseline synaptic responses (a) and potentiation immediately following HFS (b) and up to 60 min after HFS (c) were recorded. The arrowhead represents LTP induced with two trains of 1-s-long, 100-Hz stimulation, separated by 20 s. The horizontal line indicates application of Fc-RAP, Fc, or control medium. Results are shown as means±standard errors of the mean. fEPSP, field excitatory postsynaptic potential Strasser et al 2004.
[0019] FIG. 10 . Contextual fear conditioning alters Reelin levels. Wild type mice were trained with a 3-shock, contextual fear conditioning protocol (CFC). Non-shocked mice (CS) were used as a negative control and shocked, context-exposed mice (CS/US) had their hippocampus removed at 1, 5, 15, 30, and 180 minutes after training, as well as 18 hours post-training (n=4, time point). Reelin was detected in hippocampal homogenates using anti-Reelin (G10) (A) and the levels of full-length Reelin were quantitated (B). The asterisks denote statistical significance following a two-tailed t-test, where p<0.5.
[0020] FIG. 11 . HFS alters Reelin metabolism in a tPA-dependent manner. Acute hippocampal slices were stimulated using TB-STIM (theta burst stimulation) consisting of 5 trains at theta-burst across the Schaffer collateral. Hippocampi were harvested 15 minutes later and homogenates were subjected to western blot analysis and detected with anti-Reelin (G10) (n=3 per group). Non-stimulated is denoted as NS and stimulated as S. The 370 kDa was quantified and statistically analyzed using a two tailed t-test (*, p<0.05).
[0021] FIG. 12A . tPA modulates Reelin processing. A.) The ability of tPA/plasminogen to affect Reelin processing was determined by reacting Reelin (50 nM) with tPA (60 ug/ml), inactive plasminogen (18 ug/ml), tPA and plasminogen, and Plasmin (active, 0.5 U/ml) in PBS for 45 minutes at 37° C. Reactions were run on Westerns (at 1:10) and probe with anti-Reelin (G10, an N-R2 recognizing antibody) and ant-I Reelin (Ab14, a R7-8 recognizing antibody) B). The ability of tPA to affect Reelin metabolism in primary cortical neurons was determined by incubating cells in fresh supernatant for 24 hours with 70 nM tPA. Both cellular and supernatant protein extracts were subjected to Western analysis and detection with G10.
[0022] FIG. 12B . MMP-9 modulates Reelin processing. The ability of MMP-9 (active; Calbiochem, PF140) to affect Reelin processing was determined by reacting Reelin (50 nM) with different concentrations of MMP-9 (1-4 ug/ml) in PBS at 37° C. for 3 hours . EDTA (10 mM) was included as a negative control, as it blocks MMP9 activity. Western blots were run on 1:10 of the reaction and probed with anti -Reelin (G10) (B). The ability of MMP-9 (250 nM) and the MMP-9 inhibitor (25 nM; Calbiochem 444278) to affect Reelin processing in primary cortical neurons was determined after 24 hours in both cellular and supernatant extracted proteins.
[0023] FIG. 13 . Tri-epitope mapping. (A). Reelin consists of an N-terminal region followed by the CR-50 electrostatic domain (purple), an F-spondin domain (H), and 8 consecutive EGF-like repeats. (B). Antibodies that distinctly recognize the N-R2, R3-R6, and R7-R8 regions of Reelin can be used to determine the distribution of full-length Reelin and its major fragments. (C). Antibodies that will be employed in the 3-epitope approach are listed.
[0024] FIG. 14 . Illustration of constructs to be used in SA2 and SA3 and sites of Reelin cleavage. MMP-9 can cleave between regions 2 and 3, but has also been shown to cleave in region 7 during in vitro reactions only. tPA can cleave between regions 6 and 7. Proposed constructs are made without the in vitro MMP-9 binding site a with both C and N terminal tags. Rln-Res=Reelin Cleavage Resistant; Rln-Lab=Reelin labile.
[0025] FIG. 15 . Reelin effects on dendritic spine density. Reelin was applied chronically to primary hippocampal neuronal cultures to examine its effect on dendritic spine density. (A) Dendritic spines on a WT neuron are shown in an enlarged photo of a representative primary dendrite. (B and C) Dendritic spines are reduced in the HRM compared to WT mice but after treatment with reelin, spine density is rescued. (D and E) Dendritic spines are very sparse in the knockout reelin mice but after treatment with reelin, spine density deficits are rescued. (F) Dendritic spines were quantified using a confocal microscope. Dendritic spines were defined as any protrusion from a primary dendrite excluding any secondary dendrites. Dendritic spines were counted and measured every 50 um of the dendrite. There is a significant increase in spines in reelin-treated cells (n=3) versus mock-treated cells (n=3). (G) Reelin levels in culture were determined by a Western Blot. Samples were taken out of culture at 0, 6, 12, 24, 48, 72, and 96 hrs to determine the levels of reelin degradation in vitro. The last column of reelin represents the native in the concentration administered to the culture. Reelin was present up until 96 hours after introduction to culture and degradation did not begin until 72 hours.
[0026] FIG. 16 . Locomotor activity, nociception and anxiety are unaltered by drug treatments. (A) Open field behavior utilized to evaluate locomotor activity. The total distance traveled during the 15 min test was similar for the three conditions (mock HRM n=13, reelin HRM n=13, Rap WT n=10; ANOVA p=0.23). (B) Elevated Plus Maze utilized to determine anxiety. Both the percent of time spent in the open arms and the number of open arm entries were similar for the three conditions (mock HRM n=11, reelin HRM n=10, Rap WT n=13; percent time ANOVA p=0.49 and open arm entries ANOVA p=0.63). (C) Prepulse inhibition (D) Acoustic startle utilized to evaluate startle response. The startle response to a 120 dB acoustic stimulation is similar for the three conditions (mock HRM n=14, reelin HRM n=16, Rap WT n=15; ANOVA p=0.56). Results from Qiu et al. (2005) are depicted with dashed lines for reference.
[0027] FIG. 17 . HRM contextual fear conditioning deficits are rescued by application of exogenous reelin. (A) Freezing during the conditioning paradigm was similar for both conditions (mock HRM n=16, reelin HRM n=16). The tone is represented by the black bar and the shock by the black arrows. Freezing during reintroduction to the conditioning context. (B) Freezing was similar for the three conditions 1 hr post conditioning (mock HRM n=13, reelin HRM n=13). (C) Reelin-treated HRM freezing was significantly greater than mock-treated HRM 24 hrs post conditioning (mock HRM n=16, reelin HRM n=16; t-test p=0.02) and (D) 72 hrs post conditioning (mock HRM n=5, reelin HRM n=4; t-test p=0.026). (E) Shock threshold analysis to evaluate nociception. The shock intensity in which mice flinched, jumped, or vocalized was similar for both conditions (mock HRM n=3, reelin HRM n=3; ANOVA p=0.22).
[0028] FIG. 18 . Locomotor activity, nociception and anxiety are unaltered by drug treatments. (A) Open field behavior utilized to evaluate locomotor activity. The total distance traveled during the 15 min test was similar for the two conditions (Rap WT n=10). (B) Elevated Plus Maze utilized to determine anxiety. Both the percent of time spent in the open arms and the number of open arm entries were similar for both conditions (Rap WT n=13; percent time ANOVA p=0.49 and open arm entries ANOVA p=0.63). (C) Prepulse inhibition, Results from Qiu et al. (2005) are depicted with dashed lines for reference. (D) Acoustic startle utilized to evaluate startle response. The startle response to a 120 dB acoustic stimulation is similar for both conditions (Rap WT n=15; ANOVA p=0.56).
[0029] FIG. 19 . (A) Freezing during the conditioning paradigm was similar for both conditions (Rap WT n=13). The tone is represented by the black bar and the shock by the black arrows. Freezing during reintroduction to the conditioning context. (B) Freezing was similar for both conditions 1 hr post conditioning (Rap WT n=9). (C) RAP-treated WT freezing was significantly less than vehicle-treated WT (Rap WT n=13) 24 hrs post conditioning and (D) 72 hrs post (Rap WT n=6). There was no difference between mock-treated HRM freezing and Rap-treated WT freezing at any time tested (See FIGS. 17B-C ). (E) Shock threshold analysis to evaluate nociception. The shock intensity in which mice flinched, jumped, or vocalized was similar for both conditions (Rap WT n=4; ANOVA p=0.22).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Recent research has established a role for lipoprotein receptors in cognitive processes and implicated this receptor family in the pathological processes that underlie the progression of AD. Two of the major ligands for these receptors, apoE and reelin, appear to have signaling capabilities that can significantly impact synaptic function, directly interact with APP and modulate its metabolism, and are sensitive to Aβ accumulation. Aβ accumulation disrupts lipoprotein receptor signaling, resulting in concomitant disruption of cognitive function. Furthermore, interference of reelin and/or lipoprotein receptor signaling results in aberrant APP metabolism and Aβ clearance that in turn exacerbates Aβ accumulation and plaque deposition. Therefore, increased reelin signaling through direct reelin application or usage of other lipoprotein receptor agonists can be used to mitigate Aβ-dependent cognitive disruption and progression of plaque pathology.
[0031] Reelin: In the adult hippocampus, the glycoprotein Reelin is expressed by interneurons residing primarily in the hilar region of dentate gyms, and the stratum lacunosum-moleculare layer of the hippocampus proper. Reelin-expressing cells can also be found in stratum oriens and stratum radiatum of area CA1 and CA3 and is associated with pyramidal cells of the hippocampus. Induction of long-term potentiation (LTP), a form of synaptic plasticity that results in a lasting increase in synaptic efficacy, requires NMDAR (NMDARs) activation and the subsequent up-regulation of AMPA receptor expression and function. Changes in AMPA receptors (AMPARs) can be achieved either by increased subunit phosphorylation or by increased subunit synthesis and trafficking to the specific synaptic sites. In contrast, NMDARs serve as coincidence detectors and play a major role in the induction of synaptic plasticity. The opening of NMDAR ion channels requires both glutamate binding and post-synaptic membrane depolarization. Some NMDAR subunits, such as NR1, NR2A and NR2B are also subjected to modulatory phosphorylation at serine/threonine or tyrosine residues. Phosphorylation of NMDAR subunits modulates both channel kinetics and trafficking to synaptic sites. It follows that if reelin were important for modulation of synaptic plasticity, then NMDARs and AMPARs would be logical targets given their importance in induction and expression of synaptic plasticity.
[0032] APC: Activated protein C (APC) is a serine protease that possesses both anticoagulant and cytoprotective properties that are currently being exploited for the treatment of conditions such as sepsis, stroke and multiple sclerosis. The anticoagulant properties of APC are achieved through the protein C (PC) pathway, while its cryoprotective effects are orchestrated through PAR1 (protease activated receptor; and PAR3, endothelial PC receptor (EPCR) and ApoER2. In mice, APC has been found to protect against diabetic endothelial and glomerular injury, multiple sclerosis and ischemia/reperfusion injury in the kidney and lung.
[0033] APC has already been approved by the U.S. Food and Drug Administration for use in adult severe sepsis and is currently in Phase I/IIa clinical trials for the treatment of ischemic stroke. Numerous groups have also recently developed APC variants that possess less anticoagulant activity, which has proven to limit APC's clinical efficacy. Specifically, a mutant designated 3K3A-APC has 80% reduced anticoagulant activity but retains normal PAR1 and EPCR-dependent anti-apoptotic activity. Relevant to the use of APC to treat neuropathologies, APC and APC variants have been found to effectively cross the BBB via EPC-mediated transport.
[0034] Recently, APC has been found to activate the Reelin signaling cascade via high affinity ligation to ApoER2. Specifically, APC-treated monocytes demonstrated increased active Dab1 (Tyr220-p), Akt Ser473-p, and GSK3beta Ser9-p levels. Pre-treatment with RAP or knocking down of ApoER2 were found to attenuate these effects, while inhibitors of EPCR and PAR1 had no effect. Interestingly, APC was found to bind to ApoER2 with 30 nM affinity, but not to soluble VLDLR. To relate APC's effects to ApoER2 signaling, RAP was found to block APC-mediated inhibition of endotoxin-induced tissue factor pro-coagulant activity of U937 cells.
[0035] Recent work has highlighted the importance of Reelin signaling in normal learning and memory (Weeber E J, Beffert U, Jones C, et al. Reelin and ApoE receptors cooperate to enhance hippocampal synaptic plasticity and learning. J Biol Chem 2002, 277:39944-39952), as well as pathological instances where this signaling is perturbed. APC is now a candidate modulator of Reelin signaling, as it appears to have the structural moieties to bind to ApoER2 and activate downstream effectors. It is of immense scientific and clinical relevance that APC modulation of Reelin signaling be tested, as it could yield novel therapeutic avenues.
[0036] SePP1: Approximately 60% of selenium in plasma is present in selenoprotein P. This protein differs from other selenoproteins in that it incorporates up to 10 Se atoms per molecule in the form of selenocysteine as opposed to single selenocysteines. Selenoprotein P is abundant throughout the body, suggesting that one function is to serve as a primary transporter in systemic selenium delivery. This is especially evident in the CNS where selenoprotein P levels can be maintained independent of plasma selenium. However, genetic ablation of selenoprotein P results in reduced, but not a commensurate decrease in CNS-associated selenium levels, suggesting that other selenium proteins compensate for the selenoprotein P deficiency and supporting the hypothesis that basal selenium levels are essential for the brain and have a priority for systemically available selenium. Seppl (−/−) mice fed a selenium-deficient diet show severe motor dysfunction associated and associated neuronal degeneration, which can be prevented by supplementation with high dietary selenium.
[0037] Reduced dietary selenium can have significant effects on levels of selenoproteins involved in oxidative stress and their related effects on glutathione peroxidases, thioredoxin reductases and methionine sulfoxide reductases. Selenium, through incorporation into selenoproteins, provides protection from reactive oxygen species (ROS)-induced cell damage. This is interesting in light of the role of oxidative stress and subsequent production of ROS in neurodegenerative disorders such as Alzheimer's disease, Parkinson's disease and Duchenne muscular dystrophy. The inventors have previously examined the consequences of selenoprotein P deficiency on cognitive capacity and synaptic function with a focus on the hippocampus, an area of the CNS intimately involved in learning and memory processes. Seppl (−/−) mice demonstrated no overt behavioral phenotype, but were found to have a subtle disruption in acquisition of spatial learning and memory. In contrast, synaptic transmission was altered and short- and long-term synaptic plasticity was severely disrupted in area CA1 of hippocampus. Interestingly, the inventors found that when Seppl (+/+) mice were fed a low Selenium diet (0 mg/kg), they too exhibited altered synaptic transmission and synaptic plasticity. Our observations suggest an important role for both selenoprotein P and dietary selenium in overall proper synaptic function.
[0038] Fc-RAP: Reelin molecules have recently been discovered to form higher-order complexes in vitro and in vivo. This observation was further refined by showing that reelin is secreted in vivo as a disulfide-linked homodimer. Deletion of a short region, called the CR-50 epitope, located at the N-terminus of the molecule abolishes oligomerization. This mutated reelin fails to efficiently induce Dab1 phosphorylation in primary mouse neurons.
[0039] These results are in accordance with earlier observations that an antibody against the CR-50 epitope antagonizes reelin function in vitro and in vivo. Clustering of ApoER2 and/or VLDLR induces Dab 1 phosphorylation and downstream events including activation of SFKs and modulation of PKB/Akt. Furthermore, modulation of long-term potentiation (LTP), one of the biological effects of reelin, is also mimicked by reelin-independent receptor clustering. These findings strongly suggest that receptor-induced dimerization or oligomerization is sufficient for Dab1 tyrosine phosphorylation and downstream signaling events without the need for an additional co-receptor providing tyrosine kinase activity.
[0040] As shown herein, Reelin plays an active role in the processes of synaptic plasticity and learning. The invention also includes the identification and use of mechanisms for Reelin protein processing to enhance and/or repair cognitive function. For example, it is disclosed herein that: contextual fear learning and theta burst stimulation (tb-stim) cause changes in Reelin processing; the metalloproteinases, tPA and MMP-9 are differentially involved in Reelin processing during synaptic plasticity and learning; supplementation of Reelin fragment complement can enhance associative and spatial learning and memory; and reelin fragments associate with Aβ plaques, its expression and processing is altered by AD-related mutations, and Reelin supplementation can overcome the LTP deficits found in the Tg2576 AD mouse model.
[0041] Reelin-induced enhancement of long-term potentiation in acute hippocampal slices.
[0042] Reelin is a naturally occurring, secreted protein produced by interneurons of the hippocampus and cortex. Knockout (KO) mice of both reelin receptors, ApoER2 and VLDLR show deficits in long-term potentiation (LTP) in the stratum radiatum of the hippocampus. To verify the absence of reelin signaling underlies this deficit, the inventors performed a simple experiment consisting of the perfusion of purified reelin protein onto wild-type hippocampal slices. As shown in FIG. 1 , reelin application enhanced HFS-LTP induced in the stratum radiatum.
[0043] Post-synaptic mechanisms of reelin enhancement of NMDAR currents.
[0044] Reelin also demonstrates the ability to potentiate CA1 glutamatergic responses. The inventors have recently shown that ApoER2 is present post-synaptically and forms a functional complex with NMDARs in CA1 (4). The derivation of mEPSCNMDA is illustrated in FIG. 2 . Cells treated with mock had miniature excitatory post-synaptic current due to NMDA receptors (mEPSCNMDA) that were not significantly changed compared with that before mock treatment (p>0.05). Treatment with Reelin was found to significantly increase mEPSCNMDA amplitude (p<0.001).
[0045] To further verify that synaptic NMDAR response was increased as a result of postsynaptic effects of Reelin, the inventors analyzed the coefficient of variation (CV) of synaptically-evoked NMDAR whole-cell current. When 1/CV2 ratios were plotted versus mean EPSCNMDA ratios before and after a 30 minute reelin application in nine experiments, no correlation was established ( FIG. 2D ). However, the 1/CV2 ratios remain relatively unchanged across varying mean EPSCNMDA ratios, confirming reelin activation through a postsynaptic mechanism in CA1 to enhance NMDAR activity.
[0046] Differential effects of Reelin treatment on surface levels of AMPAR and NMDAR subunits.
[0047] Chronic Reelin treatment can result in the increased AMPA component of synaptic response, alteration of EPSCNMDA kinetics and ifenprodil sensitivity. The inventors sought to determine whether the protein expression levels of AMPAR and NMDAR subunits were changed by Reelin in CA1. Both total and surface levels of G1uR1, NR1, NR2A, and NR2B were probed by Western blotting. The inventors first examined whether G1uR1, an AMPAR subunit that is increasingly expressed during developmental maturation and subjected to regulate trafficking during synaptic plasticity, was increased on CA1 cell surfaces.
[0048] FIG. 3 shows that reelin treatment significantly increased levels of surface G1uR1 compared with mock-treated groups, indicating regulated expression and surface insertion via increased mEPSC AMPA and AMPA/NMDA current ratio after chronic Reelin treatment. No changes of either surface or total NR1 levels were observed. In comparison, both total and surface NR2A expression levels were significantly increased after reelin treatment versus mock treatment. Moreover, both total and surface NR2B protein levels were significantly decreased following reelin treatment. Mock treatment had no effect on different glutamate receptor subunit levels compared with non-treated control groups.
[0049] Reelin signaling translates from a role in synaptic plasticity to learning and memory.
[0050] Reelin heterozygotes show deficits in both synaptic plasticity and cognitive function. An approximate 50% reduction of Reelin expression results in deficits in both synaptic plasticity and cognitive function (Qiu, S., K. M. Korwek, A. R. Pratt-Davis, M. Peters, M. Y. Bergman, and E. J. Weeber. 2006. Cognitive disruption and altered hippocampus synaptic function in Reelin haploinsufficient mice. Neurobiol Learn Mem 85:228-242). Furthermore, bilateral infusion of the lipoprotein antagonist RAP (receptor associated protein), which effectively blocks Reelin binding to its receptors dramatically, reduced associative learning ( FIGS. 4A-4D ). These results demonstrate a requirement for Reelin for normal memory formation and raise the interesting question of whether increasing Reelin signaling can enhance memory.
[0051] The effect of Reelin deficiency on synaptic function is contrasted when Reelin concentrations are enhanced. Direct bilateral ventricle infusion of recombinant Reelin fragment compliment 3 hours prior to associative fear conditioning training enhanced memory formation when tested 24 hours after training in 3-4 month-old wild-type mice ( FIG. 4A ).
[0052] Furthermore, a single injection of Reelin into the ventricles improved spatial learning in the hidden platform water maze ( FIG. 4B ). Mice that were retrained to find a different platform location (opposite) on day 6 continued to show increased learning ability compared to saline injected mice. Mice receiving a single Reelin injection 5 days prior to training show a lower latency to find the platform on day one. A closer examination shows that the latency to find the platform is significantly reduced after a single exposure to the training paradigm ( FIG. 4C ). Mice that were retrained to find a different platform location continued to show differences between reelin and saline injections. Swim speeds and all other measurements of activity between treated and non-treated animals remained the same. This data dramatically illustrate the ability of Reelin to modulate in vivo learning and memory formation and the importance of research aimed to identify the mechanisms controlling Reelin protein processing and how the fragments subsequently modulate cognitive function.
[0053] Reelin supplementation overcame Aβ-dependent changes in synaptic plasticity.
[0054] Reelin signaling is involved in a variety of physiologic changes to the excitatory synapse, as well as normal mammalian cognitive function. Reelin metabolism is altered in three mouse models for AD (PS1-FAD, SweAPPxPS1, and Tg2576) ( FIG. 5A ). These changes in Reelin fragment complement appear to be correlated with alterations in downstream Reelin signaling, as phosphorylation of the major downstream component, Dab-1, is increased in the SweAPPXPS1 and PSI-FAD, and significantly decreased in the single SweAPP (Tg2576) mouse ( FIG. 5B ). These data suggest that Reelin metabolism is particularly sensitive to changes in APP processing and/or A13 accumulation.
[0055] The alteration in Reelin fragment complement and Dab-1 phosphorylation in the Tg2576 mice may represent a compromised Reelin signaling system, a phenomenon that if true could be responsible for the synaptic plasticity deficits reported in these mice (Mitchell, J. C., B. B. Ariff, D. M. Yates, K. F. Lau, M. S. Perkinton, B. Rogelj, J. D. Stephenson, C. C. Miller, and D. M. McLoughlin. 2009. X11beta rescues memory and long-term potentiation deficits in Alzheimer's disease APPswe Tg2576 mice. Hum Mol Genet 18:4492-4500; Kotilinek, L. A., M. A. Westerman, Q. Wang, K. Panizzon, G. P. Lim, A. Simonyi, S. Lesne, A. Falinska, L. H. Younkin, S. G. Younkin, M. Rowan, J. Cleary, R. A. Wallis, G. Y. Sun, G. Cole, S. Frautschy, R. Anwyl, and K. H. Ashe. 2008. Cyclooxygenase-2 inhibition improves amyloid-betamediated suppression of memory and synaptic plasticity. Brain 131:651-664; Jacobsen, J. S., C. C. Wu, J. M. Redwine, T. A. Comery, R. Arias, M. Bowlby, R. Martone, J. H. Morrison, M. N. Pangalos, P. H. Reinhart, and F. E. Bloom. 2006. Early-onset behavioral and synaptic deficits in a mouse model of Alzheimer's disease. Proc Natl Acad Sci USA 103:5161-5166). Acute hippocampal slices from 8 month-old Tg2576 mice were perfused with 5 nM recombinant Reelin fragment complement. The inventors find that the Reelin application rescues the LTP defect in aged Tg2576 mice ( FIG. 5C ) suggesting that the biochemical and structural machinery involved in Reelin signaling downstream of Reelin protein processing is intact in these mice. Furthermore, it is important to note that normal levels of synaptic plasticity are obtainable in this mouse model. Reelin fragments are also associated with dense core plaques in aged (15 month-old) Tg2576 mice ( FIG. 5D ). As shown in FIG. 6 , reelin and related lipoprotein receptor agonists can rescue deficits in synaptic plasticity and cognitive function that result from Aβ accumulation and/or plaque pathology. Reelin rescued the LTP deficit in 12 month-old mice modeled for AD (Tg2576) ( FIG. 6 ).
[0056] These data are supported by Reelin associated with Aβ-containing plaques detected in the hippocampus of aged wild-type mice (Madhusudan, A., C. Sidler, and I. Knuesel. 2009. Accumulation of reelin-positive plaques is accompanied by a decline in basal forebrain projection neurons during normal aging. Eur J Neurosci 30:1064-1076; Knuesel, I., M. Nyffeler, C. Mormede, M. Muhia, U. Meyer, S. Pietropaolo, B. K. Yee, C. R. Pryce, F. M. LaFerla, A. Marighetto, and J. Feldon. 2009. Age-related accumulation of Reelin in amyloid like deposits. Neurobiol Aging 30:697-716). In light of the established role for Reelin in synaptic function, changes in the integrity of Reelin metabolism and signaling plays a profound role in the learning and memory changes previously established in AD mouse models.
[0057] Other ligands of lipoprotein receptors have an effect on synaptic function.
[0058] Selenium containing Selenoprotein P (SeP) has been identified as another ligand for the lipoprotein receptor ApoER2. SEP has been shown to associate with ApoER2 in the testis and in the CNS. SeP KO mice showed various pathologies, including deficits in hippocampal-dependent LTP and cognitive function ( FIG. 7 ).
[0059] Interestingly, the LTP defect in SeP (−/−) mice can be rescued with purified SeP protein supplementation ( FIG. 8 ). Taken together, these data suggest that SeP has a similar role to Reelin by signaling through ApoER2. It is unclear whether SeP can promote receptor clustering or compete with Reelin. However, it appears that SeP is using the ApoER2 as a receptor to internalize the SeP and deliver selenium to the neuron.
[0060] Receptor Associated Protein (RAP) is an intracellular protein that can bind with very high affinity to the family of lipoprotein receptors. The Fc-RAP fusion protein is an engineered protein consisting of two RAP molecules connected to form a rough ‘dumb bell’ shape using the Fc region of an antibody. Instead of binding to and inhibiting ApoER2 and VLDLR, the Fc-RAP can cause receptor clustering and ApoER2 activation. The addition of Fc-RAP has the identical effect as reelin application by increasing LTP induction ( FIG. 9 ). The main difference is that the Fc-RAP is likely to bind all lipoprotein receptors, but only clusters ApoER2 and VLDLR.
[0061] Reelin fragment complement in the hippocampus is altered following in vivo memory formation and ex-vivo stimulation.
[0062] Reelin is cleaved at specific sites resulting in a stable pattern of Reelin fragments easily quantified by Western blot analysis. These fragments represent potential signaling molecules with properties unique from full-length Reelin. Recombinant Reelin purified from stably transfected HEK293 cells contains fragments of the same size as the major fragments found in the hippocampus. Application of recombinant Reelin fragment compliment can (1) increase synaptic transmission by facilitating AMPA receptor insertion and increasing NMDA receptor function, (2) reduce silent synapses, (3) modify synaptic morphology and (4) enhance LTP (Qiu, S., and E. J. Weeber. 2007. Reelin signaling facilitates maturation of CA1 glutamatergic synapses. J Neurophysiol 97:2312-2321; Qiu, S., K. M. Korwek, A. R. Pratt-Davis, M. Peters, M. Y. Bergman, and E. J. Weeber. 2006. Cognitive disruption and altered hippocampus synaptic function in Reelin haploinsufficient mice. Neurobiol Learn Mem 85:228-242).
[0063] Additionally, fear conditioned learning produces changes in the endogenous Reelin fragment complement. The inventors found a dramatic change in Reelin expression and fragment complement over the 18 hours following contextual fear conditioning, particularly in the 450 and 180 kDa fragments ( FIG. 10 ).
[0064] Moreover, theta burst stimulation delivered to the Schaffer collateral pathway led to significant increases in Reelin expression and fragment cleavage at 15 minutes post-stimulation ( FIG. 10 ). These results show that integration and control of Reelin signaling responsible for alterations in synaptic plasticity and modulation of learning and memory involves the processing of Reelin into functionally-distinct fragments.
[0065] The inventors also found that the efficacy of generating the 370 kDa product to be partially dependent on a candidate Reelin-cleaving enzyme, tPA. This potential mechanism of regulation has profound implications on how this signaling system is integrated into known mechanisms of neuronal regulation and coordinated to participate in physiological processes such as learning and memory.
[0066] MMP-9- and tPA-mediated Reelin processing.
[0067] Recently it was shown that the processing of Reelin by metalloproteinase(s) is essential for normal cortical plate formation (Jossin, Y., and A. M. Goffinet. 2007. Reelin signals through phosphatidylinositol 3-kinase and Akt to control cortical development and through mTor to regulate dendritic growth. Mol Cell Biol 27:7113-7124), though the specific enzyme responsible remains as yet unknown. This discovery suggests that metalloproteinase-mediated Reelin processing may be important for directed Reelin signaling in the adult brain as well. Both tPA and MMP-9 are candidate metalloproteinases with clearly demonstrated roles in regulating synaptic plasticity and cognitive function (Bozdagi, 0., V. Nagy, K. T. Kwei, and G. W. Huntley. 2007. In vivo roles for matrix metalloproteinase-9 in mature hippocampal synaptic physiology and plasticity. J Neurophysiol 98:334-344; Nagy, V., O. Bozdagi, A. Matynia, M. Balcerzyk, P. Okulski, J. Dzwonek, R. M. Costa, A. J. Silva, L. Kaczmarek, and G. W. Huntley. 2006. Matrix metalloproteinase-9 is required for hippocampal late-phase long-term potentiation and memory. J Neurosci 26:1923-1934; Huang, Y. Y., M. E. Bach, H. P. Lipp, M. Zhuo, D. P. Wolfer, R. D. Hawkins, L. Schoonjans, E. R. Kandel, J. M. Godfraind, R. Mulligan, D. Collen, and P. Carmeliet. 1996. Mice lacking the gene encoding tissue-type plasminogen activator show a selective interference with late-phase longterm potentiation in both Schaffer collateral and mossy fiber pathways. Proc Natl Acad Sci USA 93:8699-8704; Pang, P. T., and B. Lu. 2004. Regulation of late-phase LTP and long-term memory in normal and aging hippocampus: role of secreted proteins tPA and BDNF. Ageing Res Rev 3:407-430; Zhuo, M., D. M. Holtzman, Y. Li, H. Osaka, J. DeMaro, M. Jacquin, and G. Bu. 2000. Role of tissue plasminogen activator receptor LRP in hippocampal long-term potentiation. J Neurosci 20:542-549; Baranes, D., D. Lederfein, Y. Y. Huang, M. Chen, C. H. Bailey, and E. R. Kandel. 1998. Tissue plasminogen activator contributes to the late phase of LTP and to synaptic growth in the hippocampal mossy fiber pathway. Neuron 21:813-825).
[0068] Reelin is processed by both tPA and MMP-9 to generate the major Reelin fragment products found in vivo ( FIG. 12A , 12 B). As it can be seen, tPA increases the 370 kDa (N-R6) and 80 kDa (R7-8) fragments under cell free conditions ( FIG. 12A ), indicating that tPA cleaves Reelin between R6-R7 ( FIG. 13 ). Cleavage of Reelin by Plasmin results in a spectrum of products of previously unknown identity and specific retention of the 180 kDa fragment. Application of recombinant tPA to primary neurons resulted in a complete conversion of extracellular Reelin from full-length to the 370 and 180 kDa forms, and a decrease in intracellular 180 kDa Reelin. Furthermore, MMP-9 increases both the 370 kDa (N-R6) and 180 kDa (N-R2) fragments, as well as a fragment found just below the well known 180 kDa fragment ( FIG. 12B ). These results under cell free conditions support that MMP-9 can cleave Reelin at both cleavage sites, R2-3 and R6-7; however, application of MMP-9 to primary neurons led to a specific accumulation of the 180 kDa fragment in cells and MMP-9 inhibition for 24 hours led to a dramatic increase in full-length cellular Reelin and decrease in cellular 180 kDa Reelin. These results suggest that under normal conditions, MMP-9 is responsible for cleaving Reelin between R2-R3 (See fragment map; FIG. 13 ). Taken together, these preliminary data suggest that MMP-9 and tPA are sufficient for generation of the major Reelin fragments found in vivo.
[0069] As shown above, reelin protein processing in the hippocampus is susceptible to in vitro and in vivo synaptic activity. It also appears that MMP-9 and tPA are involved in the process of Reelin metabolism. Surprisingly, a single exogenous Reelin application enhances learning and memory for at least eleven days in adult wild-type mice. When considering the role of lipoprotein receptors in Aβ clearance, and the identification of Reelin association to Aβ plaques in an AD mouse model, the question of the role of Reelin in the etiology and pathogenesis of AD becomes a timely and important area of research. Moreover, the now improved understanding of the mechanisms and implications of Reelin processing provides, inter alia, AD therapeutic interventions aimed toward removal of Aβ and improvement of cognitive function.
[0070] Moreover, all that is known regarding Reelin localization in the adult brain has been generated using an antibody that recognizes the N-R2 region. The N-R2 region is present in the full-length (N-R8), N-R2 and N-R6 fragments of Reelin, but not in the other major fragments. Therefore, the 3-epitope mapping approach (( FIG. 13 ) affords unprecedented spatial resolution to monitor changes in Reelin product production and localization.
[0071] In order to characterize specific fragments produced by tPA- and MMP-9-dependent Reelin processing in the context of normal synaptic function and memory formation, the inventors generated cleavage-resistant Reelin mutant constructs using site-directed mutagenesis FIG. 14 ). Reelin mutants include constructs resistant to cleavage (Rln-Res) by tPA at R2-3, to MMP-9 at R6-7 and to both enzymes at R2-3 and R6-7. Fragments mimicking cleavage by tPA or MMP-9 with, or without a cleavage resistant site are also contemplated. One complementary Reelin construct is tagged in an identical fashion as the Rln-Res protein; however, it does not contain the two altered sites for cleavage (Reelin cleavage labile; FIG. 14 )). A tagged fragment produced with both sites mutated (negative control construct) and a tagged R3-6 fragment shown to bind ApoER2 and VLDLR (potential positive control) is included. The Reelin constructs are sub-cloned into mammalian expression vectors containing N-terminal polyhistidine tags and/or C-terminal Myc tags to allow later recognition of exogenous Reelin. The exact cleavage sites can be identified by using purified full-length Reelin reacted with either tPA or MMP-9 therefore the resultant fragments can be isolated.
[0072] Reelin application recovers spine density in HRM and Reelin-null mice
[0073] In cultured hippocampal neurons, reelin signaling is required for normal development of dendritic structures. In the absence of reelin or the intracellular adaptor protein Dab1, neurons exhibit stunted dendritic growth and a reduction in dendritic branches, a phenotype analogous to that seen in neurons lacking the reelin receptors apoER2 and VLDLR (Niu S, Renfro A, Quattrocchi C C, Sheldon M, D'Arcangelo G. Reelin promotes hippocampal dendrite development through the VLDLR/ApoER2-Dab1 pathway. Neuron 2004; 41:71-84). The HRM exhibits a deficit in hippocampal-dependent contextual fear conditioned learning and synaptic plasticity in area CA1 of the hippocampus. It is believed that these behavioral and physiologic phenotypes of the HRM are due in part to reduced or inhibited synaptic connectivity. This is supported by the observation that HRM have a reduction in spine density ( FIG. 15 ).
[0074] Dendritic spines are small protrusions that cover the surface of dendrites and bear the postsynaptic structures that form excitatory synapses. Abnormal shapes or reduced numbers of dendritic spines are found in a number of cognitive diseases, such as Fragile X syndrome, William's syndrome, Rett syndrome, Down's syndrome, Angelman syndrome and autism. A reduction in the number of dendritic spines suggests that a constitutive level of reelin/lipoprotein receptor-mediated signaling is required for development of dendritic structures, which are crucial for intensive information processing by the neurons. This notion is in agreement with studies showing that heterozygote reeler mice exhibit reduced dendritic spine densities and impaired performance in certain learning and memory behaviors.
[0075] Hippocampal neurons cultured from reeler embryos had significantly less dendritic spines, a phenotype that can be rescued by addition of exogenous recombinant reelin to the culture. Organotypic hippocampus cultures were created from 6-7 day-old wild-type, HRM and Reelin-deficient mice and treated with 5 nm Reelin for 21 days. Fluorescent dye was injected into neuronal cells by administering whole cell patch clamp current and the cells were visualized under the confocal microscope after fixation. Reelin-treated of HRM cells showed an increase in dendritic spine density after 21 days compared to age matched neurons from wild-type culture ( FIG. 15B ). In contrast, mock (conditioned media from non-stably transfected cells) application showed no change in spine density ( FIG. 15C ). The same experiment in reelin knockout mice showed that reelin application also rescued the dendritic spine density compared to mock controls ( FIGS. 15C and 15F ). Both the reelin treated cells resembled the dendritic spine morphology seen in WT cells ( FIG. 15D ) and when quantified, dendritic spines significantly increased in reelin-treated HRM cultures compared to mock treated controls and are similar to spine density levels observed in wild-type cultures ( FIG. 15A ).
[0076] Treatment of organotypic cultures consisted of repeated 5 nM Reelin application every 3 days for 21 days. To verify that this application protocol represented a chronic application of reelin, and reelin was not being degraded or actively removed from the media, the inventors removed 15 ul of media from culture plates at times of 0, 6, 12, 24, 48, 72, and 96 hours following reelin application. Western analysis of these aliquots showed no degradation or reduction in Reelin ( FIG. 15G ). Thus, the increase in spine density is due to reelin present at physiologic relevant levels for the entire 21 day application.
[0077] In vivo Reelin application effects on overall behavioral responses.
[0078] Mice lacking reelin exhibit abnormal lamination of neuronal layers, which is most severely seen in the cortex, cerebellum, and hippocampus. The Reelin knockout exhibits the “reeler” phenotype, characterized by rest tremor and ataxia. Although the Cajal-Retzius cells eventually degenerate after the completion of development, reelin continues to be expressed by GABAergic interneurons in the cortex and hippocampus. In the adult, as in the developing brain, Reelin's molecular effects are mediated through two receptors: the very low density lipoprotein receptor (VLDLR) and the apoliporotein E receptor 2 (ApoER2). Reelin-dependent signaling through ApoER2 and VLDLR occurs through hetero- or homo-dimerization of receptors and can activate the CDK-5 and PI3-K signal transduction pathways. Reelin signaling is also linked to modulation of synaptic plasticity and memory formation.
[0079] The heterozygote reelin mouse (HRM) exhibits haploinsufficiency and a 50% reduction in reelin protein levels, but does not lead to an overt “reeler” phenotype. Instead, Reelin haploinsufficiency manifests as very subtle neuroanatomical, physiologic and behavioral deficits. These include a decrease in dendritic spines in the parietal-frontal cortex (PFC) pyramidal neurons in addition to basal dendritic cells of hippocampal CA1 pyramidal neurons and cortical neuropil hypoplasia. The HRM displays a reduced density of nicotinamide-adenine dinucleotide phosphate-diaphorase (NADPH-d)-positive neurons in the cortical gray matter, altered dopaminergic markers in the mesotelencephalic dopamine pathway. The HRM shows impaired short-term and long-term plasticity in hippocampal CA1 synapses. Long-term potentiation (LTP) is disrupted using both high frequency stimulation and pairing stimulation protocols. Behaviorally, the HRM exhibits an age-dependent decrease in prepulse inhibition.
[0080] The HRM has often been referred to as a possible mouse model for human schizophrenia. Reelin mRNA and protein levels are reduced in post-mortem brains of schizophrenic patients resulting in approximately 50% of that found in normal control post mortem brains. Investigation of the Reeler heterozygote found other similarities to the human condition, including: decreased GAD67 expression, decreased tactile and acoustic prepulse inhibition, and reduced spine density. Schizophrenia is also associated with severe cognitive impairment and disordered thinking This manifests as a lack of overall attention, impairment of information processing disrupting both declarative and nondeclarative memories. Importantly, HRM show a similar cognitive dysfunction, observed as reduced associative fear conditioned learning.
[0081] An HRM breeding pair (B6C3Fe a/a-Reln r1 /+ strain) was obtained from the Jackson Laboratory. The offspring of both HRM were genotyped by using genomic DNA from a 2 mm diameter earpunch. The primer sequences were, forward: 5′-taatctgtcctcactctgcc-3′ (SEQ ID NO:1); reverse: 5′-acagttgacataccttaatc-3′(SEQ ID NO:2); reverse mutated: 5′-tgcattaatgtgcagtgttgtc-3′(SEQ ID NO:3). Animal care and use protocol was approved by the Institutional Animal Care and Use Committee of Vanderbilt University.
[0082] The culmination of research on Reelin's actions in developing CNS and adult cognitive processes raises the question of whether the cognitive deficits in HRM are due to reelin haploinsufficiency, leading to a decrease in signal transduction and LTP formation, or reduction in dendritic spines, resulting in decreased information processing and storage in areas involved in learning and memory. Alternatively, HRM show reduced spine density, thus, these deficits may be due to developmental defects that result in the mis-wiring of critical regions of the CNS.
[0083] The increase in sEPSCs in wild-type mice, but not in Reelin knockout mice despite chronic reelin exposure indicated that spine formation was not the sole factor influencing spontaneous synaptic activity in cultured neurons. This would suggest that developmental abnormalities resulting in altered synaptic connectivity in the hippocampus of HRM, and to a greater extent in the Reelin-deficient mice, were the underlying basis for the cognitive deficits in the HRM.
[0084] The HRM and wild-type mice are similar for open field and elevated plus maze. These behavioral tests are essential for evaluation and proper determination of associative fear conditioning results. In addition, the open field and elevated plus maze tasks allow assessment of any differences in locomotor activity or anxiety after the cannulation placement and injection.
[0085] For the open field tests, general locomotor activity was measured using the open field task. Animals were placed in the open field (27×27 cm) chamber for 15 min in standard room-lighting conditions. Activity in the open field was monitored by 16 photoreceptor beams on each side of the chamber and analyzed by a computer-operated (Med Associates) animal activity system.
[0086] For the elevated plus maze experiments, mice were placed in the elevated plus maze one hour after they had completed the open field task to test their levels of anxiety. The apparatus consisted of two opposing open arms (30 cm×5 cm) and two opposing closed arms (30 cm×5 cm×15 cm) connected by a central square platform and was 40 cm above the ground. Testing took place under standard-lighting conditions. Mice were placed in the open arms facing the closed arms at the beginning of the 5 minute session. The number of entries and the total time spent in the open arms were recorded.
[0087] Bilateral intracerebroventricular cannulations on HRM mice were followed by evaluating open field and elevated plus maze tests. Following a 5 day recovery period from the surgical procedure, these mice were injected with 1 ul of either mock or reelin through two PESO tubes attached to two Hamilton syringes. Mice were visually assessed daily for overall health following surgery. All mice used for these studies showed no signs of infection assessed by visual inspection of the site of incision and rectal temperature monitored daily.
[0088] The injection of 1 ul of a concentrated Reelin solution represented a final distributed concentration of 5 nM. To test for dispersion of Reelin cannulated wild type mice were injected monolateral with 1 ul Reelin and sacrificed 1 hour following injection. Brains were fixed and immunohistochemical analysis for Reelin was performed. No discernable distribution of Reelin was seen in the Reelin injected hemisphere, however, an increase in overall Reelin immunoreactivity was observed in the treated versus non treated hemispheres. This suggests that Reelin quickly diffuses from the ventricle by the time of behavioral testing.
[0089] One hour after Reelin injection the experimental mice were placed in the open field chamber and distance traveled over a 15 minute period was measured. Immediately following the open field task, mice were placed in the elevated plus maze and the number of entries and percent time in the open arms were measured. A greater amount of time spent in the closed arms compared to the open arms is an index of higher anxiety. No differences were seen between the mock and reelin treated heterozygote mice in these two tasks ( FIG. 16A-B ).
[0090] Mice normally exhibit a startle response to loud noise but if a moderate noise is presented prior to the loud noise, the startle response is attenuated, an effect known as prepulse inhibition (PPI). PPI represents another compelling behavioral phenotype of the HRM that recapitulates human schizophrenia. PPI was performed one hour after elevated plus maze. The mouse was placed in a Plexiglas cylinder in a dark PPI chamber (Med Associated Inc.; St. Albans, Vt.) with the presence of background noise provided by a fan. After mice were allowed to acclimate for 5 minutes in the chamber, they were underwent a random presentation of five stimulus trial types: 120 db stimulus startle alone, and each of a 70, 76, 82, and 88 db prepulse followed by a 120 db startle for a total of 9 trials per type. The percent prepulse inhibition and the peak startle were measured using the Startle Reflex 5 software.
[0091] The inventors have previously shown that the HRM show a deficit in PPI, specifically at the 82 dB prepulse. To determine whether Reelin rescues this deficit, the inventors performed PPI in Reelin-injected cannulated mice. Following the elevated plus maze, mice were placed in the startle reflex chamber and given a random presentation of 5 trial types: no prepulse with a 120 dB acoustic startle, or 70, 76, 82, 88 dB prepulses with a 120 dB acoustic startle. The inventors saw that there was no difference in the startle to acoustic stimulation, where no prepulse was presented with a 120 dB acoustic startle between the mock treated and reelin treated HRM ( FIG. 16D ). Additionally, there was no difference in the PPI between both treatment groups at any of the prepulse levels ( FIG. 16C ).
[0092] The HRM shows a deficit in associative learning when compared to their wild-type littermates. Contextual fear conditioning was performed on Reelin and Mock-treated HRM at 5 hours post-injection to assess whether Reelin haploinsufficiency is responsible for this change rather than permanent developmental defects. Fear conditioning was performed 2 hours after PPI. The conditioning chamber (26×22×18 cm; San Diego Instruments, San Diego, Calif.) was made of Plexiglas and was equipped with a grid floor for delivery of the unconditioned stimulus (US) and photobeams to monitor activity. The conditioning chamber was placed inside a soundproof isolation cubicle.
[0093] Training occurred in the presence of white light and background noise generated by a small fan. Each mouse was placed inside the conditioning chamber for 2 minutes before the onset of a conditioned stimulus (CS), an 85 dB tone, which lasted for 30 seconds. A 2 sec US foot-shock (0.5 mA) was delivered immediately after the termination of the CS. Each mouse remained in the chamber for an additional 60 seconds, followed by another CS-US pairing. Each mouse was returned to its home cage after another 30 seconds. The test for contextual fear memory was performed 1, 24, and 72 hours after training by measuring freezing behavior during a 3 minute test in the conditioning chamber.
[0094] Freezing was defined as lack of movement in each 2 second interval. Cued fear memory was tested in the presence of red light, vanilla odor, and the absence of background noise. The grid floor was covered and the walls were covered with alternating black and white plastic panels. Each mouse was placed into this novel context for 3 minutes at 1 hour and 24 hours after training They were exposed to the CS for another 30 min following this. Freezing behavior was recorded and processed by the SDI Photobeam Activity System software throughout each testing session.
[0095] The aversive unconditioned stimulus (US), a 5 mA foot-shock, was paired twice with an auditory tone (conditioned stimulus, CS). During the training period, both animals showed similar levels of freezing after the presentation of the US with an increasing trend of freezing ( FIG. 17A ). This indicates that the acquisition of the fear memory is similar in both groups and freezing ability is similar. Mice were placed back into the context in which they were trained at 1, 24 or 72 hours following training There was no difference between the Reelin treated mice compared to the mock treated controls at 1 hour post-training ( FIG. 17B ). However, 24 hours after training, mice were placed into the chamber for the second time to examine the effects of Reelin on long-term memory formation. Reelin-treated mice showed a significant increase in percent freezing compared to mock-treated controls ( FIG. 17C ). These levels are similar to the levels of freezing in WT mice that the inventors have previously shown (−70%), while the mock-treated controls resembled our HRM. This suggests that reelin rescues the hippocampal-dependent associative learning deficits seen in the HRM to resemble the WT mouse. When tested 72 hour following training, there is no statistical significance between the two treatment groups, although there is trend for an increase in freezing in the Reelin group compared to mock controls ( FIG. 17D ). This may represent a consolidation effect in some of the mice in that the re-introduction into the context in the absence of the aversive stimulus may lead to the recall and re-organization of the memory. The ensure that both treatment groups had similar sensitivities to the foot-shock, a shock threshold test was performed. No difference was seen between reelin-treated and mock-treated mice ( FIG. 17E ). Thus, Reelin replacement to the CNS of HRM rescues the contextual fear conditioning defect.
[0096] In vivo application of Receptor Associated Protein.
[0097] The results above show that increasing Reelin, and subsequent Reelin signaling, in the hippocampus rescues the cognitive deficit. If the decrease in ApoER2 and VLDLR signaling is responsible for the cognitive defects in HRM, then one should be able to mimic these behavioral changes by blocking ApoER2 and VLDLR. Receptor Associated Protein (RAP) serves as a molecular chaperone for the family of lipoprotein receptors allowing transport to the plasma membrane without premature binding to ligand. Applied exogenously, RAP binds to the extracellular portion of the lipoprotein receptor and acts as an effective antagonist. Exogenous application of RAP results in association of inserted receptors and can effectively block extracellular ligand-induced signaling. The use of RAP as a biological antagonist has previously been used to block receptor-induced signaling in culture and tissue, and can effectively block long-term potentiation (LTP) in wild-type hippocampus. Thus, the behavioral tests were performed on wild-type mice injected with 1 ul of concentrated GST-RAP or GST as a negative control.
[0098] Exogenous GST-RAP or GST (used as a negative control) ha no effect on overall behavior ( FIG. 18A-B ) and no change was seen in PPI or acoustic startle ( FIG. 18C-D ). There were no changes in freezing during fear condition experiments or in testing to the context 1 hour after training ( FIG. 19A-C ). However, GST-RAP injection resulted in a significant decrease in freezing to the context to a level identical to that seen in our HRM Mock treated animals and those levels previously reported in HRM mice ( FIG. 19C ). No differences were seen in shock thresholds between the two treatment groups ( FIG. 19D ).
[0099] Throughout this application various publications have been referenced within parentheses. The disclosures of these publications in their entireties are hereby incorporated by reference in this application in order to more fully describe the state of the art to which this invention pertains.
[0100] Although the invention has been described with reference to the disclosed embodiments, those skilled in the art will readily appreciate that the specific experiments detailed are only illustrative of the invention. It should be understood that various modifications can be made without departing from the spirit of the invention.
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Disclosed are methods of influencing, and enhancing, cognitive function by increasing, and/or preventing interference with, Reelin levels as well as Reelin signaling. Cognitive function is improved, in a subject in need thereof, by administering a therapeutically effective amount of Reelin, a Reelin-specific modulator or an agonist of a lipoprotein receptor to the subject. The lipoprotein receptor can be selected from candidates such as ApoER2 and VLDLR. As disclosed herein, agonists of the lipoprotein receptor for use with the inventive method include APC, Sep and Fc-RAP. In addition to administering exogenous Reelin, a Reelin-specific modulator, such as a recombinant Reelin fragment, can be used to increase Reelin levels and/or signaling.
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BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to a device for providing a level base upon which a device, such as a portable stove, can be safely supported during cooking.
2. The Prior Art
Portable stoves, such as camp stoves, generally have closed rectangular housings containing one or more burner units supported beneath a grill upon which the cooking utensil rests. The fuel supply for the burners can either be internal, i.e. mounted within the housing or, more often, canisters either attached externally to the housing or placed nearby and connected to the burners by any one of several known means, such as flexible hoses. These stoves are most often used in an outdoors environment which, even when tables are available, usually is not sufficiently level to assure that the cooking grill surface can safely support food filled utensils during cooking of a meal. It is not satisfactory to use shims under one or more corners of the housing, in an attempt to level the stove, as this can be quite dangerous. Dislodgement of the shims could result in upset of the stove, which likely would have lit burners and hot food in the utensils on the grill.
The present invention has for an object to overcome this long felt need to provide an economical means to safely support a camp stove in a level condition, regardless of the irregularities of the available surface.
SUMMARY OF THE INVENTION
The present invention is a portable stove supporting and leveling apparatus having a frame with a pair of folding leg assemblies, each with a pair of legs, at each end of the frame. Each of the four legs is provided with individually adjustable legs. The frame itself is preferably adjustable in length and width so as to accommodate stoves of various sizes.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is an isometric view of the subject invention supporting a camp stove; and
FIG. 2 is a top plan view of the subject device in a folded condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The subject stove lever 10 is shown in FIG. 1 supporting a camp stove 12 which has a rectangular housing 14 defining a cavity 16 in which one or more burners 18, 20 are fixedly mounted. The stove has a grill 22, which is generally removable, positioned above the burners. The housing 14 is closed with cover 24 which can be held in an open condition, as shown, by known locking devices (not shown). The cover 24 may be provided with known side mounted wind shields (also not shown). Fuel for the burners comes from known containers (not shown), such a propane canister, which can be mounted either internally in or externally of the housing 14 and connected to the respective burners 18, 20 by known means (not shown), such as flexible hoses. Control means 26, 28 are shown mounted on the front of the stove to control, in known fashion, flow of fuel to the respective burners 18, 20 and thus the heat generated by them.
The subject leveler 10 has a pair of front and rear parallel spaced rails 30, 32. These rails 30, 32 are interconnected at their respective ends by leg assemblies 34, 36 to form a substantially rectangular unit. The leg assemblies 34, 36 each have legs 38, 40, 42, 44 joined by end bars 46, 48. The legs are each provided, on their lower ends, with axially adjustable feet 50, 52, 54, 56. The leg assemblies are pivotally attached, at the upper ends of their respective legs, to front and rear rails by pivot means 58, 60, 62, 64. These pivot means can be any of the well known pivotal fastening devices, such as rivets and bolts.
In the preferred embodiment of the subject invention, the rails 30, 32 and the end bars 46, 48 are made adjustable in length. This can be accomplished in a number of ways, for example by making the rails and bars telescoping or by having them overlapping and selectively joined. The choice of materials for forming these rails and bars will pretty much decide their manner of adjustability. For example, metal or plastics members would be most suitable for a telescoping assembly while wooden members would be more suitable for an overlapping configuration.
In order to use the present invention, first the rails and bars are set to the proper length to accommodate for the size of the stove to be supported thereon. Then the leg assemblies 34, 36 are rotated from the stored position of FIG. 2, wherein they lie substantially within the plane of the rails, to the set up position, wherein they extend substantially normal to the plane of the rails 30, 32, as shown in FIG. 1. It is within the scope of the present invention to provide means (not shown) to lock the leg assemblies in this position. Such means could include, but are not restricted to, detents, springs, catches, pins and the like.
After the leg assemblies 34, 36 are properly positioned, the feet 50, 52, 54, 56 are individually rotated, to move axially inwardly or outwardly with respect to that leg, until the unit achieves a level and non-rocking condition. Then the burners can be lit and cooking commenced with complete safety.
It is within the scope of the present invention to include means (not shown) to hold the stove in place thereon, such as corner anchors; to permanently attach the leveler to the stove's housing by screws, bolts or latches; or to store it with the stove by means of detachable straps to assure the stove and leveler will be together when needed. It is also within the scope of the invention to provide level 66 indicator means, such as a bubble level, to assure correct leveling of the stove.
The subject leveler can be manufactured from a variety of materials, including but not restricted to, wood, aluminum, steel and plastics.
The present invention may be subject to many modifications and changes without departing from the spirit or essential characteristics thereof. The present embodiment should therefor be considered in all respects as illustrative and not restrictive of the scope of the present invention as defined by the appended claims.
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A camp stove leveler having rail members forming a support surface and leg assemblies supporting and interconnecting the rail members in parallel spaced condition. Each leg assembly has at least two legs secured at opposite ends of a cross bar, each leg having an axially adjustable foot depending from its lower free end.
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BACKGROUND OF THE INVENTION
The present invention relates to a photosensitive film usable more particularly in microlithography for producing electronic components, such as integrated circuits. Microlithography is a widely used technique in the field of the production of electronic components, where it is used for producing on a substrate designs having lines of approximately 1 micron or submicron lines.
In such microlithography techniques, on the substrate is generally deposited a photosensitive film. On said film is then formed by irradiation, designs which are then revealed by using a solvent for dissolving either the film zones which have been exposed to irradiation, or the film zones which have not been exposed to irradiation. In this way, openings are formed in the film covering the substrate and it is then possible to carry out treatments, such as etching or ion implantation on the thus revealed substrate zones.
During irradiation, there is a chemical reaction in the film, which can either lead to increased solubility of the film due to depolymerization, or to a chemical modification of the film. Conversely it can lead to an insolubility of the film in certain solvents resulting from a crosslinking or chemical modification. In addition, by choosing an appropriate treatment or solvent, it is possible to eliminate the film either at the locations where it has been irradiated, or at the locations where it has not been irradiated.
In the first case where the irradiated zones are eliminated, the photosensitive film is of the positive type, whereas in the second case where the non-irradiated zones are eliminated, the photosensitive film is of the negative type. In all cases, the photosensitive film must fulfil a double function. Firsty, it must permit a good degree of resolution, i.e. a good definition of the designs constituted e.g. by micron or submicron lines. Secondly, the non-eliminated zones of the film must be able to resist the following treatments performed for producing integrated circuits and must in particular resist dry etching by gaseous plasma. Generally, it is difficult to perfectly fulfil these two functions by means of the same photosensitive film layer. Thus, a good resolution of the design necessitates a very fine layer, generally having a thickness less than 0.5 μm, whereas a good resistance to dry etching requires the presence of a thicker layer, generally having a thickness exceeding 1 μm. Hitherto, to meet these two requirements, use has been made of multilayer systems. Such systems are more particularly described in the article by B. J. Lin, "Multilayer Resist Systems", appearing in the work published by L. F. Thompson, C. G. Willson and M. J. Bowden entitled "Introduction to Microlithography", ACS Symposium Series (Washington DC), 1983, pp. 287 to 350.
FIGS. 1 to 4 show a multilayer system of this type and illustrate its use for masking certain zones of a substrate.
In FIG. 1, it is possible to see that the substrate 1, e.g. formed by a silicon substrate, is covered by a multilayer system 3 formed by three layers 3a, 3b and 3c. The first layer 3a, directly deposited on substrate 1 is a thick resin layer, e.g. having a thickness of approximately 2 μm and it is called the levelling layer, because its function is to level out topographic variations on the substrate. The second layer 3b is an intermediate layer formed from a material resisting reactive gaseous plasmas and e.g. SiO 2 , Si, Si 3 N 4 or Al. The third layer 3c is a thin photosensitive resin layer with a thickness of 0.2 to 0.5 μm, which is used for the inscription of the patterns by irradiation with a good resolution.
In order to inscribe patterns on a substrate using a system of this type, the substrate coated at the desired locations, like that shown in FIG. 1 is irradiated, as shown by the arrows, followed by the elimination of the zones of layer 3c which have been irradiated by dissolving in an appropriate solvent. This leads to a substrate 1 covered with layers 3a, 3b and a layer 3c, on which are inscribed the desired patterns, in the manner shown in FIG. 2.
At the end of this operation, layer 3b is etched by transferring thereto the patterns inscribed by etching in layer 3c, e.g. using trifluoromethane in the case where layer 3b is made from SiO 2 , which makes it possible to eliminate layer 3b at the points where it is not protected by the resin layer 3c. This leads to the structure shown in FIG. 3.
This is followed by the transfer of the etched patterns from layer 3b in the thick resin layer 3a by the action of a reactive gaseous plasma, such as an oxygen plasma, which makes it possible to obtain the structure shown in FIG. 4 and simultaneously eliminate the upper photosensitive resin layer 3c, which does not resist the action of the reactive gaseous plasma.
This procedure gives satisfactory results with regards to the resolution of the patterns, but suffers from the disadvantage of being difficult and costly to perform. Thus, the resin layers 3a and 3c can be deposited by centrifuging, but the intermediate layer 3b of SiO 2 , Si, Si 3 N 4 or Al is deposited by sputtering or chemical vapour phase deposition, which requires complicated costly equipment and more complex operations.
SUMMARY OF THE INVENTION
The present invention specifically relates to a photosensitive film obviating the disadvantages of the aforementioned multilayer systems, while making it possible to obtain a good resolution of the patterns in microlithography.
The photosensitive film according to the invention in a given wavelength range comprises:
(a) at least one silicon-containing polymer in accordance with the formula: ##STR1## in which R 1 represents H or an alkyl radical in of one to four carbon atoms, R 2 , R 3 and R 4 , which can be the same or different, represent an alkyl radical in of one to four carbon atoms and Z represents --O--, --(CH 2 ) n --O-- with n being an integer between 1 and 4, or ##STR2## with R 5 , R 6 and R 7 , which can be the same or different, representing an alkyl radical in of one to four carbon atoms and m a number between 25 and 2000,
(b) at least one salt which can be converted into a Brunsted acid by irradiation at a wavelength in the given wavelength range, and optionally
(c) at least one photosensitizer.
For 100 parts by weight of said silicon-containing polymer or polymer, it advantageously has 2 to 25 parts and preferably 5 to 15 parts by weight of said salt or salts and 0 to 10 parts by weight of said photosensitizer or photosensitizers.
The use within the photosensitive film according to the invention of a silicon-containing polymer in accordance with formula(I) and a salt which can be converted by photolysis into a Brunsted acid makes it possible to obtain by irradiation at a wavelength corresponding to the photosensitivity range of the salt or photosensitizer, a conversion of the silicon-containing polymer of formula I into a non-silicon-containing polymer by cleaving at the level of bond O--Si or N--Si. In the case of the polymer of formula (I) with Z representing --O--, said reaction corresponds to the following reaction diagram: ##STR3##
In the case where Z represents --(CH 2 ) n --O--, the reaction is of the same type and leads to a polystyrene alcohol. In the case where Z represents. ##STR4## a polyaminostyrene is obtained.
The polyvinylphenol of formula (II), the polystyrene alcohol and polyaminostyrene produced in this way have properties which differ widely from those of the silicon-containing polymer of formula (I), particularly as regards their solubility in different solvents and their resistance to reactive gaseous plasmas. Thus, in the case where Z represents --O--, the silicon-containing polymer of formula (I) is insoluble in alcoholic solvents and alkaline solvents and resistent to reactive gaseous plasmas, whereas the polyvinylphenol of formula (II) is soluble in alkaline and alcoholic solvents and has a low resistance to reactive gaseous plasmas. Therefore, use can be made of this difference in properties between the two polymers, in microlithography, for simplifying the three-layer systems according to the prior art, by replacing the intermediate layer and the thin photosensitive layer thereof by the photosensitive film according to the invention, thus obviating costly, complex operations connected with the deposition of the intermediate layer.
Bearing in mind the properties referred to hereinbefore, said photosensitive film can be used as a positive film, whereby the irradiated zones can be selectively eliminated by dissolving in an alkaline or alcoholic medium, whilst leaving the non-irradiated zones intact.
However, it is also possible to envisage the use of the photosensitive film according to the invention as a negative film, because the polyvinyl phenol of formula (II) obtained by irradiation is insoluble in non-polar solvents, which makes it possible to dissolve the polymer of formula (I) which has not been subject to irradiation by means of an appropriate non-polar solvent.
The silicon-containing polymers according to formula (I) can be obtained by radical polymerization of monomers in accordance with formula (III): ##STR5## in which R 1 , R 2 , R 3 , R 4 and Z have the same meanings as hereinbefore.
This polymerization can be initiated by means of an initiator, such as azo-bis-isobutyronitrile. In the case where Z represents --O-- or --(CH 2 ) n --O--, the starting monomer can be obtained by reacting a compound of formula: ##STR6## with an excess of a compound of formula: ##STR7##
In the case where Z represents ##STR8## the starting monomer can be obtained by the reaction of ##STR9## with an excess of the compound of fomula ##STR10##
Examples of starting monomers which can be used are: p-trimethylsilyloxystyrene ##STR11## p-trimethylsilyloxy(α-methylstyrene) ##STR12## p-trimethylsilylethoxystyrene ##STR13## para-N,N-bis(trimethyl silyl)aminostyrene ##STR14##
In the photosensitive film according to the invention, advantageously use is made of silicon-containing polymers of formula (I), in which R 1 represents hydrogen or a methyl radical, namely polymers derived from styrene or α-methylstyrene.
In the silicon-containing polymers according to the invention, the alkyl radicals R 2 , R 3 and R 4 , as well as the alkyl radicals R 5 , R 6 and R 7 are generally identical alkyl radicals and preferably methyl radicals.
In order to be able to convert the silicon-containing polymer into a non-silicon-containing polymer by reaction with an acid, the photosensitive film according to the invention necessarily incorporates a salt which can be converted into a Brunsted acid by irradiation at a wavelength in a given range, which permits the in situ formation in the film by irradiation, the acid necessary for the conversion of the silicon-containing polymer. These salts are known as Crivello salts and are in particular described in the publication: J. V. Crivello, Advances in Polymer Science, vol. 62, 1984, pp. 1-48.
Examples of such salts are triaryl sulphonium salts, dialkyl phenacyl sulphonium salts, dialkylhydroxy phenol sulphonium salts, diaryl iodonium salts, triaryl selenonium salts and triaryl telluronium salts.
The sulphonium salts can be in accordance with the formula ##STR15## in which R 8 , R 9 and R 10 , which can be the same or different, represent aryl or alkylradicals which can optionally be substituted, M is an element of the periodic classification of elements which can form an anion with a halogen, X is a halogen atom and p is equal to v+1, with v representing the valency state of M.
In this formula, R 8 , R 9 and R 10 can represent an alkyl radical, a phenyl radical, a phenyl radical substituted by at least one substituent chosen from among the alkyl, alkoxy or alkylamido radicals, halogen atoms, the hydroxyl radical and the nitro radical.
Two of the radicals R 8 , R 9 and R 10 can also form together with the sulphur atom to which they are bonded, a heterocycle such that: ##STR16##
As an example of the cation ##STR17## reference can be made to the following cations: ##STR18##
For example, the anion MX 1 - can be chosen from among BF 4 - , AsF 6 - , PF 6 - and SbF 6 - .
The diaryliodonium salts can be in accordance with the formula ##STR19## in which R 8 and R 9 , which can be the same or different, represent an optionally substituted aryl radical, M represents an element of the periodic classification of elements able to form an anion with a halogen, X represents a halogen atom and p is equal to 1+v with v representing the valency state of M.
The aryl radicals which can be used are of the same type referred to hereinbefore for the triaryl sulphonium salts. For example, the cation Ar 2 I + can be in accordance with the following formulas: ##STR20##
In diaryliodonium salts, the anion MX p - can be one of the aforementioned anions.
Crivello salts have the property of being photosensitive in certain wavelength ranges dependent on the nature of the salt and of being convertible by irradiation in said wavelength range into a Brunsted acid.
In the case of triaryl sulphonium salts, the photosensitivity range of the salts is in the wavelength range 220 to 320 nm. In the case of diaryliodonium salts, the photosensitivity range of the salts is in the wavelength range 210 to 280 nm.
However, according to the invention, it is possible to modify the photosensitivity range of the Crivello salts referred to hereinbefore by adding to the composition a photosensitizer which can be present at a rate of 3 to 10 parts by weight per 100 parts by weight of the silicon-containing polymer.
The photosensitizer can be an aromatic hydrocarbon, such as perylene, pyrene, anthracene, tetracene, phenothiazine and acetophenone and it is chosen as a function of the Crivello salt used. Thus, in the case of triaryl sulphonium salts, it is possible to use perylene, which modifies the photosensitivy range of these salts by bringing it into the wavelength range between 386 and 476 nm, the maximum photosensitivity being observed at 436 nm and an adequate photosensitivity at 405 nm.
Within, the scope of the present invention, the term photosensitivity range of the film means the wavelength range in which the salt is photosensitive when the film contains no photosensitizer or the wavelength range in which the photosensitizer is sensitive when the film contains such a photosensitizer.
As a result of their photosensitivity and their resistance to certain reagents, particularly reactive gaseous plasmas, the photosensitive films according to the invention can be used as positive films in microlithography by being associated with a thick resin layer serving to level out topographical variations of the substrate. It is thus possible to replace the three-layer systems according to the prior art by a two-layer system according to the invention, which in particlar makes it possible to avoid the stage of depositing the intermediate layer by chemical phase vapour deposition, while also preventing the plasma etching stage of the intermediate layer.
The present invention also relates to a process for masking certain zones of a substrate, which comprises the following successive stages:
(a) depositing on said substrate a first resin layer with a thickness such that it constitutes a substrate levelling layer,
(b) depositing on said first resin layer a second layer of the photosensitive film according to the invention,
(c) irradiating the zones of the second layer corresponding to the substrate zones which are not to be masked, by means of radiation having a wavelength corresponding to the photosensitivity range of the photosensitive film, and
(d) eliminating the second photosensitive film layer and the first resin layer at the points corresponding to the zones of the second layer which have been irradiated.
According to a first embodiment of the process according to the invention, in stage (d), firstly the second photosensitive film layer is eliminated by dissolving in a solvent and then the first resin layer is eliminated by reactive ionic etching in a gaseous plasma.
As has been seen hereinbefore, the irradiation of the second photosensitive film layer converts the silicon-containing polymer of formula (I) into a non-silicon-containing polymer, e.g. into a polyphenol of formula (II), which has the property of being soluble in alkaline and alcoholic solvents, whereas the silicon-containing polymer of formula (I) is insoluble in the same solvents. It is also possible to eliminate the second photosensitive film layer at the points which have been exposed to radiation by dissolving in an alkaline solvent such as soda, potash and quaternary ammonium salts, or in an alcoholic solvent such as methanol.
It is then possible to eliminate the first layer, e.g. by reactive ionic etching in a gaseous plasma, because the silicon-containing polymer of formula (I) has a high resistance to the action of reactive gaseous plasmas, such as an oxygen plasma.
According to a second embodiment of the process according to the invention, in stage (d), there is a simultaneous elimination of the second photosensitive film layer and the first resin layer by reactive ionic etching in a gaseous plasma, such as an oxygen plasma. Thus, the non-silicon-containing polymer obtained during the irradiation has a limited resistance to the action of reactive gaseous plasmas, such as an oxygen plasma and it is therefore possible to simultaneously eliminate the first and second layers deposited on the substrate at the points corresponding to the zones of the second layer which have been irradiated. In this second embodiment of the process according to the invention, it is advantageous to use in stage (c) a substantially higher irradiation dose than in the case of the first embodiment of the process, in order to obtain a complete development.
For performing the process according to the invention, the first resin layer has to be deposited by conventional processes, e.g. by centrifuging. The deposited thickness is generally approximately 2 μm, as in the prior art processes. For forming said first layer, it is possible to use resins of the same type as in the prior art, e.g. phenol formaldehyde resins, such as novolaks, which do not resist the action of a reactive gaseous plasma. Generally, following the deposition of the first resin layer on the substrate, the latter undergoes annealing in order to harden the resin and make it inactive. This hardening is generally accompanied by a modification of the ultraviolet absorption spectrum of the resin and makes it more absorbent in the vicinity of 400 nm, which makes it possible to avoid during the irradiation of the substrate coated with two layers, reflections of the incident light on the substrate, which would be prejudicial to obtaining a good resolution of the design.
The second photosensitive film layer can also be deposited by centrifuging. Generally, the composition containing at least one silicon-containing polymer, at least one Crivello salt and optionally at least one photosensitizer is dissolved in an appropriate solvent, such a dichloromethane. The deposited film thickness does not generally exceed 0.4 μm and is advantageously 0.2 to 0.4 μm in order to obtain a good resolution. Following the deposition of the second layer, the latter undergoes drying to eliminate the solvent.
According to a preferred embodiment of the process according to the invention, the photosensitive film contains per 100 parts by weight of poly-p-trimethyl-silyloxystyrene, 5 to 15 parts by weight of triphenyl sulphonium hexafluoroarsenate and 3 to 10 parts by weight of perylene. Under these conditions, it is possible to carry out irradiation at a wavelength of 386 to 475 nm and preferably 436 nm.
The invention also relates to silicon-containing polymers usable for forming a photosensitive film and which are in accordance with the formula: ##STR21## in which R 1 represents H or an alkyl radical of one to four carbon atoms, R 2 , R 3 and R 4 , which can be the same or different, represent an alkyl radical of one to four carbon atoms, Z represents --O--, --(CH 2 ) n --O-- with n being an integer betweeen 1 and 4, or ##STR22## with R 5 , R 6 and R 7 , which can be the same or different, representing an alkyl radical of one to four carbon atoms and m is a number between 25 and 2000, provided that R 2 , R 3 and R 4 do not represent CH 2 when R 1 represents H and Z represents --O--, --O--CH 2 --CH 2 -- or --N--Si(CH 3 ) 3 .
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein show:
FIGS. 1 to 4 already described, a multilayer film according to the prior art.
FIGS. 5, 6, and 7 the use of the photosensitive film according to the invention in microlithography.
FIG. 8 the infrared absorption spectrum of a substrate coated with the photosensitive film according to the invention, before and after irradiation at 436 nm.
DETAILED DESCRIPTION OF THE INVENTION
In this example, the photosensitive film according to the invention is constituted by a film containing a silicon-containing polymer of formula: ##STR23##
This polymer was obtained by radical polymerization of p-trimethylsilyloxystyrene in solution in toluene, using as the polymerization initiator azo-bis-isobutyronitrile and performing polymerization at a temperature of 69° C. for 24 hours, which leads to a 73% yield. The polymer obtained was gas chromatographically characterized and the following results were obtained:
number-average molecular weight M n =51000
weight-average molecular weight M p (or M v )=117600
dispersion index M p /M n :2.31, and
glass transition temperature T v :75°-76° C. determined by differential thermal analysis.
The polymer obtained is soluble in tetrahydrofuran, benzene, methylene chloride, chloroform, petroleum ether, ethyl ether, acetone, toluene and carbontetrachloride. However, it is insoluble in methanol, water and alkaline solutions.
The starting monomer was obtained from 4-vinylphenol by treatment with an excess of hexamethyldisilazane of formula [(CH 3 ) 3 Si] 2 NH at a temperature of 30° C. for 10 hours. The pure monomer was isolated by fractional distillation. The reaction corresponds to a 90% yield and the boiling point of the monomer is 65° C. under 4 millibars (400 Pa).
In the photosensitive film of this example, the Crivello salt used is triphenyl sulphonium hexafluoroarsenate (melting point: 195° to 198° C.).
To make the silicon-containing polymer- Crivello salt composition photosensitive at the wavelength of 436 nm, perylene is added thereto and acts as the photosensitizer.
It is then possible to use this composition for masking certain zones of a substrate constituted in the present example by a silicon plate. On to the latter is firstly deposited by centrifuging a first layer of a novolak marketed under the trademark HPR 206 by Hunt Chemical Cy, using a speed of 4000 t/m in order to obtain a first resin layer with a thickness of approximately 2 μm acting as a levelling layer for the silicon substrate. The thus deposited resin layer then undergoes annealing at 220° C., either in an oven for one hour, or on a hot plate for 2 minutes. This annealing leads to a hardening of the resin and makes it inactive. Moreover, the hardening leads to a modification of the ultraviolet absorption spectrum of the resin and the absorption becomes high at the wavelength of 436 nm, which makes it possible to obviate reflections of the incident light on the substrate, which would be prejudicial for obtaining a high resolution. Conversely, absorption at 550 nm is slight, which makes it possible to use this wavelength for carrying out the position of the silicon plate on the irradiation device. Following these operations, on the thus coated silicon plate is deposited a layer of photosensitive film from a solution of the film in dichloromethane obtained by dissolving in 100 ml of dichloromethane 10 g of poly p-trimethylsilyloxystyrene, 1 g of triphenyl sulphonium hexafluoroarsenate and 0.5 g of perylene and by then filtering the solution over a Millipore filter having a pore size of 0.5 μm.
Deposition by centrifuging takes place in such a way as to cover the novolak resin-coated silicon plate with a second layer having a thickness of 0.4 μm. The second photosensitive film layer is then dried to eliminate the solvent at a temperature of 65° C., either for 15 minutes in an oven, or for 2 minutes on a hot plate.
In this way the coated plate according to FIG. 5 is obtained. In FIG. 5 it is possible to see that the substrate 21 constituted by the silicon plate is covered with a first resin layer 23 having a relatively large thickness (2 μm) and also a second layer 25 of the photosensitive film according to the invention.
In order to form a mask on certain zones of the substrate 21, the assembly undergoes irradiation by radiation (hν) with a wavelength of 436 nm, as shown by the arrows, using a masking device 27 placed between the radiation source and the coated silicon plate, so that only zones 25a of the photosensitive film layer 25 are irradiated.
For carrying out this irradiation, use is made of a photo repeater and a total irradiation does of 80 mJ/cm 2 . Following irradiation, the silicon-containing polymr of zones 25a of the layer of photosensitive film 25 is converted by reaction with the Brunsted acid produced by photolysis of the triphenyl sulphonium hexafluoroarsenate, in the presence of perylene, in a polyvinyl phenol of formula (II). This modification of zones 25a is revealed by infrared spectrometry of the substrate coated with the photosensitive film layer before and after irradiation.
FIG. 8 illustrates the results obtained in infrared spectrometry. Thus, in FIG. 8, curves (A) relate to the infrared absorption spectrum obtained before the irradiation of the coated substrate and curves (B) relate to the infrared absorption spectrum obtained after irradiation. It can be seen that the silicon-containing polymer has been converted into polyvinylphenol.
Following irradiation, the coated plate undergoes an annealing treatment for 5 minutes at 65° C. in order to increase the chemical reaction of converting the polymer of formula (I) into a polymer of formula (II) in zones 25a, which have undergone irradiation. In this stage, the patterns already appear on the plate, zones 25a of the second layer 25 being slightly in intaglio compared with the remainder of the layer.
This is followed by the elimination of the second layer in zones 25a by dissolving with the aid of an alcoholic solution. To this end, the plate is introduced into a methanol bath at 20° C. and for 1 minute, followed by drying under a dry nitrogen jet. This leads to the structure shown in FIG. 6, i.e. the elimination of zones 25a from the second layer 25 and the formation of intaglio patterns in said layer.
The thus formed patterns are then transferred into the first thick layer 23 of resin HPR 206. This is done by reactive ionic etching in an oxygen plasma. To this end, the silicon plate is placed on the cathode of a reactive ionic etching reactor and etching takes place by oxygen plasma under the following conditions:
oxygen pressure: 10 millitorr (1.35 Pa),
oxygen flow rate: 10 cm 3 /min,
generator frequency: 13.56 MHz
power: 0.5 W/cm 2 .
The end of the etching of layer 23 is detected by laser interferometry.
This leads to an elimination of layer 23 on the zones not protected by layer 25. Thus, under oxygen plasma etching conditions, the etching speed of resin 23 is approximately 120 nm/min, whereas for the photosensitive film 25, the erosion is substantially zero, the etching speed being 5 nm/min.
Thus, the second layer 25 acts as an in situ mask during the anisotropic etching of the first layer 23 and, at the end of the operation, the structure shown in FIG. 7 is obtained, i.e. the transfer of the patterns from layer 25 to layer 23.
By observation with the electron microscope of the structure obtained in FIG. 7, it can be seen that the etched patterns have a line width of 0.65 to 0.7 μm on thicknesses of approximately 2 μm. Thus, the submicron patterns obtained with a high resolution on the second layer 25 of the photosensitive film according to the invention have been transferred into the first resin layer 23, while retaining the line width during etching by the oxygen plasma.
In a variant, the intermediate stage shown in FIG. 6 is avoided by directly eliminating by the dry route the zones 25a of the second layer 25 and the corresponding zones of the first layer 23.
In this case, the silicon plate 21 is coated by the first layer 23 of resin HPR 206 and by the second photosensitive film layer 25 under the same conditions as hereinbefore. The coated plate then undergoes irradiation at 436 nm using the same masking device 27 and the same irradiation apparatus, but while continuing irradiation up to obtaining a dose of 100 to 120 mJ/cm 2 . In this way and as hereinbefore, there is a modification of the second layer 25 on zones 25a and, after irradiation, the assembly is annealed at a temperature of 65° C. and for 5 minutes.
Following this operation, the irradiated plate is directly exposed to the action of the oxygen gaseous plasma by placing it on the cathode of the reactive ionic etching reactor and by carrying out etching under the same conditions as hereinbefore.
This leads to the elimination of zones 25a of the second layer 25 and the elimination of the corresponding zones of layer 23, which makes it possible to directly obtain the structure shown in FIG. 7. Under these conditions, the etching speed of the second layer 25 on zones 25a and the first layer 23 are respectively 75 nm/min and 70 nm/min, whereas the etching speed of layer 25 on the points where it has not been irradiated is only 3 nm/min. Thus, a high selectivity is obtained, which makes it possible to simultaneously bring about the elimination of layers 23 and 25 at the desired points by reactive ionic etching in the oxygen gaseous plasma.
This variant is of particular interest, because it makes it possible to simultaneously develop the second layer and etch the first layer by the dry route using a plasma, which is easier to carry out, faster and makes it possible to obviate the disadvantages of development of the wet route.
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Photosensitive film which is photosensitive in a given wavelength range comprises at least one silicon-containing polymer, at least one salt which can be converted into a Brunsted acid by irradiation and optionally at least one photosensitizer. The silicon-containing polymer-based photosensitive film can be used as a masking resin in a lithography process for producing electronic components.
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INCORPORATION BY REFERENCE
[0001] The disclosure of Japanese Patent Applications No. 2010-255737 filed on Nov. 16, 2010 and No. 2011-097123 filed on Apr. 25, 2011 including the specification, drawings and abstract is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a lock device and an electric power steering system.
[0004] 2. Description of Related Art
[0005] Conventional lock devices are described in, for example, Japanese Patent Application Publication No. 2010-219816 (JP 2010-219816 A) and Japanese Patent Application Publication No. 2002-308049 (JP 2002-308049).
[0006] JP 2001-219816 describes a column-type electric power steering system provided with a steering lock device. An engagement portion is formed at a worm shaft side (input side), the worm shaft transmitting the rotation of an electric motor to a speed reducer, or at an electric motor output shaft side. A locked state is achieved by inserting a lock member into the engagement portion, and an unlocked state is achieved by removing the lock member from the engagement portion.
[0007] The lock member is advanced or retracted with the use of an elastic member that urges (advances) the lock member toward the engagement portion and an actuator that attracts the lock member to remove (retract) the lock member from engagement portion. The lock member is advanced or retracted in the following manner. When an ignition key is turned on, electric current application to a solenoid that serves as the actuator and that is fixed to a casing is controlled. Thus, an attraction force that counteracts an urging force generated by the elastic member is generated to retract the lock member provided with a moving core so that the lock member is removed from the engagement portion. As a result, the unlocked state is achieved. When the ignition key is turned off, attraction of the moving core by the solenoid is stopped, and the lock member is advanced toward the engagement portion by an urging force generated by the elastic member. As a result, the lock member is engaged with the engagement portion, whereby the locked state is achieved.
[0008] As described above, the locked state and the unlocked state are achieved at the electric motor output shaft side or at the worm shaft side that is the input side of the speed reducer (i.e., at a stage prior to output of assist torque based on the torque applied to a steering wheel). Thus, in the locked state where the lock member is engaged with the engagement portion, a large force based on the torque applied to the steering wheel is no longer applied directly to the lock member, which enables downsizing of the lock member.
[0009] However, when the ignition switch is on, electric current is applied to a coil to retract the lock member from the engagement portion. Therefore, if, for example, breakage of a harness, disconnection of a connector, or an instantaneous reduction in battery voltage occurs, electric current application to the coil is stopped. As a result, the lock member is advanced and engaged with the engagement portion due to an urging force generated by the elastic member. In some cases, the steering wheel may be locked while a vehicle is traveling. With this regards, there is still room for improvement.
[0010] JP 2002-308049 describes a structure in which a key portion and a lock mechanism portion of a steering shaft are unitized so as to be mechanically linked to each other. In the structure, a cam member that rotates together with a key rotor is provided between the key rotor and the lock mechanism portion of the steering shaft and extends to the lock mechanism portion coaxially with the key rotor. A locking lever that is linked to insertion and removal of the key is provided. When the key is turned from ACC position to LOCK position, the cam member is operated. In accordance with the operation of the cam member, the lock member that is provided at the lock mechanism on the steering shaft side is operated and is brought to a state where the lock member can be locked with the steering shaft. When the key is removed from LOCK position, the locking lever is operated. In accordance with the operation of the locking lever, the lock member is operated to be inserted in a groove of the steering shaft. Thus, the locked state is achieved.
[0011] JP 2002-308049 A describes the structure in which the key portion and the lock mechanism portion of the steering shaft are unitized so as to be mechanically liked to each other. Therefore, if the key portion is provided at an instrument panel at a driver's seat, the lock mechanism portion is located in front of the knee of a driver, which may impose restrictions on the strength and installation position of the lock mechanism portion.
[0012] In order to address this problem, the following configuration may be employed. An operation portion such as a key device and an actuator portion such as a lock mechanism are separated from each other. A lock member at the lock mechanism is moved to the lock position by a spring member. When the key is inserted and turned to ACC position (when locking is cancelled), the fact that the key is turned to ACC position is detected by, for example, detection unit, and drive unit such as a motor is driven based on a detection signal to move the lock member to the locking cancellation position.
[0013] A device is required which maintains the locking cancellation state so that the locking operation is not erroneously performed in the locking cancellation state where locking by the lock member is cancelled. Conventionally, the key portion and the lock mechanism portion of the steering shaft are mechanically linked to each other. Therefore, as long as the key rotor is at a predetermined rotation position, the locking cancellation state where locking by the lock member is cancelled is maintained by the cam member.
[0014] In the above-described structure where the operation portion such as the key device and the actuator portion such as the lock mechanism are separated from each other, there is no cam member. Accordingly, it is necessary to provide a device that maintains the locking cancellation state, at the actuator portion. For example, a locking cancellation maintaining member is attached to a plunger of a solenoid, which is an electric drive unit. An electric signal is generated based on the operation of the operation portion, the solenoid is driven according to the electric signal, and the locking cancellation state in which locking by the lock member is cancelled is maintained by the locking cancellation maintaining member. However, in the structure in which the locking cancellation maintaining member is operated by electric drive unit such as a solenoid, malfunction due to an electrical problem (e.g., breakage of a harness, disconnection of a connector, or an instantaneous reduction in battery voltage) may occur. In this regard, there is still room for improvement.
SUMMARY OF THE INVENTION
[0015] It is an object of the invention to provide a lock device that is able to reliably maintain the locked state with low power consumption while operating a lock cancellation maintaining member using an electric drive unit without being affected by an electrical trouble.
[0016] An aspect of the invention relates to a lock device that restricts movement of a movable body. The lock device includes: a lock member that is engageable with an engagement portion formed at the movable body; an urging member that urges the lock member in a direction away from the engagement portion; and an actuator that moves the lock member toward the engagement portion to engage the lock member with the engagement portion against an urging force generated by the urging member.
[0017] With the configuration described above, even if electric current application to a coil or electric current application to the actuator is stopped due to an electrical trouble, for example, breakage of a harness, disconnection of a connector or an instantaneous drop in battery voltage, it is possible to maintain the disengaged state by moving the lock member using the urging member.
[0018] As a result, even if electric current application is stopped, the lock member is maintained in the disengaged state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:
[0020] FIG. 1 is an overall view of an electric power steering system according to an embodiment of the invention;
[0021] FIG. 2 is a partial sectional view which is taken along the line II-II in FIG. 1 , and from which a steering wheel and a universal joint are omitted;
[0022] FIG. 3 is a sectional view taken along the line III-III in FIG. 2 ;
[0023] FIG. 4 is a view showing the structure of a steering lock device;
[0024] FIG. 5 is an electrical diagram for the steering lock device;
[0025] FIG. 6 is a graph showing the relationship between a stroke of a lock pin of the steering lock device and forces that act on the lock pin while electric current is not applied;
[0026] FIG. 7 is a graph showing the relationship between a stroke of the lock pin of the steering lock device and forces that act on the lock pin while electric current is applied to achieve the locked state;
[0027] FIG. 8 is a graph showing the relationship between a stroke of the lock pin of the steering lock device and forces that act on the lock pin while electric current is applied to achieve the unlocked state;
[0028] FIG. 9 is a view showing the state where the lock pin of the steering lock device is about to start advancing from the unlock end;
[0029] FIG. 10 is a view showing the state where the lock pin has advanced from the unlock end in FIG. 9 and a lock detection switch is turned on;
[0030] FIG. 11 is a view showing the state where the lock pin has further advanced and come close to the lock end;
[0031] FIG. 12 is a view showing the state where the lock pin is about to start retracting from the lock end;
[0032] FIG. 13 is a state where the lock pin has retracted from the lock end in FIG. 12 and the lock detection switch is turned off;
[0033] FIG. 14 is a state where the lock pin has further retracted and come close to the unlock end; and
[0034] FIG. 15 is a flowchart showing an operation of the steering lock device.
DETAILED DESCRIPTION OF EMBODIMENTS
[0035] Hereafter, an embodiment of the invention will be described with reference to the accompanying drawings. As shown in FIG. 1 and FIG. 2 , an input shaft 1 of an electric power steering system is rotatably supported by a steering column 2 . The input shaft 1 includes an upper shaft 4 and a lower shaft 6 . A steering wheel 3 is attached to the upper shaft 4 . The lower shaft 6 is fitted in a tubular portion 5 formed at a lower end portion of the upper shaft 4 such that relative rotation between the lower shaft 6 and the tubular portion 5 is restricted and such that relative displacement between the tubular portion 5 and the lower shaft 6 in the axial direction is allowed if an axial force equal to or larger than a predetermined value is applied. Accordingly, if a driver hits the steering wheel 3 upon a vehicle collision and an axial force equal to or larger than the predetermined value is applied to the input shaft 1 , the upper shaft 4 is displaced relative to the lower shaft 6 in the axial direction. Thus, impact energy is absorbed.
[0036] The steering column 2 includes a tubular upper column 8 and a tubular lower column 9 . The upper column 8 rotatably supports the upper shaft 4 via a bearing 7 . The lower column 9 is fitted at its upper end portion to the inner periphery of a lower end portion of the upper column 8 . An upper bracket 10 is used to fit the upper column 8 to a vehicle body. If a vehicle collision occurs and the upper column 8 is moved forward due to an impact, the upper bracket 10 is removed from the vehicle body, thus allowing the upper column 8 and the upper shaft 4 to move forward.
[0037] A housing 11 is fixed to a lower end of the lower column 9 , and fitted to the vehicle body via a lower bracket 12 . An output shaft 13 is an output member rotatably supported by the housing 11 , and is connected to the lower shaft 6 via a torsion bar 14 . The output shaft 13 is connected to steered wheels 18 via, for example, a universal joint 15 , an intermediate shaft 16 , and a rack and pinion mechanism 17 . A torque detector 19 detects a steering torque that is applied to the input shaft 1 via the steering wheel 3 . The steering torque is detected by electrically measuring a minute relative rotational displacement between the input shaft 1 and the output shaft 13 , which is proportional to torsion of the torsion bar 14 due to the steering torque.
[0038] As shown in FIG. 3 , a wheel gear 21 of a speed reducer 20 is fixed to the output shaft 13 . A worm shaft (input member of the speed reducer 20 ) 22 is rotatably supported by the housing 11 at both ends via bearings 23 , and is in mesh with the wheel gear 21 . An electric motor 24 is fixed to the housing 11 . An output shaft 25 that serves as a rotational output member of the electric motor 24 is spline-connected to the worm shaft 22 . A ring 31 having a plurality of lock holes (engagement portions) 29 in its periphery is fitted to the output shaft 25 . A steering lock device (lock device) 35 is fixed to the housing 11 . The steering lock device 35 places the output shaft 25 in the locked state by inserting a lock pin (lock member) 26 into the lock hole 29 formed in the ring 31 fitted to the output shaft 25 , and places the output shaft 25 in the unlocked state by removing the lock pin 26 from the lock hole 29 .
[0039] Next, the structure of the steering lock device 35 will be described with reference to FIG. 4 . The steering lock device 35 includes an actuator 30 and the ring 31 . The actuator 30 causes the lock pin 26 to advance toward the lock hole 29 or to retract from the lock hole 29 . The ring 31 is fitted to the output shaft 25 of the motor 24 , and has the multiple lock holes 29 in its periphery.
[0040] The actuator 30 has a plunger 51 that is secured to the lock pin 26 so as to move together with the lock pin 26 . The plunger 51 is formed of a magnet with one pole pair. For example, as shown in FIG. 4 , the left side portion of the plunger 51 is the south pole, and the right side portion of the plunger 51 is the north pole.
[0041] A coil 52 is wound around the plunger 51 to generate an electromagnetic force for advancing or retracting the lock pin 26 . The coil 54 is surrounded by a yoke 53 that serves as a magnetic path for an electromagnetic force generated by the coil 54 .
[0042] Two bushes 55 are provided between the plunger 51 and the coil 54 . Thus, the plunger 51 is smoothly advanced or retracted by an electromagnetic force generated by the coil 54 .
[0043] A front portion of the actuator 30 is covered with a front cover 56 . A compression spring (urging member) 28 , which is used to remove the lock pin 26 from the lock hole 29 formed in the ring 31 fitted to the output shaft 25 of the electric motor 24 , is provided between the front cover 56 and the left end of the plunger 51 .
[0044] A rear portion of the actuator 30 is covered with a rear cover 57 . A lock detection switch (lock detection unit) 45 , which detects the state of engagement of the lock pin 26 with the lock hole 29 based on the position of the plunger 51 , is provided between the rear rover 57 and the yoke 53 .
[0045] Next, the electrical configuration of the steering lock device 35 will be described with reference to FIG. 5 . A control unit for the steering lock device 35 includes an ECL 40 that is a main control portion, a battery 46 , an ignition switch 44 , the lock detection switch 45 , and the actuator 30 .
[0046] The ECU 40 includes a CPU 41 that executes control processes, an input interface (I/F) 42 , and an output interface (I/F) 43 . The input interface 42 receives signals from the ignition switch 44 and the lock detection switch 45 . The output interface 43 outputs electric current to the actuator 30 .
[0047] Next, the operations of the steering lock device 35 and the ECU 40 for the steering lock device 35 will be described with reference to FIGS. 6 , 7 and 8 .
[0048] With regard to the ordinate axis in FIG. 6 , the upward arrow represents a retraction force Fr for retracting the lock pin 26 from the lock hole 29 (placing the lock pin 26 in the disengaged state), and the downward arrow represents an advance force for advancing the lock pin 26 toward the lock hole 29 .
[0049] The abscissa axis represents a stroke of the lock pin 26 . When the lock pin 26 is in the state shown in FIG. 4 , the stroke is zero. The stroke in this state is indicated by an unlock end (retraction end) P 1 . As the lock pin 26 moves toward a lock end (advance end), the value of stroke shifts rightward on the abscissa axis.
[0050] L 1 indicates the relationship between the stroke of the lock pin 26 and a retraction force Fr, generated by the compression spring 28 , for retracting the lock pin 26 from the lock hole 29 . L 2 indicates an attraction force that acts between the magnet with one pole pair, which constitutes the plunger 51 , and the yoke 53 . The attraction force acts as an advance force Fa for advancing the lock pin 26 toward the lock hole 29 .
[0051] L 3 indicates a resultant of L 1 and L 2 while electric current is not applied to the coil 54 , that is, a resultant of the retraction force Fr generated by the compression spring 28 and the attraction force (advance force) Fa that acts between the plunger 51 and the yoke 53 . P 3 indicates a balance point at which the retraction force Fr generated by the compression spring 28 and the advance force Fa that acts between the plunger 51 and the yoke 53 cancel out each other. P 10 indicates a position to which the lock pin 26 is allowed to be advanced maximally by the resultant of the retraction force Fr generated by the compression spring 28 and the attraction force Fa that acts between the magnet of the plunger 51 and the yoke 53 . Note that, the lock pin 26 is configured to mechanically stop at the lock end (advance end) P 2 , therefore, the lock pin 26 never reaches P 10 .
[0052] Between P 1 and P 3 , the retraction force Fr is larger than the advance force Fa, and therefore a force for retracting the lock pin 26 acts on the lock pin 26 . Between P 3 and P 10 , the advance force Fa is larger than the retraction force Fr, and therefore a force for advancing the lock pin 26 acts on the lock pin 26 .
[0053] As a result, when the value of stroke is on the left side of P 3 , the lock pin 26 is pushed by the retraction force Fr generated by the compression spring 28 such that the lock pin 26 is directed toward the unlock end (retraction end) P 1 . That is, the unlocked state is achieved.
[0054] Next, as indicated by L 4 in FIG. 7 , a lock pin advancing current Ia is applied to the coil 54 of the actuator 30 by the ECU 40 to apply the advance force Fa that overcomes the retraction force Fr generated by the compression spring 28 to the lock pin 26 . Then, the lock pin 26 is advanced by a resultant (indicated by L 5 ) of the advance force Fa indicated by L 4 and the retraction force Fr indicated by L 3 .
[0055] The lock pin advancing current Ta is shut off at a stroke (e.g., P 4 ) at which the lock pin 26 is able to be advanced even when electric current is not applied to the coil 54 of the actuator 30 by the ECU 40 as shown by L 3 . Then, the advance force Fa is shifted from the advance force Fa indicated by L 5 to the advance force Fa indicated by L 3 at P 4 . However, the advance force Fa continuously acts on the lock pin 26 to bring the lock pin 26 to the lock end (advance end) P 2 at which the lock pin 26 mechanically stops, and the lock pin 26 is maintained at the lock end P 2 (engaged state). That is, the locked state is achieved. As described later in detail (see FIG. 15 ), whether the lock pin 26 has reached P 4 is determined based on a signal from the lock detection switch 45 and a value indicated by a lock pin advance checking timer Tr 1 . More specifically, when the lock pin 26 reaches P 4 , the lock pin 26 is in an immediately-before engaged state that is a state achieved immediately before the engaged state where the tip of the lock pin 26 reaches the lock end of the lock hole 29 formed in the ring 31 . As a result, the lock pin advancing current Ia is shut off at P 4 . Therefore, steering lock is achieved in the electric power steering system with lower power consumption.
[0056] As indicated by L 6 in FIG. 8 , a lock pin retracting current Ib is applied to the coil 54 of the actuator 30 by the ECU 40 to apply the retraction force Fr that overcomes the resultant of the compressing spring force and the attraction force that acts between the magnet that constitutes the plunger 51 and yoke 53 . With the resultant, steering lock has been maintained. Then, the lock pin 26 is retracted by a resultant (indicated by L 7 ) of the retraction force Fr indicated by L 6 and the advance force Fa indicated by L 3 .
[0057] The lock pin retracting current Ib is shut off at a stroke (e.g., P 5 ) at which the lock pin 26 is able to be retracted even when electric current is not applied to the coil 54 of the actuator 30 by the ECU 40 as shown by L 3 . Then, the retraction force Fr is shifted from the retraction force Fr indicated by L 7 to the retraction force Fr indicated by L 3 at P 5 . However, the retraction force Fr continuously acts on the lock pin 26 to bring the lock pin 26 to the unlock end (retraction end) P 1 at which the lock pin 26 mechanically stops, and the lock pin 26 is maintained at the unlock end P 1 . As described later in detail (see FIG. 15 ), whether the lock pin 26 has reached P 5 is determined based on a signal from the lock detection switch 45 and a value indicated by a lock pin retraction checking timer Tr 2 .
[0058] Next, transition of the steering lock device 35 from the unlocked state to the locked state and transition of the steering lock device 35 from the locked state to the unlocked state will be described with reference to FIG. 9 to FIG. 14 .
[0059] As shown in FIG. 9 , in the state where the plunger 51 secured to the lock pin 26 so as to move together with the lock pin 26 is standstill at the unlock end P 1 , electric current is applied to the coil 54 of the actuator 30 by the ECU 40 . Electric current is applied to the coil 54 of the actuator 30 in such a direction that the north pole is formed in the left side portion of the yoke 53 and the south pole is formed in the right side portion of the yoke 53 (see Ia in FIG. 5 ). Thus, the south pole of the plunger 51 is attracted to the north pole formed in the yoke 53 , and the plunger 51 is advanced toward the lock hole 29 .
[0060] When the plunger 51 is advanced to a predetermined position (P 4 in FIG. 7 ), the lock detection switch 45 is turned on as shown in FIG. 10 . Therefore, based on a signal from the lock detection switch 45 and a value indicated by the lock pin advance checking timer Tr 1 , electric current application to the coil 54 of the actuator 30 is stopped by the ECU 40 . The south pole of the plunger 51 has been attracted to the north pole formed in the yoke 53 , and thus the plunger 51 has been advanced. However, the north pole that has been formed in the yoke 53 disappears when electric current application to the coil 54 is stopped.
[0061] However, even if electric current application to the coil 54 of the actuator 30 is stopped by the ECU 40 when the lock pin 26 reaches the predetermined position (P 4 in FIG. 7 ), a magnetic force acts between the plunger 51 formed of the magnet with one pole pair and the yoke 53 made of magnetic material. Thus, the lock pin 26 is advanced to the lock end P 2 against a spring force of the compression spring 28 , and the lock pin 26 is maintained at the lock end P 2 (see FIG. 11 ). The lock pin advancing current Ia is shut off at P 4 . Therefore, it is possible to achieve steering lock in the electric power steering system with lower power consumption.
[0062] Next, if the ignition switch 44 is turned on when the plunger 51 is stopped at the lock end P 2 as shown in FIG. 12 , electric current is applied to the coil 54 of the actuator 30 by the ECU 40 . Electric current is applied to the coil 54 of the actuator 30 in such a direction that the south pole is formed in the left side portion of the yoke 53 and the north pole is formed in the right side portion of the yoke 53 (see Ib in FIG. 8 ). Then, the south pole of the plunger 51 repels the south pole formed in the yoke 53 , and the spring force of the compression spring 28 is added to the repelling force. With this force, the lock pin 21 secured to the plunger 51 is retracted from the lock hole 29 .
[0063] When the plunger 51 is retracted to a predetermined position (P 5 in FIG. 8 ), the lock detection switch 45 is turned off as shown in FIG. 13 . Therefore, based on a signal from the lock detection switch 45 and a value indicated by the lock pin retraction checking timer Tr 2 , electric current application to the coil 54 of the actuator 30 is stopped by the ECU 40 . However, at this time, the plunger 51 is retracted to the unlock end P 1 by a resultant of a spring force of the compression spring 28 and a magnetic force that acts between the plunger 51 and the yoke 53 (see FIG. 14 ).
[0064] Next, the operations of the steering lock device 35 and the ECU 40 will be described in detail with reference to a flowchart shown in FIG. 15 . First, it is determined whether the ignition switch 44 is off (step 101 ). If it is determined in step 101 that the ignition switch 44 is off (YES in step 101 ), the lock pin advance checking time Tr 1 is reset (step 102 : Tr 1 =0).
[0065] Next, electric current is applied to the coil 54 of the solenoid 30 in such a direction that the lock pin 26 is advanced (step 103 : apply current Ia). Further, the lock pin advance checking timer Tr 1 is incremented (step 104 : Tr 1 =Tr 1 +T 1 ).
[0066] Next, it is determined whether the value indicated by the lock pin advance checking time Tr 1 is equal to or larger than a predetermined value (step 105 : Tr 1 ≧Tr 01 ). If the value indicated by the lock pin advance checking timer Tr 1 is equal to or larger than the predetermined value (YES in step 105 : Tr 1 ≧Tr 01 ), it is determined whether the lock detection switch 45 is on (step 106 ).
[0067] If the lock detection switch 54 is on (YES in step 106 ), electric current application to the coil 54 of the actuator 30 is stopped (step 107 : stop application of current Ia), after which the process ends. Thus, the lock pin 26 is engaged with the lock hole 29 , whereby the locked state is achieved. If the value indicated by the lock pin advance checking time Tr 1 is smaller than the predetermined value (NO in step 105 : Tr 1 <Tr 01 ), or if the lock detection switch 45 is off (NO in step 106 ), step 103 is executed again to apply electric current to the coil 54 of the actuator 30 in such a direction that the lock pin 26 is advanced (step 103 :apply current Ia).
[0068] If it is determined in step 101 that the ignition switch 44 is on (NO in step 101 ), the lock pin retraction checking time Tr 2 is reset (step 108 : Tr 2 =0).
[0069] Then, electric current is applied to the coil 54 of the actuator 30 in such a direction that the lock pin 26 is retracted (step 109 : apply current Ib). In addition, the lock pin retraction checking time Tr 2 is incremented (step 110 : Tr 2 =Tr 2 +T 2 ).
[0070] Next, it is determined whether the lock detection switch 45 is off (step 111 ). If the lock detection switch 45 is off (YES in step 111 ), it is determined whether the value indicated by the lock pin retraction checking time Tr 2 is equal to or larger than a predetermined value (step 112 : Tr 2 ≧Tr 02 ). If the value indicated by the lock pin retraction checking time Tr 2 is equal to or larger than the predetermined value (YES in step 112 : Tr 2 ≧Tr 02 ), electric current application to the coil 54 of the actuator 30 is stopped (step 113 : stop application of current Ib), after which the process ends. Thus, the lock pin 26 is disengaged from the lock hole 29 , whereby the unlocked state is achieved.
[0071] If the lock detection switch 45 is on (NO in step 111 ), or if the value indicated by the lock pin retraction checking timer Tr 2 is smaller than the predetermined value (NO in step 112 : Tr 2 <Tr 02 ), step 109 is executed again to apply electric current to the coil 54 of the actuator 30 in such a direction that the lock pin 26 is retracted (step 109 : apply current Ib).
[0072] According to the present embodiment, the following operations and effects are obtained. The steering lock device 35 is configured such that, when the ignition switch is turned on, electric current is applied to the coil 54 of the actuator 30 in such a direction that the lock pin 26 secured to the plunger 51 moves away from the ring 31 that has a plurality of lock holes 29 in its periphery and that is fitted to the output shaft 25 of the electric motor 24 . In addition, the urging member for increasing a force for moving the lock pin 26 away from the ring 31 is provided.
[0073] With the configuration described above, when the ignition switch 44 is on, in other words, when the steering wheel 3 is being operated, the unlocked state is maintained by a spring force of the urging member.
[0074] With the configuration described above, even if electric current application to the coil is stopped due to an electrical problem (for example, breakage of a harness, disconnection of a connector, or an instantaneous drop of battery voltage), it is possible to maintain the disengaged state by retracting the lock member using the urging member.
[0075] As a result, even if electric current application is stopped, the lock member is maintained in the disengaged state.
[0076] In addition, the steering lock device 35 is configured such that, when the ignition switch is turned off, electric current is applied to the coil 54 of the actuator 30 by the ECU 40 in such a direction that the lock pin 26 secured to the plunger 51 is engaged with the ring 31 that has a plurality of lock holes 29 in its periphery and that is fitted to the output shaft 25 of the electric motor 24 .
[0077] When the lock detection switch 45 that detects the position of the plunger 51 secured to the lock pin 26 is turned on, electric current application is stopped based on a signal from the lock detection switch 45 and a value indicated by the lock pin advance checking timer Tr 1 . After that, the lock pin 26 is advanced by a magnetic force acting between the yoke 53 of the actuator 30 and the magnet with one pole pair, which is fitted to the plunger 51 , and then engaged with the engagement portion formed in the rotational output member of the electric motor 24 .
[0078] With the configuration described above, when the lock pin 26 is advanced beyond P 4 and approaches P 2 , even if electric current application to the coil 54 of the actuator 30 is stopped, the lock pin 26 is engaged with the engagement portion formed in the rotational output member of the electric motor 24 by a magnetic force between the plunger 51 formed of the magnet with one pole pair and the yoke 53 made of magnetic material.
[0079] As a result, steering lock in the electric power steering system is maintained with lower power consumption.
[0080] In the present embodiment, the ring 31 is provided at the output shaft 25 of the motor 24 . Accordingly, the engagement force of the lock device 35 is increased by the speed reducer 20 . As a result, steering lock is achieved with lower power consumption.
[0081] The present embodiment may be modified as follows.
[0082] In the present embodiment, the invention is applied to a column assist-type EPS. Alternatively, the invention may be applied to a rack assist-type EPS or a pinion assist-type EPS.
[0083] In the present embodiment, the steering lock device is actuated based on the on/off state of the ignition switch. However, how the steering lock device is actuated is not limited to this. The steering lock device may be actuated by a remote controller that uses radio waves or infrared rays.
[0084] In the present embodiment, the left side portion of the plunger 51 is the south pole, and the right side portion of the plunger 51 is the north pole. However, as a matter of course, the right side portion of the plunger 51 may be the south pole and the left side portion of the plunger 51 may be the north pole.
[0085] In the present embodiment, a magnet with one pole pair is used as the plunger 51 . Alternatively, a magnet with two or more pole pairs may be used as the plunger 51 .
[0086] If the steering lock device according to the present embodiment is applied to a hybrid vehicle, a plug hybrid vehicle or a electric vehicle having a large-capacity battery, it is possible to maintain steering lock state for a long period of time.
[0087] According to the invention, it is possible to provide a lock device that is able to maintain a lock member in the disengaged state and to reliably maintain the locked state with low power consumption while operating a lock cancellation maintaining member using an electric drive unit without being affected by an electrical trouble.
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A lock device that restricts movement of a movable body includes: a lock member that is engageable with an engagement portion formed at the movable body; an urging member that urges the lock member in a direction away from the engagement portion; and an actuator that moves the lock member toward the engagement portion to engage the lock member with the engagement portion against an urging force generated by the urging member.
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