description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a polypeptide containing at least a specific antigenic region of a human centromere antigen recognized by a human anti-centromere antibody, a gene encoding the polypeptide, a plasmid or a phage containing the gene, a transformant obtained by transforming a host with the plasmid or the phage, a method for producing the human centromere antigen polypeptide utilizing the transformant and a method for detecting an anti-centromere antibody using the human centromere antigen polypeptide.
2. Description of the Prior Art
Autoimmune diseases are among the nationally designated incurable diseases in Japan, and it is required to elucidate causes of the diseases and develop therapeutic methods. Various antibodies against various own cellular components (autoantibodies) are present in the serum of an autoimmune disease patient. It is thought there is an association of these autoantibodies with the diseases.
An anti-centromere antibody is one of the anti-nuclear antibodies present in the central region of a mitotic cell chromosome and reacts with a protein of "a centromere domain" which plays an important role in the separation of a chromosome in a mitotic phase. An anti-centromere antibody has been pointed out as an autoantibody related to some autoimmune diseases, particularly scleroderma. Scleroderma is a general name for the disease inclusive of various disease types, and a method of clinical assay for an easier and more precise classification of the disease type is required to be established in order to diagnose and treat the disease.
An indirect fluorescent antibody technique is currently employed for detecting an anti-centromere antibody in a patient's serum using a liver section or cultured cells as nuclear materials. In order to strictly distinguish the positive antibody from other antibodies present in the serum in the indirect fluorescent antibody method, it should be further confirmed that the anti-centromere antibody recognizes the centromere region on a chromosome further utilizing a chromosome smear of cells in a mitotic phase. The method has disadvantages in that it requires a chromosome smear preparation and a specific facility and labors for microscopic observation of the smear, so that it is not suitable for a clinical assay handling a large number of people. For an alternative method for detecting the anti-centromere antibody activity, a method using a chromosomal centromere region as an antigen prepared from human cells in large quantity is assumed, but it is still too costly and labor intensive for practical use.
Presence of human centromere antigens, each of them including centromere protein A, B or C of different molecular weight has been identified. Among them, the major antigen is human centromere protein B (CENP-B), a portion of the gene coding for the protein has been cloned [Earnshaw, W. C., et al., J. Cell Biol., 104: 817 (1987)]. However, the epitopes contained in CENP-B have not been analyzed in detail yet. For the precise detection and classification of an anti-centromere antibody, detailed analysis of epitopes of the major antigen CENP-B is desired.
In order to solve the conventional problems described above and to develop a method for measuring anti-centromere antibody specifically as well as readily, elucidation of the epitopes of the major human centormere antigen, human centromere protein B and the production of the polypeptides corresponding to each epitope in a large quantity are desired.
SUMMARY OF THE INVENTION
The polypeptide containing a human centromere protein B epitope of the present invention is a polypeptide selected from the group consisting of polypeptide I and polypeptide II having the following amino acid sequences shown by SEQ ID NO:1 and SEQ ID NO:2, and a polypeptide having a portion thereof.
______________________________________Polypeptide I (shown in SEQ ID NO:1)Asp Gly Asp Glu Val Pro Val Pro Ser Phe Gly Glu Ala MetAla Tyr Phe Ala Met Val Lys Arg Tyr Leu Thr Ser Phe ProIle Asp Asp Arg Val Gln Ser His Ile Leu His Leu Glu HisAsp Leu Val His Val Thr Arg Lys Asn His Ala Arg Gln AlaGly Val Arg Gly Leu Gly His Gln SerPolypeptide II (shown in SEQ ID NO:2)Ser Ser Glu Gly Leu Glu Ala Glu Asp Trp Ala Gln Gly ValVal Glu Ala Gly Gly Ser Phe Gly Ala Tyr Gly Ala______________________________________
The present invention comprises a gene encoding the above mentioned polypeptide containing a human centromere protein B.
The present invention comprises a plasmid or phage vector containing the above-mentioned gene.
The present invention comprises a host cell transformed with the above-mentioned plasmid or phage vector.
The method of the present invention for producing the polypeptide containing a human centromere protein B described above comprises the steps of culturing the host cell transformed with the plasmid or phage vector containing the gene described above, and isolating and purifying the polypeptide from the culture.
The method of the present invention for detecting a human anti-centromere antibody comprises the following steps of:
(a) adding the above-mentioned polypeptide to a sample to contact the polypeptide with a human anti-centromere antibody contained in the sample; and
(b) detecting the human anti-centromere antibody bound to the polypeptide.
Thus, the invention described herein, makes possible the objectives of (1) providing a polypeptide containing an epitope of human centromere protein B epitopes; (2) providing a method for producing the polypeptide on a large scale by the use of a recombinant technique; and (3) providing a method for detecting the anti-centromere antibody employing the polypeptide.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings as follows:
FIG. 1 illustrates the restriction map of Lambda gt11 Sfi-Not vector DNA (upper) and the longest fragment (lower) containing a CENP-B gene which had been inserted in the vector DNA.
FIG. 2 illustrates the restriction maps of the longest fragment (the same fragment as in FIG. 1) and the shortest fragment (the inserted DNA fragment contained in pCENP-B-1) among the inserted DNA fragments containing CENP-B gene.
FIGS. 3a and b show the inserted fragments of deletion mutant plasmids in which a deletion mutation has been introduced in one direction of pCENP-B-1. The names of each plasmid are shown at the left end and the reactivities of the polypeptides coded by the plasmids with anti-centromere antibody-positive patient sera (40 serum samples) examined by Western blot are shown at the right end.
FIGS. 4a and b show the complete nucleotide sequence for the coding region of the CENP-B gene fragment inserted in pCENP-B-1 and the corresponding amino acid sequence.
FIG. 5 illustrates the insert fragments of the deletion mutant plasmids derived from pCENP-B-1, which indicates that the region of the fragment contained in pS-1-35 is the minimum region of the epitope II. The reactivities of the polypeptides coded by the plasmids with the group II patient sera are shown at the right end.
FIGS. 6a and b illustrate the insert fragments of the deletion mutant plasmids derived from pCENP-B-1, which indicates that the region of the fragment contained in pB-2-6 is the minimum region of the epitope I. The reactivities of the polypeptides coded by the plasmids with the group I patient sera are shown at the right end.
FIG. 7 shows the nucleotide sequence of the DNA fragment I used for the preparation of pB-2-6, pB-1-1 and pB-2-16, and the corresponding amino acid sequence.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The inventors of this invention constructed a cDNA library using messenger RNAs (mRNAs) extracted from human T cell-derived human Jurkat cells to clone human centromere protein B gene, CENP-B gene. CENP-B gene was isolated from the library, from which deletion mutant genes were prepared. Then, the reactivity of the deletion mutant gene product and a patient serum containing anti-centromere antibody was analyzed to determine regions for major epitope I and II. Accordingly, the present invention was completed.
The gene coding for CENP-B of this invention can be obtained as follows. First, mRNAs are isolated from human derived tissues, cells, and cell lines, preferably from human T cell-derived Jurkat cells to construct a cDNA library. A cDNA library can be constructed according to an appropriate technique known in the art, such as the method described by Young et al. employing a Lambda gt11 phage vector [Young, R. A., et al., Proc. Natl. Acad. Sci. USA., 80: 194 (1983)]. The cDNA library so obtained (e.g. the library utilizing E. coli) can be screened for a clone expressing human centromere antigen by using anti-centromere antibody, i.e. by examining whether proteins expressed by the constructed cDNA library react with the anti-centromere antibody. In the expression of human centromere antigen described above, human centromere antigen itself can be expressed, while it can be expressed as a fusion protein of human centromere antigen and another protein, preferably as a fusion protein with E. coli β-galactosidase. In this case, the β-galactosidase activity can be used as an indicator.
Then, a phage DNA is isolated from the positive clones (E. coli) screened as described above. By restriction enzyme analysis of this DNA, the insertion of the cDNA of interest into the phage DNA can be confirmed and a restriction map can be prepared. The gene coding for human centromere protein B is selected from these clones positive for human centromere proteins obtained as described above, and cloned. This is performed by, for example, the method of selecting the clone which exhibits a restriction map similar to that of the CENP-B gene cloned by Earnshaw, et al. The restriction map of the longest fragment among the resultant DNA fragments containing human centromere gene, and the restriction map of the Lambda gt11 Sfi-Not vector DNA containing the fragment are shown in FIG. 1. In addition, the restriction maps of the longest fragment (supra) and the shortest fragment among the DNA fragments containing human centromere antigen gene are shown in FIG. 2.
Furthermore, an epitope of the CENP-B gene obtained as described above is determined. The determination of a CENP-B gene epitope is performed as follows. Various deletion mutant genes are prepared from the gene by using various restriction enzymes, exonuclease and the like, and then the determination can be performed by analyzing the reactivities of the polypeptides produced by the deletion mutant genes and the patient sera containing anti-centromere antibody. Practically, the determination is made by the following method. First, CENP-B gene fragments with various length having a deletion at 3' end of the nucleotide (shown in FIG. 3) are prepared. The method for preparing a gene fragment associated with such a deletion mutation is described in "Zoku Seikagaku Jikken Kouza, Vol. 1, `Methods for Studying Genes II` pp. 289-305, the Japanese Biochemical Society ed.". The results shown in FIG. 3 were obtained by the examination of the interactions between the polypeptides expressed by the above-described expression vectors (the names of the vectors are shown at the left end of FIG. 3) and the patient sera containing anti-centromere antibody by Western blot. Among the polypeptides having the reactivity with the patient sera, some polypeptides reacted with 40 serum samples out of the 40 serum samples while others reacted with only 11 serum samples out of the 40 serum samples, which indicates that the CENP-B antigen polypeptide coded by pCENP-B-1 (the preparation method of which is described in Example I.1-4) possesses a plural number of epitopes.
Then, the fragments shown in FIG. 5 were prepared, and the polypeptides were expressed and reacted with the sera containing anti-centromere antibody in the same way as described above, the results of which are shown in FIG. 5. This reveals that one of the CENP-B epitopes is within the amino acid sequence coded by the DNA fragment contained in pS-1-35 shown in FIG. 5, e.g. within the amino acid sequence from 462 to 487 (the amino acid numbers correspond to those of the sequence described by Earnshow, W. C., et al., J. Cell Biol., 104: 817 (1987); the amino acid sequence is shown in SEQ ID NO:2). The amino acid sequence supra is designated as polypeptide II. Furthermore, the fragments shown in FIG. 6 were prepared, and the polypeptides were expressed and reacted with the sera containing anti-centromere antibody as the same way as described above, the results of which are shown in FIG. 6. This reveals that one of the CENP-B epitopes is within the amino acid sequence coded by the DNA fragment contained in pB-2-6 shown in FIG. 6, e.g. within the amino acid sequence from 530 to 594 (the amino acids are numbered the same as described above; the amino acid sequence is shown in SEQ ID NO:1). The amino acid sequence above is designated as polypeptide I. Accordingly, one of the CENP-B epitopes is contained in the sequence consisting of 26 amino acids from 462 to 487 of the polypeptide and the other in the sequence consisting of 65 amino acids from 530 to 594 of the polypeptide. The present invention comprises the polypeptides containing these epitopes. It is possible to produce the polypeptides by microorganism such as E. coli or yeast, or by animal cells or the like using the genes encoding the polypeptides, i.e. an appropriate promoter region may be linked to the 5' end of the each gene encoding each polypeptide obtained above, which is then inserted into a suitable plasmid followed by introducing them into a microorganism such as E. coli or yeast or animal cells to culture. The polypeptide corresponding to each epitope can be expressed as itself, while it can be expressed as a fusion protein with other protein, preferably with E. coli βgalactosidase or bacteriophage T7 gene 10 protein [Studier, F., et al., J. Mol. Biol., 189: 113 (1986)]. These manipulations can be made using known techniques in the art. Each polypeptide can be isolated and purified by column chromatography or by an immunochemical method also known in the art.
Alternatively, these polypeptides can be synthesized by the conventional methods of liquid phase or solid phase peptide synthesis or enzymatic synthesis ("Zoku Seikagaku Jikken Kouza" Vol. 2, `Protein Chemistry, No. 2`, page 663, 1987).
The resultant polypeptides containing each of the epitopes are used for the determination of the anti-centromere antibody activity. The methods for the determination include conventional immunological assays such as RIA, ELISA, Western blot and the like. The process of reaction (solid phase or liquid phase), labeling, detection and the like are not limited. The samples include, but are not limited to, urine, saliva, blood, serum, tissue and feces.
When the patient sera diagnosed as positive by the conventional indirect immunofluorescence assay are determined using polypeptide I or polypeptide II of this invention, the sera are divided into those which only react with polypeptide I and others which react with the both polypeptides I and II. As described above, the patients with anti-centromere antibody can be subdivided by the recognition of the each epitope (i.e. by the reactivity with polypeptide I or II), and the subdivision may be an important indicator for a precise classification of the disease type for a patient with anti-centromere antibody.
EXAMPLES
In order that this invention may be better understood, the following examples are set forth.
EXAMPLE I
1. Extraction of Total RNAs
Jurkat cells were cultured in RPMI 1640 medium supplemented with 10% fetal calf serum, and the total RNA was extracted from these Jurkat cells by the conventional method using guanidinium thiocyanate (GuSCN) as follows [Chirgwin, J. M., et al., Biochemistry, 18: 5294 (1979)]. First, Jurkat cells (about 5×10 7 cells) were suspended in a guanidinium thiocyanate/lithium chloride solution (0.5 g of GuSCN was dissolved into 0.58 ml of 25% lithium chloride solution, then 20 μl of 2-mercaptoethanol was added thereto) and sheared by a syringe until the viscosity lowered. After that, the solution was layered on a 5.7M cesium chloride solution, then centrifuged for separation. The total RNA peletted at the bottom of the centrifuge tube was dissolved in RNAse-free water, and then recovered by ethanol precipitation. 2. Preparation of Messenger RNA
The messenger RNAs were prepared from the total RNA obtained in section 1 using an oligo dT cellulose column type 3 (Collaborative Research, Co.) as follows. First, the above-mentioned column was washed with TE buffer (10 mM Tris-HCl, 1 mM EDTA, pH 7.5), then equilibrated with a TE/NaCl solution (1:1 mixture of TE buffer and 1M NaCl solution). The precipitate of the total RNA obtained in section 1 was dissolved in TE buffer, kept at 65° C. for five minutes, and cooled down immediately. After an equal volume of 1M NaCl solution was added, the mRNA solution was loaded on the column. The column was washed with five bed volumes of the TE/NaCl solution, then mRNAs were eluted with three bed volumes of TE buffer. After the NaCl concentration of the mRNA eluate was adjusted to 0.5M, the eluate was subjected to the column for rechromatography to purify the mRNAs. The resultant purified mRNA fractions were pooled, ethanol-precipitated, and then dissolved into TE buffer.
3. Construction of a cDNA Library Using Lambda gt11 Vector
cDNAs were synthesized using 4 μg of the mRNA obtained in section 2 and 1.8 pg of Not I primer adapter (Promega Co.) [Han, J. H., et al., Biochemistry, 26: 1617 (1987); Gubler, U., et al., Gene, 25: 263 (1983)]. To the resultant cDNA, a EcoRI adapter was ligated using a RiboClone EcoRI Adapter-Ligation System (Promega Co.). 5'-OH of the EcoRI adapter was phosphorylated by T4 polynucleotide kinase upon digestion with Not I restriction enzyme. These cDNAs were separated by 1% agarose gel electrophoresis, and the cDNAs with sizes ranging from about 1.2 kb to about 7 kb were isolated. The resultant cDNAs were inserted into Lambda gt11 Sfi-Not vectors (Promega Co.) which had been double-digested with EcoRI and NotI restriction enzymes, then packaged into phage particles using a GIGAPACKII (StrateGene Co.) to obtain a cDNA library.
4. Separation of Positive Clones by Screening with Antibody and Analysis of the Clones
Patient sera diagnosed as positive for anti-centromere antibody by indirect immunofluorescence were used for the screening. The indirect immunofluorescence was performed according to the conventional technique [Motoki, Nihon Rinsho, 48: pp. 580-583 (1990 Suppl.)].
The screening with an antibody was performed by the following method using an Express Blot Assay Kit (BioRad Co.).
E. coli Y1090 was infected with the phage particles obtained in section 3 for plaque formation. The nitrocellulose filter, which was soaked into 10 mM IPTG and air-dried, was placed on the plate having about 500,000 to 600,000 phage plaques produced (about 20,000 plaques per dish) and the plate was incubated at 37° C. for two hours to induce the gene products of the inserted cDNAs (i.e. fusion proteins with β-galactosidase), so that the gene products were transferred onto the filter. After cooling at 4° C. for 10 minutes, the filter was removed from the plate and treated in a blocking solution (3% gelatin, 20 mM Tris-HCl, pH 7.6, 0.5M NaCl) at a room temperature for one hour, then washed with a TBS solution (20 mM Tris-HCl, pH 7.6, 0.5M NaCl). The above-mentioned human anti-centromere antiserum was diluted about 10,000 fold with an antibody diluting solution (1% gelatin, 20 mM Tris-HCl, pH 7.6, 0.5M NaCl, 0.05% Tween 20), and then the diluted serum was reacted with the gene product on the filter at 4° C. overnight with shaking. The filter was washed with a T-TBS solution (a TBS solution containing 0.05% Tween 20) three times, then soaked in a diluted alkaline phosphatase-conjugated goat anti-human antibody solution (BioRad Co.), which was diluted 3000 fold with the antibody diluting solution, with shaking at room temperature for several hours. After the filter was washed subsequently with a T-TBS solution once and a TBS solution twice, a BCIP.NBT (BioRad Co.) substrate solution for alkaline phosphatase was added to develop color.
The rescreening of the positive clones which developed the color by the procedure described above was performed by the same procedure as described above using human anti-centromere antiserum. As the result, 13 clones which reproducibly reacted with human centromere antibody were obtained. These clones were designated as clones Lambda gt11 CENP-1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 and 13, respectively.
Phage DNAs were isolated from these 13 clones according to the standard method. After the phage DNA was double-digested with restriction enzymes EcoRI and NotI, the DNA was separated by 1% agarose gel electrophoresis for size determination of the inserted fragments.
One of 13 clones, Lambda gt11 CENP-1 was selected, and its inserted DNA fragment was used as a probe for the Southern blot hybridization of the remaining 12 clones according to the standard method. As the result, the inserted DNA fragments of nine clones (Lambda gt11 CENP-3, 5, 6, 8, 9, 10, 11, 12 and 13) were found to be hybridized with the probe. The same procedure was repeated for the remaining three clones using an inserted DNA fragment derived from one clone (i.e., Lambda gt11 CENP-2) among the remaining three clones as the probe. As the result, the remaining two clones (Lambda gt11 CENP-4 and 7) were hybridized with the probe. From these experiments, it was found that the 13 clones can be divided into two groups; A (Lambda gt11 CENP-1, 3, 5, 6, 8, 9, 10, 11, 12 and 13) and B (Lambda gt11 CENP-2, 4 and 7).
The inserted DNA fragments of these groups were digested with various restriction enzymes, and the cleaved DNA fragments were subjected to agarose gel electrophoresis for size determination to obtain the restriction maps. The inserted DNA fragments of the A group were found to belong to the same group of CENP-B gene which had been cloned previously by Earnshaw, et al. [Earnshaw, W. C., et al., J. Cell Biol., 104: 817 (1987)], while the restriction maps of the inserted DNA fragments of the B group did not correspond to the CENP-B gene of Earnshaw et al. and was thought to code other human centromere antigen. The restriction map of the clone which contains the longest DNA insert in the A group is shown in FIG. 1. The unit of figures in parentheses in FIG. 1 is kb. The arrow indicates the orientation of the reading frame of the gene.
The DNA inserts of the ten clones belonging to the A group which are assumed to contain CENP-B gene were recloned into a EcoRI-NotI site of a plasmid vector pGEMEX-12, each of which was designated as pCENP-B-1, 3, 5, 6, 8, 9, 10, 11, 12 and 13, respectively. A plasmid vector pGEMEX™-1 manufactured by Promega Co. was used to prepare pGEMEX-12, and the vector pGEMEX-12 was prepared by double-digestion with restriction enzymes SfiI and SacI, then the 3' overhang removed by Klenow fragment followed by ligation. By this procedure, the SfiI and SacI cleavage sites present in the multicloning site of pGEMEX™-1 were removed. E. coli BL21 (DE3) transformed with each of these plasmids pCENP-B-1, 3, 5, 6, 8, 9, 10, 11, 12 and 13 were cultured individually under the presence of IPTG, and ten species of CENP-B antigen polypeptides were obtained. All of the DNA inserts recloned in pGEMEX-12 are in frame of T7 gene 10, and the produced CENP-B antigen polypeptides are fusion proteins with T7 gene 10 protein. The CENP-B antigen polypeptides obtained were assayed by Western blot [Towbin, H., et al., Proc. Natl. Acad. USA., 76: 4350 (1979)] using 40 patient sera diagnosed as positive for anti-centromere antibody and four sera from healthy individuals diagnosed as negative for anti-centromere antibody by indirect immunofluorescence. As the result, these ten species of CENP-B antigen polypeptides were positive for all the 40 patient sera and negative for all the four sera from healthy individuals.
Consequently, pCENP-B-1 containing the shortest DNA insert among these ten clones was used for analysis of the epitope of CENP-B antigen. The restriction map of the clone containing the longest inserted DNA fragment and the restriction map of the inserted DNA fragment of pCENP-B-1 are shown in FIG. 2. The orientation of the reading frame is in the direction from left to right in FIG. 2.
5. Preparations of a Mutant Plasmid Having a Deletion (at 3' End and a Polypeptide Having a Deletion at the Carboxyl Terminus Using the Mutant Plasmid
A mutant plasmid of pCENP-B-1 with a deletion at 3' end of CENP-B gene, i.e. with a deletion from the NotI site in FIG. 2 was prepared using a Deletion Kit manufactured by Nippon Gene Co. Firstly, pCENP-B-1 was cleaved with restriction enzymes NotI and EcoT22I followed by being reacted with E. coli exonuclease III to obtain a double-stranded DNA having the deletion in one direction. Preparation of a plasmid with an introduced deletion in one direction utilizing exonuclease III is described in detail in "Zoku Seikagaku Jikken Kouza, Vol. 1, `Methods for Studying Genes II`, The Japanese Biochemical Society ed., pp. 289-305". E. coli JM109 was transformed with each of the deletion mutant plasmids having the deletion in one direction obtained as described above to prepare plasmid clones with the deletion in one direction. A double-stranded DNA was prepared from each of the plasmid clones, and the extent of the deletion was analyzed by the restriction enzyme cleavage pattern, and then DNAs were prepared from suitable clones, pl-26, pl-35, p2 -16, pl-1 and p2-6 (the restriction maps of these clones are shown in FIG. 3). E. coli BL 21 (DE 3) was transformed with each of the DNAs and cultured in the presence of IPTG to obtain each of the polypeptides (a fusion protein of the polypeptide coded by each of the deletion mutant plasmids fused with T7 gene 10 protein). The reactivity of each of the polypeptides with the 40 patient sera positive for anti-centromere antibody used in item 4 above, was analyzed by Western blot using each of the polypeptides as the antigen. This method was also employed in the examples below for examining the reactivity with the sera. The results with each of the corresponding deletion mutant plasmids are shown in FIG. 3. The solid lines represent translated regions and the dashed lines represent non-translated regions in FIG. 3. The numbers shown on the scale at the top of the figure represent the numbers of nucleotides (kb), and the numbers below each of the restriction map represent the amino acid sequence number. The amino acid sequence number corresponds to those described in the literature by Earnshaw, et al. (supra). The above-mentioned definitions can be applied in FIGS. 5 and 6 described below. According to the results, the CENP-B antigen polypeptide coded by pCENP-B-1 contains a plurality of epitopes. At least one epitope is contained in a portion up to the amino acid No. 487 and another epitope is contained in a portion up to the amino acid No. 594.
Determination of Polynucleotide Sequence
Using each of the deletion mutant plasmids (see FIG. 3) obtained in section 5 as a template, the nucleotide sequence of each of the DNA fragments was determined by the dideoxynucleotide method [Sanger, F., et al., Proc. Natl. Acad. Sci. USA., 74: 5463 (1977)] using a SP6 primer (Promega Co.) and Sequenase™ (U.S. Biochemicals Co.). Furthermore, the complete nucleotide sequence of the coding region of CENP-B gene (the short fragment at 5' end shown in FIG. 2) inserted in pCENP-B-1 was determined by each of the nucleotides sequence of the DNA fragments. The complete nucleotide sequence and the deduced amino acid sequence are shown in SEQ ID NO:3 in Sequence Listing and in FIG. 4. Both amino acid numbers in FIGS. 3 and 4 were numbered corresponding to those in the literature by Eranshaw et al. (supra). As the result, three nucleotides were different between the data of Earnshaw et al. and our data, and so were the amino acids corresponding to each of the nucleotides, which are underlined in FIG. 4. The corresponding amino acids are replaced with ATG(Met) for AGG(Arg), with CTT(Leu) for GTT(Val),and with CTA(Leu) for CGA(Arg) in the data by Earnshaw et al.
7. Identification of the Epitope (Epitope II) Coded Within pCENP-B-1
The analysis for the epitope II was performed using patient sera positive for both of the polypeptides coded within pl-35 and p2-6, the sera are referred to as group II below, among the deletion mutant plasmids pl-26, pl-35, p2-16, pl-1 and p2-6 (see FIG. 3) obtained in section 5. Firstly, pCENP-B-1 was cleaved with restriction enzymes ApaI and NotI followed by the treatment with Klenow fragment to make blunt ends, then religated to prepare a plasmid pl-A in which the ApaI-NotI fragment was deleted. The fragment contained in the plasmid is shown in FIG. 5. The polypeptide coded by pl-A did not react with group II patient sera. Next, pl-35 described in section 5 was cleaved with restriction enzymes EcoRI and SacI followed by the treatment with Klenow fragment to make blunt ends, then religated to prepare a plasmid pS-1-35 in which the EcoRI-SacI fragment was deleted. The fragment contained in the plasmid was shown in FIG. 5. This fragment is in frame of T7 gene 10. The polypeptide obtained from this plasmid reacted with group II patient sera. The fragments contained in each of the plasmids and the reactivities of the polypeptides obtained from the plasmids are shown in FIG. 5. In the section for reactivity, (+) represents for positive and (-) for negative in FIG. 5. The restriction sites shown in parentheses are absent because of the treatment with a Klenow fragment in FIG. 5, and also in FIG. 6. The solid lines represent coding regions and the dashed lines represent non-coding regions.
According to the results described above, epitope II recognized by group II patient sera was identified as the polypeptide contained in the 26 amino acid sequence of 462 to 487.
8. Identification of the Epitope (Epitope I) Coded Within pCENP-B-1
The analysis for the epitope I region was performed as follows using the positive patient sera (group I) which reacted only with the polypeptide coded by p2-6 (see FIG. 3) shown in section 5.
Firstly, pCENP-B-1 was double-digested with NcoI and NotI followed by the treatment with Klenow fragment to make blunt ends, then religated to prepare a plasmid p1-N in which the NcoI-NotI fragment was deleted from pCENP-B-1. The fragment contained in the plasmid is shown in FIG. 6.
Next, about 1.3 kb EcoRI-NotI fragment obtained by EcoRI/NotI double digestion of pCENP-B-1 was recloned into the EcoRI-NotI site of the plasmid vector pGEMEX™-1 (Promega Co.) followed by the cleavage with EcoRI, then partially digested with NcoI. The fragment was treated with a Klenow fragment to make all the ends blunt, then religated to prepare two species of deletion mutant plasmid, pLN and pSN. The DNA fragments contained in pLN and pSN are shown in FIG. 6. All of pl-N, pLN, and pSN are in frame of T7 gene 10. The polypeptides coded in these deletion mutant plasmids did not react with the above-mentioned group I patient sera.
Accordingly, polypeptides with extension from the amino terminus of the polypeptide coded in pLN were examined. The double-stranded DNA fragment I shown in FIG. 7 was prepared by synthesizing each of the strands of the DNA in an automated DNA synthesizer manufactured by Pharmacia, then annealing both strands. This DNA fragment encodes the amino acid sequence from Asp at 530 (98 in SEQ ID NO:3) to Met at 548 (116 in SEQ ID NO:3), to the amino terminus of which an EcoRI cleavage site is added and to the carboxyl terminus of which is altered to contain a NcoI cleavage site. The following deletion mutant plasmids were prepared using this DNA fragment. After the double-digestion of p2-6 (see FIG. 3) described in section 5 with EcoRI and NcoI, the DNA fragment was inserted and religated to prepare pB-2-6. Similarly, pB-1-1 was prepared by inserting DNA fragment I from EcoRI/NcoI double-digested pl-1, and pB-2-16 was prepared by inserting DNA fragment I from EcoRI/NcoI double-digested p2-16. The DNA fragments contained in pB-2-6, pB-1-1 and pB-2-16 are shown in FIG. 6. All these fragments are in frame of T7 gene 10. The polypeptide coded by pB-2-6 reacted with the above-mentioned group I patient sera, while the peptides coded by pB-1-1 or pB-2-16 did not. These results are shown in FIG. 6.
According to these results, the epitope recognized by the group I patient sera (epitope I) was identified as the polypeptide which is present within a 65 amino acid sequence from 530 to 594. There are amino acid differences at three sites in total in the epitope I from the data of Earnshaw et al. as described in the section 6.
EXAMPLE II
Each of E. coli BL 21 (DE 3) transformed with the plasmid pS-1-35 obtained in section 7 of Example I and with the plasmid pB-2-6 obtained in section 8 of Example I respectively was cultured in the presence of IPTG. By using each of the fusion proteins of the obtained polypeptides fused with T7 gene 10 protein as the antigen, which contains the epitope I and the epitope II respectively, the reactivities of the polypeptides with the 40 patient sera diagnosed as positive for anti-centromere antibody and the four sera from healthy individuals diagnosed as negative by immunofluorescence were assayed on Western blot. The results are shown in TABLE 1.
TABLE 1______________________________________ Serum sample (positive/number of samples)CENP-B antigen polypeptides healthy patient______________________________________pB-2-6 derived polypeptide 0/4 40/40 (epitope I)pS-1-35 derived polypeptide 0/4 11/40 (epitope II)______________________________________
According to the present invention, epitope regions of human centromere protein B are elucidated, and polypeptides containing the epitope are provided. The polypeptides can be produced in a large quantity by chemical synthesis, by an enzymatic method, and by genetic engineering. By using the obtained polypeptides, it is possible to detect human anti-centromere antibody readily and precisely. Furthermore, determinations using the polypeptides containing each epitope allow a precise classification of disease type of a patient having human anti-centromere antibody.
Various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be broadly construed.
The following specific sequence information and descriptions are provided in order to comply with the formal requirements of the submission of sequence data to the United States Patent and Trademark Office and are not intended to limit the scope of what the inventors regard as their invention. Variations in sequences which become apparent to those skilled in the art upon review of this disclosure and which are encompassed by the attached claims are intended to be within the scope of the present invention. Further, it should be noted that efforts have been made to insure accuracy with respect to the specific sequences and characteristic description information describing such sequences, but some experimental error and/or deviation should be accounted for.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 4(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 65 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: internal fragment(vi) ORIGINAL SOURCE:(A) ORGANISM: human(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:AspGlyAspGluValProValProSerPheGlyGluAlaMetAlaTyr151015PheAlaMetValLysArgTyrLeuThrSerPheProIleA spAspArg202530ValGlnSerHisIleLeuHisLeuGluHisAspLeuValHisValThr354045ArgLysAsn HisAlaArgGlnAlaGlyValArgGlyLeuGlyHisGln505560Ser65(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear( ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: internal fragment(vi) ORIGINAL SOURCE:(A) ORGANISM: human(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:SerSerGluGlyLeuGluAlaGluAspTrpAlaGlnGlyValValGlu151015Ala GlyGlySerPheGlyAlaTyrGlyAla202526(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 489 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: double(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA to mRNA(vi) ORIGINAL SOURCE:(A) ORGANISM: human(ix) FEATURE:(A) NAME/KEY: CDS(B) LOCATION: 1 to 489(C) IDENTIFICATION METHOD: by experiment(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:GAAGGAGAGGAATTGGGGGAGGAAGAGGAGGTGGAGGAGGAGGGTGAT48GluGlyGluGluLeuG lyGluGluGluGluValGluGluGluGlyAsp151015GTTGATAGTGATGAAGAAGAGGAGGAAGATGAGGAGAGCTCCTCGGAG96ValAspSerAspGlu GluGluGluGluAspGluGluSerSerSerGlu202530GGCTTGGAGGCTGAGGACTGGGCCCAGGGAGTAGTGGAGGCCGGTGGC144GlyLeuGluAlaGluAsp TrpAlaGlnGlyValValGluAlaGlyGly354045AGCTTCGGGGCTTATGGTGCCCAGGAGGAAGCCCAGTGCCCTACTCTG192SerPheGlyAlaTyrGlyAlaGl nGluGluAlaGlnCysProThrLeu505560CATTTCCTGGAAGGTGGGGAGGACTCTGATTCAGACAGTGAGGAAGAG240HisPheLeuGluGlyGlyGluAspSerAspS erAspSerGluGluGlu65707580GACGATGAGGAAGAGGATGATGAAGATGAAGACGACGATGATGATGAG288AspAspGluGluGluAspAspGluAsp GluAspAspAspAspAspGlu859095GAGGATGGTGATGAGGTGCCTGTACCCAGCTTTGGGGAGGCCATGGCT336GluAspGlyAspGluValProValPro SerPheGlyGluAlaMetAla100105110TACTTTGCCATGGTCAAGAGGTACCTGACCTCCTTCCCCATTGATGAC384TyrPheAlaMetValLysArgTyrLeuTh rSerPheProIleAspAsp115120125CGCGTGCAGAGCCACATCCTCCACTTGGAACACGATCTGGTTCATGTG432ArgValGlnSerHisIleLeuHisLeuGluHisA spLeuValHisVal130135140ACCAGGAAGAACCACGCCAGGCAGGCGGGAGTTCGAGGTCTTGGACAT480ThrArgLysAsnHisAlaArgGlnAlaGlyValArgGlyLeu GlyHis145150155160CAAAGCTGA489GlnSer162(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 162 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: protein(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:GluGlyGluGluLeuGlyGluGluGluGluValGluGluGluGlyAsp15101 5ValAspSerAspGluGluGluGluGluAspGluGluSerSerSerGlu202530GlyLeuGluAlaGluAspTrpAlaGlnGlyValValGluAlaGlyGly 354045SerPheGlyAlaTyrGlyAlaGlnGluGluAlaGlnCysProThrLeu505560HisPheLeuGluGlyGlyGluAspSerAsp SerAspSerGluGluGlu65707580AspAspGluGluGluAspAspGluAspGluAspAspAspAspAspGlu8590 95GluAspGlyAspGluValProValProSerPheGlyGluAlaMetAla100105110TyrPheAlaMetValLysArgTyrLeuThrSerPheProIleAs pAsp115120125ArgValGlnSerHisIleLeuHisLeuGluHisAspLeuValHisVal130135140ThrArgLysAsnHisAla ArgGlnAlaGlyValArgGlyLeuGlyHis145150155160GlnSer
|
The present invention provides polypeptides composing epitopes of human centromere protein B, genes encoding therefor, plasmids or phages containing the genes, transformants obtained by introducing the plasmids or phages containing the genes, a method for producing the human centromere antigen polypeptide using the transformant, and a method for detecting anti-centromere antibody using the human centromere antigen polypeptide. Analysis of the above-mentioned epitope was accomplished using CENP-B gene obtained from a cDNA library prepared using mRNAs isolated from Jurkat cells. The present invention allows the production of the human centromere protein B epitope region in a large quantity, which in turn allows the detection of human anti-centromere antibody readily and precisely using the peptide obtained. Furthermore, it becomes possible to make a precise classification of the disease type of a patient having human anti-centromere antibody by determinations using each of the epitopes.
| 2
|
RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/847,111, filed Aug. 29, 2007, now U.S. Pat. No. 7,892,479 which is a continuation of U.S. patent application Ser. No. 10/721,581, filed Nov. 24, 2003, now U.S. Pat. No. 7,264,673 which is a continuation-in-part of U.S. patent application Ser. No. 09/996,528, filed Nov. 28, 2001, now U.S. Pat. No. 6,802,896 which claims priority on Australian Provisional Patent Application No. 2003905445 dated Oct. 3, 2003.
FIELD OF THE INVENTION
The present invention relates generally to shaped articles that are formed from fly ash and to methods of forming such articles. The invention has been developed especially, but not exclusively, for the manufacture of structural elements and the invention is herein described in that context. However it is to be appreciated that the invention has broader application and may be used for the production of a vast range of articles, both structural and non structural.
BACKGROUND OF THE INVENTION
Fly ash is a by-product from the burning of coal in coal fired power stations. Fly ash is made in abundance and typically contains heavy metals such as cadmium, chromium, zinc and lead that make disposal problematic. In trying to minimise the environmental impact of fly ash, various uses of fly ash have been contemplated to both aid in fly ash disposal and to obtain some economic return.
One such use is in the manufacture of bricks that contain fly ash as a constituent part. These bricks usually include fly ash blended with clay and are fire hardened. Whilst these bricks find a use for fly ash, they have not been seen as a viable structural building element. In particular, difficulties have been encountered in manufacturing bricks containing fly ash that are cost competitive with existing bricks, are of a consistent quality, and perform adequately over a range of structural properties.
SUMMARY OF THE INVENTION
In a first aspect, there is provided a method of forming a shaped article having a matrix containing sintered fly ash, the method comprising the steps of:
blending fly ash together with water to produce a fly ash dough; forming a green article in a desired shape from the fly ash dough; curing the green article to at least partially solidify the article at between 30-80° C. and 20%-60% relative humidity; and firing the green article so that the shaped article is hardened by sintering its fly ash matrix.
In the above method, the green article is cured before it is fired. During curing, the water reacts with the fly ash so as to solidify the article.
The solidification of the green article during this curing process may be contributable to several different reactions. Whilst not binding the invention to theory, the inventors consider that where the fly ash is the only cementitious material in the matrix, the only compound that can give certain quick solidification is the calcium oxide. This compound is available in small quantity in class F fly ash and in much larger quantities in class C fly ash. The reaction between water and calcium oxide results in the formation of calcium hydroxide which lends some solidification to the article. Subsequently, a pozzolanic reaction occurs where the main oxides in the fly ash, primarily the silica and the alumina, react with the calcium hydroxide to form a much harder and more cementing material than the hydroxide. The resulting material is a complex crystalline and amorphous mixture of products that contain in their lattice molecules of silicon oxides, aluminium oxides, calcium oxides and water.
In a particular embodiment, any free water in the dough is reduced from the matrix whilst the green article is cured. In the above form, the green article is subjected to low to moderate heating during this curing process. The advantage of this arrangement is that the gentle heating can reduce the free water without causing undue cracking of the matrix. Also, the slow withdrawal of water still gives time for some of the water to react with the fly ash both by hydrating the cementitious material in the fly ash and under the pozzolanic reaction. In one form, the green article is heated under elevated humidity. The advantage of this arrangement is that it can promote the solidifying of the green article more evenly throughout the article.
This curing process consumes free water that is already in the dough and may need some additional water to compensate for self desiccation. In the above form the additional water can be drawn from the humid atmosphere.
In the process according to the above form, use is made of two separate reactions; first by gaining initial solidification through the formation of calcium hydroxide, and second by gaining further solidification through the pozzolanic reaction. If the process only relied on the former of these reactions, the solidification of the green article before firing would be limited due to the limited amount of calcium oxide in the fly ash. The advantage of solidifying the green article is that it improves its capacity to be handled, and its dimensional stability during firing, both of which are important in commercial manufacture of the shaped article.
In one form, the green article is cured in a temperature in the range of 30° C. to 80° C. In one form, the green article is cured in a temperature the range of 55° C. to 65° C.
In one form, the green article is subjected to conditions where the humidity is in the range of 20% relative humidity to 60% relative humidity. In one form, the green article is subjected to conditions where the humidity is in the range of 35% relative humidity to 45% relative humidity.
When done under gentle or moderate heat and high humidity, the duration of curing may vary considerably as extended curing time is unlikely to cause the matrix of green article to crack. Typically, for bricks, the curing time will be in the order of 12 hours to 5 days, and more preferably between 1 and 3 days. Whilst the curing is important to remove water and to solidify the green article, it is desirable to reduce the curing time to minimise the manufacturing process time. In one form, the inventors have found 2 days sufficient for curing.
In one form, e water is added in excess of that which is absorbed by the fly ash so that the dough contains free water so as to be in at least a partially fluid state. In one form, at least a portion of the free water from the fly ash dough is removed during and/or after forming of the green article.
In one form, the majority, if not all, of the free water is removed prior to firing of the green article. As such, the porosity of the fired article can be better controlled as the firing process will not generate cracking or bursting as a result of water vaporising in the matrix.
In one form, the moisture content remaining in the green article prior to firing is in the range of 1% to 5%. In one form, the moisture content remaining in the green article prior to firing is in the range of 2% to 4%. Typically the moisture remaining in the article is made up of two components. The first is the moisture entered into the hydration reaction and produced solid products of calcium silicate and aluminium silicate hydrate complexes. The second part is that which is trapped as moisture within the internal pores. The first component resists crumbling of the brick during handling and to withstand internal pressures of the escaping gases during firing. The second component is a main source of porosity that remains in the brick structure.
In a particular embodiment, a superplasticiser is blended with the fly ash and water. The advantage of using a superplasticiser is that it reduces the amount of free water that is required to make the dough in a workable state. This in turn alleviates the amount of water that may need to be subsequently removed to achieve the desired properties in the article, thereby allowing for more efficient processing of the article and also allowing for better control over the shape and size of the article during its production.
In another aspect, there is provided a method of forming a shaped article having a matrix containing sintered fly ash, the method comprising the steps of:
forming a fly ash dough incorporating fly ash, water and a superplasticiser; forming a green article in a desired shape from the fly ash dough; and firing the green article so that the shaped article is hardened by sintering its fly ash matrix.
In one form, the method principally uses three ingredients, namely fly ash, water and a plasticiser. As fly ash is a by-product, it is an inexpensive and readily available constituent. Further, the method can be used in a production line fashion, akin to clay brick manufacture. By controlling the water content in the dough, the articles may be initially shaped without the need of a mould as the dough may exhibit adequate dimensional stability. Also, the properties of the article can be readily controlled by controlling the water content of the green article, and the firing temperature and duration. Each of these parameters can be controlled during manufacture thereby allowing for articles to be produced of consistent quality.
In any form described above, it is to be appreciated that other additives may be incorporated into the mixture if required. For example pigments may be incorporated to impart certain coloration to the article. Also further additives may be incorporated to improve the properties of the mixture or resulting in green article. For example, quantities of carboxymethyl cellulose (CMC) may be incorporated in minute quantities to gel the mixture without the need of excessive water. Such additives also protect the dough from potential shrinkage, and cracking in the case of prolonged curing periods. Similar effects to that of CMC may also be obtained from the addition of minute quantities of calcium chloride solution.
The methods disclosed above have particular application for the manufacture of structural elements such as bricks. The inventors have found that bricks formed solely, or at least principally, from sintered fly ash have a higher compressive strength and modulus of rupture than conventional clay bricks. Also, by controlling the water content in the green article and the firing temperature and duration, it is possible to control the structure of the fly ash matrix and its surface characteristics. This in turn allows for the initial rate of absorption and absorption capacity of the article to be controlled, both of which are important properties, particularly in brick manufacture. Further, reducing the free water reduces the risk of bursting when the green article is fired and thus provides for a more uniform sintering process that is as free as possible from internal and external cracking.
Other techniques, such as pressing or the like of the dough or the green article may be used instead of, or in conjunction with, subjecting the article to a controlled environment of heat and humidity, to reduce the water content.
As indicated above the inventors have found that absorption properties of the fired article can be regulated by the temperature and duration of firing, particularly where the free water is substantially removed from the green article.
In the arrangement where the shaped articles are bricks, in one form, the firing temperature is in the range of 10000° C. to 13000° C. In another form, the firing temperature is in the range of between 11000° C. to 12500° C. The duration of firing may be in the range of 30 minutes to 6 hours. The duration of firing may be in the range of 1 to 4 hours.
The sintered fly ash matrix of bricks fired in this range tends not to be glazed and exhibit excellent absorption characteristics both in terms of initial rate of absorption and absorption capacity.
In a further aspect, there is provided a building element having a matrix of sintered fly ash and having a compressive strength of greater than 30 MPa, a modulus of rupture greater than 5 Mpa, an initial rate of absorption (IRA) of between 0.2 to 5 kg/m 2 /min and an absorption capacity of between 5-20%.
Building elements formed with these properties are ideally suited as a direct replacement for conventional clay bricks. They are stronger than conventional clay bricks, particularly in tension, and are capable of bonding well with mortar due to their absorption properties. Whilst the strength of the elements is due to the sintered fly ash matrix, the absorption properties are due to the porosity of the elements and their surface characteristics. As such, the building elements according to this aspect are ideally suited to be manufactured by the earlier aspect of the invention where the porosity and surface characteristics can be controlled.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
It is convenient to hereinafter describe an embodiment with reference to the accompanying drawings. It is to be appreciated that the particularity of the drawings and the related description is to be understood as not superseding the preceding broad description of inventions.
The accompanying drawings illustrate the invention. In such drawings:
FIG. 1 is a photograph of a cross section of a brick having a sintered fly ash matrix;
FIG. 2 is a flow chart illustrating the steps in manufacturing fly ash bricks;
FIG. 3 is a graph of absorption capacity of a fly ash brick as a function of firing temperature;
FIG. 4 is a graph of initial rate of absorption of the fly ash brick as a function of firing temperature;
FIG. 5 is a graph of moisture content of bricks as a function of time of curing;
FIG. 6 in a micrograph of the fly ash brick matrix when fired at a temperature of 1200° C.; and
FIG. 7 is a micrograph of the fly ash brick matrix when fired at a temperature of 1040° C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning firstly to FIG. 1 , a fly ash brick 10 is disclosed which incorporates a matrix 11 which is made from sintered fly ash 12 having voids 13 dispersed therethrough. The structure of the sintered fly ash and the arrangement and dispersion of the voids dictate the structural strength of the brick 10 and its absorption capacity (both the initial rate of absorption as well as the total absorption capacity).
In general, the voids 13 are dispersed throughout the matrix and comprise predominantly small interconnected voids 14 and larger isolated voids 15 . The small voids 14 make the brick 10 porous and capable of absorbing water. These small voids 14 are largely a function of the packing density of the fly ash, and the degree of compaction of the fly ash dough undertaken in manufacture of the brick. Of equal importance, these voids are a function of the efficiency of the sintering process that is controlled by the firing temperature and duration. The smaller voids 14 are also partly due to the superplasticiser used in manufacture the dough. The inclusion of a superplasticiser reduces the amount of water required to blend the fly ash dough whilst allowing ease of workability. The dispersant effect of the superplasticiser is such that the water is held in the form of droplets that allow the fly ash particles to roll on them and when dried through evaporation and/or self desiccation, the droplets leave behind their traces as air bubbles.
Fly ash particles typically have a particle size ranging from 1 μm to 150 μm. Typically, more than 66% of fly ash particles have a diameter smaller than 45 μm. The median diameter ranges from 2 μm to 10 μm and the reactivity of the ash increases with the smaller size particles. While the packing density may be regulated by grading of the fly ash, the inventors have found that no such screening is required to give the required properties of strength and absorption capacity as detailed below. This has the distinct advantage that no pre-treating of the fly ash is required. The fly ash can be collected from source (typically a power station) and used directly as a constituent in the brick manufacturing process.
The fly ash used in the brick of FIG. 1 is Class F. Class F fly ash is produced from bituminous coal and is mainly silicious. According to ASTM classification, class F fly ash contains a total of at least 70% of its compounds being of silicon oxide, aluminium oxide and iron oxide. Another type of fly ash is known as class C fly ash. This is derived from sub-bituminous and lignite coal. Class C fly ash is rich with calcium oxide. Whilst the typical content of calcium oxide in class F fly ash is between 2-4% and is generally lower than 10% by dry weight, the typical content of calcium oxide in class C fly ash is between 10% and 20% and can be as high as 26%. Whilst bituminous class F fly ash is used in this embodiment, it should be understood that this disclosure is not restricted to this type and is applicable to type C fly ash as well. Moreover, the high content of calcium oxide present in the class C fly ash serves to accelerate solidification and reduce the curing time and hence reduces the time required for handling and firing processes to proceed.
The larger voids 15 are formed primarily from air entrapped in the matrix when the brick is being formed. These voids 15 are partly a function of the manufacturing process and in particular the initial mixing of the fly ash and water to form a dough, and the compaction of that dough. The superplasticiser through its dispersant and hydrophobic effect may also contribute to the formation of larger voids in the dried product.
Ideally, the matrix 11 does not include an excessive amount of the larger voids 15 as they weaken the matrix. However, these larger voids can contribute to the brick properties as they serve to alleviate possible pressure build-up while firing and serve to alleviate stresses that may occur in the finished product in places where freezing and thawing are encountered. As the brick 10 was manufactured under laboratory conditions, there was some restriction on controlling the presence of larger voids 15 . It is anticipated that the generation of the larger voids would be better controlled under commercial procedures where the formation of the fly ash matrix could be better controlled.
As illustrated in the photograph of FIG. 1 , the outer margins 16 of the brick, adjacent the outer peripheral edge 17 , are still porous. Whilst the brick 10 incorporates a skin 18 formed on firing of the brick it is not glazed and still incorporates the smaller voids 14 . As such the skin does not form a barrier to water penetration into the brick 10 .
Also, there is an absence of major cracks or fissures extending through the brick matrix that would significantly reduce the brick strength and promote inconsistent water absorption of the brick.
The structure of the brick matrix 11 provides consistent strength and water absorption characteristics that make the brick 10 ideally suitable as a replacement for conventional clay bricks as will be discussed in more detail below.
FIG. 2 is a flow chart that schematically represents the process 20 of manufacturing the brick 10 . In a first stage 21 , the constituents of the brick are provided in their appropriate quantities. The constituents comprise fly ash, water and a plasticiser.
Fly ash was weighed and placed in a suitable concrete mixer or similar. About seventy percent of the total amount of water was then added and the dough mixture blended and rotated for three minutes. The total quantity of water to fly ash was 26 liters of water to 100 kg of fly ash. The fly ash used in this experiment was a Class F fly ash conforming to ASTM standard. This is available in abundance from power stations that use coal. However, it will be appreciated that the use of a particular fly ash is not a necessity although it should conform to a local quality standard.
A superplasticiser was then added and mixing continued for another period of three minutes. The superplasticiser was used in order to facilitate the workability of the fly ash slurry or dough. The superplasticiser was a pure sodium salt of a polynapthalene sulphonate made by Handy Chemicals and commercially available under the trade name DISAL. However, it will be apparent that the use of a particular superplasticiser is not necessary. It is only important to achieve consistent workability with minimum amount of water, and the use of a suitable superplasticiser should be satisfactory provided the dosage is relevant to the particular superplasticiser that is used. In this case, where DISAL was the superplasticiser, the dosage was at the rate of 200 ml per 100 kg of fly ash.
The rest of the water was then added and the mixing was continued for three more minutes when the mixing was complete.
The mixing of the constituents to form the dough occurs at step 22 . At that time, the dough may be compacted to limit the voids 13 (particularly the larger voids 14 ). The compaction may be done by any suitable technique and in the experiments carried out by the inventors, the fly ash dough was placed into a tray and compacted or vibrated on a vibrating table in a similar manner to concrete placing. The compaction or compression was stopped when the dough mixture started to bleed. However in a production environment, the fly ash dough may typically be mixed and extruded under pressure which would result in compaction of the dough.
At step 23 , the green bricks are formed. In the experiments conducted, the dough was cut into the green bricks by cutter moulds forced into the dough. These bricks were then removed from the tray. In a commercial scale operation, where the dough is extruded, the brick would be produced in a manner adopted for clay brick manufacture where the dough would be fed on a conveyor belt and cut by wire cutters.
At step 24 the individual green articles are cured by being placed in a curing chamber at 58° C. and 37% relative humidity for a period of 48 hours. As indicated previously, the curing process is designed to solidify the green articles and also to draw out the majority of the water from the fly ash matrix.
FIG. 5 is a graph of the moisture content of the green fly ash brink during curing. This graph shows the moisture content from the time of mixing until the time of firing which is typically between 24 to 72 hours after curing. It is evident that under the conditions of curing the moisture content stabilisers at about 3.5% after 48 hours. The main loss of moisture occurs within the first 24 hours. This period is the most critical for encouraging solidification and driving out unnecessary moisture. From two days onwards the remaining moisture is made up of two components. The first is the moisture that enters into the hydration reaction and produces solid products of calcium silicate and aluminium silicate hydrate complexes. The second part is that of which is trapped as moisture within the internal pores. The first component is necessary to resist crumbling of the brick during handling and to withstand internal pressure of the escaping gases during firing. The second component is a main source of porosity that remains in the brick structure. The cured bricks are then fired at step 25 so as to sinter the fly ash matrix. In the experiments, the cured articles were placed in a kiln and the temperature was raised to 1200° C. and the bricks were fired for 3.5 hours.
In a final stage of the process, the sintered fly ash bricks were then allowed to cool down to room temperature as represented at step 26 .
Various properties of the fly ash brick were tested and table 1 below represents the properties of the fly ash bricks compared to common clay bricks.
Initial Rate of
Brick
Compressive
Modulus of
Absorption
Absorption
Average
Type
Strength
Rupture
(IRA)
Capacity
Density
Clay
Typical is from
From less
Typical range
5-20%
1800-2000
Bricks
12 to 40 MPa.
Than 1 MPa
between 0.2
kg/m 3
Minimum
to greater
and 5 Kg/m 2 /min.
Accepted by
than 2 MPa.
Australian
Default
Standard: 7
value is 0.8
MPa.
MPa.
The tests conducted to determine the above properties were as follows:
Compressive Strength:
Performed according to Australian/New Zealand Standard AS/NZS 4456.4:1997, Method 4: Determining Compressive Strength of Masonry Units.
Modulus of Rupture:
Performed twice, one time according to Australian/New Zealand Standard AS/NZS 4456.15:1997, Method 15: Determining Lateral Modulus of Rupture, and the second time on unit bricks. The reason why this was done is that the Standard method requires forming a beam by horizontally bonding three bricks. The glue used was Epirez, an epoxy mortar binder. This method worked very well with normal clay bricks because the glue is stronger in tension than the clay bricks and the failure line was through the brick. In the case of our fly ash bricks, failure occurred through the glue line at 7.2 MPa. This meant that the bricks are stronger than that and the 7.2 MPa is the strength of the glue. Hence the testing was done again on single bricks that involved no glue. The result confirmed that the value of the modulus of rupture fro the fly ash bricks is higher than 7.2 value and is in fact 10.3 MPa.
Initial Rate of Absorption:
Performed according to Australian/New Zealand Standard AS/NZS 4456.17:1997, Method 17: Determining Initial Rate of Absorption (Suction).
Absorption Capacity:
Performed according to Australian/New Zealand Standard AS/NZS 4456.14:1997, Method 14, Determining Water Absorption Properties.
Average Density:
Performed according to Australian/New Zealand Standard AS/NZS 4456.8:1997 Method 8: Determining Moisture Content and Dry Density.
Accordingly, from the above table, it is clear that the fly ash bricks 10 exhibits excellent properties compared to conventional clay bricks.
Two important properties of building bricks are the initial rate of absorption (IRA) and the absorption capacity. These two properties are of particular importance for bricks. The IRA is of great importance for the laying of the bricks and bonding with the mortar. A high IRA results in too quick drying of the mortar and thus weakens the mortar and reduces its adherence to the brick. On the other hand if the IRA is too low, the surface of the brick adjacent to the mortar would not absorb the excess water and would result in very weak layer of the mortar that would not have penetrated enough into the surface crevices and pores of the brick. The property of total absorption capacity is also very important for the performance of the brick. A very high absorption results in vulnerability to volume changes that would result in cracking of the bricks and structural damage in buildings. It also would lead to cracking in the event of freezing and thawing of the water inside the pores. Too little absorption however is also not desired. This is because rain water, rather than get partially absorbed by the brick, would tend to run off very quickly towards the joints and may find its way into the building as well as reduce the durability of the mortar joints.
Further tests were conducted by the inventors on the effects of the firing temperature on the total absorption capacity and the initial rate of absorption. These tests were conducted using green bricks made in accordance with the above procedure. The only difference being the firing temperature used. The results of these tests are illustrated in FIGS. 3 and 4 .
As is clearly apparent from the FIGS. 3 and 4 is that the temperature of firing has a major effect on the absorption properties of the sintered fly ash bricks. Further, as can be seen from the above results, by maintaining the temperature rate between 1100° C. to 1250° C., it is possible to obtain excellent absorption properties consistent with conventional clay bricks.
FIGS. 6 and 7 are micrographs of the fly ash brick matrix when fired at different temperatures. FIG. 6 has a firing temperature of 1200° C. whereas FIG. 7 is the brick matrix when fired at a temperature of 1040° C. In the micrograph of FIG. 6 the matrix of the brick exhibits finer and more consistent pores throughout the matrix structure. The fly ash is substantially sintered without being glassified. In contrast, in the matrix disclosed in FIG. 7 , where the brick was fired at 1040° C., the fly ash is not sintered enough thereby leading to excessive porosity and a reduction in its structural strength.
Accordingly, the invention provides methods of manufacturing articles from fly ash which can be produced on a commercial scale and which exhibit excellent properties both in terms of strength and absorption capacity which makes such articles ideally suited as a substitute for conventional clay bricks.
Although several embodiments have been described in some detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
|
Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticizer is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.
| 2
|
CLAIM OF PRIORITY
This application claims priority from U.S. provisional patent application “METHOD OF GENERATING UNIQUELY IDENTIFIABLE WORKS OF ART,” Application No. 60/355,264, filed Feb. 8, 2002, incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a computer software application and system for creating and distributing digital works of art.
2. Description of the Related Art
The era of digital media is changing the way original content is created, used and distributed. Because of its nature, digital content can be copied any number of times, without its quality being substantially effected. For example, a digital version of a song can easily be extracted from the original CD, copied and compressed on a user's hard disk and/or published on the Internet through readily available peer-to-peer software applications, such as Napster and Kazaa. Using such peer-to-peer software applications, anybody with the appropriate equipment can download and listen to songs, with the same or near-same sound quality as contained on the original CD.
A large part of the media industry's current success is based on the duplication and selling of large quantities of unique works of arts. Millions of copies of a single original version are made and sold. With the proliferation of computing and networking, content creators and owners of digital products like music, movies, software and the like are facing critical piracy problems. Currently, the music and the software industries are being particularly impacted by piracy. Despite the fact that digital products have never been distributed in larger quantities than today, revenues are decreasing. This is at least in part due to an increasing number of products being illegally copied and distributed. In order to protect revenues, the media industry is trying to stop or at least limit illegal copying of their products.
Multiple solutions to arrest piracy problem have already been attempted.
One solution that attempts to solve the piracy problem is to encrypt content. In an encryption system, the content is encrypted before it is distributed to a user. The user can use the music, software, video or other media with a decoder. The decoder verifies the existence of a valid copyright for the product and, if the user is authorized, the content is decrypted and may be accessed.
Although an encryption system offers some protection, this kind of system can easily be bypassed. As an example for music and movies, because a user must hear and/or see the decrypted content, the user can always record the content from the digital or analog stream after the media has been decoded. In the case in which a user captures the analog signal, this is well known in the art as an “analog hole.” After been recorded, the content can be freely distributed in any convenient format. Moreover, since typically a single encryption algorithm is used to encrypt the content, if any one person is able to ‘crack’ the algorithm, he or she can publish the method on the Internet, thus allowing anyone to make use of it.
Another attempted solution to the piracy problem is to embed a digital watermark (for example, a serial number) in the host content. Most commonly, digital watermarking is applied to media such as images, audio signals, and video signals. However, it may also be applied to other types of media, including documents (e.g., through subtle line, word or character shifting), software, multi-dimensional graphics models, and surface textures of objects.
For software, a serial number or a CD key is embedded into the code of a software application.
For music protected by watermark technology, an imperceptible digital watermark signal is embedded in the host content. In fact, robust watermark systems have been developed in order to even be persistent with content quality degradation (compression, analog recording,). However, according to Professor Edward Felton of Princeton University, all the watermarks techniques have been or can be broken. I has been shown that, if some imperceptible signal is introduced into the content, it is possible to disturb or remove the signal without altering the quality of the perceptible content. Professor Felton further indicated that in theory, a good psycho perceptive compression could remove a watermark from a watermarked file without altering the perception of the content.
The solution to the problem of piracy is extends beyond content codification. To continue to ensure that the media industry continues to generate revenue by controlling the duplication and distribution of their products, the media industry must actively seek out solutions to address the problem of piracy. Currently, thanks the proliferation of computer hardware and software in the duplication, processing and communication arenas, the media industry is losing its monopoly on the duplication and distribution of its products.
What is needed is a system and method of creating and distributing works of art that takes advantage of the possibilities of duplication and distribution offered by modern computing and telecommunication, while preserving the rights of the authors
SUMMARY OF THE INVENTION
The present invention proposes a process for creating and distributing works of art to users, while protecting the rights of the authors. A work of art is any piece of information digitally encoded or available as an analog signal. An author is an individual or group of persons involved in the creation of an original digital work of art: By way of example only, an author may be a composer, writer, player, musician, engineer, producer, actors, singer, mixer, programmer, analyst or any other individual or group involved in the creation of a digital work of art. A user is any person or entity that received the right to use a digital work of art: By way of example only, a user may be a consumer, a DJ, a Movie theater, a radio station, a Television station or network, a promoter, or any other person or entity that will view, listen to or in any other way perceive the digital work of art.
In one simplified embodiment, a different version of the work of art is delivered to each user. Each version is slightly, yet perceptibly different in content. Therefore, each version is an original and unique or fixed work of art. Each version may then be delivered and assigned to a single user. Information identifying the features of each version and the associated user may be stored.
By later analyzing the content of a fixed or unique version and reviewing the stored version/user data, the user associated with a given version the user of a specific version can be readily identified. If a user illegally copied and distributed a fixed or unique version, the original user can be identified from the content of the fixed or unique version. The fixed version need not contain hidden tagging, watermarking or additional identification data. However in alternate embodiments, such tags, watermarks or additional information may be included in the fixed or unique version.
The identification information is the content of the version itself and therefore cannot be removed without degrading the content. Since the content of the work of art is different for each version, the author can provide limitation on the variations in the preparation of the multiple versions. However, in alternate embodiments, the author may not provide any guidance or limitations.
Various aspects of one embodiment of a system are described paragraphs, (a), (b), (c) and (d), below. However, various other embodiments are contemplated.
(a) An author creates a variable work of art that can be used to generate multiple versions. This variable work of art is a creation with a broader content than a classical work of art. In a variable work of art, the content is not completely determined, but prepared with some non-fixed options. That is, the variable work of art can contain specific locations in the content where the author will permit modifications or deviations from a the base work. However in alternate embodiments, the author may specify the entire content as being variable or any specific segment or segments of the content as being variable. This variable work of art is used to generate the multiple versions of the work art for distribution.
(b) From the variable work of art described in above, a plurality of different, fixed versions can be automatically generated. The content of each fixed version is perceptibly different for all other fixed versions in at least one place. In this way, each generated version is unique. Generally, the fixed versions are generated in such a way that removal or modification of the perceptible difference in each version would degrade the content of the fixed version. However, in alternate embodiments fixed versions can be generated such that removal or modification of the perceptible do not substantially impact the content of the fixed version. In one embodiment, generation of a fixed version can occur at the time a user requests a version.
(c) After generation of each fixed version, the rights for each unique version can be assigned and/or delivered to one or more users. In one embodiment, each fixed version can be assigned and/or delivered to only one user. In the one-fixed-version-one user embodiment, each fixed version is reserved for private use by the assigned user. In one embodiment, each unique version is delivered to the assigned user via any convenient method. In an alternate embodiment, a record of each delivery can be kept in a rights management database. The database can contain information sufficient to identify the delivered fixed version and information identifying the user associated with the specific fixed version.
(d) To identify unauthorized distribution of a fixed version, publicly available data sources such as Internet transmissions, Web sites, Peer-to-peer networks, Intranets, company networks and the like can be scanned to determine if a previously assigned fixed version is being transmitted or is located on a system. From the content of the fixed version, unique characteristics can be extracted and compared to the characteristics of fixed versions stored in a database. When the version is identified, the assigned user of a fixed version can be identified.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with respect to the particular embodiments thereof. Other objects, features, and advantages of the invention will become apparent with reference to the specification and drawings in which:
FIG. 1 is a simplified overview of the a fixed version generation system and associated components.
FIG. 2 is an schematic representation of the tools and components used to generate and distribute fixed versions.
FIG. 3 is a diagram showing the stream of events contained in a digital work of art.
FIG. 4 is a schematic diagram showing the components used by an author to create and test a variable work of art.
FIG. 5 is a diagram showing an embodiment of a creation component for a variable work of art.
FIG. 6 is a diagram showing a component for generating a fixed version from a variable work of art.
FIG. 7 is an overview of a version generation component applied to work of art.
FIG. 8 is a diagram showing an embodiment of a version generation component for a musical work of art.
FIG. 9 is a diagram depicting a dual phase identification component for fixed or unique version and/or user identification
FIG. 10 is a diagram showing a simple example of a variable musical work of art.
FIG. 11 shows a simplified example of user interface for the selection of a musical work of art.
DETAILED DESCRIPTION
FIG. 1 shows an overview of one embodiment of a method implemented by the present invention. In the embodiment shown in FIG. 1 , an author [ 101 ] can create a variable work of art. A variable work of art is a creation that has a broader content than a classical or fixed work of art. The content of a variable work of art is not completely determined, but contains open options. That is, a variable work of art includes places in the content where multiple possibilities are available. In alternate embodiments, any portion of the variable work of art may contain multiple available options. The creation of a variable work of art is accomplished through the variable work creation process [ 102 ].
In the embodiment shown in FIG. 1 , once a variable work of art exists, multiple fixed or unique versions of the variable work of art can be generated from it either automatically or on demand. The step of generating unique works of art from the variable work of art is the unique version generation process [ 103 ]. In the embodiment shown in FIG. 1 , the generation of a unique version is performed in response to a user [ 104 ] request for a copy of the work of art. However in alternate embodiments, multiple unique versions may be generated without a user request. The generated unique versions are “copies” of the variable work of art in which the variable portions have been uniquely fixed. Thus, the generated unique versions are classical work of arts, in which the content is completely determined. In the embodiment shown if FIG. 1 , the differences between two unique versions are perceptible and the unique versions are generated in a manner such that the removal or modification of the unique differences would degrade the content of the work of art. In the embodiment shown in FIG. 1 , each generated version is unique. That is, no two versions are ever fixed the same way, so that the contents of any 2 unique versions is never the same. Additionally, in the embodiment shown in FIG. 1 , user [ 104 ] input can be used to specify preferences for some characteristics of the unique version or the unique version can be generated without any user input.
In the embodiment shown in FIG. 1 , when a unique version is generated it is delivered to a single user [ 104 ]. Thus, each unique version is reserved for the use by a single user. However in alternate embodiments, a single unique version may be delivered to multiple users [ 104 ]. In the embodiment shown in FIG. 1 , the unique version is delivered via a secured digital communication method. However, in alternate embodiments, the unique version may be delivered to a user in any convenient manner. In alternate embodiments this may include downloading the unique version via the internet, custom creation of digital or analog media or any other method for delivery of works of art known in the art. In the embodiment shown in FIG. 1 , the communication is secured to ensure identification of the user and the safe delivery of the unique version.
In the embodiment shown in FIG. 1 , a record identifying the user and the characteristics of the unique version associated with the user is stored in a rights management database [ 105 ]. This database can contain information on all unique versions that have been generated and the identity information for each user associated with a unique version. Thus, if the user improperly makes a unique version publicly available or improperly distributes a unique version via the internet, web sites, peer-to-peer networks, intranets, company networks or the like, the user associated with the improperly used unique version can be identified by comparing the content of the unique version to the rights management database.
In one embodiment, networks can be continuously or periodically scanned for publicly available or publicly distributed works of art. The contents of discovered works of art can be analyzed through the unique version identification process [ 106 ] and the users associated with any improperly available unique versions can be identified. In the embodiment shown in FIG. 1 , the unique version identification process compares characteristics of the content of discovered works of art with unique version and user information available in the rights management database [ 105 ]. If a match between a discovered work of art and a unique version is found, the user associated with the unique version can be identified.
FIG. 2 shows the components and tools used to implement one embodiment of the present invention. In the embodiment shown in FIG. 2 , an author [ 201 ] creates a variable work of art by using the variable authoring component [ 202 ] and a classical digital authoring tool [ 203 ]. There are numerous authoring tools that are able to handle data of any kind such as music, movies, books, software, drawing and the like. These authoring tools allow an author to create a fixed work of art. To specify variable parts within the authors variable work of art, additional software or hardware components can be added, such as a variable authoring tool [ 202 ], which allows the author to establish limitations on part and attributes of the variable work of art that can be modified [ 206 ]. Once the variable work of art is completed, it may be stored in a storage medium [ 205 ] for later retrieval and/or use. In the embodiment shown in FIG. 2 , a commercially available database tool is used to store the variable work of art. However, in alternate embodiments, any searchable data structure may be used.
In the embodiment shown in FIG. 2 , to publish the work of art, a selection interface is presented to the user [ 210 ]. In one embodiment, this interface can be an application that identifies the user [ 211 ] and allows the user to specify various attributes of the variable the work of art [ 204 ]. This interface can be achieved using various available content management software applications which can be deployed over the internet, an intranet network, or various other software or hardware combinations. In one embodiment, when a user [ 211 ] requests a “copy” of the work of art, a unique version of the variable work of art [ 213 ] is generated. To generate the unique version, information regarding the variable work of art, previously generated unique versions and the user are obtained. Once the information is compiled, generation of a new unique version is commenced with the aid of a classical authoring tool. With this information, the unique version generation component [ 212 ] can fix variables parts and attributed within the content and generate a unique version [ 213 ], with the help of a classical authoring tool [ 203 ]. As with the creation of the variable work of art, the authoring tool can be a standard work of art authoring tool known in th art. In one embodiment, the authoring tool can be configured such that it can generate unique version automatically either with or without human intervention.
In the embodiment shown in FIG. 2 , a version generation component [ 212 ] initiates the generation process with the determined fixed values for the variable parts and attributes of the variable work of art. Once a unique version is generated, the unique version is delivered to the user [ 211 ] through a delivery tool [ 210 ]. In the embodiment shown in FIG. 2 , the delivery tool delivers a digital version of the unique version of the work of art to the user. However in alternate embodiments, other delivery methods are contemplated, such as custom generation, via a hardware component, of a tangible product, such as a CD, video cassette or the like, that may be delivered to the user. In the embodiment shown in FIG. 2 , the delivery function is handled by the content management software. However in alternate embodiments, the delivery function may be handled by a separate delivery tool.
In the embodiment shown in FIG. 2 , the version generation component [ 212 ] can store the selected attribute values for the unique versions into the rights management database [ 208 ].
For the detection of improperly publicly available works of art, a retrieval tool [ 219 ] may be used to retrieve the suspected versions [ 219 ]. The retrieval process depends on the type of work of art and the digital data source of the work or art. In the embodiment contemplated in FIG. 2 , the data source would be the internet, an intranet or a company network. However, various tools known in the art may be used to search other sources of improperly available works of art. The embodiment described with regards to FIG. 2 relates to searching sources such as Web bots and Peer-to-peer applications. The scanning tool [ 217 ] can continuously or periodically scan the publicly available digital data sources [ 218 ] to locate publicly available works of art. In the embodiment shown in FIG. 2 , suspect works of art [ 219 ] that are found can be sent to the version identification component [ 220 ]. This component can use reference versions [ 221 ] and/or reference attribute data from the unique version generation component [ 212 ] to determine if the suspect version is being improperly distributed. A reference version is a generated version that is not delivered to a user, but that is used internally by the present invention to serve as a reference when analyzing and comparing unique version contents. In alternate embodiments, the version identification component [ 220 ] can also use content analysis tools [ 222 ] to uniquely identify a unique version.
If a suspect work of art is identified as having attributes matching a unique version contained in the rights management database, the version identification component [ 220 ] can retrieve the identification information for the user that the unique version was originally distributed to.
FIG. 3 is a generic representation of digital content that may be contained in a digital work of art. This diagram is provided by way of example only for better understanding of the nature of a variable work of art. In alternate embodiments, the work of art may be in any other convenient form; The present example is given for a music content, however, the same description can be applied to any work of art.
An author creates a work of art by defining its content. The content of a digital work of art is a continuous binary stream (for example a music song in .WAV format) [ 301 ]. This binary content is generated by the assembly and combination of multiple binary sub-streams [ 302 – 310 ] in known manners (combination might be a complex process that involves transformation of the streams: for example in a software application: the source code compilation). Each sub-stream can be seen as the digital representation of an event (for example the note C played on a piano [ 306 ]). Each event results from the creative action of the author. Each event possesses one or more attributes [ 311 ] that totally characterize the event—for example, the length of the note is an attribute of the event of the note C being played on a piano. Different types of events have different values. Each attribute has a corresponding value [ 312 ] (for example: 1.2 second for the length of the note C played on a piano).
In classical digital authoring, the author fixes all values for all attributes of all events in his work of art [ 312 ]. Therefore, the content of the author's creation is fixed. The present invention allows the author to select multiple possible values [ 312 – 315 ] for some or all attributes, instead of requiring the author to fix all attribute values. Thus, the work of art can have multiple variations based upon how the attributes of the variable are fixed. By combining the values of the different attributes, multiple versions of a work of art can be generated.
To preserve the coherence of a work of art, logical links between values of attributes of events can be defined (for example: all piano note should be played 1.2 sec). These links can establish a dependence between values depending on how much variability the original author would like to leave in the work of art. Logical links can also tie together values of different attributes [ 316 ] (sustain only if piano note is shorter than 1.2 sec.). In fact, links can be very generic relationships between values that can be used to maintain coherence of the variable work of art and the unique versions by preventing conflicting attribute values from being assembled. The links are constraint for the selection of valid values and therefore decreases the number of generated versions. Thus, the greater the number of links, the fewer the number of unique versions can be generated from a variable work of art.
FIG. 4 depicts the variable work creation component. In the embodiment shown in FIG. 4 , the component [ 401 ] works with a classical digital authoring tool [ 402 ] to produce a variable work of art [ 403 ]. There are numerous authoring tools that are able to handle data of any kind: Music, movies, books, software, drawing and the like. In the embodiment shown in FIG. 4 , the authoring tools present an interface to the author to help him assemble the individual pieces of the work of art.
Classical authoring tools only allow an author to create a fixed work of art. In the embodiment shown in FIG. 4 , author [ 406 ] interfacing is conducted through a specific interface [ 404 ] for control of the variable parts of the work of art and a classical interface [ 405 ] for the control of assembly and combination [ 413 ] of the various components.
In the embodiment shown in FIG. 4 , for generation of the variable work of art, the content source [ 407 ] is managed by the authoring tool [ 402 ] which will select, transform, arrange and/or combine the content to prepare the combined variable work of art [ 408 ]. However, at least since some events have variable attributes, the assembly is not finished. In one embodiment, the author [ 406 ] encodes the variable content attributes and can provide ranges for possible values [ 413 ] through the variable content interface [ 404 ]. Additionally, the author [ 406 ] can also encode the logical links between values (for work of art coherence) through the interface [ 404 ]. However, in alternate embodiments, the author may leave all attributes independently variable.
All the variable attribute information is stored into a variable attribute definition [ 409 ]. The content of the combined work of art [ 408 ] (unfinished assembly) and variable attribute definition [ 409 ] makes together the variable work of art [ 403 ] that can be stored.
For testing purposes, in one embodiment, the variable authoring component [ 401 ] can produce sets of test values [ 410 ] for variable attributes. The test value sets can be used to generate unique versions [ 411 ] through the classical authoring tool. The author [ 406 ] can use them to test and validate the selections of the variable values.
In another of embodiment, the author [ 406 ] can add complementary information to the variable selection [ 412 ]. This information can characterize the possible values [ 413 ] and can be used to help the user specify his preferences (user preference are choices the user can make about the work of art that will be generated for him).
In yet another embodiment, the authoring component [ 401 ] can compute, in real time, the total number of versions that can be safely generated from the current set of variable attributes [ 403 ] and provide this information to the author. In another embodiment, this information is displayed to the author [ 406 ] through the variable content interface [ 404 ], thus providing the author some feedback during the variable work of art creation process.
In a still further alternate embodiment, the author [ 406 ] can establish a limit on the total number of versions that can be generated. This information is saved as part of the variable attribute definition [ 409 ]. In this manner, the author can limit the total number of copies of a given work that are distributed.
FIG. 5 depicts an embodiment of the variable work creation component applied to digital music. In the configuration shown in FIG. 5 , a classical audio mixing tool [ 501 ] is used. In the process of creating a musical work of art, the components of the work are recorded on separated tracks (voice on one track, drums on another, . . . ) and a classical audio mixing tool [ 501 ] is used to combine and arrange the recorded tracks of the song [ 504 ]. This process is called mixing and is the last step in the creation of a classical musical work of art. In one embodiment, the mixing device can be a software application. The mixing tool can take musical tracks [ 504 ] as input and generate mixed content [ 505 ] as an output. The author [ 507 ] can control the parameters of the mixing tool [ 501 ] to achieve a desired result.
In one embodiment, the mixing parameters can be recorded by the tool [ 501 ] into a mixing configuration file [ 512 ]. The mixing configuration file contains information regarding the way tracks are to be combined.
During the mixing process, the mixing tool allows content transformation through effects plugins [ 502 ] which are designed to modify the resulting product. An effect plugin can be a software or hardware sub-component that is utilized by the mixing tool. It is designed to receive the content [ 506 ] of one or multiple music tracks (channels) from the mixing tool [ 501 ], to modify the content and to return the transformed content to the mixing tool [ 501 ].
In the embodiment shown in FIG. 5 , the content [ 506 ] transferred to and from the plugin is simply the digital representation of the track. A very wide range of effects plugins can be used (volume, tone, panning, delay, echo and others). The plugins are parameterized and exchange control parameters information [ 503 ] with the mixing tool. Thus, the author [ 507 ] is able to control the plugins by changing the control parameters in the mixing software application [ 501 ].
The control parameters [ 503 ] can be seen as attributes of the content [ 506 ] processed by the plugin. Thus, in one embodiment, the variable authoring tool [ 401 ] can be implemented as multiple plugins [ 508 ] where the plugins can be installed between the audio mixing tool [ 501 ] and the classical effect plugin [ 502 ]. The mixing tool may not be aware of the presence of the classical plugin [ 502 ] as the mixing tool may only interact with the variable content plugin [ 508 ]. Each plugin [ 508 ] may rely on the corresponding plugin [ 502 ] for all the content [ 510 ] processing or may operate independently.
In generation of the variable work of art, the controls parameters contain the classical plugin control parameters [ 503 ] plus extra information to define the range of accepted values for the classical parameters [ 503 ] (attribute values). The extra parameters are presented to the author [ 507 ] as standard plugin parameters. The extra parameters define the identification of the controlled plugin [ 502 ], the range of allowed values, the links between values (for musical coherence) and the time at which the variables should change (variable attributes definition [ FIG. 4 : 409 ]). More generally, the variable content plugin [ 508 ] changes the parameters of the controlled classical plugin [ 502 ] according to the desired attribute variation. Examples of attributes (parameters) definitions are:
Volume variation—The author [ 507 ] defines a range of volume values for the track (−90 dB, +2 dB, by steps of 2 dB). In one embodiment, the value can change over time as a function or randomly.
Panoramic movement—The author [ 507 ] defines a track position. The track is split into different output tracks by the plugin [ 502 ]. The groups of values are the relative % of the sound that goes to each output track. In one embodiment, the values changes overtime to generate movement function or randomly.
Tuning—The author [ 507 ] defines a range of tune variation values (+10%, −10%, increments of 1%) that the plugin [ 502 ] will apply to the track. In one embodiment, he value can changes over time as a function or randomly.
3D. During the creation, the author defines a 3D zone where a track can be placed. As for Panoramic movement, the track is split by the plugin [ 502 ]. The values define a window of possible positions for the track. In one embodiment, the panoramic effect can be designed to move in accordance with a function or randomly.
Sound dropping—The author [ 507 ] defines different positions where a sound (sample) could be played as well as the number of times the sound should be played. When needed, the plugin [ 502 ] is ordered by the plugin [ 508 ] to drop a sound into the content [ 506 ]. Additionally, in one embodiment, a sample may be added to the content in accordance with a function or randomly.
Example of linked values:
In an alternate embodiment, the author [ 507 ] can define a set of exclusive tracks. The tracks can be switched at different positions (cross points) during the generation of a unique version. For each cross point the author can define parameters for the crossover method. Additionally, the involved plugins [ 502 ] can have exclusive volume parameters.
The parameters for generating unique versions can also be defined by function calls. When the author [ 507 ] records valid mixing configuration, the extra parameters are saved into a file [ 511 ]. This file represents the variable attribute definition [ FIG. 4 : 409 ]. This information grouped with the original music track [ 504 ] and mixing configuration information [ 512 ] makes the variable song [ 513 ].
For testing purpose, the author [ 507 ] can generate temporary unique outputs [ 505 ] utilizing the function calls. In another embodiment, the author can lock the values of variable attributes to be able to listen to a generated test version [ 505 ] multiple times.
In yet another embodiment, the author [ 507 ] can characterize the combinations of plugin [ 502 ] parameters that will generate a particular type of version (For example ‘cooler’ music is achieved with lower value on volume parameter for drums). This information is saved into the parameter file [ 511 ].
FIG. 6 describes the unique version generation component. In the embodiment shown in FIG. 6 , the unique version generation component [ 601 ] works in conjunction with a classical authoring tool [ 602 ], a user interface tool [ 603 ] and a version delivery tool [ 604 ]. However, in alternate embodiments, the unique version generation component may function independently.
In the embodiment shown in FIG. 6 , the unique version generation component [ 601 ] transforms the variable work of art [ 605 ] into a user [ 606 ] specific unique version [ 607 ]. Once a unique version is requested, the authoring tool [ 602 ] assembles the various parts of the variable work of art and fixes attribute values to generate a unique version.
In the embodiment shown in FIG. 6 , the user interface [ 603 ] is a software application that permits the user to request a “copy” of the work of art and specify a limited number of values for some attributes. In one embodiment, this tool could be an content management tool deployed over Internet. However, in alternate embodiments this tool may be any convenient hardware or software device or a program.
In the embodiment shown in FIG. 6 , the delivery tool [ 604 ] is a software application that will be used to deliver the generated work of art to the user. In one embodiment, this would be a service provided on internet. However, as described above various distribution methods are contemplated, such as custom generation, electronic delivery and web access to the unique version without the ability to download it.
As shown in FIG. 6 , a user [ 606 ] requests a “copy” through the user interface tool and provide identifying information about him or herself. Additionally, the user may provide preferences with regards to attributes that will be included in the user's unique version. The request and identifying information together with any user preferences [ 608 ] are passed to the generation component [ 601 ]. The component [ 601 ] retrieves the variable work [ 605 ] and selects attribute values for the generation of a unique version [ 607 ] that will generate a unique version that conforms with the user's preferences, if possible.
For all the variable attributes, the values are chosen and combined so that:
1. the values of attributes used in the unique version fall within those selected by the author for those attributes
2. the values of attributes used in the unique version respect the defined logical links between values
3. the values of attributes used in the unique version provide sufficient difference form previously generated versions
4. the values of attributes used in the unique version provide a protection against the removal of the uniqueness of the unique version.
5. The values of attributes used in the unique version correspond, if possible, to the user's choices (user preferences)
Items 1 and 2 are accomplished by re-using the information about variable attributes provided in the variable work of art [ 605 ].
Item 3 is attained by choosing different attributes for each generated version. The number of differences is maximized with respect to the number of versions that will be generated. The component [ 601 ] uses the list of already generated versions [ 609 , 610 ] for this work of art [ 605 ]. That information is coming from the right management database [ FIG. 2 : 208 ].
Item 4 is provided by an algorithm of the generation component based on intertwined attributes links and the perceptibility of the differences.
Item 5 is reached by using user preferences [ 608 ] if received through the interface tool [ 603 ].
Once the a value set for the attributes is selected, the corresponding binary sub-streams [ 612 ] are computed with the help of the authoring tool [ 602 ] and combined into the final content [ 607 ] or unique version. In the embodiment shown in FIG. 6 , this generation happens automatically, without the need for the author intervention. However, in alternate embodiment, an intermediate review step may be included prior to generation of the unique version.
In the embodiment shown in FIG. 6 , each generated versions [ 607 ] is different, yet logically coherent and in line with the author's choices. That is, each version is an original work of art. Once a version [ 607 ] is generated, a 1 to 1 link is made between the identification of the user [ 610 ] and the selected attributes of the generated version [ 609 ]. This information can be used to find a user from a version or vice versa. This information is stored in the right management database [ FIG. 2 : 208 ] for later use.
Although the system described above details a one-to-one, relationship between unique versions and users, in alternate embodiments, more that one user may be assigned to a single unique version.
The unique version generation component [ 601 ] also generates reference versions [ 611 ] to be used in the identification processes (A reference version is an internally generated version used as a reference when analysing and comparing version contents)
In another embodiment of the present invention, all the versions [ 607 ] are generated in advance. The user [ 606 ] will only choose a version from the still available version list presented in the user interface tool [ 603 ].
In another embodiment, only some of the variations of the work [ 605 ] are fixed. In this case, the generated version [ 607 ] is still partially variable. The user [ 606 ] can then generate more versions from delivered version [ 607 ]. In that case, the unique part of the generated version must carefully respect the identification constraints to retain its uniqueness.
In another embodiment, a version [ 607 ] can be regenerated in case the version is lost by the user [ 606 ] or during the communication process [ 613 ]. This regeneration process uses the stored selected values [ 609 ] of the original version [ 607 ]. The regenerated version is exactly the same as the lost version. This characteristic is an advantage over encryption systems that do not allow multiple deliveries of the work of art.
FIG. 7 shows an overview of the version generation component applied to digital music. In the music environment, the last step in the creation of a song is the mixing process. Each component of the song is recorded on a different track [ 701 ]. To generate the final song [ 703 ], the tracks are combined in a process called mixing [ 702 ]. Just before being combined, each track goes into a channel [ 704 ] where its content can be transformed (volume, delay, pitch or any other transformation). In the embodiment shown in FIG. 7 , the way transformations will be applied on in a channel is defined by one or more parameters [ 705 ]. The parameters can take a range of values (for example 0 for no transformation to 10 for maximum transformation). For each of those values, the output of the channel [ 704 ] is different, so is the generated song. This process is handled by all the existing mixing tools used in the music industry. The present invention adds to this process a parameter generation component [ 706 ] that will generate values for the channel parameters. Thus, in one embodiment, the generated values can be different for each generated version [ 703 ]. This parameter generation process will respect the range of possible values for the parameters [ 707 ] that have been defined by the author in the variable work of art [ 708 ]. In one embodiment, the parameter value generation component can respect the 5 rules defined in the description of FIG. 6 . However, in alternate embodiments more, fewer or no rules may be specified.
FIG. 8 shows an embodiment of the version generation component applied to digital music. In the configuration shown a ‘CPU time’ audio mixing tool [ 801 ] is used. Mixing tools are used by authors to create their works of art, since the author can listen to the result of the mixing, mixing process happens in ‘real time’. That is, the execution speed is matched with the speed of music playback.
In the embodiment shown in FIG. 8 , for the unique version generation, listening to the result is not needed (no one is listening-however, in alternate embodiments, the unique version may be reviewed prior to delivery), but the version must be mixed in an expedited manner, for a faster delivery. This kind of mixing is called CPU time mixing because the mixing process happens at the maximum speed the CPU is capable of processing the information.
There are multiple audio mixing tools that provide CPU time processing functionality that are known in the art. The architecture for unique version generation is similar to the plugins [ 802 , 803 ] architecture found in FIG. 5 , with the difference that the plugins will also work in CPU time. With this configuration, the variable song [ 809 ] components are split to provide the music tracks [ 804 ] and the mixing configuration [ 805 ] to the mixing tool [ 801 ], and the mixing configuration [ 805 ] and the variable attribute definition [ 806 ] (extra parameters from the creation process plugin [ FIG. 5 : [ 508 ]) to the plugin [ 802 ].
Furthermore, the parameter values [ 807 ] inherent to the currently generated version are provided to the plugin [ 802 ]. The output of the mixing tool is the desired generated version [ 808 ]. This process can be invoked either to deliver a user version or a reference version (internally generated version used when analysing and comparing version contents). In the embodiment shown in FIG. 8 , the parameters [ 807 ] are provided by the invoker. However in alternate embodiments, the parameters may be internally generated.
FIG. 9 shows the version identification component. The actual data sources (internet, intranet, company networks, and the like) [ 901 ] are excellent media for exchanging information. Furthermore, searching and retrieving tools [ 903 ] (like peer-to-peer systems) allows easy publication of works of art. Since those system [ 903 ] tend to provide more and more anonymity, it will soon be impossible to know the source of an exchanged work of art. However, by retrieving works of art [ 902 ] through those systems [ 903 ] and by analysing their content and comparing the retrieved works of art with the attributes of unique versions [ FIG. 6 : 607 ] stored in the rights management database [ FIG. 2 : 208 ], the identification information of the associated user [ FIG. 6 : 606 ] can be found.
In one embodiment, the analysis of suspect digital works of art is conducted in 2 phases. Phase I [ 904 ] roughly analyses the binary stream (content) of a suspected work of art [ 905 ] provided by the scanning tool. The content is checked to determine if it could correspond to a group of unique versions, but not to find a specific version. In one embodiment, phase I [ 904 ] is an automated process that is conducted by a high speed processor and is fast.
Phase 1 selects possible candidates [ 906 ] for a second phase analysis based on comparison with references version [ 908 ]. A reference version is a version generated with neutral values and used as a reference when analysing and comparing version contents. A variable work of art can have a plurality of reference versions [ 908 ]. The analysis and comparison can be performed with the help of a digital analysing tool [ 909 ] that is able to extract meaningful information from a digital content. In one embodiment, a specific digital analysis tool can be adapted to the kind of content [ 910 ] being analyzed.
The second phase analysis [ 907 ] analyzes the digital content [ 906 ] in much more details to identify the exact version that is being improperly distributed. Attribute values associated with actual delivered unique versions [ 911 , 912 ] stored in the rights management database [ FIG. 2 : 208 ] are used in phase II. The analysis is eventually performed by more precise tools [ 914 ] and, in one embodiment, human intervention [ 915 ] is contemplated. Since a user ID [ 912 ] is attached to each version, once a version is clearly identified, the corresponding infringing user ID [ 916 ] can be found in the rights management database [ FIG. 2 : 208 ].
In another embodiment, can use a fingerprint tool to perform the version comparison [ 909 , 914 ]. Fingerprint tools extract a short but very significant ID from the content. The IDs of reference versions [ 908 , 911 ] can be rapidly compared to the IDs of suspect versions [ 905 , 906 ].
FIG. 10 shows a simple example of the creation and usage of a variable work of art related to the music industry. The work of art is song entitled “Thank you”; the author is a famous American artist. The song is divided into one intro, two verses, one chorus, one verse, one chorus, one verse, and two choruses (separated by cross points [ 1001 ]). For the purpose of this example, the content of the song as been recorded on 6 tracks (numbered from 1 to 6):
1. Guitar 1 [1002]
2. Guitar 2 [1003]
3. Guitar 3 [1004]
4. Drums [1005]
5. Voice [1006]
6. Bass [1007]
Tracks 1 to 3 are three different recordings of the guitar. The other tracks are self-explanatory. At the time of mixing, variable effects plugins are added on the tracks. The configuration is done through the mixing application [ FIG. 5 : 501 ], with the variable content plugin [ FIG. 5 : 508 ]. According to the present invention, an example of variable attribute definition [ FIG. 4 : 409 , FIG. 5 : 511 ] for this song would be:
On track 4 (drums) a ‘tuning’ effect is applied. This effect is defined as variable by the author. The accepted values for the effect are values from −10% to +10% by increment of 1% (21 values: −10%, −9%, −8%, . . . , 9%, 10%).
On track 5 (voice) a ‘volume’ effect is applied. The accepted effect values are +5 dB, 0 dB, −10 dB, −30 dB, −¥ dB. This variation is defined as a user's preferences parameter (for example, the user could select −¥ dB to receive a karaoke version of the song).
On tracks 1, 2 and 3, a ‘volume’ effect is applied. The only accepted values for this effect are 0 dB and −¥ dB (Normal or mute). The values are linked so that only one track at a time has a volume of 0 dB. Thus, in one embodiment only 1 track of the 3 is played at any time. However, a cross point [ 1001 ] is defined at the beginning of the verse, chorus and intro (9 cross point). A those points, the values are allowed to changed. The result is that the Guitar is played randomly from each track (one track at a time). Possible groups of values are (track # at 0 dB) {1,1,1,1,1,1,1,1,1}, {1,1,1,1,1,1,1,1,2}, . . . , {3,3,3,3,3,3,3,3,3,3}. For this example, fixed position crossovers are used. The 6 tracks and the variable attribute definition, with their possible values, define the variable work of art [ FIG. 4 : 403 , FIG. 5 : 513 ].
When a version of the song is to be generated, the same mixing tool and plugins are used, but in CPU time. For this simple example, there are 21*3 9 =413,343 unique versions that can be generated from this variable work of art (Since the volume level for the voice is selected by the user, it is not taken into account for uniqueness). For the sake of this example, the parameter values generation [ FIG. 7 : 706 ] sequentially generate all the possible unique versions, numbering them from 1 to 413,343 and link the versions to the user numbers.
In an alternate embodiment, the algorithm used for the value generation is much more elaborate. When the values for the version are fixed, the song is generated, stored in a file and delivered to the user through, for example, the internet.
FIG. 11 presents a simple example of a user interface for the selection of a musical work of art. In this example, an interface is shown to the user who want to download a song via the internet. Through this interface the user can view the selected song [ 1101 ]. The user has the opportunity to select the digital audio format [ 1102 ] of the song that will be delivered. Additionally, the user can select preferences about the volume of the voice in the song with the control [ 1103 ]. In alternate embodiments significantly more controls may be added that are related to specific variable attributes.
In the embodiment shown in FIG. 11 , the user can preview the unique version by triggering the button [ 1105 ] to listen to a low quality version of the beginning or some other portion of the song. If the user is satisfied with the selection, the user can download the song by triggering the button [ 1104 ]. In one embodiment, at the time the button [ 1104 ] is triggered, the unique version generation tool is invoked with the parameters selected (volume level of the voice). The unique version is generated at that time and then the unique version of the work of art is delivered to the user.
In alternate embodiments, this user interface can be any convenient interface. In one embodiment, it may be a physical device directly associated with a CD burning device that can be used to create a custom CD containing the user's unique version. In alternate embodiments, the user interface may be virtual and implemented over the internet or any other convenient communication mechanism.
|
What is disclosed is a method of creating and distributing works of art that takes advantage of the possibilities of duplication and distribution offered by modern computing and telecommunication, while preserving the rights of the authors. Unique versions of a work of art are generated from a source variable work of art such that each unique version is perceptibly different from all other unique versions of the work of art. Unique versions can then be distributed to specific users so that specific unique versions are associated with specific unique versions. In the event a unique version is improperly shared, the user associated with the improperly shared unique version can be identified.
| 6
|
The present application is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 12/267,457 filed Nov. 7, 2008, currently pending, which is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 10/461,451 filed Jun. 16, 2003, now U.S. Pat. No. 7,533,548 B2, which claims priority to Korean Patent Application No. 85521/2002, filed Dec. 27, 2002, the entire contents of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a drum type washing machine, and more particularly, to a drum type washing machine which can maximize a capacity of a drum without changing an entire size of a washing machine.
2. Description of the Related Art
FIG. 1 is a side sectional view showing a drum type washing machine in accordance with the conventional art, FIG. 2 is a front sectional view showing the drum type washing machine in accordance with the conventional art.
The conventional drum type washing machine comprises: a cabinet 102 for forming an appearance; a tub 104 arranged in the cabinet 102 for storing washing water; a drum 106 rotatably arranged in the tub 104 for washing and dehydrating laundry; and a driving motor 110 positioned at a rear side of the tub 104 and connected to the drum 106 by a driving shaft 108 thus for rotating the drum 106 .
An inlet 112 for inputting our outputting the laundry is formed at the front side of the cabinet 102 , and a door 114 for opening and closing the inlet 112 is formed at the front side of the inlet 112 .
The tub 104 of a cylindrical shape is provided with an opening 116 at the front side thereof thus to be connected to the inlet 112 of the cabinet 102 , and a balance weight 118 for maintaining a balance of the tub 104 and reducing vibration are respectively formed at both sides of the tub 104 .
Herein, a diameter of the tub 104 is installed to be less than a width of the cabinet 102 by approximately 30˜40 mm with consideration of a maximum vibration amount thereof so as to prevent from being contacted to the cabinet 102 at the time of the dehydration.
The drum 106 is a cylindrical shape of which one side is opened so that the laundry can be inputted, and has a diameter installed to be less than that of the tub 104 by approximately 15˜20 mm in order to prevent interference with the tub 104 since the drum is rotated in the tub 104 .
A plurality of supporting springs 120 are installed between the upper portion of the tub 104 and the upper inner wall of the cabinet 102 , and a plurality of dampers 122 are installed between the lower portion of the tub 104 and the lower inner wall of the cabinet 102 , thereby supporting the tub 104 with buffering.
A gasket 124 is formed between the inlet 112 of the cabinet 102 and the opening 116 of the tub 104 so as to prevent washing water stored in the tub 104 from being leaked to a space between the tub 104 and the cabinet 102 . Also, a supporting plate 126 for mounting the driving motor 110 is installed at the rear side of the tub 104 .
The driving motor 110 is fixed to a rear surface of the supporting plate 126 , and the driving shaft 108 of the driving motor 110 is fixed to a lower surface of the drum 106 , thereby generating a driving force by which the drum 106 is rotated.
In the conventional drum type washing machine, the diameter of the tub 104 is installed to be less than the width of the cabinet 102 with consideration of the maximum vibration amount so as to prevent from being contacted to the cabinet 102 , and the diameter of drum 106 is also installed to be less than that of the tub 104 in order to prevent interference with the tub 104 since the drum is rotated in the tub 104 . According to this, so as to increase the diameter of the drum 106 which determines a washing capacity, a size of the cabinet 102 has to be increased.
Also, since the gasket 124 for preventing washing water from being leaked is installed between the inlet 112 of the cabinet 102 and the opening 116 of the tub 104 , a length of the drum 106 is decreased as the installed length of the gasket 124 . According to this, it was difficult to increase the capacity of the drum 106 .
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a drum type washing machine which can increase a washing capacity without changing an entire size thereof, in which a cabinet and a tub is formed integrally and thus a diameter of a drum can be increased without increasing a size of the cabinet.
Another object of the present invention is to provide a drum type washing machine which can increase a washing capacity by increasing a length of a drum without increasing a length of a cabinet, in which the cabinet and a tub are formed integrally and thus a location of a gasket is changed.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a drum type washing machine comprising: a cabinet for forming an appearance; a tub fixed to an inner side of the cabinet and for storing washing water; a drum rotatably arranged in the tub for washing and dehydrating laundry; and a driving motor positioned at the rear side of the drum for generating a driving force by which the drum is rotated.
The tub is a cylindrical shape, and a front surface thereof is fixed to a front inner wall of the cabinet.
Both sides of the tub are fixed to both sides inner wall of the cabinet.
A supporting plate for mounting the driving motor is located at the rear side of the tub, and a gasket hermetically connects the supporting plate and the rear side of the tub, in which the gasket is formed as a bellows and has one side fixed to the rear side of the tub and another side fixed to an outer circumference surface of the supporting plate.
A supporting unit for supporting an assembly composed of the drum, the driving motor, and the supporting plate with buffering is installed between the supporting plate and the cabinet.
The supporting unit comprises: a plurality of upper supporting rods connected to an upper side of the supporting plate towards an orthogonal direction and having a predetermined length; buffering springs connected between the upper supporting rods and an upper inner wall of the cabinet for buffering; a plurality of lower supporting rods connected to a lower side of the supporting plate towards an orthogonal direction and having a predetermined length; and dampers connected between the lower supporting rods and a lower inner wall of the cabinet for absorbing vibration.
The drum is provided with a liquid balancer at a circumference of an inlet thereof for maintaining a balance when the drum is rotated.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a side sectional view showing a drum type washing machine in accordance with the conventional art;
FIG. 2 is a front sectional view showing the drum type washing machine in accordance with the conventional art;
FIG. 3 is a side sectional view showing a drum type washing machine according to one embodiment of the present invention;
FIG. 4 is a front sectional view showing the drum type washing machine according to one embodiment of the present invention;
FIG. 5 is a lateral view showing a state that a casing of the drum type washing machine according to one embodiment of the present invention is cut;
FIG. 6 is a front sectional view of a drum type washing machine according to a second embodiment of the present invention;
FIG. 7 is a front sectional view showing a drum type washing machine according to a third embodiment of the present invention;
FIG. 8 is a longitudinal sectional view of the drum type washing machine according to the third embodiment of the present invention; and
FIG. 9 is a rear sectional view showing the drum type washing machine according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 3 is a side sectional view showing a drum type washing machine according to one embodiment of the present invention, and FIG. 4 is a front sectional view showing the drum type washing machine according to one embodiment of the present invention.
The drum type washing machine according to one embodiment of the present invention comprises: a cabinet 2 for forming an appearance of a washing machine; a tub 4 formed integrally with the cabinet 2 and for storing washing water; a drum 6 rotatably arranged in the tub 4 for washing and dehydrating laundry; and a driving motor 8 positioned at the rear side of the drum 6 for generating a driving force by which the drum 6 is rotated.
The cabinet 2 is a rectangular parallelpiped, and an inlet 20 for inputting and outputting laundry is formed at the front side of the cabinet 2 and a door 10 for opening and closing the inlet 20 is formed at the inlet 20 .
The tub 4 is formed as a cylinder shape having a predetermined diameter in the cabinet 2 , and the front side of the tub 4 is fixed to the front inner wall of the cabinet 2 or integrally formed at the front inner wall of the cabinet 2 . Both sides of the tub 4 are contacted to both sides inner wall of the cabinet 2 or integrally formed with both sides inner wall of the cabinet 2 thus to be prolonged.
Herein, since both sides of the tub 4 are contacted to both sides inner wall of the cabinet 2 , a diameter of the tub 4 can be increased.
Also, the supporting plate 12 is positioned at the rear side of the tub 4 and the gasket 14 is installed between the supporting plate 12 and the rear side of the tub 4 , thereby preventing washing water filled in the tub 4 from being leaked.
The gasket 14 is formed as a bellows of a cylinder shape and has one side fixed to the rear side of the tub 4 and another side fixed to an outer circumference surface of the supporting plate 12 .
The supporting plate 12 is formed as a disc shape, the driving motor 8 is fixed to the rear surface thereof, and a rotation shaft 16 for transmitting a rotation force of the driving motor 8 to the drum 6 is rotatably supported by the supporting plate 12 . Also, a supporting unit for supporting the drum 6 with buffering is installed between the supporting plate 12 and the inner wall of the cabinet 2 .
The supporting unit comprises: a plurality of upper supporting rods 22 connected to an upper side of the supporting plate 12 and having a predetermined length; buffering springs 24 connected between the upper supporting rods 22 and an upper inner wall of the cabinet 2 for buffering; a plurality of lower supporting rods 26 connected to a lower side of the supporting plate 12 and having a predetermined length; and dampers 28 connected between the lower supporting rods 26 and a lower inner wall of the cabinet 2 for absorbing vibration.
Herein, the buffering springs 24 and the dampers 28 are installed at a center of gravity of an assembly composed of the drum 6 , the supporting plate 12 , and the driving motor 8 . That is, the upper and lower supporting rods 22 and 26 are prolonged from the supporting plate 12 to the center of gravity of the assembly, the buffering springs 24 are connected between an end portion of the upper supporting rod 22 and the upper inner wall of the cabinet 2 , and the dampers 28 are connected between an end portion of the lower supporting rod 26 and the lower inner wall of the cabinet 2 , thereby supporting the drum 6 at the center of gravity.
A diameter of the drum 6 is installed in a range that the drum 6 is not contacted to the tub 4 even when the drum 6 generates maximum vibration in order to prevent interference with the tub 4 at the time of being rotated in the tub 4 .
Operations of the drum type washing machine according to the present invention are as follows.
If the laundry is inputted into the drum 6 and a power switch is turned on, washing water is introduced into the tub 6 . At this time, the front side of the tub 6 is fixed to the cabinet 2 and the gasket 14 is connected between the rear side of the tub 6 and the supporting plate 12 , thereby preventing the washing water introduced into the tub 6 from being leaked outwardly.
If the introduction of the washing water is completed, the driving motor 8 mounted at the rear side of the supporting plate 12 is driven, and the drum 6 connected with the driving motor 8 by the rotation shaft 16 is rotated, thereby performing washing and dehydration operations. At this time, the assembly composed of the drum 6 , the driving motor, and the supporting plate 12 is supported by the buffering springs 24 and the dampers 28 mounted between the supporting plate 12 and the inner wall of the cabinet 20 .
FIG. 6 is a front sectional view of a drum type washing machine according to a second embodiment of the present invention.
The drum type washing machine according to the second embodiment of the present invention has the same construction and operation as that of the first to embodiment except a shape of the tub.
That is, the tub 40 according to the second embodiment has a straight line portion 42 with a predetermined length at both sides thereof. The straight line portion 42 is fixed to the inner wall of both sides of the cabinet 2 , or integrally formed at the wall surface of both sides of the cabinet 2 .
Like this, since the tub 40 according to the second embodiment has both sides fixed to the cabinet 2 as a straight line form, the diameter of the tub 40 can be increased. Accordingly, the diameter of the drum 6 arranged in the tub 40 can be more increased.
FIG. 7 is a front sectional view showing a drum type washing machine according to a third embodiment of the present invention, FIG. 8 is a longitudinal sectional view of the drum type washing machine according to the third embodiment of the present invention, and FIG. 9 is a rear sectional view showing the drum type washing machine according to the third embodiment of the present invention.
The drum type washing machine according to the third embodiment of the present invention comprises: a cabinet 2 for forming an appearance of a washing machine; a tub 50 formed integrally with the cabinet 2 and for storing washing water; a drum 6 rotatably arranged in the tub 50 for washing and dehydrating laundry; and a supporting unit positioned at the rear side of the tub 50 and arranged between the supporting plate 12 to which the driving motor 8 is fixed and the cabinet 2 for supporting the drum 6 with buffering.
The tub 50 is composed of a first partition wall 52 fixed to the upper front inner wall and both sides inner wall of the cabinet 2 ; and a second partition wall 54 integrally fixed to the lower front inner wall and both sides inner wall of the cabinet 2 .
The first partition wall 52 of a flat plate shape is formed at the upper side of the cabinet 2 in a state that the front side and both sides are integrally formed at the inner wall of the cabinet 2 or fixed thereto. Also, the second partition wall 54 of a semi-circle shape is formed at the lower side of the cabinet 2 in a state that the front side and both sides are integrally formed at the inner wall of the cabinet 2 or fixed thereto.
The supporting unit comprises: a plurality of upper supporting rods 56 connected to the upper side of the supporting plate 12 and having a predetermined length; buffering springs 58 connected between the upper supporting rods 56 and the upper inner wall of the cabinet 2 for buffering; a plurality of lower supporting rods 60 connected to the lower side of the supporting plate 12 and having a predetermined length; and dampers 62 connected between the lower supporting rods 60 and the lower inner wall of the cabinet 2 for absorbing vibration.
Herein, the upper supporting rods 56 are bent to be connected to the upper side of the supporting plate 12 and positioned at the upper side of the first partition wall 52 , and the buffering springs 58 are connected to the end portion of the upper supporting rods 56 . Also, the lower supporting rods 60 are bent to be connected to the lower side of the supporting plate 12 and positioned at the lower side of the second partition wall 54 , and the dampers 62 are connected to the end portion of the lower supporting rods 56 .
In the drum type washing machine according to the present invention, a size of the drum can be maximized by fixing the tub in the cabinet, thereby increasing washing capacity of the drum without increasing a size of the cabinet.
Also, since the front surface of the tub is integrally formed at the inner wall of the cabinet and the gasket is installed between the rear surface of the tub and the supporting plate, a length of the drum can be increased and thus the washing capacity of the drum can be increased.
As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.
|
A drum type washing machine is provided. The drum type washing machine may include a cabinet, a tub fixed to an inner side of the cabinet, a drum rotatably arranged in the tub, and a driving motor positioned at a rear side of the drum for generating a driving force that rotates the drum. The washing machine may also include a supporting plate to rotatably support a rotational shaft extending between the motor and the drum, and a plurality of supporters connected between the supporting plate and the cabinet. Such an arrangement may increase washing capacity by increasing a diameter of the drum without increasing an external size of the cabinet.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority of Korean Patent Application No. 10-2009-0123272 filed on Dec. 11, 2009, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a motor, and more particularly, to a motor capable of having a control function for low-speed rotation by including an encoder on the bottom surface of a ring member mounted on a rotor case, and an encoder sensor located corresponding to the encoder.
2. Description of the Related Art
In general, a spindle motor installed inside an optical disc drive rotates a disc so that an optical pickup mechanism can read data written to the disc.
Recently, an optical disc drive equipped with a LightScribe function has been increasingly released onto the market. Here, the LightScribe function allows users to print letters (characters) or images freely on the upper side of a disc such as a DVD, a CD or the like.
According to the related art, only LightScribe discs that support the LightScribe function by having a printed encoder generating an FG pulse for low-speed control are able to be used in order to implement the LightScribe function. Here, typical discs for recording cannot be used in realizing the LightScribe function.
That is, in order to use the LightScribe function, a spindle motor needs to rotate at a low speed of 40 rpm to 300 rpm or less. Thus, an encoder generating a separate FG pulse is printed on the side of a disc, since the FG pulse of the spindle motor itself, cannot be used for the LightScribe function.
However, the use of such LightScribe discs has limitations in that the discs are costly and are not easy to buy.
In addition, since LightScribe printing is performed on the opposite side to the read/write-side of a disc, the LightScribe disc is repetitively taken out from and put back into a chucking device. This may damage an encoder printed on the LightScribe disc.
Further, the encoder, when printed on a disc in a non-uniform manner, fails to perform precise low-speed control and impairs printing quality.
SUMMARY OF THE INVENTION
An aspect of the present invention provides a motor capable of having a control function for low-speed rotation (hereinafter “low-speed rotation control”) by including an encoder on the bottom surface of a ring member mounted on a rotor case, and an encoder sensor located corresponding to the encoder.
According to an aspect of the present invention, there is provided a motor including: a rotor case; a ring member mounted on the rotor case and including an encoder on a bottom surface thereof extending outside of the rotor case; and an encoder sensor detecting speed information of the rotor case from the encoder such that the rotor case rotates at low speeds enabling a LightScribe operation.
The ring member may be fixed to a chucking device on which a disc is mounted.
The encoder may be inkjet-printed on the bottom surface of the ring member.
The encoder may be provided as an adhesive film and bonded with the bottom surface of the ring member.
The encoder may be formed uniformly on the bottom surface of the ring member.
The ring member may include, on a top surface thereof, a disc mounting portion on which a disc is mounted.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, 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:
FIG. 1 is a schematic plan view illustrating a motor according to an exemplary embodiment of the present invention;
FIG. 2 is a schematic perspective view illustrating a motor according to an exemplary embodiment of the present invention;
FIG. 3 is a cross-sectional view illustrating a motor according to an exemplary embodiment of the present invention;
FIG. 4 is a schematic view illustrating the bottom of a ring member according to an exemplary embodiment of the present invention; and
FIGS. 5A and 5B are schematic views illustrating how an encoder is formed on the bottom surface of a ring member according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. While those skilled in the art could readily devise many other varied embodiments that incorporate the teachings of the present invention through the addition, modification or deletion of elements, such embodiments may fall within the scope of the present invention.
The same or equivalent elements are referred to by the same reference numerals throughout the specification.
FIG. 1 is a schematic plan view illustrating a motor according to an exemplary embodiment of the present invention. FIG. 2 is a schematic perspective view illustrating a motor according to an exemplary embodiment of the present invention. FIG. 3 is a cross-sectional view illustrating a motor according to an exemplary embodiment of the present invention. FIG. 4 is a schematic view illustrating the bottom of a ring member according to an exemplary embodiment of the present invention.
Referring to FIGS. 1 through 4 , a motor 10 , according to an exemplary embodiment of the present invention, may include a rotor case 32 , a ring member 20 and an encoder sensor 25 .
As for the internal construction of the motor 10 , the motor 10 may include a base plate 70 , a rotor 30 , a stator 40 , a bearing assembly 60 , and a chucking device 80 .
The base plate 70 serves as a support that supports the stator 40 . A flexible circuit board 72 may be formed on the base plate 70 . The flexible printed circuit board 72 may be provided with a circuit pattern applying power to the motor 10 .
The encoder sensor 25 is a data detector that receives information regarding the rotation of a disc D. Notably, the encoder sensor 25 may detect speed information of the rotor case 32 from an encoder formed on the ring member 20 .
The rotor 30 includes a rotor case 32 having a cup shape. The rotor case 32 includes a ring-shaped magnet 35 provided on the inner circumferential portion of the rotor case 32 and corresponding to a coil 46 of the stator 40 . The magnet 35 is a permanent magnet that generates a predetermined level of magnetic force as N poles and S poles are alternately magnetized in a circumferential direction.
The rotor case 32 includes a rotor hub 34 press-fitted to a shaft 62 , and a magnet coupling portion 36 having an inner surface on which the ring-shaped magnet 35 is disposed.
The rotor hub 34 is bent in an axial direction along the upper portion of the shaft 62 in order to maintain an unmating force with the shaft 62 . The chucking device 80 on which a disc D is mounted is coupled with the outer surface of the rotor hub 34 .
The stator 40 includes a support portion 42 supported from the outside of a sleeve 66 , a plurality of cores 44 fixed to the support portion 42 , and a winding coil 46 wound around the cores 44 .
The magnet 35 , provided on the inner surface of the magnet coupling portion 36 , opposes the winding coil 46 . The rotor 30 is rotated by the electromagnetic interaction between the magnet 35 and the winding coil 46 .
Further, the bearing assembly 60 is disposed inside of the support portion 42 of the stator 40 , and includes the shaft 62 supporting the rotation of the rotor 30 , and the sleeve 66 in which the shaft 60 is rotatably installed.
Terms regarding directions are defined as follows: the axial direction refers to a vertical direction with reference to the shaft 62 in FIG. 1 , and outer and inner diameter directions refer to a direction toward the outer edge of the rotor 20 from the shaft 62 , and a direction toward the center of shaft 62 from the outer edge of the rotor 30 , respectively.
The chucking device 80 is coupled and fixed to one end portion of the rotor hub 34 , and allows for the detachable mounting of a disc thereon. The chucking device 80 includes a chuck base 82 , a spring 84 , and a chuck chip 86 .
A center hole is formed in the center of the chuck base 82 . The one end portion of the rotor hub 34 may be inserted into the center hole and coupled with the motor 10 .
The chuck chip 86 is received in the chuck base 82 , and may protrude toward the outside of the chuck base 82 . The spring 84 may be provided to elastically support the chuck chip 82 in an outward direction of the chuck base 82 , thereby allowing the chuck chip 82 to protrude to the outside of the chuck base 82 .
The ring member 20 may be mounted on the top surface of the rotor case 32 by being inserted below the chucking device 80 in the axial direction. That is, the ring member 20 may be fixed to the chucking device 80 .
A disc D may be mounted on the top surface of the ring member 20 . A disc mounting portion 24 may be provided on the top surface of the ring member 20 such that the disc D can be mounted stably thereon.
An encoder 22 may be formed on a portion of the bottom surface of the rotor case 32 extending outside of the rotor case 32 in the outer diameter direction.
The encoder 22 is formed by alternating reflective and non-reflective patterns on the bottom surface of the ring member 20 along the circumference of the ring member 20 , such that the encoder 22 reflects light coming out of the encoder sensor 25 to allow the encoder sensor 25 to receive the reflected light.
The encoder sensor 25 absorbs light reflected from the encoder 22 to thereby obtain a pulse signal. The pulse signal is transferred to a controller (not shown) that controls a speed of the motor 10 , and the controller performs rotation control for a low speed of the motor 10 .
FIGS. 5A and 5B are schematic views illustrating how the encoder 22 is formed on the bottom surface of the ring member 20 according to an exemplary embodiment of the present invention.
From FIGS. 5A and 5B , it can be seen how the encoder 22 is formed on the bottom surface of the ring member 20 .
Referring to FIG. 5A , the encoder 22 is inkjet-printed on the bottom surface of the ring member 20 by using an inkjet printer 100 . Referring to FIG. 5B , the encoder 22 is provided in the form of an adhesive film 200 and is bonded with the bottom surface of the ring member 20 .
The motor, according to the present invention, eliminates the need for LightScribe discs, and is capable of low-speed control required for the LightScribe function even when typical discs for recording are used.
Also, the encoder, formed on the ring member, is not damaged even if a disc is repetitively taken out from and put back into the chucking device.
Since the encoder is printed uniformly, precise low-speed control is ensured, and printing quality is improved.
As set forth above, according to the motor according to exemplary embodiments of the invention, LightScribe discs are not necessary, and low-speed control required to implement the LightScribe function can be performed even when typical discs for recording are used.
Since the encoder is formed on the ring member, the encoder is prevented from being damaged even if a disc is repetitively placed in and out of the chucking device.
The uniform encoder print state allows for precise low-speed control, as well as the enhancement of printing quality.
While the present invention has been shown and described in connection with the exemplary embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims.
|
Disclosed is a motor. The motor includes a rotor case, a ring member mounted on the rotor case and including an encoder on a bottom surface thereof extending outside of the rotor case, and an encoder sensor detecting speed information of the rotor case from the encoder such that the rotor case rotates at low speeds enabling a LightScribe operation.
| 7
|
This is a division of application Ser. No. 07/096,953, filed Sept. 15, 1987, now U.S. Pat. No. 4,832,864.
FIELD OF THE INVENTION
The invention relates to the manufacture of clothing from dyed cellulosic fabrics. More particularly, the invention relates to pumice-free compositions and processes used in the manufacture of a clothing item, preferably from denim fabric dyed with indigo, that can produce in a clothing item a distressed, "used and abused" appearance that is virtually indistinguishable from the appearance of "stone washed" clothing items made by traditional pumice processing.
BACKGROUND OF THE INVENTION
Clothing made from cellulosic fabrics such as cotton and in particular indigo dyed denim fabrics have been common items of clothing for many years. Such clothing items are typically sold after they are sewn from sized and cut cloth. Such clothes and particularly denim clothing items are stiff in texture due to the presence of sizing compositions used to ease manufacturing, handling and assembling of the clothing items and typically have a fresh dark dyed appearance. After a period of wear, the clothing items, particularly denim, can develop in the clothing panels and on seams, localized areas of variations, in the form of a lightening, in the depth or density of color. In addition a general fading of the clothes can often appear in conjunction with the production of a "fuzzy" surface, some pucker in seams and some wrinkling in the fabric panels. Additionally, after laundering, sizing is substantially removed from the fabric resulting in a softer feel. In recent years such a distressed or "used and abused" look has become very desirable, particularly in denim clothing, to a substantial proportion of the public. To some extent, a limited pre-worn appearance, which has a uniform color density different than the variable color density in the typical stone-washed item, can be produced through prewashing or preshrinking processes.
The preferred methods for producing the distressed "used and abused" look involve stone washing of a clothing item. Stone washing comprises contacting a denim clothing item or items in large tub equipment with pumice stones having a particle size of about 1 to 10 inches and with smaller pumice particles generated by the abrasive nature of the process. Typically the clothing item is tumbled with the pumice while wet for a sufficient period such that the pumice abrades the fabric to produce in the fabric panels, localized abraded areas of lighter color and similar lightened areas in the seams. Additionally the pumice softens the fabric and produces a fuzzy surface similar to that produced by the extended wear of the fabric.
The 1 to 10 inch pumice stones and particulate pumice abrasion by-products can cause significant processing and equipment problems. Particulate pumice must manually be removed from processed clothing items (de-rocking) because they tend to accumulate in pockets, on interior surfaces, in creases and in folds. In the stone washing machine, the stones can cause overload damage to electric motors, mechanical damage to transport mechanisms and washing drums and can significantly increase the requirements for machine maintenance. The pumice stones and particulate material can clog machine drainage passages and can clog drains and sewer lines at the machine site. Further, the abraded pumice can clog municipal sewer lines, can damage sewage processing equipment, and can significantly increase maintenance required in municipal sewage treatment plants. These problems can add significantly to the cost of doing business and to the purchase price of the goods.
In view of the problems of pumice in stone washing, increasing attention has been directed to finding a replacement for stone washing in garment manufacture (see the Wall Street Journal, May 9, 1987, p. 1.). One avenue of investigation involves using a replacement stone such as a synthetic abrasive. In particular, ceramic balls such as those used in ball mills and irregular hard rubber pieces, which can be used without producing abraded by-products, have been experimented with in stone washing processes. These materials reduce the unwanted effects caused by particulate by-product pumice but do not significantly reduce machine damage caused by stones or the required maintenance on stone-containing laundry tubs. As a result, significant attention has been directed to producing a stone-free or pumice-free "stone washed" process that can produce a stone-washed denim look.
One disadvantage in pumice processing is that pumice cannot be used in tunnel washers, the largest commercial washing machines. Pumice cannot be circulated through the tunnel machines due to machine internal geometry. The use of larger-scale tunnel washers could significantly increase the productivity of the processes with the use of a stone or pumice-free composition that produces a genuine "stone-washed" look.
Barbesgarrd et al, U.S. Pat. No. 4,435,307 teach a specific cellulase enzyme that can be obtained from Humicola insolens which can be used in soil removing detergent compositions. Martin et al, European patent application Ser. No. 177,165 teach fabric washing compositions containing a surfactant, builders, and bleaches in combination with a cellulase composition and a clay, particularly a smectite clay. Murata et al, U.K. patent application Ser. No. 2,095,275 teach enzyme containing detergent compositions comprising an alkali cellulase and typical detergent compositions in a fully formulated laundry preparation. Tai, U.S. Pat. No. 4,479,881 teaches an improved laundry detergent containing a cellulase enzyme in combination with a tertiary amine in a laundry preparation. Murata et al, U.S. Pat. No. 4,443,355 teach laundry compositions containing a cellulase from a cellulosmonas bacteria. Parslow et al, U.S. Pat. No. 4,661,289 teaches fabric washing and softening compositions containing a cationic softening agent and a fungal cellulase in conjunction with other typical laundry ingredients. Suzuki, U.K. patent application Ser. No. 2,094,826 teaches detergent laundry compositions containing a cellulase enzyme.
Dyed cellulosic clothing (such as denim) have been treated with desizing enzymes, detergents, bleaches, sours and softeners in prewashing and preshrinking processes. These variations are not intended to and do not duplicate the "stone-washed " look. A stone or pumice-free "stone-washed" process that produces the true stone-washed look has yet to be developed.
BRIEF DESCRIPTION OF THE INVENTION
We have found that the "stone washed" appearance that takes the form of variations in local color density in fabric panels and seams of dyed cellulosic fabric, particularly in denim, clothing items can be substantially obtained using a stone or pumice-free process in which the clothing items are mechanically agitated in a tub with an aqueous composition containing amounts of a cellulase enzyme that can degrade the cellulosic fabric and can release the fabric dye or dyes.
The aqueous treatment compositions are obtained by diluting a novel "stone-wash" liquid or solid concentrate consisting essentially of a cellulase enzyme and a diluent such as a compatible surfactant composition, a non-aqueous solvent or a solid-forming agent capable of suspending the cellulase without significant loss of enzymatic activity.
The use of cellulase enzyme preparations is known in laundry cleaning or detergent compositions. Such detergent compositions that are designed for soil removal typically contain surfactants (typically anionic), fillers, brighteners, clays, cellulase and other enzymes (typically proteases, lipases or amylases) and other laundry components to provide a full functioning laundry detergent preparation. The cellulase enzymes in such laundry preparations are typically used (at a concentration less than 500 to 900 CMC units per liter of wash liquor) for the purpose of removing surface fibrils or particles produced by fabric wear which tend to give the fabric a used or faded appearance. The cellulase enzymes in combination with the surfactants used in common laundry compositions for cleaning apparently can remove particulate soil and can restore the new appearance of clothing items. Such compositions are not known to introduce, into clothing, areas of variation in color density which can generally be undesirable in the laundry processing.
For the purpose of this invention, the terms stone-washed appearance and variations in local color depth or density in fabric materials are synonymous. The stone-washed appearance is produced in standard processing in fabric through an abrasion process wherein pumice apparently removes surface bound dye in a relatively small portion of the surface of a garment. Such an abraded area varies from the surrounding color or depth density and is substantially lighter in color. The production of such relatively small local areas of lightness or variation in color depth or density is the goal of both pumice containing stone washing processes in the prior art and Applicant's stone-free chemical treatment methods and compositions.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a graph demonstrating the similarity in visual spectrophotometric character of authentic stone-washed jeans when compared to jeans produced by the compositions and methods of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The stone free "stone washed" methods of the invention involve contacting clothing items or denim fabric with an aqueous solution containing a cellulase enzyme composition and agitating the treated fabric for a sufficient period of time to produce localized variations in color density in the fabric. The fabric items can be wet by the solution and agitated apart from the bulk aqueous liquors or can be agitated in the liquor. Typically the aqueous solution contains the cellulase enzyme and a cellulase compatible surfactant that increases the wetting properties of the aqueous solution to enhance the cellulase effect.
The aqueous treatment solutions are typically prepared from a liquid or solid concentrate composition which can be diluted with water at appropriate dilution ratios to formulate the aqueous treatment. The "stone wash concentrate" compositions typically contain the cellulase enzyme and a diluent such as a compatible surfactant, a non-aqueous solvent or a solid-forming agent that can produce in a treatment liquor a suspension of the cellulase enzyme without significant enzyme activity loss.
The solid concentrate compositions typically comprise a suspension of the cellulase enzyme composition in a solid matrix. The solid matrices can be inorganic or organic in nature. The solid concentrates can take the form of large masses of solid concentrate or can take the form of granular or pelletized composition. The solid concentrates can be used in commercial processes by placing the solid concentrate materials in dispensers that can direct a dissolving spray of water onto the solid or pellet material thereby creating a concentrated solution of the material in water which is then directed by the dispenser into the wash liquors contained in the commercial drum machines.
CELLULASE ENZYME
Enzymes are a group of proteins which catalyze a variety of typically biochemical reactions. Enzyme preparations have been obtained from natural sources and have been adapted for a variety of chemical applications. Enzymes are typically classified based on the substrate target of the enzymatic action. The enzymes useful in the compositions of this invention involve cellulase enzymes (classified as I.U.B. No. 3.2.1.4., EC numbering 1978). Cellulase are enzymes that degrade cellulose by attacking the C(1→4) (typically beta) glucosidic linkages between repeating units of glucose moieties in polymeric cellulosic materials. The substrate for cellulase is cellulose, and cellulose derivatives, which is a high molecular weight natural polymer made of polymerized glucose. Cellulose is the major structural polymer of plant organisms. Additionally cellulose is the major structural component of a number of fibers used to produce fabrics including cotton, linen, jute, rayon and ramie, and others.
Cellulases are typically produced from bacterial and fungal sources which use cellulase in the degradation of cellulose to obtain an energy source or to obtain a source of structure during their life cycle. Examples of bacteria and fungi which produce cellulase are as follows: Bacillus hydrolyticus, Cellulobacillus mucosus, cellulobacillus myxogenes, Cellulomonas sp., Cellvibrio fulvus, Celluvibrio vulgaris, Clostridium thermocellulaseum, Clostridium thermocellum, Corynebacterium sp., Cytophaga globulosa, Pseudomonas fluoroescens var. cellulosa, Pseudomonas solanacearum, Bacterioides succinogenes, Ruminococcus albus, Ruminococcus flavefaciens, Sorandium composition, Butyrivibrio, Clostridium sp., Xanthomonas cyamopsidis, Sclerotium bataticola, Bacillus sp., Thermoactinomyces sp., Actinobifida sp., Actinomycetes sp., Streptomyces sp., Arthrobotrys superba, Aspergillus aureus, Aspergillus flavipes, Aspergillus flavus, Aspergillus fumigatus, Aspergillus fuchuenis, Aspergillus nidulans, Aspergillus niger, Aspergillus oryzae, Aspergillus rugulosus, Aspergillus sojae, Aspergillus sydwi, Aspergillus tamaril, Aspergillus terreus, Aspergillus unguis, Aspergillus ustus, Takamine-Cellulase, Aspergillus saitoi, Botrytis cinerea, Botryodipiodia theobromae, Cladosporium cucummerinum, Cladosporium herbarum, Coccospora agricola, Curvuiaria lunata, Chaetomium thermophile var. coprophile, Chaetomium thermophile var. dissitum, Sporotrichum thermophile, Taromyces amersonii, Thermoascus aurantiacus, Humicola grisea var. thermoidea, Humicola insolens, Malbranchea puichella var. sulfurea, Myriococcum albomyces, Stilbella thermophile, Torula thermophila, Chaetomium globosum, Dictyosteiium discoideum, Fusarium sp., Fasarium bulbigenum, Fusarium equiseti, Fusarium lateritium, Fusarium lini, Fusarium oxysporum, Fusarium vasinfectum, Fusarium dimerum, Fusarium japonicum, Fusarium scirpi, Fusarium solani, Fusarium moniliforme, Fusarium roseum, Helminthosporium sp., Memnoniella echinata, Humicola fucoatra, Humicola grisea, Monilia sitophila, Monotospora brevis, Mucor pusillus, Mycosphaerella citrulina, Myrothecium verrcaria, Papulaspore sp., Penicillium sp., Penicillium capsulatum, Penicillium chrysogenum, Penicillium, frequentana, Penicillium funicilosum, Penicillium janthinellum, Penicillium luteum, Penicillium piscarium, Penicillium soppi, Penicillium spinulosum, Penicillium turbaturn, Penicillium digitatum, Penicillium expansum, Penicillium pusitlum, Penicillium rubrum, Penicillium wortmanii, Penicillium variabile, Pestalotia palmarum, Pestalotiopsis westerdijkii, Phoma sp., Schizophyllum commune, Scopulariopsis brevicaulis, Rhizopus sp., Sporotricum carnis, Sporotricum pruinosum, Stachybotrys atra, Torula sp., Trichoderma viride (reesei), Trichurus cylindricus, Verticillium albo atrum, Aspergillus cellulosae, Penicillium glaucum, Cunninghamella sp., Mucor mucedo, Rhyzopus chinensis, Coremiella sp., Karlingia rosea, Phytophthora cactorum, Phytophthora citricola, Phytophtora parasitica, Pythium sp., Saprolegniaceae, Ceratocystis ulmi, Chaetomium globosum, Chaetomium indicum, Neurospora crassa, Sclerotium rolfsii, Aspergillus sp., Chrysosporium lignorum, Penicillium notatum, Pyricularia oryzae, Collybia veltipes, Coprinus sclerotigenus, Hydnum henningsii, Irpex lacteus, Polyporus sulphreus, Polyporus betreus, Polystictus hirfutus, Trametes vitata, Irpex consolus, Lentines lepideus, Poria vaporaria, Fomes pinicola, Lenzites styracina, Merulius lacrimans, Polyporus palstris, Polyporus annosus, Polyporus versicolor, Polystictus sanguineus, Poris vailantii, Puccinia graminis, Tricholome fumosum, Tricholome nudum, Trametes sanguinea, Polyporus schweinitzil FR., Conidiophora carebella, Cellulase AP (Amano Pharmaceutical Co., Ltd.), Cellulosin AP (Ueda Chemical Co., Ltd.), Cellulosin AC (Ueda Chemical Co., Ltd.), Cellulase-Onozuka (Kinki Yakult Seizo Co., Ltd.), Pancellase (Kinki Yakult Seizo Co., Ltd.), Macerozyme (Kinki Yakult Seizo Co., Ltd.), Meicelase (Meiji Selka Kaisha, Ltd.), Celluzyme (Nagase Co., Ltd.), Soluble sclase (Sankyo Co., Ltd.), Sanzyme (Sankyo Co., Ltd.), Cellulase A-12-C (Takeda Chemical Industries, Ltd.), Toyo-Cellulase (Toyo Jozo Co., Ltd.), Driserase (Kyowa Hakko Kogyo Co., Ltd.), Luizyme (Luipold Werk), Takamine-Cellulase (Chemische Fabrik), Wallerstein-Cellulase (Sigma Chemicals), Cellulase Type I (Sigma Chemicals), Cellulase Serva (Serva Laboratory), Cellulase 36 (Rohm and Haas), Miles Cellulase 4,000 (Miles), R & H Cellulase 35, 36, 38 conc (Phillip Morris), Combizym (Nysco Laboratory), Cellulase (Makor Chemicals), Celluclast, Celluzyme, Cellucrust (NOVO Industry), and Cellulase (Gist-Brocades). Cellulase preparations are available from Accurate Chemical & Scientific Corp., Alltech, Inc., Amano International Enzyme, Boehringer Mannheim Corp., Calbiochem Biochems, Carolina Biol. Supply Co., Chem. Dynamics Corp., Enzyme Development, Div. Biddle Sawyer, Fluka Chem. Corp., Miles Laboratories, Inc., Novo Industrials (Biolabs), Plenum Diagnostics, Sigma Chem. Co., Un. States Biochem. Corp., and Weinstein Nutritional Products, Inc.
Cellulase, like many enzyme preparations, is typically produced in an impure state and often is manufactured on a support. The solid cellulase particulate product is provided with information indicating the number of international enzyme units present per each gram of material. The activity of the solid material is used to formulate the treatment compositions of this invention. Typically the commercial preparations contain from about 1,000 to 6,000 CMC enzyme units per gram of product.
SURFACTANT
A surfactant can be included in the treatment compositions of the invention. The surfactant can increase the wettability of the aqueous solution promoting the activity of the cellulase enzyme in the fabric. The surfactant increases the wettability of the enzyme and fabric. The surfactant facilitates the exclusion of air bubbles from fabric surfaces and the enzyme preparation, and promotes contact between enzyme and fabric surface. The properties of surfactants are derived from the presence of different functional groups.
Surfactants are classified and well known categories including nonionic, anionic, cationic and amphoteric surfactants.
Nonionic surfactants are surfactants having no charge when dissolved or dispersed in aqueous medium. The hydrophilic tendency of nonionic surfactants is derived from oxygen typically in ether bonds which are hydrated by hydrogen bonding to water molecules. Hydrophilic moieties in nonionics can also include hydroxyl groups and ester and amide linkages. Typical nonionic surfactants include alkyl phenol alkoxylates, aliphatic alcohol alkoxylates, carboxylic acid esters, carboxylic acid amides, polyalkylene oxide heteric and block copolymers, and others.
Nonionic surfactants are generally preferred for use in the compositions of this invention since they provide the desired wetting action and do not degrade the enzyme activity. Preferred nonionic surfactants include polymeric molecules derived from repeating units of ethylene oxide, propylene oxide, or mixtures thereof. Such nonionic surfactants include both homopolymeric, heteropolymeric, and block polymeric surfactant molecules. Included within the preferred class of nonionic surfactants are polyethylene oxide polymers, polypropylene oxide polymers, ethylene oxide-propylene oxide block copolymers, ethoxylated C 1-18 alkyl phenols, ethoxylated C 1-18 aliphatic alcohols, pluronic surfactants, reverse pluronic surfactants, and others.
Particularly preferred nonionics include: polyoxyethylene alkyl or alkenyl ethers having alkyl or alkenyl groups of a 10 to 20 average carbon number and having 1 to 20 moles of ethylene oxide added; polyoxyethylene alkyl phenyl ethers having alkyl groups of a 6 to 12 average carbon number and having 1 to 20 moles of ethylene oxide added; polyoxypropylene alkyl or alkenyl ethers having alkyl groups or alkenyl groups of a 10 to 20 average carbon number and having 1 to 20 moles of propylene oxide added; polyoxybutylene alkyl or alkenyl ethers having alkyl groups of alkenyl groups of a 10 to 20 average carbon number and having 1 to 20 moles of butylene oxide added; nonionic surfactants having alkyl groups or alkenyl groups of a 10 to 20 average carbon number and having 1 to 30 moles in total of ethylene oxide and propylene oxide or ethylene oxide and butylene oxide added (the molar ratio of ethylene oxide to propylene oxide or butylene oxide being 0.1/9.9 to 9.9/0.1); or higher fatty acid alkanolamides or alkylene oxide adducts thereof. Less preferred surfactants include anionic, cationic and amphoteric surfactants.
Anionic surfactants are surfactants having a hydrophilic moiety in an anionic or negatively charged state in aqueous solution. Commonly available anionic surfactants include carboxylic acids, sulfonic acids, sulfuric acid esters, phosphate esters, and salts thereof.
Cationic surfactants are hydrophilic moieties wherein the charge is cationic or positive when dissolved in aqueous medium. Cationic surfactants are typically found in amine compounds, oxygen containing amines, amide compositions, and quaternary amine salts. Typical examples of these classes are primary and secondary amines, amine oxides, alkoxylated or propoxylated amines, carboxylic acid amides, alkyl benzyl dimethyl ammonium halide salts and others.
Amphoteric surfactants which contain both acidic and basic hydrophilic structures tend to be of reduced utility in most fabric treating processes.
SOLVENTS
Solvents that can be used in the liquid concentrate compositions of the invention are liquid products that can be used for dissolving or dispersing the enzyme and surfactant compositions of the invention. Because of the character of the preferred nonionic surfactants, the preferred solvents are oxygen containing solvents such as alcohols, esters, glycol, glycol ethers, etc. Alcohols that can be used in the composition of the invention include methanol, ethanol, isopropanol, tertiary butanol, etc. Esters that can be used include amyl acetate, butyl acetate, ethyl acetate, esters of glycols, and others. Glycols and glycol ethers that are useful as solvents in the invention include ethylene glycol, propylene glycol, and oligomers and higher polymers of ethylene or propylene glycol in the form of polyethylene or polypropylene glycols. In liquid concentrates the low molecular weight oligomers are preferred. In solid organic concentrates the high molecular weight polymers are preferred.
SOLID FORMING AGENTS
The compositions of the invention can be formulated in a solid form such as a cast solid, large granules or pellets. Such solid forms are typically made by combining the cellulase enzyme with a solidification agent and forming the combined material in a solid form. Both organic and inorganic solidification agents can be used. The solidification agents must be water soluble or dispersible, compatible with the cellulase enzyme, and easily used in manufacturing equipment.
Inorganic solid forming agents that can be used are typically hydratable alkali metal or alkaline earth metal inorganic salts that can solidify through hydration. Such compositions include sodium, potassium or calcium, carbonate, bicarbonate, tripolyphosphate silicate, and other hydratable salts. The organic solidification agents typically include water soluble organic polymers such as polyethylene oxide or polypropylene oxide polymers having a molecular weight of greater than about 1,000, preferably greater than about 1,400. Other water soluble polymers can be used including polyvinyl alcohol, polyvinyl pyrrolidone, polyalkyl oxazolines, etc. The preferred solidification agent comprises a polymer of polyethylene oxide having an average molecular weight of greater than about 1,000 to about 20,000, preferably 1,200 to 10,000. Such compositions are commercially available as CARBOWAX® 1540, 4000, 6000. To the extent that the nonionic surfactants and other ingredients are soluble in solid polymer compositions, the solid organic matrices can be considered solvent.
Additionally, the solid pellet-like compositions of the invention can be made by pelletizing the enzyme using well known pressure pelletizing techniques in which the cellulase enzyme in combination with a binder is compacted under pressure to a tablet or pellet composition.
ALKALIS OR INORGANIC ELECTROLYTES
The composition may also contain 1-50 wt-%, preferably 5-30 wt-% of one or more alkali metal salts selected from the following compounds as the alkali or inorganic electrolyte: silicates, carbonates and sulfates. Further, the composition may contain organic alkalis such as triethanolamine, diethanolamine, monoethanolamine, and triisopropanolamine.
MASKING AGENTS FOR FACTORS
INHIBITING THE CELLULASE ACTIVITY
The cellulases are deactivated in some cases in the presence of heavy metal ions including copper, zinc, chromium, mercury, lead, manganese, or silver ions or their compounds. Various metal chelating agents and metal-precipitating agents are effective against these inhibitors. They include, for example, divalent metal ion sequestering agents as listed below with reference to optional additives as well as magnesium silicate and magnesium sulfate.
Cellubiose, glucose and gluconolactone can act as an inhibitor. It is preferred to avoid the co-presence of these saccharides with the cellulase if possible. In case the co-presence is unavoidable, it is necessary to avoid the direct contact of the saccharides with the cellulase by, for example, coating them.
Long chain fatty acid salts and cationic surfactants act as the inhibitors in some cases. However, the co-presence of these substances with the cellulase is allowable if the direct contact of them is prevented by some means such as tableting or coating.
The above-mentioned masking agents and methods may be employed, if necessary, in the present invention.
CELLULASE-ACTIVATORS
The activators vary depending on variety of the cellulases. In the presence of proteins, cobalt and its salts, magnesium and its salts, and calcium and its salts, potassium and its salts, sodium and its salts or monosaccharides such as mannose and xylose, the cellulases are activated and their deterging powers can be improved.
ANTIOXIDANTS
The antioxidants include, for example, tert-butylhydroxytoluene, 4,4'-butylidenebis(6-tert-butyl-3-methylphenol), 2,2'-butylidenebis(6-tert-butyl-4-methylphenol), monostyrenated cresol, distyrenated cresol, monostyrenated phenol, distyrenated phenol and 1,1-bis(4-hydroxyphenyl)cyclohexane.
SOLUBILIZERS
The solubilizers include, for example, lower alcohols such as ethanol, benzenesulfonate salts, lower alkylbenzenesulfonate salts such as p-toluenesulfonate salts, glycols such as propylene glycol, acetylbenzenesulfonate salts, acetamides, pyridinedicarboxylic acid amides, benzoate salts and urea.
The detergent composition of the present invention can be used in a broad pH range of about 6.5 to 10, preferably 6.5 to 8.
BUILDERS
Divalent Sequestering Agents
The composition may contain 0-50 wt-% of one or more builder components. For the purpose of this invention, the term builder (or builder salt) means a substance that increases the effectiveness of a surfactant or detergent by adding to its detergent power. Builders act as a source of alkalinity, as water softeners, and as sequestering and buffering agents. Such builder salt may be selected from the group consisting of alkali metal salts and alkanolamine salts of the following compounds: phosphates such as orthophosphate, pyrophosphate, tripolyphosphate, metaphosphate, hexametaphosphate and phytic acid; phosphonates such as ethane-1,1-diphosphonate, ethane-1,1,2-triphosphonate, ethane-1-hydroxy-1,1-diphosphonate and its derivatives. ethanehydroxy-1,1,2-triphosphonate, ethane-1,2-dicarboxy-1,2-diphosphonate and methanehydroxyphosphonate; phosphonocarboxylates such as 2-phosphonobutane-1,2-dicarboxylate, 1-phosphonobutane-2,3,4-tricarboxylate and α-methylphosphonosuccinate; salts of amino acids such as aspartic acid, glutamic acid and glycine; aminopolyacetates such as nitrilotriacetate, ethylenediaminetetraacetate, diethylenetriaminepentaacetate, iminodiacetate, glycol ether diamine tetraacetate, and hydroxyethyliminodiacetate; high molecular electrolytes such as polyacrylic acid, polyaconitic acid, polyitaconic acid, polycitraconic acid, polyfumaric acid, polymaleic acid, polymesaconic acid, poly-α-hydroxyacrylic acid, polyvinylphosphonic acid, sulfonated polymaleic acid, maleic anhydride/diisobutylene copolymer, maleic anhydride/styrene copolymer, maleic anhydride/methyl vinyl ether copolymer, maleic anhydride/ethylene copolymer, maleic anhydride/ethylene crosslinked copolymer, maleic anhydride/vinyl cetate copolymer, maleic anhydride/acrylonitrile copolymer, maleic anhydride/acrylic ester copolymer, maleic anhydride/butadiene copolymer, maleic anhydride/isoprene copolymer, poly-β-ketocarboxylic acid derived from maleic anhydride and carbon monoxide, itaconic acid/ethylene copolymer, itaconic acid/aconitic acid copolymer, itaconic acid/maleic acid copolymer, itaconic acid/acrylic acid copolymer, malonic acid/methylene copolymer, mesaconic acid/fumaric acid copolymer, ethylene glycol/ethylene terephthalate copolymer, vinylpyrrolidone/vinyl acetate copolymer, 1-butene-2,3,4-tricarboxylic acid/itaconic acid/acrylic acid copolymer, polyester polyaldehydocarboxylic acid containing quaternary ammonium group, cis-isomer of epoxysuccinic acid, poly[N,N-bis(carboxymethyl)acrylamide], poly(hydroxycarboxylic acid), starch/succinic acid or maleic acid or terephthalic acid ester, starch/phosphoric acid ester, dicarboxystarch, dicarboxymethylstarch, and cellulose/succinic acid ester; non-dissociating polymers such as polyethylene glycol, polyvinyl alcohol, polyvinyl pyrrolidone and cold water soluble, urethanated polyvinyl alcohol; and salts of dicarboxylic acids such as oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid and decane-1,10-dicarboxylic acid; salts of diglycolic acid, thiodiglycolic acid, oxalacetic acid, hydroxydisuccinic acid, carboxymethylhydroxysuccinic acid and carboxymethyltartronic acid; salts of hydroxycarboxylic acids such as glycolic acid, malic acid, hydroxypivalic acid, tartaric acid, citric acid, lactic acid, gluconic acid, mucic acid, glucuronic acid and dialdehydrostarch oxide; salts of itaconic acid, methylsuccinic acid, 3-methylglutaric acid, 2,2-dimethymalonic acid, maleic acid, fumaric acid, glutamic acid, 1,2,3-propanetricarboxylic acid, aconitic acid, 3-butene-1,2,3-tricarboxylic acid, butane-1,2,3,4-tetracarboxylic acid, ethanetetracarboxylic acid, ethenetetracarboxylic acid, n-alkenylaconitic acid, 1,2,3,4-cyclopentanetetracarboxylic acid, phthalic acid, trimesic acid, hemimellitic acid, pyromellitic acid, benzenehexacarboxylic acid, tetrahydrofuran-1,2,3,4-tetracarboxylic acid and tetrahydrofuran-2,2,5,5-tetracarboxylic acid; salts of sulfonated carboxylic acids such as sulfoitaconic acid, sulfotricarballylic acid, cysteic acid, sulfoacetic acid and sulfosuccinic acid; carboxymethylated sucrose, lactose and raffinose, carboxymethylated pentaerythritol, carboxymethylated gluconic acid, condensates of polyhydric alcohols or sugars with maleic anhydride or succinic anhydride, condensates of hydroxycarboxylic acids with maleic anhydride or succinic anhydride, and the like.
In somewhat greater detail, the clothing items can be contacted with an aqueous solution containing cellulase enzyme and a surfactant to promote the action of the cellulase for a sufficient time to produce local variations in color density in the surface of the fabric. The amount of solution used to treat the clothing items typically depends on the ratio of cellulase in the product and the dry weight of the clothing items to be washed. Typically the solutions used in the methods of the invention can contain a minimum of about 6,000 CMC units of cellulase per pound of clothes, preferably 6,500 to 75,000 units per pound, most preferably 12,000 to 60,000 units per pound to obtain the "stone-washed" look.
The treatment solutions used to contact the clothes can typically have the following ingredients.
TABLE 1______________________________________Aqueous Treating CompositionsIngredient Useful Preferred Most Preferred______________________________________Cellulase >1,000 2,500-30,000 6,000-20,000Enzyme*Surfactant 0-1,000 ppm 10-900 ppm 15-750 ppmWater Balance Balance Balance______________________________________ *Amounts in CMC C.sub.2 units per liter.
TABLE 2______________________________________Concentrate CompositionsIngredient Useful Preferred Most Preferred______________________________________Cellulase 1-90 wt % 2-80 wt % 5-75 wt %EnzymeSurfactant 99-0 wt % 98-5 wt % 95-10 wt %Solvent Balance Balance Balance______________________________________
TABLE 3______________________________________Inorganic Solid ConcentrateIngredient Useful Preferred Most Preferred______________________________________Cellulase 25-90 wt % 30-85 wt % 35-80 wt %EnzymeHydratable 20-60 wt % 20-55 wt % 25-50 wt %InorganicSalt BufferSystemSequestrant 0-25 wt % 5-20 wt % 7-15 wt %Water of Balance Balance BalanceHydration______________________________________
TABLE 4______________________________________Organic Solid ConcentrateIngredient Useful Preferred Most Preferred______________________________________Cellulase 25-90 wt % 30-85 wt % 35-80 wt %EnzymeSurfactant 99-0 wt % 98-5 wt % 95-10 wt %PEG* 20-60 wt % 20-55 wt % 25-50 wt %Sequestrant 0-25 wt % 5-20 wt % 7-20 wt %Buffer System 0-5 wt % 1-4 wt % 1.5-3.5 wt %______________________________________ *PEG = polyethylene oxide (M.W. 1,000-9,000).
The liquid concentrate compositions of this invention can be formulated in commonly available industrial mixers. Typically a solution of the surfactant is prepared in the solvent and into the surfactant solution is added the cellulase enzyme sufficiently slowly to create a uniform enzyme dispersion in the solvent. The concentrates can be packaged in typical inert packaging such as glass, polyethylene or polypropylene, or PET. Care should be taken such that agitation does not significantly reduce the activity of the cellulase enzyme.
The inorganic solid concentrate compositions of this invention can be made by combining the cellulase enzyme with the inorganic (alkali metal or alkaline earth metal) hydratable carbonate, bicarbonate, silicate or sulfate in an aqueous slurry containing sufficient water to cause the hydration and solidification of the inorganic components. The slurries can be made at elevated temperatures to reduce viscosity and increase handleability. The inorganic slurry compositions can then be cast in molds and after solidification can be removed from the mold, packaged and sold. Alternatively, the materials can be cast in reusable or disposable containers, capped and sold. Such materials usually are manufactured in a 1 ounce to 10 pound size. Solid concentrates can be in the form of a pellet having a weight of 1 gram to 250 grams, preferably 2 grams to 150 grams. The large cast object can be about 300 grams to 5 kilograms, preferably 500 grams to 4 kilograms.
The organic enzyme concentrate compositions can typically be made by slurrying the enzyme material in a melted polymer matrix that can contain water for viscosity control purposes. Once a uniform dispersion of the enzyme, and other optional ingredients, are included in the organic polymer matrix, the materials can be introduced into molds or reusable or disposable containers, cooled, solidified and sold. Alternatively both the organic and inorganic solid concentrates can be made by combining the ingredients, and forming the compositions into pellets in commercially available pelletizing machines using either the temperature solidification, the hydration solidification mechanism, or a compression pelletizing machine using a binding agent well known in the art. All of the liquid and solid concentrate compositions of the invention can include additional ingredients that preserve or enhance the enzyme activity in the pumice-free stone wash processes of the invention.
The compositions of this invention are typically diluted in water in household, institutional, or industrial machines having a circular drum held in a horizontal or vertical mode in order to produce the "stone-washed" appearance without the use of pumice or other particulate abrasive. Most commonly the denim or other fabric clothing items are added to the machine according to the machine capacity per the manufacturer's instructions. Typically the clothes are added prior to introducing water into the drum but the clothes can be added to water in the machine or to the pre-diluted treatment composition. The clothing is contacted with the treatment composition and agitated in the machine for a sufficient period to ensure that the clothing has been fully wetted by the treatment composition and to ensure that the cellulase enzyme has had an opportunity to cleave cellulose in the fabric material. At this time if the treatment composition is to be reused, it is often drained from the tub and saved for recycle. If the treatment composition is not to be reused, it can remain on the clothing for as long as needed to produce color variation. Such treatment periods are greater than 5 minutes, greater than 30 minutes and up to 720 minutes, depending on amount of enzyme, during all or part of the mechanical machine action used to produce in the cellulase treated fabric the variations in color density. We believe that there is an interaction between the cellulase modified fabric and mechanical tumbling or action which removes cellulose from the fabric surface and the indigo dye to create a variation in color density from place to place on fabric panels and seams. Further, the action of the enzyme appears to cause puckering in the seams and a creation of a soft, wrinkled look in fabric panels.
The above specification provides a discussion of the compositions of the invention and methods of making and using the compositions in the "stone-washing" of fabric clothing items. The following Examples provide specific details with respect to the compositions and methods of the invention and include a best mode.
EXAMPLES I-III
Into a Milnor 35 lb. capacity washing machine was placed new blue denim jeans and into the machine was placed 25 gallons of 120° F. water containing an amylase enzyme desizing stripper composition. The contents of the machine was agitated for 9 minutes and the aqueous solution was dumped. Into the machine was placed 25 gallons of water at 120° F. containing an amount of cellulase enzyme (see Table 5 below) and 10 milliliters of a sour comprising an aqueous solution containing 23 wt-% H 2 SiF 6 and 50 wt-% citric acid. The jeans were agitated in the celluzyme composition for 1 hour and the aqueous composition was dumped. The jeans were then rinsed in three successive hot water rinses at 120° F., 110° F., and a final rinse at 100° F. containing 5 milliliters of the sour product.
TABLE 6______________________________________Visible Spectrophotometer Scan ofStone Washed Jeans and Product of Example IIWave StoneLength Washed Jeans Example II Differences______________________________________380 11.50 11.01 -0.49390 15.71 15.32 -0.39400 18.57 18.49 -0.08410 21.70 21.99 0.69420 23.01 24.22 1.20430 22.96 24.24 1.28440 22.19 23.53 1.34450 21.31 22.62 1.31460 20.38 21.64 1.26470 19.43 20.63 1.20480 18.60 19.71 1.10490 17.91 18.92 1.01500 17.18 18.08 0.90510 16.35 17.13 0.77520 15.40 16.06 0.66530 14.40 14.92 0.52540 13.47 13.88 0.41550 12.77 13.08 0.31560 12.32 12.60 0.28570 11.94 12.15 0.21580 11.42 11.59 0.17590 10.85 10.97 0.12600 10.35 10.39 0.04610 9.95 9.94 -0.01620 9.60 9.56 -0.04630 9.15 9.07 -0.08640 8.75 8.64 -0.11650 8.44 8.30 -0.14660 8.35 8.21 -0.14670 8.66 8.58 -0.08680 9.70 9.73 0.03690 11.83 12.12 0.29700 15.83 16.60 0.77710 22.62 23.99 1.37720 32.13 33.84 1.71730 42.55 43.96 1.41740 51.26 51.92 0.65750 57.04 57.03 -0.01______________________________________
TABLE 5______________________________________ Concen-Ex- trate CMCU/ Grams/ample Grams/L CMCU*/L CMCU*/LB Pair Pair______________________________________I 200 7,459 32,000 48,000 20II 300 11,189 48,000 72,000 30III 400 14,918 64,000 96,000 40______________________________________ *Carboxymethyl cellulose units
DETAILED DISCUSSION OF THE DRAWINGS
FIG. 1 is a graphical representation of the data in the above table. The graph appears to be a single line consisting of dots and dashes, however the graph shows that the percent reflectance of the stone washed denims and the denims produced using the compositions and methods of this invention are virtually identical. The differences shown in column 4 of the above table indicate that at certain wavelengths minor differences occur, however the curves are virtually superimposable.
|
Denim having a stone washed appearance is produced without stones by treating with a cellulase enzyme. Unsewn dyed denim fabric or a newly manufactured garment made of dyed denim fabric is contacted with an aqueous composition containing at least about 2500 CMCS units of cellulase per liter, and subjected to mechanical action. Preferably, the aqueous composition provides at least about 6000 CMC units of cellulase per pound of unsewn fabric or garment. The aqueous may also contain an electrolyte, a buffer, a builder salt a cellulase activator, an antioxidant and a solubilizer.
| 3
|
This is a division of application Ser. No. 178,176, filed Apr. 6, 1988, now U.S. Pat. No. 4,897,987.
FIELD OF THE INVENTION
The present invention relates to processes for preparing bicyclic compounds and intermediates thereof. Such compounds are useful as anti-allergic, anti-inflammatory and/or cytoprotective agents.
BACKGROUND OF THE INVENTION
Processes for making certain bicyclic compounds and intermediates have been described in various publications, such an U.S. Pat. Nos. 4,684,727; 4,628,055; 4,680,298; 4,492,702; 4,452,800; in Japanese Patent Disclosure 11,649; in European Patent Application No. 0127135; and in the article "Phosphorous Pentoxide in Organic Synthesis, III--A New Synthesis of Pyrido [2,3-d]-pyrimidin-4(3H)-ones, O. Andersen and E. Pederson Liebigs Ann. Chem. 1982, 1012-1015. It would be desirable to provides processes for preparing bicyclic compounds and their intermediates whose yields are as good as or better then methods previously taught. It would also be desirable to provide a process for preparing said bicyclic compounds and intermediates which requires even fewer steps than methods previously taught.
SUMMARY OF THE INVENTION
In one embodiment, the present invention is directed toward a process for preparing a bicyclic compound of a formula ##STR1##
wherein W 1 and W 2 independently represent --CH═ or --N═;
R 2 , R 3 , R 4 and R 5 independently represent H, alkyl having from 1 to 12 carbon atoms, alkenyl having from 3 to 8 carbon atoms, alkynyl having from 3 to 8 carbon atoms, alkoxyalkyl having from 1 to 6 carbon atoms in the alkoxy portion and from 2 to 6 atoms in the alkyl portion thereof, hydroxyalkyl having from 2 to 8 carbon atoms, cycloalkyl having from 3 to 8 carbon atoms, acyloxyalkyl having from 1 to 6 carbon atoms in the acyloxy portion and from 2 to 8 carbon atoms in the alkyl portion thereof, and --R 6 --CO 2 R 0 wherein R 6 represents an alkylene group having from 1 to 6 carbon atoms and R 0 represents hydrogen or an alkyl group having from 1 to 6 carbon atoms, with the provisos that the OH of the hydroxyalkyl group and the acyloxy of the acyloxyalkyl group are not joined to the same carbon atom as another heteroatom and that, when R 2 and/or R 3 are alkenyl or alkynyl, there is at least one carbon-carbon single bond between the nitrogen atom and the carbon-carbon double or triple bond and also with the proviso that R 3 does not represent hydrogen;
in addition, one of R 2 or R 3 can be an aryl group or an aromatic heterocyclic group, either of which can be substituted with one to three substituents Y as defined below;
in further addition, R 2 and R 3 can be joined together to represent a ring which can contain from 2 to 8 carbon atoms, said ring optionally containing a --O--, --S-- and/or --NR 4 -- heteroatomic group (wherein R 4 is as defined above) and/or optionally containing a carbon-carbon double bond, and said ring optionally being substituted with one to three additional substituents R 7 which substituents may be the same or different and are each independently selected from OH with the proviso that OH is not on a carbon already joined to a hetero atom, --O--acyl having from 1 to 6 carbon atoms, hydroxyalkyl having from 1 to 8 carbon atoms, alkoxyalkyl having from 1 to 6 carbon atoms in each alkyl portion thereof, alkyl having from 1 to 6 carbon atoms, alkenyl having from 3 to 8 carbon atoms, alkynyl having from 3 to 8 carbon atoms, --COOR 10 wherein R 10 is H, alkyl or aryl, or any two R 7 substituent groups may represent a hydrocarbon ring having from 4 to 8 total carbon atoms;
in still further addition, both R 2 and R 3 can be joined together to represent a polycyclic ring, which polycyclic ring can optionally be substituted by one to three substituents groups R 7 as defined above;
m is an integer of from 0 to 3;
n is an integer of from 0 to 2;
Q represents an aryl or an aromatic heterocyclic group which can optionally be substituted with 1 to 3 substituents Y as defined below;
each Y substituent is independently selected from the group consisting of hydroxy, alkyl having from 1 to 6 carbon atoms, halogen, NO 2 , alkoxy having from 1 to 6 carbon atoms, trifluoromethyl, cyano, cycloalkyl having from 3 to 7 carbon atoms, alkenyloxy having from 3 to 6 carbon atoms, alkynyloxy having from 3 to 6 carbon atoms, hydroxyalkyl having from 1 to 6 carbon atoms, --S(O) n --R 8 (wherein R 8 represents alkyl having from 1 to 6 carbon atoms and n is as defined above), --SO 2 NH 2 , --CO--R 9 (wherein R 9 represents OH, --NH--R 8 or --O--R 8 , where R 8 is as defined above), --O--B--COR 9 (wherein B represents an alkylene group having from 1 to 4 carbon atoms and R 9 is as defined above), --NH 2 , --NHCHO, --N--CO--R 9 (wherein R 9 is as defined above, with the proviso that it is not hydroxy), --NH--COCF 3 , --NH--SO 2 R 8 (wherein R 8 is as defined above), and --NHSO 2 CF 3 .
The process (i.e. Process A) comprises the step of contacting an amino acetamide compound of the formula ##STR2## wherein Y, W 1 , W 2 , R 2 , R 3 , R 4 , R 5 , Q, m and n are as defined hereinbefore, and
R is any of the values for R 4 or R 5 with the proviso that R is not hydrogen,
with a base effective to selectively remove a proton from the methyl group (i.e. --CH 2 --) of said amino acetamide compound (V) in order to intramolecularly cyclize said compound to the bicyclic compound of formula (VII).
In preferred embodiments, as to the amino acetamide compound of formula (V) preferably Y is hydrogen, W 1 is preferably nitrogen and W 2 is preferably CH, R is alkyl, more preferably methyl and m is 0, and R 2 and R 3 are joined together to represent a ring containing four carbon atoms, and Q is phenyl. Preferably the base is potassium t-butoxide. As to the bicyclic compound of formula (VII), preferably Y is hydrogen, W 1 is nitrogen, W 2 is CH, m is zero, Q is phenyl, and R 2 and R 3 are joined together to represent a ring of four carbon atoms. The process has the advantages of being able to prepare the compound of formula (VII) in high yield, good purity, with low by-product formation using relatively mild reaction conditions. The process also has the advantage of providing a reaction medium which allows a simplified means for recovery of the desired product.
Another embodiment of the present invention is directed to a second process (i.e. Process B) for also preparing bicyclic compounds of formula (VII). The process comprises the steps of contacting a secondary substituted amine of the formula ##STR3## wherein Y, W 1 , W 2 , R 4 , R 5 , Q, m and n are as defined hereinbefore;
with an amino-substituted acetic acid derivative of the formula:
R.sup.1 OOC--CH.sub.2 --NR.sup.2 R.sup.3 (VI)
wherein R 2 and R 3 are as defined hereinbefore; and R 1 represents the same values as for with a base effective to cyclize said secondary substituted amine (IV) with said amino-substituted acetic acid derivative (VI) to give the desired bicyclic compound (VII).
As to the substituted secondary amine compound (IV) preferably Y is hydrogen, W 1 is nitrogen, W 2 is CH, R is as to the substituted secondary amine compound (IV), Q is phenyl and m is zero. As to the amino-substituted acetic acid derivative, preferably R 1 is alkyl, preferably ethyl, R 2 and R 3 are joined together to represent a ring of four carbon atoms.
Also preferred is that the base is sodium hydride or potassium t-butoxide.
The present invention (i.e. Process B) has the advantages of being able to prepare the bicylic compound (VII) in high yields and good purity with low-byproduct formation. Another advantage of the present invention is that it provides a process whose reaction mixture allows a simplified means of recovery of the desired bicyclic compound (VII).
In yet another embodiment, the present invention is directed toward a process (i.e. Process C) for preparing a substituted acetamide compound of the formula ##STR4## wherein Y, W 1 , W 2 , R, R 4 , R 5 , Q, m and n are as defined hereinbefore; and X is halogen.
The process comprises the step of contacting a secondary amine compound of the formula ##STR5## wherein Y, W 1 , W 2 , R, R 4 , R 5 , Q, m and n are as defined hereinbefore;
with a substituted acetic acid derivative of the formula
X--CH.sub.2 COR.sup.7 (II)
wherein
X 1 is as defined hereinbefore; and
R 7 is a leaving group which is halogen, tosylate, mesylate or anhydride of the formula
--OCOCH.sub.2 X.sup.1
wherein X 1 is hydrogen or halogen; and said contacting is performed in the presence of a proton accepting compound. The substituted acetamide compound (III) is useful as an intermediate in preparing the bicyclic compound (VII).
With regard to the secondary amine compound (I), preferably Y is hydrogen, W 1 is nitrogen, W 2 is CH, R is alkyl, more preferably methyl, m is zero, and Q is phenyl.
With regard to the substituted acetic acid derivative of formula (II), preferably X is halogen and R 7 is halogen, more preferably chloro. Where the leaving group is an anhydride preferably X 1 is halogen, more preferably chloro. Preferably the proton accepting compound is an epoxide, most preferably propylene oxide. The process of the present invention (i.e. Process C) has the advantage of providing a process useful for preparing a substituted acetamide compound (III) useful for subsequently preparing the bicyclic compound (VII). The present process also has the advantage of preparing substituted acetamide compounds (III) in high yields, good purity, with low by-product formation using relatively mild reaction conditions.
DETAILED DESCRIPTION OF THE INVENTION
The processes of the present can be schematically illustrated as follows: ##STR6##
It is understood and intended that the bicyclic compounds (VII) prepared by the processes of the present invention can exist in a zwitterionic form, such as illustrated below. ##STR7##
When utilized herein the terms listed hereinbelow, unless otherwise indicated, are defined as follows:
halogen or halo - fluoro, chloro, bromo and iodo;
alkyl and alkoxy - comprise straight and branched carbon chains and, unless otherwise specified, contain from 1 to 6 carbon atoms;
alkenyloxy - comprise straight and branched carbon chains and, unless otherwise specified, contain from 3 to 8 carbon atoms and comprising a carbon to carbon double bond;
alkynyloxy - comprise straight and branched carbon chains and, unless otherwise specified, contain from 3 to 8 carbon atoms and comprising a carbon to carbon triple bond;
aryl - a carbocyclic group containing at least one benzene ring, with the aryl groups preferably containing from 6 to 15 carbon atoms, more preferably being phenyl or Y-substituted phenyl, e.g., phenyl, naphthyl, indenyl, indanyl, 4-chlorophenyl, 4-fluorophenyl, etc.;
aromatic heterocyclic - cyclic groups having at least one O, S and/or N heterogroup interrupting the ring structure and having a sufficient number of unsaturated carbon to carbon bonds, nitrogen to carbon bonds, etc., to provide aromatic character, with the aromatic heterocyclic groups preferably containing from 4 to 14 carbon atoms, e.g., pyridyl, furyl, thienyl, thiazolyl, imidazolyl, pyrimidinyl, pyrazinyl, pyridazinyl, 1,2,4-triazinyl, benzofuranyl, indolyl, pyrazolyl,. oxazolyl, etc. Many times such heterocyclic groups can be bonded via various positions on the ring and all such variations are contemplated, e.g. 2- or 3-furanyl, 2-, 3- or 4-pyridyl, etc.
The compounds of the invention are comprised of a --(CR 4 R 5 ) m -- substituent wherein each R 4 group and each R 5 group may vary independently. Thus, for example, when m equals 2 the following patterns of substitution (wherein hydrogen and CH 3 are used to represent any substituent, R 4 or R 5 ) are contemplated: --C(CH 3 ) 2 CH(CH 2 --, --CH 2 C(CH 3 ) 2 --, --CH 2 CH(CH 3 )--, --CH(CH 3 )CH 2 --, --(C(CH 3 )H) 2 -- and the like. In addition when m equals 3, substituents such as --C(CH 3 ) 2 CH(C 2 H 5 )-- CH 2 --, --CH(CH 3 )--CH 2 CH(C 2 H 5 )--, and CH 2 --CH(i--C 3 H 7 )CH(C 2 H 5 )-- are also contemplated.
The R 2 and R 3 groups on the amino nitrogen in the compounds of the invention can be the same or different. In some instances as noted above, two of such groups or three of such groups may together represent a heterocyclic ring system with the nitrogen of the amino group being part of such ring, e.g., a monocyclic or bicyclic ring. Examples of suitable groups include the protonated secondary amino groups such as --NH(CH 3 ), --NH(--CH 2 --CH═CH 2 ), --NH(phenyl), --NH(--CH 2 --CH═CH 2 ), --NH(phenyl), --NH(4-pyridyl), etc.; tertiary amino groups such as --NH(CH 3 ) 2 , --N(CH 2 CO 2 H)C(CH 2 OH) 3 , etc.;
As noted above, the compounds of the invention may include one to three Y substituents on the bicyclic ring system. Also, the Q group may include one or two Y substituents. In cases where there is more than one such Y substituent, they may be the same or different. Thus, compounds having combinations of different Y substituents are contemplated within the scope of the invention. Examples of suitable Y substituents include OH, methyl, chloro, bromo, methoxy, cyclohexyl, allyloxy, 2-propynyloxy, hydroxyethyl, methylthio, methylsulfonyl, carboxy, acetoxy, N-methylaminocarbonyl, acetoxymethoxy, acetamido, methylsulfonamido and the like.
Turning to the processes of the present invention, in process A the bicyclic compounds of formula (VII) are prepared by contacting an amino acetamide compound of formula (V) with a base in amounts and under conditions effective to selectively remove a proton from the methyl group of said amino acetamide compound (V) in order to intramolecularly cyclize said compound (V). The amino acetamide compound of formula (V) can be contacted with the base at temperatures ranging from about -100° C. to about 100° C., preferably from about -70° to about 40° C., depending upon the base employed. The reactants can be contacted at ambient pressures although pressures less than or greater than ambient can be employed. The reactants can be stirred or not stirred during the contacting, although stirring is preferred. The reactants are contacted for a time effective to complete the reaction to the desired extent, for a period ranging from about 5 minutes to about 24 hours or more. The contacting can be conducted neat although generally compatible solvents can be employed. Such solvents include but are not limited to the chlorinated hydrocarbons such as carbon tetrachloride (CCl 4 ), methylene chloride (CH 2 Cl 2 ), and dichloroethane; to aliphatics such as C-1 to C-20 alkanes, cyclic or acyclic; aromatics such as benzene, toluene, xylene, alkylbenzenes and the like; to ethers such as diethyl ether and tetrahydrofuran (THF) and tertiary butyl-methyl ether; and to solvents such as dimethylformamide (DMF), dimethylsulfoxide (DMSO), or mixtures thereof.
The base employed in Process A is any substance which will remove a proton from the methyl (--CH 2 --) group of the moiety ##STR8## in order to intramolecularly cyclize the amino acetamide compound of formula (V).
Bases which can be employed in process A are generally non-aqueous bases such as organo-alkali metals such as primary, secondary and tertiary butyl lithiums, such as lithium diisopropyl amide, lithium hexamethylsilazenes, sodium hexamethylsilazenes and potassium hexamethylsilazenes; potassium t-butoxide or sodium methoxide; bases of alkali and alkaline earth metals including carbonates such as sodium, potassium and cesium carbonates; hydroxides such as sodium and potassium hydroxides; hydrides such as sodium or potassium hydrides; preferably the base is sodium hydride, sodium methoxide, most preferably potassium t-butoxide. Other bases which may be suitably employed are disclosed in "Modern Synthetic Reactions" by H. House, W. A. Benjamin, Inc., Menlo Park, Calif., 1972, 856 pages. The amino acetamide compounds of formula (V) can be contacted with the base in an amount effective to cyclize compound (V). The amount of base is employed in ratios ranging from about 1,000 to 2:1 mole; preferably from about 20 to 2:1, most preferably from about 8 to 2:1 (moles of base:mole amino acetamide (V)). Where employed, the solvents can range from about 1% to about 500% by weight of the amino acetamide compound (V).
After the reaction is completed, the desired bicyclic compound of formula (VII) is recovered by conventional separatory and recovery methods such as chromatography, distillation, crystallization and the like.
In process B for preparing the bicyclic compound of formula (VII), a secondary substituted amine of formula (IV) is contacted with an amino-substituted acetic acid derivative of formula (VI) in amounts and under conditions effective to yield the desired bicyclic compound of formula (VII). The bases and solvents employed in process B are essentially the same as those in process A, described hereinbefore. The secondary substituted amine of formula (IV) is contacted with the amino-substituted acetic acid derivative of formula (V) at temperatures ranging from about -40° to about 200° C., preferably from about 25° to about 180° C. The contacting is performed at ambient pressures although pressures is greater or less than ambient can be employed. The contacting of the reactants can be carried out from about 5 minutes to about 72 hours or more until the reaction is substantially completed, preferably from about 1 hour to about 48 hours. Also preferred is that the reactants are stirred during the contacting procedures. The amino-substituted acetic acid derivatives of formula (VI) can be contacted with the secondary substituted amines of formula (IV) in ratios ranging from about 100 to 1:1 mole; preferably from about 10 to 1:1, most preferably from about 6 to 1:1 (moles amino-substituted acetic acid derivative (VI):mole secondary substituted amine (IV)).
The base is employed in amounts ranging from about 1,000 to 3:1 mole, preferably from about 330 to 3:1, most preferably from about 15 to 3:1, (moles base:mole secondary substituted amine (IV)).
The reactants can be contacted neat, although preferably a solvent is employed. A solvent can be employed in amounts ranging from about 1 to 5,000% by weight of the secondary substituted amine (IV), preferably from about 2% to about 1,000% by weight, more preferably from about 2 to 50 percent.
After the reaction is completed, the desired bicyclic compound of formula (VII) is recovered by conventional separatory and recovery methods such as described hereinbefore.
In yet another embodiment of the present invention, i.e. process C, the substituted acetamide compound of formula (III) is prepared by contacting a secondary amine compound of formula (I) with a substituted acetic acid derivative of formula (II) in the presence of a proton acceptor in amounts and under conditions effective to give the substituted acetamide compound (III).
The substituted acetic acid derivative (II) is employed in amounts ranging from about 100 to 1:1 mole, preferably from about 25 to 1:1, most preferably from about 5 to 1:1 mole (moles substituted acetic acid derivative (II): mole secondary amine compound of formula (I)).
The term "proton acceptor" is defined as a compound which accepts either a proton from an acid, or free protons in the reaction mixture, but generally will not accept a proton from the methyl group of the formula ##STR9## wherein --CH 2 -- is the methyl group. The proton acceptor should be compatible with the reactants and can be a base such as ammonia (NH 3 ) or an organic base including primary amines such as methylamine, β-naphthylamine, aniline, n-butyl amine, sec-butylamine, tert-butylamine, p-toluidine, 2,3-dimethylbenzenamine, 2-phenylethanamine, benzylamine, cyclohexylamine, ethylamine, ethylenediamine, o-toluidine, m-toluidine, p-toluidine, urea; a secondary amine or a compound containing at least one secondary amine such as dimethylamine, diphenyl amine, N-methylpropylamine, diethylamine, diisopropyl amine, N-methylaniline, piperazine, piperidine, pyrrolidine; a tertiary amine such as trimethylamine, dimethylaniline, N,N-dimethyl-n-propylamine, N-methylpiperidine, N,N-diethylbutylamine, triethylamine; heterocyclic nitrogen containing compounds such as isoquinoline, morpholine, purine, pyridine, pyrazine, pyrimidine, quinoline or polyvinyl pyridine; or to inorganic bases such as those of alkali or alkaline earth metals discussed hereinbefore. The proton acceptor can also be an epoxide of the formula: ##STR10## wherein T 1 , T 2 , T 3 and T4 independently represent hydrogen, alkyl, alkenyl, alkynyl, alkoxyalkyl, hydroxyalkyl, cycloalkyl, as defined hereinbefore, and phenyl, halophenyl, alkyl phenyl having 1 to 6 carbons in the alkyl portion, alkoxyphenyl having 1 to 6 carbons in the alkoxy portion, benzyl, halo benzyl, alkyl benzyl having 1 to 6 carbons in the alkyl portion, alkoxy benzyl having 1 to 6 carbon atoms in the alkoxy portion, halo alkyl and cycloalkalkyl having 1 to 6 carbon atoms in the alkyl portion. Representative epoxides suitable as proton acceptors include but are not limited to ethylene oxide, propylene oxide, ethyl glycidate, epichlorohydrin, styrene oxide or mixtures thereof; and also to polymer bound and/or supported epoxides. Preferably, the epoxide is propylene oxide. Alternatively, the epoxide can be prepared in-situ in the reaction mixture. The proton acceptor can also include mixtures of the base and epoxide whose ratios can range from about 0.0001 to 10,000 parts by weight base to 1 part by weight epoxide.
The proton acceptor or accepting compound is used in amounts effective to effectively scavange the requisite protons. Such amounts can range from about 10,000 to 1:1 mole, preferably from about 100 to 1 mole:1, most preferably from about 20 to 1:1 mole (moles proton acceptor:mole secondary amine compound of formula (I)).
Process C can be conducted neat, although a solvent is preferred. Where a solvent is employed the contacting is conducted in the presence of a solvent whose amounts can range from an amount sufficient to at least partially solubilize one or both of the reactants and/or the desired product to an excess of either starting reactant. Generally the amount of solvent can range from about 1 to 5,000 percent or more by weight of the individual reactant, preferably from about 2 to 1,200 percent by weight. The contacting of the reactants is conducted for a time effective to substantially complete the reaction, preferably from about 5 minutes to about 24 hours or more, preferably from about 15 minutes to about 4 hours. Generally the reactants are stirred during the contacting.
Optionally, the process can be conducted in the presence of a catalyst such as N,N-dimethylaniline, 4-dimethylaminopyridine or phase-transfer catalysts. The term "phase transfer catalyst" is intended to mean a material which catalyzes a reaction by the transfer of one phase to another. Phase transfer catalysts suitable for carrying out the process of the present invention include the quaternary ammonium and phosphonium salts, ethers and tertiary amines, such as tributyl amine, such as those described in U.S. Pat. No. 3,969,360.
Where a catalyst is employed, a catalytic amount is used ranging from about 0.0001 to about 0.5 parts by weight of reactant, preferably from about 0.001 to about 0.1 parts by weight.
The reactants are contacted in Process C at a temperature effective to yield the derived product, generally at temperatures ranging from about -40° to about 200° C., preferably from about 0° to about 80° C., depending upon the boiling point of the epoxide, solvent or starting materials. The contacting is performed at ambient pressures, although pressures greater than or less than ambient can be employed.
The following examples illustrate the present invention in a manner of which it can be practiced but, as such, should not be construed as limitations upon the overrall scope of the same.
EXAMPLE 1
Preparation of 4 -Hydroxy-1-Phenyl-3-(1-Pyrrolidinyl)-1,8-Naphthyridin-2-(1H)-One ##STR11##
To a suspension of 1.4 g (4.1 millimoles (mM) of 3-pyridinecarboxylic acid-2(((1-pyrrolidinyl)acetyl) phenylamino)methyl ester in t-butylmethylether at 0°-5° C., 1.03 g (9.2 mM) potassium-t-butoxide is added. The reaction mixture is stirred for an additional 0.5 hour at -5° C. and allowed to warm up to room temperature. Next 0.75 mL glacial acetic acid is added very slowly. The resultant solid is filtered, washed with t-butylmethylether, methylene chloride, acetone, water and acetone. The product is air dried to give 0.94 g (73% yield) of title compound, a white solid.
EXAMPLE 2
Preparation of 4-Hydroxy-1-Phenyl-3-(1-Pyrrolidinyl)-1,8-Naphthyridin-2-(1H)-One ##STR12##
To a solution of 1.5 g (6.5 mM) 2-anilinonicotinic acid, methylester, in dry xylenes at room temperature is added 0.69 g (14.54 M) of sodium hydride (NaH) (50 percent (%) oil emulsion) followed by addition of a small amount of N,N-dimethylformamide (DMF). The reaction mixture is heated to a temperature ranging between 85-95 degrees Centigrade (° C.) and 1.05 milliliters (mL) (6.5 mM) of ethyl-1-pyrrolidineacetate in xylene is slowly added over a period of 10 minutes. The reaction mixture is heated for 1 to 3 hours prior to the addition of aliquots of 0.32 g NaH followed by 1.05 mL of ethyl-1-pyrrolidineacetate as described above (total 3 aliquots). Following addition of the aliquots, the reaction mixture is cooled to 0° C., quenched with a slow addition of glacial acetic acid, and then water is added. The product is filtered and washed with water, acetone, methylene chloride, and acetone. The solid then obtained is dried in vacuo to give 1.20 g (60% yield) of title compound, a white solid.
EXAMPLE 3
Preparation of 3-Pyridine Carboxylic Acid, 2-((Chloroacetyl)Phenylamino), Methylester ##STR13##
To a stirred solution of 26.3 g 2-anilinonicotinic acid methylester (11.5 mM) in t-butylmethylether at 50° C. (oil bath) under nitrogen atmosphere, 20.2 mL chloroacetylchloride (25.39 mM) followed by 32.4 mL propylene oxide (46 mM) is added. The reaction mixture is stirred at 50° C. for 2 additional hours, cooled to room temperature, diluted with t-butylmethyl ether and washed with water containing NaHCO 3 . The layers are separated, the aqueous layer is extracted with t-butylmethylether, the combined organic layers are dried over anhydrous Na 2 SO 4 and concentrated in vacuo to obtain a gummy solid which is recrystallized from t-butylmethyl ether to give 30.5 g (87% yield) of title compound, an off-white solid.
IR (CHCl 3 ) 1700,1740 cm -1 ,
NMR (CDCl 3 δ4.1 (chloromethyl).
EXAMPLE 4
Preparation of 1-(1,2-Dihydro-4-Hydroxy-1-Phenyl-2-Oxo-1,8-Naphthyridin-3-Yl)-Pyrrolidinium Hydroxide, Inner Salt
Step A: To a stirred solution of 25.45 g (0.11 M) of methyl-2-phenylamino-nicotinate in 160 mL of t-butyl methyl ether (tBuOMe) (dried over 3A° sieves) heated to 50° (under N 2 ) 19.5 mL (2.2×0.11 M) of chloroacetylchloride followed by 31 mL (4×0.11 M) of propylene oxide was added. The reaction mixture was heated at 50° C. for 1.5 hours and then 300 mL tBuOMe was added. This solution (cooled to room temperature) was washed with 200 mL H 2 O containing 9.37 g (0.11 M) of NaHCO 3 followed by 30 mL of saturated aqueous NaCl solution. At this stage the product that crystallized out was dissolved in 100 mL CH 2 Cl 2 and this CH 2 Cl 2 was mixed with tBuOMe solution. The solution, as is, was used for the next reaction.
Step B: To the above solution at room temperature under N 2 , 37.2 mL (4×0.11 M) of pyrrolidine was added and this solution was gently refluxed overnight. 9.3 mL (0.11 M) of pyrrolidine was added, and the reaction was refluxed for an additional two hours. This mixture was diluted with 600 mL tBuOMe and washed with 300 mL H 2 O and the aqueous layers were back extracted with 200 mL tBuOMe. The combined organic (tBuOMe) layer was washed with 150 mL saturated aqueous NaCl soln., dried over anhydrous Na 2 SO 4 , and then concentrated in vacuum (oil pump vacuum) to 64.6 g of a crude brown semisolid, which was the methyl ester of 2-[[1-pyrrolidinyl acetyl]phenylamino]-3-pyridine carboxylic acid.
Step C: The solid from step B above was suspended in 600 mL of cold (0° C.) tBuOMe (dried over 3A° sieves) under N 2 . To this cold stirred mixture, 27.5 g (2.2×0.11 M) potassium t-butoxide was added, the reaction mixture was stirred for 1 hour, and then it was quenched with 15 mL (2.4×0.11 M) of glacial acetic acid.
The stirred reaction mixture was allowed to attain room temperature and then 350 mL H 2 O was added to it. The resultant solid was filtered, washed with tBuOMe, H 2 O, a small amount of CH acetone, and then air dried to obtain 27.09 g of the white product 1-(1,2-dihydro-4-hydroxy-1-phenyl-2-oxo-1,8-naphthyridin-3-yl)-pyrrolidinium hydroxide, inner salt. The crude product was crystallized from 300 mL CH 3 OH+16 mL conc. H at 50° C. +3 g carbon; filtered, diluted with 575 mL H 2 O, cooled to 0° C. and filtered; and draft oven dried at 60° C. for about 18 hours to give 22.2 g (82%) of crystallized white product.
Preparation of Starting Materials
The starting materials employed in processes A, B and C are known or can be prepared from known procedures. See, for example, U.S. Pat. Nos. 4,684,727; 4,452,800, 4,492,702 and 4,680,298 whose preparative teachings are incorporated herein by reference.
The present example, illustrates one method of which starting materials of the present invention may be prepared, but as such, should not be contrued as limitations upon the overall scope of the same.
EXAMPLE 5
Preparation of 3-Pyridine Carboxylic Acid, 2(((1-Pyrrolidinyl)Acetyl)Phenylamino)Methyl Ester ##STR14##
To a gently refluxing stirred solution of 1 gram (g) (3.3 (mM) of 3-pyridinecarboxylic acid-2((chloroacetyl)phenylamino)methyl ester in t-butylmethyl ether, 1.1 milliter (mL) pyrrolidine (13.2 mM) is added. The reaction mixture is refluxed for 2.5 hours, diluted with t-butylmethyl ether, and washed with water. The water layer is extracted with t-butylmethyl ether, and the combined organic phases are washed with a saturated aqueous sodium chloride (NaCl) solution, dried over anhydrous sodium sulfate (Na 2 SO 4 ) and then concentrated in vacuo to give 1.1 g (93% yield) of title compound, a tan solid.
IR (CHCl 3 ) 1685, 1725 cm -1 ,
NMR (CDCl 2 ) δ3.25 (N--CO--CH 2 --N).
While the present invention has been described in conjunction with the specific embodiments set forth above, many alternatives, modifications, and variations thereof will be appoint to those of ordinary skill in the art. All such alternatives, modifications and variations are intended to fall within the spirit and scope of the present invention.
|
The process for making certain bicyclic compounds and intermediates which are useful as anti-allergic, anti-inflammatory and cytoprotective agents.
| 2
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to compositions useful for development of muscle mass in animals, and specifically relates to such compositions, particularly dietary supplements, which contain well-tolerated and ingestible nicotine and/or nicotinic acetylcholine receptor agonists in therapeutically effective amounts to enhance muscle mass development in animals.
[0003] 2. Description of Related Art
[0004] Researchers have shown that administration of nicotine or nicotinic acetylcholine receptor (nAChR) agonists have beneficial effects in producing angiogenesis and vasculogenesis, particularly in wound healing events. Nicotine and nAChR agonists have also been shown to have beneficial effects in neuromuscular development. That is, experimental data has demonstrated that administration of pharmaceutical grade nicotine or nAChR agonists dissolved in water can, for example, stimulate certain growth factors, such as fibroblast growth factor (FGF), which facilitates proliferation of vascular endothelial cells in vitro. Other experimental data has shown that pharmaceutical grade nicotine dissolved in water and administered to pregnant rats has a positive effect on improving muscle strength in the neonatal offspring.
[0005] It has further been disclosed in pending U.S. Published Application No. 2004/0167179 A1 that pharmaceutical grade nicotine or nAChR agonists, when dissolved in water and administered in connection with exercise, has an enhancing effect on recruiting and mobilizing endogenous stem cells to a specific muscle mass for development of that muscle area or mass that is subjected to exercise. It is suggested that the beneficial effects of administering pharmaceutical grade nicotine or nAChR agonists in the described manner are relevant to those who, in particular, are desirous of improving muscle mass or body tone as a result of weight lifting or similar exercise.
[0006] The pharmaceutical grade nicotine and nAChR agonists that have been used in these past endeavors, while providing the intended effect, have been shown to be intolerable for human and animal consumption because of the inherent unpleasant taste and non-comestibility of the pharmaceutical grade nicotine and nAChR agonists. This is particularly significant since the primary mode of nicotine absorption takes place through the membranes or lining of the mouth. Consequently, the fact that pharmaceutical grade nicotine and nAChR agonists are not well-tolerated or suited for human and animal consumption undermines any beneficial effect that may be derived from administering nicotine and nAChR agonists.
[0007] Thus, it would be advantageous in the art to provide compositions containing therapeutically effective amounts of nicotine and nAChR agonists for enhancing the development of muscle mass in both humans and animals which is well tolerated and comestibly suitable for ingestion by humans and animals so that they might derive the beneficial effects thereof.
BRIEF SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, compositions are provided which contain nicotine and/or nicotinic acetylcholine receptor agonists in therapeutically effective amounts for providing enhanced muscle mass development in animals, where the nicotine an/or nicotinic acetylcholine receptor agonists are derived from natural sources that provide an improved tolerance and ingestibility of the nicotine to thereby render the compositions tolerable for ingestion by both humans and animals.
[0009] The compositions of the present invention contain nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists which are derived from sources that render the nicotine and nAChR agonists more well-tolerated for consumption, and thereby more ingestible. The nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists are particularly derived from natural plant sources that may be referred to herein as “green source.” Green source nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists render a composition that is more palatable and more tolerated when ingested, and can provide increased concentrations of nicotine than are available through use of pharmaceutical grade nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists, such as has been used in the prior art.
[0010] While nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists are found in a number of plant sources, it was discovered by the inventors that not all plant sources provide nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists which are well-tolerated and ingestible or of the highest extracted concentration. It has been found that nicotine and/or nicotinic acetylcholine receptor agonists from certain green sources disclosed herein provide not only a more well-tolerated nicotine or nAChR agonist extract, but provide improved concentrations of those materials.
[0011] The compositions of the present invention further comprise additional ingredients that may enhance the ingestibility of the nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists by not only enhancing the tolerability of the nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists, but by increasing the effectiveness of the nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists in enhancing muscle mass development.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The compositions of the present invention comprise a blend of botanical ingredients where the principal active ingredient is nicotine and/or nicotinic acetylcholine receptor (nAChR) agonists that is derived from selected plant sources (i.e., green source) determined to provide nicotine and/or nAChR agonists that are well-tolerated and ingestible. Nicotine and nAChR agonists can be found in a number of plant sources, particularly those plants that are in the Solanaceae family, such as tobacco and tomatoes.
[0013] Plants in the genus Nicotiana , which includes tobacco, are those sources that most readily come to mind in terms of producing nicotine. However, it is nicotine and nAChR agonists derived from those sources that have been used in the past to effect angiogenesis, vasculogenesis and neuromuscular development, and such nicotine and nAChR agonists have proven to be poorly tolerated at ingestion. Because of their characteristic of poor tolerance and uningestibility, the use of such nicotine and nAChR agonists from the genus Nicotiana has proven to limit their usefulness in administration for, among other things, enhancing muscle mass development.
[0014] Thus, it has been discovered that certain other genera, species and cultivars of the Solanaceae family provide sources for deriving nicotine and nAChR agonists that are more well-tolerated and ingestible, and which, in some cases, provide a higher concentration of extracted nicotine and nAChR agonists than can be derived from the traditionally-used or known plant sources. Another source of well-tolerated nicotine or nAChR agonists is the horsetail plant, which is in the Equistetaceae family.
[0015] It has been determined, for example, that nicotine and nAChR agonists derived from the genus Lycopersicon (tomatoes), Solanum (potatoes and eggplant) and Physalis (tomatillo), all in the Solanaceae family, are particularly well-tolerated and ingestible. More particularly, it has been determined that nicotine and nAChR agonists derived from green tomatoes is not only well-tolerated and ingestible, but provides an increased concentration of nicotine and nAChR agonists upon extraction from that plant source.
[0016] An exemplar process by which nicotine and nAChR agonists may be derived from any of the identified plant sources is as follows:
[0000] Extraction Process
[0017] Raw plant material (e.g., green tomato or potato) that has been dried by any conventional process, including air drying or placement in a dehydrator, is processed to a dry flake form. From between 5.0 Kg to 10.0 Kg of dried raw plant material is then weighed and placed in a milling machine for processing to a selected size (e.g., about 0.2 mm to about 1.2 mm, or from about 15 mesh to 35 mesh). The milled product is then hydrated using a solvent (e.g., 50% ethanol-water mixture). The hydrated material is then macerated in a stainless steel macerator for a period of from about one hour to six hours, during which time a solid-liquid extraction occurs providing a mother liquor and extracted liquid. The extracted liquid is then distilled to remove or condense the alcohol content in the liquid, and approximately 40% to 70% of the volume of extracted liquid is retained. The resulting distillate is then mixed with the mother liquor to produce a final liquid extract and the liquid extract is placed in a 20.0 liter capacity container. The liquid extract is placed in a drying chamber and dried for a period sufficient to produce a dried powder having a water content of 5% or less. The resulting powder extract derived from the drying process is then tested to assure that it contains from 4 to 7 μg of nicotine or nAChR agonist, and preferably about 6 μg of nicotine or nAChR agonist.
[0018] In compositions of the present invention, the nicotine and nAChR agonists extracts may be blended with other phytonutrients or extracts including antioxidants, such as grape seed extract, green tea polyphenols, beta carotenes, vitamin C ascorbic acid and derivatives thereof, Vitamin A retinols and derivatives thereof, Vitamin E tocopherols and tocotrienols and derivatives thereof, oligomeric procynidins and derivatives thereof, carotenoids (e.g., lyopene, lutein, zeaxathine, etc.) resveratrol, carnosic acids and derivatives thereof, and ellagic acid and derivatives thereof.
[0019] The compositions may also include anti-inflammatory agents, such as quercetin, rutin, white willow bark (salicylic acid), essential fatty acids (EFA) such as omega-3 fatty acids from vegetable sources or marine sources, hyssop ( Arnica montana ), scutellaria baicalensis and acacia catechu , and combinations thereof, alfalfa, ashwaganda ( withania somnifera ), autumn crocus ( colchicum autumnale ), barberry ( berberis vulgaris ), beta-sitosterol, bitter orange ( citrus aurantium ), bittersweet nightshade ( solanum dulcamara ), boldo ( peumus boldus ), buchu ( agathosma betulina ), cat's claw ( uncaria tomentosa ), cinnamon, comfrey ( symphytum officinale ), devil's claw ( harpagophytum procumbens ), dong quai ( angelica sinensis ), emblica ( emblica officinalis ), Emu oil ( dromaius novae - hollandiae ), fenugreek, frankincense ( boswellia serrata ), ginger, horse chestnut ( aesculus hippocastanum ), kalanji ( nigella sativa ), kalmegh ( andrographis paniculata ), milk thistle ( silybum marianum ), ocgacosanol, papaya, propolis ( propolis balsam ), poria ( poria cocos ), perilla frutescens, Royal jelly, savory ( Satureja hortensis ), sour cherry ( prunus cerasus ), tinospora cordifolia and witch hazel ( hamamelis viginiana ). The anti-oxidant and anti-inflammatory extracts may be beneficial in ameliorating certain effects of more strenuous exercise on muscles when the compositions of the present invention are administered to humans and animals in the development of muscle mass.
[0020] The compositions of the present invention may also include one or more vitamins, including but not limited to retinol, thiamin, riboflavin, niacin, pyridoxine, ascorbic acid and Vitamin D. The compositions may also include one or more minerals, such as calcium, iron, magnesium, selenium and zinc.
[0021] In further formulation of the compositions, various ingredients may be included in the compositions to improve the aesthetic qualities of the compositions, such as taste, color and ingestibility. Such ingredients would include, for example, flavorings, colorants, binders, fillers, flow agents and lubricating agents. These agents are well-known in the pharmaceutical and dietary supplement industries for formulating compositions into various forms, including tablets, capsules, powders and the like.
[0022] An exemplar formula for the present composition may comprise the following:
INGREDIENT Percent by weight Nicotine/nAChR agonist extract 3-9% (e.g., from green tomato extract containing from 3-7 μg of nicotine or NAChR agonist) Antioxidant(s) 0.001-0.10% (e.g., grape seed extract 95%) Anti-inflammatory agent(s) 0.001-0.10% (e.g., quercetin dihydrate, rutin) Flavoring agents 75-92% Vitamins and/or minerals 1-5% Lubricating agents 1-3% Binding agents 0.1-1% Flow agents 0.1-1% Colorants 0.1-1%
[0023] The foregoing exemplar formulation is not intended to limit the compositions of the present invention. Other ingredients may be added to, and indeed may be eliminated from, the general formula set forth above and still be within the scope of the invention as set forth in the claims. It is requisite to the invention, however, to provide a therapeutically effective amount of nicotine or nAChR agonists in the formula to provide enhanced development of muscle mass.
[0024] One exemplary and suitable composition directed to enhancement of muscle mass in humans comprises a 200 mg tablet formulated as follows:
Nicotine/nAChR agonist extract (containing about 3-9 mg 6 μg of nicotine/nAChR agonist Antioxidants (green tea and grape seed extracts) 0.001-0.002 mg Anti-inflammatory agents (quercetin and rutin) 0.001-0.002 mg Tomato concentrate from tomato paste (flavoring 20-27 mg agent) Sucrose (primarily a binding agent and flavoring 110-130 mg agent) Other flavoring agents (bitter masking flavor, 2-3 mg Prosweet flavoring agent) Sodium chloride 4-8 mg Vegetable flavor FG-3294 0.2-1.0 mg Riboflavin (B2) 12-22 mg Stearic acid 4-8 mg Magnesium stearate 0.5-1.5 mg Silicon dioxide 0.5-1.5 mg FD&C red #40 lake 0.5-1.5 mg
[0025] Although the foregoing exemplar composition may be formed into a tablet form, capsule forms and powdered forms are also within the scope of the invention and are within the skill in the art to form by known methods. However, by way of example, tablets comprising the ingredients noted above may be formulated by mixing the ingredients, all of which are in a dry powder form, in a ribbon blender until well blended. The resulting mixture is then compressed to a specified weight (e.g., 200 mg), a specified thickness (e.g., 0.135 inches) and specified hardness (e.g., 1118-25 Kp) using a suitable tablet press.
[0026] Tablets or capsules of the composition of the present invention may further be formed or formulated for timed- or delayed-release by, for example, providing a suitable outer or intermediary coating on or in the tablet or capsule, in known manner, to provide a selected time release of the composition. Any suitable means known in the art by which tablets and capsules may be formed or formulated for timed- or delayed-release may be used.
[0027] As previously noted, the compositions of the present invention are particularly suitable for use in enhancing muscle mass development in humans and animals. The enhancement of muscle mass development is mediated, in particular, by administration of the compositions of the present invention in conjunction with the performance of exercise. Thus, administration of a dosage of the composition prior to the performance of exercise has been shown to be effective for increasing muscle mass development (as described, for example, in U.S. Published Application No. 2004/0167179 A1).
[0028] For humans, a daily dosage of the compositions of the present invention containing a therapeutically effective amount of nicotine and/or nAChR agonist extract is from three to nine mg. The daily dosage is preferably administered thirty to sixty minutes before commencement of an exercise session. The daily dosage is taken, preferably, by placing the dosage form (e.g., tablet, capsule, powder) under the tongue or in the side of the mouth, allowing the composition to be absorbed slowly in the mouth. The compositions of the present invention may be particularly beneficial when taken in conjunction with the performance of very rigorous exercise (i.e., at or near the exhaustion of a given muscle mass).
[0029] The present compositions may also be administered to animals for the enhancement of muscle mass development. For smaller animals, such as dogs or other similarly sized animals (e.g., weighing from about 30 to about 180 pounds or more), a daily dosage of a therapeutically effective amount of nicotine and/or nAChR agonist extract is from about 20 mg to about 35 mg, or from between about 10 μg and 38 μg of nicotine and/or nAChR agonist. For larger animals, such as horses or similarly sized animals (e.g., weighing greater than about 700 pounds), a daily dosage of a therapeutically effective amount of nicotine and/or nAChR agonist extract is from about 45 mg to about 100 mg, or from between about 22 μg and 112 μg of nicotine and/or nAChR agonist. Such daily dosages may be administered to animals in conjunction with the imposition of an exercise regimen, most especially a rigorous regimen, for the subject animal to improve muscle mass development to overcome injuries or to train the animal for improved performance, such as for racing.
[0030] The formulas and constituent ingredients described herein are merely examples of various formulations for the compositions of the present invention and are not intended to limit the scope of the invention. Those of skill in the art will understand that the compositions of the present invention, in addition to providing the requisite therapeutically effective amount of nicotine and/or nAChR agonist extract as described herein, may include other ingredients to facilitate the formulation of the compositions.
|
Compositions containing nicotine and/or nicotinic acetylcholine receptor agonists are provided for administration in therapeutically effective amounts to enhance muscle development in animals, the nicotine and/or nicotinic acetylcholine receptor agonists being particularly derived from natural sources that produce beneficially high amounts nicotine and/or nicotinic acetylcholine receptor agonists which is also well-tolerated and ingestible for the intended purpose.
| 0
|
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/434,509, filed on Dec. 18, 2002, hereby incorporated herein in its entirety by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates generally to internal combustion engines and in particular the present invention relates to directing the flow of oil in an internal combustion engine.
BACKGROUND OF THE INVENTION
[0003] One type of internal combustion engine is an overhead camshaft diesel engine that is commonly used in diesel-electric locomotives and in marine and power generation applications. This engine can be produced in a “V” configuration, where two banks of cylinder assemblies form the “V”, or as a straight block where the cylinder assemblies are in a straight line.
[0004] Each bank of cylinder assemblies has an upper deck assembly that covers the cylinders. The upper deck assembly is typically comprised of metal that is formed to fit around the cylinders in addition to a cover that is connected to the top of the metal sides. The upper deck assembly is bolted to the engine block with a gasket between the upper deck sides and the engine block. The gasket prevents oil from within the engine from leaking out during normal operation.
[0005] Each bank of cylinder assemblies has at least one overhead camshaft comprised of cam lobes that engage followers on rocker arms as the layshaft rotates. This action can be used to actuate valve mechanisms and other mechanical devices.
[0006] To ensure proper operation of the layshafts, each camshaft is supplied with lubricating oil, as is each bearing through which the camshaft rotates. A portion of the lubricating oil comes from oil sprayed by various moving parts of the engine including the rocker arms and followers.
[0007] The gasket between the engine block and upper deck assembly cannot always keep oil from leaking out of the engine due to uneven clamping of the upper deck assembly to the engine block. Additionally, imperfections in the surface of the upper deck frame that forms one side of the gasket joint can allow oil out of the engine. This can result in damage to the engine from the oil on the exterior of the engine. There is a resulting need in the art to prevent oil from leaking out from between the upper deck assembly and the engine block.
SUMMARY
[0008] The embodiments of the present invention encompass an oil deflector apparatus. In one embodiment, the apparatus is used in an internal combustion engine having an engine block, an upper deck assembly, and a gasket between the engine block and the upper deck assembly. At least one surface of the gasket is internal to the engine.
[0009] A first portion of the apparatus extends lengthwise over the gasket. The first portion is capable of being coupled to the engine block. A second portion is coupled to and extends lengthwise along the first portion. The second portion is coupled to the first portion at an angle such that the surface of the gasket that is internal to the engine is substantially covered.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 shows an exploded view of one embodiment of the upper deck oil deflector apparatus of the present invention.
[0011] [0011]FIG. 2 shows a detailed view of one embodiment of the interconnection of the parts of the upper deck oil deflector apparatus in accordance with the embodiment of FIG. 1.
[0012] [0012]FIG. 3 shows a cross-sectional view of one embodiment of the interconnection parts of the upper deck oil deflector apparatus of the present invention.
[0013] [0013]FIG. 4 shows a perspective view of one embodiment of the upper deck oil deflector apparatus of the present invention as installed around a layshaft support in an internal combustion engine.
[0014] [0014]FIG. 5 shows a cross-sectional view of one embodiment of the upper deck oil deflection apparatus as installed in an internal combustion engine.
[0015] [0015]FIG. 6 shows a detailed view of one embodiment of the upper deck oil deflector apparatus of the present invention in accordance with the embodiment of FIG. 5.
[0016] [0016]FIG. 7 shows a side perspective view of one embodiment of an internal combustion engine incorporating the upper deck oil deflection apparatus of the present invention.
DETAILED DESCRIPTION
[0017] The upper deck oil deflector apparatus of the embodiments of the present invention deflects oil away from the gasket that is between the upper deck assembly and the engine block. The deflector substantially reduces the amount of oil that can leak out from between the upper deck assembly and the engine block.
[0018] [0018]FIG. 1 illustrates an exploded view of one embodiment of the upper deck oil deflector apparatus of the present invention. This embodiment is comprised of three separate sections ( 101 - 103 ) that are connected together at the end ( 106 and 107 ) as described subsequently with reference to FIGS. 2 and 3. As will be seen in these figures, the end portions ( 106 and 107 ) have half the thickness of the rest of the section ( 101 - 103 ) so that when the end portions ( 106 and 107 ) are overlapped with the connecting sections, the entire thickness of the apparatus is substantially uniform.
[0019] Alternate embodiments are not limited to any predetermined quantity of sections or length of sections. For example, one embodiment may be only one section for the entire deflector apparatus. Additional embodiments may incorporate more or fewer than three sections.
[0020] The deflector apparatus, in one embodiment, is comprised of an injection molded polyurethane material. Alternate embodiments may use different materials and different manufacturing methods.
[0021] The deflector apparatus has a horizontally molded portion ( 110 ) that incorporates mounting holes through which mounting bolts or other types of fasteners can be inserted. These mounting holes are discussed subsequently in greater detail with reference to FIGS. 2 and 3.
[0022] A vertically molded portion ( 112 ) incorporates camshaft support extensions ( 130 - 137 ) that wrap around the camshaft bearing supports in the engine block. These extensions improve the oil deflection characteristics of the apparatus by keeping the oil sprayed from the camshaft bearing area from the gasket.
[0023] Since the deflector apparatus is injection molded, the horizontal ( 110 ) and vertical portions ( 112 ) are constructed as one unit. The layshaft support extensions ( 130 - 137 ) that are distributed lengthwise along the apparatus are also injection molded as one unit with the rest of the apparatus. However, alternate embodiments that use different manufacturing methods may construct each section ( 101 - 103 ) of the apparatus from separate portions ( 110 and 112 ). Additionally, the terms vertical and horizontal are used only for purposes of clarity in describing the apparatus. The two portions of the oil deflector apparatus of the embodiments of the present invention are not necessarily horizontal and vertical nor are they required to be orientated 90° to each other as illustrated in the embodiment of FIG. 1. The orientation of the lengthwise portions that comprise the deflector apparatus is determined by the engine configuration to which the apparatus is mounted. In alternate embodiments, the two lengthwise portions may be angled in a range between 0° and 180°.
[0024] In one embodiment, the two end sections ( 101 and 103 ) of the oil deflector apparatus have a short “L” portion incorporated at the outside end ( 150 and 151 ) of each section ( 101 and 103 ). This “L” portion extends up the side of each end of the upper deck assembly. Alternate embodiments may not incorporate this feature.
[0025] The embodiment illustrated in FIG. 1 does not have a symmetrical construction with regard to the mounting holes and the layshaft support extensions. The locations of these items are determined by the engine to which the deflector apparatus is mounted. Therefore, the present invention is not limited to any one configuration of mounting holes and layshaft support extensions. In fact, one embodiment may not even require the layshaft support extensions if the engine's layshaft is mounted far enough below the deflector apparatus so as not to interfere with the mounting of the apparatus over the gasket.
[0026] As described subsequently with reference to FIG. 5, a typical internal combustion engine uses two of the oil deflector apparatuses of the present invention. One deflector apparatus is installed over the gasket on the outside of each bank of cylinder assemblies.
[0027] [0027]FIG. 2 illustrates a detailed view of one embodiment of the interconnection of two of the sections ( 101 and 102 ) of the upper deck oil deflector apparatus in accordance with the embodiment of FIG. 1. This detailed view shows the plurality of mounting holes ( 225 - 229 ) through which mounting bolts ( 205 ) or other types of fasteners are inserted. The ends ( 220 and 221 ) of each section ( 102 and 101 ) are approximately half as thick as the remaining portions of the section ( 101 or 102 ) so that when the two sections ( 101 and 102 ) are joined, the combined thickness is substantially uniform with the remainder of the sections.
[0028] In the embodiment of FIG. 2, the sections ( 101 and 102 ) are connected with a bolt ( 205 ), and a flanged spacer ( 210 ). When the oil deflector apparatus is mounted on an engine, the connecting bolt ( 205 ) is one of the plurality of bolts used to mount the apparatus to the engine. These bolts are inserted through the mounting holes ( 225 - 229 ) into threaded holes in the engine block. In one embodiment, the same bolts that mount the upper deck assembly to the engine block are used to mount the oil deflector apparatus over the gasket that is between the upper deck assembly and the engine block.
[0029] The mounting hole in the bottom section ( 102 ) that is joined to the upper section ( 101 ) is substantially the same size as the mounting hole in the upper section ( 101 ). A cross sectional view of this mounting detail is illustrated in FIG. 3 and described subsequently.
[0030] The embodiment of FIG. 2 also illustrates one of the layshaft support extensions ( 240 ). If these extensions are required, the shape, size, and position of the extensions ( 240 ) will vary depending on the engine.
[0031] As discussed previously, the different sections ( 101 and 102 ) of the deflector apparatus are not symmetrical. Therefore, each section must be joined to the appropriate end of another section. The assembly can be made more foolproof by the addition of symbols ( 230 and 231 ) on each end to be joined with another. In the embodiment of FIG. 2, these symbols are rectangles. In other words, when the rectangles are matched up, those ends are properly orientated. The other sections of FIG. 1 to be joined will have different symbols to differentiate them. For example, they may have circles indicating a proper orientation. Alternate embodiments may use other orientation symbols such as alphanumeric characters.
[0032] [0032]FIG. 3 illustrates a cross-sectional view of one embodiment of the interconnection parts of the upper deck oil deflector apparatus of the present invention. This figure illustrates the same bolt ( 205 ) and flange-type spacer ( 210 ) as illustrated in FIG. 2.
[0033] [0033]FIG. 3 shows two sections ( 301 and 302 ) of the oil deflector apparatus being connected with the interconnection hardware ( 205 and 210 ). Each section has an end portion ( 310 and 315 ) that functions as an overlap joint when the sections are joined. These portions ( 310 and 315 ) are half as thick as the remainder of their respective sections ( 301 and 302 ) so that when they are joined together with the interconnection hardware ( 205 and 210 ) the completed assembly has the same thickness as the remainder of the oil deflector apparatus.
[0034] In one embodiment, the mounting hole in the upper section ( 301 ) is substantially the same size as the mounting hole in the lower section ( 302 ). This provides a mounting hole through which the one-piece flanged spacer ( 210 ) can be inserted prior to inserting the mounting bolt ( 205 ).
[0035] The remaining section oil deflection apparatus has similar mounting holes for connecting the remaining section to complete the apparatus and mount it to the engine. Alternate embodiments may use different size mounting holes in each section, depending on the mounting hardware used.
[0036] The bolt ( 205 ) is inserted into threaded mounting holes in the engine block in order to hold the oil deflector apparatus in place over the gasket. This mounting configuration is described subsequently.
[0037] [0037]FIG. 4 illustrates a perspective view of one embodiment of one section of the upper deck oil deflector apparatus of the present invention as installed around a layshaft support in an internal combustion engine. This view shows a layshaft support extension ( 400 ) that mounts around the layshaft support hardware ( 410 ) in the engine.
[0038] As is well known in the art, the layshaft support ( 410 ) contains a bearing through which the layshaft ( 415 ) rotates. Oil from this bearing can be splashed on the gasket. The layshaft support extension ( 400 ) prevents this oil from reaching the gasket as well as allowing the oil deflector apparatus to fit the length of the engine block around these supports.
[0039] [0039]FIG. 5 illustrates a cross-sectional view of one embodiment of the upper deck oil deflection apparatus as installed in an internal combustion engine. This figure shows a typical internal combustion engine having an engine block ( 530 ) that contains the crankshaft, pistons, and other engine hardware. The embodiment of FIG. 5 is comprised of two banks of cylinder assemblies ( 501 and 502 ). Each cylinder assembly is covered with an upper deck ( 510 and 511 ). The gasket ( 512 and 513 ) to be protected is located between the upper deck ( 510 and 511 ) and the engine block ( 530 ).
[0040] In one embodiment, the oil deflector apparatus ( 520 and 521 ) of the present invention is mounted over the gaskets ( 512 and 513 ) on the outer sides of the engine block ( 530 ). These are the gaskets that receive the most oil contact from the internal splashing of oil. Alternate embodiments mount the oil deflector apparatus ( 520 and 521 ) over all of the gaskets between each upper deck ( 510 and 511 ) and the engine block ( 530 ).
[0041] As discussed above, due to the asymmetrical character of some engines, the oil deflector apparatus ( 520 ) that is mounted on one side of the engine block ( 530 ) will not fit on the other side of the engine block ( 530 ). This is due to the mounting holes and layshaft support hardware being in different locations on each side. In such an embodiment, the first oil deflector apparatus ( 520 ) is a mirror image of the second oil deflector apparatus ( 521 ). In alternate embodiments where the engine mounting holes and layshaft supports are symmetrically laid out, the same oil deflector apparatus can be used on either side of the engine. The area ( 500 ) of one of the oil deflector apparatuses ( 520 ) is illustrated in greater detail in FIG. 6.
[0042] [0042]FIG. 6 shows a cross sectional view of a portion of the left side upper deck assembly ( 510 ) mounted over the left portion of the engine block ( 530 ). The gasket ( 600 ) to be protected is mounted between them. The upper deck oil deflection apparatus ( 520 ) is mounted over the mounting surface ( 601 ) of the upper deck assembly ( 510 ). The same bolts that mount the upper deck assembly to the engine block ( 530 ) are used to mount the oil deflection apparatus ( 520 ).
[0043] A sealing lip ( 605 ) extends lengthwise along the sections of the apparatus ( 520 ) and projects upward to contact the upper deck assembly ( 510 ). The sealing lip provides extra protection against oil getting between the upper deck assembly ( 510 ) and the oil deflection apparatus ( 520 ).
[0044] [0044]FIG. 7 illustrates a right side perspective view of a typical internal combustion engine incorporating the upper deck oil deflection apparatus of the present invention. The upper deck assembly, in this embodiment, is comprised of the formed walls ( 701 ) with a cover ( 710 ) to enclose the cylinder assembly. The upper deck assembly ( 701 and 710 ) is then connected to the engine block ( 705 ) as described above. The oil deflection apparatus ( 700 ) is mounted lengthwise along the engine to cover the gasket. This is repeated for the second upper deck assembly on the other side of the engine.
[0045] The embodiment of FIG. 7 shows only the gaskets on the outer sides of the engine being protected by the oil deflector apparatus. In alternate embodiments, variations of the deflector apparatus can be mounted over any of the gaskets between the upper deck assembly and the engine block. To accomplish this, only the length, layout of the mounting holes, and locations of the layshaft extensions of the deflector apparatus need to be changed.
[0046] The embodiments described above mount the apparatus in the upper deck assembly of an internal combustion engine. However, the oil deflector apparatus of the present invention is not limited to only the upper deck assembly. Alternate embodiments could mount the oil deflector in any location in the engine in which it is desired to reduce oil contact.
[0047] In summary, the oil deflector apparatus of the present invention reduces oil leakage by deflecting oil away from the gasket. This reduces expensive maintenance required due to the oil leakage. The apparatus can be installed without any modifications to the existing engine other than mounting the apparatus over the gasket internal to the upper deck assembly.
[0048] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown. Many adaptations of the invention will be apparent to those of ordinary skill in the art. Accordingly, this application is intended to cover any adaptations or variations of the invention. It is manifestly intended that this invention be limited only by the following claims and equivalents thereof.
|
The oil deflector apparatus can be installed in an internal combustion engine to deflect oil from gaskets mounted between an upper deck assembly and the engine block. The apparatus has a first portion that extends lengthwise along the upper deck assembly and includes mounting holes that accept mounting hardware to couple the apparatus to the engine block. A second portion is coupled lengthwise along the first portion and is angled downward to cover any exposed surface of the gasket from the internal oil generated by the engine operation. Layshaft support extensions are distributed lengthwise along the apparatus to permit the apparatus to fit around the layshaft support hardware in the engine and to keep oil splashed from the layshaft from reaching the gasket.
| 5
|
BACKGROUND OF THE INVENTION
The present application is a continuation in part application of application Ser. No. 07/856,639, filed Mar. 24, 1992, U.S. Pat. No. 5,307,598.
FIELD OF THE INVENTION
This invention related to adjustable mounting systems and in particular to tube mounting systems for cantilever coupling of a tube onto a vertical post.
PRIOR ART
Posts and even ground mounting arrangements therefor for adjusting or tilting the post to a vertical attitude are not new. A recent patent to Deike, U.S. Pat. No. 4,603,520, shows an example of a mounting base for a sign post that will accommodate rotational, tilting and height adjustment. Where, like one embodiment the present invention, the Deike patent shows a ball and seat arrangement for providing tilting capability to a sign post, Deike utilizes four corner bolts to maintain that post tilted attitude rather than a ball and seat with a single bolt mounting like that of the present invention. Further, there is no teaching of a mail or newspaper box mounting to the mounting post in the Deike patent.
Additionally, a number of ground anchor arrangements for mounting posts, such as road side type sign posts, have been developed. Examples of such are shown in a U.S. Patents to Galloway, et al, U.S. Pat. No. 3,011,597, that involves an auger type post mount; Smith, U.S. Pat. No. 3,152,668, that teaches an anchor with a guy wire; Brisse, U.S. Pat. No. 3,186,523, that shows a wire anchoring system; Deike, U.S. Pat. Nos. 3,676,965 and 4,320,608, for sign post support sockets; and Klenk, et al U.S. Pat. No. 4,339,899, that sets out a system for coupling a power transmission tower to a support base. None of which above cited patents involve a post and ground mount for a mail box system, like that of the present invention, whereby the post can be quickly and easily aligned to the vertical and provide for securely mounting a mail box, or the like, onto which post.
Additional to the above cited U.S. patents, a ball and socket mount utilizing a single bolt and nut combination for positioning and securing a transit to a horizontal attitude is provided in a transit system identified as an automatic level, manufactured by Nikon Corp. of Japan, Manufacturers Part No. AX-1 and AX-1S. Which Nikon system is, of course, for a different use and application than the arrangement of the system of the present invention.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a unique peg arrangement for use in a right angle mounting of a mail or newspaper tube cantilevered outwardly from a vertical post.
Another object of the present invention is to provide a peg arrangement maintained to provide a bar or friction mount locking when installed, restricting removal.
Another object of the present invention is to provide a peg arrangement for use in a cantilever mounting of a tube to a post that is arranged to shear, to release the tube from the post should the tube receive a force directed against the side thereof as could damage the tube and post.
Still another object of the present invention is to provide a peg arrangement that is simple and inexpensive to produce and install by a person having only rudimentary tools and little or no mechanical skills.
The present invention is for use with an inexpensive, simple to install and yet durable post system. The post system includes a ground stake to be driven into the earth, mounted in cement, or the like. Which ground stake includes and arrangement for connecting, at an upper surface thereof, an adjustable mount wherefrom a post insert extends. Which post insert attitude to the vertical is adjustable and is maintained by a mounting that utilizes single nut and bolt fastener.
In one embodiment of the invention, the adjustable mount is a ball section and seat combination, where the ball section is maintained onto the top of the ground stake or anchor. The ball section to receive seat having a hemispherical inner surface that are positioned and held together by a single bolt coupling. The bolt is fitted through a hole formed through which seat and ball section, which ball section hole is tapered from a bottom end outwardly to a top end to allow for the bolt to tilt across the hole. So arranged, the seat is positionable across the ball section surface. A nut is provided for turning over a threaded end of which bolt within the post insert for clamping the seat onto the ball section surface. Alternatively, a friction gasket can be included therebetween, or the ball section surface can be grooved or scored for providing a non-slip coupling surface.
A second embodiment of which adjustable mounting involves a pair of sloping or tapered washers that are center holed to fit together as a stack and receive a bolt therethrough. Which bolt is also fitted through holes formed in opposing plates that are secured respectively, across the post insert bottom and the ground stake or anchor top surface. The washers fitted over one another have their tapered surface arranged juxtaposition to one another. The rotation of one of which washers over the other therefore increases or decreases, respectively, the thickness of the opposite washer stack edge. The washer stack top surface can therefore be angled to the vertical relative to its lower surface. Which angle translates to a tilt of the post, which post angle is maintained by turning a nut over which bolt threaded end.
The post insert is for receiving an end of a post, such as a post for mounting a mail box, fitted thereover. For which coupling, screw holes are formed through both the post and post insert that, with the post telescoped thereon, align to receive screws turned therethrough, securing the components together. Resilient spacers are preferably arranged between the opposing surfaces of which post and post insert to provide a tight coupling. Alternatively, the ball seat can be imbedded directly into the bottom of the post to eliminate the post insert.
The post can receive a mail box, or the like, secured across a top end thereof, may mount an open newspaper tube, or the like, cantilevered thereto, may be arranged as a fence post, or may be utilized for any function involving or requiring an upright, ground mounted post within the scope of this disclosure. A preferred cantilever mounting is provided by horizontally slotting the mail box post with a pair of parallel slots that are each to receive one of a pair of tabs formed as extensions of the tube end. Which tabs are holed, each hole to receive a peg that is formed to be easily manually fitted therethrough. The pegs are for binding in the tab holes to inhibit their withdrawal, and may include, as shown in one shear peg embodiment, a structurally weakened section thereacross along which the shear peg will shear to release the cantilevered tube, as when a significant force is applied to the tube as could damage the post if the tube is not released therefrom.
A mail box can be secured across the post top end utilizing a mount that includes a recess formed in the mount undersurface for receiving the post end, with screws turned through the contacting surfaces. Or, a frame for mount the mail box to the post end can be employed that is secured across the post end.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will become more apparent from the following description in which the invention is described in detail in conjunction with the accompanying drawings.
FIG. 1 shows an exploded side elevation perspective view of one embodiment of the post system of the present invention shown with ball segment and seat post to ground stake mounting and a tube cantilever mounted to an upper end thereof;
FIG. 2 shows a side elevation sectional view of an upper post portion and tube of FIG. 1;
FIG. 3A shows a side elevational sectional view taken within the line 3--3 of FIG. 2;
FIG. 3B shows an enlarged side elevation view of a peg of FIGS. 2 and 3A taken within the line 3B--3B of FIG. 3A;
FIG. 3C shows a view like that of FIG. 3B only showing another peg embodiment;
FIG. 3D shows a broken away section of a post and cantilevered tube with shear pegs of the invention aligned for fitting into holes of the parallel tabs of the tube end that has been fitted into parallel slots formed across the post;
FIG. 3E shows a sectional view take along the line 3E--3E of FIG. 3D;
FIG. 3F shows a view like FIG. 3D only showing the shear pegs fully inserted into the tab holes, as showing in FIG. 3E, and showing with arrow A a side force directed against the cantilevered tube causing the shear pegs to each brake across their weakened section;
FIG. 4 shows a side elevation sectional view of another ground stake, post insert with post segment showing another embodiment of an adjustable post to ground stake mounting of the present invention shown as a pair of tapered washers that are positionable relative to one another into a stack, the washer relative positioning to one another providing a tilt to the vertical of the post insert;
FIG. 4A shows a top plan sectional view of the top of the pair of tapered washers of FIG. 4 with tabs of which washers, that extend from a narrowest portion of each washer edge, extending oppositely;
FIG. 5 shows a side elevation sectional view like that of FIG. 4 except that the ground anchor is shown tilted from the vertical, which tilt is shown corrected by the alignment of the tapered washers tabs, that provides a tilt to the washer stack, whereby the connected post is aligned to the vertical;
FIG. 5A shows a top plan sectional view that is like that of FIG. 4A except that the tapered washer tabs are shown aligned over one another;
FIG. 6 shows a view like that of FIG. 4 except that a ball segment and seat mount like that of FIG. 1 is shown arranged between the ground anchor top and post insert bottom surfaces;
FIG. 7 shows an enlarged profile sectional view taken along the line 7--7 of FIG. 6 of the ball and seat segment mounting;
FIG. 7A shows a view like that of FIG. 7 except the seat is show moved out of center with the ball segment for aligning a connected post to the vertical;
FIG. 8 shows a top plan view of a friction gasket for arrangement between the surfaces of the ball and seat segment of FIG. 7;
FIG. 9 shows a top plan view of a washer for fitting between the top of the seat segment and the bottom surface of which post insert seat of the adjustable mounting;
FIG. 10 shows a profile perspective view of an upper section of the post of FIG. 1, the top end thereof shown aligned for receiving a first embodiment of a mail box mount thereon;
FIG. 11 shows a side elevation sectional view of the assembled post top end and mail box mount of FIG. 10;
FIG. 12 shows a top plan sectional view taken along the line 12--12 of FIG. 11;
FIG. 13 shows a side elevation view of another embodiment of a ground anchor and a side elevation sectional view of a post insert and post section secured thereto by another variation of a ball segment and seat adjustable mounting of the present invention;
FIG. 14 shows a side elevation perspective view of the tubular ground anchor of FIG. 13;
FIG. 15 shows an exploded view of a ball segment and seat adjustable mounting that is like that of FIG. 14 except that it is shown for use with a concrete mounted base plate;
FIG. 16 shows an exploded view of the ball segment and seat adjustable mounting of FIG. 13;
FIG. 17 shows an exploded side elevation perspective view of a mail box, a frame mount and cantilevered tube of the present invention;
FIG. 18 shows an end view of the mail box, frame mount and cantilevered tube of FIG. 17 in their connected attitude mounted to a post;
FIG. 19 shows a top plan view of a frame mount like that of FIGS. 17 and 18, except the frame of this embodiment is adjustable and is arranged for mounting a mail box onto a top end of a wood post by screws turned through mount bars and directly into top of a wood post;
FIG. 20 shows a profile perspective view of an adjustable mail box mount of the present invention;
FIG. 21 shows an enlarged end sectional view of the mail box pivoting cross bar taken within the line 21--21 of FIG. 20;
FIG. 22 shows a perspective view of the adjustable mail box mount of FIG. 20 utilized for mounting a mail box onto a wood beam;
FIG. 23 shows an end elevation view of the adjustable mail box mount of FIG. 20 mounting a mail box onto a wood post end, the pivoting cross bar shown pivoted to the vertical, with screws turned therethrough and into the post sides; and
FIG. 24 shows a top plan view of the adjustable mail box mount of FIG. 20, with the pivoting cross bars shown pivoted to the horizontal and with screws turned therethrough and into the end of a wood post.
DETAILED DESCRIPTION
The present invention is in a post system that includes a number of novel and unique elements. FIG. 1 shows an exploded profile perspective view of one arrangement of post system 20, hereinafter referred to as system. In FIGS. 1 and 2, the system 20 is shown used for mounting a mail or newspaper tube 21, hereinafter referred to as tube, cantilevered out from the side of a post 22. Which post 22, its ground mounting arrangements and fastener components, as set out hereinbelow, are also useful for mounting a mail box as shown in FIGS. 10 through 12, and 17 through 19. Though, of course, the system 20 and the other embodiments therein could be utilized as a post alone, for example a fence post, or could be used for mounting any item, within the scope of this disclosure.
The system 20 of FIG. 1 includes a ground stake 23, shown as a section of angle iron 24 that is pointed at a lower end 25. The upper or top end of which angle iron section includes a cap 26 fixed thereover that is formed as a square tube with walls 27 with a flat plate 28 arranged thereover. The angle iron section 24 top end is telescoped into which square tube, one of which tube walls includes a bar 27a secured thereacross to present an anchor that binds into the ground wherein the ground stake is driven, inhibiting ground stake movement and withdrawal, as set out below. The flat plate 28 that is arranged across the square tube top end is shown as including a keyhole 28a, that allows an eye bolt 29 head end 30 to be fitted therethrough. Which head end 30 is holed at 30a to receive a bolt 31 fitted through a hole 31a formed in tube wall 27 and secured in the opposite tube wall. The eye bolt 29 is thereby secured to the square tube 26, a threaded end extending at a right angle upwardly from the flat plate 28. Shown in FIG. 1, the eye bolt 29 threaded end 29a is fitted through an open center portion or hole 33 of a ball segment 32. Which opening or hole 33 is tapered outwardly from a lesser diameter bottom end to a greater diameter top end, the bolt threaded end 29a thereby being free to swing across which hole 33 top end. The eye bolt 29 threaded end 29a is fitted through a gasket 34 that preferable has a like surface area to the ball segment 32 surface, as shown also in the top plan view of FIG. 8.
Shown in FIGS. 1, 7 and 7A the eye bolt 29 threaded end 29a is for fitting through an adjustable mount that consists of ball segment 32 with tapered hole 33 and gasket 34 and a square post mount 35 containing a seat. The square post mount includes a center hole 36 that eye bolt 29 threaded end 29a is fitted through with a washered nut 37 turned thereover. The washered nut 37 turned on the eye bolt 29 couples the ball section 32 and seat together with gasket 34 therebetween providing a capability for adjusting the attitude to the vertical of a post 40 secured onto which square post mount 35, as set out hereinbelow. In another mounting embodiment, as shown in FIGS. 4 and 5, as well as the ball segment and seat mounting embodiment of FIG. 6, a post insert 39 is utilized for receiving post 39 telescoped thereover.
Shown in FIGS. 1, 7, 7A, 13 and 16, the post 22 is for telescoping over the square post mount 35, resting on a lip 38 formed around a lower edge of which mount, the post preferably secured thereon as by gluing, with a snap-in arrangement, or the like, in a manufacturing setting. For attaching the square post mount 35 onto the ball segment 32, the eye bolt threaded end 29a is fitted through the center hole 36, extending into the post 22. So arranged, an operator, not shown, positions the post 22 to a desired attitude to the vertical and fits the washer nut 37 through a portal 40 formed through the post side and onto the eye bolt threaded end 29a. He then turns and tightens that washer nut 37 onto the eye bolt threaded end 29a, compressing a seat 51 formed in the undersurface of which square post mount 35 tightly against the ball segment 32 surface, sandwiching gasket 34 therebetween, and locking the post 22 square post mount end in place with the ball segment 32. Which gasket 34 is formed of a course material to provide a non-slip surface between which ball segment surface and seat coupling. Thereafter, a window 41 having shoulders 41a is snapped into to cover over portal 40, completing mounting.
FIGS. 4 and 5, show another post 22 mounting embodiment that includes a post insert 39 that is a square open tube that utilizes a tapered washer stack, shown also in FIGS. 4A and 5A, as the post 22 mount rather than the ball segment seat, as discussed above. The post insert 39, like the post mount 35, is to receive the post 22 telescoped thereover, as set out and discussed hereinbelow. Further, it should be understood, other post mounts and tubes and tube configurations, such as round, could be so used within the scope of this disclosure.
Shown best in FIGS. 7 and 7A, the ball segment seat 51 formed across the undersurface of the square post mount 35 of FIG. 1 is hemispherical in shape to conform to the surface of the ball segment 32. This seat 51 is also shown with the square post mount 35 of FIG. 6 and in the bottom plan view of FIG. 9. Further, it should be understood, where the ball segment seat 51 is set out above as formed in the square post mount 35 or across a lower end of the post insert 39, that seat can also be formed across a lower end of the post 22 itself, within the scope of this disclosure. Which post mounts of FIGS. 6, 7, 7A and 16, do not include the gasket 34, but instead employ a roughening at 32a of the ball segment surface to provide a friction surface therebetween, that is shown best in FIG. 16. A ball segment and seat coupling is thereby provided that allows the post 22 to be tilted across the ball segment 32 surface, as illustrated best in FIGS. 7 and 7A, for adjusting the post attitude relative to the top surface 28 of the ground stake 23.
FIGS. 4, 5 and 6, as set out above, utilize a post insert 39 that is adjusted to the vertical for receiving the post 22 end telescoped thereover. To maintain a secure coupling of which post insert 39 and post 40 end, spacers 43 are arranged between opposing surfaces of which post insert and post. Which spacers 43 are preferably each a saddle having a center slot with parallel legs thereacross and are formed from a resilient material. The spacers 43 are fitted, as shown in FIGS. 4, 5 and 6, across the post insert top edge 39a and across a top edge of a slot 45, or slots 45, that are formed in the side of which post insert. Two points of spacers 43 contact with the post 22 interior walls are thereby provided for preventing movement of the post 22 relative to the post insert 39.
As set out above, the embodiments of the invention shown in FIGS. 1, 6, 7 and 7A, as do the adjustable mountings shown in FIGS. 13, 15, and 16, all employ variations of ball segment and seat mountings between the ground stake and post mount or post insert. The ball and seat arrangement of FIG. 1, and as shown in FIGS. 7 and 7A, is a ball segment 32 for fitting it in a hemispherical seat 51 of the square post insert 35. A gasket 34 is shown sandwiched between which ball segment and seat in FIG. 1 and the ball segment surface is shown roughened at 32a in FIGS. 7 and 7A, for prohibiting relative movement or slippage of the mount components when they are clamped together.
Functionally, the ball segment and seat arrangements of FIGS. 1, 6, 7 and 7A, are alike, as are the ball and seat arrangements of FIGS. 13, 15 and 16. Except that the mountings of FIGS. 1, 6, 13 and 15 include gasket 34, while the mountings of FIGS. 7, 7A, and 16, show as a roughened surface 32a included on the ball segment 32 surface.
FIGS. 13 and 16, involve a tubular or cylindrical ground stake 52, shown best in FIG. 13 as a cylinder 53, that includes a pointed lower end 54. The upper or top end of which cylinder includes a cap 55 that is formed as a square tube with walls 56 and with a flat plate 57 arranged thereover. The cylinder 53 top end is telescoped into and secured in which square tube 55, the flat plate 57 closing off the tube end. Which flat plate 57 has a hole 58 formed therethrough that is counter sunk on the flat plate undersurface to receive a tapered undersurface of a the head 61 of a flat head bolt 60 that is fitted therethrough. Which bolt 60 functions like the described eye bolt 29 except, of course, it relies on a frictional engagement between the countersunk portion of hole 58 and head 61 undersurface to allow a washer nut 37 to be tightened thereover. Otherwise the functioning of which eye bolt 29 and bolt 60 should be taken as being the same.
As shown in FIGS. 13 and 16, the cylinder 53 is to be driven into the ground, pointed end first, as a ground anchor. For further anchoring which cylinder 53, each square tube wall 56 includes a tab 59 cut therein, that cut section then bent outwardly to present an edge to engage and bind into the ground wherein the ground stake is driven, inhibiting its withdrawal.
FIG. 15, shows another post 22 mounting that includes the ball segment 32 secured onto a top surface of a bracket 63 that has a raised center portion and planar sides that are holed for receiving cement fasteners 64 fitted therethrough and driven into a cement, concrete, or like surface, securing the bracket thereto. Which bracket 63 raised center portion is center holed to receive the bolt 60 fitted therethrough prior to mounting. While the bolt head 61 is shown for receiving a screw driver blade, it should be understood that a hex shaped head could be so used as head 61 that would accommodate a wrench head fitted under the bracket 63, to hold that head while the washer nut 37 is turned onto the bolt 60 threaded end.
As set out above the open center portion or hole 33 through the ball segment 32 is tapered from a lesser diameter at its base to a greater diameter at its top, to allow for tilting of bolt 31. Which angle of taper, as shown in FIGS. 7, 7A and 13 is to the vertical. Preferably an angle of taper of up to twenty degrees (20°) is preferred to provide an angle of tilt to the attached post of up to twenty degrees (20°). This tilting capability allows for positioning the post 22 or post insert 39 back to the vertical so as to compensate for the ground stake the top surface not being horizontal.
FIGS. 4 through 6, show another embodiment of a ground stake 65 that includes a platform 66 and pointed stake 67, which stake is shown as having been pounded into the ground. FIG. 5 shows the stake 67 as having displaced from the vertical in that driving, necessitating a topping of the post insert 39 to compensate to position the post 22 telescoped thereon to the vertical.
Hereinabove have been set out a number of ball segment and seat configurations for attaching a post insert 39 onto the top of a ground stake to allow for a tilt of that post insert to where it is in a vertical attitude. FIGS. 4, 4A, 5 and 5A, show another post insert mounting arrangement that also allows for tilting of the post inset 39. As shown, this tilting arrangement consists of a pair of tapered washers 70 and 72, that overlay one another forming a stack. In FIG. 4 the washers 70 and 72 tapered surfaces are shown to slope oppositely, with the top and bottom surfaces of which stack thereby being essentially parallel. To provided for washer positioning each washer includes a tab 71 and 73, respectively, that extends outwardly from the thinnest washer side. Shown in FIG. 4A the tab 71 of he washer 70 extends for one side of the stack, with the tab 73 of the washer 72 shown extending outwardly from the other stack side, indicating that the washer tapered surfaces slope oppositely. So arranged, the washer stack would have essentially parallel top and bottom surfaces. FIG. 5A shows the tapered washers 70 and 72 as having been turned to where the tabs 71 and 73 align, the tapers overlay one another, providing a tilt to the stack top surface relative to the bottom, as shown in FIG. 5. This tilt, as shown, is to compensate for the positioning of the ground stake pointed stake 67 being at other than the vertical. Functionally, with the tapered washers 70 and 72 positioned to provide a desired angle to the post insert 39, the washer nut 37 is turned onto the bolt, whereafter the post 22 is installed onto the post insert 39, as described above.
The post 22 mounted to the post mount 35 or is telescoped over the post insert 39 is then useful for: mounting a newspaper tube 21, or the like, cantilevered outwardly from the post top end, as shown in FIGS. 1 and 2; mounting a mail box mount 75 across a top post end, as shown in FIGS. 10 through 12, to receive a mail box thereon; mounting mail box across the post 22 top end by a frame mount, as shown in FIGS. 19, 20, 23 and 24; mounting a newspaper tube 21, or the like, cantilevered from the post 22 top end that, in turn, mounts a mail box as shown in FIGS. 17 and 18, or mounting a mail box onto a horizontal wood beam, as shown in FIG. 20.
The newspaper tube 21, shown in FIGS. 1 and 2, is preferably an open tube or hollow, the top and bottom sides of which tube at one end, are formed into outwardly extending top and bottom end tabs 80 and 81, respectively. The end tabs 80 and 81 are each for fitting in one of parallel lateral slots 82 formed across a post 22 side, and each end tab 80 and 81 has at least one, and preferably has two holes 83 formed therethrough. To install the newspaper tube 21 cantilevered from the post 22 and receive pegs 85 of FIG. 3C, pegs 90 of FIGS. 3A and 3B, or shear pegs 94 of FIGS. 3D through 3F that are passed through the post 22 top end and are individually fitted through the end tabs 80 and 81 holes 83. This operation is preferably performed manually and accordingly the pegs 85 and 90 and shear pegs 94 are preferably formed from a molded material, such as a plastic, and are configured for ease of installation. FIGS. 1, 2 and 3C show the first peg 85 embodiment that includes a broad head 86 and tapered body 87. A locking ridge 88 is shown extending outwardly from the peg body 87, opposite to broad head 86. Which locking ridge 88, with peg insertion into an end tab hole 83, as shown best in FIG. 3C, extends into the post lateral slot 82, for preventing peg withdrawal.
The second peg 90 embodiment is shown in FIGS. 3A and 3B. The peg 90, like the described peg 85, has a broad head 91 and includes a tapered body 92. Rather than a locking ridge, however, the peg 90 includes spaced teeth, serrations, barbs, or threads 93 that are formed along and to extend outwardly from the tapered body 92, below the broad head 91. Shown best in FIG. 3B, with the peg 90 installed in hole 83, a side of one or more of the teeth, serrations, barbs, or threads 93 will engage the tab hole 83 edge, prohibiting peg withdrawal.
A shear peg 94 is shown in FIGS. 3D through 3F that, like pegs 85 and 90, includes a broad head 94a with a tapered body 94b. A tapered or curved section 94c of the tapered body 94b, is shown best in FIG. 3E. Distinct from tapered sections of pegs 85 and 90, however, the shear peg tapered or curved section 94c is not immediately below a long section of the broad head 94a, rather, it is formed on the opposite or rear facing side of the tapered body 94b. Shown best in FIG. 3E, the curved section is essentially initially straight, is formed at a right angle to an end of the broad head 94a, and curves toward a tapered body 94b front side, terminating in a pointed end 94d. Preferably, the tapered boy 94b sides are stepped inwardly at a stepped section 94e formed in each side across the body, and proximate to the middle thereof, which stepped sections 94e provide for narrowing the tapered body cross section from the middle thereof to the pointed end 94d. The lateral stepped section 94e is for positioning, as shown in FIGS. 3D and 3F, to be slightly above the edge of tab holes 83. To encourage separation or peg shearing along the lateral stepped section 94e, as with an application of a side force to the tube 21, shown as arrow A in FIG. 3F, such forces directed through the cantilevered tube 21, and into a hole or depression 94f that is formed into the shear peg tapered body 94b. The combination of the narrowing of the shear peg 94 at the lateral stepped section 94c and the hole or depression 94f, provides for a shear peg weakening thereacross that will encourage the peg to break across the depression 94f, as shown in FIG. 3F. So arranged, a force, arrow A, applied to the tube 21 to bend it across the coupling to post 22 will tend to break the shear pegs 94, as illustrated by the cracks shown in the shear pegs in FIG. 3F, allowing the tube tabs 80 to pull out of slots 82, separating the tube 21 from the post 22 without damage to the post.
A cap 95, shown in FIGS. 1 and 2, is preferably installed onto, to cover, the post 22 open top end. Prior to which cap 95 installation the pegs, as described, are fitted through that post open end and into the tab holes 83. Which cap 95, shown in FIGS. 10 through 12, is replaced by mail box mount 75, or a mail box mounted thereon. Which mail box mount 75 consists of a flat top plate 76 that has downwardly extending right angle flanges 77 that project from along opposite edges. Equidistantly spaced plates 78 are secured across which downturned flanges 77, the flanges and plates thereby forming a square center recess that is for receiving a square post 22 end fitted therein. For providing overlying coupling surfaces where the flanges intersect the post surfaces, opposite side end sections of which post 22 may be removed leaving tabs 79. Shown best in FIGS. 11 and 12, the tabs 79 and plates 78 are to be fitted together in juxtaposition arrangement with holes 79a through each aligned to receive pins 79b fitted therein securing the mail box mount 75 onto the post 22 end. So arranged, the flat top plate 76 is for receiving a mail box secured thereon.
FIGS. 17 and 18 show another mounting 100 for a mail box 110. The mounting 100 includes a pair of brackets 101 that are each connected to the ends of a pair of parallel bars 102. The bars 102 space the brackets 101 apart in parallel relationship forming a rectangular frame. To construct this frame, each bracket 101 includes as a pair of flanges 104 that extend outwardly and parallel from along the top and bottom edges, respectively, of a bracket web. The bar 102 ends are for fitting between which flanges 104, each receiving a coupling device, that is preferably a pivot, and is fitted through the bracket flanges and a bar end. The bars 102 have holes 105 formed through the mid-portions thereof for receiving fasteners 106, as set out below. Which mounting 100 is either for mounting onto the top surface of the newspaper tube 21 that is cantilevered from a top end portion of post 22, as shown in FIGS. 17 and 18 or onto a post 22 end, as shown in FIG. 19.
To provide for mounting mail box 110, as shown in FIGS. 17 and 18,the bracket 101 webs, proximate to their ends, include longitudinal slots 103 that receive fasteners, shown as bolts 107, fitted therethrough and through corner holes formed in a cover 111 of mail box 110. Prior to which mail box 110 mounting fasteners 106, shown as bolts, are fitted through center openings 105 formed through the bars that are, in turn, fitted through holes formed through the newspaper tube 21 top, with nuts 106a, shown in FIG. 18, turned over the bolt ends. Wood screws can be used in place of bolts 106 and nuts 106a, within the scope of this disclosure. With the frame mounted to the newspaper tube 21, the mail box 110 is seated, as set out above, and the bolts 107 are fitted through the mail box cover corner holes and through the bracket web slots 103 to receive washers 109 and nuts 108 turned onto which bolt 107 ends, as shown best in FIG. 18.
FIG. 19 shows another framed arrangement for mounting a mail box onto a post 22 end, which post 22 is shown as formed of wood, through it could be formed of solid plastic, or could be tubular with a top end insert, or a like arrangement, within the scope of this disclosure. The frame arrangement of FIG. 19, like that of FIG. 17, includes a pair of brackets 101, each with parallel flanges 104 extending from the edges thereof, and with a pair of bars 102 for positioning between which brackets. One of which bars 102, like the arrangement of FIG. 17, is connected at its ends between the flanges 104 by fasteners 104a, with the other bar 102 ends mounted to slide freely in longitudinal slots 104b formed in the flanges 104. With the mounting 100 fitted onto a post top end, shown in FIG. 19 as a wood post, and the bar 102 whose ends are mounted in longitudinal slots 104b moved to where the bar holes 102a in both bars 102 aligned with the wood post top surface, screws 113, or the like, are turned through holes 102a and into the post top, securing the mounting 100 thereto. Thereafter the mail box 110 is installed to the mounting as described hereinabove with respect to FIGS. 17 and 18.
FIG. 20 shows another embodiment of a mounting 120 for mail box 110. The mounting 120, like the mounting 100, includes a pair of brackets 121 with bars 122 arranged therebetween. The brackets 121 each include parallel flanges 123 extending from opposite edges of a mid-section of a web 124, and include cross braces 125 secured therebetween, providing a rigid bracket structure. Shown best in FIGS. 20 and 21, the bar 122 ends are each necked down into sleeve 126 that is drilled longitudinally and threaded to receive a bolt 127 turned therein. Each bolt 127, as shown best in FIGS. 21 and 23, is fitted though a hole 128 formed through the bracket 121 and turned into the bar sleeve 126 end, forming a pivot coupling of which bar to the bracket. The bar 122 pivot coupling allows end bar to be pivoted to the attitudes shown, respectively: in FIGS. 20 and 22, where wide mid-portions 129 of each bar 122 extend oppositely; in FIGS. 21 and 23 where the mid-portions 129 are parallel and point downwardly; and FIG. 24, where in mid-portions 129 point towards one another. Which bar 122 positioning is maintained by turning the bolt 127 fitted through flange hole 128 tightly into the bar sleeve 126. With the bar 122 appropriately positioned fasteners, such as screws 130 can be turned through holes 131 formed in the bar mid-portions and into a wood beam, like that shown in FIG. 22, or into a top end of a wood post, like that shown in FIGS. 23 and 24, securing the mounting 120 onto which beam or post end. Thereafter, a mail box 110 can be mounted onto which mounting 120 utilizing the bolts, nuts, and washers 107, 108, and 109, respectively, shown in FIG. 17, secured through elongate slots 132, formed in the bracket 121 ends, as shown in FIG. 22. Where the mounting 120 is shown utilized for attaching a mail box 110 onto a wood beam or wood post, it should be understood that, like mounting 100 it can be used also for mounting a mail box onto a cantilevered plastic tube or post end, or like beam or post arrangement, within the scope of this disclosure.
Herein have been shown and described preferred arrangements of a post system and component elements and mountings thereof of the present invention. It should, however, be understood that the present disclosure is made by way of example only and that changes can be made thereto without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims I regard as my invention.
|
A cantilever mounting system for mounting a tube to a post to extend at approximately a right angle from the post that is maintained in a vertical attitude to the ground. The erected post can be utilized as a fences post, sign post, mail box post, or the like, and can be used for mounting the tube, or the like, that may be intended for receiving delivered items, such as mail and/or newspapers, and the tube includes at least one tab extending from one tube end that is for fitting into a slot that includes at least one hole formed therethrough. The tab hole is for receiving a peg type fastener that is fitted through the hole and blocks withdrawal of the tab from the slot to provide the tube cantilever mounting. The peg type fastener includes an arrangement for inhibiting peg withdrawal from the tab hole, and, in its manufacture, the peg may be weakened to promote shearing thereacross as when a force is applied against the tube as could damage the tube and post, the peg shearing allowing release of the tube tab out of the post slot.
| 4
|
BACKGROUND OF THE INVENTION
The present invention relates broadly to textile machine lubricating apparatus and more particularly to a device for supplying oil to shearing blades attached to a rotating cylinder of a textile material shearing machine.
When processing napped and pile fabrics, the upstanding fabric loops or yarns may be mechanically cut or trimmed from the face of the fabric using a machine to shear off the fabric pile or nap. The amount of shearing varies according to the desired height of the nap or pile and on some fabrics, a very close shearing may be given. Typically, shearing machines use a rotating blade system formed as a large cylinder having two end portions and a series of very sharp curved blades which extend helically between the end portions forming the circumferential periphery of the cylinder. A ledger blade is disposed closely adjacent the periphery of the rotating cylinder and oriented so that the edges of the rotating blades pass over the edge of the ledger blade with an extremely close tolerance to produce a shearing action between the respective blades. A vertically oriented wedge-like cloth rest is provided immediately ahead of the ledger blade, with respect to the rotation of the cylinder. The fabric to be sheared is caused to travel over the cloth rest and as the fabric passes over the tip of the cloth rest, the nap is caused to "stand up" and be presented for shearing. The distance between the tip of the cloth rest and the cylindrical plane defined by the rotating blades determines the amount of shearing because during shearing, the nap projects upwardly from the tip of the cloth rest a predetermined distance into the cylindrical shearing plane. As the blades rotate into the projecting nap, the yarns are forced against the edge of the ledger blade and the portion of the yarns extending beyond the edge of the ledger blade is sheared off.
The shearing blades must remain very sharp to prevent unevenness in shearing a pile or nap. Shear marks can also result from slubs or knots that are caught or nipped by the blades of the shearing device. Shear marks show up badly when light strikes the cloth. This problem is aggravated when the blades become dull from use. Further, due to the relatively high rotational speeds of the shearing blades, heat buildup can cause the blades to become dull due to the frictional contact of the shearing blades with the ledger blade. Accordingly, the shearing blades are commonly lubricated with a suitable oil to slow the dulling process and provide a smooth and effective cut.
As may be suspected, if the shearing blades are supplied with too much oil, it can impregnate and ruin the finished fabric. If too little oil is supplied to the shearing blades, heat can build up and the aforementioned problems occur.
Additionally, shearing machines will typically employ some form of vacuum arrangement to remove cut fibers from the shearing area and this vacuum arrangement can remove oil from the blades as well as any lubricating apparatus accessible by the vacuum.
Accordingly, there exists a need for a shear roller lubricating apparatus which can apply oil to the rotating blades of a shearing machine in a controlled amount and maintain the proper lubrication level while the shearing machine is in operation and further to mitigate the effects of the vacuum arrangement on proper blade lubrication.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a shear roller lubricating apparatus which addresses the aforesaid problems. More specifically, it is an object of the present invention to provide a shear roller lubricating apparatus which applies oil to the shearing blades of a shear roller during operation thereof at a controlled rate while mitigating the effects of the aforesaid vacuum arrangement on the shear roller lubricating system. Further, it is an object of the present invention to provide a shear roller lubricating apparatus which, upon activation of the shear roller after a predetermined amount of time, can supply lubricating oil to the rollers in sufficient quantity to resupply the rollers with oil after a prolonged shut down period.
According to the present invention, a shear roller lubricating apparatus for a textile shearing machine having a generally cylindrical roller with shearing blades attached thereto includes an assembly for applying lubricating oil to the shearing blades, an arrangement for delivering the lubricating oil to the oil application assembly, and a control arrangement for selectively regulating the delivery of the lubricating oil at predetermined time intervals to the oil application assembly by the delivery arrangement for application of lubricating oil to the shearing blades during operation thereof.
According to the preferred embodiment of the present invention, the assembly for applying the lubricating oil includes an oil distribution header, an oil delivery pad mounted to the oil distribution header in oil-receiving communication therewith and an oil application pad mounted to the oil distribution header and being in oil-transferring contact with the oil delivery pad, the oil application pad being oriented for peripherally contacting the cylindrical roller at the shearing blades for application of lubricating oil thereto. The oil delivery pad and the oil application pad are disposed in localized surface abutting contact between the pads adjacent the point of contact between the oil application pad and the shearing blades. An air impermeable blocking plate is disposed intermediate the oil delivery pad and the oil application pad and mounted to the oil distribution header. The distribution header includes a plurality of oil flow passages for application of lubricating oil to the oil delivery pad at a plurality of spaced locations for generally even distribution of lubricating oil to the oil delivery pad. Preferably, the oil delivery pad and the oil application pad are each formed of felt or a similar oil absorptive material.
As previously stated, the shearing machine may include a vacuum arrangement for removal of cut fibers from the area of shear roller blades. According to the present invention, the air impermeable plate of the oil application assembly serves as a blocking arrangement for retarding withdrawal of the lubricating oil from the oil application assembly by the vacuum arrangement. Specifically, the disposition of the air impermeable plate intermediate the oil delivery pad and the oil application pad substantially blocks suction air flow through the pads. Only the outer edge portion of the oil delivery pad and the outer edge portion of the oil application pad extend beyond the plate and are in surface abutting contact for oil transfer from the delivery pad to the application pad and in turn to the shearing blades.
Preferably, the oil delivery arrangement includes a metering pump communicating with the oil application assembly for delivering the lubricating oil thereto at a selected rate. It is also preferred that the control arrangement have the capability for alternately activating and deactivating the metering pump at predetermined time intervals during operation of the shear roller and for selectively varying the predetermined time intervals, including the ability for continuously operating the metering pump. In the preferred embodiment, the control arrangement is a microprocessor or other microcontroller.
According to the preferred embodiment of the present invention, the control arrangement includes a timing device or function operable upon deactivation of the shear roller for determining whether the deactivation time of the shear roller exceeds a predetermined time period and an arrangement for continuously operating the metering pump for a predetermined time interval upon reactivation of the shear roller after the deactivation period has exceeded the predetermined time period for replenishment of the lubricating oil which was removed from the retaining and applying arrangement during deactivation of the shear roller.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a shear roller lubricating apparatus according to the preferred embodiment of the present invention;
FIG. 2 is a side elevational view of the shear roller lubricating apparatus of FIG. 1; and
FIG. 3 is a partial cross-sectional view of the oil retaining and applying arrangement of the shear roller lubricating apparatus of the present invention, taken along lines 3--3 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and more particularly to FIG. 1, a shear roller lubricating apparatus for textile shearing machines according to the preferred embodiment of the present invention is indicated generally at 10 and includes an oil application assembly 12, a controller such as a microprocessor 14, and an oil delivery arrangement 16.
Textile shearing machines are well known to those persons skilled in the art and, accordingly, only the shear roller which is to be lubricated by the present invention is partially illustrated in FIG. 1, indicated generally at 18, and basically includes a pair of laterally spaced generally circular end hubs 20 between which a plurality of blades 22 extend longitudinally to form a generally cylindrical outer periphery of the shear roller 18. The blades 22 are curved in a helical fashion to provide optimal shearing engagement of the fabric by the cutting surface of the blades 22 when the blades 22 are rotating. In operation, the shear roller 18 rotates at high speed. A vacuum arrangement (not shown) is provided in the shearing machine for removal of cut fibers from the fabric shearing area.
As best seen in FIGS. 1 and 2, the oil application assembly 12 includes an oil distribution header 26, an oil delivery pad 23, an oil application pad 24, and a blocking plate 28. The oil distribution header 26 is an elongate member, generally square in overall cross section, having an upper planar surface 26' and a generally rectangular channel 27 formed in the bottom surface thereof and extending substantially the full linear extent of the header 26. The oil delivery pad 23 and the oil application pad 24 are generally planar rectangular members formed of felt or other such oil-absorbent material. One longitudinal edge of each pad 23,24 is mounted to the oil distribution header 26 in the channel 27. The blocking plate 28 is also a generally planar rectangular member which is provided for substantially blocking air flow through the pads 23,24 as will be explained in greater detail hereinafter. The blocking plate 28 is preferably formed of an air and oil impervious material such as Teflon® produced by E. I. du Pont De Nemours and Co. of Wilmington, Del., or another suitably comparable material. The blocking plate 28 is mounted to the distribution header 26 in the channel 27 intermediate the oil delivery pad 23 and the oil application pad 24. As best seen in FIG. 2, a flange 28' is formed on the edge of the plate 28 fitted into the channel 27, extending perpendicularly outwardly therefrom. The flange 28' is positioned between the upper edge of the oil application pad 24 and the header 26 insuring separation of the application pad 24 from the delivery pad 25 and the header 26. The plate 28 is comparable in size to the pads 23,24 except that the outer edge portions 23', 24' of the pads 23,24 extend beyond the outer edge of the plate 28 and are in surface abutting contact.
The oil delivery pad 23, the plate 28, and the oil application pad 24 are all attached to the header using conventional bolts 34 which extend through aligned openings formed in the sidewalls 26" of the header 26, the oil delivery pad 23, the plate 28, and the oil application pad 24. Conventional nuts 35 hold the bolts 34 in place. As seen in FIG. 1, the bolts 34 are arranged at spaced intervals substantially the full linear extent of the oil distribution header 26. The header 26 is supported on the frame of the shearing machine (not shown) and oriented with the oil delivery pad 23, the plate 28, and the oil application pad 24 extending angularly downwardly and outwardly from the header 26 so as to be angled away from vertical approximately 25° with the oil delivery pad at the upper extent and the oil application pad 24 in tangential, peripheral contact with the shear roller 18. The above-defined angular relationship will be explained in greater detail presently.
With reference to FIG. 3, a portion of the oil application assembly 12 is shown in lengthwise cross-section, illustrating the header 26 construction. Oil application openings 36 are formed through the header 26 along the upper surface 26' thereof and intermediate the bolt openings 30, each oil application opening 36 having a cylindrical entrance portion 36' which extends a distance into the oil distribution header 26 and opens into an outwardly flared oil flow discharge channel portion 36". Each oil flow discharge channel portion 36" extends longitudinally along the header 26 from its respective oil entrance portion 36' to a position closely adjacent the two adjacent bolt openings 30 and opens into the channel 27 formed in the oil distribution header 26 immediately adjacent the upper edge of the oil delivery pad 23, to be in oil-transferring communication therewith. Oil flow fittings 32, which are generally tubular members, are mounted to the distribution header 26 at the oil application openings 36 and project outwardly therefrom. The oil fittings 32 accept oil from the oil delivery system 16 (see FIG. 1) through suitable conduits, indicated only at 40 in FIG. 1, for application to the oil delivery pad 23 which will be explained more thoroughly hereinafter.
Lubricating oil is supplied to the oil application fittings 32 from the oil delivery arrangement 16 as will be explained in greater detail hereinafter. With reference to FIG. 2, and as is shown by the directional arrows, oil thus supplied advances under pressure through the oil application fittings 32, through the entrance portions 36' thereof, and into the discharge channel portions 36" wherein the oil contacts the upper edge of the oil delivery pad 23. From there, the oil gravitationally flows through the oil delivery pad 23 as well as being drawn thereinto by the wicking action of the absorbent oil delivery pad 23. The lubricating oil migrates continually to the terminal end portion 23' of the oil delivery pad 23 where, due to physical contact between the two absorptive pads 23,24, oil is wicked from the terminal end portion 23' of oil delivery pad 23 into the terminal end portion 24' of the oil application pad 24 adjacent the area of blade 22 contact. Due to the aforesaid 25° angular orientation of the oil application assembly 12 away from vertical, and since, in operation, the terminal end portion 23' of the oil delivery pad is laden heavily with oil, the terminal end portion 23' gravitationally sags vertically downwardly into surface abutting contact with the terminal end portion 24' of the oil application pad 24 at a position opposite the contact point of the oil application pad 24 with the blades 22 (not shown in FIG. 2) of the shear roller 18. This orientation gravitationally assists the aforesaid wicking action to further enable oil transfer from the oil delivery pad 23 to the oil application pad 24. With the terminal edge portion 24 of the oil application pad 24 in peripheral contact with the shear roller 18, its blades 22 will brush across the terminal end portion 24' of the oil application pad 24 causing a small portion of lubricating oil to be applied to the cutting edge of each blade 22, as will be explained in greater detail hereinafter.
When in use, oil is continually being removed from the oil delivery pad 23 through the oil application pad 24 primarily by the action of the blades 22 and partially the vacuum arrangement. As a result, and with reference to FIG. 1, the oil delivery pad 23 must be replenished from a central oil supply 45 to maintain sufficient lubricating oil in the oil application pad 24 for proper blade lubrication. For that purpose, the oil delivery system shown generally at 16 includes a metering pump 42, which receives oil from an oil supply 45 through conventional piping 46, and supplies the oil under pressure through a main supply manifold 44 and therefrom through individual oil supply lines 40, shown only in broken lines in FIG. 1, to the oil fittings 32. The oil metering pump 42 may be any type of pump capable of pumping oil at a controlled rate with sufficient endurance for prolonged operation with periodic start up and shut down, as will be explained in greater detail hereinafter.
The metering pump 42 is controlled by a microprocessor 14 which includes an internal timing function for regulating the duty cycle of the metering pump 42. The microprocessor 14 provides a variety of possible operating modes. For example, during the normal, ongoing shearing operation, the microprocessor can control cycling of the pump between an activated and deactivated state at predetermined time intervals to provide a replenishing supply of lubricating oil to the oil application pad 24 at a rate as necessitated by depletion of the lubricating oil from the oil delivery pad 23 and the oil application pad 24 by the blades 22 without causing excess oil buildup in either the oil delivery pad 23 or the oil application pad 24. The predetermined time intervals may be selectively varied by appropriate programming of the microprocessor 14. This operational mode serves to provide the lubricating apparatus of the present invention with the ability to supply sufficient oil to keep the blades 22 lubricated while preventing excess oil from being distributed to the oil delivery pad 23 and the oil application pad 24, which could result in oil fouling the fabric undergoing treatment by the shearing machine.
During any period of prolonged deactivation of the shearing machine, the microprocessor 14 deactivates operation of the pump 42 and the blocking plate 28 of the oil delivery arrangement 12 serves to retard and minimize oil depletion from the oil delivery pad 23 by the vacuum arrangement by largely preventing vacuum air flow through the oil delivery pad 23. Nevertheless, the action of the vacuum arrangement on the oil application pad 24 and other factors, such as drainage, act to remove oil from the oil application pad 24 and, in turn, the oil delivery pad 23. Upon reactivation of the shearing machine, oil depletion from either or both of the oil application pad 24 and the oil delivery pad 23 could result in insufficient lubrication of the shearing blades 22. Therefore, the microprocessor 14 is programmed to indicate to the operator that "pre-oiling" is recommended, prevent rotation of the blades, and allow the operator to selectively control the pump 42 to provide an increased supply of oil to the oil delivery pad 23 upon restart of the shearing machine after any deactivation exceeding a predetermined time period in order to replenish a depleted oil application pad 24. The microprocessor 14 monitors the main power supply of the shearing machine (not shown) as to whether the shearing machine is operational thereby allowing the microprocessor 14 to determine how long any given period of deactivation lasts. When the shearing machine is restarted after a period of deactivation exceeding the predetermined time period defined and monitored by the microprocessor 14, the microprocessor will act to operate the metering pump 42 continuously in a "pre-oiling" mode for a period of time to replenish the oil supply which has been removed from the oil delivery pad 23 and the oil application pad 24. After a predetermined period of time, the microprocessor 14 will revert to its operational mode and cycle the metering pump 42 in the manner previously discussed. The microprocessor 14 will also provide a warning signal to the operator under conditions of low oil level, low oil pressure, or if problems exist within the vacuum arrangement.
While it is preferred that the control be provided by a microprocessor, it is contemplated that acceptable results may be obtained using an electro-mechanical system configured to provide the necessary adjustments using switches, rheostats, or other suitable devices or apparatus.
In summary, oil supplied from the metering pump 42 is delivered through the oil supply manifold 44 and thereby distributed to the oil application assembly 12 through oil supply lines 40. The oil fittings 32 direct the oil into the header 26. Oil entering the header 26 through the oil fittings 32 is directed into the end portions 36' of the oil openings 36 and from there to the oil flow discharge channel portions 36". The oil flow discharge channel portions 36" distribute the oil over a wide portion of the upper edge of the oil delivery pad 23. The oil delivery pad 23 wicks oil from the oil flow discharge channel portions 36" and by the combined effects of gravity and the aforesaid wicking action, oil is distributed throughout the oil delivery pad 23. Contact between the oil delivery pad 23 and the oil application pad 24 allows the transfer of lubricating oil to the oil application pad 24 for application to the shearing blades 22. The metering pump 42 is cycled on and off by the microprocessor 14 to provide a replenishing supply of oil at regular intervals to the oil delivery pad 23 and, ultimately, to the shearing blades 22.
By the present invention, a controlled supply of oil is provided for lubricating shear roller blades 22. By controlling the flow of oil to the oil retention and application assembly 12, sufficient lubrication is provided while eliminating the possibility of fouling the fabric being trimmed with excess oil. Further, the possibility of oil starvation is reduced by the use of the Teflon® blocking panel 28 and the felt oil pads 23,24. Additionally, during periods of known oil depletion, e.g., during start up, the present invention acts to provide an increased oil supply thereby maintaining sufficient blade lubrication under controlled conditions.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
|
A shear roller lubricating apparatus for textile shearing machines having cylindrically oriented rotating shearing blades includes an oil delivery pad, an oil application pad, and an airflow-blocking plate sandwiched therebetween, the pads and the plate being mounted to an oil distribution header with the outer terminal ends of the pads projecting beyond the plate for end abutment of the pads. This assembly is mounted to the shearing machine with the outer end of the application pad arranged to tangentially contact the shearing blades. A microprocessor controlled metering pump supplies oil to the delivery pad and thereby to the application pad at selected time intervals and may be operated continuously to provide an increased supply of oil to the delivery and application pads after deactivation of the shear rollers for an extended period of time.
| 3
|
BACKGROUND OF THE INVENTION
The increase in the power requirement for hydraulically controlled mobile equipment requires a corresponding increase in the valve required to control the flow of hydraulic fluid to such equipment. The increase in size of the directional control valve makes the valve more difficult to control manually. Further, locating the control valve close to the actuator results in faster and more positive response, shorter high pressure lines requiring fewer connections, and enhanced operator safety since high pressure lines are no longer present in the operator station.
SUMMARY OF THE INVENTION
The power assist servo controller according to the present invention utilizes pilot pressure fluid to control a force amplifying piston assembly which is connected to the directional control valve. The pilot pressure control can be located at a remote operator's station thus allowing for either an electric or low pressure hydraulic line to control the force amplifying piston assembly which is mounted on the directional control valve.
DRAWINGS
FIG. 1 is a sectional view of the power assist controller according to the present invention which is controlled by a pair of proportional solenoid valves;
FIG. 2 is a sectional view of a power assist controller which is controlled by a hydraulic control valve.
DESCRIPTION OF THE INVENTION
The remote controlled power assist servo control 10 of the present invention is used to control a directional control valve 12. The directional control valve is of the conventional type having a valve spool 14 which is movable in a bore 16 in the valve housing 18 to control fluid flow from an inlet passage 20 to pressure passages 22, 24 and exhaust passages 26, 28. An end cap 30 is provided on the valve housing at one end of the valve spool 14 and includes a chamber 32 connected to the inlet pressure passage by passages 34, 36. The spool is biased to a neutral position within the valve housing by means of a main centering spring 38 which is seated on a spring retainer 40 that is seated on the end of the main spool 14.
In accordance with the invention, the remote controlled power assist servo control 10 is mounted on the valve housing 18 at the other end of the valve spool 14. The remote controlled servo control 10 generally includes a force amplifier 44 and a pilot operated remote controller 46. In this regard, the remote controller shown in FIG. 1 is electrically actuated. In FIG. 2, as described hereinafter, the remote controller is hydraulically actuated.
The force amplifier 44 includes a valve housing 48 having a control pressure chamber 50 adjacent the end of the valve spool 14 and a bore 52 connected to the opposite end of the chamber 50. The pressure chamber 50 is connected to the exhaust passage 28 by means of a flow passage 29 in the seal plate 33 and a passage 31.
The position of the valve spool 14 is controlled by means of a power piston 54 having a piston head 55 located in the chamber 50. The power piston includes an annular groove 49 at one end and a piston rod 56 which extends into the bore 52 at the other end. The piston head 55 is sealed in the chamber 50 by means of an O-ring seal 53 positioned in the annular groove 51 in the outer periphery of the piston head 55. The end of the power piston 54 is seated against the end of the valve spool 14.
An annular groove 68 is provided on the outer surface of the rod 56. An axial bore 62 is provided through a portion of the power piston 54. The bore 62 is connected to the pressure chamber 50 on one side of the piston head 55 by means of a first set of radial ports 64 and to the chamber 50 on the other side of the piston head 55 by means of a second set of radial ports 66. The bore 62 is connected to the groove 68 by means of a third set of ports 69. The piston rod 56 is supported in the bore 52 by means of a support member 58.
In this regard, the support member 58 is provided with a radial flange 60 and an annular groove 70, the radial flange 60 abutting against the end of the pressure chamber 50. The groove 70 is connected to the annular groove 68 in the piston rod 56 by means of a fourth set of ports 72, the annular groove 70 also being connected to the inlet fluid passage 20 by means of fluid passages 74 and 76.
The power piston 54 is biased to engage the end of the valve spool 14 by means of a spring 88.
The flow of fluid to the control pressure chamber 50 is controlled by means of a pilot spool 78 positioned within the bore 62 in the power piston rod 56. The pilot spool 78 is provided with an annular groove 80 at the inner end and an annular groove 82 which is spaced from the annular groove 80 to define a control land 84. As seen in FIG. 1, the control land 84 has a width equal to the diameter of the ports 66. The pilot spool is biased outwardly by means of a spring 86 provided between the end of the pilot spool 78 and the end of the bore 62. The power piston position is controlled by moving the pilot spool 78 relative to the ports 66 to either allow for the admission of inlet pressure fluid into the control chamber 50 or the exhaust of fluid from the control chamber 50 through the bore 62, ports 64, groove 49, port 29 and passage 31.
The force amplifier 44 is operated by means of the remote controller 46 which includes a housing 96 mounted on the housing 48 of the force amplifier 44. A pressure balanced pilot piston 98 is mounted within the housing 96 and is operatively connected to the pilot spool 78 by means of a pilot connecting rod 100. By controlling the pressure on either side of the pilot piston 98, the piston will move to the right or left moving the pilot spool 78 relative to the ports 66. As described above, movement of the pilot spool will allow for the admission of inlet pressure fluid or the exhaust of fluid from chamber 50. A drop in pressure in chamber 50 allows the valve spool 14 to move to the right due to the force inlet pressure fluid in chamber 32 acting on the end of the valve spool. An increase in pressure in chamber 50 will move the valve spool to the left in FIG. 1.
More particularly, the controller 46 includes a bore 102 having a threaded counterbore 104 at one end and a counterbore 106 at the other end which terminates at a groove 108. The counterbore 106 is connected to the exhaust passage 31 by means of flow passage 107 in seal plate 109. The bore 102 is closed at one end by means of a threaded end cap 110 and at the other end by means of a plug 112 which is retained in the bore 102 by means of a snap ring 114 positioned in the groove 108.
The end cap 110 includes a threaded bore 116. An adjustment screw 118 is provided at the inner end of bore 116. A threaded cap 120 is provided at the outer end of bore 116.
The pilot piston 98 is spring balanced to a neutral position in the bore 102 by means of springs 122 and 124. The spring 122 is positioned between the pilot piston 98 and a spring retainer 126 positioned on the end of the adjusting screw 118. The spring 124 is positioned between the plug 112 and the other side of the pilot piston 98.
The connecting rod 100 is supported in the bore 102 by means of the plug 112. In this regard, the plug 112 is provided with a bore 128 in which the connecting rod 100 is slidably positioned. The pilot spool 78 is biased by the spring 86 to follow the movement of the connecting rod 100.
Pilot pressure fluid is admitted into the bore 102 on each side of the pilot piston through a fluid passage network 130 which generally includes a blind bore 132, a connecting passage 134, a blind bore 136 and a pair of orifices 138 and 140. The bore 132 is connected to the inlet fluid passage 74 so that inlet fluid can flow through the network 130 into the bore 102.
The flow of inlet fluid into the pilot pressure network 130 is controlled by means of a pilot stage flow regulator 142 which includes a hollow sleeve 144 positioned in the blind bore 132. The sleeve 144 includes an inlet orifice 146. The sleeve 144 is free to move inwardly in the bore 132 and terminates short of the edge of the passage 134. The sleeve 144 is biased by means of a spring 148 outwardly into engagement with the valve housing 48. Inlet fluid passing through the orifice 146 normally flows through the sleeve 144, passage 134, bore 136 and orifices 138 and 140 into the bore 102.
In the event of a sudden drop in pressure in passage 134, the sleeve 144 will close passage 134 due to the force of the pressure of inlet fluid on the end of sleeve 144. The flow of fluid through orifice 146 will increase pressure in passage 132 moving sleeve 144 to the left to open passage 134. Thus the flow regulator 142 maintains a constant flow rate to the passage 134 regardless of changes in the inlet flow pressure or changes in pilot pressures in bore 102.
In order to actuate the pilot piston 98 to move the main spool 14, means are provided to restrict the flow of fluid flowing from bore 102 through intermediate orifices 150(a) and 152(a) to the outlet orifices 150, 152 which are connected to exhaust passage 31. Such means is in the form of a pair of proportional force solenoids 154, 156. The proportional force solenoids are conventional and assume predetermined positions depending on the current to the solenoid. Energizing one of the solenoids 154 or 156 results in the gradual closing of the corresponding orifice, increasing the resistance to fluid flow through the orifice 150 or 152, respectively, which in turn results in differential pressure build up across the piston 98. The piston 98 moves in proportion to the current energization of the solenoid. Since proportional force solenoids can be precisely controlled, they can (through the force amplifier 44) accurately control the movement of valve spool 14.
In operation, fluid is admitted to the inlet passages 74, 76 from the directional valve housing which pressurizes the entire system. As the fluid pressure increases in the chamber 32, the spool 14 will tend to move to the right. This tendency of the spool 14 to move the power piston 54 to the right in the chamber 50 will be balanced by the control pressure acting on the right side of power piston 54. If fluid under pressure is required for the pressure passage 24, the main spool 14 has to be moved to the left to connect the pressure passage 24 to the inlet fluid passage 20.
This is accomplished by energizing the proportional force solenoid 154 to close the orifice 150. This results in an increase in pressure in the bore 102 on the right side of the pilot piston 98, allowing the piston 98 to move to the left. The motion of the pilot piston 98 will be transmitted by the connecting rod 100 to the pilot spool 78 to open the port 66 allowing inlet fluid to enter chamber 50. The increase in pressure in the chamber 50 will move the power piston 54 to the left pushing the main spool 14 to the left.
The power piston will continue to move until port 66 is closed by land 84 on pilot spool 78. It should be noted that the pilot piston will assume a fixed position in bore 102 depending on the flow rate through orifice 150.
When solenoid 154 is deenergized, the orifice 150 will open, and pressures on both sides of piston 98 will equalize moving the pilot piston 98 to the neutral position. The pilot spool, power piston and main spool 14 will follow the pilot piston to the neutral position.
If the main spool 14 is to be moved to the right to connect the pressure passage 22 to the inlet fluid passage 20, the proportional force solenoid 156 is energized to close the orifice 152. Fluid in the bore 102 on the left side of the pilot piston 98 will increase in pressure, allowing the pilot piston 98 to move to the right. The pilot spool 78 and connecting rod 100 will follow the motion of the pilot piston 98 due to the bias of the spring 86. Movement of the pilot spool 78 will open the ports 66 allowing fluid in chamber 50 to flow through the port 66 into the bore 62 in the power piston 54 and out through the ports 64, groove 49 and port 29 into the exhaust passage 31. The drop in pressure in chamber 50 will allow the main spool 14 to move to the right due to the force of the inlet pressure fluid in chamber 32 acting on the end of the main spool 14. The power piston 54 will continue to move to the right until the land 84 on the pilot spool 14 closes the port 66. The main spool 14 will remain in this position as long as fluid is allowed to flow through the orifice 150 into the exhaust passage 31.
When the solenoid 156 is de-energized to open orifice 152, the pressures on both sides of piston 98 will equalize returning the pilot piston 98 to the neutral position. The movement of the pilot piston to the left in returning to the neutral position will move the pilot spool 78 to the left allowing inlet fluid to again enter the chamber 50 move the power piston to the left returning the main spool 14 to the neutral position.
In the embodiment of the invention shown in FIG. 2, a hydraulically controlled remote controller 160 is shown which is used to control the force amplifier 44 and the main spool 14 of the directional control valve 12. The force amplifier and directional control valve are identical to the force amplifier and directional control valve shown in FIG. 1 and are, therefore, numbered with the same numbers. The hydraulic remote control 160 is substantially identical to the electrically controlled remote controller 46 and where identical has been numbered with the corresponding numbers.
In the hydraulic controller 160, control of the flow of fluid through the orifices 150(a) and 152(a) is controlled by means of two manually adjustable hydraulic relief valves 162(a) and 162(b) located in the remote controller 162 shown schematically in FIG. 2. The bias forces of the springs 182 are controlled by means of a manual control handle 190 pivotally mounted on the remote controller housing. Pivotal movement of the handle 190 to the right or left in FIG. 2 will increase the bias force of one of the springs 182, resulting in a corresponding increase in pressure in lines 168 or 170. The increase in pressure differential across the piston 98 will allow the piston to move to the right or left. On release of the handle 190, the springs 182 will return the handle to neutral opening the line 168 or 170.
|
A power assist remotely controlled servo controller for proportionally controlling the operation of a directional control valve, the controller including a servo-controlled force amplifying piston assembly to operate the directional control valve and a pilot pressure balanced piston connected to the servo-controlled piston assembly to control the directional control valve. The balanced pilot pressure forces acting on the pressure balanced piston being controlled by either a hydraulic or electric controller from a remote location.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of application Ser. No. 13/686,372 filed Nov. 27, 2012, which is incorporated herein by reference, and which claims priority on Russian patent application 2011149370, filed Dec. 5, 2011, which priority claim is repeated here.
FIELD OF THE INVENTION
[0002] The present invention is in the field of food industry and healthcare. More specifically, the present invention relates to method for the dietary management of anxiety.
BACKGROUND OF THE INVENTION
[0003] Major depression is a disorder characterized by a combination of symptoms such as lowered mood, loss of energy, loss of interest, feeling of physical illness, poor concentration, altered appetite, altered sleep and a slowing down of physical and mental functions resulting in a relentless feeling of hopelessness, helplessness, and guilt. National Institute of Mental Health estimates prevalence of major depressive disorder (MDD) as 6.7% of U.S. adult population, 56.8% of those with disorders are receiving treatment. Worldwide, MDD is a major cause of disability and premature death. Average-age-of onset of MDD is estimated as of 32 years old. The exact cause of MDD is not known. Present treatment of depression consists of psychotherapy, antidepressant drugs, or a combination of both. However, there are no special nutritional requirements related to the dietary management of patients with MDD.
[0004] Water is an essential nutrient. Total water intake includes drinking water, water in beverages, and water contained in food. The adequate intake for total water was set based on the median total water intake from U.S. survey data as 3.7 and 2.7 liters per day for men and women, respectively. Dietary Guidelines for Americans , 2005, U.S. Department of Health & Human Services. The natural water is a composition of nine water isotopologues (H 2 16 O, H 2 17 O, H 2 18 O, H 16 O, H 17 OD, H 18 OD, D 2 16 O, D 2 17 O, D 18 O) formed by stable isotopes of hydrogen (H and D) and oxygen ( 16 O, 17 O, 18 O), wherein content of major water isotopologue H 2 O (H 2 16 O) is 99.7317 molecular % (mol. %) and major deuterium-containing isotopologue HOD (H 16 OD) is 0.0311 mol. % (Vienna Standard Mean Ocean Water, VSMOW). Rothman et al., J. Quant. Spectrosc. Radiat. Transfer, 1998, 60, 665. Rothman et al., J. Quant. Spectrosc. Radiat. Transfer, 2003, 82, p. 9. Because of process of evaporation and condensation of ocean water, HOD levels in natural water slightly vary on Earth district. Only exclusion is natural water of Antarctica, which water contains HOD at levels of about 0.0178 mol. % (Standard Light Antarctic Precipitation, SLAP). A majority of people reside at Earth districts, where they consume natural water with HOD levels from 0.0280 to 0.0311 mol. %. On a calculation basis, when consume 2.7 and 3.7 liters of natural water per day, women and men consume no less than 0.8 and 1.0 ml of HOD as the obligate nutrient per day, respectively.
[0005] We discovered that HOD is a highly undesirable nutrient for a subject suffering from depression and HOD restriction may represent a special medically determined nutrient requirement, the dietary management of which cannot be achieved by the modification of the normal diet alone. Surprisingly, we found that mammals are highly sensitive to HOD levels in drinking water and even change of HOD content in drinking water within the range of its natural concentrations provides a significant effect on susceptibility to psychosocial stress and predisposition to the development of depression. Thus, the dietary management of major depression can be achieved by restriction of HOD daily consumption.
[0006] It is an object of the present invention is to provide a medical food for the dietary management of major depression comprising a water containing from 0.0002 to 0.0278 molecular % of isotopologue HOD.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The present invention provides a medical food for the dietary management of major depression comprising a water containing from 0.0002 to 0.0278 molecular % of isotopologue HOD.
[0008] In a preferred embodiment of the invention, the medical food comprises water containing from 0.0178 to 0.0278 molecular % of isotopologue HOD.
[0009] As used herein, the term “medical food” refers to a food which is formulated to be consumed or administered enterally under the supervision of a physician and which is intended for the specific dietary management of depression and/or anxiety, for which distinctive nutritional requirements, based on recognized scientific principles, are established by medical evaluation.
[0010] In a preferred embodiment of the invention, the medical food is specially formulated and processed as a drink product. Such drink products include, but are not limited by, drinking water, beverage, and liquid food.
[0011] As used herein, the term “major depression” (also known as major depressive disorder) refers to a mental disorder typically characterized by a lasting sad mood and/or loss of interest or pleasure in most activities.
[0012] As used herein, the term “isotopologue” is in accordance with IUPAC Compendium of Chemical Terminology 2nd Edition (1997) and refers to a molecular entity that differs only in isotopic composition (number of isotopic substitutions). Examples of such isotopologues include H 2 16 O, H 2 17 O, H 2 18 O, H 16 OD, H 17 OD, 1 H 18 OD, D 2 16 O, D 2 17 O, and D 2 18 O. The isotopologue H 16 OD is indicated in the present invention as HOD.
[0013] In preferred embodiments of the invention, HOD content in the water can be determined by methods well-known from the art. HOD levels can be directly measured by laser spectrometry. R. Van Trigt. R. van Trigt. Laser Spectrometry for Stable Isotope Analysis of Water Biomedical and Paleoclimatological Applications. 2002, Groningen: University Library Groningen. Also, HOD levels can be determined by conventional isotope mass-spectrometry as D/H ratio and re-calculated to HOD contents given that content of other deuterium-containing isotopologues in water is negligible as compared to HOD. For the reference, VSMOW water contains 0.00006 mol. % H 18 OD; 0.00001 mol. % H 17 OD; and less than 0.00001 mol. % for sum of isotopologues D 2 16 O, D 2 17 O, and D 2 18 O. The range 0.0002 to 0.0278 mol. % of isotopologue HOD in the water of the invention corresponds to the range of D/H ratio 1 to 139 ppm. The range 0.0178 to 0.0278 mol. % of isotopologue HOD in the water of the invention corresponds to the range of deuterium content 89 to 139 ppm.
[0014] In preferred embodiments of the invention, the water containing 0.0002 to 0.0278 mol. % of isotopologue HOD can be prepared by a variety of industrial procedures well-known from the art, e.g. vacuum distillation of natural water. The water containing 0.0178 to 0.0278 mol. % of isotopologue HOD can be obtained from rare natural sources (e.g. Antarctic precipitations) or prepared by a variety of industrial procedures well-known from the art, e.g. vacuum distillation of natural water.
[0015] In practicing the invention, the water containing 0.0002 to 0.0278 mol. % of isotopologue HOD may contain other water isotopologues at levels equal or other than in VSMOW standard of natural water, e.g. 0<H 2 18 O≦0.2000 mol. %; 0<H 2 17 O≦0.0370 mol. %; 0<H 17 O≦0.0270 mol. %; 0<H 18 OD≦0.0270 mol. %; 0<D 2 18 O≦0.0270 mol. %; 0<D 2 17 O≦0.0270 mol. %; 0<D 2 18 O≦0.0270 mol. %, and 0<H 2 16 O≦99.9998 mol. %.
[0016] The medical food of the invention may be prepared by well-known procedures using well-known optional ingredients. Such optional ingredients generally are used individually at levels from about 0.0005% to about 10.0%, preferably from about 0.005% to about 1.0% by weight of the composition. Examples of suitable optional ingredients include, but are not limited to, buffers, sweeteners, colorants, carriers, and etc.
[0017] In the preferred embodiments of the invention, the medical food is a liquid medical food specially formulated and manufactured in form of drinking water or beverage. The liquid medical food may be prepared by saturation of water containing 0.0002 to 0.0278 mol. % of isotopologue HOD with carbon dioxide or/and inorganic salts typically abandoned in natural drinking water. The examples of such salts include, but are not limited to, sodium chloride, sodium bicarbonate, calcium chloride, magnesium sulfate, etc.
[0018] In practicing the invention, the medical food can be administered orally for a period of one day or longer and in amounts as prescribed by a physician which manages the diet and/or provides medical supervision.
[0019] In practicing the invention, the medical food may be formulated as the drinking water or beverage that can be administered in amounts from 0.1 to 4.0 liters per subject per day.
[0020] In practicing the invention, the medical food may be consumed by mammals. Nonexclusive examples of such mammals include, but are not limited to, animals such as a dog, a cat, a horse, and a human. Preferably, the medical food is consumed by a human.
[0021] The following examples are presented to demonstrate the invention. The examples are illustrative only and are not intended to limit the scope of the invention in any way.
EXAMPLE 1
[0022] This example demonstrates the preparation of water samples with different contents of isotopologue HOD. The samples were prepared by mixing in certain proportions the conventional distilled water containing 0.0300 mol. % HOD and water containing 0.0002 mol. % HOD, wherein the last water was prepared by high-effective vacuum distillation of the conventional distilled water at 60° C. and pressure 0.2 bars using the distillation column of 10 m of height. HOD levels were measured by isotope laser spectroscopy using Los Gatos Research (LGR) Liquid Water Isotope Analyzer. Table 1 shows water samples comprising 0.0002 to 0.0278 mol. % of isotopologue HOD and D/H ratios corresponding therewith.
[0000]
TABLE 1
Water samples
Sample
HOD content, mol. %
D/H ratio, ppm
Water No 1
0.0278
139
Water No 2
0.0240
120
Water No 3
0.0178
89
Water No 4
0.0002
1
EXAMPLE 2
[0023] This example demonstrates the medical food for the dietary management of major depression. The medical foods were formulated as mineralized drinking waters with HOD content as indicated in Table 2.
[0000]
TABLE 2
Medical foods
Ingredient (HOD, mol. %)
Content, wt. %
Medical food 1
Water No 1 (0.0278)
99.953
Calcium Chloride
0.015
Magnesium Chloride
0.007
Sodium Bicarbonate
0.025
Medical food 2
Water No 2 (0.0240)
99.953
Calcium Chloride
0.015
Magnesium Chloride
0.007
Sodium Bicarbonate
0.025
Medical food 3
Water No 3 (0.0178)
99.953
Calcium Chloride
0.015
Magnesium Chloride
0.007
Sodium Bicarbonate
0.025
Medical food 4
Water No 4 (0.0002)
99.953
Calcium Chloride
0.015
Magnesium Chloride
0.007
Sodium Bicarbonate
0.025
[0024] The medical foods No 1 through 4 were prepared by dissolution of Calcium Chloride, Magnesium Chloride, and Sodium Bicarbonate in Waters No 1 through 4, respectively, and subsequent bottling in bottles of 330 ml volume.
EXAMPLE 3
[0025] This example shows that deuterium-containing isotopologue HOD dose-dependently predisposes to the development of depression. Water samples of Table 3 were prepared by mixing in certain proportions of two equally mineralized waters having HOD level of 0.0184 mol. % (D/H ratio=92 ppm) and HOD level 0.0282 mol. % (D/H ratio=141 ppm).
[0000]
TABLE 3
Water samples
Water sample
HOD content, mol. %
D/H ratio, ppm
W1
0.0184
92
W2
0.0240
120
W3
0.0258
129
W4
0.0282
141
[0026] Three-months-old male C57Bl/6 mice were randomly assigned by 15 animals per group and received W1, W2, W3, and W4 (Table 3) as drinking waters ad libitum for 14 days and then were tested for depressive-like behavior in a forced swim test and novel cage test, commonly accepted paradigms for pre-clinical testing of a depressive-like behavior. Antidepressant Imipramine (15 mg/kg per day) was administered to mice that were taken as positive control in the test. Results of forced swim test are presented in Table 4 as mean±SEM latency to floating (Latency) and duration of floating (Duration). As shown in Table 4, the increase in HOD levels in drinking water results in significant decrease in the latency to floating and increase in the duration of floating, meaning that deuterium-containing isotopologue HOD predisposes to the development of depression.
[0000]
TABLE 4
Forced swim test
Sample (HOD, mol. %)
Latency, s
Duration, s
W1 (0.0184)
46 ± 6 #
89 ± 15 #
W2 (0.0240)
48 ± 9 #
80 ± 14 #
W3 (0.0258)
47 ± 11
86 ± 19 #
W4 (0.0282)
31 ± 6*
128 ± 12*
Imipramine
58 ± 4* #
79 ± 8 # *
*Differs significantly of W1 (p < 0.05).
# Differs significantly of W4 (p < 0.05).
[0027] Results of novel cage test are presented in Table 5 as mean±SEM number of exploratory rearings in the new cage. As found, the increase in HOD levels in drinking water results in significant decrease in the number of exploratory rearings in the new cage, meaning that deuterium-containing isotopologue HOD predisposes to the development of depression.
[0000]
TABLE 5
Novel cage test
Sample (HOD, mol. %)
Number, n
W1 (0.0184)
35.0 ± 1.5 #
W2 (0.0240)
35.5 ± 1.5 #
W3 (0.0258)
33.0 ± 1.5
W4 (0.0282)
30.0 ± 1.0*
Imipramine
34.0 ± 1.5 #
*Differs significantly of W1 (p < 0.05).
# Differs significantly of W4 (p < 0.05).
[0028] Thus, these results suggest that deuterium-containing water isotopologue HOD in drinking water predisposes to depressive-like behavior. Therefore, HOD is a very undesirable nutrient for subjects with major depressive disorder and HOD restriction may represent a special medically determined nutrient requirement, the dietary management of which cannot be achieved by the modification of the normal diet alone.
EXAMPLE 4
[0029] This example demonstrates that deuterium-containing isotopologue HOD predisposes to the development of anhedonia, the core symptom of depression. Young adult male C57Bl/6J mice received ad libitum waters W1 or W4 (Table 3) for one week prior the onset of stress and during the ten days of a chronic stress. Citalopram 15 mg/kg per day per os was used as the reference antidepressant drug. There was no difference between groups at baseline. At 10th day of the stress procedure, animals were tested on the sucrose preference, common test for assessment of anhedonia. Results are presented in Table 6 as mean±SEM percent of sucrose preference.
[0000]
TABLE 6
Sucrose preference test
Group (HOD, mol. %)
Sucrose preference, %
W1 (0.0184)
73.5 ± 3.0 #
W4 (0.0282)
62.5 ± 2.0*
Citalopram
70.0 ± 3.0 #
*Differs significantly of W1 (p < 0.05).
# Differs significantly of W4 (p < 0.05).
[0030] As shown in Table 6, the increase in HOD levels in drinking water results in significant decrease in sucrose preference, meaning that deuterium-containing isotopologue HOD predisposes to the development of anhedonia, the core symptom of depression. Therefore, HOD is a very undesirable nutrient for subjects with major depressive disorder and HOD restriction may represent a special medically determined nutrient requirement, the dietary management of which cannot be achieved by the modification of the normal diet alone.
EXAMPLE 5
[0031] This example demonstrates that deuterium-containing isotopologue HOD predisposes to the development of depression in elderly. Table 7 shows that sucrose preference in old C5Bl/6J mice is significantly decreased in comparison with young adult C5Bl/6J mice, meaning that normal aging induces spontaneous anhedonia in mice.
[0000]
TABLE 7
Group
Sucrose preference, %
Young adult C57BI/6J mice (3 months old)
78.0 ± 2.5
Old C57B1/6J mice (18 months old)
60.6 ± 3.1*
*Differs significantly of young adult mice (p < 0.05).
[0032] To estimate effect of HOD on anhedonia in elderly, 18 month old male C57Bl/6J mice received ad libitum waters W1 or W4 (Table 3) for 14 days. There was no difference between groups at baseline. At the end of the experiment, mice were tested in sucrose preference test. Results are presented in Table 8 as mean±SEM percent of sucrose preference. As found, the increase in HOD levels in drinking water results in significant decrease in sucrose preference, meaning that deuterium-containing isotopologue HOD predisposes to the development of anhedonia, the core symptom of major depression, in elderly.
[0000]
TABLE 8
Sucrose preference test
Group (HOD, mol. %)
Sucrose preference, %
W1 (0.0184)
81.3 ± 1.9
W4 (0.0282)
69.4 ± 4.4*
*Differs significantly of W1 (p < 0.05).
[0033] To estimate effect of HOD on depressive-like behavior in elderly, 18 month old male C57Bl/6J mice received ad libitum waters W1 or W4 (Table 3) for 14 days. There was no difference between groups at baseline. At the end of the experiment, mice were tested in forced swim test. Results are presented in Table 9 as mean±SEM of latency to floating (Latency) and duration of floating (Duration). As found, the increase in HOD levels in drinking water results in decrease in the latency to floating and significant increase in the duration of floating, meaning that deuterium-containing isotopologue HOD predisposes to the development of depression in elderly.
[0000]
TABLE 9
Forced swim test
Group (HOD, mol. %)
Latency, s
Duration, s
W1 (0.0184)
17.4 ± 4.2
126.7 ± 13.9
W4 (0.0282)
13.7 ± 3.1
186.7 ± 10.0*
*Differs significantly of W1 (p < 0.05).
[0034] Therefore, HOD is a very undesirable nutrient for elderly subjects with depressive disorders and HOD restriction may represent a special medically determined nutrient requirement, the dietary management of which cannot be achieved by the modification of the normal diet alone.
|
A method for the dietary management of anxiety includes administering to a subject in need thereof water containing from 0.0002 to 0.0278 mol. % of isotopologue HOD, preferably, from 0.0178 to 0.0278 mol. % of isotopologue HOD.
| 0
|
TECHNICAL FIELD
[0001] The present invention relates to a process for producing fluorine-containing olefin.
BACKGROUND ART
[0002] Fluoroolefins represented by the formula: CF 3 (CX 2 ) n CF═CH 2 , the formula: CF 3 (CX 2 ) n CH═CHF, or the like, are compounds that have a useful structure as various functional materials, solvents, refrigerants, blowing agents, and monomers for functional polymers or starting materials of such monomers. For example, fluoroolefins are used as monomers for modifying ethylene-tetrafluoroethylene copolymers. Further, of the fluoroolefins mentioned above, the compound represented by CF 3 CF═CH 2 (HFO-1234yf) and the compound represented by CF 3 CH═CHF (HFO-1234ze) have recently gained attention because they offer promising prospects as refrigerants with low global-warming potential.
[0003] As one of the processes for producing fluoroolefins represented by the formulae above, many methods have been reported regarding a process in which a starting material chlorine-containing alkane or chlorine-containing alkene having the same number of carbon atoms as that of a target fluoroolefin is reacted with a fluorinating agent such as an anhydrous hydrogen fluoride in the presence of a catalyst (Patent Literature 1 to 6). In this process, a chromium oxide catalyst, antimony catalyst, or the like is used as a catalyst. In particular, it has been reported that an amorphous chromium oxide catalyst is effective (Patent Literature 6). Further, when an amorphous chromium oxide catalyst is used, a method of entraining O 2 or the like with a reactant to maintain the catalyst activity has been reported. However, in this method, a side reaction of the entrained O 2 with the reactant sometimes produces CO 2 as a by-product, or produces several by-products other than CO 2 , which cannot be converted into target products. This causes problems such as a decrease in the yield of target fluoroolefin, complications in a purification step, and a rise in the costs of the equipment used in the purification step.
CITATION LIST
Patent Literature
[0000]
PTL 1: WO 07/079435
PTL 2: WO 07/079431
PTL 3: WO 08/002500
PTL 4: WO 08/060614
PTL 5: WO 09/125199
PTL 6: WO 10/013796
SUMMARY OF INVENTION
Technical Problem
[0010] The present invention is made in light of the current state of the technical field as mentioned above, and a main object is to provide a process for producing fluoroolefins by reacting a fluorinating agent with a chlorine-containing alkane or a chlorine-containing alkene, which is used as a starting material, the process being capable of efficiently producing fluoroolefins by improving the conversion rate of the starting material and inhibiting the generation of impurities, which cause problems in separation and yield.
Solution to Problem
[0011] The present inventors conducted extensive research to achieve the above object. As a result, they found the following. When a chromium oxide catalyst, at least part of which is crystallized, or a catalyst obtained by fluorinating the chromium oxide catalyst is used to produce a fluoroolefin compound by reacting a fluorinating agent with a chlorine-containing alkane represented by a specific formula or a chlorine-containing alkene represented by a specific formula, which is used as a starting material, the conversion rate of the starting material is improved, and the selectivity of the target fluoroolefin is increased, which allows efficient fluoroolefin production. In particular, by adjusting the crystallite diameter of the chromium oxide catalyst, or allowing the presence of a specific amount of oxygen during the reaction, the conversion rate of the starting material and the selectivity of the target fluoroolefin can be increased. The present invention was accomplished based on these findings.
[0012] Specifically, the present invention offers the following process for producing fluoroolefins.
[0000] Item 1. A process for producing a fluoroolefin comprising:
[0013] reacting a fluorinating agent and a chlorine-containing compound in a gas phase in the presence of at least one catalyst selected from the group consisting of chromium oxide, at least part of which is crystallized, and fluorinated chromium oxide obtained by fluorinating the chromium oxide,
[0014] the chlorine-containing compound being at least one compound selected from the group consisting of a chlorine-containing alkane represented by formula (1): CX 3 (CX 2 ) n CClYCH 2 Z, wherein each X is independently F or Cl, and Y is H or F, and when Y is H, Z is Cl or F, and when Y is F, Z is H, and n is an integer of 0 to 2; a chlorine-containing alkane represented by formula (2): CX 3 (CX 2 ) n CH 2 CHX 2 , wherein each X is independently F or Cl, at least one X is Cl, and n is an integer of 0 to 2; a chlorine-containing alkene represented by formula (3): CX 3 (CX 2 ) n CCl═CH 2 , wherein each X is independently F or Cl, and n is an integer of 0 to 2; a chlorine-containing alkene represented by formula (4): CX 3 (CX 2 ) n CH═CHX, wherein each X is independently F or Cl, at least one X is Cl, and n is an integer of 0 to 2; and a chlorine-containing alkene represented by formula (5): CH 2 XCCl═CX 2 , wherein each X is independently F or Cl, the fluoroolefin to be obtained being a compound represented by formula (6): CF 3 (CF 2 ) n CA=CHB, wherein one of A and B is F and the other is H, and n is an integer of 0 to 2, provided that n is 0 when the chlorine-containing alkene represented by formula (5) is used as a starting material.
[0000] Item 2. The process for producing a fluoroolefin according to Item 1, wherein the chromium oxide, at least part of which is crystallized, has a crystallinity of 30% or more.
Item 3. The process for producing a fluoroolefin according to Item 1, wherein the chromium oxide, at least part of which is crystallized, has a crystallinity of 60% or more.
Item 4. The process for producing a fluoroolefin according to Item 1, wherein the chromium oxide, at least part of which is crystallized, has a crystallinity of 70% or more.
Item 5. The process according to any one of Items 1 to 4, wherein the chromium oxide has an average crystallite diameter of 50 nm or less.
Item 6. The process according to any one of Items 1 to 5, wherein the chromium oxide has a specific surface area of 10 m 2 /g or more.
Item 7. The process according to any one of Items 1 to 6, wherein a catalyst supported on a carrier is used.
Item 8. The process according to Item 7, wherein the carrier is at least one member selected from the group consisting of SiO 2 , Al 2 O 3 , zeolite, activated carbon, and zirconium oxide.
Item 9. The process according to any one of Items 1 to 8, wherein the catalyst comprising the chromium oxide, at least part of which is crystallized, is fluorinated, and then the chlorine-containing compound is reacted with the fluorinating agent.
Item 10. The process for producing a fluoroolefin according to any one of Items 1 to 9, wherein the fluorinating agent is anhydrous hydrogen fluoride.
Item 11. The process for producing a fluoroolefin according to any one of Items 1 to 10, wherein the chlorine-containing compound used as a starting material is at least one member selected from the group consisting of a chlorine-containing alkane represented by formula (1): CX 3 (CX 2 ) n CClYCH 2 Z, a chlorine-containing alkene represented by formula (3): CX 3 (CX 2 ) n CCl═CH 2 , and a chlorine-containing alkene represented by formula (5):CH 2 XCCl═CX 2 , and the fluoroolefin to be obtained is a compound represented by formula (6-1): CF 3 (CF 2 ) n CF═CH 2 , wherein n is an integer of 0 to 2, provided that n is 0 when the chlorine-containing alkene represented by formula (5) is used as a starting material.
Item 12. The process for producing a fluoroolefin according to Item 11, wherein the chlorine-containing compound used as a starting material is at least one member selected from the group consisting of CF 3 CHClCH 2 Cl (HCFC-243db), CCl 3 CCl═CH 2 (HCO-1230xf), CF 3 CCl═CH 2 (HCFO-1233xf), and CH 2 ClCCl═CCl 2 (HCO-1230xa), and the fluoroolefin to be obtained is CF 3 CF═CH 2 (HFO-1234yf).
Item 13. The process for producing a fluoroolefin according to Item 12, wherein the chlorine-containing compound used as a starting material is CF 3 CCl═CH 2 (HCFO-1233xf), and the fluoroolefin to be obtained is CF 3 CF═CH 2 (HFO-1234yf).
Item 14. The process for producing a fluoroolefin according to any one of Items 1 to 10, wherein the chlorine-containing compound used as a starting material is at least one member selected from the group consisting of a chlorine-containing alkane represented by formula (2): CX 3 (CX 2 ) n CH 2 CHX 2 and a chlorine-containing alkene represented by formula (4): CX 3 (CX 2 ) n CH═CHX, and the fluoroolefin to be obtained is a fluoroolefin represented by formula (6-2): CF 3 (CF 2 ) n CH═CHF, wherein n is an integer of 0 to 2.
Item 15. The process for producing a fluoroolefin according to Item 14, wherein the chlorine-containing compound used as a starting material is at least one member selected from the group consisting of CCl 3 CH═CHCl (HCO-1230zd) and CF 3 CH═CHCl (HCFO-1233zd), and the fluoroolefin to be obtained is CF 3 CH═CHF (HFO-1234ze).
Item 16. The process for producing a fluoroolefin according to Item 15, wherein the chlorine-containing compound used as a starting material is CF 3 CH═CHCl (HCFO-1233zd) and the fluoroolefin to be obtained is CF 3 CH═CHF (HFO-1234ze).
[0015] Hereinbelow, the process for producing a fluoroolefin of the present invention is specifically explained.
Starting Material
[0016] In the present invention, used as a starting material is at least one chlorine-containing compound selected from the group consisting of a chlorine-containing alkane represented by formula (1): CX 3 (CX 2 ) n CClYCH 2 Z, wherein each X is independently F or Cl, and Y is H or F, and when Y is H, Z is Cl or F, and when Y is F, Z is H, and n is an integer of 0 to 2; a chlorine-containing alkane represented by formula (2): CX 3 (CX 2 ) n CH 2 CHX 2 , wherein each X is independently F or Cl, at least one X is Cl, and n is an integer of 0 to 2; a chlorine-containing alkene represented by formula (3): CX 3 (CX 2 ) n CCl═CH 2 , wherein each X is independently F or Cl, and n is an integer of 0 to 2; a chlorine-containing alkene represented by formula (4): CX 3 (CX 2 ) n CH═CHX, wherein each X is independently F or Cl, at least one X is Cl, and n is an integer of 0 to 2; and a chlorine-containing alkene represented by formula (5): CH 2 XCCl═CX 2 , wherein each X is independently F or Cl.
[0017] By reacting such a chlorine-containing compound as a starting material with a fluorinating agent in the presence of a specific catalyst according to the conditions described below, it is possible to obtain a fluoroolefin represented by formula (6): CF 3 (CF 2 ) n CA=CHB, wherein one of A and B is F and the other is H, and n is an integer of 0 to 2, provided that n is 0 when the chlorine-containing alkene represented by formula (5) is used as a starting material, with high selectivity and a high conversion rate of the starting material.
[0018] Of the chlorine-containing compounds represented by formulae (1) to (5) above, compounds in which the number of carbon atoms is 3, i.e., n is 0, are preferred because they have an appropriate boiling point to perform a gas phase reaction. Preferable examples of the compounds in which n is 0 include CCl 3 CHClCH 2 Cl (HCC-240db), CF 3 CHClCH 2 Cl (HCFC-243db), and the like as the chlorine-containing alkane represented by formula (1); CCl 3 CH 2 CHCl 2 (HCC-240fa), CF 3 CH 2 CHCl 2 (HCFC-243fa), and the like as the chlorine-containing alkane represented by formula (2); CCl 3 CCl═CH 2 (HCO-1230xf), CF 3 CCl═CH 2 (HCFO-1233xf), and the like as the chlorine-containing alkene represented by formula (3); CCl 3 CH═CHCl (HCO-1230zd), CF 3 CH═CHCl (HCFO-1233zd), and the like as the chlorine-containing alkene represented by formula (4); and CH 2 ClCCl═CCl 2 (HCO-1230xa), and the like as the chlorine-containing alkene represented by formula (5). Of these compounds, CF 3 CCl═CH 2 (HCFO-1233xf) and CF 3 CH═CHCl (HCFO-1233zd) are particularly preferred. HCFO-1233xf is a known compound and can be easily obtained, for example, by adding chlorine to 3,3,3-trifluoro-1-propene to form HCFC-243db, and then subjecting the HCFC-243db to dehydrochlorination with alkali or the like.
[0019] In the present invention, the aforementioned starting materials can be used singly or in a combination of two or more.
Catalyst
[0020] In the process for producing fluoroalkene of the present invention, at least one member selected from the group consisting of chromium oxide, at least part of which is crystallized, and fluorinated chromium oxide obtained by fluorinating the chromium oxide can be used as a catalyst.
[0021] Chromium oxide used as a catalyst should be chromium oxide, at least part of which is crystallized. In particular, to increase the conversion rate of the starting material and the selectivity of the target fluoroolefin, the crystallinity is preferably about 30% or more, more preferably about 40% or more, even more preferably about 60% or more, and particularly preferably about 70% or more.
[0022] The crystallinity of the chromium oxide means the ratio of crystallized chromium oxide to all of the chromium oxide constituting the catalyst. A crystallinity of 100% indicates that substantially all of the chromium oxide is crystallized; a crystallinity of 50% indicates that 50 wt % of chromium oxide constituting the catalyst is crystallized.
[0023] In the present invention, crystallinity is determined according to the result of XRD measurement. Specifically, crystallinity means the ratio determined by comparison between the diffraction peak area of the all the crystal planes of the standard sample with that of the target chromium oxide, each area being calculated from a diffraction pattern obtained by XRD measurement performed under the same conditions. The standard sample substantially has a crystallinity of 100%. For example, when the diffraction peak area of all the crystal planes of the standard sample is 100 and the diffraction peak area of all the crystal planes of the measurement target chromium oxide is 50, the crystallinity is 50%.
[0024] Alternatively, the crystallinity can also be determined using an internal standard substance, which has a different diffraction pattern from that of the chromium oxide. Specifically, the crystallinity can be determined by comparison of the relative value of the diffraction peak area of all the crystal planes of the chromium oxide having a substantial crystallinity of 100% to that of the internal standard substance with the relative value of the diffraction peak area of all the crystal planes of the measurement target chromium oxide to that of the internal standard substance. Amorphous chromium oxide does not show a substantial XRD diffraction peak.
[0025] Further, by adjusting, within the aforementioned crystallinity range, the average crystallite diameter of the crystallized chromium oxide and the specific surface area, etc., of the chromium oxide, at least part of which is crystallized and which is used as a catalyst in the present invention, a target fluoroolefin can be produced at a high conversion rate of the starting material and high selectivity.
[0026] The average crystallite diameter of the crystallized chromium oxide is not particularly limited, and generally about 50 nm or less, preferably about 40 nm or less, and more preferably about 35 nm or less. The lower limit of the average crystallite diameter is not particularly limited, and it may be about 2 nm or more, preferably about 10 nm or more, and more preferably about 20 nm or more.
[0027] In the present specification, the average crystallite diameter is the average of the crystallite diameters of crystal planes obtained according to Scherrer's equation (D=Kλ/B cos θ, wherein D is the crystallite diameter, K is the Scherrer constant, λ is the X-ray wavelength/Cu radiation source, B is the full width at half maximum, and θ is half of diffraction angle 2θ), using the full width at half maximum of the XRD diffraction pattern of the chromium oxide.
[0028] Further, the chromium oxide, at least part of which is crystallized, preferably has a BET specific surface area of about 10 m 2 /g or more.
[0029] Regarding the composition of the chromium oxide, at least part of which is crystallized, the crystallized chromium oxide portion can be represented by formula Cr 2 O 3 . The amorphous chromium oxide portion can be, for example, represented by composition formula CrO m (1.5≦m≦3). Of these, m is preferably in the range of 1.5<m<3, more preferably 1.8≦m≦2.5, and even more preferably 2.0≦m≦2.3. Further, a mixture of chromium oxides having a different m value in the aforementioned m range can also be used.
[0030] The process for producing chromium oxide, at least part of which is crystallized, is not particularly limited. For example, the chromium oxide can be obtained by calcinating chromium hydroxide obtained by a coprecipitation method. In this case, by appropriately setting the calcination conditions, the crystallinity of chromium oxide or the crystallite diameter of crystallized chromium oxide can be adjusted. Specific examples of the catalyst production method are shown below.
[0031] First, for a coprecipitation method, an aqueous solution of chromium salt (chromium nitrate, chromium chloride, chromium alum, chromium sulfate, chromium acetate, or the like) and aqueous ammonia are mixed to obtain a precipitate of chromium hydroxide. For example, 10% aqueous ammonia is added dropwise to a 5.7% chromium nitrate aqueous solution in an amount about 1 to 1.2 equivalent per equivalent of chromium nitrate to obtain a precipitate of chromium hydroxide. The precipitate of chromium hydroxide is filtered, washed with distilled water, and dried. The drying may be performed in air at about 70° C. to 200° C. for about 1 to 100 hours. After the product is disintegrated into a powder, the resulting powder is calcined directly, or after being molded into a desired size and shape. In molding, for example, graphite is mixed as necessary in an amount of about 3 wt % or less, and is formed into a pellet with a tableting machine. The pellet may have, for example, a diameter of about 3.0 mm and a height about 3.0 mm.
[0032] The calcination can be performed in an inert gas flow, such as nitrogen, helium, and argon, an air flow, a water-vapor flow, an oxygen flow, or a mixed gas flow in which oxygen and the aforementioned inert gas are adjusted to have an appropriate composition. By selecting an atmosphere gas for the calcination and adjusting the calcination temperature, the crystallinity of the chromium oxide after calcination and the crystallite diameter can be adjusted.
[0033] For the relation between the calcination conditions and the crystallinity of chromium oxide or the crystallite diameter, in general, the greater the calcination temperature and the calcination time, the greater the crystallinity and the crystallite diameter; and the greater the concentration of a gas component having oxidizing ability in an atmosphere gas, e.g., oxygen, the greater the crystallinity and the crystallite diameter. Further, the lower the temperature increase rate during calcination, the more moderate the crystal growth, thus increasing the crystallite diameter. Therefore, for example, to increase the crystallinity and decrease the crystallite diameter, a method can be used in which an inert gas such as N 2 is used as an atmosphere gas and the calcination is performed in a very short time by setting the calcination temperature high and raising the temperature increase rate. Since these conditions vary depending on the heating device or calcination apparatus used in calcination, and the amount of the catalyst to be calcined, appropriate calcination conditions need to be determined according to a specific calcination method.
[0034] Amorphous chromium oxide, for example, can be obtained by calcinating a pellet that has been molded after drying and disintegrating the chromium hydroxide obtained by the coprecipitation method, described above, at about 380° C. to 460° C. for about 1 to 5 hours in an inert gas flow such as a nitrogen flow. It is possible to obtain chromium oxide having a crystallinity of about 40% and a crystallite diameter (crystallized portion) of about 34 nm when a product in the form of powder obtained by drying and disintegrating chromium hydroxide, which is obtained by the coprecipitation method, is introduced into a heat-resistant container such as a melting pot, allowed to stand in a heating furnace, and calcined at 350° C. for 2 hours in an air flow. Similarly, it is possible to obtain chromium oxide having a substantial crystallinity of about 100% and an average crystallite diameter of about 35 nm when a product in the form of powder obtained by drying and disintegrating chromium hydroxide, which is obtained by the coprecipitation method, is introduced into a heat-resistant container such as a melting pot, allowed to stand in a heating furnace, and calcined at 700° C. for 2 hours in an air flow.
[0035] The combination of these conditions and the crystallinity or the crystallite diameter is an example, and a desired crystallinity and crystallite diameter can be adjusted by appropriately selecting the kind of atmosphere gas, calcination temperature, calcination time, temperature increase rate to reach the calcination temperature, chromium oxide form (e.g., powder or molded product), furnace used in calcination, container used during calcination, filling conditions in the container, etc.
[0036] Further, it is possible to mix two or more different types of chromium oxide, each having a different crystallinity and a different crystallite diameter adjusted according to the above method or the like.
[0037] The fluorinated chromium oxide used as a catalyst is obtained by fluorinating the chromium oxide, which satisfies the above conditions and at least part of which is crystallized. The fluorinated chromium oxide can be produced by gradually promoting fluorination of the chromium oxide during the reaction of a chlorine-containing compound used as a starting material and a fluorinating agent; however, until the chromium oxide catalyst is sufficiently fluorinated, a chlorine-containing compound used as a starting material, a target product, or an intermediate may cause a side reaction, which sometimes reduces the yield of the target product or the catalyst activity by accumulation of a reaction inhibitor on the catalyst. For this reason, fluorinated chromium oxide produced by fluorinating the chromium oxide before the reaction is preferably used. To fluorinate the chromium oxide before the reaction, the chromium oxide placed in a reaction container may be, for example, brought into contact with a fluorinating agent before the reaction of a chlorine-containing compound and the fluorinating agent. The specific fluorination conditions in this case are such that the chromium oxide is heated at about 100° C. to 460° C. in an anhydrous hydrogen fluoride flow.
[0038] Although the degree of fluorination of fluorinated chromium oxide is not particularly limited, for example, the fluorinated chromium oxide having a fluorine content of about 10 to 30 wt % is preferably used.
[0039] Further, chromium oxide, at least part of which is fluorinated, and fluorinated chromium oxide obtained by fluorinating the chromium oxide may contain metal element(s) other than chromium. The amount of the metal element(s) other than chromium is not particularly limited, and is about 1 to 20 wt % based on the total catalyst.
[0040] The catalyst of the present invention may be supported on a carrier. The carrier is not particularly limited, and examples include SiO 2 , Al 2 O 3 , zeolite, activated carbon, zirconium oxide, and the like.
Reaction Process
[0041] In the present invention, the above-mentioned starting material and the fluorinating agent should be reacted in a gas phase in the presence of at least one catalyst selected from the group consisting of chromium oxide, at least part of which is crystallized, and fluorinated chromium oxide obtained by fluorinating the chromium oxide.
[0042] Usable fluorinating agents are fluorine gas, anhydrous hydrogen fluoride, etc.; anhydrous hydrogen fluoride is preferred.
[0043] In a process of reacting the starting material and the fluorinating agent in a gas phase, the starting material and the fluorinating agent are in a gaseous state when the starting material and the fluorinating agent are brought into contact with the catalyst. When the starting material and the fluorinating agent are supplied, they may be in a liquid state. For example, when the starting material is liquid at ordinal temperature and normal pressure, the starting material is vaporized by a vaporizer (vaporization region), then allowed to pass through a preheating region, and supplied to a mixing region in which the starting material is brought into contact with the catalyst. Thus, the reaction can be carried out in a gas phase. Alternatively, the starting material is supplied to a reactor in a liquid state, while a catalyst layer placed in the reactor is heated above the vaporization temperature of the starting material. When the starting material arrives at a region for reaction with the fluorinating agent, the starting material is vaporized and reacted.
[0044] The proportion of the fluorinating agent and the starting material to be introduced is not particularly limited. However, when the amount of the fluorinating agent is too low, the conversion rate of the starting material tends to decrease. In contrast, when the proportion of the fluorinating agent is too high, productivity is reduced because the amount of the fluorinating agent removed increases after the reaction. Considering these points, when anhydrous hydrogen fluoride is used as the fluorinating agent, in general, anhydrous hydrogen fluoride is preferably used in an amount of 5 equivalents or more, and more preferably 5 to 20 equivalents or more per equivalent of the starting material.
[0045] A specific example of the embodiment of the process of the present invention is a process in which the above-mentioned catalyst is placed in a tubular flow-type reactor, and a chlorine-containing compound, which is used as a starting material, and the fluorinating agent are introduced into the reactor.
[0046] The reactor is preferably made of a material resistant to the corrosive action of hydrogen fluoride, such as Hastelloy, Inconel, or Monel.
[0047] The above-mentioned starting material may be directly supplied to the reactor; alternatively, nitrogen, helium, argon, or another gas that is inert to the starting material and catalyst may be present together. The concentration of the inert gas may be about 0 to 80 mol % based on the amounts of the inert gas and the gas components introduced into the reactor, i.e., the chlorine-containing compound and the fluorinating agent.
[0048] In the process of the present invention, when the reaction is performed in the presence of oxygen, a decrease in catalytic activity can be prevented and the target fluoroolefin can be produced continuously for a long period of time and with high selectivity. Although the method of performing the reaction in the presence of oxygen is not particularly limited, oxygen may be generally supplied to the reactor together with the chlorine-containing compound used as a starting material.
[0049] The amount of oxygen supplied is, although not particularly limited, preferably about 0.001 mol or more, and more preferably about 0.001 to 0.3 mol, per mol of the chlorine-containing compound used as a starting material.
[0050] In particular, in order to achieve the effect of improving the starting material conversion rate while maintaining high selectivity, it is preferable to use as a catalyst a chromium oxide having a crystallinity of 30% or more and an average crystallite diameter of about 10 to 40 nm, or a fluorinated chromium oxide obtained by fluorinating the chromium oxide, and to supply oxygen in an amount as relatively small as about 0.001 to 0.3 mol per mol of the chlorine-containing compound used as a starting material. Especially, it is preferable to use as a catalyst a chromium oxide having a crystallinity of 60% or more and an average crystallite diameter of about 20 to 35 nm, or a fluorinated chromium oxide obtained by fluorinating the chromium oxide, and to supply oxygen in an amount as relatively small as about 0.001 to 0.3 mol per mol of the chlorine-containing compound used as a starting material. Performing the reaction in the presence of oxygen under such conditions can effectively provide an effect of preventing catalyst deterioration and effectively reduce the amount of CO 2 generated as a by-product. Accordingly, it is possible to solve the problem of reduction in purification efficiency due to the presence of non-condensable gas in the purification step, which is caused by the presence of excess oxygen. The danger of an explosion occurring when the starting material or generated gas is flammable can also be avoided.
[0051] In contrast, the use of an amorphous chromium oxide catalyst leads to the generation of a large amount of by-product such as carbon dioxide, thus relatively reducing the yield of the target product when compared under the same reaction conditions using the same oxygen introduction amount.
[0052] Further, in the process of the present invention, by performing the reaction in the presence of molecular chlorine, as necessary, a decrease in catalytic activity can be prevented, thus obtaining the target fluoroolefin continuously for a long period of time and with high yield. Although the method of performing the reaction in the presence of molecular chlorine is not particularly limited, molecular chlorine is generally supplied to the reactor together with the chlorine-containing compound used as a starting material.
[0053] The amount of molecular chlorine supplied is preferably about 0.001 to 0.05 mol, and more preferably about 0.002 to 0.03 mol, per mol of the chlorine-containing compound used as a starting material.
[0054] In addition, according to the process of the present invention, when the chlorine-containing compound used as a starting material and the fluorinating agent are reacted in a gas phase while controlling the moisture content of the reaction system to a low level, a decrease in catalytic activity is prevented, resulting in production of the target fluoroolefin continuously for a long period of time and with high yield. In this case, examples of the moisture of the reaction system include moisture contained in the chlorine-containing compound, which is used as a starting material, moisture contained in the fluorinating agent, and moisture contained in the optional components, such as molecular chlorine, oxygen, and inert gas. The total amount of such moisture is preferably controlled to the amount of 300 ppm or less, and more preferably 100 ppm or less, based on the weight of the chlorine-containing compound used as a starting material.
[0055] The method of reducing the moisture content of the reaction system is not particularly limited, and the chlorine-containing compound, which is used as a starting material, hydrogen fluoride, and other additives may be dehydrated by a known method before use in the reaction. For example, these components are subjected to the reaction after dehydration, or dehydrated and continuously supplied to the reaction system. Such methods can be suitably applied.
[0056] As a method for dehydrating the chlorine-containing compound used as a starting material, a distillation method and a method using a dehydrating agent can be applied. Considering efficiency, a moisture removing method using a dehydrating agent is preferred. As the moisture removing method using a dehydrating agent, a method in which moisture is adsorbed using zeolite is preferred. The form of zeolite is not particularly limited, and zeolite in the form of powder, granule, or agglomerate can be used. Zeolite having a pore size of about 2.0 to 6.0 Å can be used. The method of bringing the chlorine-containing compound into contact with zeolite is not particularly limited; however, it is generally preferred from the viewpoint of efficiency to pass the chlorine-containing compound in a gas or liquid form through a container filled with zeolite.
[0057] Even without separately providing a container filled with a dehydrating agent, the reaction can be performed with a reduced moisture content in the reaction system by providing a filling layer of a dehydrating agent before a catalyst filling layer in a reaction apparatus (tubular reactor), and passing the starting material introduced in the reaction apparatus (tubular reactor) through the filling layer of the dehydrating agent and then the catalyst layer. Although the location of the filling layer of the dehydrating agent is not particularly limited, it is preferable to provide the layer at a portion having a temperature of 100° C. or less and before the catalyst layer because moisture adsorbed from the dehydrating agent is desorbed at a temperature exceeding 100° C.
[0058] As a method for dehydrating the fluorinating agent, a distillation method, etc., can be applied.
[0059] Specific dehydration conditions may be determined by performing a preliminary experiment according to the moisture content in the starting material, the additive components, or the like, and the type and the structure of the device used so that the amount of moisture of the reaction system attains a desired level.
[0060] Regarding the reaction temperature, a temperature too low results in a great reduction in the conversion rate of the starting material, while a temperature too high leads to an increase in the production of by-product impurities and a decrease in selectivity. Considering these points, the reaction temperature is preferably about 200° C. to 550° C., and more preferably about 250° C. to 380° C.
[0061] The pressure during the reaction is, although not particularly limited, preferably in the range of atmospheric pressure to 3 MPa, and more preferably in the range of atmospheric pressure to about 0.3 MPa. When the pressure during the reaction is increased, the conversion rate of the starting material may be enhanced; however, a pressure too high is not preferred, because safety risks and economic risks are increased, and a fluorine-containing alkane in which hydrogen fluoride is added to a resulting target fluoroolefin is obtained in a large amount; consequently, the selectivity of the desired product may be reduced.
[0062] Although the reaction time is not particularly limited, for example, contact time W/F 0 represented by the ratio of the amount of catalyst used W (g) to the total flow rate F 0 (flow rate at 0° C. and 0.1 MPa: mL/sec) of the starting material gas introduced into the reaction system is preferably in the range of 0.1 to 100 g·sec/NmL, and more preferably about 5 to 50 g·sec/NmL. The total flow rate of the starting material gas in this case refers to the total of the flow rate of the chlorine-containing compound and fluorinating agent, and the flow rate of, when used, inert gas, molecular chlorine, oxygen, etc.
Reaction Product
[0063] According to the process described above, the fluorination reaction of the above starting material results in production of a fluoroolefin represented by formula (6): CF 3 (CF 2 ) n CA=CHB, wherein one of A and B is F, and the other is H, and n is an integer of 0 to 2, provided that n is 0 when a chlorine-containing alkene represented by formula (5) is used as a starting material, with a high conversion rate of the starting material and good selectivity.
[0064] More specifically, when the starting material is at least one chlorine-containing compound selected from the group consisting of a chlorine-containing alkane represented by formula (1): CX 3 (CX 2 ) n CClYCH 2 Z, a chlorine-containing alkene represented by formula (3): CX 3 (CX 2 ) n CCl═CH 2 , and a chlorine-containing alkene represented by formula (5): CH 2 XCCl═CX 2 , it is possible to obtain a compound of formula (6) wherein A is F, and B is H, that is, a compound of formula (6-1): CF 3 (CF 2 ) n CF═CH 2 , wherein n is an integer of 0 to 2, provided that n is 0 when a chlorine-containing alkene represented by formula (5) is used as a starting material. Further, when the starting material is at least one chlorine-containing compound selected from the group consisting of a chlorine-containing alkane represented by formula (2): CX 3 (CX 2 ) n CH 2 CHX 2 and a chlorine-containing alkene represented by formula (4): CX 3 (CX 2 ) n CH═CHX, it is possible to obtain a compound of formula (6) wherein A is H, and B is F, that is, a fluoroolefin represented by formula (6-2): CF 3 (CF 2 ) n CH═CHF wherein n is an integer of 0 to 2.
[0065] For example, when the starting material is CF 3 CHClCH 2 Cl (HCFC-243db), which is a chlorine-containing alkane represented by formula (1), CCl 3 CCl═CH 2 (HCO-1230xf) or CF 3 CCl═CH 2 (HCFO-1233xf), which is a chlorine-containing alkene represented by formula (3), CH 2 ClCCl═CCl 2 (HCO-1230xa)), which is a chlorine-containing alkene represented by formula (5), or the like, it is possible to obtain 2,3,3,3-tetrafluoropropene represented by formula: CF 3 CF═CH 2 (HFO-1234yf). The resulting product may also contain 1,3,3,3-tetrafluoropropene represented by formula: CF 3 CH═CHF (HFO-1234ze), together with HFO-1234yf. Moreover, when the starting material is CCl 3 CH═CHCl (HCO-1230zd) or CF 3 CH═CHCl (HCFO-1233zd), which is a chlorine-containing alkene represented by formula (4), or the like, it is possible to obtain 1,3,3,3-tetrafluoropropene represented by formula: CF 3 CH═CHF (HFO-1234ze).
[0066] Furthermore, a mixture of a fluoroolefin represented by formula (6-1) and a fluoroolefin represented by formula (6-2) can be obtained when the starting material is a mixture of at least one chlorine-containing compound selected from the group consisting of a chlorine-containing alkane represented by formula (1): CX 3 (CX 2 ) n CClYCH 2 Z, a chlorine-containing alkene represented by formula (3): CX 3 (CX 2 ) n CCl═CH 2 , and a chlorine-containing alkene represented by formula (5): CH 2 XCCl═CX 2 , with at least one chlorine-containing compound selected from the group consisting of a chlorine-containing alkane represented by formula (2): CX 3 (CX 2 ) n CH 2 CHX 2 and a chlorine-containing alkene represented by formula (4): CX 3 (CX 2 ) n CH═CHX.
[0067] The reaction product can be recovered after purification by distillation or the like. Further, unreacted fluorinating agent, starting materials, or intermediates obtained from the outlet of the reactor can be recycled by returning them to the reactor after separation and purification. Because of the recycling of the unreacted starting materials and fluorinating agent, high productivity can be maintained even if the conversion rate of the starting material is not high.
[0068] In the production of 2,3,3,3-tetrafluoropropene (HFO-1234yf), 1,1,1,2,2-pentafluoropropane (HFC-245cb), which is a main component of the by-product contained in the product, can be easily converted into 2,3,3,3-tetrafluoropropene (HFO-1234yf) by hydrogen fluoride-elimination reaction; therefore, 1,1,1,2,2-pentafluoropropane (HFC-245cb) contained in the product is also a useful compound. Moreover, in the production of 1,3,3,3-tetrafluoropropene (HFO-1234ze), 1,1,1,3,3-pentafluoropropane (HFC-245fa), which is a main component of the by-product contained in the product, can be easily converted into 1,3,3,3-tetrafluoropropene (HFO-1234ze) by hydrogen fluoride-elimination reaction; therefore, 1,1,1,3,3-pentafluoropropane (HFC-245fa) contained in the product is also a useful compound.
Advantageous Effects of Invention
[0069] According to the process of the present invention, the target fluoroolefin can be obtained from at least one chlorine-containing compound represented by a specific formula, which is used as a starting material, with a high conversion rate of the starting material and good selectivity by using chromium oxide, at least part of which is crystallized, or fluorinated chromium oxide obtained by fluorinating the chromium oxide as a catalyst.
[0070] Therefore, the process of the present invention is industrially advantageous as a process for producing fluoroolefins by fluorination of chlorine-containing compounds.
BRIEF DESCRIPTION OF DRAWINGS
[0071] FIG. 1 shows an XRD pattern of the amorphous chromium oxide obtained in Production Example 2, and a XRD pattern index of Cr 2 O 3 crystal.
[0072] FIG. 2 shows XRD patterns of the chromium oxide, at least part of which is crystallized, obtained in Production Examples 3 to 7, and a XRD pattern index of Cr 2 O 3 crystal.
DESCRIPTION OF EMBODIMENTS
[0073] The present invention is described in more detail below with reference to Production Examples of catalysts used in the present invention and Examples of the present invention.
Production Example 1
Preparation of Chromium Oxide Catalyst Precursor
[0074] 10% aqueous ammonia (118 g) was added to 900 g of an aqueous solution in which 77 g of chromium nitrate nonahydrate was dissolved to precipitate chromium hydroxide by neutralization. The chromium hydroxide precipitate was collected by filtration with a Buchner funnel, washed with water (3 L), and filtered, thereby obtaining chromium hydroxide.
Production Example 2
Preparation of Amorphous Chromium Oxide Catalyst
[0075] The solid obtained in Production Example 1 was dried at 120° C. for 12 hours. After making the solid into a powder, graphite was added in an amount of 3% based on the total weight, and the resulting mixture was molded into pellets (2-mm dia.×2 mm) and calcined at 400° C. in a nitrogen flow for 2 hours, thereby obtaining chromium oxide.
[0076] According to the XRD pattern of the oxide powder, the diffraction pattern derived from crystal was not observed, and the oxide was amorphous. In FIG. 1 , the diffraction peak around 2θ=26.5° indicated added graphite.
Production Example 3
Preparation of Partially Crystallized Chromium Oxide Catalyst: Crystallinity: 38%, Average Crystallite Diameter: 32.3 nm
[0077] The solid obtained in Production Example 1 was dried at 120° C. for 12 hours. After making the solid into a powder, the powder was calcined at 350° C. in an air flow for 3 hours, thereby obtaining chromium oxide.
[0078] According to the XRD pattern of the oxide powder, the diffraction pattern derived from α-Cr 2 O 3 was observed, the crystallinity obtained from the pattern area was 38%, and the oxide was chromium oxide containing a crystal portion and an amorphous portion. Based on the full width at half maximum, the crystallized chromium oxide had an average crystallite diameter of 32.3 nm.
Production Example 4
Preparation of Partially Crystallized Chromium Oxide Catalyst: Crystallinity: 62%, Average Crystallite Diameter: 25.3 nm
[0079] The solid obtained in Production Example 1 was dried at 120° C. for 12 hours. After making the solid into a powder, the powder was calcined at 400° C. in an air flow for 3 hours, thereby obtaining chromium oxide.
[0080] According to the XRD pattern of the oxide powder, the diffraction pattern derived from α-Cr 2 O 3 was observed, the crystallinity obtained from the pattern area was 62%, and the oxide was chromium oxide containing a crystal portion and an amorphous portion. Based on the full width at half maximum, the crystallized chromium oxide had an average crystallite diameter of 25.3 nm.
Production Example 5
Preparation of Partially Crystallized Chromium Oxide Catalyst: Crystallinity: 73%, Average Crystallite Diameter: 24.0 nm
[0081] The solid obtained in Production Example 1 was dried at 120° C. for 12 hours. After making the solid into a powder, the powder was calcined at 550° C. in an air flow for 3 hours, thereby obtaining chromium oxide.
[0082] According to the XRD pattern of the oxide powder, the diffraction pattern derived from α-Cr 2 O 3 was observed, the crystallinity obtained from the pattern area was 73%, and the oxide was chromium oxide containing a crystal portion and an amorphous portion. Based on the full width at half maximum, the crystallized chromium oxide had an average crystallite diameter of 24.0 nm.
Production Example 6
Preparation of Crystallized Chromium Oxide Catalyst: Crystallinity: 100%, Average Crystallite Diameter: 34.3 nm
[0083] The solid obtained in Production Example 1 was dried at 120° C. for 12 hours. After making the solid into a powder, the powder was calcined at 700° C. in an air flow for 3 hours, thereby obtaining chromium oxide.
[0084] According to the XRD pattern of the oxide powder, the diffraction pattern derived from α-Cr 2 O 3 was observed, the crystallinity obtained from the pattern area was 100%, and the oxide was crystalline chromium oxide. Based on the full width at half maximum, the crystallized chromium oxide had an average crystallite diameter of 34.3 nm. In FIG. 2 , the diffraction peak around 2θ=26.5° indicated graphite added for molding.
Examples 1 to 4
[0085] Each of the chromium oxide catalysts (7.0 g) prepared in Production Examples 3 to 6 was placed in a 1 m-long tubular Hastelloy reactor.
[0086] The reactor was heated, and the catalyst was first fluorinated by introducing nitrogen gas and hydrogen fluoride gas. To avoid the deterioration of the catalyst due to the rapid reaction of the catalyst and hydrogen fluoride, the reaction was gradually performed in two steps using heating temperatures and introduction rates shown below.
[0000] Step 1 : Nitrogen gas at 450 Nml/min (flow rate at 0° C. and 0.1 Mpa, the same as below) and hydrogen fluoride gas at 50 Nml/min for 1 hour at 200° C.
Step 2 : Nitrogen gas at 100 Nml/min, hydrogen fluoride gas at 400 Nml/min for 1 hour at 330° C.
[0087] Between Steps 1 and 2 , it took 1.5 hours to change the temperature and the flow rate of the nitrogen gas and the hydrogen fluoride gas.
[0088] The temperature of the reactor was raised to 350° C., and anhydrous hydrogen fluoride gas and oxygen gas were supplied to the reactor at flow rates of 42 NmL/min and 0.42 NmL/min, respectively, and maintained for 0.5 hours. Thereafter, CF 3 CCl═CH 2 (HCFC-1233xf) gas was supplied at a flow rate of 4.2 NmL/min. About 30 hours later, the effluent gas from the reactor was analyzed by gas chromatography.
[0089] Table 1 shows the results. Since HFC-245cb in the product is a useful compound that can be converted into HFO-1234yf by a hydrogen fluoride elimination reaction, Table 1 also shows the total selectivity of HFO-1234yf and HFC-245cb. In addition, Table 1 shows the conversion rate of the starting material, and the total yield of HFO-1234yf and HFC-245cb based on the starting material, calculated on the total selectivity of HFO-1234yf and HFC-245cb.
[0090] The symbols shown in the table indicate the following compounds:
[0000]
1233xf
CF 3 CCl═CH 2
1234yf
CF 3 CF═CH 2
245cb
CF 3 CF 2 CH 3
1234ze
CF 3 CH═CHF
1233zd
CF 3 CH═CHCl
Comparative Example 1
[0091] Fluorination treatment of a catalyst and fluorination reaction were performed as in Example 1, except that the amorphous chromium oxide obtained in Production Example 2 was used as a catalyst. Table 1 shows the results.
[0000]
TABLE 1
Comp.
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 1
Catalyst
Prod.
Prod.
Prod.
Prod.
Prod.
preparation
Ex. 3
Ex. 4
Ex. 5
Ex. 6
Ex. 2
example
Crystallinity
38
62
73
100
0
(%)
Specific
20
24
11
10
203
surface area
(m 2 /g)
Average
32.3
25.3
24.0
34.3
—
crystallite
diameter (nm)
1233xf
11
20
20
20
17
conversion
(GC %)
1234yf
68
68
67
68
66
selectivity
(GC %)
245cb
23
22
23
23
23
selectivity
(GC %)
1234ze
0.6
3.4
3.9
4.3
2.8
selectivity
(GC %)
1233zd
0.5
1.4
1.6
1.3
0.9
selectivity
(GC %)
CO 2
2.6
1.8
1.7
0.9
4.2
selectivity
(GC %)
Other by-
5.3
3.4
2.8
2.5
3.1
product
selectivity
(GC %)
1234yf + 245cb
91
90
90
91
89
selectivity
(GC %)
1234yf + 245cb
10
18
18
18
15
total yield
(%)
[0092] As is clear from Table 1, Examples 2 to 4, in which partially or wholly crystallized chromium oxide satisfying the conditions that the crystallity degree was 60% or more, the average crystallite diameter was 24 to 35 nm, and the specific surface area was 10 m 2 /g or more was used as a catalyst, showed high levels in the selectivity and the total yield of HFO-1234yf and HFC-245cb, which are useful compounds, as well as a high HCFC-1233xf conversion rate compared to those of Comparative Example 1, in which amorphous chromium oxide was used as a catalyst. In particular, Example 4, in which chromium oxide having a crystallinity of 100% was used as a catalyst, showed the highest 1234yf+245cb selectivity, i.e., 91%; thus, an excellent effect was attained.
[0093] In the aforementioned Examples and in Comparative Example 1, the highest HCFC-1233xf conversion rate was 20%, and thus an unreacted starting material will be recycled and reused in the actual process. Accordingly, the greater the 1234yf+245cb selectivity, the greater the yield of the target product in the actual process. When compared under the same conditions, the greater the 1233xf conversion rate, the lower the equipment costs. This is because the recycled amount of an unreacted starting material is reduced.
[0094] Consequently, the processes of Examples 2 to 4 in which chromium oxide with a crystallinity of 60% or more, an average crystallite diameter of 24 to 35 nm, and a surface area of 10 m 2 /g or more was used as a catalyst, are industrially advantageous because they have a high 1233xf conversion rate and high 1234yf+245cb selectivity.
[0095] Example 1, in which chromium oxide having a crystallinity of 38% was used as a catalyst, showed a low HCFC-1233xf conversion rate and a low total yield of HFO-1234yf and HFC-245cb compared to Comparative Example 1, but had high HFO-1234yf and HFC-245cb selectivity. Therefore, in the actual process, in which the starting material is reused, the total yield of HFO-1234yf and HFC-245cb is higher than in a process in which an amorphous chromium oxide is used as a catalyst; thus, the process of Example 1 is industrially advantageous
|
The present invention provides a process for producing a fluoroolefin by reacting, in a gas phase, a fluorinating agent and a chlorine-containing alkene or a chlorine-containing alkane in the presence of at least one catalyst selected from the group consisting of chromium oxide, at least part of which is crystallized, and fluorinated chromium oxide obtained by fluorinating the chromium oxide. According to the present process, a target fluoroolefin can be obtained at a high conversion rate of the starting material and with high selectivity.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The application is a non-provisional, and claims priority benefit, of U.S. Patent Application Ser. No. 61/630,358 file Dec. 9, 2011 which is incorporated herein by specific reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT.
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO APPENDIX
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The invention disclosed and taught herein relates to the enhancement of oil and gas wells and more specifically related to the means to provide radial boreholes into an oil and gas formation.
[0007] 2. Description of the Related Art
[0008] U.S. Patent Application Publication no. 61/630,358 discloses radial drilling boreholes into a formation were as the extension requires no specific radius to transform from vertical to horizontal direction.
[0009] U.S. Patent Application Publication no. 61/630,358 discloses the detail in which the casing is parted and the boreholes are provided.
[0010] The invention disclosed and taught herein is directed to an improved system for radial drilling systems.
BRIEF SUMMARY OF THE INVENTION
[0011] The Radial Drilling System comprising of a downhole full automatic system, which can part downhole, steel casing and extend outward into an oil and gas formation. The purpose of the system is to increase the area, which is exposed to drainage of a formation. The oil and gas wells are drilled vertically or horizontally by standard means. The standard boreholes are cased with steel tubes and are cemented via the annulus between the casing and the drilled borehole. Once the cement has been installed, it is tested to determine its bond strength and coverage.
[0012] Once the well, which has been drilled, cemented and tested, the Radial Drilling System can be employed. The location of the radial holes is determined by an engineering study employing specific instruments which locate the area of interest and defines the measurements of the oil and gas potential. The engineering logs indicate the area of interest as measured from a surface benchmark.
[0013] The casing string is coupled via threaded joints, which are larger than the casing body. The coupling locations are illustrated on a collar log. The collar log illustrates the location of the collar with relation to a measurement from the surface. Prior to performing this radial drilling process, the casing is installed. The collar location is known and the oil and gas location is identified. Therefore, an operational plan is realized which avoids the drilling of the couplings when parting the casing.
[0014] The radial process has specific surface equipment, which is operated with the downhole drilling tools. The primary standard workover or drilling rig is employed to move the radial tools from the surface to the downhole location and return to the surface. The depth of the well will outline the size of the workover or drilling rig to be employed based on a specific well. The radial tool system, surface equipment, is in addition to the standard drilling or workover rig.
[0015] In standard practice, the drilling rig is equipped with a drilling mud pump, which has a high volume with pressure levels between 3,000 and 5,000 psi. The high-pressure pump is part of the radial drilling surface equipment. The pump capacity is 20,000 psi. Fluids that are employed onto the radial system must be filtered to particle sizes of less than 5 microns. The high-pressure pump is equipped with bag filters which produce a pumping fluid with particle size less than 5 microns.
[0016] The fluids that can be employed in the radial system are water, saltwater, lease water, oil, diesel, acid, or other apparent fluids. In all cases, the fluids must be filtered for high-pressure pumping. The pumping of fluids at high pressure will not accept input of air. The main primer pump must have a system to “bleed” off any air in the system and that the fluid is considered non-compressible. Extra care must be provided to pre-charge the high-pressure pump via a “close loop” pump, which will not allow any air intake. Therefore, the fluid is free of any air and is non-compressible.
[0017] The control and operation of the downhole tool requires non-compressible fluids to operate. The pump transfers the fluid to the “work string” via a high-pressure hose. The hose is connected to a high-pressure swivel which allows the “work string” to rotate. The high-pressure pumping system has a safety valve, which prevents excessive pressuring of the system to occur.
[0018] The tool is moved to the downhole location via high-pressure tubing (work string), which is connected together via tool joints. The tubing is of high tensile strength and will have an operating pressure of 20,000 psi. Hence, the fluid pressure is transferred to the borehole location. Small pressure drops occur pending the depth of the borehole and oil and gas formation location due to internal friction.
[0019] The work string tool joints are larger than the tube but will be of a size to operate through the bore of the casing. For example, the well can be cased with 4½″ casing having a 4″ ID. The tool joints are 2⅛″ in diameter, thus there is sufficient annulus to operate and allow the fluid return to reach the surface.
[0020] Typical rotation of the work string is 100 to 150 rpm. At this speed, the tool joints do not cause damage to the ID of casing. The work string has sufficient tension and compression strength to operate the fully automated system. Depending upon the well depth, the work string will stretch or elongate. Special calculations can be provided to determine the stretch of the pipe measure in a unit length. The pipe stretch must be known to locate the downhole tool adjacent to oil and gas formation.
[0021] Exact positioning of the downhole tool is accomplished via a “gamma ray” unit. The “gamma ray” tool is a common method to locate tools downhole. Therefore, the radial tool assembly can be operated employing the surface equipment and work string.
[0022] The collar logs also identify the area along the axis of the casing where the casing can be parted without any contact with the casing collar. It is imperative that the casing is parted without cutting the casing couplings.
[0023] As stated before, the “gamma ray” will allow the operator to know the limits of the formation thereby allowing a drilling plan to be provided.
[0024] The drilling of radial boreholes must be conducted in an automatic condition due to the remote location. The drilling system must be programmed and the system must locate, part casing and drill out without surface control. The following is a description of the automatic drilling system:
[0025] In order to lock the tool in an operating mode, the tool must be anchored to the sidewalls of the casing. A tool assembly having a double set of slips is engaged and is locked in to anchor the downhole tool. This method is conducted in standard oil and gas operations. Directly above the anchor is a magnetic tool to be used as a metal chips gathering system.
[0026] The drilling of the boreholes is conducted in two events, i.e., parting of the casing and drilling of the boreholes. Hence, the casing-parting tool is operated first and the drilling is the second operation.
[0027] The parting of the casing and the bore of the hole are conducted in two parts but in one event. A specially designed extension tube is provided. The tube is a NiTi alloy, which allows flexibility in bending and rotating.
[0028] The tube is fitted with spheres, which are spaced and fastened to the NiTi tube via electron beam welding process. The spheres serve two functions, i.e., lateral support and a positive movement device for deployment of the extension tube. The special extension tube is rotated allowing the bit/mill to be powered for cutting purposes.
[0029] The special extension tube is matched via a grooved wheel. The wheel has grooves to accept the size of the sphere. The spacing of the grooves over the wheel is the same cord distance as the location of the sphere mounting location. The grooved wheel is powered by a gear rack assembly. The rack and extension tube is controlled from the surface. The extension upstream of the grooved wheel is in tension or neutral not compression as the drill string is lowered. The rack powers the groove wheel thereby causing the extension tube to be moved outward. The spheres are employed to avoid any slippage of the extensions or to provide a positive drive at all times.
[0030] The extension tube is rotated via the drill string from the surface. Fluid pressure exits the drill string and enters a tailing tube. The tailing tube is connected to the extension tube. The assembly, once activated, is moved through a guide, which is equipped with a low friction material thereby lowering tension drag and torsional drag. The mill/bit parts the casing at a speed approximately 50 to 75 rpm. The pressure level is 3500 psi. Once the casing is parted, the pressure is elevated to 20,000 psi and the tool speed of 150 rpm in set.
[0031] Once the full length of the extension tube is extended, a weep hole indicates the full extent of the tube movement. Once the hole is bored, the speed is reduced to 50 rpm and pressure is reduced to 3500 psi. The process is complete. The extension tube is retracted from the surface and placed in the stowed location. Once the assembly is in a stowed location, a weep hole is activated thereby indicating the location of the tool in a stowed location.
[0032] Due to the oil and gas formation requiring certain direction control of the radial holes, special instruments are indicate the direction of the exit part of the tool.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0033] FIG. 1 illustrates the general arrangement of the surface equipment and the downhole tools.
[0034] FIG. 2 illustrates a typical layout of surface equipment illustrating the various components.
[0035] FIG. 3 illustrates the basic components of the downhole tool.
[0036] FIG. 4 illustrates the extension drive assembly.
[0037] FIG. 5 illustrates the extension tube with lateral support spheres.
[0038] FIG. 6 illustrates the drilling system boring unit employing high-pressure jetting action and PDC cutter.
[0039] FIG. 7 illustrates the nozzle extension tube, nozzle and drive wheel.
[0040] FIG. 8 illustrates the extension tube, guide tube and low friction buffer tube.
[0041] FIG. 9 illustrates the rack extension tube.
[0042] FIG. 10 illustrates the magnetic hole cleaner.
[0043] FIG. 11 illustrates the tool anchoring system.
[0044] FIG. 12 illustrates an oil and gas formation which requires radial boreholes in thin seams.
DETAILED DESCRIPTION OF THE INVENTION
[0045] FIG. 1 illustrates the surface equipment 10 and the downhole tools 11 . The oil and gas formation 12 is the area of interest regarding the Radial Drilling System.
[0046] The downhole tools are connected to the surface equipment by a work string 13 . The distance between the surface equipment 10 and the oil and gas formation can be 30,000 maximum and as little as 500′.
[0047] The thickness of the formation 12 can be as large as 1,500′ and as little as 3′. The oil and gas formation is the area, which the radial tool will be employed.
[0048] The original vertical or horizontal borehole is drilled by standard methods and is cased with a steel tube 14 FIG. 1-A .
[0049] The surface equipment is provided to operate the downhole tool 11 from the surface. The work string 13 is the umbilical link between the surface equipment and the downhole radial tools.
[0050] FIG. 1-A illustrates the casing 14 . The diameter of the casing varies from 4½″ through 36″ and wall thickness from ¼″ to 3″. The casing string varies in size from the surface to the formation allowing the larger casing to be shallow and the smallest casing to be at the location of the oil and gas formation.
[0051] FIG. 2 illustrates the surface equipment employed in the invention. FIG. 2 illustrates the equipment from a plan view.
[0052] The well center 15 illustrates the exit of the casing and work string from the formation. The workover or drilling rig 16 is used to operate and maneuver the work string in and out of the well.
[0053] The pipe rack area 17 is used to marshal pipe once it has been removed from the earth.
[0054] The radial unit 18 , which houses the controls and pumping system, is mounted adjacent to the well center. Supporting the pumping system is the completion fluid tank 19 . The fluid tank contains special operational fluids. The fluids are transferred to the pumping unit 18 via a low pressure pump 20 .
[0055] FIG. 3 illustrates the Radial Drilling System and components. The radial tool is a complete system which can locate, anchor, part casing and extend outward to provide lateral holes in an oil and gas formation. The tool is installed into the original borehole via the work string 13 . Once the tool has reached the target area, the anchor 22 is engaged and via hardened dies the tool is fixed to the casing. Directly above the anchor 22 is the metal shavings collection component 23 . Above the shavings collection component 23 is a protection tube 24 , which guards the rack assembly 29 , when it is in a fully extended position. Above the protection tube 24 is the external body 25 of the nozzle extension system. Contained in the external body 25 are several components of the radial system.
[0056] The rack 29 is attached to the gear head 31 and is engaged into the extension gear wheel 27 . The rack 29 has machined teeth on one side of the structural member. The extension wheel 27 is a member that is mounted on bearings and grips the extension tube 30 causing the mill/bit 46 to enter the oil and gas formation.
[0057] FIG. 4 illustrates the high-pressure gear rack device. Power is transmitted to the gear head via the work string 13 . A sub 32 accepts the power transmitted from the work string. A spur gear 37 is mounted about the sub 32 . Sub 32 is supported by special bearings and seals 33 . An output shaft 30 accepts the power from the spur gear 37 via a gear 35 . The gear 35 is fastened to the output shaft/extension tube 30 . The gear head enclosure 31 is sealed to withstand a working pressure of 20,000 psi through the fluid passage 38 .
[0058] A gear rack assembly 29 has a double gear rack attached to the underside of the annulus. The gear rack 29 extends to the extension wheel and when the vertical movement occurs, the racks provide rotation of the wheel. The complete assembly is timed to prevent the extension tube 30 to be subjected to a compression force.
[0059] The gear head assembly, its power input and power output, has been designed to operate the extension tube and the cutting nozzle. The general operation of the unit allows the power to be accepted by the gear head assembly 31 via the work string 13 . The speed and internal pressure is controlled from the surface. As the decision to part the casing and construct the radial borehole is made, a fluid pressure of 3,500 psi. is established. The work string rotation is set between 75 and 90 rpm. The drilling of the casing is conducted either manually or via an automatic feed device.
[0060] The movement of the milling cutter will be 2″ measured axially along the extension tube. Once the casing has been parted, the power is elevated to 20,000 psi surface pressure and the rotation are increased to 250 rpm. The oil and gas formation is being drilled at a rate pre-determined and with relationship to the strength of the rock foundation. Depending upon the strength, the drilling of the radial holes is timed. Once the extension tube 30 reaches the extent of the length, a pressure valve is opened thereby bypassing the fluid and illustrating a sharp drop in the system pressure.
[0061] The pressure drop alerts the operator that the extension tube is in its furthest outbound position. The operation reduces the pump pressure to 3,500 psi and the rotating speed of the extension tube 30 to 75 rpm. The operational or automatic feeding unit retracts the extension tube and nozzle.
[0062] Once the extension tool is retracted, a valve is opened illustrating to the operator that the extension tube is in a stowed position. The operator then reduces the pump pressure to zero and the rotation to zero. The operator unlocks the anchor and moves the tools to a new location.
[0063] FIG. 5 illustrates the construction of the extension tube and the stabilizer spheres. The tube 41 is attached to a threaded joint 39 via a weldment. The weldment employs an electron beam welding system. The tube is NiTi (nitinol) alloy. The electron beam welding system does not require “filler materials”. The electron beam welding method provides a very small heat effective zone, thereby providing that a weldment has the same physical and chemical properties as the base tube material.
[0064] The opposite end of the NiTi tube is a welded connection, which provides a female threaded member. The same electron beam welding system is employed. The threaded connection has a transition area, which causes a method to disperse the bending strength moment at the connection. The threaded connection 44 accepts a PDC bit unit via the threaded connection. Internally of the threaded connection is a jet opening 46 . The jet opening is fitted with a sapphire stone with a specific nozzle size.
[0065] The extension tube 41 is fitted with a spherical member 42 about the basic tube 41 . The spherical members are attached to the tube via an electron beam weldment. The internal surface of the spherical stabilizers 42 have a curved surface with allows the ID of the spherical stabilizer 42 to make contact with the extension tube at a low contact. The contact point is the electron beam weldment as illustrated in 43 .
[0066] The spherical stabilizers can be rotated and “pulled” without detachment from the extension tube 41 . The placement of the spherical stabilizer 42 along the axis of the tube 41 is specific. The spherical stabilizers are placed at an exact distance to allow the extension wheel to function. The mill/bit unit has PDC inserts mounted in a form to allow machining of the casing and cutting of the oil and gas formation. Replacement of the bit is conducted by unscrewing the bit head from the extension tube body 41 . The tube and threaded connection are constructed in one length.
[0067] FIG. 6 illustrates the mill/bit assembly 46 , which has been designed to part the casing and drill the formation. The dual-purpose device is novel and is an important area of this invention. The threaded assembly 48 is welded to the extension tube at 47 . Due to the high rotational speed, the tube and mill/bit assembly must be in line no more than 0.0005″ eccentricity.
[0068] The mill/bit is equipped with PDC cutter and an internal high-pressure nozzle 51 . The nozzles have one orifice, which is protected via a sapphire stone. The nozzle “up ramp” considering a focus jet action which is directed to the center of the bit. Steel milling cutters are designed to perform with metallic materials. Hence, any steel machining arrangement would cut the casing 14 . However, once the casing has been parted drilled a borehole in the formation is required.
[0069] PDC (stabilized) inserts have caused great improvement in the drilling of oil and gas wells. FIG. 6 illustrates a typical bull nose metal machinery bit. Item 50 illustrates a typical PDC arrangement regarding a bit to drill oil and gas formations. A combination of milling cutters and formation cutters are included in the mill/bit design. The machining of the steel and the formation are considered to be classed as a “shaving” operation. Hence, a specific “layer” of material is removed with respect to each reduction. Hence, small quantities of vertical (normal) load are necessary for cutting the casing or the formation. The arrangement of cutters is novel regarding the mill/bit 46 unit.
[0070] FIG. 7 illustrates the extension wheel 27 . The design requires that the extension tube be operated in which the tube area above the extension wheel 27 is in tension at all times. As the gear rack 29 is pushed downward, the pinion 53 is rotated causing the movement of the extension tube 41 ; thereby, entering the formation. The extension tube, which is outbound of the extension wheel, is in compression. The extension tube that is fitted with spherical stabilizers 42 protects the NiTi tube 41 from buckling under compressive loading. As the extension wheel is rotated via the gear rack assembly 29 , the grooves grip the spherical stabilizer 42 and move the assembly outward at a positive rate without slippage. The extension wheel is mounted on a suitable bearing to maintain centerline of the tool.
[0071] FIG. 8 illustrates the extension tube guide. The extension tube 41 is fitted with spherical members 42 along its axis. The extension tube will be subjected to tension loading and torsional loading. The speed ranges of the extension tube are 50 rpm minimum, 250 rpm maximum. It is necessary that friction is reduced. The extension tube 41 is guided by a protected tube 57 . The tube is stainless steel. The inside of the guide tube is fitted with a very low level of friction material such as UHMW. The combination allows rotation and axial movement with a minimum drag.
[0072] FIG. 9 illustrates the rack protective casing 24 . The protective casing is equipped with guides 59 , which support and marshals the racks. The length of the protective casing is +two feet longer than the rack assembly.
[0073] FIG. 10 illustrates a hole cleaning component 23 . The component is designed to gather all metallic shavings, which are produced by the casing parting action. Particles or shavings from the milling operation can cause a malfunction of other mechanical tools in the borehole. The tool component is cleared during each trip in the borehole. The magnets 60 are replaceable.
[0074] FIG. 11 is a typical standard anchor 61 , which attaches the radial tool to the casing via quick setting drive. This assembly is part of the standard radial tool but is a commercial product.
[0075] FIG. 12 illustrates a completed radial borehole located in a thin formation. The surface 62 is illustrated were the support equipment is located. The formation upper level 63 and the formation lower level 64 defines a thin formation, i.e. 3″-6″ The completed borehole 65 is illustrated.
GENERAL FIELD OPERATIONS OF THE INVENTION
[0076] The oil and gas reserves have been deposited over millions of years in specific layers. The formation layers are of varying thicknesses ranging from 2′ to 2,000′. The formations are produced employing a method known as perforation. Explosive charges are employed to part the casing and extend outward several inches into the formation. There are many disadvantages to this process.
[0077] Horizontal drilling is employed which allows a borehole to be extended employing a “turn” from vertical to horizontal in a 100′ or more radial pattern. Formations made of small thickness cannot support horizontal drilling.
[0078] In order to harvest oil and gas reserves from thin seams, the radial invention has been developed. Due to the design, the radial system does not require a radius to translate a vertical borehole to a horizontal borehole. The radial system departs the casing at 90 degrees, directly into the oil and gas formations. The size and length of the radial borehole is predetermined.
[0079] The following is the work procedures concerning the development of radial boreholes in oil and gas formations:
[0080] Procedure 1
[0081] Surface equipment 10 , FIG. 1 , is mobilized about a typical well location.
[0082] Procedure 2
[0083] The support components are arranged about the well center as illustrated in FIG. 2 . The workover Rig 16 is placed adjacent to the well center 15 . The radial tool control console is also placed adjacent to the well center. The fluid tank 19 and transfer pump 20 is placed adjacent to the radial tool control unit.
[0084] Procedure 3
[0085] The downhole radial tool illustrated in FIG. 3 is lowered into the well bore via a tubular work string.
[0086] Procedure 4
[0087] A gamma ray instrument is employed to place the exit mill/bit 26 at the formation to be serviced. Once the location is identified, the tool anchor 22 is set; thereby locating the tool with relation to the formation.
[0088] Procedure 5
[0089] The work string extends above the workover rig 16 drill floor. A connection of the rig's power swivel is made to the workstring. The pressure pump located on the radial support unit is elevated to 3,500 psi. The system is pumped until circulation is determined at the surface.
[0090] Procedure 6
[0091] Once circulation is established at the surface, the power swivel is engaged and the speed is adjusted to 75 rpm. The torque ready is observed.
[0092] Procedure 7
[0093] Once the 3,500 psi pressure is attained, a pressure lug is released, disconnecting the extension tool assembly from the radial tool body.
[0094] Procedure 8
[0095] The workstring is lowered causing a compressive load to be placed onto the mill/bit 26 . The mill/bit 26 cuts the steel casing to a specific size and depth.
[0096] Procedure 9
[0097] Once the casing milling is complete, a drop in torsion is observed. Also, a drop in pressure is observed once the extension tube has advanced 5″.
[0098] Procedure 10
[0099] Once the initial casing is parted, the pumping pressure is elevated to 20,000 psi and the rotational speed is increased to 150 rpm.
[0100] Procedure 11
[0101] Once the formation drilling conditions are met, the workstring is lowered at a rate which has been preset regarding the harness of the formation.
[0102] Procedure 12
[0103] The mill/bit 26 is extended outward to the designed tube length. Once the extension is completed, a valve is opened (weep hole) indicating that the full length has been reached (pressure drop indicator).
[0104] Procedure 13
[0105] Once the extension tube is extended, the pump system provides fluids to clear the radial borehole, allowing the cuttings to be transmitted to the surface.
[0106] Procedure 14
[0107] Once the radial borehole is cleared of cuttings, the workstring is retracted pulling the extension tube into the original stowed location.
[0108] Procedure 15
[0109] The goals of the radial tool are to provide completed boreholes as shown in FIG. 12 . The boreholes can be placed in several series and groups. The drilling plan will allow radial holes located at the most efficient areas with respect to oil and gas production.
[0110] Procedure 16
[0111] Thick formation forms, 12′-300′, can also be serviced by the radial tool. Depending on the residual oil and gas quantities, several radial holes can be constructed and placed in any direction.
|
The invention being designed in this application relates to a radial drilling method. Boreholes are placed into oil and gas formations to provide openings for the removal of the product.
Oil and gas wells extend to different depths and downhole well conditions. The radial system has been designed to accommodate the well conditions and to jet or drill different oil and gas formation. The radial system provides a mill/bit which is rotated from a downhole motor or a surface swivel. The mill ports, the steel casing, and the bit extend outward into the formation forming a borehole to a predetermined length. The borehole is provided without an entrance radius into the formation. Several radial holes can be provided considering a one trip event.
| 4
|
TECHNICAL FIELD
[0001] The present invention relates, in general, to handwriting, and in particular, to a method and a device for inputting handwriting character.
BACKGROUND OF THE INVENTION
[0002] Today a writing input device is becoming more and more popular. Users can easily make an input on a touch screen of an electronic device either by a finger or by a special input device such as a stylus.
[0003] However, a conventional operation of editing via handwriting input is not quite efficient and friendly. During editing, the user has to locate an input target before the actual input. That is, the conventional operation has two separate steps: 1) the user locates the input target by touching the intended input/editing area; and 2) after the input target gets located, the user can then start inputting or editing.
[0004] The same problem exists during the user corrects the input when the user input wrong character or the device wrongly recognized the input. In this case, the conventional operation has three separate steps: 1) the user has to locate the target on a specific area of the touch screen where an error occurs; 2) the user has to delete the wrong input (e.g., a character) before making a new input; and 3) then the user may make the new input, e.g., input a complete and correct character, at the same location.
[0005] Accordingly, there is a need for an efficient way of editing and correcting the handwriting input on the touch screen of the electronic device.
SUMMARY OF THE INVENTION
[0006] An aspect of the present invention provides a method for inputting handwriting character. The method comprises steps of: adding a handwriting input on a touch screen, where the touch screen has a plurality of input areas; detecting a position of an initial point of the handwriting input; determining an input area for the handwriting input among the plurality of input areas of the touch screen based on the position of the initial point of the handwriting input; determining an operation of the handwriting input based on the position of the initial point of the handwriting input and performing the determined operation; and upon completion of the handwriting input, recognizing the input as a character and displaying the recognized character in the determined input area on the touch screen.
[0007] Another aspect of the present invention provides an electronic device for inputting handwriting character. The device comprises a touch screen having a plurality of input areas, a memory configured to store non-transitory computer-executable instructions, and a processor, coupled to the memory and the touch screen, configured to perform a set of functions including: adding a handwriting input on the touch screen; detecting a position of an initial point of the handwriting input; determining an input area for the handwriting input among the plurality of input areas of the touch screen based on the position of the initial point of the handwriting input; determining an operation of the handwriting input based on the position of the initial point of the handwriting input and performing the determined operation; and upon completion of the handwriting input, recognizing the input as a character and displaying the recognized character in the determined input area on the touch screen.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention, and explain various principles and advantages of those embodiments.
[0009] FIG. 1 is a block diagram illustrating an electronic device according to an embodiment of the present invention.
[0010] FIGS. 2A, 2B, and 2C show a first example of inputting handwriting character according to the embodiment of the present invention.
[0011] FIGS. 3A and 3B show a second example of inputting handwriting character according to the embodiment of the present invention.
[0012] FIGS. 4A and 4B show a third example of inputting handwriting character according to the embodiment of the present invention.
[0013] FIGS. 5A and 5B show a fourth example of inputting handwriting character according to the embodiment of the present invention.
[0014] FIGS. 6A, 6B, and 6C show a fifth example of inputting handwriting character according to the embodiment of the present invention.
[0015] FIGS. 7A, 7B, and 7C show a sixth example of inputting handwriting character according to the embodiment of the present invention.
[0016] FIGS. 8A, 8B, 8C, and 8D show a seventh example of inputting handwriting character according to the embodiment of the present invention.
[0017] FIG. 9 is a flowchart illustrating a method for inputting handwriting character according to the embodiment of the present invention.
[0018] FIG. 10 is a flowchart illustrating a process for determining an operation of the handwriting input according to the embodiment of the present invention.
[0019] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
[0020] The method and device components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention is directed to simplify the operation by combining the input target locating step with the user actual inputting/editing step. According to an embodiment of the present invention, the user may directly make a handwriting input on a touch screen and a position of an initial touch point of the input (in other words, a start of a first stroke of the input) is detected and the intended input area is determined based on the detected position. In this case, the detected position is determined as a point in the intended input area. There is no need for the user to “tell” the device where the user would make the handwriting input before the actual input operation. The device automatically determines the input area on the touch screen based on the detected position of the initial touch point of the input as long as the touch area is valid for input. The device may accept the input and recognize it and display the recognized result in the determined input area.
[0022] In the case of correcting an error input, the user may directly write the input on the error character without locating and deleting the error character in advance. The device may automatically determine the error character based on the detected position of the initial point of the input and replace it with a new input. In this embodiment, the position of the initial point of the input falls on the error character. During the correcting operation, in a preferred embodiment, after determining the error character, the device may automatically recognize the character by combine the original (error) character with the new input (stroke), e.g., by providing possible results to the user for choosing in the touch screen. After selection by the user or automatically, the new and correct character is displayed at the proper position (for example, in a word or a sentence) on the touch screen.
[0023] FIG. 1 is a block diagram illustrating an electronic device according to an embodiment of the present invention. As shown in FIG. 1 , according to the embodiment of the present invention, the electronic device 100 includes a touch screen 101 , a memory 102 , and a processor 103 . The touch screen 101 is well-know to the ordinary skilled in the art and is used to display or provide the information to the user on one hand and to make an input by the user on the other hand. The user may use one or more fingers, or a stylus, to make the input such as character(s). The memory 102 is used to store non-transitory computer-executable instructions. The processor 103 is coupled to the touch screen 101 and the memory 102 . The processor 103 is configured to perform a set of functions which, when executed, cause the electronic device 100 to implement the embodiment of the present invention.
[0024] FIGS. 2A, 2B, and 2C show a first example of inputting handwriting character according to the embodiment of the present invention. The first example shows a case where the user starts writing a first character on the touch screen.
[0025] Referring to FIG. 2A , FIG. 2A shows two input areas—a first input area and a second input area (shown as “input area 1 ” and “input area 2 ” respectively)—in which the user may make the input, on the touch screen 101 of FIG. 1 in the first example. The ordinary skilled in the art should understand that, although only two input areas are shown in FIG. 2A (and also only two input areas are shown in FIGS. 2B, 2C, 3A, 3B, 4A, 4B, 5A, 5B, 6A, 6B, 6C, 7A, 7B, 7C, 8A, 8B, 8C, and 8D ), the number of the input areas on the touch screen may be more than two, for example, three or four or etc. Moreover, although in the above figures, the input areas are arranged from top to bottom of the touch screen, the ordinary skilled in the art should understand that the input areas may be arranged from left to right of the touch screen, or in other proper directions or ways. Further, although in the above figures, the input areas are arranged in a rectangle shape, the ordinary skilled in the art should understand that the input areas may be arranged in other proper shapes such as triangle, square, diamond, circle, ellipse, or etc.
[0026] FIG. 2B shows a handwriting input by the user in the first example. As shown in FIG. 2B , the user directly starts writing a character on the touch screen at the intended input area. In this case, the user would like to write a character “c” in the first input area. As the user makes the input, the input is added and displayed on the touch screen so that the user can view what he or she is writing. As shown in FIG. 2B , since the position of the initial point of the input (a small circle shown in FIG. 2B ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. Referring to FIG. 2B , the user continues writing the character “c”.
[0027] Upon completion of the input, the processor 103 of the electronic device 100 recognizes the input as the character “c”. Since the first input area is determined as the intended input area, the recognized character “c” is displayed in the first input area, as shown in FIG. 2C .
[0028] Then, the use may correct the character “c” if it is a wrong character, or may continue writing another character after the character “c” or in another input area.
[0029] FIGS. 3A and 3B show a second example of inputting handwriting character according to the embodiment of the present invention. The second example shows a case where the user continues writing another character after the character “c”.
[0030] FIG. 3A shows a handwriting input by the user in the second example. As shown in FIG. 3A , the user directly starts writing a character on the touch screen at the intended input area. In this case, the user would like to write a character “h” in the first input area and immediately after the existing character “c”. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing. As shown in FIG. 3A , since the position of the initial point of the input (a small circle shown in FIG. 3A ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is after the existing character “c”, the processor 103 of the electronic device 100 determines that the user continues writing the character after the existing character. Referring to FIG. 3A , the user continues writing the character “h”.
[0031] Upon completion of the input, the processor 103 of the electronic device 100 recognizes the new input as the character “h”. Since the first input area is determined as the intended input area, and it is determined that the user continues writing the character after the existing character, the recognized character “h” is displayed in the first input area and immediately after the existing character “c”, as shown in FIG. 3B . Referring to FIG. 3B , a character combination “ch” is displayed in the first input area on the touch screen.
[0032] Then, the use may correct any character of the character combination “ch” if there is a wrong character, may continue writing another character after the character “h” or in another input area, or may insert another character between the existing characters “c” and “h”.
[0033] FIGS. 4A and 4B show a third example of inputting handwriting character according to the embodiment of the present invention. The third example shows a case where the user continues writing another character in another input area on the touch screen.
[0034] FIG. 4A shows a handwriting input by the user in the third example. As shown in FIG. 4A , the user directly starts writing a character on the touch screen at the intended input area. In this case, the user would like to write a character “i” in the second input area, instead of the first input area in which the character combination “ch” exists. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing. As shown in FIG. 4A , since the position of the initial point of the input (a small circle shown in FIG. 4A ) falls in the second input area, the second input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is neither after any existing character nor between the characters, the processor 103 of the electronic device 100 determines that the user writes the first character in the second input area. Referring to FIG. 4A , the user continues writing the character “i”.
[0035] Upon completion of the input, the processor 103 of the electronic device 100 recognizes the new input as the character “i”. Since the second input area is determined as the intended input area, and it is determined that the user writes the first character in the second input area, the recognized character “i” is displayed in the second input area as the first character, as shown in FIG. 4B . Referring to FIG. 4B , a character combination “ch” is displayed in the first input area on the touch screen and the character “i” is displayed in the second input area on the touch screen.
[0036] Then, the use may correct any character of the character combination “ch” and the character “i” if there is a wrong character, may continue writing another character after the character “h” or “i”, or may insert another character between the existing characters “c” and “h”.
[0037] FIGS. 5A and 5B show a fourth example of inputting handwriting character according to the embodiment of the present invention. The fourth example shows a case where the user corrects an existing character on the touch screen.
[0038] When an error input or a false recognition occurs, a correction operation is needed. According to the present invention, the user does not have to specify the input target, followed by a deletion operation and an insertion operation. Instead, the user may directly write the correct character on the touch screen and just make sure that the position of the initial point of the new input is right on the wrong character to be corrected.
[0039] FIG. 5A shows a handwriting input by the user in the fourth example. As shown in FIG. 5A , the user directly starts writing a character on the touch screen at the intended input area. In this case, the user would like to change the character “c” in the first input area to a character “g”. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing. As shown in FIG. 5A , since the position of the initial point of the input (a small circle shown in FIG. 5A ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is just on the character “c”, the processor 103 of the electronic device 100 determines that the user corrects the existing character “c” in the first input area. Referring to FIG. 5A , the user makes a supplemental input to the existing character “c” to change it into the character “g”.
[0040] In this case, the user does not have to make a complete character “g”, but only makes the supplemental input. That is, a new stroke or a missing stroke is added onto the existing character without repeatedly inputting an existing stroke of the existing character. In this way, the new input is combined with the existing character “c” to form a new character “g”. That is, the processor 103 of the electronic device 100 recognizes the new input as the character “g” by combining the new input with the existing (and correct) stroke of the existing character.
[0041] Although FIG. 5A shows a case where the user adds a new stroke onto the existing character to replace the existing character with a new character which is a combination of the new stroke and the existing (original) character, the ordinary skilled in the art should understand that the fourth example of inputting handwriting character according to the embodiment of the present invention, i.e., the correction operation, should also include another case where the user would like to change a wrong stroke of the existing character into a new and correct stroke so that the original and wrong character with the wrong stroke can be replaced with the new and correct character with the new and correct stroke. In the first case, i.e., in the case as shown in FIG. 5A , the existing character is corrected by directly adding a missing stroke onto the existing character without repeatedly inputting an existing and correct stroke of the existing character. In the second case, the existing character is corrected by directly replacing a wrong stroke with a new stroke without repeatedly inputting an existing and correct stroke of the existing character.
[0042] Since the first input area is determined as the intended input area, and it is determined that the user corrects the character “c”, the newly recognized character “g” is displayed in the first input area and the existing character combination “ch” in the first input area is changed to “gh”, as shown in FIG. 5B . Referring to FIG. 5B , a correct character combination “gh” is displayed in the first input area on the touch screen and the character “i” remains unchanged and is still displayed in the second input area on the touch screen.
[0043] Then, the use may continue correcting any character of the character combination “gh” and the character “i” if there is a wrong character, may continue writing another character after the character “h” or “i”, or may insert another character between the existing characters “g” and “h”.
[0044] FIGS. 6A, 6B, and 6C show a fifth example of inputting handwriting character according to the embodiment of the present invention. The fifth example shows a case where the user inserts a character between two existing characters.
[0045] When a word is incorrectly input because, for example, a character is missed, the user may correct it by using the present invention. According to the present invention, the user does not have to accurately specify the input target within the whole word, as how the user normally does today. Instead, the user may directly start writing on the intended location, e.g., directly on the position where a character is missed, e.g., between two existing characters.
[0046] FIG. 6A shows a character combination “bok” having the existing character “b”, “o”, and “k” displayed in the first input area on the touch screen. In this case, the correct word should be “book”, however a character “o” is missed between the characters “o” and “k”.
[0047] FIG. 6B shows a handwriting input by the user in the fifth example. As shown in FIG. 6B , the user directly writes a character on the touch screen at the intended input area. In this case, the user would like to insert another character “o” between the existing characters “o” and “k” in the first input area. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing. As shown in FIG. 6B , since the position of the initial point of the input (a small circle shown in FIG. 6B ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is between the existing characters “o” and “k”, the processor 103 of the electronic device 100 determines that the user inserts a character between the existing characters in the first input area on the touch screen. Referring to FIG. 6B , the user continues writing the character “o”.
[0048] Upon completion of the input, the processor 103 of the electronic device 100 recognizes the new input as the character “o”. Since the first input area is determined as the intended input area, and it is determined that the user inserts a character between the existing characters, the recognized character “o” is displayed between the original characters “o” and “k” in the first input area, as shown in FIG. 6C . Referring to FIG. 6C , a character combination “book” is displayed in the first input area on the touch screen. That is, the wrong character combination “bok” is changed to a correct word “book” by inserting a character “o” between the original characters “o” and “k”.
[0049] Then, the use may continue correcting any character of the character combination “book” if there is still a wrong character, may continue writing another character or another word after the character “k” or the character combination “book”, or may insert another character between the existing characters “b” and “o”, “o” and “o”, and “o” and “k”.
[0050] FIGS. 7A, 7B, and 7C show a sixth example of inputting handwriting character according to the embodiment of the present invention. The sixth example shows a case where the user corrects a plurality of characters in one word or in several words in different input areas on the touch screen.
[0051] A more complete scenario is shown in FIGS. 7A, 7B, and 7C , which illustrate how to correct a word with some error characters. Due to input error or false recognition, there may be several error characters in a word. For example, as shown in FIG. 7A , the word “ghost” in the first input area has two error characters “c” (should be “o”) and “l” (should be “t”), and the word “internet” in the second input area also has two error characters “o” (should be “e”) and “c” (should be “e”). According the present invention, without additional in-efficient operation of locating the error character, deleting it, and then inputting the correct one, the user may directly make an input on the error character, and even no need to write the whole character but just supplement the strokes, just like the user usually does on a paper. the electronic device of the present invention may automatically locate the error character and try to recognize the character again by combining the new stroke with the original (error) character to get a new result. The original character may be replaced with the new result. By this way, the correction operation would be much more efficient than how the user does today.
[0052] FIG. 7B shows a handwriting input by the user in the sixth example. As shown in FIG. 7B , the user directly starts writing a character on the touch screen at the intended input area. In this case, the user would like to change the characters “c” and “l” in the first input area to the correct characters “o” and “t”, and change the characters “o” and “c” in the second input area to the correct characters “e” and “e” respectively. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing.
[0053] As shown in FIG. 7B , for the error character “c” of the character combination “ghcsl”, since the position of the initial point of the input (a first small circle shown in FIG. 7B ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is just on the character “c”, the processor 103 of the electronic device 100 determines that the user corrects the existing character “c” in the first input area. Referring to FIG. 7B , the user makes a supplemental input to the existing character “c” to change it into the character “o”.
[0054] In this case, the user does not have to make a complete character “o”, but only makes the supplemental input. That is, a new stroke or a missing stroke is added onto the existing character without repeatedly inputting an existing stroke of the existing character. In this way, the new input is combined with the existing character “c” to form a new character “o”. That is, the processor 103 of the electronic device 100 recognizes the new input as the character “o” by combining the new input with the existing (and correct) stroke of the existing character.
[0055] As shown in FIG. 7B , for the error character “l” of the character combination “ghcsl”, since the position of the initial point of the input (a second small circle shown in FIG. 7B ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is just on the character “l”, the processor 103 of the electronic device 100 determines that the user corrects the existing character “l” in the first input area. Referring to FIG. 7B , the user makes a supplemental input to the existing character “l” to change it into the character “t”.
[0056] In this case, the user does not have to make a complete character “t”, but only makes the supplemental input. That is, a new stroke or a missing stroke is added onto the existing character without repeatedly inputting an existing stroke of the existing character. In this way, the new input is combined with the existing character “l” to form a new character “t”. That is, the processor 103 of the electronic device 100 recognizes the new input as the character “t” by combining the new input with the existing (and correct) stroke of the existing character.
[0057] As shown in FIG. 7B , for the error character “o” of the character combination “intornct”, since the position of the initial point of the input (a third small circle shown in FIG. 7B ) falls in the second input area, the second input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is just on the character “o”, the processor 103 of the electronic device 100 determines that the user corrects the existing character “o” in the second input area. Referring to FIG. 7B , the user makes a supplemental input to the existing character “o” to change it into the character “e”.
[0058] In this case, the user does not have to make a complete character “e”, but only makes the supplemental input. That is, a new stroke or a missing stroke is added onto the existing character without repeatedly inputting an existing stroke of the existing character. In this way, the new input is combined with the existing character “o” to form a new character “e”. That is, the processor 103 of the electronic device 100 recognizes the new input as the character “e” by combining the new input with the existing (and correct) stroke of the existing character.
[0059] As shown in FIG. 7B , for the error character “c” of the character combination “intornct”, since the position of the initial point of the input (a fourth small circle shown in FIG. 7B ) falls in the second input area, the second input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is just on the character “c”, the processor 103 of the electronic device 100 determines that the user corrects the existing character “c” in the second input area. Referring to FIG. 7B , the user makes a supplemental input to the existing character “c” to change it into the character “e”.
[0060] In this case, the user does not have to make a complete character “e”, but only makes the supplemental input. That is, a new stroke or a missing stroke is added onto the existing character without repeatedly inputting an existing stroke of the existing character. In this way, the new input is combined with the existing character “c” to form a new character “e”. That is, the processor 103 of the electronic device 100 recognizes the new input as the character “e” by combining the new input with the existing (and correct) stroke of the existing character.
[0061] Although FIG. 7B shows a case where the user adds a new stroke onto the existing character to replace the existing character with a new character which is a combination of the new stroke and the existing (original) character, the ordinary skilled in the art should understand that the sixth example of inputting handwriting character according to the embodiment of the present invention, i.e., the correction operation, should also include another case where the user would like to change a wrong stroke of the existing character into a new and correct stroke so that the original and wrong character with the wrong stroke can be replaced with the new and correct character with the new and correct stroke. In the first case, i.e., in the case as shown in FIG. 7B , the existing character is corrected by directly adding a missing stroke onto the existing character without repeatedly inputting an existing and correct stroke of the existing character. In the second case, the existing character is corrected by directly replacing a wrong stroke with a new stroke without repeatedly inputting an existing and correct stroke of the existing character.
[0062] Since it is determined that the user corrects the characters “c” and “l” in the first input area and the characters “o” and “c” in the second input area, the newly recognized characters “o” and “t” in the first input area and the newly recognized characters “e” and “e” are displayed in the first input area and the second input area respectively and the existing character combination “ghcsl” in the first input area and the existing character combination “intornct” in the second input area are changed to the correct word “ghost” and the correct word “internet” respectively, as shown in FIG. 7C . Referring to FIG. 7C , the correct words “ghost” and “internet” are respectively displayed in the first input area and the second input area on the touch screen.
[0063] The present invention is typically useful for the non-English languages, like Chinese, or other ideographic languages such as Japanese. Such languages have complex shapes and normally require more strokes for one character. People may prefer to use handwriting input method on an English based input device when applicable, where the present invention can improve input efficiency much more greatly.
[0064] FIGS. 8A, 8B, 8C, and 8D show a seventh example of inputting handwriting character according to the embodiment of the present invention. The seventh example shows a case where the user corrects an existing Chinese character on the touch screen. Although FIGS. 8A, 8B, 8C, and 8D relate to a correction operation, the ordinary skilled in the art should understand that, besides the correction operation, all other operations illustrated in above figures are also applicable to the Chinese character.
[0065] FIG. 8A shows a handwriting input by the user in the seventh example. As shown in FIG. 8A , the user directly starts writing a Chinese character on the touch screen at the intended input area. In this case, the user would like to change the Chinese character “ ” in the first input area to another Chinese character “ ”. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing. As shown in FIG. 8A , since the position of the initial point of the input (a small circle shown in FIG. 8A ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is just on the character “ ”, the processor 103 of the electronic device 100 determines that the user corrects the existing character “ ” in the first input area. Referring to FIG. 8A , the user makes a supplemental input to the existing character “ ” to change it into the character “ ”.
[0066] In this case, the user does not have to make a complete character “ ”, but only makes the supplemental input. That is, one or more new strokes or one or more missing strokes are added onto the existing character without repeatedly inputting an existing stroke of the existing character. In this way, the new input is combined with the existing character “ ” to form a new character “ ”. That is, the processor 103 of the electronic device 100 recognizes the new input as the character “ ” by combining the new input with the existing (and correct) stroke of the existing character “ ”.
[0067] Since the first input area is determined as the intended input area, and it is determined that the user corrects the character “ ”, the newly recognized character “ ” is displayed in the first input area and the existing character “ ” in the first input area is replaced with “ ”, as shown in FIG. 8B . Referring to FIG. 8B , a correct character “ ” is displayed in the first input area on the touch screen.
[0068] FIG. 8C continues showing the handwriting input by the user in the seventh example. As shown in FIG. 8C , the user directly starts writing a Chinese character on the touch screen at the intended input area. In this case, the user would like to change the Chinese character “ ” in the first input area to another Chinese character “ ”. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing. As shown in FIG. 8C , since the position of the initial point of the input (a small circle shown in FIG. 8C ) falls in the first input area, the first input area is determined as the input target, i.e., the intended input area. In addition, since the position of the initial point of the input is just on the character “ ”, the processor 103 of the electronic device 100 determines that the user corrects the existing character “ ” in the first input area. Referring to FIG. 8C , the user makes a supplemental input to the existing character “ ” to change it into the character “ ”.
[0069] In this case, the user does not have to make a complete character “ ”, but only makes the supplemental input. That is, one or more new strokes or one or more missing strokes are added onto the existing character without repeatedly inputting an existing stroke of the existing character. In this way, the new input is combined with the existing character “ ” to form a new character “ ”. That is, the processor 103 of the electronic device 100 recognizes the new input as the character “ ” by combining the new input with the existing (and correct) stroke of the existing character “ ”.
[0070] Since the first input area is determined as the intended input area, and it is determined that the user corrects the character “ ”, the newly recognized character “ ” is displayed in the first input area and the existing character “ ” in the first input area is replaced with “ ” as shown in FIG. 8D . Referring to FIG. 8D , a correct character “ ” is displayed in the first input area on the touch screen.
[0071] Although FIGS. 8A and 8C show the case where the user adds a new stroke onto the existing character to replace the existing character with a new character which is a combination of the new stroke and the existing (original) character, the ordinary skilled in the art should understand that the seventh example of inputting handwriting character according to the embodiment of the present invention, i.e., the correction operation, should also include another case where the user would like to change a wrong stroke of the existing character into a new and correct stroke so that the original and wrong character with the wrong stroke can be replaced with the new and correct character with the new and correct stroke. In the first case, i.e., in the case as shown in FIGS. 8A and 8C , the existing character is corrected by directly adding a missing stroke onto the existing character without repeatedly inputting an existing and correct stroke of the existing character. In the second case, the existing character is corrected by directly replacing a wrong stroke with a new stroke without repeatedly inputting an existing and correct stroke of the existing character.
[0072] Then, the use may continue correcting the character “ ” if it is a wrong character, or may continue writing another character after the character “ ”.
[0073] FIG. 9 is a flowchart illustrating a method for inputting handwriting character according to the embodiment of the present invention.
[0074] The method according to the embodiment of the present invention starts at 901 in FIG. 9 .
[0075] At 903 , a handwriting input is added on a touch screen. As shown in FIGS. 2-8 , the user directly makes the input in the intended input area on the touch screen. As the user makes the input, the input is added on the touch screen so that the user can view what he or she is writing.
[0076] At 905 , a position of an initial point of the handwriting input is detected. The position of the initial point of the input will be used to determine both the intended input area and the operation of the input.
[0077] At 907 , an input area is determined based on the position of the initial point of the handwriting input. For example, if the position of the initial point of the handwriting input falls in the first input area, the first input area is determined as the intended input area.
[0078] At 909 , an operation of the handwriting input is determined based on the position of the initial point of the handwriting input, and then the determined operation is performed. For example, if the position of the initial point of the input falls on an existing character, the operation of the input is determined as a correction operation. In this operation, the existing character is replaced with a new character. The detailed description is made later with reference to FIG. 10 .
[0079] At 911 , the handwriting input is recognized as a new character and the recognized character is displayed in the input area determined at 907 on the touch screen. In the case of correcting the character, the input is recognized as the new character by combining the input with the existing and correct stroke of the existing character. In this case, the recognized character is displayed by replacing the existing character with the newly recognized character.
[0080] In the preferred embodiment of the present invention, during the recognition of the input, only the character is considered. That is, the recognition is performed with respect to the character instead of a word or a sentence containing the character. In other words, the method according to the present invention may more applicable to an ideographic language such as Chinese and Japanese than an alphabet language such as English and Spanish. Notwithstanding, the present invention may be used for the alphabet language such as English and Spanish, as shown in FIGS. 2-7 .
[0081] The method ends at 913 .
[0082] FIG. 10 is a flowchart illustrating a process for determining an operation of the handwriting input according to the embodiment of the present invention.
[0083] The process starts at 909 of FIG. 9 .
[0084] At 1001 , it is determined whether the position of the initial point falls on the existing character.
[0085] If the position of the initial point falls on the existing character (“YES” for 1001 ), the operation of the handwriting input is determined as correcting the existing character. Referring to FIGS. 5A, 5B, 7A, 7B, 7C, 8A, 8B, 8C, and 8D , the operation of correcting the existing character is performed at 1003 . The correcting operation may includes replacing a wrong stroke with a new stroke or adding a missing stroke onto the existing character without repeatedly inputting an existing and correct stroke of the existing character. Then the process proceeds with 911 of FIG. 9 .
[0086] If the position of the initial point of the handwriting input does not fall on an existing character (“NO” for 1001 ), at 1005 , it is determined whether the position of the initial point of the handwriting input falls between two existing characters.
[0087] If the position of the initial point of the handwriting input falls between the two existing characters (“YES” for 1005 ), the operation of the handwriting input is determined as inserting a character between the two existing characters. Referring to FIGS. 6A, 6B, and 6C , the operation of inserting a character between the two existing characters is performed at 1007 . Then the process proceeds with 911 of FIG. 9 .
[0088] If the position of the initial point of the handwriting input does not fall between the two existing characters (“NO” for 1005 ), at 1009 , it is determined whether the position of the initial point of the handwriting input falls after an existing character.
[0089] If the position of the initial point of the handwriting input falls after the existing character (“YES” for 1009 ), the operation of the handwriting input is determined as continuing writing a character after the existing character. Referring to FIGS. 3A and 3B , the operation of continuing writing a character after the existing character is performed at 1011 . Then the process proceeds with 911 of FIG. 9 .
[0090] If the position of the initial point of the handwriting input does not fall after the existing character (“NO” for 1009 ), the operation of the handwriting input is determined as writing a first character of a word or a sentence. Referring to FIGS. 2A, 2B, 2C, 4A, and 4B , the operation of writing a first character of a word or a sentence is performed at 1013 . Then the process proceeds with 911 of FIG. 9 .
[0091] The present invention improves the user experience when the user edits or corrects a character on a writing input device. According to the present invention, an input target is quickly determined by combining the input target locating operation with the directly user inputting/editing operation. In the correcting operation, the error character is quickly determined. Also in the correcting operation, an error input is quickly corrected. The user directly makes the input on the error character without firstly locating and deleting it. The device automatically combines the new input with the original error character for reorganization and then for recognition.
[0092] According to the embodiment of the present invention, an efficient and friendly way of editing and correcting the character on the handwriting device is provided. Specifically, a method for determining the input target by combining the input target locating operation with the actual user inputting/editing operation for editing the character on the handwriting device is provided. In another aspect, a method for determining and identifying the error input character for correcting operation on the handwriting device is provided. In a further aspect, a method for quickly correcting the error character on the handwriting device is provided. When correcting the error character, the handwriting device combines the new input with the original error character to try to recognize the user intended change.
[0093] The present invention provides some enhancement (with some tradeoffs) for western languages, but is significantly better for ideographic languages where the inclusion of a single stoke can completely change the meaning of a character.
[0094] With the present invention, the user experience can be improved greatly where the editing and correcting operations become efficiently and friendly. The present invention is much more useful for non-English languages such as Chinese, Japanese and such like. Typically those languages have complex shapes and more strokes, so the user usually prefers to make a handwriting input on an English based input device.
[0095] Moreover, the present invention permits improved handwriting recognition error correction by enabling the user to identify the word or character to be modified and make the addition/replacement directly, without having to explicitly select the erroneous word or character. In this fashion it also supports stroke addition or replacement to correct a prior entry error and update the selected character.
[0096] In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings.
[0097] The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.
[0098] Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The term “coupled” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed.
[0099] It will be appreciated that some embodiments may be comprised of one or more generic or specialized processors (or “processing devices”) such as microprocessors, digital signal processors, customized processors and field programmable gate arrays (FPGAs) and unique stored program instructions (including both software and firmware) that control the one or more processors to implement, in conjunction with certain non-processor circuits, some, most, or all of the functions of the method and/or apparatus described herein. Alternatively, some or all functions could be implemented by a state machine that has no stored program instructions, or in one or more application specific integrated circuits (ASICs), in which each function or some combinations of certain of the functions are implemented as custom logic. Of course, a combination of the two approaches could be used.
[0100] Moreover, an embodiment can be implemented as a computer-readable storage medium having computer readable code stored thereon for programming a computer (e.g., comprising a processor) to perform a method as described and claimed herein. Examples of such computer-readable storage mediums include, but are not limited to, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a ROM (Read Only Memory), a PROM (Programmable Read Only Memory), an EPROM (Erasable Programmable Read Only Memory), an EEPROM (Electrically Erasable Programmable Read Only Memory) and a Flash memory. Further, it is expected that one of ordinary skill, notwithstanding possibly significant effort and many design choices motivated by, for example, available time, current technology, and economic considerations, when guided by the concepts and principles disclosed herein will be readily capable of generating such software instructions and programs and ICs with minimal experimentation.
[0101] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.
|
A method and an electronic device for inputting handwriting character are provided. The electronic device comprises a touch screen, a memory, and a processor. The processor is configured to perform the functions of the method. The method comprises steps of: adding a handwriting input on the touch screen; detecting a position of an initial point of the handwriting input; determining an input area for the handwriting input among the plurality of input areas of the touch screen based on the position of the initial point of the handwriting input; determining an operation of the handwriting input based on the position of the initial point of the handwriting input and performing the determined operation; and upon completion of the handwriting input, recognizing the input as a character and displaying the recognized character in the determined input area on the touch screen.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to novel benzoylpiperazine esters and to a process for producing such esters.
More particularly, the invention is concerned with a benzoylpiperazine ester represented by the following formula (I): ##STR3## wherein A represents a single bond or an alkylene group, vinylene group, --O--alkylene group or methine group; R 1 represents a bicyclic carbon ring residue which may be substituted with a lower alkyl group, lower alkoxy group, oxo group or nitro group or a halogen atom, or may be partially saturated; a fluorene residue which may contain an oxo group; a fluorenylidene group; an anthracene residue; a phenanthrene residue which may be substituted with a lower alkyl group, or may be partially saturated; a benzofuran residue or thianaphthene residue which may be substituted with a lower alkyl group or lower alkoxy group; a benzopyran residue or benzoazine residue which may be substituted with an oxo group or phenyl group and partially saturated; a phthalimide residue; a benzodiazine residue; an isooxazole residue which may be substituted with a lower alkyl group or phenyl group; or an alkylene dioxybenzene residue or xanthene residue; and R 2 represents an alkyl group, cycloalkyl group, cycloalkylalkyl group or aralkyl group, excepting the case where A is a single bond, R 1 is ##STR4## and R 2 is a methyl group.
DESCRIPTION OF THE PRIOR ART
The present inventors have previously discovered that various phenyl esters have excellent chymotrypsin inhibitive effects (see Japanese laid-open patent specification No. 158737/1981).
The inventors have further synthesized analogous compounds to study their pharmacological effects. In the studies leading to the present invention, it has been found that novel benzoylpiperazine derivatives represented by the formula (I) above and acid addition salts thereof exert more excellent chymotrypsin inhibitive effects.
SUMMARY OF THE INVENTION
Accordingly, it is one object of the invention to provide benzoylpiperazine esters of the formula (I) which possess substantially superior chymotrypsin inhibitive activity and can be widely used, for example, as medicines such as those for the therapy of pancreatopathy.
Another object of the invention is to provide a process for producing such esters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compounds of the formula (I) of the invention can be produced by esterification of carboxylic acids of the formula (II) and substituted phenols of the formula (III), for example, in accordance with the following reaction scheme. ##STR5## wherein the symbols each have the same meaning as above.
The esterifying reaction between the compounds of the formulae (II) and (III) is carried out using any conventional techniques. Suitable techniques useful in the invention include a method of reacting a reactive derivative of the compound (II), for example, an acid halide, an acid anhydride, a mixed acid anhydride, an active ester, an active azide or the like, with the compound (III), and a method of reacting the compounds (II) and (III) in the presence of a dehydrating agent such as dicyclohexyl carbodiimide.
Eligible bicyclic carbon ring residues for the symbol R 1 in the formula (I) include such residues as derived from an indene group, naphthyl group and benzosberyl group. Eligible benzoazine residues include such residues as derived from quinoline and isoquinoline. Eligible benzodiazine residues include such residues as derived from quinoline and quinoxaline. Eligible alkylene dioxybenzene residues include such residues as derived from methylene dioxybenzene and benzodioxane.
The compound (I) obtained in this way may be further converted by a conventional method to an inorganic acid salt, for example, of hydrochloric acid, sulfuric acid, phosphoric acid or hydrobromic acid; and an organic acid salt, for example, of acetic acid, propionic acid, maleic acid, fumaric acid, tartaric acid, citric acid, methane sulfonic acid, benzene sulfonic acid or toluene sulfonic acid.
The chymotrypsin inhibitive activity of the compounds according to the invention will be readily understood by reference to the following test results.
MEASURING METHOD
A solution prepared by mixing 0.1 ml of a dimethylsulfoxide solution containing a compound to be tested, 0.1 ml of water and 0.1 ml of a buffer solution containing 10 ug/ml of chymotrypsin (0.1M tris-hydrochloric acid buffer solution, pH 8.0) was incubated for 10 minutes by the method of Muramatsu et al. [see The Journal of Biochemistry, 62, 408 (1967)]. 0.2 ml of a buffer solution containing 25 mM of an acetyl-L-tyrosine ethyl ester was mixed with the above-prepared solution and reacted at 30° C. for 30 minutes. The amount of the remaining substrate was determined by causing the same to develop color by the Hestrin Method and measuring the absorbance at 530 nm. For comparative purposes, use was made of tosylphenylalanine chloromethyl ketone which was known as a chymotrypsin inhibitor (Comparative Compound I).
RESULTS
The results are as shown in Table 1.
TABLE 1______________________________________ Chymotrypsin inhibitive activity [50% inhibitionTest compounds concentration (M)]______________________________________Present 1 3 × 10.sup.-6compounds 2 1 × 10.sup.-7 3 9 × 10.sup.-7 4 5 × 10.sup.-6 9 1 × 10.sup.-6 15 8 × 10.sup.-7 17 8 × 10.sup.-7 18 6 × 10.sup.-7 20 5 × 10.sup.-6 21 9 × 10.sup.-6 22 3 × 10.sup.-6 24 5 × 10.sup.-7 30 9 × 10.sup.-6 32 7 × 10.sup.-6 40 1 × 10.sup.-6 65 8 × 10.sup.-7 66 9 × 10.sup.-7 67 8 × 10.sup.-7 68 9 × 10.sup.-7Comparative I 5 × 10.sup.-4compound______________________________________ Note: The number for each test compound of the invention indicates the corresponding example as will appear hereinafter.
The above disclosure generally describes the present invention. A more complete understanding will be obtained by the following specific examples which are provided for purposes of illustration only and are not construed as limiting to the invention.
EXAMPLE 1
1-Isopropyl-4-[4-(5,6,7,8-tetraphydronaphthalene-1-acetyloxy)benzoyl]piperazine.hydrochloride
To a 20 ml ethyl acetate solution containing 1.9 g (10 mmol) of 5,6,7,8-tetrahydronaphthalene-1-acetic acid, 2.48 g (10 mmol) of 1-(4-hydroxybenzoyl)-4-isopropylpiperazine and 122 mg (1 mmol) of 4-dimethylaminopyridine was added 2.48 g (12 mmol) of dicyclohexyl carbodiimide, and the mixture was stirred at room temperature for 3 hours. Any insoluble matter was then removed by filtration, and the filtrate was extracted up to 20 ml of 1N hydrochloric acid. After being washed with ethyl acetate, the extract was neutralized with sodium hydrogen carbonate and then extracted with ethyl acetate. After being washed with saturated saline water, the extract was dried over sodium sulfate and then concentrated under reduced pressure. Purification of the concentrate on silica gel column chromatography (80 g of silica gel, eluting solution: chloroform-methanol 30:1) gave a colorless oily substance in a quantitative yield, and the oily substance was then dissolved in 20 ml of ethanol. The resulting solution was added under ice cooling, with an ethanol solution containing an equimolar amount of hydrogen chloride, and thereafter, further with ether, thereby obtaining colorless crystals.
______________________________________Yield 2.96 g (64.7%)Melting point 214-216° C.Elementary analysis as C.sub.26 H.sub.32 N.sub.2 O.sub.3.HCl C H N______________________________________Calculated (%) 68.33 7.28 6.13Measured (%) 68.30 7.24 6.28______________________________________
EXAMPLE 2
1-Isopropyl-4-[4-(9-fluorenylidene acetyloxy)benzoyl]piperazine
To a 20 ml chloroform solution containing 2.67 g (12 mmol) of 9-fluorenylidene acetic acid, 2.48 g (10 mmol) of 1-(4-hydroxybenzoyl)-4-isopropylpiperazine and 122 mg (1 mmol) of 4-dimethylaminopyridine was added 2.48 g (12 mmol) of dicyclohexyl carbodiimide, and the mixture was stirred at room temperature for 3 hours. Any insoluble matter which had formed was removed by filtration, and the filtrate was concentrated under reduced pressure. Thereafter, any insoluble matter was removed by filtration using 20 ml of ethyl acetate, and the filtrate was extracted up to 60 ml of 1N hydrochloric acid. After being washed with ethyl acetate, the extract was neutralized with sodium hydrogen carbonate and extracted up to 60 ml of chloroform. After being washed twice with water, the extract was dried over magnesium sulfate and concentrated under reduced pressure to obtain yellow crystals. Recrystallization of the crystals from ethyl acetate-petroleum ether gave yellow prismatic crystals.
______________________________________Yield 56.7%Melting point 169-170° C.Elementary analysis as C.sub.29 H.sub.28 N.sub.2 O.sub.3 C H N______________________________________Calculated (%) 76.97 6.24 6.19Measured (%) 76.97 6.19 5.97______________________________________
EXAMPLE 3
1-Isopropyl-4-[(4-(thianaphthene-2-acetyloxy)benzoyl]piperazine.methanesulfonate
To a 40 ml of chloroform solution containing 2.2 g of 1-isopropyl-4-(4-hydroxybenzoyl)piperazine and 2.0 g of thianaphthene-2-acetic acid was added 2.2 g of dicyclohexyl carbodiimide, and the mixture was stirred overnight at room temperature. Any insoluble matter was then removed by filtration, and the filtrate was extracted with 24 ml of 0.5N hydrochloric acid. After the extract was washed with ethyl acetate, the aqueous phase was neutralized with 2N sodium hydroxide and then extracted with ethyl acetate. The extract was washed with water and dried, followed by removal of the solvent by distillation, to give a crude oily product. The product was further converted in a conventional manner to methanesulfonate, thereby obtaining colorless prismatic crystals.
______________________________________Yield 2.1 g (45.7%)Melting point 175-177° C.Elementary analysis as C.sub.24 H.sub.26 N.sub.2 O.sub.3 S.CH.sub.3 SO.sub.3 H C H N______________________________________Calculated (%) 57.89 5.85 5.40Measured (%) 57.63 5.93 5.12______________________________________
EXAMPLES 4-64
The same procedures as in Examples 1-3 were repeated to obtain various compounds shown in Table 2.
TABLE 2__________________________________________________________________________ ##STR6## (Ia)In Formula (Ia) Acid Addi- Yield Melting PointExampleR.sub.1 A R.sub.2 tion Salt (%) Appearance (°C.)__________________________________________________________________________ ##STR7## -- ##STR8## HCl 54.7 Needle-like pale yellow crystals 222˜226 (decomp.)5 ##STR9## CH.sub.2 ##STR10## HCl 41.5 Needle-like colorless crystals 243˜2446 ##STR11## -- ##STR12## HCl 61.8 Platy colorless crystals 236˜237 (decomp.)7 ##STR13## -- ##STR14## HCl 80.4 Colorless crystals 252˜257 (decomp.)8 ##STR15## CH.sub.2 ##STR16## CH.sub.3 SO.sub.3 H 32.4 Colorless crystals 211˜2129 ##STR17## CH.sub.2 ##STR18## HCl 40.1 Needle-like pale yellow crystals 208˜21010 ##STR19## CH.sub.2 ##STR20## -- 18.2 Colorless crystals 131˜13511 ##STR21## OCH.sub.2 ##STR22## CH.sub.3 SO.sub.3 H 29.6 Colorless crystals 175˜17712 ##STR23## -- ##STR24## CH.sub.3 SO.sub.3 H 58.5 Platy colorless crystals 165˜16713 ##STR25## CH.sub.2 ##STR26## HCl 49.3 Needle-like colorless crystals 218˜21914 ##STR27## CH.sub.2 CH.sub.2 ##STR28## HCl 64.6 Needle-like colorless crystals 206˜20815 ##STR29## -- ##STR30## CH.sub.3 SO.sub.3 H 73.7 Colorless prismatic crystals 178˜18016 ##STR31## -- ##STR32## (COOH).sub.2 8.9 Yellow prismatic crystals 135˜13817 ##STR33## -- ##STR34## CH.sub.3 SO.sub.3 H 42.7 Needle-like colorless crystals 190˜19618 ##STR35## -- ##STR36## CH.sub.3 SO.sub.3 H 61.9 Needle-like colorless crystals 218˜21919 ##STR37## -- ##STR38## CH.sub.3 SO.sub.3 H 33.0 Platy colorless crystals 167˜16920 ##STR39## -- ##STR40## -- 29.7 Colorless crystals 85˜8721 ##STR41## -- ##STR42## CH.sub.3 SO.sub.3 H 51.4 Needle-like colorless crystals 180˜185 (decomp.)22 ##STR43## CH.sub.2 ##STR44## HCl 53.6 Needle-like colorless crystals 224˜22623 ##STR45## -- ##STR46## -- 55.7 Colorless crystals 117˜11924 ##STR47## CH.sub.2 ##STR48## CH.sub.3 SO.sub.3 H 81.2 Colorless crystals 197˜201.525 ##STR49## OCH.sub.2 ##STR50## -- 57.4 Needle-like colorless crystals 107˜10926 ##STR51## CH.sub.2 CH.sub.2 ##STR52## HCl 41.0 Needle-like colorless crystals 188˜19127 ##STR53## CHCH ##STR54## -- 78.8 Needle-like colorless crystals 123˜12428 ##STR55## -- ##STR56## -- 72.0 Needle-like colorless crystals 142˜14329 ##STR57## CH.sub.2 ##STR58## -- 60.1 Colorless crystals 115˜11730 ##STR59## OCH.sub.2 ##STR60## -- 62.0 Needle-like colorless crystals 103˜10531 ##STR61## CHCH ##STR62## -- 75.8 Needle-like colorless crystals 141˜14232 ##STR63## CH.sub.2 CH.sub.2 ##STR64## HCl 47.4 Needle-like colorless crystals 233˜234.533 ##STR65## -- ##STR66## CH.sub.3 SO.sub.3 H 67.2 Powderous colorless crystals 200˜21234 ##STR67## -- ##STR68## HCl 62.2 Colorless crystals 213˜21435 ##STR69## -- ##STR70## -- 46.4 Needle-like colorless crystals 95˜9636 ##STR71## -- ##STR72## -- 44.5 Prismatic pale yellow crystals 126˜12837 ##STR73## -- ##STR74## -- 40.1 Needle-like pale yellow crystals 148˜15038 ##STR75## CHCH ##STR76## -- 54.4 Pale yellow crystals 192˜19539 ##STR77## -- ##STR78## HCl 36.5 Colorless crystals 195.5˜20140 ##STR79## CH.sub.2 ##STR80## HCl 58.0 Colorless crystals 225˜22841 ##STR81## -- ##STR82## -- 63.3 Prismatic yellow crystals 134˜13642 ##STR83## -- ##STR84## -- 66.7 Platy yellow crystals 140˜14743 ##STR85## -- ##STR86## -- 14.4 Prismatic colorless crystals 181˜18344 ##STR87## -- ##STR88## (COOH).sub.2 9.6 Needle-like colorless crystals 136˜139 (decomp.)45 ##STR89## -- ##STR90## -- 45.8 Colorless crystals 118˜12046 ##STR91## CH.sub.2 ##STR92## -- 27.0 Platy colorless crystals 117˜11847 ##STR93## CHCH ##STR94## -- 67.6 Colorless crystals 159˜16048 ##STR95## -- ##STR96## -- 54.4 Pale yellow crystals 92˜9449 ##STR97## CH.sub.2 ##STR98## CH.sub.3 SO.sub.3 H 75.8 Pale yellow crystals 205˜20750 ##STR99## -- ##STR100## CH.sub.3 SO.sub.3 H 20.0 Needle-like colorless crystals 150˜15651 ##STR101## -- ##STR102## -- 8.1 Needle-like colorless crystals 110˜12052 ##STR103## -- ##STR104## -- 92.1 Needle-like colorless crystals 168˜17053 ##STR105## -- ##STR106## -- 58.5 Prismatic colorless crystals 120˜12254 ##STR107## -- ##STR108## -- 50.5 Prismatic pale yellow crystals 118˜12055 ##STR109## -- ##STR110## -- 51.7 Needle-like colorless crystals 135˜13756 ##STR111## -- ##STR112## -- 52.6 Needle-like colorless crystals 124˜12757 ##STR113## -- ##STR114## -- 29.5 Needle-like pale yellow crystals 138˜14058 ##STR115## CH.sub.2 ##STR116## -- 65.4 Colorless crystals 113˜11559 ##STR117## -- ##STR118## -- 20.4 Pale yellow crystals 103˜10460 ##STR119## -- ##STR120## HCl 43.1 Needle-like yellow crystals 238 (decomp.)61 ##STR121## -- ##STR122## HCl 29.6 Needle-like colorless crystals 253˜25562 ##STR123## -- ##STR124## -- 56.4 Prismatic colorless crystals 87˜8963 ##STR125## CH.sub.2 ##STR126## -- 67.4 Colorless crystals 113˜114.564 ##STR127## -- ##STR128## -- 14.4 Prismatic colorless crystals 133˜134__________________________________________________________________________
EXAMPLE 65
1-Methyl-4-[4-(7-methoxyl-1,2,3,4-tetrahydro-1-naphtoyloxy)benzoyl]piperazine.methanesulfonate
To a 100 ml solution of actonitrile containing 4.4 g of 1-methyl-4-(4-hydroxybenzoyl)piperazine and 4.94 g of 7-methoxy-1,2,3,4-tetrahydro-1-naphthylcarboxylic acid was added 4.94 g of dicyclohexyl carbodiimide, and the mixture was stirred overnight at room temperature. After removal of any insoluble matter by filtration, the filtrate was concentrated under reduced pressure, incorporated with 50 ml of 0.5N hydrochloric acid and washed with ethyl acetate. After being neutralized with a saturated solution of sodium bicarbonate, the aqueous phase was extracted with ethyl acetate. The extract was washed with water and dried, followed by removal of the solvent by distillation, to obtain a crude oily product. Purification of the product on silica gel column chromatography (eluting solution: chloroform-methanol 30:1) gave 7.57 g of an oily product. The oily product was further converted in a conventional manner to methanesulfonate, thereby obtaining 6.2 g of needle-like pale yellow crystals having a melting point of 150°-151° C. (yield: 61.6%).
EXAMPLES 66-73
The same procedure as in Example 65 was repeated to obtain several compounds shown in Table 3.
TABLE 3__________________________________________________________________________In Formula (Ia) Acid Addi- Yield Melting PointExampleR.sub.1 A R.sub.2 tion Salt (%) Appearance (°C.)__________________________________________________________________________66 ##STR129## -- ##STR130## CH.sub.3 SO.sub.3 H 86.2 Needle-like colorless crystals 205˜20767 ##STR131## -- ##STR132## CH.sub.3 SO.sub.3 H 89.7 Needle-like colorless crystals 180˜18268 ##STR133## -- CH.sub.2 CH.sub.3 CH.sub.3 SO.sub.3 H 69.2 Needle-like colorless crystals 140˜14369 ##STR134## -- CH.sub.3 -- 56.8 Colorless oils --70 ##STR135## -- ##STR136## CH.sub.3 SO.sub.3 H 77.4 Needle-like colorless crystals 188˜19071 ##STR137## -- CH.sub.3 -- 42.2 Oils --72 ##STR138## -- CH.sub.2 (CH.sub.2).sub.4 CH.sub.3 CH.sub.3 SO.sub.3 H 52.5 Pale yellow crystals 153˜15573 ##STR139## -- ##STR140## CH.sub.3 SO.sub.3 H 55.4 Colorless crystals 227˜229__________________________________________________________________________
EXAMPLE 74
1-Methyl-4-[3-(1,2,3,4-tetrahydro-1-naphthoyloxy)-benzoyl]piperazine.hydrochloride
The same procedure as in Example 65 was repeated using 1-methyl-4-(3-hydroxybenzoyl)piperazine and 1,2,3,4-tetrahydro-1-naphthylcarboxylic acid to obtain the title compound having a melting point of 218°-220° C. as needle-like pale yellow crystals
(yield: 62.7%).
EXAMPLES 75 AND 76
The same procedure as in Example 74 was repeated to obtain two compounds shown below.
______________________________________Appearance Colorless crystalsMelting point 175-178° C.Yield 39.5%Appearance Needle-like pale yellow crystalsMelting point 193-197° C.Yield 42.6%______________________________________
This invention now being fully described, it is apparent to those skilled in the art that many changes and modifications can be made thereto without departing the spirit or scope of the invention set forth herein.
|
A benzopylpiperazine ester of the following formula: ##STR1## wherein A represents a single bond or an alkylene group, vinylene group, --O--alkylene group or methine group, R 1 represents a bicyclic carbon ring residue which may be substituted with a lower alkyl group, lower alkoxy group, oxo group or nitro group or a halogen atom, or may be partially saturated; a fluorene residue which may contain an oxo group; a fluorenylidene group; an anthracene residue; a phenanthrene residue which may be substituted with a lower alkyl group, or may be partially saturated; a benzofuran residue or thianaphthene residue which may be substituted with a lower alkyl group or lower alkoxy group; a benzopyran residue or benzoazine residue which may be substituted with an oxo group or phenyl group and partially saturated; a phthalimide residue; a benzodiazine residue; an isozazole residue which may be substituted with a lower alkyl group or phenyl group; or an alkylene dioxybenzene residue or xanthene residue; and R 2 represents an alkyl group, cycloalkyl group, cycloalkylalkyl group or aralkyl group, excepting the case where A is a single bond, R 1 is ##STR2## and R 2 is a methyl group, exhibits excellent chymotrypsin inhibitive activity.
| 2
|
This application is a continuation, of application Ser. No. 602,173, filed Apr. 19, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a heavy duty "draw" or clamping type cabinet lock for securely releasably retaining a closure such as a relatively large cabinet door in its closed position. A lock embodying the preferred practice of the invention is particularly well suited for use with a cabinet (1) that is provided with gasketing and/or shielding to minimize penetration through the juncture of its closed door and its door frame of dust, moisture and/or interfering electromagnetic radiation, and/or (2) that needs its closure securely clamped closed at one or more locations about its closure opening.
2. Prior Art
Cabinet locks are known that are designed to releasably retain a closure in its closed position, and to effect engagement with and/or compression of closure seals including gasketing and shielding. However, these prior lock proposals have inadequately addressed a number of problems.
A problem that is encountered when locks are used with enclosures that house certain types of electronic equipment is that the cabinets and their doors must cooperate to provide an adequate degree of shielding against emission and absorption of interfering electromagnetic radiation. When such cabinets have doors that are quite large, locks are needed that are capable of clamping the doors and their associated cabinets securely together at a plurality of spaced locations along the doors in order for such seals and/or shields as are provided on these structures to function properly in blocking transmission of unwanted electromagnetic radiation. When such cabinets have doors that are small, locks that snugly clamp the closures closed at single locations along each closure will frequently fulfill requirements. Prior proposals have not yielded locks that adequately address typical needs of these types that are encountered with large and small specialty electronics enclosures.
Still another problem that is encountered with electronic equipment enclosures is that the types of seals that must be employed in order to provide adequate emissions shielding tend to resist not only door closing movements but also door opening movements. Some of these seals are positioned between a closed door and its door frame, and must be compressed as the doors are closed; others are arranged to frictionally engage portions of a door or its door frame as the door is closed. In order for doors to be closed and opened easily where such seals are in use, door locks are needed that have capabilities for forcefully moving doors both into and out of their closed positions, i.e., both toward and away from their associated cabinetry.
While a wide variety of proposals have been made to provide cabinet locks with desired features, there remains a need for a clamping type cabinet lock that can be easily adapted for use in a wide variety of installations, that is capable of effecting clamping of a closure at a single location or at a plurality of spaced locations about a closure opening to securely bias a closure toward a position of engagement with an associated opening-defining frame, and that is easily adjusted not only to accommodate installation tolerances and wear, but also to provide a closing action that is characterized by a desired degree of "draw" and by a clamping action that holds the closure closed with a desired degree of forcefulness.
SUMMARY OF THE INVENTION
The present invention addresses the foregoing and other needs by providing a heavy duty "draw" or clamping type cabinet lock for securely releasably retaining a closure such as a cabinet door in a closed position relative to an opening-defining structure such as a door frame of a cabinet. The lock includes interengageable assemblies for mounting on a door and its associated door frame, including an operating unit and at least one strike unit. In preferred practice, (1) the operating unit is carried by a cabinet door and has strike-engaging formations that are carried on one or more projecting arms, and (2) one or more strike units are carried on an associated door frame, with each of the strike units defining a strike channel and being operable to receive and releasably retain in its channel such strike-engaging formations as are carried on a separate one of the projecting arms. In preferred practice the strike-engaging formations take the form of rollers that are mounted on the projecting arms, and that are releasably received between forwardly and rearwardly facing track surfaces which define the strike channels.
The operating unit preferably includes a pivotally mounted handle for positioning the projecting arm or arms. When a plurality of projecting arms are utilized, the operating unit preferably includes an operating member that moves the arms in unison.
Preferably a novel lost-motion, toggle type linkage is employed in establishing a driving connection between the handle and the arm or arms. The linkage provides a mechanical advantage to aid the operator both in opening and closing the door so that such resistance forces as may be offered to door movement by various forms of gasketing and/or emission shields can be overcome with ease. The toggle linkage permits the handle to be moved from its nested position to a position where it can be securely grasped by an operator (1) before requiring the operator to forcefully move the handle to effect roller movement, and (2) before subjecting the handle to the influence of such back pressure forces as may have been generated by the clamping action of the lock.
The handle is movable between a nested position wherein it preferably extends substantially flush with the door, and an operating position wherein the handle preferably projects forwardly from the door. When the handle is in its operating position, the linkage and the operating member cooperate with the handle to orient the arm-carried rollers in what is referred to as a "released" position for entry into and withdrawal from the strike channels. Once the rollers have entered the strike channels, pivotal movement of the handle toward its nested position will cause cooperative movements of the linkage, the operating member, and the arm-carried rollers, whereby the rollers are caused to move in unison along the strike channels from their "released" position to a "clamped" position. As the rollers so move within the strike channels, wedging actions take place that cause the door and its door frame to be drawn relatively toward each other such that the door is clamped toward the door frame at the locations of the strike units. A tool or key operated locking sub-assembly preferably forms part of the operating unit and serves to releasably secure the handle in its nested position, whereby the door may be locked in its closed position.
One feature of a lock that incorporates the preferred practice of the invention lies in the spring-biased mounting of track members that form components of the strike units. If an attempt is made to close the door while the handle is in its nested position, i.e., while the rollers are out of position for proper entry into the strike channels, the arm-carried rollers are caused to engage the spring-biased track members so that the door will not be permitted to close, but rather literally will be "bounced" toward its open position. This "bounce open" feature not only helps to assure that a full and correct closing of the door will ultimately be effected by the operator, but also serves to minimize damage to components of the lock if an incorrect closure is forcibly attempted.
A further feature lies in the versatile character of the lock design that enables accomodations to be made quite easily to provide substantially any desired positioning of the handle along the operating unit, and to utilize substantially any desired number of strike units that are located at substantially any desired arrangement of spacings along the operating unit. Since a simple dual element system comprising an elongate frame and an elongate operating member is used to mount and drivingly interconnect the roller-carrying arms of the operating unit, substantially any desired number of these arms can be incorporated in an operating unit at substantially any desired spacing.
Still another feature of the preferred practice lies in the provision of adjustable elements on the operating unit and the strike unit that enable adjustments to be made with ease to accomodate installation tollerances and wear, and to provide the lock with a clamping action that is characterized by desired degrees of "draw" as well as desired degrees of forcefulness.
From an aesthetic point of view, a lock embodying the preferred practice of the present invention does nothing to distract from the appearance of a specialty enclosure on which it is installed. Indeed, despite the fact that the lock includes an extensive, rugged operating mechanism which may well extend along a majority of the length of a door on which it is mounted, all that needs to be exposed for ready access from the exterior of the enclosure are the front faces of the lock's operating handle and the locking sub-assembly that serves to releasably retain the handle in its nested position. A relatively small rectangular opening formed through the front face of a door is typically all that is needed to render these components accessible.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages, and a fuller understanding of the invention may be had by referring to the following description and claims, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of an electronic equipment enclosure including an open front cabinet having a hinged door and employing one form of a lock that embodies the preferred practice of the present invention for releasably maintaining the door in its closed position;
FIG. 2 is a perspective view similar to FIG. 1 but with the door in its open position, showing the lock's operating unit as mounted on the door, and the lock's strike units as mounted on the cabinet;
FIG. 3 is a foreshortened side elevational view, on an enlarged scale, of the lock as utilized in the enclosure of FIG. 1, with portions of the frames of the strike unit broken away and shown in cross section, and with portions of the enclosure being depicted in phantom;
FIG. 4 is a foreshortened rear elevational view of the lock's operating unit;
FIG. 5 is a foreshortened side elevational view similar to FIG. 3, but with components of the lock oriented in a released position that permits the door to be opened, and with portions of the frame of the operating unit broken away and shown in cross section;
FIG. 6 is a front elevational view, on an enlarged scale, of portions of a handle assembly that is employed in the operating unit;
FIG. 7 is a rear elevational view thereof;
FIG. 8 is a sectional view thereof as seen from planes indicated by a broken line and by arrows 8--8 in FIG. 7;
FIG. 9 is a front elevational view of selected parts of the handle assembly, with portions of the handle broken away to permit elements of an underlying lost-motion, toggle type handle linkage to be viewed;
FIG. 10 is a side elevational view thereof, with portions broken away and shown in cross section, and with the handle shown in its nested position;
FIG. 11 is a side elevational view similar to FIG. 9, but with the handle projected to a position that is intermediate its nested and operating positions, which view, when compared with FIG. 10, illustrates the range of lost motion movement that is provided by a slotted link in the handle linkage;
FIG. 12 is a side elevational view similar to FIGS. 10 and 11, but with the handle fully projected, i.e., in its operating position;
FIG. 13 is a side elevational view similar to FIG. 11, but with the handle less than fully projected, which view, when compared with FIG. 10, illustrates the range of lost motion movement that is provided by a slotted link in the handle linkage;
FIG. 14 is an exploded perspective view of components of a locking sub-assembly that forms a part of the operating unit, with both tool-operated and key-operated lock cylinders being shown, either of which may be employed with the remaining components of the sub-assembly;
FIG. 15 is a rear elevational view of portions of the operating unit, with portions broken away to enable elements of the locking sub-assembly to be seen;
FIG. 16 is a sectional view thereof as seen from a plane indicated by arrows 16--16 in FIG. 15;
FIG. 17 is a front elevational view, on an enlarged scale, of a strike unit that embodies features of the present invention;
FIG. 18 is a rear elevational view thereof;
FIG. 19 is a sectional view as seen from a plane indicated by arrows 19--19 in FIG. 18;
FIG. 20 is a side elevational view thereof, with portions broken away and shown in cross section, illustrating how the strike unit may be adjusted;
FIG. 21 is a foreshortened side elevational view similar to FIG. 5 of an alternate form of lock embodying the preferred practice of the present invention, wherein a total of three projecting arms are employed to position rollers in engagement with a total of three strike units; and,
FIG. 22 is a foreshortened side elevational view similar to FIG. 5 of still another alternate form of lock embodying the preferred practice of the present invention, wherein a single projecting arm is employed to position rollers in engagement with a single strike unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, an enclosure for electronic equipment is indicated generally by the numeral 10. The enclosure 10 includes a door 12 and a cabinet 14. The door is pivotally connected to the cabinet 14 by suitable hinges (not shown) for movement between a closed position shown in FIG. 1, and an open position shown in FIG. 2.
Referring to FIG. 2, the cabinet 14 has an opening-defining portion or door frame 16 that defines a forwardly-facing opening 18. When the door 12 is in its closed position, the door 12 is positioned closely alongside the door frame 16 and closes the opening 18.
A seal 20 is carried on the door frame 16 of the cabinet 14 for sealingly engaging the door 12 when the door 12 is closed. While the seal 20 is depicted as comprising a ribbon of resilient gasket material of the type that is intended to be compressed between the door 12 and the door frame 16 when the door 12 is closed, those skilled in the art will understand that more elaborate commercially available seals and/or shields may be employed in conjunction with or in substitution for the seal 20 to minimize migration and/or transmission through the juncture of the closed door 12 and the cabinet 14 of dust, moisture, interfering electromagnetic radiation and the like. While such seals and/or shields as may be selected for use with the door 12 and the cabinet 14 have nothing to do with the preferred practice of the present invention, locks that embody the present invention are sufficiently versatile to accommodate the use of almost any desired type of seal, and to provide a means for closing and opening the door 12 even if a selected seal and/or shield is of the type that provides a forceful "drag" on the door 12 that inhibits both closing and opening movements of the door 12.
Referring to FIGS. 1-3, a clamping type lock embodying one form of preferred practice of the present invention is indicated generally by the numeral 90. The lock 90 is arranged to releasably retain the door 12 in its closed position. The lock 90 includes a door-carried operating unit that is indicated generally by the numeral 100, and a plurality of cabinet-carried strike units 600 that are indicated generally by the numeral 600. Referring to FIG. 1, the door-carried operating unit 100 includes a handle 350 and a handle locking sub-assembly 500 which project through a generally rectangular opening 30 that is formed in the front face of the door 12. From an aesthetic point of view, a feature of the lock 90 lies in the fact that, despite the extensive nature of the lock's operating mechanism and its rugged, heavy duty construction, the only elements of the lock 90 that need be exposed to view through the enclosure 10 are the components 350, 500, which project through the rectangular hole 30 formed in the door 12.
Before turning to a detailed description of the various components of the operating unit 100, an overview of the components of the operating unit 100 will be presented.
Referring to FIGS. 3 and 4, the door-carried operating unit 100 includes an elongate frame 110 that pivotally mounts the handle 350 and a plurality of projecting arms 200. In the lock embodiment 90 of FIGS. 1-13, only two projecting arms 200 are employed. The handle 350 is movable between a "nested" position shown in FIGS. 1, 3, 4 and 6-10, and an "operating" position shown in FIGS. 2, 5 and 12. The projecting arms 200 are movable between a "released" position shown in FIGS. 2 and 5, and a "clamped" position shown in FIGS. 3 and 4. An elongate operating member 250 drivingly interconnects the projecting arms 200. The operating member 250, the frame 110 and the arms 200 cooperate to define a parallelogram linkage which assures that the arms 200 will pivot in unison relative to the frame 110.
Referring to FIG. 5, a lost-motion, toggle type linkage 400 drivingly interconnects the handle 350 and the operating member 250 for moving the operating member 250 to position the projecting arms 200 in response to movement of the handle 350. The locking sub-assembly 500 is carried by the frame 110 to releasably retain the handle 350 in its nested position.
The operating unit 100 also includes a plurality of strike engaging formations that take the form of rollers 300. The rollers 300 are mounted on the projecting arms 200. When the arms 200 are in their released position shown in FIGS. 2 and 5, the rollers 300 are oriented for entry into or withdrawal from channels 650 that are defined by the strike units 600. Once the rollers 300 have entered the strike channels 650, pivotal movement of the handle 350 will cause pivotal movement of the arms 200 to effect movement of the rollers 300 toward their clamped position shown in FIGS. 3 and 4. The rollers 300 are retained in their clamped position by the locking sub-assembly 500 which engages the handle 350 to releasably retain the handle 350 in its nested position. As will be explained in greater detail, the strike channels 650 are oriented such that, as the rollers 300 move along the channels 650 toward their clamped position, a wedging action takes place which causes the door 12 to be clamped toward a position of engagement with the door frame 16 of the cabinet 14.
Turning now to a more detailed description of the operating unit 100, the frame 110 is preferably formed as an elongate stamping from a sheet of steel. Referring to FIGS. 3-5, the frame 110 has a generally U-shaped cross-section, as defined by a front wall 112 and a pair of side walls 114, 116 that extend rearwardly from opposite sides of the front wall 112. A generally rectangular opening 118 is formed through the front wall 112.
An elongate housing 120 is welded to the rear face of the front wall 112 and overlies the region of the rectangular opening 118. The housing 120 has a back wall 122, a pair of forwardly extending side walls 124, 126, and a pair of mounting flanges 128 that are secured to the rear face of the front wall 112, preferably by welding. An elongate slot 130 is formed in the upper end region of the back wall 122. Referring to FIGS. 4 and 7, a tab-like portion of the back wall 122 projects into the slot 130 and defines a spring engaging formation 132. Referring to FIGS. 3 and 8, a pair of holes 134 are formed through the back wall 122. A weld nut 136 that defines a pair of threaded passages 138 which align with the holes 134 is welded to the rear side of the back wall 122.
Referring to FIGS. 3-5, a pair of brackets 140 are welded to the rear face of the front wall 112 near opposed end regions thereof. The brackets 140 are of generally U-shaped cross-section as defined by a back wall 142, a pair of opposed side walls 144, 146 that extend forwardly from the back wall 142, and a pair of mounting flanges 148 that engage the rear surface of the front wall 112 and are secured thereto, preferably by welding. The back wall 142 does not join the opposed side walls 144, 146 along their entire lengths, but rather defines a stop surface 150 that extends between the side walls at position about midway along the lengths of the side walls 144, 146. Aligned holes (not shown) are formed through the side walls 144, 146 to receive rivets 160. The rivets 160 pivotally mount the projecting arms 200 on the brackets 140 for pivotal movement relative to the frame 110. The stop surfaces serve to engage the arms 200 when the arms 200 are in their released position.
The projecting arms 200 are identical one with another. Referring to FIG. 4, each of the arms 200 is formed as a welded assembly of a pair of doglegged plates 204, 206. Referring to FIGS. 3 and 4, the plates 204, 206 have forwardly extending portions 210 that are spaced apart and extend substantially parallel to each other, and rearwardly-extending portions 212 that are welded together. A first set of aligned holes (not shown) are formed through the forwardly-extending portions 210 to receive rivets 160, whereby the arms 200 are pivotally connected to the brackets 140. A second set of aligned holes (not shown) are formed through the plates 204, 206 at positions about midway along the lengths of the arms 200 to receive rivets 240 that connect the arms 200 to the operating member 250. A third set of aligned holes (not shown) are formed through the rearwardly-extending portions 212 to receive rivets 260 that mount the rollers 300 on the arms 200.
The projecting arms 200 are drivingly interconnected by the operating member 250 and are caused to move in unison as the operating member 250 is moved relatively to the frame 110 in directions that extend longitudinally along the frame 110, whereby the rollers 300 are caused to pivot in unison about the axes along with their associated arms 200 that are connected to the frame 110 by the rivets 160.
The rollers 300 are preferably formed from a wear resistant plastics material, e.g., Nylon. The rollers 300 are journaled by the rivets 260 such that the rollers 300 are free to rotate relative to the arms 200.
Referring to FIGS. 6-8, the handle 350 is preferably formed from die cast metal, and has a flat front wall 352 that is of generally rectangular configuration. The handle 350 has a pair of rearwardly extending side walls 354, 356. The handle 350 has a recessed tip portion 358 on its upper end region, and a bolt receiving recess 360 formed in its lower end region. The recess 360 is defined in part by a downwardly extending shoulder 362 that is engaged by a slide bolt 550 which forms a part of the locking sub-assembly 500, as will be explained. A pair of mounting holes (not shown) are formed through the upper portion of the handle 350 to receive rivets 370, 380. The rivet 370 extends through aligned holes (not shown) that are formed through the side walls 124, 126 of the housing 120 to establish a fixed pivot axis for the handle 350 and to pivotally mount the handle 350 on the housing 120. The rivet 380 extends through a hole that is formed through one end of a slotted operating link 480 that forms part of the lost-motion, over center handle linkage 400.
The lost-motion, over center handle linkage 400 provides a very simple mechanism for achieving several significant objectives. The linkage 400 is adjustable to aid the lock 90 in accomodating installation tollerances and in providing a clamping action that is characterized by desired degrees of "draw" and clamping forcefulness. The linkage 400 permits an operator to move the handle 350 from its nested position to a position illustrated in FIG. 11 wherein the handle 350 can be securely grasped before the handle 350 becomes subjected to such forces as are being carried by toggle links 430, 460 of the linkage 400. The links 430, 460 perform a "toggle" function, move "over center," and are caused to execute their "toggle" and "over center" movements in response to applications of force from the operating link 480 which is slotted as at 482 to provide for a "loss of motion" in transmitting movement to the toggle links 430, 460 from the handle 350, hence the reasons why the linkage 400 is referred to as a "lost-motion, over-center toggle linkage."
Referring to FIGS. 5 and 8-13, the linkage 400 includes a mounting link 410 that is rigidly (but adjustably) secured to the housing 120 by threaded fasteners 412. As is best seen in FIG. 8, the mounting link 410 has a base portion 414 that extends along the back wall 122 of the housing 120, and a forwardly extending portion 416 that resides between the side walls 124, 126 of the housing. Elongate slots 418 are formed through the base portion 414. The fasteners 412 extend through the slots 418 and through the back wall holes 134 into the threaded holes 138 that are provided by the double weld nut 136. The fasteners 42 are securely tightened in place so that the mounting link 410 normally does not move with respect to the housing 120, but may be loosened so that the link 410 can be adjusted by moving it longitudinally with respect to the housing 120 as is permitted by the lengths of the elongate slots 418. A hole is formed through the forwardly extending portion 416 of the link 418 to receive a rivet 420.
Toggle links 430 and 460 interconnect the mounting link 410 and the operating member 250. The toggle link 430 has an end region 432 that carries a rivet 440 which extends through aligned holes that are formed through the side walls 254, 256 of the operating member 250 to pivotally connect the toggle link 430 to the operating member 250. A rivet 470 extends through aligned holes formed through the toggle link 430 and through the one end region of each of the side-by-side toggle links 460 to pivotally interconnect the toggle links 430, 460. The other end regions of the side-by-side toggle links 460 have aligned holes that receive the rivet 420 to pivotally connect the toggle links 460 to the mounting link 410.
A slotted operating link 480 has a hole formed through one of its end regions to receive the handle-carried rivet 380, whereby the operating link 480 is pivotally connected to the operating handle 350. An elongate slot 482 is formed in the operating link 480 to receive the toggle link interconnecting rivet 470 to provide a "lost motion" connection between the handle 350 and the toggle links 430, 460. By this arrangement, the handle 350 can move relative to the toggle links 430, 460 without causing corresponding movement of the toggle links 430, 460, and visa versa. Such movement of the handle 350 relative to the toggle links 430, 460 without causing corresponding movement of the toggle links 430, 460 is illustrated in the drawings, e.g., a comparison of the positions of the handle 350 in FIG. 12 with the position of the handle 350 in FIG. 13 shows that the handle 350 has moved while the toggle links 430, 460 have remained stationary; likewise, a comparison of the positions of the handle 350 and the toggle links 430, 460 in FIGS. 10 and 11 shows the same type of "lost motion" movement has taken place by virtue of the engagement of the rivet 470 with opposed ends of the elongate slot 482 of the operating link 480.
Referring to FIG. 10, the toggle link 430 has a nose formation 484 that is configured to engage the forwardly projecting portion 416 of the mounting link 410 when the toggle links 430, 460 are in the "over center" positions of the FIGS. 10 and 11. The point of engagement of the links 430, 410 is designated by the numeral 425 in FIGS. 10 and 11. This engagement limits the "over center" travel of the toggle links 430, 460. The type of "over center" movement that is executed by the links 430, 460 is best understood by observing the alignment of the rivets 440, 420 which engage the distal ends of the links 430, 460, in comparison with the position of the rivet 470 that interconnects the links 430, 460. In FIGS. 10 and 11 a line 456 interconnects the centers of the rivets 440, 420, whereby it is readily apparent that the location of the link interconnecting rivet 470 is to the rear (to the left as viewed in FIGS. 10 and 11) of the line 456. In FIGS. 12 and 13, however, the location of the link interconnecting rivet 470 is seen to lie forward (to the right as viewed in FIGS. 12 and 13) of the line 456 which interconnects the centers of the rivets 440, 420. The type of movement that has been executed by the toggle links 430, 460 in moving from the positions illustrated in FIGS. 10 and 11 wherein the location of the rivet 470 is on one side of a line interconnecting the centers of the rivets 440, 420, to the positions illustrated in FIGS. 12 and 13 wherein the location of the rivet 470 is on the other side of the line 456, is called an "over center" movement in that the location of the rivet 470 moves over the center line 456 that interconnects the centers of the rivets 440, 420.
The consequence of this "over center" movement is quite significant. When the toggle links 430, 460 are positioned as shown in FIGS. 10 and 12 such that the rivet 470 lies rearwardly of the center connecting line 456, the clamping and back pressure forces that are transmitted from the door 12 to the cabinet 14 (i.e., from the door 12 to the frame 110 to the housing 120, through the mounting link 410 and through the rivet 420 to the interconnected toggle links 430, 460 to the rivet 440 and to the operating member 250 for transmission to the arms 200 and thence through the rollers 300 to the strike units 600 and to the cabinet 14) tend to "collapse" or "fold" the toggle links 430, 460 in a rearward direction of travel such that these forces are not transmitted through the operating link 480 to the handle 350. Thus, when the toggle links 430, 460 are positioned as is illustrated in FIGS. 5 and 8, the handle 350 is relieved from the influence of such forces as may be imposed on the toggle links 430, 460, whereby the handle 350 can be moved freely between the nested position illustrated in FIGS. 8 and 10 and, the readily graspable position illustrated in FIG. 11. Continued forward movement of the handle 350 (starting with the lock components positioned as illustrated in FIG. 11) will cause the operating link 480 to pull the toggle links 430, 460 "over center," whereupon the influence of such forces as are being transmitted through the toggle links 430, 460 between the door 12 and the cabinet 14 will be imposed on the operating link 480 and will be transmitted to the handle 350. The advantage of this arrangement is that the handle 350 can be moved freely out of its nested position to the position illustrated in FIG. 11 where the handle 350 can be securely grasped by an operator before the handle 350 is subjected to the influence of such forces as may be loading the toggle links 430, 460, whereby the operator can be assured of having good control over the handle 350 at a time when the handle 350 is subjected to the influence of such forces as are being carried by the toggle links 430, 460. Such forces as are transferred to the handle 350 tend to be diminished as they are relieved by the "lost motion" movement capability that is provided by the slotted operating link 480.
A similar advantage is provided by the over center toggle linkage 400 when the handle 350 is moved from its fully extended or "operating" position as shown in FIG. 17 toward its nested position shown in FIG. 5. Preliminary rearward movement of the handle 350 is a "lost motion" type of movement due to the slotted character of the operating link 480, as will be apparent from comparing the positions of the handle 350 in FIGS. 12 and 13; in FIG. 13 the handle 350 has pivoted rearwardly relative to the position that is assumed by the handle 350 in FIG. 12 (leftwardly as viewed in these Figures), but no corresponding movement of the toggle links 430, 460 has taken place. As the handle 350 continues to be pivoted rearwardly, the operating link 480 drivingly engages the rivet 470, whereupon the influence of such forces as are transmitted between the door 12 and the cabinet 14 through the toggle links 430, 460 is felt by an operator as he forcefully moves the handle 350 toward its nested position. As the handle 350 closely approaches its nested position, a rearward "over center" movement of the toggle links 430, 460 takes place, whereupon the links 430, 460 pivot rearwardly, thereby relieving the handle 350 from the influence of such forces as are being transmitted through the links 430, 460.
In the lock embodiment 90, a pair of idler links 490 are provided to interconnect the rivets 370, 440 to help assure that proper spacing is maintained between the handle 350 and the operating member 250. In an alternate lock embodiment 90' shown in FIG. 21, a projecting arm 200 that carries rollers 300 is substituted for the idler links 490, and a third strike unit 600 is provided to receive the rollers 300 of the third projecting arm 200. In still another alternate embodiment 90" shown in FIG. 22, a single projecting arm 200 is directly operated in the manner of the added arm 200 in the embodiment 90' of FIG. 21. The embodiment 90" employs no operating member 250 since there is no plurality of arms 200 to be interconnected for coordinated movement. As those skilled in the art will readily understand, the lock embodiments 90' and 90" differ from the embodiment 90 substantially only in the provision these embodiments make for the use of a greater or a lesser number of strike units 600, rollers 300, and projecting arms 200 than are used by the embodiment 90.
Referring to FIGS. 9 and 10, a torsion coil spring 492 has opposed end regions 494, 496, and a center portion 498 that encircles the rivet 370. One of the opposed end regions 494 engages the spring receiving formation 132 of the back wall 122 of the housing 120, as has been described. The other end region 496 of the spring 492 engages the back face of the front wall 352 of the handle 350. The spring 492 serves to bias the handle 350 away from its nested position so that, when the locking sub-assembly 500 releases its engagement with the nested handle 350, the handle 350 will pivot forwardly under the influence of the spring 492 to the position illustrated in FIG. 11.
Referring to FIGS. 8 and 14-16, the locking sub-assembly 500 includes a body 502 that is preferably formed from die cast metal. The body 502 has a generally flat front wall 504, and a back wall 506. A lock cylinder receiving passage 510 is formed through the body 502 and opens through the front and back walls 504, 506. The passage 510 is formed by a hole 512 that has a pair of grooves 514, 516 (see FIG. 8) that extend along its opposed sides. One of the grooves 514 extends the full length of the hole 512, i.e. the groove 514 opens through the front wall 504 and through the back wall 506. The other of the grooves 516 opens through the front wall 504 but extends along the hole 512 only to a position near (but not opening through) the back wall 506. A lock cylinder 520 is positioned in the passage 510. The lock cylinder 520 is of generally cylindrical configuration, except for a rearwardly ard radially projecting formation 522 that extends beyond the back wall 506. In order to insert the cylinder 520 into the passage 510, the projecting formation 522 is aligned with the groove 514 so that the cylinder 520 can be slided into place in the passage 510, whereafter the lock cylinder 520 is rotated with respect to the body 502 about the axis of the hole 512 to move the projecting formation 522 out of alignment with the groove 514. The projecting formation 522 cooperates with the back wall 506 to retain the cylinder 520 in place in the passage 510.
The lock cylinder 520 can, as is depicted in FIGS. 8 and 14, comprise a tool-operated plug 520' that has a tool-receiving formation 530' in its forwardly-facing end, or can comprise a standard key operated lock cylinder 520" of the type shown in FIG. 14 that has tumblers 532" which project from one or both of its opposed sides when an appropriately configured key (not shown) is absent from the cylinder 520". Regardless of whether a tool-operated plug 520 or a key-operated lock cylinder 520" is used, the purpose of these members is to provide a means for moving the projecting formation 522 between a locked position shown in FIG. 8, and an unlocked position shown in FIG. 15. Where the cylinder is a tool-operated plug 520', a hole 540' is preferably formed in the side of the cylinder 520', and a compression coil spring 542' followed by a hardened steel ball 544' are inserted into the hole 540' to provide a spring projected detent that is engageable with either of the grooves 514, 516 to selectively retain the cylinder 520' in its locked and unlocked positions.
A slide bolt 550 is carried by the housing 120 for movement between a latched position shown in FIGS. 8 and 15, and an unlatched position (not shown) wherein a tapered projecting end 552 of the bolt 550 is withdrawn from extending into the handle passage 360. A compression coil spring 570 is interposed between the body 502 and the slide bolt 550 to bias the slide bolt 550 toward its projected, latched position.
A push-button 580 is slidably carried in a passage 582 that extends through the body 502. The push-button 580 is movable between a normally projected position shown in FIGS. 8 and 16, and a depressed, operating position (not shown) wherein interacting cam surfaces 584, 586 which are formed on the button 580 and on the slide bolt 550 cooperate to cause the slide bolt 550 to retract from its projected position in response to depression of the button 580 from its normal projected position into the passage 582. A compression coil spring 590 is interposed between the back wall 122 of the housing 120 and the button 580 for biasing the button 580 toward its normally projected position.
The locking sub-assembly 500 is operable, when the lock cylinder 520 is positioned in its unlocked position, to permit the button 580 to be depressed to effect retracting movement of the slide bolt 550, whereby the tapered end region 552 of the slide bolt 550 will no longer overlie the latching formation 362 of the handle 350, and the handle 350 will therefore be permitted to pivot forwardly under the influence of the torsion spring 490 to the intermediate position shown in FIG. 11. When the handle 350 is in its nested position, and when the lock cylinder 520 is operable to position the projecting formation 522 in its locked position, the projecting formation 522 engages the slide bolt 550 and prevents its being retracted by depression of the button 580, whereby the slide bolt 550 retains the handle 350 in its nested position despite efforts an operator may make to release the handle 350 by trying to depress the button 580.
Referring to FIGS. 17-19, the strike units 600 each include a frame 610 that has a front wall 612 and one rearwardly extending side wall 614. A generally rectangular opening 616 is formed through the front wall 612. A bracket 620 is welded to the back face of the front wall 612. The bracket has a back wall 622 and a pair of forwardly extending side wall members 624, 626 that have integrally formed mounting flanges 628. The flanges 628 extend along and are welded to the front wall 612.
The side wall members 624, 626 define curved, forwardly facing track surfaces 634, 636. A track member 640 has a pair of arms 644, 646 that extend across the rectangular front wall opening 616. The arms cooperate to define an entry passage 650 for the arm-carried rollers 30, and to define forwardly facing abutment surfaces 652, and rearwardly facing track surfaces 654. The lower end region of the track member 640 is pivotally connected to the side wall members 624, 626 by a rivet 642. A tension spring 652 biases the upper end region of the track member 640 toward a position of engagement with a stop assembly 660. The stop assembly 660 includes a set screw 662 that is adjustable, as is best seen in FIG. 20, using an Allen wrench 664 to control the angle of inclination of the rearwardly facing track surfaces 654.
The spring biased mounting of the track member 640 serves the function of preventing damage from occurring to the rollers 300 if an attempt is made to close the door 12 when the handle 350 is in its nested position (or when the rollers 300 are not otherwise aligned for passage through the entry passage 650).
The strike units 600 function in three ways to engage the arm-carried rollers 300. A first manner of interaction between the arm-carried rollers 300 and the strike units 600 comes as the result of the spring-biased mounting of the track members 640 on the frames 610 of the strike units 600. Should an attempt be made to engage the rollers 300 with the strike units 600 when the rollers 300 are not properly aligned for entry through the strike channel entry passages 650, the rollers will engage the forwardly-facing surfaces 634, 636 of the track members 640, and will cause the track members 640 to be pivoted rearwardly in opposition to the springs 652. As the springs 652 cushion the movement of the door 12, the springs 652 return the track members 640 to their normal positions wherein they engage the stop assemblies 660, which movement biases the door 12 toward its open position with the biasing action being of a resilient, bounce-like nature that literally "bounces" the door 12 open.
A second type of interaction that occurs between the arm-carried rollers 300 and the strike units 600 takes place when the rollers 300 are inserted through the strike channel entry passages, and the operating handle 350 is then moved toward its nested position to move the rollers 300 along the rearwardly-facing track surfaces 654 that are defined by the track members 640. As the rollers 300 move in the strike channels along the rearwardly-facing track surfaces 640, the pivoting of the arms 200 about their axes of pivotal connection with the operating unit's frame 110 causes the rollers 300 to be clamped securely into engagement with the rearwardly-facing track surfaces 640, whereby the door 12 is drawn toward, i.e., clamped toward, the door frame 16 of the cabinet 14. Stated in another way, as the rollers 300 move along the strike channels, a wedging action takes place that causes the toggle links 430, 460 to be subjected to clamping forces that remain in operation while the door 12 is held in its closed position.
A third type of interaction that occurs between the arm-carried rollers 300 and the strike units 600 takes place when the handle 350 is operated to open the door 12. When the handle 350 is raised toward its fully projected operating position, the rollers 300 are moved into engagement with the forwardly-facing track surfaces 634, 636 that are defined by the side wall members 624, 626 of the strike units 600, whereby the curved track surfaces 634, 636 cause the rollers 300 to execute a downwardly and forwardly oriented movement that forces the door 12 toward its open position and thereby aids in overcoming any resistance to door movement that may be provided by such gasketing or shielding as may be utilized about the door frame 16.
As should be apparent from the foregoing description, the lock of the present invention provides a means for securely releasably retaining a closure 12 in securely clamped relationship with an associated opening-defining structure 16. The types of interaction that are provided between the operating unit 100 and the strike units 600 aids in moving the door 12 both toward and away from its closed position. Locks embodying described features of the preferred practice of the present invention are particularly suited for use with electronic equipment enclosures where snug clamping of relatively movable closure and cabinet parts are needed to prevent unwanted transmission and absorption of electomagnetic wave interference.
Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. It is intended that the patent shall cover, by suitable expression in the appended cliams, whatever features of patentable novelty exist in the invention disclosed.
|
A clamping type cabinet lock that is mounted on a cabinet door includes a link-and-lever type of operating assembly which moves a vertical bar. End regions of the vertical bar are connected to pivotally mounted latch members. The latch members have latch formations that enter between and move behind keeper formations that define channels in which the latch formations are moveable. As the latch formations are moved in the keeper channels, the door is caused to be clamped toward a closed position.
| 4
|
BACKGROUND OF THE INVENTION
This invention is directed to an improved digital display driving circuit for driving digital display cells, and in particular, to a digital display driving circuit for only effecting AC driving of liquid crystal display cells in order to avoid deterioration thereof.
Due to the minimum current requirement of liquid crystal display cells, such display cells are particularly advantageous for use in miniaturized, battery-operated electronic measuring, testing and calculating instruments, such as pocket and desk type calculators and electronic wristwatches. Nevertheless, there are two characteristics of liquid crystals that must be taken into account, when utilizing same in battery-operated electronic instruments.
First, in order to avoid rapid deterioration of the liquid crystals, the liquid crystal display cells must be driven by an alternating current, hereinafter referred to as "AC drive". Specifically, the voltage across the respective electrodes defining the liquid crystal display cell must be energized in such manner as to reverse the potential across the liquid crystals during each successive energizing thereof. To this end, liquid crystal display driving circuits include interfacing circuits adapted to receive an AC driving signal and a data signal for selecting the display cells to be energized. However, if the AC driving signal ceases to be applied to the interfacing circuit, the selected liquid crystal display cells continue to be driven by the direct current applied to the interfacing circuit to energize same, thereby effecting a rapid deterioration of the liquid crystals.
Secondly, the voltage produced by the DC battery is insufficient to effect driving of liquid crystal display cells, thereby requiring a booster circuit for elevating the voltage applied to the display drive interface circuit. Usually, such booster circuits receive an AC signal produced by the same source utilized to generate the AC signal applied to the interface circuit to effect AC drive of the display cells. Because such AC signals are usually produced by an oscillator circuit energized by the DC supply, when the DC supply voltage begins to drop, an insufficient voltage is provided for effecting oscillation of the oscillator circuit producing the AC drive signals. Accordingly, the AC drive signals are no longer applied to the booster circuit and/or interface circuit, thereby causing the display cells to be driven by the unboosted direct current voltage produced by the DC supply. In such event, the contrast in the energized display cell is less than completely satisfactory and, as detailed above, the liquid crystals rapidly deteriorate. Accordingly, circuitry for preventing a DC drive current from being applied to the liquid crystal display cells is desired.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the invention, a digital display driving circuit for driving digital display cells forming a digital display is provided. The driving circuit includes an interfacing circuit adapted to be energized. The interfacing circuit in response to being energized receives a first data signal for selectively energizing certain of the display cells and a second driving signal for effecting an AC drive of the display cells selected by the data signal. A DC supply is coupled to the interfacing circuit for producing a voltage adapted to energize the interfacing circuit. A detecting circuit is coupled immediate the DC supply and the interfacing circuit, the detecting circuit being adapted to detect when the drive signal is applied to the interfacing circuit, and in response thereto apply the energizing voltage produced by the DC supply to the interfacing circuit, the detecting circuit being further adapted to detect when the drive signal is not applied to the interfacing circuit and in response thereto prevent the interfacing circuit from being energized by the DC supply voltage.
Additionally, the instant invention is characterized by the DC supply including a booster circuit, the booster circuit being adapted to receive a further drive signal and in response thereto elevate the energizing voltage applied to the interfacing circuit by the DC supply. The detecting circuit is further adapted to prevent the elevated energizing signal from being applied to the interfacing circuit in response to the further driving signal not being applied to the booster circuit.
Accordingly, it is an object of this invention to provide an improved digital display driving circuit for effecting only AC drive of the display cells.
A further object of the instant invention is to provide a liquid crystal display driving circuit for preventing deterioration of the liquid crystals by preventing DC driving thereof.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawing, in which:
FIG. 1 is a circuit diagram of a liquid crystal digital display driving circuit constructed in accordance with the prior art; and
FIG. 2 is a circuit diagram of a liquid crystal digital display driving circuit constructed in accordance with a preferred embodiment of the instant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to FIG. 1, wherein a liquid crystal digital display driving circuit constructed in accordance with the prior art is depicted. An interfacing circuit 8 is adapted to drive a liquid crystal digital display. The liquid crystal digital display is formed in a conventional manner by disposing liquid crystals between spaced apart electrodes, each pair of spaced apart electrodes defining a distinct display cell. Each display cell defines a segment in a 7-segmented display digit. The interfacing circuit 8 includes decoder and driving circuitry, which circuitry in response to data signals D applied thereto selects the segement display cells in each digit to be energized. The interfacing circuit 8 further receives a first intermediate frequency AC drive signal φ B having a frequency on the order of 32 Hz. A DC cell and/or battery is coupled to the interfacing circuit in order to apply a DC voltage to the interfacing circuit in order to permit same to effect decoding and driving of the liquid crystal display cells.
The AC drive signal φ B is applied to the interfacing circuit in order to effect an AC drive of the liquid crystal display cells. Specifically, an AC drive refers to the driving of the liquid crystal display cells by rendering the liquid crystals between pairs of electrodes defining each display cell visually distinguishable from the remaining regions of liquid crystals forming the digital display by applying electric fields of sufficient strength and by reversing the orientation of the energizing fields during alternating drive cycles. Accordingly, by selecting the AC drive signal φ B to be on the order of 30 to 35 Hz, the display cells are flickered at a sufficient rate so as not to be discerned by the human eye.
In miniaturized electronic measuring instruments, such as pocket sized calculators and electronic wristwatches, the effective voltage of the DC cell utilized to drive same is usually not sufficient to effect driving of liquid crystal display cells. Accordingly, a booster circuit is utilized to elevate the DC voltage produced by the DC cell. Referring to FIG. 1, a booster circuit is disposed intermediate the DC cell 1 and the interfacing circuit 8, and is controlled by a further intermediate frequency control signal φ A . Intermediate frequency control signal φ A is produced by the same source as the AC drive signal φ B but is of a higher frequency. If, for example, the digital display driving circuit depicted in FIG. 1 is utilized in an electronic wristwatch, the divider circuit 14 would be utilized as the source of the AC drive signal φ B and the booster circuit control signal φ A .
The booster circuit control signal φ A is applied to a pair of complementary coupled P-channel and N-channel MOS transistors 2 and 3. The P-channel MOS transistor 2 and the N-channel MOS transistor 3 have commonly coupled gate electrodes for receiving the booster circuit control signal φ A . The respective source terminals of the C-MOS transistors are coupled across the DC cell 1. The drain terminals of the C-MOS transistors are commonly coupled through a capacitor 4 and diode 5 to the negative side of the DC cell 1. A capacitor 7 defines the output of the booster circuit and is coupled to the source terminal of the P-MOS transistor 2 and through a diode 6 to a junction defined by diode 5 and capacitor 4.
The booster circuit is operated as follows. When the booster control signal φ A is at a LOW level, the P-channel MOS transistor 2 is switched ON, and the N-channel MOS transistor 3 is switched OFF. Thus, during the LOW level half cycles of the booster control signal φ A a closed current path with the DC cell 1 includes the positive electrode of the DC cell 1, the source-drain current path defined by P-channel MOS transistor 2; capacitor 4; diode 5; and the negative electrode of DC cell 1. Accordingly, during the LOW level half cycles of the control signal φ A , the capacitor 4 is charged to a potential opposite to the potential of the DC cell.
When the booster control signal φ A is at a HIGH level, the P-channel MOS transistor 2 is turned OFF, and the N-channel MOS transistor 3 is turned ON thereby defining a closed current loop including: the positive electrode of the DC cell 1; capacitor 7; diode 6; capacitor 4; the drain-source current path defined by the N-MOS transistor 3 and the negative electrode of the DC cell 1. Accordingly, during the HIGH level half cycles of the booster control signal φ A , a voltage approaching twice that of the DC battery is generated across the capacitor 7 by the capacitor 4 and DC cell 1, thereby causing a boosted or elevated DC voltage to be applied to the interfacing circuit 8 to effect driving of same. It is noted that the capacitor 7 effects a smoothing of the DC voltage applied to the interfacing circuit.
When the source of the booster control signal φ A stops oscillating, the MOS transistors are no longer switched, and the elevated voltage obtained by subtracting the voltage in the forwardly biased direction of the diodes from the battery voltage is generated at both ends of the capacitor 7. Moreover, if the AC drive signal φ B also ceases to be applied to the interfacing circuit, the liquid crystal display is driven by the DC voltage produced by DC cell 1 thereby causing rapid deterioration of the liquid drystals.
As an example, when the liquid crystal display driving circuit is utilized in an electronic wristwarch, the oscillator circuit ceases to produce a time standard signal when the supply voltage produced by the DC cell drops to a voltage level of 1.2 V, thereby causing the booster control signal φ A and the AC drive signal φ B to cease being applied to the booster circuit and interfacing circuit respectively. Moreover, a supply voltage on the order of 0.8 V is applied to the liquid crystal display cell by the interfacing circuit, thereby causing the display cells to be hardly visually distinguishable and the liquid crystals to become rapidly deteriorated. In such an electronic wristwatch, the booster control signal φ A would have a frequency of 256 Hz, and the AC drive signal φ B would be 1/8th that of the booster control signal φ A or 32 Hz.
Accordingly, the prior art digital display driving circuits are characterized by a DC voltage being supplied to the liquid crystal display when the osciallator circuit malfunctions, or alternatively, the voltage level of the DC cell drops a sufficient amount to prevent oscillation of the oscillator circuit, thereby causing rapid deterioration of the liquid crystal display cells. Moreover, it is noted, that when the oscillator circuits malfunction, and there is no drop in the voltage level of the DC cell, an even higher DC voltage is applied to the DC cells, thereby further advancing the rate of deterioration of the liquid crystals.
Reference is now made to FIG. 2, wherein a liquid crystal digital display driving circuit constructed in accordance with the instant invention is depicted, like reference numerals being utilized to denote like elements depicted and described in FIG. 1. An enhancement type N-channel MOS transistor 9 is disposed intermediate the DC supply 1 and booster circuit and the interfacing circuit in order to prevent a DC voltage from being applied to the interfacing circuit in the absence of the booster control signal φ A and the AC drive signal φ B being applied to the booster circuit and interfacing circuit, respectively. Specifically, the gate electrode of the MOS transistor 9 is coupled to the junction defined by diode 5 and the source electrode of N-channel transistor 3. The source-drain electrodes of the MOS transistor 9 couple the junction between capacitor 7 and diode 6 to the interfacing circuit and accordingly, couple said junction to the interfacing circuit when the MOS transistor 9 is turned ON, and defines an open circuit therebetween when the MOS transistor 9 is turned OFF.
In operation, when the booster circuit is operated by the booster control signal φ A , the switching operation of the booster circuit references the gate electrode of the MOS transistor 9 to a sufficient voltage to turn same ON, and the elevated voltage produced by the booster circuit is applied to the interfacing circuit 8. Nevertheless, once the booster control signal φ A is no longer applied to the booster circuit, the source electrode and gate electrode of N-channel MOS transistor 9 are referenced to the same potential, thereby switching the enhancement transistor 9 OFF. Accordingly, the switching OFF of the MOS transistor 9 thereby cuts off the DC voltage supplied to the interfacing circuit 8 and prevents the use of the DC voltage to drive the liquid crystal display cells. Moreover, due to the higher resistance between the source and drain terminals of the transistor 9 with respect to the resistance offered by the diodes 5 and 6, the effect of leakage currents caused by leakage between the source and drain can be ignored.
Accordingly, the instant invention is characterized by the MOS transistor 9 cutting off the supply of DC voltage to the interfacing circuit in response to detecting the absence of the booster control signal φ A and/or the AC drive signal φ B being applied to the booster circuit and interfacing circuit, respectively. Since such condition would only result from a malfunction of the circuitry producing the respective AC frequency signals, or alternatively, from a drop in the voltage level supplied by the DC cell, which drop would cause the circuitry producing such AC frequency signal from applying same to the booster and/or interfacing circuits, deterioration of the liquid crystals utilized in the liquid crystal display cells is prevented. For example, when a liquid crystal display is utilized in electronic wristwatches, and the electronic wristwatch stops working, due to the DC cell or battery utilized to energize same being exhausted, a failure to replace same immediately will not cause deterioration of the liquid crystals to occur.
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 above construction without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
|
An improved digital display driving circuit for driving digital display cells forming a ditigal display is provided. The driving circuit includes an interfacing circuit that in response to being energized receives a first data signal for selectively energizing certain of the display cells and a second drive signal for effecting AC driving of the display cells selectively energized by the data signal. The improved driving circuit is characterized by a DC supply coupled to the interfacing circuit, the AC supply being adapted to energize the interfacing circuit, and a detecting circuit coupled intermediate the DC supply and the interfacing circuit for selectively controlling the energizing of the interfacing circuit by the DC supply in response to the presence or absence of the drive signal being applied to the interfacing circuit to thereby prevent DC driving of the display cells.
| 6
|
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a U.S. National Stage application of International Application PCT/FI00/00129 filed Feb. 21, 2000 and claims priority on Finnish Application Nos. FI 990370, filed Feb. 22, 1999, and FI 19991908, filed Sep. 8, 1999.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to a method and a device in the drying section of a paper machine or the like, such as a board machine or a finishing machine.
Then the invention relates particularly to a method and a device in which
the web is conveyed, supported by a supporting fabric such as a wire or a felt, over a cylinder, such as a drying cylinder, a roll, or the like, between the cylinder and the supporting fabric, supported by the supporting fabric the web is guided from the opening nip between the cylinder and the supporting fabric toward a roll, such a suction roll, a turn roll, a wire guide roll, another cylinder, or the like, and in which the run of the web from the opening nip toward said roll is supported by a negative pressure created on that side of the wire which is opposite the web.
The invention is particularly intended to be applied in the drying sections of paper, paperboard or finishing machines or the like. The intention is then to be able to apply the invention in drying sections provided with a single wire or a twin wire run, where a wire pocket is formed between two drying cylinders and a roll below them redirecting the wire travel. An intention is also to be able to apply the invention in drying sections provided with a so called inverted run, i.e. in such drying sections where the roll redirecting the wire travel is arranged above the drying cylinders, or in solutions where drying cylinders are arranged above each other on two or more levels. Further the intention is to be able to apply the invention in drying sections provided with combinations of the above mentioned drying sections. The intention is further to be able to apply the invention in suitable respects in other parts of the above mentioned machines.
Previously it has been noted that there is a great need for a negative pressure in the wire pocket, particularly at the opening gap between the drying cylinder and the wire, in order to be able to ensure that the wire comes off from the surface of the drying cylinder. However, increasement of the negative pressure in the whole pocket to the required negative pressure level will cause certain disadvantages. Large amounts of energy must be used when the whole pocket space must be brought to the same high negative pressure level. Large air leaks may make it impossible to reach a sufficiently high negative pressure and to maintain it. So far it has generally been possible to increase the negative pressure sufficiently with the aid of blow boxes.
Further, increasing the negative pressure of the whole pocket to a high negative pressure level may cause other disadvantages. On long wire runs with the length of the pocket height a high negative pressure may bend the wire and the web. Thus the wire can come to touch the surfaces of the blow box or other inflexible surfaces, which causes wire damages and impairs the runability. The central part and edge parts of the web may bend in different ways, which causes stretching in the web. This impairs the runability. Further it has been noted that a high negative pressure at the opening nip may shift the wire disengaging point higher on the drying cylinder.
An aim has been to secure the travel of the web in the opening gap between the drying cylinder and the wire by increasing the draw in the paper web. Draw means that a velocity difference is used to create tension in the web. However, it is not always possible to increase the draw, because a too high draw will decrease the tensile strength of the paper, impair the paper quality, and often impair the runability, i.e. create more web breaks.
Previously it has also been proposed to arrange a special suction box at the opening nip between the cylinder and the wire to create a higher negative pressure. The American patent publication U.S. Pat. No. 5,341,579 proposes to arrange a particular small suction box at the opening nip, with which a certain negative pressure is maintained at this point. The negative pressure at this suction box 20 and the suction roll 12 is created by the same negative pressure blower 32 . Thus they can not be controlled separately.
U.S. Pat. No. 5,782,009 presents a suction box mounted in the pocket between two drying cylinders, whereby the suction box is divided into two sections. The suction box section 1 having a higher negative pressure is arranged in the region of the disengaging point between the drying cylinder and the wire. The region is separated from the environment with the aid of mechanical seals. In the cross direction of the web the section 1 with the higher negative pressure can be divided into several parts, where different negative pressures can be created in order to secure the travel of the edges of the web.
U.S. Pat. No. 4,359,827 presents a multi-section suction box arranged in the pocket formed between two drying cylinders. One section of the suction box is arranged in front of the wire at the first drying cylinder regarding the travelling direction of the wire, before the disengaging point between the drying cylinder and the wire. A higher negative pressure is arranged in this section of the suction box than in the other sections of the suction box which border on the wire.
SUMMARY OF THE INVENTION
Thus the particular object of the present invention is such a method and a device, in which the negative pressure in the so called intensified negative pressure region, i.e. close to the disengaging point between the supporting fabric and the cylinder, is higher than the negative pressure in the so called smaller negative pressure region, i.e. at a distance from this disengaging point.
Now it has been surprisingly found that the web to be dried does not in all circumstances result in an optimal running result, despite the higher negative pressure level used at the opening nip. Despite the efforts the web does not always disengage properly from the drying cylinder, or after the disengagement the web may be stretched so that it is not able to follow the wire in a desired way. There occurs web breaks and faults are created in the web.
FIG. 1 shows the forces F acting on the web 16 in the region of the wire pocket 20 . At the beginning of the opening nip K 1 between the drying cylinder 10 and the wire 18 a high and narrow “force peak” F 1 acts on the web, whereby the magnitude of the peak can vary. This peak stretches the web, causing for instance in some conditions a “bubble” in the web, which “bubble” is not anymore able to follow the wire sufficiently well. A weak spot is formed in the web at the location of the “bubble”, which impairs the runability of the wire. At other points on the wire run, such as at the closing nip K 2 between the wire and the roll 14 , the forces F 2 acting on the web are substantially smaller as shown in FIG. 1 , or they are directed so that they press the web close against the wire.
Thus the object of the invention is to provide an improved method and device in the drying section where the above mentioned problems are minimised.
Then the object is to provide a method and a device, with which the run of the web, particularly at the wire pocket, can be controlled during running conditions.
The object is particularly to provide a method and a device, with which the above mentioned drying section runability problems caused by the behaviour of the web in the opening nip can be minimised in different running conditions.
A further object is to provide a method and a device, with which it is possible to create a suitable level of the higher negative pressure at the location of the above mentioned opening nip.
The respective need for the negative pressure in the drying section of a paper machine, in the pocket space formed between the drying cylinder and the wire, depends generally on many factors, both on the production parameters and the quality of the paper being run.
Now we have found in addition that in some situations for instance the speed of the paper machine, the solid contents of the web, the used pulp quality, the web characteristics, the wire tension, the temperature of the drying cylinder, have a direct effect particularly on that force which is required to keep the web close against the drying wire at the opening nip of the wire, and thus these factors have a particular effect on the runability. Thus a controllable negative pressure is required to disengage the web from the surface of the cylinder at the opening nip, at that side of the web which is opposite the cylinder, in order to compensate for the other varying forces attaching the web against cylinder. It must be possible to control the negative pressure at the opening nip separately from the general negative pressure control in the pocket space.
According to a typical method according to the invention the negative pressure pnip is thus controlled in the intensified negative pressure region of the drying section according to one or more parameters which act on the runability of the web and which can be varied or which vary during the run, such as
the velocity of the web, the solid contents of the web, the composition of the pulp being used, the paper or paper board quality which is produced, the grammage of the web, a characteristic of the web, such as the porosity, the draw acting in the web, or the web tension, the cylinder temperature, and/or the running situation, such as a web break, a threading situation, or a normal run, so that the web will disengage from the surface of the cylinder in a controlled manner and so that an optimal runability is maintained between the cylinder and the roll.
Thus, according to the invention it is possible to control the level of the higher or intensified negative pressure region according to the parameters defined by the respective run and paper quality. Now it has been noted that it is advantageous to keep the negative pressure in the intensified negative pressure region the higher-the more humid the web,
the higher the running speed, the hotter the surface of the drying cylinder, the weaker the web, or the better runability that is aimed at.
The dry solid contents of the web has an essential influence on the disengagement of the web from the drying cylinder. The more humidity the web contains, the more difficult it has been to disengage the web from the cylinder, and the more difficult it has been to achieve a good runability. Previously it has thus been an aim to increase the dry solid contents of the web to as high level as possible already at the presses, so that the web should have a good runability in the drying section. Regarding the runability it is not necessary to observe, to the same extent as previously, the humidity of the web coming to the drying section, when the invention is applied. With a solution according to the invention even a relatively moist web can be directed from the press to the drying section, because a controlled disengagement from the drying cylinder, which affects the runability, can be secured with a high negative pressure in the opening nip of the drying cylinder. When applying the invention, a humidity can be chosen so that a final product with the desired characteristics is obtained, for instance a bulky product which is only moderately pressed.
In the intensified negative pressure region it is possible to maintain and control a higher negative pressure until the web for instance at a dry solid contents of 65% has reached such a sufficient strength that the higher negative pressure is not required anymore to compensate for the forces which are due to the humid web and which prevent the disengagement of the web. The high negative pressure is maintained and controlled typically at the beginning of the drying section until it is found that the web has dried and/or shrunk so much that the internal tension in the web causes it to disengage in a controlled manner from the surface of the drying cylinder and to follow the wire. Particularly in such cases, where a pulp with very poor quality is used, it may be advantageous to use an intensified negative pressure in the whole drying section.
The invention makes it possible to use threading with a full width in the press and in the drying section. Then the threading at the press is made for instance as follows: The pick-up roll is lowered against the full width web coming from the wire part, and then the full width web is conveyed through the press, supported by the supporting fabric. In the transfer from one supporting fabric to the next in the press the web transfer is aided by a negative pressure. Thus the web is transported with the full width from the press to the first drying cylinder of the drying section. In the drying section the web may be immediately allowed to continue its travel through the drying section so that it has the full width. Then the negative pressures in the pockets between the drying cylinders, both the intensified negative pressure and the negative pressure in the other regions of the pocket must be switched on. A high negative pressure in the intensified negative pressure region attaches rapidly and effectively the arriving full width web to the supporting fabric at each opening nip of a drying cylinder.
On the other hand, the web coming from the press can be first stopped at the doctor blade of the first drying cylinder in the drying section, and then the web is allowed to flow downwards into the pulper or the like below the machine. The passage of the web into the pulper or the like can be assisted by a drop blow arranged in a box or the like in the region of the first pocket of the drying section over the whole width of the web, and by closing the suctions and blows of the box arranged in the pocket as well as the suctions of the first turn roll of the wire.
Then the actual threading of the web through the drying section is made as follows: The press loads are set for the desired line pressure. In the pocket regions the suctions and blows are switched on in the boxes provided with ejection nozzles and/or suction, in the turn rolls or the like, and then the web which has passed over the first drying cylinder is immediately cut with a blow, preferably simultaneously both from the front side and the back side of the machine. The high negative pressure in the intensified negative pressure region, which according to the invention is regulated to be suitable for threading, ensures that the full width web starts to follow the drying wire forwards in the drying section. Thus the web can have the full width when it is guided by the suctions and negative pressures formed in the pockets, up to a desired point in the drying section, and then the forward passage of the full width web can be stopped at a suitable drying cylinder by closing the suctions and blows carrying the web after this cylinder. When the web is stopped a conventional leader can be cut from the web with the aid of an angle cutter, and with the aid of this leader the head of the web can be threaded through the rest of the drying section in a conventional manner.
With the solution according to the invention the web disengagement from a drying cylinder can be secured at different running speeds by controlling the negative pressure pnip in the intensified negative pressure region according to the formula
ⅆ p ⅆ x = 48 μ vR 2 x 4
where p=pressure
x=distance from the disengaging point m=viscosity of the air V=speed of the web R=radius of the cylinder.
The formula provides a suggestive value about the negative pressure level. The calculated value can often be higher than the value obtained in practice, as there are restricting factors which affect the negative pressure level in practice. For instance, the maximum level of the negative pressure is determined by the combined permeability of the web and the wire.
The higher the speeds of the paper machine rise the more difficult it will become to control the passage of the web in the opening nip between a drying cylinder and the wire in conventional drying sections, because the web, which is relatively firmly attached to the cylinder surface, will tend to the follow the drying cylinder all the more as the speeds increase. A speed increase of a few hundred meters may require a doubled negative pressure level, for instance from a negative pressure of 500 Pa to a negative pressure of 1000 Pa.
By controlling the negative pressure level in the intensified negative pressure region it is also often possible to use a pulp which is of a lower quality than usually, for instance smaller amounts of chemical pulp, without the runability suffering from this. A part of the fibres may possibly be replaced by a filler which is cheaper than fibre. A part of the additives may possibly be replaced by cheaper additives. A suitably high negative pressure level ensures that the web is disengaged from the drying cylinder.
The paper runability and the efficiency of the drying section can be optimised to a level which is substantially higher than previously, only by controlling the negative pressure level at the opening nip in accordance with the machine speed, the dry solid contents of the paper and/or the paper quality.
When applying the solution according to the invention it is often possible to raise the temperatures of the drying cylinders to a level which is higher than previously, because with a controllable intensified negative pressure it is possible to compensate for the change in the strength of the web due to the higher temperature. When applying the invention it is thus often possible to provide an extra capacity in the drying section, due to the higher temperatures of the drying cylinders.
Previously the difference in the draw, for instance between the press section and the drying section, has been chosen mainly on the basis of the runability. When applying the invention, i.e. when improving the runability at the opening nip with the aid of the negative pressure control, it is possible to choose the tension difference also on other grounds. The choice of the difference in the draw can be made on the basis of the paper quality, the paper characteristics, such as the porosity, the stretch at break.
As the machine speeds increase, the difference in the draw between the press and the drying section in conventional solutions must be increased so much that the quality of the web decreases. A negative pressure control according to the invention makes it possible to keep the difference in the draw at a so low level that the quality characteristics of the web, such as the porosity, will not change over this distance, at least substantially. A typical total difference in the draw, before the web has dried to a solid contents of 65%, can be kept lower than 4.5%, even lower than 3%, when the invention is applied.
Previously it has been necessary to divide the drying section into different groups in order to obtain the required difference in the draw to disengage the web from the drying cylinder in a controlled manner. As in the solution according to the invention it is not necessary to influence the runability in the same amount as previously, a drying group longer than previously can be arranged at the beginning of the drying section.
When applying the invention in fast paper machines with speeds of 1500 to 2500 m/minute, typically about 2000 m/minute, it is thus possible to arrange a single wire run drying group at the beginning of the drying section, the group having typically >8, preferably about 10, or even more drying cylinders. A long drying group saves costs.
In a solution according to the invention there is typically maintained in the intensified negative pressure region a negative pressure level which is >500 Pa, more generally 3 1000 Pa, but however <20000 Pa, preferably <10000 Pa, depending on the running situation. It is, of course, possible to increase or decrease the negative pressure from the above mentioned values when required. However, the negative pressure level is typically higher than the negative pressure proll, which prevails on the surface of the turn roll of the wire. The negative pressure level in other parts of the wire pocket is considerably lower, i.e. on the level of about 10 to 700 Pa, preferably 100 to 500 Pa, typically 200 to 300 Pa.
The intensified negative pressure region is typically arranged to cover the wire run at the opening nip of the cylinder, so that the intensified negative pressure region begins at a short distance before the actual disengaging point between the cylinder and the wire, and extends the required distance forwards. The greatest need for negative pressure exists particularly at the disengaging point. During the run the disengaging point may move forward or backward, so the blow box must be arranged so that the provision of a sufficient negative pressure is guaranteed during all running conditions. In a drying section provided with single wire run the intensified negative pressure region can typically be a region at the opening nip with a length of typically 50 to 500 mm, preferably 100 to 200 mm. The length of the intensified negative pressure region means the distance in the travel direction of the web between two means, such as seals, throttling means, blow nozzles, between which means there is created a higher negative pressure in the pocket space than in the spaces adjacent to this region.
The region with the intensified negative pressure forms a narrow gap-like region in the cross direction of the web. As the region is small, and the leaks relating to it are small, the negative pressure is easily and at low costs maintained at a desired level. As the region is short in the travel direction of the web, it affects the web and the supporting fabric only during a very short moment, and therefore, despite the high negative pressure, it does not form a harmful stretching or other disadvantageous changes in them.
As seen in FIG. 1 , the “force peak” which the negative pressure must overcome, is located in a very limited area. It has been found that the intensified negative pressure region could be located in a region which extends at most 300 mm, preferably 40 to 140 mm, typically 80 mm from the disengaging point between the wire and the drying cylinder in the direction of the opening nip, i.e. in the travel direction of the web. Correspondingly, the intensified negative pressure region would extend at most 300 mm, preferably 40 to 100 mm, typically 70 mm from the disengaging point between the wire and the drying cylinder against the travel direction of the web.
The invention is preferably applied in drying sections where the negative pressure assisting the travel of the web is created with the aid of a blow box, a blow box combination, or a suction box or a suction box combination, extending over the whole width of the web and being arranged in the wire pocket in front of the wire run coming from the drying cylinder. With the aid of the negative pressure created by these boxes the web is kept attached to the wire, even over a desired distance after the opening nip. In conventional drying sections the blow box or the suction box occupies a large part of that pocket, the so called wire pocket, which is formed between two drying cylinders and the turn roll between them, the turn roll being e.g. a suction roll.
A blow box which is suitable for the application of the invention is typically combined with means generating the blowing air, and arranged on that side of the wire which is away from the cylinder, mainly at the opening nip between the wire and the cylinder so that it extends, from the actual disengaging point between the wire and cylinder, a short distance forward in the travel direction of the web. The blow box is typically provided with two nozzles, such as ejection nozzles arranged cross-wise regarding the web's direction of travel and close to wire, or with one ejection nozzle and one sealing means.
The first ejection nozzle or seal is preferably arranged mainly at the opening nip between the wire and the cylinder, however preferably before the actual disengaging point between the wire and the cylinder. The second nozzle or seal may be arranged, in the travel direction of the web, at a distance from the first nozzle and the opening nip, for instance at the closing nip (gap) of the turn roll or the suction roll, or it can be arranged on the other side of the pocket, for instance at the second drying cylinder or at the roll between the drying cylinders.
The ejection nozzles are arranged in the blowing device to blow air jets away from the gap between the blowing device and the wire, so that the air jets discharged from the nozzles prevent extra air from entering the gap and/or suck with their ejection effect air away from the gap between the blowing device and the wire, and thus a negative pressure required to support the web is maintained in the gap.
The actual intensified negative pressure region is provided by dividing the gap between the wire and the blow box into two regions with the aid of a throttling means, an ejection nozzle or the like, and by increasing the negative pressure in the first sub-region of the gap regarding the travel direction of the web, i.e. in that part which covers the area around the disengaging point of the wire. In the second sub-region of the gap it is possible to maintain a substantially smaller negative pressure level.
If the throttling means dividing the gap is simply a mechanical seal, then the negative pressure in the intensified negative pressure region can be controlled for instance by controlling the air flow of the first ejection nozzle. With the aid of the control it is possible to increase or decrease the negative pressure in the intensified negative pressure region. Due to the throttling means, the control does not substantially influence the negative pressure in the other parts of the negative pressure region.
On the other hand, if the throttling means is an ejection nozzle it is also possible to control the negative pressure in the intensified negative pressure region by controlling the air flow of this ejection nozzle. The air discharged by the throttling means from the negative pressure region may be allowed to flow into the rest of the negative pressure region, because the amount of this air is usually small in relation to the size of the negative pressure region, or this discharged air can be guided, immediately after the nozzle, totally away from the negative pressure region with the aid of guide plates or discharge channels.
A blow box suitable for applying the invention is typically connected to means creating a negative pressure, such as to suction channels, and arranged on that side of the wire or the supporting fabric which is away from the cylinder, mainly in the same way as an ejecting blow box. The blow box can be connected directly, and/or via a suction roll which is located between the drying cylinders and which redirects the travel of the web, to means which are arranged outside the pocket and which create a negative pressure. The gaps between the suction box and the wire can be sealed by flexible or deflecting mechanical scaling ledges or ejection nozzles.
The separate sub-region with the intensified negative pressure according to the invention can be created also in other negative pressure regions of the most various kinds which are created with blowing devices. The blowing device can be a blow box which covers a part of the wire run in a drying section provided with a single wire run or a twin wire run, or which e.g. in a paper machine covers some other wire run or felt run where the web is disengaged from the roll and/or is kept attached to the wire with the aid of a negative pressure, and where a smaller negative pressure region provided with an intensified negative pressure is required in addition to the conventional negative pressure.
It is, of course, possible to use a plurality of throttling means, such as e.g. mechanical seals, flow barrer plates or ejection nozzles, in order to divide the negative pressure region between the box and the wire run into more than two different regions. There can be several consecutive negative pressure regions with staggered negative pressures.
The actual blowing device can comprise a single, simple box structure, or it can be formed by a plurality of structural box components. Between the structural box components there can be formed e.g. air channels in order to transport air away from a negative pressure region to another region or to the environment.
The nozzles generating the negative pressure can be simple gap nozzles which are arranged so that the air flowing out from them prevents air from penetrating into the negative pressure region and/or which generates an ejecting effect at a desired point between the box and the wire. Particular ejection nozzles can be advantageously used in the blow boxes, the nozzles being resiliently or pivotally mounted ejection nozzles which, when required, move flexibly away from the wire, when e.g. a paper lump pushes the wire against the nozzle, so that they thus do not break the wire.
In order to guide air away from the intensified negative pressure region the solution according to the invention uses advantageously such surfaces which are convex and which utilising the Coanda effect can controllably direct the air into a desired direction, even outside the intensified negative pressure region. With the aid of surfaces utilising the Coanda effect it is possible to direct the air, which is discharged from the intensified negative pressure region, into the smaller negative pressure region toward the air discharge opening or even into the discharge opening, from which opening the air further can be discharged into a desired space by ejection or by utilising suction.
The negative pressure generated with the solution according to the invention in the intensified negative pressure region can be further intensified by arranging suction creating means in this region. The suction can be created by forming in the blow box a suction opening which is connected to this intensified negative pressure region, whereby the suction opening communicates e.g. via a suction channel with devices creating the suction. It is easy to control the negative pressure level in a simple way with the means which are arranged in the blow box and which create suction. Then it is not necessary to control the ejection nozzles of the box individually, and they can be connected to common means creating the blow.
Suction can be advantageously used particularly when the throttling means is a mechanical limiting means, which itself does not actively and in a controllable manner increase the negative pressure. However, the suction can be used as an addition and to control the negative pressure also in other cases. It is advantageous to arrange a net or the like in front of the suction opening to prevent paper lint coming into the negative pressure region from reaching the suction channels.
In contrast to the case with suction boxes, the box and the wire do not come into mutual contact when suction is used in connection with the blow box solution according to the invention, where air is blown at the location of the means defining the intensified negative pressure region between the wire and the box.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail below with reference to the enclosed drawings.
FIG. 1 shows schematically forces which act on the web in the wire pocket region.
FIG. 2 shows correspondingly negative pressures created with the aid of a solution according to the invention, these negative pressures creating counter forces to the forces occurring in the pocket, as shown in FIG. 1 .
FIG. 3 shows schematically a vertical cross section of the pocket between two drying cylinders in the drying section of a paper machine which is provided with a single wire run, whereby a blow box provided with a controllable intensified negative pressure level according to the invention is arranged in the pocket.
FIG. 4 shows a solution according to FIG. 3 in a drying section provided with a twin wire run.
FIG. 5 shows a variation of FIG. 3 .
FIG. 6 shows a variation of FIG. 3 .
FIG. 7 shows a variation of FIG. 3 .
FIG. 8 shows a solution according to FIG. 3 , where a blow box provided with a controllable negative pressure level is arranged in the pocket.
FIG. 9 shows a variation of FIG. 3 .
FIG. 10 shows a variation of FIG. 3 .
FIG. 11 shows a table which presents how the required negative pressure depends on the machine speed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows a schematic drawing of the forces F acting on the web, and of the negative pressures p compensating for these forces in the pocket 20 formed between the two drying cylinders 10 , 12 , the turn roll 14 , the web 16 and the wire 18 . In the case of FIG. 2 the turn roll can be e.g. a perforated or grooved suction roll, in which the negative pressure is provided via the axis at the end of the roll. The negative pressure can be provided in the turn roll also via the peripheral sector adjacent to the pocket space. The turn roll can have a smooth surface or a grooved surface. The paper web 16 runs in a winding manner supported by the wire 18 , alternately over a cylinder 10 , 12 and alternately over a turn roll 14 , so that it forms a pocket 20 between the cylinders and the turn roll.
The wire 18 is disengaged from the periphery of the first cylinder 10 in the so called opening nip 22 and runs to the turn roll 14 so that it forms a so called input wire run 24 between the first cylinder and the turn roll. Correspondingly, the wire runs from the turn roll as a so called output wire run 26 toward the second drying cylinder 12 and passes in the closing nip 28 to run over the second drying cylinder.
At the input side of the pocket there are formed force peaks F 1 and F 2 disengaging the web from the wire outside the pocket at the opening nip 22 and the closing nip 22 ′. F 1 is substantially greater than F 2 . Between these forces only a small disengaging force F 3 acts on the web. At the turn roll 14 the centrifugal force F c tends to disengage the web from the periphery of the roll. At the output side of the pocket, in the opening nip 28 ′ and the closing nip 28 , force peaks F 4 and F 5 holding the web are formed.
A blow box or a suction box is mounted within the pocket in order to compensate for the forces disengaging the web, this box creating on the other side of the web a negative pressure which compensates for the forces disengaging the web. At the opening nip 22 there is arranged an intensified negative pressure region A nip , where the negative pressure is p nip , and in other regions of the pocket a smaller negative pressure region A pocket , where the negative pressure is p pocket . A suction with the negative pressure p roll is arranged in the turn roll.
When the force F 1 , which is formed at the opening nip on the input side of the pocket and which disengages the web, changes according to different running parameters, as shown as an example with broken lines, the intensified negative pressure P nip can be correspondingly controlled to a value p nip ′ so that it in a controlled way compensates for the changed force F 1 ′.
FIG. 3 shows one exemplary solution for maintaining the desired negative pressure level in the pocket 20 between two drying cylinders 10 , 12 . FIG. 3 uses the same reference numerals as FIG. 2 .
In the case of FIG. 3 the blow box 30 extending over the web is mounted in the pocket 20 so that one of its sides 32 together with the input wire run 24 forms a relatively narrow gap 34 , in which the blow box creates a negative pressure. In the upper part of the blow box side 32 there is arranged an ejecting blow nozzle 36 which projects from the box 30 toward the wire 18 , however without touching the wire. The blow nozzle 36 is arranged in the box above the opening nip 22 , i.e. so that air is discharged from the nozzle gap 38 of the nozzle mainly against the travel direction of the wire, and so that the air is discharged at a point which is above the actual disengaging point 40 between the wire 18 and the cylinder 10 , i.e. before the disengaging point in relation to the wire travel direction. The air discharged from the nozzle 36 prevents air travelling with the wire from entering the gap 34 between the box 30 and the wire, and further it ejects air away from the gap creating a negative pressure in the gap. The nozzle 36 is fastened to the box with the aid of a spring 42 which presses the nozzle in a suitable manner toward the wire, however so that it enables the nozzle to be pushed into the box, for instance when a paper lump passes the nozzle between the wire and the cylinder. Advantageously the nozzle 36 comprises a Coanda surface known per se, which guides the air flow discharged from the nozzle.
At the other end of the blow box 30 , at its lower end, there is formed a second nozzle, a simple gap-like nozzle 44 , having air jets which are directed against the rotation direction of the turn roll and which thus prevent air from passing with the turn roll toward the closing nip between this roll 14 and the wire 18 . The blows of the nozzle can also eject air away from the gap between the box and the wire. In many drying sections a suction roll, for instance a Vac roll from the applicant, is used as the turn roll, which in the manner shown by the arrows sucks air from the pocket region.
Further, a second ejection nozzle 46 is arranged in the blow box 30 close to the closing nip 28 of the second cylinder 12 , slightly after the closing nip, i.e. at a point where the wire is already attached to the cylinder. The air jets of this second nozzle are directed away from the pocket, mainly in the direction of the wire travel. The air jets prevent air from entering the negative pressure pocket through the gap between the nozzle and the wire. In this way a negative pressure can be maintained in the whole pocket.
In addition, it is possible, when required, to mount in the blow box, e.g. above the nozzle 44 , a so called drop nozzle (not shown) which blows an air jet directly against the web and thus prevents the web 16 from following the wire 18 to the turn roll 14 at the beginning of the threading phase. The drop nozzle makes the web to pass toward the doctor blade 11 below the cylinder 10 , whereby the doctor blade guides the web downwards, for instance to a pulper or the like below the machine.
According to the invention a throttling means 50 is arranged in the blow box at a short distance from the first nozzle 36 , the throttling means dividing the gap 34 between the box 30 and the wire 18 into two sections, the section 34 ′ having an intensified negative pressure and the section 34 ″ having a smaller negative pressure. In the case of FIG. 3 the throttling means is a mechanical seal which prevents, or at least reduces, the air flow from the section 34 ″ to the section 34 ′. The ejection nozzle 36 is in the case of FIG. 3 arranged to remove air from a small part 34 ′ of the pocket 20 , whereby it is relatively easy to generate even a very high negative pressure in this small part, compared to the negative pressure in the other parts of the pocket. When desired, it is possible to use another ejection nozzle as the throttling means 50 , which actively removes air into the travel direction of the web, so that it assists in generating the negative pressure in the intensified negative pressure region 34 ′.
In the case presented in FIG. 3 it is thus possible to increase the negative pressure at the wire disengaging point 40 by isolating the gap between the wire and the box in this region from the other regions having a smaller negative pressure. A resilient throttling means or a throttling means fastened resiliently to the box can be arranged in the box so that it projects very close to the wire, even to a distance of <10 mm from the wire, and thus effectively separates the negative pressure region 34 ′ from the rest of the surrounding space. When, in addition, the distance of the nozzle 36 from the wire is short, <20 mm, even <10 mm, and when the air jets from this nozzle are sufficient, we obtain a negative pressure at the opening nip which is sufficient for many running requirements, without any further actions. In other parts of the pocket it is then possible to keep the negative pressure at a substantially lower level, which is sufficient for these regions. In this way wire bending is avoided, and due to this the runability is improved.
The intensified negative pressure in the section 34 ′ assists in disengaging the web from the surface of the cylinder 10 , mainly at the wire disengaging point 40 , and to attach the web firmly to the wire. The smaller negative pressure in the section 34 ″ is sufficient to keep the web, which already has disengaged from the cylinder, further attached to the wire until the turn roll. Typically suction is arranged in the turn roll in order to keep the web attached to the surface of the turn roll. The suction has also an effect in the pocket. The second ejection nozzle 46 seals the gap between the box and the second drying cylinder and ensures the negative pressure in the pocket, and as well that the web does not form a pouch in the closing nip 28 . In the solution according to the invention a relatively low negative pressure, typically 200-300 Pa negative pressure, may be sufficient in other parts of the pocket, except in the gap 34 ′.
In the solution shown in FIG. 3 the blow box is relatively narrow and occupies only a part of the pocket. A relatively large air space is left between the turn roll and the box. When desired, it is possible to make the blow box structure so large that it occupies almost the whole pocket space and that only a small air gap is left between the lower part of the box 30 and the turn roll. In this case the nozzle 44 can be arranged in the lower edge of the box, on the side of the closing nip, i.e. on the side of the leaving web 26 .
A common blowing air supply, or an air supply which is individually controlled at each nozzle, may be arranged for the blow nozzles in the box 30 . When the nozzle 36 has its own supply the intensified negative pressure level can be separately controlled with this nozzle. According to the invention the air supply can be arranged so that it depends on those running parameters, in relation to which the negative pressure is intended to be controlled.
In the solution according to the invention it is further possible to form between the nozzle 36 and the throttling means 50 a suction opening 54 connected to the suction channel 52 , such as a gap extending across the whole web with which more air can be removed from the intensified negative pressure region through the gap 34 ′, when required.
In front of the suction opening there is advantageously arranged a net or the like which prevents paper lint or other rubbish from reaching the suction channel. The suction channel can be formed so that when a web break occurs the suction channel can be connected to a blower in order to blow air into the gap 34 ′ and to clean the gap.
The suction operation is made possible by the blow nozzle 36 , which prevents the supporting fabric and the web to be sucked too close to the box. The blows prevent the supporting fabric from coming into contact with the box structures.
In the solution according to the invention the negative pressure level in the intensified negative pressure region can be controlled in many different ways in addition to or alternatively to the above presented. For instance, the negative pressure level can be controlled by controlling the air discharge through the suction opening 54 . Then the air streams blown from the ejection nozzles can even be kept constant, when desired. On the other hand, the negative pressure level can be controlled by controlling the distance of the Coanda surface of the nozzle 36 and/or the throttling means 50 from the web 24 , or for instance by controlling the amount of air blown from the ejection nozzle 36 .
In FIG. 4 the solution according to the invention is applied in a drying section provided with a twin wire run. The upper wire 18 of the drying section passes in a winding manner from the first drying cylinder 10 via the turn roll 14 to the second cylinder 12 . In this way a pocket 20 defined by the wire and the turn roll is formed between the cylinders. In the pocket there is arranged a blow box 30 , which is mainly similar to that of FIG. 3 , and in which the ejection nozzle 36 and the throttle 50 define an intensified negative pressure region 34 ′ at the wire disengaging point. A second blow nozzle 46 is also arranged in the blow box in order to prevent leaking air from flowing into the pocket space.
A corresponding blow box according to the invention can be used in the drying section shown in FIG. 4 , in the region of the lower wire run, for disengaging the web 16 from the lower drying cylinder 10 ′ so that it runs on the lower wire 18 ′ over a short distance.
FIG. 5 shows a variation of FIG. 3 . Then the same reference numerals as in FIG. 3 are used in FIG. 5 , when applicable. The lower part of the box 30 in FIG. 5 is widened so that it covers a large part of the periphery of the turn roll 14 . In this way there is a small gap 31 between the periphery of the turn roll and the lower surface of the box. Passage of air along with the turn roll through the gap 31 to the gap 34 on the wire input side is prevented in the case of FIG. 5 by a sealing ledge 33 or the like arranged at the beginning of the gap 31 . Then the box has no air blow 44 according to FIG. 3 in the closing nip between the turn roll 14 and the wire run 24 . In the case of FIG. 5 there is neither needed an ejecting nozzle between the box 30 and the second cylinder 12 . The gap 37 between the output wire run 26 and the box 30 can be made upward widening, whereby air entering the gap is easily removed from the gap. In the case of FIG. 5 the roll 14 is a suction roll which sucks air from the gaps 34 , 31 and 37 .
FIG. 6 shows a variation of FIGS. 3 and 5 , where the blow box 30 covers a large part of the pocket 20 . The first side of the box forms the intensified negative pressure region 34 ′ at the disengaging point between the drying cylinder 10 and the wire. The blow box has a separate suction box 30 ″, having a suction which is directed into the intensified negative pressure region.
The second side of the box 30 further extends very close to the engagement point between the second cylinder 12 and the wire. Only a narrow gap is left between the box wall and the output wire run 26 , so that the gap restricts the air flow from the outside of the pocket into the pocket. In this way the desired negative pressure can be maintained in the pocket.
FIG. 7 shows also a variation of FIG. 3 . The same reference numerals as in the previous Figures are used in FIG. 7 when applicable. The blow box 30 of FIG. 7 is smaller than the box in FIG. 3 , and it does not extend up to the second drying cylinder 12 . A box like this can be used, if the negative pressure provided by the box is not needed at the wire run 26 between the turn roll 14 and the second drying cylinder. The nozzles 36 and 44 of the box 30 are connected to different blow chambers 30 ′ a and 30 ′ b , and they can be separately controllable. A resilient throttling means 50 divides the negative pressure region into two sections 34 ′, 34 ″ where different negative pressure levels can be maintained.
FIG. 8 shows still another variation of FIG. 3 . The same reference numerals as in the previous Figures are used in FIG. 8 when applicable. In FIG. 8 a suction box 60 with the size of mainly the whole pocket is arranged in the pocket space 20 . Narrow gaps 62 , 62 ′ are formed between the suction box and the wire runs. The lower part 64 of the suction box having openings 66 is curved so that it follows the form of the turn roll 14 , so that a narrow space 68 is left between the suction box and the roll. The edges of the space are sealed at the wire runs with mechanical means 70 , 70 ′. The surface of the suction box is open, e.g. perforated, whereby the suction box can create a negative pressure in the turn roll. The turn roll sucks air from the gaps 62 , 62 ′ between the wire runs and the suction box, creating the negative pressure in the gaps required for the travel of the web.
An intensified negative pressure region is formed in the upper part of the input gap 62 by isolating the top part 63 from the gap with sealing means 72 , 72 ′ and by connecting this top part of the gap to a suction opening 74 , which via the discharge channel 76 is connected to a separately controlled discharge blower 75 . An intensified negative pressure level which is optimal for the respective situation can be created in this region of the wire disengaging point, by controlling the air flow discharged from the gap 63 , so that this negative pressure level in a controlled way guides the web from the drying cylinder to the turn roll.
It is, of course, conceivable to connect the blow nozzle shown in FIG. 3 to the suction box in order to eject air away from the gap 62 .
FIG. 9 shows still one variation of FIG. 3 . In FIG. 9 there is a box 30 consisting of several sections, where there are two positive pressure box sections 30 ′ a , 30 ′ b and one negative pressure box section 30 ″, the box sections being mainly mounted between on one hand the disengaging point 40 between the first drying cylinder 10 and the wire 18 and on the other hand the engagement point 40 ′ between the second drying cylinder 12 and the wire, at a distance from the turn roll 14 . The box mainly occupies only the upper part of the pocket. The negative pressure is created in the pocket 20 by the suction effect of the roll 14 and additionally by ejection nozzles 36 , 46 arranged in the blow box, whereby the ejection nozzles remove air from the pocket, or at least prevent air from entering the pocket.
An intensified negative pressure is created in the intensified negative pressure region 34 ′ by an ejection nozzle 50 , which is arranged in the lower section 30 ′ b of the blow box, close to the wire and at a short distance from the wire disengaging point 40 in the travel direction of the wire. Air is ejected from the gap 34 ′ between the wire and the box into the lower part of the pocket. The amount of air removed with the ejection nozzle from the gap 34 ′ is small and it does not noticeably influence the negative pressure level in the pocket below the box. Thus air can be removed from the intensified negative pressure region 34 ′ by ejection in two directions. In addition or alternatively, air can be discharged through the suction opening 54 formed in the suction box section 30 ″ and through the discharge channel 52 provided with a control plate. If it is desired to discharge air only with the aid of suction, then the ejection nozzles can be replaced by seals.
Further FIG. 9 shows channels 80 , 82 provided with control plates 80 ′, 82 ′, through which air is blown with the aid of a blower 84 into the blow box sections 30 ′ a and 30 ′ b , which are connected to the ejection nozzles 36 and 50 at the borders of the intensified negative pressure region. The negative pressure in the intensified negative pressure region can be controlled according to the invention with the control plates 52 ′, 80 ′ and 82 ′ shown in FIG. 9 , so that the negative pressure has a desired magnitude in relation to the prevailing running situation.
Finally FIG. 10 shows still one variation of FIG. 3 . An ejection nozzle 50 is arranged in the blow box of FIG. 10 at the bottom edge of the intensified negative pressure region, so that the ejection nozzle discharges air from the region 34 ′. The air discharged from the region 34 ′ is directed out from the pocket 20 through the gap between the box 30 and the second drying section 12 with the aid of the channel 86 mounted in the lower section of the box 30 . The input opening 88 of the channel 86 is open to the air flow leaving the intensified negative pressure region. In addition the channel 86 is shaped to be curved downwards so that it extends almost up to the surface of the turn roll 14 , whereby a narrow space 90 is formed between the channel 86 and the roll 14 , the space limiting this air flow in the rotation direction of the turn roll from the output side 20 ″ of the pocket to its input side 20 ′.
FIG. 11 is a table which as an example shows those negative pressure limits at different machine speeds which enable a good runability. The curve a represents a case where the running conditions are good, and where a relatively small constant negative pressure is required to achieve a good runability. The curve b represents a case where the running conditions are bad, but however, where a relatively high negative pressure is able to provide a good runability. The curve b′ represents a situation where some running conditions are good and some are bad, and where a suitably increased negative pressure provides a good runability despite the bad conditions. If the running conditions are very bad, it is still possible in some cases, i.e. depending on which running conditions are bad, to achieve a good runability also below the curve b by increasing the negative pressure, but this is not possible in all cases. Often the running conditions are such that the negative pressure should be controlled to be somewhere between the curves a and b.
In the intensified negative pressure region the negative pressure is controlled by control means according to a measured or in some other manner determined varying parameter, such as the speed, the dry solid contents, the difference in the draw, or the web tension. The measurement information for observing the need for control and for setting the correct control level can be obtained to the control device e.g. from the process information. On the other hand, the need for control can also be observed by ocular inspection. For instance, a decreased web tension can often be detected by ocular inspection.
According to the invention the negative pressure levels can be controlled e.g. so that a desired difference in the draw, e.g 3%, is obtained at the press, whereby the paper characteristics can be optimised according to the needs of further processing.
The invention is not intended to be limited to the above presented exemplary embodiments, but the invention is intended to be widely applicable within the scope defined in the claims presented below. Thus the invention is not intended to be limited to relate to the improvement of the runability only in a drying section. The invention can also find application for other objects, such as in guiding the web from the press to the drying section.
The intensified negative pressure region can extend across the web, or only over a part of the web in its transversal direction. The intensified negative pressure region can be arranged e.g. only at the edge regions of the web, or only on the front side in the threading region. In addition to the control of the negative pressure in the intensified negative pressure region according to the running conditions, it is possible to control it differently at different locations of the web in the transversal direction of the web.
|
A web ( 16 ) running from an opening nip (K 1 ) between a cylinder ( 10 ) and a supporting fabric ( 18 ) toward a roll ( 14 ), is supported by a negative pressure created by a blow box ( 30 ). In an intensified negative pressure region ( 34 ′), i.e. close to the disengaging point ( 40 ) between the supporting fabric and the cylinder, the pressure is greater than at a distance from this disengaging point. The negative pressure is controlled according to parameters which act on the runability of the web and which can be varied, such as web velocity, web solid contents, pulp composition, paper or paper board quality, web grammage, a characteristic of the web, such as porosity, traction acting in the web, or web tension, cylinder temperature, and/or the running situation, such as a web break, a threading situation, or a normal run, so the desired runability is maintained between the cylinder and the roll.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/344,835, filed Dec. 21, 2001. This application is related to co-pending application 10/290,118, entitled PANEL FORMING SYSTEM AND COMPONENTS, filed Nov. 7, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to forms and form supports used for creating cured pre-cast structures. More specifically, the present invention relates to configurations of pre-cast panel forming systems and various components of such systems.
[0003] Many residential and commercial construction methods involve the use pre-cast structures. Pre-cast panels, for example, are integral to the tilt-up construction process. In the tilt-up approach, concrete forms are arranged on a flat casting surface in the shape and dimension of the desired tilt-up panel, then filled with concrete. When the concrete cures, the panel and the form are separated and the panel is tilted up into a preferred, typically vertical, orientation, where it can be joined to structural frames or other panels. The present inventors have recognized a need for improvements in pre-cast panel forming systems and in various components of the panel forming systems. The improvements introduced by the present invention have applicability in the tilt-up construction process and in other pre-cast construction processes.
BRIEF SUMMARY OF THE INVENTION
[0004] This need is met by the present invention wherein improvements in pre-cast panel forming systems and in various components of the panel forming systems are introduced. In accordance with one embodiment of the present invention, a bulkhead is disclosed. The bulkhead includes an upstanding form and a base clip. The upstanding form is used to constrain the flow of uncured material that is introduced adjacent the longitudinal dimension of the upstanding form. The base clip comprises a plurality of attachment members, including a first configured to secure the base clip to the upstanding form, and a second configured to secure the base clip to the panel-forming surface. The second attachment portion includes a laterally-disposed arm such that it increases a base clip footprint formed on the panel-forming surface relative to that formed by a connection between the first attachment portion and the upstanding form.
[0005] Optionally, the base portion and upstanding form together define a unitary, monolithic structure. In addition, the second attachment portion can be substantially planar to more easily engage the panel-forming surface. In the present context, the term “substantially” is utilized represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. As such, it refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may, in practice embody something slightly less than exact. The term also represents the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. The second attachment portion can further include an aperture in the laterally-disposed arm to accept a fastener therethrough. The first attachment portion may also include one or more projections configured to engage a complementary projection on the upstanding form. In one form, the first attachment portion is engaged with the upstanding form through a frictional fit between cooperating projections. More particularly, the projections engage one another through a plurality of interlocking prismatic members. Preferably, the angle subtended between the second attachment portion and the projection of the first attachment portion is substantially ninety degrees. Furthermore, the upstanding form includes a pair of substantially planar walls that are disposed substantially parallel to one another, thereby defining a thickness dimension from outer face to opposing outer face. Preferably (although not out of necessity), the thickness dimension is less than that of the smaller dimension of a conventional two-by-four piece of lumber. For example, the thickness dimension is less than about one and one-half inches, and can be narrower, for example less than about one inch, one-half inch, or other desired dimension. The upstanding form may further comprise one or more chamfers, wherein the chamfer may further comprise a knife-edge sealing projection configured for substantially discrete engagement with the panel-forming surface. The chamfers can include a projection similar to that that of the aforementioned first attachment portion such that upon securing the base clip to the upstanding form, the projection from the chamfer engages the first attachment portion, thus further securing the two. In one form, one chamfer is positioned on one side of the upstanding form while another chamfer is positioned on an opposing side of the upstanding form. Like the upstanding portion, the base clip can include one or more chamfers, which may be integrally formed with the base clip. The material making up the bulkhead can be any that facilitate simple, low-cost manufacture that combine desirable structural properties. In one form, the material can be extrudable, and more particularly, a plastic. By way of example, either or both of the upstanding form and base clip can be fabricated from the group consisting of plastic, metal, fibrous composites, or combinations thereof. In an additional option, the bulkhead is an extruded member, and more particularly, an extruded plastic member.
[0006] According to another embodiment of the present invention, a bulkhead is disclosed. The bulkhead includes an upstanding form and a base clip. The upstanding form is substantially similar to that of the previous embodiment, while the base clip includes a first attachment portion configured to engage the upstanding portion and a second attachment portion configured to engage the panel-forming surface. The second attachment portion includes a proximal end and a distal end. The first attachment portion is located at the proximal end of the second attachment portion and extends away from an attachment plane defined by the second attachment portion. The distal end of the second attachment portion is substantially free of structure extending away from the attachment plane. Optionally, the second attachment portion defines a substantially planar profile from the proximal end to the distal end. In addition, the second attachment portion defines a substantially planar base clip anchoring zone between the proximal end and the distal end. The base clip can also be configured such that substantially all structure extending away from the attachment plane is defined by the first attachment portion. More particularly, it can be configured such that substantially all of the first attachment portion extends from the proximal end of the second attachment portion.
[0007] According to another embodiment of the present invention, a bulkhead with an upstanding form and a base clip is disclosed. The upstanding portion is similar to that of the previous embodiments. The base clip includes an upper anchoring member, a lower anchoring member substantially aligned with the upper anchoring member along a fastening axis such that both the members are configured to accept a fastener therethrough, and a pedestal that couples the upper anchoring member to the lower anchoring member. Unlike the previous embodiments, the base clip is configured such that any fastener attached thereto is disposed not only below the upstanding form, but beneath it as well. In the present context, one item is considered to be “below” another when it occupies a lower vertical position relative to the other without regard to axial alignment along the vertical axis, while the same item would be considered “beneath” the other when it is not only below the other, but also directly underneath it such that they at least partially lie along the same vertical axis.
[0008] Optionally, the upper anchoring member is substantially planar. In one form, the upstanding form defines a monolithic structure, and may further include one or more chamfers disposed substantially adjacent the second end of the upstanding form. The upper anchoring member may further define an aperture therein for receiving the fastener. The pedestal can be configured to engage at least one complementary surface on the upstanding form. For example, the complementary surfaces engage one another through a plurality of interlocking prismatic members. In one form, the pedestal can include a pair of laterally-spaced projections that together are configured to form a friction fit with the upstanding form. More particularly, a plurality of interlocking prismatic members can be used to promote the friction fit. Preferably, the base clip is free of projections above the upper anchoring member. In another option, the lower anchoring member defines a flange, which may additionally extend laterally beyond the upstanding form, thus allowing the flange and the pedestal to form a detent receiving chamber between them. In still another option, one end of the upstanding form terminates in at least one projecting detent such that the detent can fit within the detent receiving chamber upon connection of the upstanding form to the base clip. A fastener can further be included to extend from the upper anchoring member through the lower anchoring member.
[0009] According to another embodiment of the present invention, a panel forming system is disclosed. The system includes a plurality of bulkheads, each similar to that of one or more of the previous embodiments, and a plurality of connectors. The plurality of connectors may include at least one of a corner connector, in-line joint connector and a T-joint connector, each of which can be disposed between adjacent end portions of respective bulkheads to provide connectivity between them. The connectors and the bulkheads can be arranged to produce a panel of desired shape and dimension, including a substantially rectangular panel form. Through the use of multiple bulkheads and connectors, multiple-cavity panels can be formed. In the case of substantially rectangular panels, the forms include at least four bulkheads and at least four corner connectors. The pair of substantially rectangular panel forms can further include a plurality of in-line joint connectors to make extended-size panels.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
[0011] [0011]FIG. 1A is a sectional view of one bulkhead of the panel-forming system of the present invention, showing it being secured to a panel-forming surface;
[0012] [0012]FIG. 1B shows the bulkhead of FIG. 1A with the components thereof in their separated state;
[0013] [0013]FIG. 2 is a schematic illustration of a panel forming system according to the present invention;
[0014] [0014]FIG. 3 is an alternate configuration of the bulkhead of FIG. 1;
[0015] [0015]FIG. 4A is an alternate configuration of the bulkhead of FIG. 1;
[0016] [0016]FIG. 4B is an alternate configuration of the lower projecting edge of the chamfer of FIG. 4A;
[0017] [0017]FIG. 5 is a perspective view of a corner connector according to the present invention;
[0018] [0018]FIG. 6 is a perspective view of a T-joint connector according to the present invention; and
[0019] [0019]FIG. 7 is a perspective view of an in-line connector according to the present invention.
DETAILED DESCRIPTION
[0020] Referring first to FIGS. 1A, 1B and 2 , a single bulkhead 10 and a panel-forming system 60 made from a plurality of bulkheads 10 , both according to the present invention, are shown. By contrast to traditional wooden forms, which may be dimensioned as two-by-four, two-by-six or two-by-twelve (or similar related size, depending on the application) pieces of lumber that are placed edgewise into channels of a separate base, the thickness dimension T of the present bulkhead 10 may be significantly smaller. This reduced dimension, while still possessive of the necessary strength and rigidity, leads to considerably lighter components that are both more portable and storable than that of the prior art. Each bulkhead 10 may comprise a monolithic upstanding form 15 and base clip 20 that together define the bulkhead 10 . For the purposes of defining and describing the present invention, it is noted that a monolithic structure is one of unitary construction, such that it constitutes a single unit devoid of any disconnecting joints or seams. Such structures can be produced through a variety of known fabrication techniques, such as casting, molding or extrusion, the last of which is frequently used where the finished product has a constant cross-section along its longitudinal dimension. In operation, the upstanding form 15 is placed edgewise into base clip 20 , the latter being secured to a panel-forming surface 5 . When the desired panel shape is created (typically with one or more of the bulkheads 10 ) the material that will make up the panel is introduced, in uncured form, into one or more panel cavities 62 , 64 (shown with particularity in FIG. 2), flowing until it encounters bulkhead 10 , which then substantially constrains the further flow of the material to that along the longitudinal dimension of the bulkhead 10 until the shape defined by the cavities 62 , 64 is filled, after which the material is allowed to harden.
[0021] The upstanding form 15 is defined by a first end 12 and a second end 13 . The upstanding form 15 comprises a pair of walls 16 defining a height dimension H and are spaced from each other to define a thickness dimension T. Each of the upstanding walls 16 comprises an exterior face 17 and an interior face 18 , the latter between which one or more cross-sectional support members 19 may extend. At least one of the cross-sectional support members 19 may be located at a point along the height dimension of the upstanding form 15 so as to provide substantial resistance to reduction of the width dimension under pressure applied to one of the exterior faces 17 . In this manner, the integrity of the panel shape defined by each panel cavity 62 , 64 of the panel forming system 60 may be maintained under the significant pressure created by uncured panel-forming material present therein. The cross sectional support members 19 may simply comprise a single linear extension that is substantially perpendicular to the pair of upstanding walls 16 , or as more complex structures arranged in perpendicular or non-perpendicular configurations. For example, as shown in the figure, the bulkhead 10 can employ a plurality of these types of cross sectional support members 19 spaced along the height dimension H of walls 16 , including at or near one or both of the opposing ends. The first end 12 may comprise an end cap 12 A or a locking channel (not shown) to permit repeatable engagement and disengagement between adjacent upstanding forms 15 , or between the upstanding form 15 and connectors or braces (to be discussed later). Details of such features can be found in co-pending application 10/290,118, entitled PANEL FORMING SYSTEM AND COMPONENTS, filed Nov. 7, 2002, assigned to the present assignee and incorporated herein by reference.
[0022] The base clip 20 is used to secure the upstanding form 15 to the panel-forming surface 5 . To effect this, the base clip 20 can accommodate any number of suitable securing means, including adhesives, adhesive tapes, and mechanical fasteners, such as nails or screws. As shown with particularity in FIG. 1B, the base clip 20 , being removable from bulkhead 10 , is not part of the aforementioned monolithic structure defined by the upstanding form 15 , although it is not outside the scope of the present invention for the base clip 20 to be integrated into the monolithic structure. The base clip 20 includes a first attachment portion (made up of projections 20 A and 20 B) and a second attachment portion 20 C that extends laterally such that an upper surface of the second attachment portion 20 C can be accessed from above without either of projections 20 A and 20 B or any other projection (not shown) on base clip 20 getting in the installer's way. Since the space between projections 20 A and 20 B defines a relatively deep, narrow channel 20 E that is generally not conducive for attaching a conventional fastener 9 , the second attachment portion 20 C (in the form of an arm-like extension), with its extended and substantially planar lower surface, allows easy access for an installer to secure the base clip 20 to the panel-forming surface 5 . This is advantageous in that it allows an installer to align and secure the base clip 20 to the panel-forming surface 5 (such as through fastener 9 , both of which are shown in FIG. 1A) prior to the attachment of the second end 13 of upstanding form 15 to the base clip 20 without interference from projections that would otherwise hamper the ability to place and subsequently secure the fastener 9 . The inclusion of the laterally-disposed second attachment portion 20 C also increases the footprint of base clip 20 , making it more stable prior to being secured to the panel-forming surface 5 , thereby allowing the installer additional flexibility and “fine-tuning” in arranging various bulkheads 10 . This extra footprint is especially helpful for thin bulkheads that would otherwise be more susceptible to tipping prior to being secured to the panel-forming surface 5 . Second attachment portion 20 C of base clip 20 can also have an aperture 20 D placed through its generally planar surface to facilitate the placement and subsequent anchoring of fastener 9 . The first attachment portion engages complementary projections 15 A, 15 B and 15 C that extend downwardly from the second end 13 of upstanding form 15 . Although not shown, it will be appreciated by those skilled in the art that base clip 20 may alternatively be attached to the panel-forming surface 5 with an adhesive instead of a fastener 9 .
[0023] Various configurations for the cooperative engagement between the upstanding form 15 and the base clip 20 are possible. Referring with particularity to FIGS. 3 and 4A, an alternative configuration for the connection between the bulkhead 10 and the panel-forming surface 5 is shown. Unlike the previous configuration, where the portion of the base clip 20 that receives the fastener 9 is laterally offset relative to the connection between the upstanding form 15 and the base clip 20 (as shown in FIGS. 1A and 1B), the components of the present base clips 120 , 220 are in substantial alignment with one another along a fastening axis F. Thus, in the orientation shown, an upper anchoring member 120 A, 220 A represents the vertically uppermost portion of the base clip 120 , 220 , and forms a generally planar surface through which a fastener 9 can be placed. A lower anchoring member 120 B, 220 B is configured to rest upon panel-forming surface 5 , and is substantially aligned with upper anchoring member 120 A, 220 A along fastening axis F such that fastener 9 can engage with surfaces of both members to secure the base clip 120 , 220 to panel-forming surface 5 . A pedestal 120 C, 220 C connects the upper anchoring members 120 A, 220 A to lower anchoring members 120 B, 220 B, and also defines a projection that can be used to engage complementary surfaces on upstanding form 15 . The projection formed by pedestal 120 C, 220 C preferably achieves engagement with upstanding form 15 through a frictional fit. Particular forms of frictional fit are emphasized in the two figures. FIG. 3 represents one form, where numerous interlocking prismatic retention members 120 D interact with complementary surfaces on the downward-projecting lower surfaces of upstanding form 15 . The prismatic retention members 120 D could be triangular, saw-tooth or trapezoidal in shape, for example. In one embodiment, the relationship between the prismatic retention members 120 D and the surface of the second end 13 of upstanding form 15 is such that a permanent lock can be formed, while in another, the relationship can be readily engaged and disengaged. In the present context, a locking arrangement is considered “permanent” where the connection between two members is such that they cannot be separated without severely curtailing or disabling their subsequent connective properties. FIG. 4A includes a detent receiving chamber 220 D formed by T-shaped pedestal 220 C that can grab and hold a pair of detents 15 D extending from the second end 13 of the upstanding form 15 . As with the prismatic retention members 120 D of FIG. 3, the engagement between the detent receiving chamber 220 D and detents 15 DA of FIG. 4A can be configured to be permanent or repeatably engageable. By virtue of having there be no projections extending upward from the base clip 120 , 220 of the embodiments of FIGS. 3 and 4A above the upper anchoring member 120 A, 220 A, the attachment of the base clip 120 , 220 to a panel-forming surface 5 is made easier, as an installer can grasp and place fastener on the upper anchoring surface 120 A, 220 A, even in situations where the lateral thickness dimension T of the upstanding form 15 is relatively narrow compared to a conventional two-by-four or related form.
[0024] Referring again to FIG. 2, a plurality of bulkheads 10 are joined by connectors 30 , 40 , 50 to form a panel-forming system 60 . Typically, the panel-forming system 60 is placed on a substantially smooth, planar surface, such as panel-forming surface 5 . A panel-forming material may be poured or otherwise introduced into respective cavities 62 , 64 of the panel forming system 60 and subsequently cured to form monolithic panels (not shown). The cured panels may be removed from the cavities 62 , 64 and used in a variety of applications including, but not limited to, tilt-up and other pre-cast construction applications. A rustication 120 may be utilized to create a particular profile or pattern in the surface of the panel. The panel forming system 60 and its various components may be formed from any of variety of suitable materials including, but not limited to, plastics, metals, resins, fibrous composites, and combinations thereof. These materials may be partially or fully synthetic, and in one form, can be an extrudable material such as an extrudable plastic. Indeed, certain embodiments of the present invention relate directly to the bulkhead as an extruded member. As will be appreciated by those familiar with the art of extrusion, an extruded member defines a substantially uniform extruded cross section that extends along substantially the entire length of the member. Insignificant variations in the uniformity of the cross section due to fabrication process errors or post fabrication process steps are contemplated. For example, holes may be drilled in an extruded member in specific locations after the member is extruded. Similarly, cuts or cutouts may be formed in the extruded member after it is extruded.
[0025] Referring again to FIGS. 1A, 1B, 3 and 4 A, the bulkhead 10 may further include chamfers 22 A, 22 B to form beveled surfaces on the edges of the panels. The chamfers may be formed integral with the upstanding form 15 , the base clip 20 , or both. For example, as shown with clarity in FIG. 1B, the upstanding form 15 can include an integrally formed chamfer 22 A extending from one of the walls 16 at or near second end 13 , while the base clip 20 include an integrally formed chamfer 22 B extending from one of the projections 20 B of the first attachment portion. It will be appreciated by those skilled in the art that the configuration depicted in the figure is notional, and that it is within the scope of the present invention to have the chamfers mounted in other ways, such as having both chamfers 22 A, 22 B formed with the upstanding form 15 , an example of which is depicted in FIGS. 3 and 4A. Moreover, the surface of the chamfer that engages the panel-forming surface 5 need not be planar; referring with particularity to FIG. 4B, an alternate configuration of the end of chamfer 22 A that engages the panel-forming surface 5 is shown. In this configuration, rather than forming a substantially planar lower surface, the chamfer 22 A forms a more discrete, knife-edge contact at end 25 . This shape, disclosed in co-pending application Ser. No. 09/918,965, entitled TILT-UP CONSTRUCTION CHAMFERS, filed Jul. 31, 2001, assigned to the present assignee and incorporated herein by reference, helps to form a seal between the chamfer 22 A and the panel-forming surface 5 , thereby reducing or eliminating the leakage of uncured panel material into the space between the bulkhead and the surface 5 . Although the knife-edge seal 25 is notionally shown on chamfer 22 A, it will be appreciated that such an edge is equally applicable to any of the other chamfers shown or described herein.
[0026] Referring now to FIGS. 5 through 7, the bulkhead connectors 30 , 40 , 50 are shown. Each connector 30 , 40 , 50 comprises a base portion 32 , 42 , 52 and an upstanding portion 34 , 44 , 54 . As with the bulkhead 10 (shown previously), the connectors 30 , 40 , 50 can be defined by a monolithic structure. The upstanding portions 34 , 44 , 54 comprise at least one pair of walls 36 , 46 , 56 . Each connector defines at least one bulkhead receiving area 38 , 48 , 58 bounded in part by the pair of walls 36 , 46 , 56 and the base portion 32 , 42 , 52 . Each of the bulkhead receiving areas 38 , 48 , 58 defines dimensions sufficient to accommodate an end portion of bulkhead 10 securely therein. The extent to which the connectors 30 , 40 , 50 are secured to the bulkheads 10 is preferably sufficient to serve as a barrier to the flow of uncured panel-forming material between the connectors 30 , 40 , 50 and the bulkhead 10 . The connectors 30 , 40 , 50 are characterized by a rigidity sufficient to resist significant deformation and breakage under cross-longitudinal panel forming pressure exerted upon a bulkhead under the load of poured panel-forming material. In a manner analogous to the upstanding form 15 of FIG. 1A, the connectors 30 , 40 , 50 may further comprise at least one cross-sectional support member 39 , 49 , 59 extending between walls 36 , 46 , 56 , while the base portion 32 , 42 , 52 may comprise chamfers 22 . The connectors 30 , 40 , 50 may further comprise connector caps 35 , 45 , 55 sized and configured to complement the size and configuration of the upstanding portions 34 , 44 , 54 of the connectors 30 , 40 , 50 . The connector caps 35 , 45 , 55 may be configured to form a sealed interface with the upstanding portions 34 , 44 , 54 and may comprise locking projections 33 , 43 , 53 configured to engage an end portion of a bulkhead secured within the bulkhead receiving areas 38 , 48 , 58 . It will be appreciated that the connector configuration shown is exemplary only, as other connectors of suitable design could also be used.
[0027] Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.
|
A pre-cast panel forming system. The system includes one or more bulkheads to constrain the flow of uncured panel-forming material. The bulkhead is made up of an upstanding form and a base clip to secure the upstanding form to a panel-forming surface. The base clip is configured to promote ease of attachment to the panel-forming surface, even though the thickness dimension of the upstanding form is reduced relative to conventional forms. In accordance with 37 CFR 1.72(b), the purpose of this abstract is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract will not be used for interpreting the scope of the claims.
| 4
|
BACKGROUND OF THE INVENTION
Within the last hundred years there have been numerous attempts to develop collapsible crutches. For the most part, these crutches while collapsible require significant time and effort to reduce them in elongation. Some of these feature a telescoping tubular lower member wherein the inner section is retained as by a cross bolt and nut within a slightly wider outer section. For these it is necessary for the user to sit down in order to collapse the crutch for ready temporary storage as in a restaurant, theater or other public place. Once collapsed, when the event at which the user has been in attendance is over, again significant effort must be exerted to re-extend the telescoping leg to its desired position. Oftentimes it is next to impossible to relocate the exact length of the telescoping member in order to determine the desired elongation of the crutch.
There is a need therefore for a self-adjusting collapsible crutch. It is an object therefore of this invention to provide a self-adjusting collapsible crutch.
It is yet another object to provide a collapsible crutch that can be closed while the user is in either the standing or sitting position.
It is yet another object to provide a crutch that needs no tools for extension and reduction in elongation.
Still another object is to provide a lightweight easy to collapse crutch.
A still further object is to provide a collapsible crutch with an improved support handle.
This and other objects of the invention will in part be obvious and will in part appear hereinafter.
The invention accordingly comprises the product possessing the features, properties and the relation of components which are exemplified in the following detailed disclosure and the scope of the application of which will be indicated in the claims.
For a fuller understanding of the nature and objects of the invention reference should be made to the following detailed description taken in conjunction with the accompanying drawings.
KNOWN PRIOR ART
As a result of a patent novelty search, applicant is aware of the following references:
______________________________________ 2,426,074 Watters 2,264,015 Bennett 1,156,747 Briscoe 2,544,957 Henry 2,641,491 Mueller 4,182,364 Gilbert______________________________________
The subject matter of the claims set forth below is not disclosed nor is it obvious from any of the references cited above, alone or in combination with each other.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a front elevational view of this invention with the moveable central post retracted.
FIG. 2 is a side perspective view thereof.
FIG. 3 is a view similar to FIG. 1 with the moveable central post in an extended position.
FIG. 4 is a close-up view of the top area of this invention.
FIG. 5 is a close-up exploded view of an intermediate area of this invention.
FIG. 6 is an enlarged close-up partially sectional view of a detail shown in FIG. 5.
FIG. 7 is a close-up elevational view of a detail shown in FIG. 1.
FIG. 8 is a close-up exploded view of a part of the central post of this invention.
FIG. 9 is another close-up of a different part of the central post of this invention.
FIG. 10 is an elevational view of a variant in the construction of this invention.
FIG. 11 is a close-up view of the preferred handgrip forming part of this invention.
FIG. 12 is an elevational view of another variant in the same portion of the invention as FIG. 10.
FIG. 13 is a front elevational close-up view similar to FIG. 4 that illustrates a variant in the construction of this area of the device of this invention.
FIG. 14 is a perspective view, partially cutaway, of the variant shown in FIG. 13 of the top area of the device of this invention.
FIG. 15 is an exploded view of a variant of the portion of the central post shown in FIG. 8. Hereto, the view is a close-up.
FIG. 16 is a view similar to FIG. 15 but showing the compression valve component assembled in a fixed and locked position. Part of this figure is in cutaway to show internal portions of the valve.
FIG. 17 is a top plan view of an improved handgrip cover employable as part of this invention, shown mounted on a handgrip.
SUMMARY OF THE INVENTION
A self-adjusting height crutch which contains a central portion having both a fixed and a moveable central post, one of which nests within the other. A prepositionable height fastener cooperates with a coupling collar, both of which are disposed on the central portion to predetermine the amount of extension of the moveable central post. When the height fastener has been located and the coupler are in and out of cooperation, the leg can be extended and retracted repeatedly the exact same distance.
A hand grip featuring improved gripability is also disclosed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The crutch of this invention is seen to be formed of a pair of spaced lateral fixed posts which are retained in an arm piece at their upper end, and in a base boot at their lower end. Intermediate these posts is a central portion comprised of a nestable fixed post and a moveable post coupled together, with the moveable post projecting through the base boot for contact with the ground.
Turning now to FIG. 1 and 2, there is shown the crutch 10, of this invention. The crutch 10 features an arm piece 45, (which will be described in detail infra with respect to the discussion of FIG. 4), from which descend two spaced lateral posts 21, 23. These are of a fixed length, of about 34" in length, and constructed of tubing about 0.75 to 1" in diameter and extend from the arm piece at their upper ends to locations on the base boot at their respective lower ends.
A central portion 24 is disposed with the arm piece 45, at its upper end with an extension coupler 25 which engages the base boot 11 at its lower end, details of the central portion will be held in abeyance until after the discussion of the base boot, in order to obtain a basic understanding of the construction of the crutch of this invention. See also FIG. 6.
Base boot II is a generally W-shaped member with a trio of upwardly extending arms, the outer of which may be taller than the center arm. Boot 11 includes what will arbitrarily be referred to as a left arm 12A, extending upwardly from a base 12B. Spaced from arm 12A and extending upwardly on the opposite end of base 12B is a similar right arm 12C. Intermediate these two arms is a central arm 12D. Each of these arms is tubular and the base 12B may be tubular but need not be so. The diameter of the central arm is greater than that of the lateral arms 12A, 12C, for reasons that will appear obvious from the discussion below.
Boot 11's details may be seen in FIG. 5. Thus each lateral arm 12A, 12C includes a top opening 15, while center arm 12D includes a top interior threaded opening 14. A cross bore 17 extends through each lateral arm 12A, 12C at a disposition to be aligned with a bore (not seen) through each lateral arm 12A, 12C near the lower end thereof (a lateral arm being disposed in each arm of base boot II). A bolt 18 extends through each bore 17, of the lateral arms 12A, 12C and the unseen counterpart bores in the lateral arms 21, 23. The bolts are retained by nuts 22, per FIG. 2. While only one bolt and nut combination 18, 22 is shown associated with each lateral arm, at least one extra bore 17 may be placed in each of arm and in each lateral post such that additional bolts and nuts may be utilized for extra rigidity.
As noted previously, central arm 12D is internally threaded 14, to receive the second, i.e. lower threads 26 of the annular cylinder shaped extension coupler 25. See also FIG. 6.
Extension coupler 25, which has a vertical central opening 28 therethrough, also includes an area of greater diameter upon which are the upper outside threads 27 to matingly engage coupling collar 31's interior threads 31IT as seen in the outaway area of coupler 31 in FIG. 9.
The discussion moves now to the central portion 24. As shown it comprises a fixed or stationary inner post 37 nesting within a moveable outer post 29. Reference is made to FIGS. 1, 2, and 3. The inner post may comprise a tubular member of about 1/2 to 3/4 inch outside diameter, while the outer post may comprise a tubular member of from 3/4 to 1 inch outside diameter. One or both may be metal such as aluminum or plastic such as polycarbonate.
The outer central post 29 features a plurality of vertically spaced height adjustment bores 39 on at least one quadrant of the tubular member. These bores may also comprise throughbores, and as such would be found on two quadrants of the perimeter of the moveable post. Further details of the moveable outer post are recited below.
These height adjustment bores are utilized by the height adjustment fastener 33, which comprises a tubular member 33T-per FIG. 9 having a disc washer 33D with a greater outside diameter than the opening in 33T on its underside. The opening in the tubular member 33T and the disc washer 33D are of the same diameter. Elements 33T and D may be made integrally as by plastic molding or one may be adhered or otherwise secured to the other.
The diameter of disc 33D is sized to be small enough to pass through the interior of coupling collar 31, but wide enough to permit the inward extending top lip 31L of coupling collar 31 to rest thereupon.
The height adjustment fastener also includes a bore through the wall of the tubular section 33T which bore is designated 33B, see FIG. 9. This bore receives self-tapping screw 36, per FIG. 3 for insertion into one of the height adjustment bores 39. Such insertion constitutes the mode of presetting the height adjustment of the moveable leg of the crutch for a limit of its downward travel.
Coupling collar 31 is a tubular section in configuration and includes an inward extending circumscribing lip 31L per FIG. 9. Coupling collar 31 also includes internal threads 311T which threadedly engage exterior threads 27 of coupler 25.
Returning now to FIGS. 1, 2, and 3 it is seen that the upper end of the moveable central post 29 is closed off by a valve receiver 41, which valve receiver has a friction fitting barrel disposed into the open end of the moveable central post 29. Of course, this valve receiver 41 may be adhered or otherwise secured therein as by a crosspin not shown. This valve receiver 41 is open at the top and is internally threaded to receive compression valve 40's valve body 43's lower threads 43'. Valve body 43's upper threads 43" are engaged by lock nut 44, per FIG. 8.
As is seen the fixed post 37 of the central portion passes readily through the lock nut 44 and the compression valve body 43 and the valve receiver 41 into the interior of the moveable central post 39.
A conventional split compression sleeve 38 while shown spaced slightly distant from threads 43" does in fact rest in an internal chamber within the upper portion of 43. However the opening 44' of the lock nut 44 is sized in diameter such that it does not permit passage of said sleeve 38 therethrough.
Thus, when the nut 44 is threadedly engaged to upper threads 43", the tightening of the lock nut 44's opening 44' on the sleeve 38 causes the compression sleeve to bind onto the fixed post 37 at the location of the sleeve on the fixed post via the action of the internal chamber within 43 forcing the sleeve to tighten on the post 37.
Contrast the relative positioning of the moveable post in FIGS. 1 and 3. The binding previously discussed limits the upward mobility of the moveable post and retains the moveable post in a fixed position at the exact extension of the moveable post as is desired by the crutch user.
Turning now to the details of FIG. 4, one sees the connection of the three posts to arm piece 45. Arm piece 45 is of a generally rectangular configuration having spaced front and rear walls and spaced side walls and having an open bottom 45B and a solid top wall 45T. Depending down from the top wall within the interior are a trio of aligned tubular post receivers 48, 49 and 50. Naturally receiver 49 is of a small diameter since the fixed post 37 that fits therein is of a smaller diameter than the lateral posts. Each post receiver is on slightly larger in diameter than the post it receives in order to achieve a snug friction fit. Each post receiver 48, 49, and 50 has a cross bore 51 to receive self-tapping screws 52 for insertion into bores 53 at the upper end of each respective post 21, 23, and 37, which bores 53 are in axial alignment with their respective bores 51. These screws 52 retain the posts in the arm piece. Arm piece 45 is protected by arm piece cover 47 which is made of cloth or rubber and which fits over the arm piece 45 as is known in the art. See FIG. 4.
FIG. 7 depicts a view of part of the moveable central post 29 with a conventional rubber foot 35 mounted thereon. This may be by friction fit, Velcro® or adhesive, all of which are again traditional in the crutch art.
In FIG. 10 there are shown several variants in the construction of the crutch. Here the base boot is designate 112 with one outer arm designated 112C. This arm is threaded adjacent its opening to threadedly engage the threads of lateral post 121. One of the threads would be external and the other internal. The choice is a designer's choice. Center arm 112D includes a bore 112F to receive a self-tapping screw 112G shown rotated out of position for purposes of illustration for insertion into a bore 126B of a modified coupler 125 the lower end of which, 125A, fits within bore 112H.
Referring now to FIGS. 1, 2 and 3, it is seen that a pair of tubular T-hand grip retainers 57 are mounted at the same elevation on each of the lateral posts via self-tapping screws 59 being inserted into bores 60, which bores align with other bores not seen in each lateral post. A generally U-shaped hand grip 55 is attached by any convenient method to the retainers 57 or they may be integrally formed. The outward extending section of each T may be of any suitable shape to be engaged by or attachable to the arms of the U-shaped hand grip 55. A cover 56 of soft rubber may be disposed over the intermediate section of the U-shaped handgrip 55.
A preferred handgrip 155 is shown in FIG. 11. Here the handgrip includes a pair of L-shaped arms 155A having opposed openings 1550 into which is disposed a rotatable rod 155R. Disposed over rod 155R and best seen in FIG. 17 is a new contoured cover 156 which is fixedly attached to rotatable rod 155R to thereby provide maximum hand comfort. More details on this cover member are provided below.
If desired a series of bores 61 (see FIG.2) may be placed in each lateral post in aligned pairs such that the location of the handgrip may be varied upwardly or downwardly as may be desired.
Whereas the handgrip 55 shown in FIGS. 1, 2 and 3 is a fixedly disposed handgrip, the handgrip 155 in FIG. 11 is a rotatable one. In FIG. 17 there is shown a new hand grip cover 163 which may be adapted to replace the 56, by utilizing the specifically sculpted configuration of the cover of FIG. 17 to replace the soft rubber tubular member 56.
This improved asymmetric grip cover 163, which is somewhat tubular features a rear edge 164 of a first diameter. The grip then uniformly tapers narrowingly at first portion 165, to an outwardly uniformly tapering second portion 166. The third portion is an unsymmetrical bulbous portion 169 having an arcuate inner edge 167, and a relatively flat outer edge 168. This unsymmetrical portion 169 is bulbous along edge 167, such that the cover extends beyond the diameter of edge 164 along edge 167, but not so along edge 168. This third portion 169 is also bulbous in a downwardly direction as well as per FIG. 3, but not the same extent. A fourth portion 170 of a smaller diameter is interposed between the third portion and a fifth portion 17i. The fourth portion tapers outwardly slightly to join the fifth portion.
It is seen therefore that two slight recesses are formed for the natural disposition of the hand; namely between the first and third portions and between the third and fifth portions. The angle of the grip 63 cover 163 to the central post coincides with the approximate angle of the body's skeletal structure at rest at the user's side. Thus this grip conforms naturally to the body structure thus enabling the arms to reduce the weight upon the underarms by the natural downward pressure applied on the grips by the user.
As can be appreciated there is a left hand and a right hand model of the cover 163. In use, the fifth finger falls into the crevice at the second portion, as does the fatty part of the palm of the hand. The fifth finger helps to stabilize the crutch against rotations thereof. The second and third fingers rest upon edge 167 of the third portion. These fingers help hold the crutch steady. The thumb falls over the top of the grip in the recess at the fourth portion and meets the index finger to lock the grip to the user's hand.
Let us turn now to FIG. 12 which depicts another variant in the construction of a portion of this invention; namely, the base boot which here is designated 211. The upstanding arms serve the same function as previously described and are designated 212A, 212C, and the central one is 212D. All of these extend from base 212B. In this embodiment, the exterior arms include at least one, and as shown a pair of, bores 212F to receive self-tapping screws 212G or equal to secure lateral posts therein. Of course this presupposes that such lateral posts have been predrilled with suitable apertures that align with bores 212F.
The other change in this variant in construction is the use of internal threads in the lower end of base 225, said threads being 225B in FIG. 10, and which threads engage external threads 212ET on arm 212D. In all other aspects coupler 225 is the same as coupler 25.
The discussion now turns to alternative means of attaching the 3 posts to the arm piece 145, as is shown in FIGS. 13 and 14. In FIG. 13, arm piece 145 is seen to have 3 post receiving tubes 148, 149 and 150. Each of these tubes has a pair of aligned bores 180 degrees apart, each bore being designated 151. The bores 151 are all horizontally aligned.
Each post 121, 123 and 127 also has a pair of 180 degree spaced bores 153, all six of which are horizontally aligned. As seen in FIG. 14, threaded pin 152 is disposed through opening 158 of arm piece 145 such that its flat head 152H is countersunk into the arm piece. Pin 152 extends through all bores 151 and all bores 153 to retain each of the three posts in a fixed position in the post receiving tubes, pin 152 is retained in position by nut 154.
The discussion now turns to FIG. 15, and FIG. 16 which depict a variant in the construction shown in FIG. 8. FIG. 15 depicts the variants components unengaged, while in FIG. 16 they are engaged. Here too it is seen that the upper end of the moveable post 229 is closed off by a compression valve 240 comprised of a valve body 243, a sleeve 238 and a lock nut 244, with the valve body 243 here being directly disposed in moveable post 229, thereby eliminating the need for a valve receiver 41 as seen in FIG. 8. The valve body's lower threads 243' are internal and are threadedly engaged to external threads 229' of moveable post 229. The valve body's upper threads 243" are engaged by lock nut 244, per FIG. 15. As is seen the fixed post 237 passes readily through the lock nut 244, (FIG. 16) and the compression valve body 243 into the interior of the moveable central post 229. Sleeve 238 while shown spaced slightly distant from threads 243" again for purposes of illustration, in fact rests in an internal chamfer within the upper portion of 243 as may again be seen in FIG. 16 in the area of the cutaway. But said sleeve 238 can not pass through the opening 244' of the lock nut 244. Thus the tightening of the lock nut 244's opening 244' on the conventional compression sleeve, 238, when the lock nut is threadedly engaged to upper threads 243" causes the compression sleeve to bind onto the fixed leg at the then specific location of the valve 240 relative to the fixed post by way of the action of the internal chamber within 243 forcing the sleeve to tighten on the fixed post as can be seen in FIG. 16. Such binding which is known to the art, limits the upward mobility of the moveable post and retains the moveable post in a fixed position relative to the fixed post, i.e. the exact extension of the moveable post to be used by the crutch user.
ADJUSTMENT OPERATION
Reference is made again to FIGS. 1, 2, and 3. FIGS. 1 and 2 show the crutch 10 of this invention in the closed or storage position, while FIG. 3 shows it in its extended or use position. In the first or stored position, the lock nut 44 is tightened against the compression valve at the junction of the fixed central post 37 with the arm piece 45. Coupling collar 31 will rest on the disc 33D (see FIG. 9) of the height adjustment fastener 33 wherever that has been preset as previously discussed.
In order to utilize the crutch, the lock nut 44 is loosened; the crutch held vertically to permit the moveable central post 29 to move downwardly through the coupler 25 until the disc 33D disposed on the moveable central post 29 comes to rest upon coupler 25. The user then holds the crutch up at a convenient height, but vertically with one hand and then couples the coupling collar 31 to coupler 25 by engaging the threads of the coupler to those of the collar. The lock nut 44 is then retightened on to the compression valve 40 to secure the moveable central post 29 relative to the fixed central post 37.
To return the crutch to the storage position, the procedure is merely reversed.
It is seen that any suitable materials such as plastic or metal or wood, as employed in conventional crutches, may be employed for the crutch of this invention.
It is seen that by selectively securing the height fastener to the moveable central post, the maximum travel downward of the moveable post through the collar is defined every time as that predetermined amount. The disc 33D of the fastener impacts the coupler at the point of maximum travel. This permits the collar 31 which rests upon the disc to threadedly engage the coupler's external threads to retain the moveable post at a set location relative to the fixed post.
It is of course recognized that the variants disclosed herein can be utilized in a mix and match situation. Thus the pivotable handle of FIG. 11 may be employed with either the construction of FIG. 8 or with the construction of FIG. 15 for example.
The reader should understand that certain screws and/or bolts have been shown in the drawings adjacent the bore they fit into in order to render the drawings easier to understand. Reference is made for example to FIGS. 2, 12 and 12.
It is also to be appreciated that the underside of the grip 163 which is not shown in FIG. 17 is similar to the upper surface that is shown in that figure.
Since certain changes may be made in the above apparatus without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
|
A self-adjusting crutch containing a central portion having both a fixed and a moveable central post, one of which nests within the other. A prepositionable height fastener cooperates with a coupling collar, both of which are disposed on the central portion to predetermine the amount of extension. When the fastener and coupler are in cooperation, the leg can be extended and retracted repeatedly the exact same distance.
An improved hand grip is also disclosed.
| 0
|
This is a continuation of application Ser. No. 08/698,971, filed on Aug. 16, 1996; now abandoned, which is a continuation of application Ser. No. 08/138,552, filed on Oct. 15, 1993, now U.S. Pat. No. 5,713, 892 which is a continuation of application Ser. No. 07/746,446, filed on Aug. 16, 1991, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to ophthalmological surgery techniques which employ an ultraviolet laser used to provide photodecomposition of the surface of the cornea in order to correct vision defects.
Ultraviolet laser based systems and methods are known for enabling ophthalmological surgery on the surface of the cornea in order to correct vision defects by the technique known as ablative photodecomposition. In such systems and methods, the irradiated flux density and exposure time of the cornea to the ultraviolet laser radiation are so controlled as to provide a surface sculpting of the cornea to achieve a desired ultimate surface change in the cornea, all in order to correct an optical defect. Such systems and methods are disclosed in the following U.S. patents and patent applications, the disclosures of which are hereby incorporated by reference: U.S. Pat. No. 4,665,913 issued May 19, 1987 for "METHOD FOR OPHTHALMOLOGICAL SURGERY"; U.S. Pat. No. 4,669,466 issued Jun. 2, 1987 for "METHOD AND APPARATUS FOR ANALYSIS AND CORRECTION OF ABNORMAL REFRACTIVE ERRORS OF THE EYE"; U.S. Pat. No. 4,732,148 issued Mar. 22, 1988 for "METHOD FOR PERFORMING OPHTHALMIC LASER SURGERY"; U.S. Pat. No. 4,770,172 issued Sep. 13, 1988 for "METHOD OF LASER-SCULPTURE OF THE OPTICALLY USED PORTION OF THE CORNEA"; U.S. Pat. No. 4,773,414 issued Sep. 27, 1988 for "METHOD OF LASER-SCULPTURE OF THE OPTICALLY USED PORTION OF THE CORNEA"; U.S. patent application Ser. No. 109,812 filed Oct. 16, 1987 for "LASER SURGERY METHOD AND APPARATUS"; and U.S. patent application Ser. No. 081,986 filed Aug. 5, 1987 for "PHOTOREFRACTIVE KERATECTOMY".
In the above-cited U.S. Pat. No. 4,665,913 several different techniques are described which are designed to effect corrections for specific types of optical errors in the eye. For example, a myopic condition, which is typically caused by excessive curvature in the anterior surface of the cornea, is corrected by laser sculpting the corneal surface to flatten the curvature. In addition, an astigmatic condition, which is typically caused by a cylindrical component of curvature departing from the otherwise generally spherical curvature of the surface of the cornea, is corrected by effecting cylindrical ablation about the axis of cylindrical curvature of the eye. Other optical errors can be corrected in a similar fashion.
The technique for providing the flattening of the corneal curvature for myopia error correction involves selectively varying the area of the cornea exposed to the laser beam radiation to produce an essentially spherical surface profile of reduced curvature. This selective variation of the irradiated area may be accomplished in a variety of ways. U.S. Pat. No. 4,732,148 cited above discloses the technique of providing a movable opaque element having apertures of various diameters and passing the laser beam through different ones of the apertures in a programmed fashion, starting either with a smallest diameter aperture and progressively increasing the surface area of exposure using apertures of wider diameters, or using the reverse process. Another technique for accomplishing varying areal exposure employs a variable diameter iris for controlling the area of the cornea exposed to the laser beam. Still another technique for providing the flattening of the corneal curvature for myopia error correction involves the use of a laser beam attenuator which varies the energy distribution of the laser beam to sculpt the surface of the cornea in conformance with the varied energy distribution. The attenuator typically includes a positive lens-shaped portion with a laser energy absorbing material and end caps having planar outer surfaces and the same refractive index as the positive portion, which prevents refraction of the laser beam upon passing through the attenuator. This technique is disclosed in U.S. Pat. No. 4,838,266, issued Jun. 13, 1989 for "LENS SHAPING DEVICE USING A LASER ATTENUATOR", the disclosure of which is hereby incorporated by reference. The astigmatic cylinder correction is typically performed by providing a pair of movable blades which intercept the laser beam and permit only a rectangular area of the cornea to be exposed to the beam through the width of the slit formed by the confronting edges of the blades, and by controlling the width of the slit in a predetermined manner so that a rectangular area of the cornea of either increasing or decreasing width is exposed to the laser beam. The '466 U.S. patent noted above discloses such a variable width slit mechanism.
In practice, the laser sculpturing ophthalmological surgical system is typically provided with delivery system optics which include both the variable diameter beam shaping element and the variable width slit mechanism in order to afford both myopia and astigmatism corrections. In some patients, there are both myopia and astigmatism defects in the same eye, requiring correction of both errors in order to improve vision. In the past, such compound errors have been corrected in systems having a variable diameter element and a variable width slit mechanism in a sequential fashion, with the astigmatic correction typically being performed first with the slit mechanism, followed by the correction for myopia using the variable diameter element. This has the disadvantage that the length of the operation is maximized, which increases the time that the patient's eye must be completely immobilized. This increases the physical strain and stress on the patient.
In addition, the cylindrical ablations required to correct astigmatic errors normally result in sharp transitions in the cornea at the extreme ends of the sculpted area. It has been observed that the eye responds to such sharp transitions by promoting growth of the epithelium and the stroma to smooth out sharp edges in the surface of the cornea. This has an adverse optical effect, sometimes termed the "hyperopic shift", which causes vision regression and thus reduces the effectiveness of the laser sculpting technique. In addition, such sharp transitions have the potential to induce changes in corneal curvature, such as flattening along the cylindrical axis of ablation. In the past, attempts have been made to reduce the hyperopic shift by laser sculpting smoothing transition zones. This has been accomplished by manipulating the diameter of a circular aperture at the ends of the slit to form sigmoidal or "s" shaped transition zones. However, therapeutic patients undergoing large area ablations questionable since many of such patents still exhibit hyperopic shifts.
SUMMARY OF THE INVENTION
The invention comprises a method and apparatus for providing both spherical myopic and cylindrical astigmatic corrections to the cornea of an eye which eliminates the sharp transitions at the ends of the cylindrical ablation and which reduces the time required to perform both types of optical error correction.
From a method standpoint, the invention comprises the steps of concurrently correcting myopic sphere and astigmatic cylinder errors in an eye by selective ultraviolet radiation and ablative photodecomposition of the corneal surface in a volumetric removal of corneal tissue and with depth penetration into the stroma to effect toric ablation. The toric ablation is effected by passing the ultraviolet radiation in the form of a laser beam through a slit of varying width and an aperture of varying diameter. Preferably, the slit width is varied from a minimum value to a maximum value, while the aperture diameter is contemporaneously varied from a maximum value to a minimum value. The inverse operation of the slit and the aperture is also effective, though less preferred. Alternatively, the toric ablation is effected by passing the ultraviolet radiation in the form of a laser beam through a variable aperture modulator to produce an elliptical beam profile of variable dimensions. The elliptical beam profile is preferably produced in this embodiment by angularly directing the laser beam at a variable aperture element having a plurality of circular apertures of different diameters, and progressively positioning different ones of the apertures into the path of the beam. The laser beam encounters a series of elliptical apertures of varying axial dimension, depending on the tilt angle and the aperture diameter.
In another method aspect, the invention comprises a method of changing the anterior surface of the cornea of an eye from initial spherical and cylindrical curvature having myopic and astigmatic optical properties to a subsequent curvature having correctively improved optical properties, which method comprises exposing the surface of the cornea and passing ultraviolet laser radiation through a variable aperture element to selectively ablate the exposed surface of the cornea by photodecomposition, with penetration into the stroma and substantially simultaneous spherical and cylindrical volumetric scupturing removal of corneal tissue to such penetration depth and profile as to characterize the anterior surface of the cornea with said subsequent curvature.
In a still further aspect of the invention, the invention comprises a method of using an ultraviolet laser to concurrently correct myopic and astigmatic optical errors of an eye, which method comprises the steps of adjusting the intensity of laser beam projection to a level at which laser beam projection onto the exposed surface of the cornea of the eye will result in a corneal tissue ablation per unit time which is a function of a predetermined maximum ablation depth into the stroma of the cornea, and directing the laser beam at the exposed surface of the cornea in a controlled program of circular and rectangular area coverage as a function of time to redefine the exposed surface curvature by volumetric removal of corneal tissue in the course of selective ablative sculpture of the stroma. The step of directing the laser beam at the exposed surface of the cornea is performed by passing the laser beam through an aperture and a slit and varying the diameter of the aperture and the width of the slit to effect toric ablation of the stroma.
For a fuller understanding of the nature and advantages of the invention, reference should be had to the ensuing detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an ophthalmological laser surgery system for performing the invention;
FIG. 2 is a schematic plan view showing the movable slit and variable diameter aperture;
FIG. 3 is a schematic diagram illustrating the geometry of an elliptical ablation; and
FIG. 4 is a graph showing variation of the minor axis length with correction ratio for different major axis lengths.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, FIG. 1 illustrates a block diagram of an ophthalmological surgery system for performing the invention. As seen in this Fig., a personal computer (PC) work station 10 is coupled to a single board computer 21 of a laser surgery unit 20 by means of a first bus connection 11. PC work station 10 and the subcomponents of laser surgery unit 20 are known components and preferably comprise the elements of the VISX TWENTY/TWENTY EXCIMER LASER SYSTEM available from Visx, Incorporated of Sunnyvale, Calif. Thus, the laser surgery system 20 includes a plurality of sensors generally designated with reference numeral 22 which produce feedback signals from the movable mechanical and optical components in the laser optical system, such as the elements driven by an iris motor 23, an image rotator 24, and astigmatism motor 25 and an astigmatism angle motor 26. The feedback signals from sensors 22 are provided via appropriate signal conductors to the single board computer 21, which is preferably an STD bus compatible single board computer using a type 8031 microprocessor. The single board computer 21 controls the operation of the motor drivers generally designated with reference numeral 27 for operating the elements 23-26. In addition, single board computer 21 controls the operation of the Excimer laser 28, which is preferably an argon-fluorine laser with a 193 nanometer wavelength output designed to provide feedback stabilized fluence of 160 mJoules per cm 2 at the cornea at the patient's eye 30 via the delivery system optics generally designated with reference numeral 29. Other ancillary components of the laser surgery system 20 which are not necessary to an understanding of the invention, such as a high resolution microscope, a video monitor for the microscope, a patient eye retention system, and an ablation affluent evacuator/filter, as well as the gas delivery system, have been omitted to avoid prolixity. Similarly, the keyboard, display, and conventional PC subsystem components (e.g., flexible and hard disk drives, memory boards and the like) have been omitted from the depiction of the PC work station 10.
The iris motor 23 is used to control the diameter of a variable diameter iris schematically depicted in FIG. 2. The astigmatism motor 25 is used to control the separation distance between a pair of cylinder blades 35, 36 which are mounted on a platform 38 for bi-directional translatory motion in the direction of arrows 40, 41. Platform 38 is rotatably mounted on a second platform (not illustrated) and is rotationally driven by astigmatism angle motor 26 in a conventional way in order to enable alignment of the slit axis (illustrated in a vertical orientation in FIG. 2) with the cylinder axis of the patient's eye. Iris 32 is driven by iris motor 23 in a known way to change the diameter of the iris opening from a fully opened position (the position illustrated in FIG. 2) to a fully closed position in which the aperture is closed to a minimum diameter of 0.8 mm. It is understood that the variable diameter iris 32 and the cylinder blades 35, 36 are positioned with respect to the output of laser 28 in such a manner as to intercept the beam prior to irradiation of the corneal surface of the patient's eye 30. For the purpose of this application, it may be assumed that iris 32 and cylinder blades 35, 36 are part of the delivery system optics subunit 29 shown in FIG. 1.
The system of FIGS. 1 and 2 is used according to the invention to concurrently effect myopic spherical and astigmatic cylindrical corrections to the surface of the cornea by toric ablation. Toric ablation is effected by controlling the combined movement of the cylinder blades 35, 36 and iris 32 over a desired range of movement. The constant depth contour map of a toric ablation consists of a series of concentric ellipses. As seen in FIG. 3, the contour of the outer edge of such an ablation in a flat surface is an ellipse. The ablation geometry along the major and minor axes of the ellipse is spherical, and the ablation has both spherical and cylindrical refractive power.
The refractive power of an elliptcal ablation for treating myopia and myopic cylinder is most easily understood using minus notation for the cylinder. The cylinder axis is located along the major axis of the ellipse, while the refractive power of the cylinder is located along the minor axis. For such an ablation in a flat surface, the spherical refractive power can be calculated from the central depth of ablation, the length of the major axis and the index of refraction of the ablated material. The refractive power along the minor axis can similarly be calculated from the length of the minor axis, the depth of ablation and the index of refraction of the ablated material. The cylindrical power can then be calculated by subtracting the refractive (spherical) power along the major axis from the refractive power along the minor axis. The equations set forth in "Photorefractive keratectomy: A technique for laser refractive surgery" authored by Munnerlyn, et al., J. Cataract Refract Surg-Vol. 18, pages 46-52 (January 1988), the disclosure of which is hereby incorporated by reference, can be used to calculate the ablation geometry in corneal tissue along the major and minor axes of the ellipse. Along the major axis, the length of the major axis, S maj , is substituted for the treatment diameter, and the dioptric correction entered into the equations is the spherical correction. To determine the ablation geometry along the minor axis, the sum of the spherical and cylindrical corrections is entered into the equations as the dioptric correction, and the length of the minor axis, S min , is substituted for the treatment diameter.
The relative sizes of the major and minor axes will depend upon the ratio of cylindrical to spherical correction. Assuming that the length of the major axis is held constant, the length of the minor axis is approximated by
S.sub.min ˜S.sub.maj [D.sub.cyl /D.sub.sph)+1].sup.-1/2
In the above equation, S min is the length of the minor axis, S maj the length of the major axis, D cyl the cylindrical correction and D sph the spherical correction. As noted above, this equation assumes minus notation for the cylindrical portion of the correction.
To be effective clinically, an elliptical ablation must have a sufficiently large minor axis comparable in size to the maximum diameter of the corneal treatment zone. As shown in FIG. 4, which plots varying ratios of cylindrical to spherical corrections for constant major axis length, there are certain practical limits to the maximum ratio of cylindrical to spherical corrections. In particular, for a given major axis length the length of the minor axis decreases as the ratio of cylindrical to spherical correction increases. For example, for a major axis of 6.0 mm (corresponding to a laser capable of producing a maximum treatment diameter of 6.0 mm), the minor axis for equal spherical and cylindrical corrections is 4.25 mm. This suggests that the clinical use of toric ablations to correct refractive cylinder should be limited to patients having at least as much spherical error as cylindrical error (for a 6.0 mm maximum treatment diameter). For larger maximum treatment diameters (e.g., the upper curve in FIG. 4 corresponding to a 7.0 mm treatment diameter), the ratio constraints will be different.
Returning to FIG. 2, in the preferred embodiment toric ablations are produced by relative motion of the cylinder blades 35, 36 while varying the diameter of the iris 32. Initially, the cylinder blades 35, 36 are completely closed and the iris 32 is opened to the maximum desired diameter. Thereafter, the cylinder blades 35, 36 are progressively opened while the iris 32 is progressively closed by the respective motors 25, 23. As the cylinder blades 35, 36 are opened, the cylindrical component is ablated in the surface of the cornea. As the diameter of iris 32 is closed contemporaneously with the opening of the cylinder blades 35, 36, the spherical component is ablated in the corneal surface. The combined progressive motion of the cylinder blades 35, 36 and the iris 32 produces the toric ablation desired.
As an example, consider the case of a patient with a refraction of -3.0-2.0×175, average keratometry of 44.5 D and a desired 6.0 mm treatment zone. The iris 32 is initially imaged to a 6.0 mm diameter, and cylinder blades 35, 36 are initially placed in the closed position and rotated to the desired angular orientation in the plane of FIG. 2. Thereafter, as laser 28 is pulsed the cylinder blades 35, 36 are progressively opened to effect a -2.0 D cylindrical correction. At the same time, iris 32 is progressively closed to effect a -3.0 D spherical correction.
The preferred embodiment uses laser 28 to ablate a thin layer of tissue from the surface of the cornea with each pulse. The desired ablation depth along each axis can be predetermined by computer control. The iris 32 is programmed to close at a rate which corresponds to the spherical correction, and the cylindrical blades 35, 36 open at a rate corresponding to the cylindrical correction. The transverse displacement of each aperture between pulses corresponds to the change in desired cut depth for the appropriate aperture (i.e., iris 32 or blades 35, 36). The change in desired cut depth is equal to the amount of material removed with each pulse. Thus, for a -3.0-2.0×175 correction, the iris 32 is closed to create a -3.0 D ablation while the cylinder blades 35, 36 open to create a -2.0 D cylindrical correction. Along the minor axis of the ellipse, the combined effect of the iris 32 and cylinder blades 35, 36 produces a -5.0 D ablation, while the major axis of ellipse has a -3.0 D ablation.
A significant advantage of the preferred embodiment is that the boundaries of the elliptical ablated area are determined by the combined motion of the iris 32 and the cylinder blades 35, 36. As the simultaneous refractive correction proceeds, the intersection of the cylinder blades and iris mark the outer edge of the ablation. The ratio of the minor to major axes is determined by the relative motion of the iris 32 and the cylinder blades 35, 36. Thus, the exact geometry of the ablated area need not be solved for explicitly, and can be varied depending upon the correction required.
Since the number of laser pulses required to effect the spherical correction will usually be greater than the number of laser pulses required to effect the cylindrical correction (assuming equal treatment values of S in the equations of Munnerlyn et al.), cylinder blades 35, 36 will be fully opened to the 6.0 mm position while the iris 32 is not yet fully closed in the above example. Cylinder blades 35, 36 are left at the 6.0 mm position without further movement while the laser finishes the extra pulses required until iris 32 is fully closed. It should be noted that an alternate method of operating the iris 32 and the cylinder blades 35, 36 is to start with the iris 32 initially closed and the cylinder blades 35, 36 initially opened to the maximum slot width, followed by progressive opening of the iris 32 and progressive closing of the blades 35, 36. If the number of pulses required to effect the spherical correction is greater than that required to effect the cylindrical correction (which will be the case whenever the ratio of cylinder-to-sphere shown in FIG. 4 is less than 1.0 and the programmed treatment diameters are equal), motion of blades 35, 36 must be delayed until the extra number of pulses required for the spherical correction have been produced. Otherwise, the blades 35, 36 will be fully closed before the spherical correction is completed. This alternate method of operation thus requires additional capability in the system of FIG. 1 to delay the operation of the astigmatism motor 25 in the closing direction until the extra number of laser pulses required for the spherical correction have been produced.
While the embodiment employing the iris 32 and cylinder blades 35, 36 described above is preferred, the toric ablation may also be effected by employing a variable aperture laser beam modulator to produce an elliptical beam profile of variable dimensions. This may be done by using a mask rotatably mounted in the beam path and having a plurality of variable dimension elliptical apertures with progressive sizes required to produce the desired toric ablation. Alternatively, the mask may have circular apertures of different diameters, and the mask may be positioned at an angle with respect to the laser beam axis so that each circular aperture provides an elliptical profile to the laser beam. The apertured mask is progressively re-positioned between pulses of the laser beam so as to vary the area of the corneal surface exposed to the laser beam from a smallest elliptical area to a largest elliptical area (or the reverse). Care must be taken to ensure that the major axis of each ellipse is collinear with the desired axis of cylindrical ablation throughout the surgery, and this requires precise positioning of the cornea with respect to the elliptical axes. This alternative embodiment has the advantage of employing apertured masks which may already be present in an existing system, such as those shown in the above-referenced U.S. Pat. No. 4,732,148 (particularly FIGS. 9 and 24).
As will now be apparent, the invention enables both spherical and cylindrical corrections to be concurrently effected to the eye of a patient, thus eliminating the prior need with variable aperture and slit systems to first perform the one type of correction (usually the astigmatic correction using the slit) followed by the other correction (typically the spherical correction using the variable aperture). This reduces the total number of pulses required to effect both types of correction to simply the number required to perform the spherical correction. Since the laser beam cross section and intensity can vary over time and with repeated pulsing, the invention reduces the likelihood of error in effecting the desired contoured shaping of the corneal surface. In addition, by sculpting the corneal surface using a toric ablation, the steep vertical "walls" with depth equal to the astigmatic ablation depth are not formed at each end of the cylindrical ablation: consequently, there is no need to produce the sigmoidal transition zones, which simplifies the procedure. In addition, the absence of any steep edges in the corneal ablation reduces the tendency of the eye to produce excessive growth of the epithelium over the ablated surface and this reduces the hyperopic shift phenomenon.
It is understood that the invention encompasses various techniques used to prepare the anterior surface of the cornea for the laser based ablation. For example, removal of the epithelium by both surgical scraping and peeling to expose the corneal surface, as well as laser ablation of the epithelium prior to or contemporaneously with the laser sculpting of the corneal surface, are encompassed by the invention. Thus, the term "corneal surface" refers to the surface to be sculpted to the desired corrective curvature, regardless of whether or not the epithelium or Bowman's membrane (or both) intervene with the actual corneal surface.
While the above provides a full and complete disclosure of the preferred embodiments of the invention, various modifications, alternate constructions and equivalents may be employed as desired. For example, while the invention has been described with specific reference to the system of FIGS. 1 and 2, other arrangements may be employed to produce the variable rectangular and circular areal irradiation desired. Therefore, the above description and illustrations should not be construed as limiting the invention, which is defined by the appended claims.
|
A method for performing concurrent spherical and cylindrical corrections to the corneal surface of the eye to reduce myopia and astigmatism. A laser beam irradiates the corneal surface via a variable diameter iris and a slot produced by a pair of translatable blades. The width of the slot and the diameter of the iris are varied as the laser is pulsed to produce a toric ablation of the corneal surface. Alternatively, the laser beam is passed through a succession of apertures in a tilted variable aperture element to produce toric ablation. The total number of laser pulses required to effect both types of correction is equal to the number required for the spherical correction alone, reducing the laser power and the procedure time. The toric ablation produces no steep end walls as with standard cylindrical ablation procedures, thereby eliminating hyperopic shift and minimizing flattening along the ablated cylinder axis.
| 0
|
RELATED APPLICATION
This application claims priority to and is a continuation of U.S. patent application Ser. No. 11/339,977, filed Jan. 26, 2006, now U.S. Pat. No. 7,485,740 the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention concerns devices incorporating polymeric chiroptical switching materials and methods of making and using the same.
BACKGROUND OF THE INVENTION
Controlling and switching the chiroptical properties of (macro)molecules is of continued interest because of potential applications in sensor data storage, optical devices, and liquid crystalline displays. Chiroptical switch can be controlled by temperature (Bradbury, E. M. et al. Biopolymers 1968, 6, 837; Watanabe, J. et al. Macromolecules 1996, 29, 7084; Maeda, K.; Okamoto, Y. Macromolecules 1999, 32, 974; Cheon, K. S. et al. Angew. Chem., Int. Ed. 2000, 39, 1482; Tang, K. et al J. Am. Chem. Soc. 2003, 125, 7313; Fujiki, M. J. Am. Chem. Soc. 2000, 122, 3336; Fujiki, M. et al. A. Silicon Chem. 2002, 1, 67; Fujiki, M. et al. J. Am. Chem. Soc. 2001, 123, 6253; Teramoto, A. et al. J. Am. Chem. Soc. 2001, 123, 12303; Tabei, J. et al. Macromolecules 2004, 37, 1175; Cheuk, K. K. L. et al. Macromolecules 2003, 36, 9752; Nakako, H. et al. Macromolecules 2001, 34, 1496; Tabei, J. et al. Macromolecules 2003, 36, 573; Yashima, E. et al. J. Am. Chem. Soc. 2001, 123, 8159), solvent (Khatri, C. A. et al. J. Am. Chem. Soc. 1997, 119, 6991; Bradbury, E. et al. Macromolecules 1971, 4, 557; Toniolo, C. et al. Biopolymers 1968, 6, 1579), additives (Novak, B. M.; Schlitzer, D. S. J. Am. Chem. Soc. 1998, 120, 2196; Yashima, E. et al. Nature 1999, 399, 449; Ishikawa, M. et al. J. Am. Chem. Soc. 2004, 126, 732; Miyake, H. et al. J. Am. Chem. Soc. 2004, 126, 6524; Su, S.-J. et al. Macromolecules 2002, 35, 5752; Berl, V. et al. Nature 2000, 407, 720), irradiation (Koumura, N. et al. Nature 1999, 401, 152; Huck, N. P. M. et al. Science 1996, 273, 1686; Janicki, S. Z.; Schuster, G. B. J. Am. Chem. Soc. 1995, 117, 8524; Mayer, S. et al. Macromolecules 1998, 31, 8522; Muller, M.; Zentel, R. Macromolecules 1994, 27, 4404; Maxein, G.; Zentel, R. Macromolecules 1995, 28, 8438; Muller, M.; R. Zentel Macromolecules 1996, 29, 1609; Mayer, S.; Zentel, R. Macromol. Chem. Phys. 1998, 199, 1675) and electron redox (Zahn, S.; Canary, J. W. Science 2000, 288, 1404; Zahn, S.; Canary, J. W. Trends Biotechnol. 2001, 19, 251), with thermo-driven chiroptical switching polymers being the most extensively studied. Examples include poly(L-aspartate β-esters) (Bradbury, E. M. et al, Biopolymers 1968, 6, 837; Watanabe, J. et al., Macromolecules 1996, 29, 7084), polyisocyanates (Maeda, K.; Okamoto, Y. Macromolecules 1999, 32, 974; Tang, K. et al. J. Am. Chem. Soc. 2003, 125, 7313), polysilanes, (Fujiki, M. J. Organomet. Chem. 2003, 685, 15; Fujiki, M. J. Am. Chem. Soc. 2000, 122, 3336; Fujiki, M. et al. Silicon Chem. 2002, 1, 67; Fujiki, M. et al. J. Am. Chem. Soc. 2001, 123, 6253; Teramoto, A. et al. J. Am. Chem. Soc. 2001, 123, 12303) and polyacetylenes (Tabei, J. et al. Macromolecules 2004, 37, 1175; Cheuk, K. K. L. et al. Macromolecules 2003, 36, 9752; Nakako, H. et al. Macromolecules 2001, 34, 1496; Tabei, J.; Nomura, R.; Masuda, T. Macromolecules 2003, 36, 573). Solvent-driven chiroptical switching has been reported for poly(L-aspartate β-esters) (Bradbury, E. M. et al., Biopolymers 1968, 6, 837; Bradbury, E. M. et al. Macromolecules 1971, 4, 557; Toniolo, C. et al. Biopolymers 1968, 6, 1579) and poly(propiolic esters) (Nakako, H. et al. Macromolecules 2001, 34, 1496).
To date, however, all chiroptical switching polymers are synthesized from chiral monomers, possessing stereo centers in the main or side chains. Herein, we wish to report the first chiroptical switching polymer (poly[N-(1-anthryl)-N′-octadecylguanidine], poly-1b, see Scheme 2), which possesses no chiral moieties in polymer chains. Poly-1b is synthesized by a highly regioregular, stereoregular, helix-sense-selective polymerization.
The helix-sense-selective polymerization of achiral monomers using chiral catalysts or chiral solvents yields kinetically controlled helical polymers, e.g., polyisocyanides (Deming, T. J.; Novak, B. M. J. Am. Chem. Soc. 1992, 114, 7926; Nolte, R. J. M. et al. J. Am. Chem. Soc. 1974, 96, 5932; Kamer, P. C. J. et al. J. Am. Chem. Soc. 1988, 110, 6818), poly(quinoxaline-2,3-diyl)s, (Ito, Y et al., Macromolecules 1998, 31, 1697; Ito, Y et al., Chem., Int. Ed. Engl. 1992, 31, 1509), poly(trityl methacrylates) (Okamoto, Y.; Nakano, T. Chem. Rev. 1994, 94, 349; Nakano, T.; Okamoto, Y. Macromolecules 1999, 32, 2391; Okamoto, Y. et al. J. Am. Chem. Soc. 1979, 101, 4763; Nakano, T. et al. J. Am. Chem. Soc. 1992, 114, 1318), poly(trityl methacylamides) (Hoshikawa, N. et al. J. Am. Chem. Soc. 2003, 125, 12380), polyacetylenes, (Aoki, T. et al. J. Am. Chem. Soc. 2003, 125, 6346), and polyisocyanates (Okamoto, Y. et al. Polym. J. 1993, 25, 391).
Recently, we reported our preliminary results on the helix-sense-selective polymerization of achiral carbodiimides using [(R)- and/or (S)-binaphthoxy](diisopropoxy)titanium(IV), R-1 and/or S-1, catalysts (Scheme 1) (Tang, H.-Z. et al. J. Am. Chem. Soc. 2004, 126, 3722; Tian, G. et al. J. Am. Chem. Soc. 2004, 126, 4082). However, the helical polyguanidines obtained possess regioirregular backbones. We concluded that it is resulted from the multiple catalytically active species, such as monomer, dimers, and trimers of titanium complexes. (Boyle, T. J. et al. Organometallics 1992, 11, 1112; Balsells, J. et al. J. Am. Chem. Soc. 2002, 124, 10336; Davis, et al. Org. Lett. 2001, 3, 699; Pescitelli, G. et al. Organomettallics 2004, 23, 4223). To precisely control the regioselectivity in the polymerization of unsymmetrical carbodiimides, structurally well-defined monomeric titanium catalysts are required. However, to date, monomeric titanium alkoxide complexes are few in number.
SUMMARY OF THE INVENTION
A first aspect of the present invention is a polycarbodiimide polymer that is reversibly switchable between two distinct optical orientations. The polymer is useful as a filter, storage medium, actuator, etc., as explained further below.
Polycarbodiimide polymers of the invention may be formed from the polymerization of chiral or achiral monomers with an optically active organometallic catalyst. The polycarbodiimide polymer comprises repeating units each containing a polycyclic group or ring (e.g., an anthracene ring) which polycyclic group is, in some embodiments, substituted with at least one polar or ionic group.
A further aspect of the present invention is a device (such as a liquid crystal display, a microactuator, an optical filter, a memory storage device, etc.) comprising (a) a substrate; and (b) a polycarbodiimide polymer as described herein on said substrate. The polycarbodiimide polymer is reversibly switchable between two distinct optical orientations.
The device may further comprise at least one electrode, or at least two electrodes, operatively associated with the polycarbodiimide polymer. The polycarbodiimide polymer can be one that is reversibly switchable between said two distinct optical orientations in response to a change in electric field (e.g., applied, changed, or removed by the electrode or electrodes).
The polycarbodiimide polymer and/or the electrode can in some embodiments be patterned on the substrate to provide discrete storage sites and/or permit the formation of alphanumeric characters, symbols or the like.
A further aspect of the invention is a method of switching the optical orientation of a polymer from a first optical orientation to a second optical orientation, comprising: (a) providing a polycarbodiimide polymer in a first optical orientation; and then (b) passing an electric field through said polycarbodiimide polymer to switch the polycarbodiimide polymer from the first optical orientation to the second optical orientation. The method of switching may be carried out when the polymer is in a device as described herein.
A further aspect of the invention is titanium complex catalysts useful for carrying out the present invention, along with compositions formed therefrom.
The foregoing and other objects and aspects of the present invention are explained in greater detail in the drawings herein and the specification set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a first apparatus of the present invention.
FIG. 2 is a schematic diagram of a second apparatus of the present invention.
FIG. 3 is a schematic diagram of a third apparatus of the present invention.
FIG. 4 is a schematic diagram of a fourth apparatus of the present invention.
FIG. 5 . Variable-temperature 1 H NMR spectra of R-3 in CD 2 Cl 2 .
FIG. 6 . Stereoregular structures of non-symmetrically substituted polyguanidines prepared through the polymerization of an achiral carbodiimide with catalyst R-1.
FIG. 7 . GPC chromatograms of poly-1a and poly-1b eluting with chloroform at a rate of 1.0 mL/min.
FIG. 8 . Optical rotations, [α] D , of poly-1a and poly-1b versus annealing time in toluene at 80° C. (c=0.1 g/100 mL).
FIG. 9 . Variable-temperature [α] D of poly-1b in toluene (c=0.1 g/100 mL) at a heating rate of 1.5° C./min.
FIG. 10 . Variable-temperature CD (top) and UV-visible (bottom) spectra of poly-1b in toluene (c=2.1×10 −4 M, path length=10 mm).
FIG. 11 . Variable-temperature CD (top) and UV-visible (bottom) spectra of poly-1b in toluene (c=2.1×10 −4 M, path length=10 mm) in the heating-cooling-heating thermal cycle. The sample is the same as that in FIG. 7 . The measurement was performed six month later compared to that in FIG. 7 .
FIG. 12 . Variable-temperature g abs (top) and UV-visible (bottom) spectra of poly-1b in chloroform (c=2.1×10 −4 M, path length=10 mm).
FIG. 13 . Variable-temperature g abs spectra of poly-1b in THF (c=2.1×10 −4 M, path length=10 mm).
FIG. 14 . g abs -values at 380 nm of poly-1b in toluene/THF at 25° C.
FIG. 15 . A possible mechanism of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
The disclosures of all United States Patent references cited herein are to be incorporated by reference herein as if fully set forth.
1. DEFINITIONS
“Halo” as used herein refers to any suitable halogen, including —F, —Cl, —Br, and —I.
“Mercapto” as used herein refers to an —SH group.
“Azido” as used herein refers to an —N 3 group.
“Cyano” as used herein refers to a —CN group.
“Hydroxyl” as used herein refers to an —OH group.
“Nitro” as used herein refers to an —NO 2 group.
“Alkyl” as used herein alone or as part of another group, refers to a straight or branched chain hydrocarbon containing from 1 or 2 to 10, 20 or 50 carbon atoms (e.g., C1 to C4 alkyl; C4 to C10 alkyl; C11 to C50 alkyl). Representative examples of alkyl include, but are not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl, n-hexyl, 3-methylhexyl, 2,2-dimethylpentyl, 2,3-dimethylpentyl, n-heptyl, n-octyl, n-nonyl, n-decyl, and the like. “Loweralkyl” as used herein, is a subset of alkyl, in some embodiments preferred, and refers to a straight or branched chain hydrocarbon group containing from 1 to 4 carbon atoms. Representative examples of loweralkyl include, but are not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, tert-butyl, and the like. The term “alkyl” or “loweralkyl” is intended to include both substituted and unsubstituted alkyl or loweralkyl unless otherwise indicated and these groups may be substituted with groups selected from halo, alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclo, heterocycloalkyl, hydroxyl, alkoxy, alkenyloxy, alkynyloxy, haloalkoxy, cycloalkoxy, cycloalkylalkyloxy, aryloxy, arylalkyloxy, heterocyclooxy, heterocyclolalkyloxy, mercapto, alkyl-S(O) m , haloalkyl-S(O) m , alkenyl-S(O) m , alkynyl-S(O) m , cycloalkyl-S(O) m , cycloalkylalkyl-S(O) m , aryl-S(O) m , arylalkyl-S(O) m , heterocyclo-S(O) m , heterocycloalkyl-S(O) m , amino, carboxy, alkylamino, alkenylamino, alkynylamino, haloalkylamino, cycloalkylamino, cycloalkylalkylamino, arylamino, arylalkylamino, heterocycloamino, heterocycloalkylamino, disubstituted-amino, acylamino, acyloxy, ester, amide, sulfonamide, urea, alkoxyacylamino, aminoacyloxy, nitro or cyano where m=0, 1, 2 or 3.
“Alkylene” as used herein refers to a difunctional linear, branched or cyclic alkyl group, which may be substituted or unsubstituted, and where “alkyl” is as defined above.
“Alkenyl” as used herein alone or as part of another group, refers to a straight or branched chain hydrocarbon containing from 2 to 10, 20 or 50 carbon atoms (e.g., C2 to C4 alkenyl; C4 to C10 alkenyl; C11 to C50 alkenyl) (or in loweralkenyl 2 to 4 carbon atoms) which include 1 to 4 double bonds in the normal chain. Representative examples of alkenyl include, but are not limited to, vinyl, 2-propenyl, 3-butenyl, 2-butenyl, 4-pentenyl, 3-pentenyl, 2-hexenyl, 3-hexenyl, 2,4-heptadienyl, and the like. The term “alkenyl” or “loweralkenyl” is intended to include both substituted and unsubstituted alkenyl or loweralkenyl unless otherwise indicated and these groups may be substituted with groups as described in connection with alkyl and loweralkyl above.
“Alkenylene” as used herein refers to a difunctional linear, branched or cyclic alkyl group, which may be substituted or unsubstituted, and where “alkenyl” is as defined above.
“Alkynyl” as used herein alone or as part of another group, refers to a straight or branched chain hydrocarbon containing from 2 or 20 to 10, 20 or 50 carbon atoms (e.g., C2 to C4 alkynyl; C4 to C10 alkynyl; C11 to C50 alkynyl) (or in loweralkynyl 2 to 4 carbon atoms) which include 1 triple bond in the normal chain. Representative examples of alkynyl include, but are not limited to, 2-propynyl, 3-butynyl, 2-butynyl, 4-pentynyl, 3-pentynyl, and the like. The term “alkynyl” or “loweralkynyl” is intended to include both substituted and unsubstituted alkynyl or loweralknynyl unless otherwise indicated and these groups may be substituted with the same groups as set forth in connection with alkyl and loweralkyl above.
“Alkynylene” as used herein refers to a difunctional linear, branched or cyclic alkynyl group, which may be substituted or unsubstituted, and where “alkynyl” is as defined above.
“Alkylidene chain” as used herein refers to a difunctional linear, branched, and/or cyclic organic group, which may be substituted or unsubstituted, which may be saturated or unsaturated, and which may optionally contain one, two or three heteroatoms selected from the group consisting of N, O, and S. Examples include but are not limited to alkylene, alkenylene, alkynylene, arylene, alkarylene, and aralkylene. See, e.g., U.S. Pat. No. 6,946,533. The alkylidene chain may contain any suitable number of carbon atoms (e.g., a C1 to C4; C4 to C10; C10 to C20; C20 to C50).
“Alkoxy” as used herein alone or as part of another group, refers to an alkyl or loweralkyl group, as defined herein, appended to the parent molecular moiety through an oxy group, —O—. Representative examples of alkoxy include, but are not limited to, methoxy, ethoxy, propoxy, 2-propoxy, butoxy, tert-butoxy, pentyloxy, hexyloxy and the like.
“Acyl” as used herein alone or as part of another group refers to a —C(O)R group, where R is any suitable substituent such as aryl, alkyl, alkenyl, alkynyl, cycloalkyl or other suitable substituent as described herein.
“Haloalkyl” as used herein alone or as part of another group, refers to at least one halogen, as defined herein, appended to the parent molecular moiety through an alkyl group, as defined herein. Representative examples of haloalkyl include, but are not limited to, chloromethyl, 2-fluoroethyl, trifluoromethyl, pentafluoroethyl, 2-chloro-3-fluoropentyl, and the like.
“Alkylthio” as used herein alone or as part of another group, refers to an alkyl group, as defined herein, appended to the parent molecular moiety through a thio moiety, as defined herein. Representative examples of alkylthio include, but are not limited to, methylthio, ethylthio, tert-butylthio, hexylthio, and the like.
“Aryl” as used herein alone or as part of another group, refers to a monocyclic carbocyclic ring system or a bicyclic carbocyclic fused ring system having one or more aromatic rings. Representative examples of aryl include, azulenyl, indanyl, indenyl, naphthyl, phenyl, tetrahydronaphthyl, and the like. The term “aryl” is intended to include both substituted and unsubstituted aryl unless otherwise indicated and these groups may be substituted with the same groups as set forth in connection with alkyl and loweralkyl above.
“Arylalkyl” as used herein alone or as part of another group, refers to an aryl group, as defined herein, appended to the parent molecular moiety through an alkyl group, as defined herein. Representative examples of arylalkyl include, but are not limited to, benzyl, 2-phenylethyl, 3-phenylpropyl, 2-naphth-2-ylethyl, and the like.
“Amino” as used herein means the radical —NH 2 .
“Alkylamino” as used herein alone or as part of another group means the radical —NHR, where R is an alkyl group.
“Arylalkylamino” as used herein alone or as part of another group means the radical —NHR, where R is an arylalkyl group.
“Disubstituted-amino” as used herein alone or as part of another group means the group —NR a R b , where R a and R b are independently selected from the groups alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclo, heterocycloalkyl.
“Acylamino” as used herein alone or as part of another group means the group —NR a R b , where R a is an acyl group as defined herein and R b is selected from the groups hydrogen, alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclo, heterocycloalkyl.
“Acyloxy” as used herein alone or as part of another group means the group —OR, where R is an acyl group as defined herein.
“Ester” as used herein alone or as part of another group refers to a —C(O)OR group, where R is any suitable substituent such as alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Formyl” as used herein refers to a —C(O)H group.
“Carboxylic acid” as used herein refers to a —C(O)OH group.
“Sulfoxyl” as used herein refers to a compound of the formula —S(O)R, where R is any suitable substituent such as alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Sulfonyl as used herein refers to a compound of the formula —S(O)(O)R, where R is any suitable substituent such as alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Sulfonate” as used herein refers to a compound of the formula —S(O)(O)OR, where R is any suitable substituent such as alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Sulfonic acid” as used herein refers to a compound of the formula —S(O)(O)OH.
“Amide” as used herein alone or as part of another group refers to a —C(O)NR a R b group, where R a and R b are any suitable substituent such as H, alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Sulfonamide” as used herein alone or as part of another group refers to a —S(O) 2 NR a R b group, where R a and R b are any suitable substituent such as H, alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Urea” as used herein alone or as part of another group refers to an —N(R a )C(O)NR a R b group, where R a , R b and R c are any suitable substituent such as H, alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Alkoxyacylamino” as used herein alone or as part of another group refers to an —N(R a )C(O)OR b radical, where R a , R b are any suitable substituent such as H, alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Aminoacyloxy” as used herein alone or as part of another group refers to an —OC(O)NR a R b radical, where R a and R b are any suitable substituent such as H, alkyl, cycloalkyl, alkenyl, alkynyl or aryl.
“Cycloalkyl” as used herein alone or as part of another group, refers to a saturated or partially unsaturated cyclic hydrocarbon group containing from 3, 4 or 5 to 6, 7 or 8 carbons (which carbons may be replaced in a heterocyclic group as discussed below). Representative examples of cycloalkyl include, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, and cyclooctyl. These rings may be optionally substituted with additional substituents as described herein such as halo or loweralkyl. The term “cycloalkyl” is generic and intended to include heterocyclic groups as discussed below unless specified otherwise.
“Heterocyclic group” or “heterocyclo” as used herein alone or as part of another group, refers to an aliphatic (e.g., fully or partially saturated heterocyclo) or aromatic (e.g., heteroaryl) monocyclic- or a bicyclic-ring system. Monocyclic ring systems are exemplified by any 5 or 6 membered ring containing 1, 2, 3, or 4 heteroatoms independently selected from oxygen, nitrogen and sulfur. The 5 membered ring has from 0-2 double bonds and the 6 membered ring has from 0-3 double bonds. Representative examples of monocyclic ring systems include, but are not limited to, azetidine, azepine, aziridine, diazepine, 1,3-dioxolane, dioxane, dithiane, furan, imidazole, imidazoline, imidazolidine, isothiazole, isothiazoline, isothiazolidine, isoxazole, isoxazoline, isoxazolidine, morpholine, oxadiazole, oxadiazoline, oxadiazolidine, oxazole, oxazoline, oxazolidine, piperazine, piperidine, pyran, pyrazine, pyrazole, pyrazoline, pyrazolidine, pyridine, pyrimidine, pyridazine, pyrrole, pyrroline, pyrrolidine, tetrahydrofuran, tetrahydrothiophene, tetrazine, tetrazole, thiadiazole, thiadiazoline, thiadiazolidine, thiazole, thiazoline, thiazolidine, thiophene, thiomorpholine, thiomorpholine sulfone, thiopyran, triazine, triazole, trithiane, and the like. Bicyclic ring systems are exemplified by any of the above monocyclic ring systems fused to an aryl group as defined herein, a cycloalkyl group as defined herein, or another monocyclic ring system as defined herein. Representative examples of bicyclic ring systems include but are not limited to, for example, benzimidazole, benzothiazole, benzothiadiazole, benzothiophene, benzoxadiazole, benzoxazole, benzofuran, benzopyran, benzothiopyran, benzodioxine, 1,3-benzodioxole, cinnoline, indazole, indole, indoline, indolizine, naphthyridine, isobenzofuran, isobenzothiophene, isoindole, isoindoline, isoquinoline, phthalazine, purine, pyranopyridine, quinoline, quinolizine, quinoxaline, quinazoline, tetrahydroisoquinoline, tetrahydroquinoline, thiopyranopyridine, and the like. These rings include quaternized derivatives thereof and may be optionally substituted with groups selected from halo, alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclo, heterocycloalkyl, hydroxyl, alkoxy, alkenyloxy, alkynyloxy, haloalkoxy, cycloalkoxy, cycloalkylalkyloxy, aryloxy, arylalkyloxy, heterocyclooxy, heterocyclolalkyloxy, mercapto, alkyl-S(O) m , haloalkyl-S(O) m , alkenyl-S(O) m , alkynyl-S(O) m , cycloalkyl-S(O) m , cycloalkylalkyl-S(O) m , aryl-S(O) m , arylalkyl-S(O) m , heterocyclo-S(O) m , heterocycloalkyl-S(O) m , amino, alkylamino, alkenylamino, alkynylamino, haloalkylamino, cycloalkylamino, cycloalkylalkylamino, arylamino, arylalkylamino, heterocycloamino, heterocycloalkylamino, disubstituted-amino, acylamino, acyloxy, ester, amide, sulfonamide, urea, alkoxyacylamino, aminoacyloxy, nitro or cyano where m=0, 1, 2 or 3.
“Polar group” as used herein refers to a group wherein the nuclei of the atoms covalently bound to each other to form the group do not share the electrons of the covalent bond(s) joining them equally; that is the electron cloud is denser about one atom than another. This results in one end of the covalent bond(s) being relatively negative and the other end relatively positive; i.e., there is a negative pole and a positive pole. Examples of polar groups include, without limitations, hydroxy, alkoxy, carboxy, nitro, nitrile, cyano, amino (primary, secondary and tertiary), amido, ureido, sulfonamido, sulfinyl, sulfhydryl, silyl, S-sulfonamido, N-sulfonamido, C-carboxy, O-carboxy, C-amido, N-amido, sulfonyl, phosphono, morpholino, piperazinyl, tetrazolo, and the like. See, e.g., U.S. Pat. No. 6,878,733, as well as alcohol, thiol, polyethylene glycol, polyol (including sugar, aminosugar, uronic acid), sulfonamide, carboxamide, hydrazide, N-hydroxycarboxamide, urea, metal chelates, carboxylates, esters, ketones, etc.
“Ionic group” as used herein includes anionic and cationic groups, and includes groups (sometimes referred to as “ionogenic” groups) that are uncharged in one form but can be easily converted to ionic groups (for example, by protonation or deprotonation in aqueous solution). Examples include but are not limited to carboxylate, sulfonate, phosphate, amine, N-oxide, and ammonium (including quaternized heterocyclic amines such as imidazolium and pyridinium as described above) groups. See, e.g., U.S. Pat. Nos. 6,478,863; 6,800,276; and 6,896,246. Additional examples include uronic acids, carboxylic acid, sulfonic acid, amine, and moieties such as guanidinium, phosphoric acid, phosphonic acid, phosphatidyl choline, phosphonium, borate, sulfate, etc. Note that compounds of the present invention can contain both an anionic group as one ionic substituent and a cationic group as another ionic substituent, with the compounds hence being zwitterionic. Note also that the compounds of the invention can contain more than one anionic or more than one cationic group.
“Polycyclic group” or “polycyclic ring” as used herein refers to an organic group comprising or containing two or more fused rings. Polycyclic groups are well known. See, e.g., U.S. Pat. Nos. 6,982,140; 6,960,665; 6,930,118; 6,929,871; 6,906,154; and 6,887,820. The polycyclic groups may be aromatic, aliphatic, or partially saturated or unsaturated. The polycyclic groups may optionally contain one or more (e.g., 2, 3, 4, 5) hetero atoms such as an O, S, or N atom (e.g., may contain one or more heterocyclic ring as described above). The polycyclic groups may be substituted or unsubstituted (e.g., substituted from 1 to 4, 8, or 10 or more times with a substituent as described above). Examples of polycyclic groups include but are not limited to those having 2, 3, 4, 5, 6, 7, 8, 9, or 10 or more fused rings.
Particular examples of polycyclic groups containing two fused rings include but are not limited to: naphthalene, benzofuran, isobenzofuran, indole, isoindole, benzothiophene, benzo[c]thiophene, benzimidazole, purine, indazole, benzoxazole, benzisoxazole, benzothiazole, quinoline, isoquinoline, quinoxaline, quinazoline, and cinnoline, along with the partially of fully saturated analogs thereof, all of which may be coupled to the monomer at any position, and all of which may be unsubstituted or substituted (e.g., from one to four or six times) with any of the substituents given above.
Particular examples of polycyclic groups containing three or four fused rings include but are not limited to: anthracene, acridene, chrysene, and fluoranthene, along with the partially of fully saturated analogs thereof, all of which may be coupled to the monomer at any position, and all of which may be unsubstituted or substituted (e.g., from one to four or six times) with any of the substituents given above.
Particular examples of polycyclic groups containing five to ten fused rings include but are not limited to: perylene, pentacene, dibenzopyrene, dibenzofluoranthene, benzoperylene, dibenzoperylene, rubicene, and decacyclene, along with the partially of fully saturated analogs thereof, all of which may be coupled to the monomer at any position, and all of which may be unsubstituted or substituted (e.g., from one to four or six times) with any of the substituents given above.
“Linker group” as used herein, are aromatic or aliphatic groups (which may be substituted or unsubstituted and may optionally contain heteroatoms such as N, O, or S) that are utilized to couple one substituent to another. Examples include, but are not limited to, aryl, alkyl, alkenyl, alkynyl, arylalkyl, alkylarylalkyl, heteroaryl, alkylheteroaryl, heteroalkyl (e.g., oligoethylene glycol), alkylheteroalkyl, etc. Particular examples include C1-C4 alkylene linkers such as —CH 2 CH 2 CH 2 —, —CH 2 CH 2 —, and —CH 2 —.
2. MAKING POLYCARBODIIMIDE POLYMERS
As noted above, the present invention provides titanium complex catalysts or metal alkoxide catalysts in optically active form that are useful for making the polymers described herein. In one embodiments such catalyst compounds are compounds of Formula I:
wherein:
R 1 and R 2 are each independently selected from the group consisting of halo and trialkylsilyl;
R 21 and R 22 are each independently selected from the group consisting of alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkylalkenyl, cycloalkylalkynyl, heterocyclo, heterocycloalkyl, heterocycloalkenyl, heterocycloalkynyl, aryl, aryloxy, arylalkyl, arylalkenyl, arylalkynyl, heteroaryl, heteroarylalkyl, heteroarylalkenyl, and heteroarylalkynyl,
or one pair of either R 1 and R 21 or R 12 and R 22 are joined by a linking group; R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , and R 12 are each independently selected from the group consisting of H, alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkylalkenyl, cycloalkylalkynyl, heterocyclo, heterocycloalkyl, heterocycloalkenyl, heterocycloalkynyl, aryl, aryloxy, arylalkyl, arylalkenyl, arylalkynyl, heteroaryl, heteroarylalkyl, heteroarylalkenyl, heteroarylalkynyl, alkoxy, halo, mercapto, azido, cyano, acyl, formyl, carboxylic acid, acylamino, ester, amide, hydroxyl, nitro, alkylthio, amino, alkylamino, arylalkylamino, disubstituted amino, acyloxy, sulfoxyl, sulfonyl, sulfonate, sulfonic acid, sulfonamide, urea, alkoxylacylamino, and aminoacyloxy, or an adjacent pair of R 4 and R 5 , R 5 and R 6 , R 6 and R 7 , R 5 and R 9 , R 9 and R 10 , or R 11 and R 12 together form an annulated ring system;
and each dashed line represents an optional double bond.
Such compounds can be made in accordance with known techniques or variations thereof that will be apparent to those skilled in the art based upon the present disclosure. One specific example of a compound of Formula I is a compound of the formula:
Catalyst compositions generally comprise or consist essentially of a catalyst compound as described above solubilized in an organic solvent. Any suitable organic solvent can be used, including but not limited to polar or nonpolar aprotic solvents and including chlorinated alkyl and aromatic solvents, such as toluene and chloroform. In some embodiments the “solvent” is the monomer for the reactions described below and the reaction is carried out in “neat” form. In some embodiments the catalyst compound is solubilized in said solvent in monomeric form. Any suitable amount of catalyst compound may be included in the catalyst composition, e.g. from 0.001 to 20 or 30 percent by weight of catalyst in the composition, with the inclusion of more catalyst generally producing polymers of shorter chain length.
With the foregoing catalysts, the present invention provides a method of making polycarbodiimide polymers as described herein. Thus, the invention provides a method of making a polycarbodiimide polymer of formula II:
wherein A is a polycyclic group, L is a linker group or covalent bond, B is an organic group (e.g., a linear, branched or cyclic, saturated or unsaturated, C7-C30 alkyl optionally containing 1-3 hetero atoms selected from the group consisting of N, O and S); and n is an integer corresponding to the desired average molecular weight of the polymer, e.g., an integer of from 6 to 100, 500 or more. The method comprises the steps of polymerizing a carbodiimide precursor of the formula:
wherein A, L and B are as given above, with an optically active metal alkoxide complex catalyst (e.g., a compound of formula I as given above) to produce the polycarbodiimide polymer of formula II. The monomers may be chiral or achiral, but in some embodiments are achiral to advantageously permit the use of less expensive starting materials. The reaction conditions are not critical and may be carried out for any suitable time and temperature, for example from 0 to 100 degrees Centigrade for 10 minutes to several weeks The reaction composition may or may not include solvent as noted above, and will in general comprise, consist of or consist essentially of 0 to 50 percent by weight solvent; 1 to 99.9 percent by weight of monomer; and 0.001 to 20 or 30 percent by weight of catalyst.
Polycyclic groups used to carry out the present invention may be substituted or unsubstituted, as noted above. In some embodiments the polycyclic group is substituted with at least one polar or ionic group. The inclusion of at least one (e.g., 1 or 2, to 4, 6 or 10 or more) polar and/or ionic group on the polycyclic rings is 1) to tune the switching energy; 2) to make the strong interactions with external additives or substrates possible for preparing sensors, etc.; and 3) to introduce large-dipole-chromophores along the polymer backbone to furnish non-linear-optical (NLO) materials without harsh poling process. When the polycyclic group does contain at least one polar or ionic group, the polycyclic group may still optionally be substituted with the other substituents noted above.
A variety of polycyclic groups may be used to carry out the present invention. In some embodiments the polycyclic group contains two fused rings (e.g., a naphthylene or naphthyl group). In some embodiments the polycyclic group contains three fused rings (e.g., an anthracyclene group). In some embodiments the polycyclic group contains at least three fused rings. (e.g., from 3 to 6, 8 or 10 or more fused rings).
Chain terminating groups are not shown in formula II and are not critical, as the terminal groups may be removed and substituted with other groups such as surface attachment groups if desired. In general, for catalysts of formula I, one terminal group is R 21 or R 22 , and the other terminal group is H or an amine.
3. DEVICES AND METHODS OF USE
A variety of different devices can be made from the polycarbodiimide polymers as described above, as further discussed below.
FIG. 1 is a schematic diagram of a first apparatus of the present invention. In general the device comprises a substrate 11 having the polycarbodiimide polymer 12 deposited thereon and an optional cover or protecting portion 13 . A pair of electrodes 14 , 15 are provided, through which an electric field may be applied to the polymer.
FIG. 2 is a schematic diagram of a second apparatus of the present invention. Again the device comprises a substrate 21 having the polycarbodiimide polymer 22 deposited thereon and an optional cover or protecting portion 23 . A pair of electrodes 24 , 25 are provided, through which an electric field may be applied to the polymer. In contrast to the device of FIG. 1 , the electrodes are in this device in physical contact with the polymer and positioned on opposite sides of the polymer.
FIG. 3 is a schematic diagram of a third apparatus of the present invention, in this case a storage device. The device comprises a substrate 31 having the polycarbodiimide polymer 32 deposited thereon and a pair of electrodes 34 , 35 positioned below the polymer. To detect a change in optical orientation, as in a memory device, a light source 37 and a light detector 38 are provided, here with the detector positioned for detecting reflected light. Any suitable configuration is possible and in one alternative, where the substrate is optically transparent, the light source could be positioned on the other side of the substrate opposite the detector.
In FIGS. 1-3 the electrodes are positioned on both sides of the polymer, but alternatively the electrodes could be positioned on opposite sides of the polymer. FIG. 4 is a schematic diagram of a fourth apparatus of the present invention, a microactuator, comprised of a substrate 41 , a polycarbodiimide polymer 42 , and an actuator 43 . A pair of electrodes 44 , 45 are again provided. The actuator is connected to the polycarbodiimide polymer so that, when the substrate is held in a substantially fixed position and the orientation of the polymer is switched, the actuator is moved relative to the substrate by the change in orientation of the polymer.
While the devices of FIGS. 1-4 have been shown with pairs of electrodes above, it will be appreciated that numerous different configurations are possible. Indeed electrodes are optional as the electric field may be applied as an electrostatic field or by far removed electrodes, or the optical orientation may be switched by alternate means such as a change in solvent or change in temperature. With electrodes, where the device is a storage device containing polymer deposited at multiple separate and discrete locations, each location could be provided with one or more unique electrodes and multiple locations could share a common electrode. A single electrode can be applied in conjunction with a semiconductor substrate. The electrodes can themselves be comprised of conductive or semiconductive materials, including metals and conducting polymers, and can be formed by any suitable technique including lithography, vapor deposition, microstamping, etc. In some embodiments the electrodes can be optically transparent. Likewise the polycarbodiimide polymer can be deposited on the substrate per se, solubilized in a solvent such as described above, and/or as a mixture with other ingredients (such as liquid crystal display constituent ingredients) by any suitable technique, including but not limited to microstamping, doctor blading, dip coating, spin coating, free meniscus coating, etc., or by pre-forming the polymer into a sheet, pattern, or any other suitable form and subsequenting adhering, contacting or securing the polymer to the substrate.
The substrate of FIGS. 1-4 may comprise, consist of or consist essentially of an organic or inorganic substrate or composites thereof, can in some embodiments be a microelectronic substrate, a semiconductor, or an insulator, and can in some embodiments be optically transparent (that is, at least partially transmit at least one wavelength of light; such optically transparent substrates can therefore be visually transparent, visually opaque, or intermediate therebetween, e.g., a “tinted” appearance on visual inspection). Protecting covers or portions 13 , 23 and actuator 43 may be formed from the same materials.
A further aspect of the invention is a method of switching the optical orientation of a polymer from a first optical orientation to a second optical orientation, comprising: (a) providing a polycarbodiimide polymer in a first optical orientation; and then (b) passing an electric field through said polycarbodiimide polymer to switch the polycarbodiimide polymer from the first optical orientation to the second optical orientation.
In some embodiments, the polycarbodiimide polymer switches (under the conditions of the particular electric field applied, removed, or otherwise changed) from said first optical orientation to said second optical orientation at a rate of, or within, at least 2, 1 or 0.1 seconds, or in some embodiments at a rate of or within 10 or 1 milliseconds, at room temperature (e.g., 25° C.).
The present invention is explained in greater detail in the following non-limiting Examples.
EXAMPLES
We pursued two approaches to prevent the d 0 Ti(IV) aggregation and increase its reactivity by introducing bulky and electron-withdrawing groups onto the 3,3′-positions of naphthalene rings, and tuning the bulkiness of alkoxy groups. Among the titanium complexes synthesized, [(R)-3,3′-dibromo-2,2′-binaphthoxy](di-tert-butoxy)titanium(IV), R-3 (Scheme 1), exists as a dimer in the solid state and a monomer in the solution state at room temperature. Catalyzed by R-3, helix-sense-selective polymerization of achiral carbodiimide of N-(1-anthryl)-N′-octadecylcarbodiimide (1) yielded poly-1b with high regioregularity, stereoselectivity and a relatively narrow molecular-weight distribution of 2.7. Although poly-1b possesses no chiral moieties in the polymer chains, this material exhibits thermo-driven and solvent-driven reversible chiroptical switching phenomena.
Scheme 1
R 1
Ligand
R 2
Catalyst
Existing form
—H
L1
i Pr
R-1
Aggragated
—H
L1
t Bu
R-2
Aggregated
—Br
L2
t Bu
R-3
Monomeric
—SiMe 3
L3
i Pr
R-4
Aggregated
—SiMe 3
L3
t Bu
R-5
Monomeric
—SiMe 2 Ph
L4
i Pr
R-6
Aggregated a
—SiMe 2 Ph
L4
t Bu
R-7
Monomeric
—SiMePh 2
L5
Et
R-8
Aggregated
—SiMePh 2
L5
i Pr
R-9
Monomeric
—SiPh 3
L6
Et
R-10
Monomeric
a Slightly aggregation indicated by the well-resolved methine
resonance and small featureless methyl resonance peaks
in 1 H NMR spectrum.
Results and Discussion. Chiral titanium complexes were synthesized from (R)-2,2′-binaphthoxy ligands (L1-L6) with an equivalent of the corresponding Ti(IV) alkoxide in toluene or benzene (Scheme 1). Complexation rates of these ligands are retarded from L1 to L6, probably due to steric effects. For example, reacting bulky bis(triphenylsilyl) substituted ligand, L6, with Ti(OEt) 4 in refluxing toluene for a day yielded a mixture of R-10 and the starting material L6, as evidenced by the remaining resonance peak at 4.64 ppm (—OH) in the 1 H NMR spectrum. In contrast, the reaction of the parent ligand, L1, with Ti(O-i-Pr) 4 or Ti—(O-t-Bu) 4 at room temperature was complete within 1 h. R-10 is monomeric, as evidenced by its light yellow color in solution and the single set of well-resolved quadruplet resonance peaks at 3.25 ppm (—OCH 2 CH 3 ) in the 1 H NMR spectrum. The less bulky bis(diphenylmethylsilyl) substituted ligand, L5, gave monomeric R-9 having bulkier isopropoxide groups, but aggregated, R-8, with the less bulky ethoxide groups, indicated by the featureless alkyl-H resonance peaks in the 1 H NMR spectrum and the red-orange color in solutions. This reveals that the bulkiness of R2 also plays an important role in determining the existing forms of the titanium complexes. Complexes R-4 and R-6 possessing the isopropoxide groups exist in aggregated forms in solution, but using the more bulky tert-butoxide groups leads to monomeric R-5 and R-7 with ligands L3 and L4. The light yellow color of R-3 solutions indicates that R-3 exists as a monomer. Parent ligand L1 produced aggregated R-1 and R-2 with red-orange colors. Preliminary polymerization experiments were carried out to test the activity of these monomeric titanium catalysts. The bromo substituted catalyst R-3 shows the highest polymerization activity as compared to other monomeric complexes. This rate enhancement can be explained by both steric effects and the electron-withdrawing character of the brominated binaphthol ligand. In the following study, we therefore focused on the new catalyst, R-3. The X-ray-quality single crystals were grown by extremely slow diffusion of a nonsolvent, acetonitrile, into methylene chloride solution of R-3. R-3 exists as a dimer with a crystallographic C 2 symmetry in solid, in which the naphthylate oxygens are bridging the titanium centers, and the t-BuO alkoxides are all terminal. The coordination environment about each titanium center is best described as a highly distorted trigonal bipyramid, with a bridging naphtholate (i.e., O1a) ligand and one t-BuO (i.e., O4) ligand occupying the axial positions with respect to titanium, and one t-BuO (i.e., O3), a terminal naphtholate (i.e., O2) and a bridging naphtholate (i.e., O1) ligand occupying the remaining equatorial sites. This structure is quite similar to the dimer of R-11 [(R)-3,3′-dimethyl-2,2′-binaphthoxy](diisopropoxy)titanium(IV)] (Scheme 1) (Boyle, T. J. et al. Organometallics 1992, 11, 1112). As listed in Table 1, Ti—O-t-Bu distances are nearly 0.1 Å shorter than Ti—ONp distances, revealing that the bonds between Ti—O-t-Bu are stronger due to the greater electron rich character of the oxygen of the —O-t-Bu group. Meanwhile, compared to the dimer of R-11, three significant differences are found: (1) The two —O-t-Bu groups in R-3 are in different environments; one is confined, but another has two orientations. (2) The dimer of R-3 displays an exact crystallographic C 2 symmetry, whereas the dimer of R-11 has a slight puckering of 1,3-dioxadititanacycle and shows virtual C 2 symmetry. (3) All the Ti—O distances in R-3 are longer (0.01-0.05 Å) than those in R-11 (Table 1), revealing that R-3 occupies a larger space due to the overall more crowded environment in R-3.
FIG. 5 shows the variable-temperature 1 H NMR spectra in the aromatic regions of R-3 in CD 2 Cl 2 . When the temperature was lowered, the well-resolved resonance peaks observed at −40° C. were broadened at −50° C., and new resonance peaks appeared below −60° C. These results are interpreted as R-3 existing as a monomer above −50° C. but a monomer and dimer mixture below −60° C. This equilibrium is also supported by the single methyl resonance peak at 1.02 ppm above −50° C. and a split peak below −60° C. This NMR study strongly supports the previous conclusion of the monomeric nature of R-3 that was based on the observation of the light yellow color of R-3 in solution. We previously reported that R-1 and S-1 catalysts will polymerize achiral, but non-symmetrically substituted carbodiimides (e.g., N-(1-isopropyl-6-methylphenyl)-N′-methylcarbodiimide (2)) to yield helix-sense-selective polymers that do not fully racemize through helix inversions upon annealing (Tian, G. et al. J. Am. Chem. Soc. 2004, 126, 4082). We attribute this unusual behavior to a second level of embedded chirality that results from the stereoselective orientation of both the aromatic substituents and the imine groups ( FIG. 6 ). Full racemization of these stereoregular structures requires not only helix reversals but rotations around the N-aryl bonds and/or inversion of the imine nitrogens. Because of steric interactions between neighboring groups, these normally low energy processes are strongly inhibited.
Catalyzed by R-3, helical poly-1b was obtained by polymerization of 1 in toluene at room temperature (Scheme 2). Both poly-1a and poly-1b show high solubility in toluene, chloroform, and tetrahydrofuran (THF). As shown in FIG. 7 , compared to poly-1a (M w =234 000, PDI=19.3), poly-1b (M w =16 000) has much narrower polymer dispersion index, PDI=2.7, indicating that the single site catalyst R-3 offers superior control over the polymerization. Furthermore, contrary to the regioirregular polymer structure of poly-1a, poly-1b has a well-defined regioregular backbone as evidenced by the single C═N stretching at 1642 cm −1 in FT-IR spectrum
The C 2 symmetric titanium catalyst possesses two different Ti—O bonds of Ti—OR 2 (a) and Ti—ONp (b). Based on the previously proposed mechanism (Shibayama, K. et al. Macromolecules 1997, 30, 3159), bond a or b selectively inserts into a carbodiimide and R 2 O— or NpO— becomes the end group of the polymer chain. In this competition, the nucleophilicity of —OR 2 is greater than —ONp due to its greater electron-rich character of its oxygen. Once completed, the polymerization is quenched and the titanium alkoxide endgroup is protonolysis removed from the amidinate chain end using methanol. This mechanism predicts that the achiral R 2 O— not the chiral NpO is the end groups in the helical polyguanidines. To confirm this, we carried out the polymerization of N,N′-dihexylcarbodiimide (3) catalyzed by R-1 (the molar ratio of [3]/[R-1] is 5), and found that Ar—H resonance peaks completely (i.e., the residual chiral catalyst) disappeared after the purification by reprecipitation of the polymer solution in THF or chloroform into methanol. It demonstrates that no chiral binaphthyl groups remain in the resulting polyguanidines.
FIG. 8 shows the optical rotations, [α] 80 D , of poly-1a and poly-1b in toluene at 80° C. versus annealing time. Compared to poly-1a, the initial [α] 80 D , −560°, of poly-1b is much greater in intensity indicative of greater diastereoselectivity but opposite in sign. The racemization rate (t 1/2 ) for poly-1b is 27 h, 6 times longer than that of poly-1a. It is worth pointing out the racemization rate of poly-1b is the slowest of all the polyguanidines measured to date. This experiment, however, leads to a puzzle. Why is it that poly-1b and poly-1a show optical rotations of opposite sign in toluene at +80° C.? To explore this, we measured the optical rotations of poly-1b at different temperatures. The first observation is that these polymers show a drastic temperature dependence in their optical rotations both in terms of magnitude and sign. As shown in FIG. 9 , [α] D of poly-1b converts its sign from positive (e.g., [α] 31 D )=+300°) at lower temperature to negative ones (e.g., [α] 44 D )=−205°) at higher temperature. The chiroptical switching temperature is 38.5° C. As reported previously, [α] 20 D of poly-1b in toluene is +130°. Both positively signed optical rotations of poly-1a and poly-1b at lower temperatures indicate that the same M-conformations of R-1 and R-3 give the same preferred screw-sense polymers at the polymerization conditions.
To further understand the chiroptical switching phenomenon, variable temperature CD and UV-visible spectra were recorded ( FIG. 10 ). At 25° C., poly-1b shows a positively signed Cotton effect with the maximum Δε=+4.69 M −1 cm −1 at 380 nm, corresponding to the UV-visible absorption maximum at 384 nm. The Kuhn's dissymmetry ratio, g abs (=Δε/ε), is +8.2×10 −4 , comparable to that (+14.2×10 −4 ) of the stable helical {poly′N-(1-anthryl)-N′-[(R)-3,7-dimethyloctyl]guanidine}(poly-4R, Scheme 2). When poly-1b was heated in a toluene solution, it showed a weak Cotton effect at 40° C., but gave an almost mirror-image Cotton effect at higher temperature with that at room temperature; and the UV-visible absorption decreased slightly. For example, at 80° C., poly-1b gave a negatively signed Cotton effect with maximum Δε=−4.69 M −1 cm −1 at 372 nm, corresponding to the maximum UV-visible absorption at 382 nm. g abs , is −12.7×10 −4 , comparable to that (−11.0×10 −4 ) of the stable helical poly{N-(1-anthryl)-N′-[(S)-3,7-dimethyloctyl]guanidine}. (poly-4S, Scheme 2) in toluene at 80° C. The most interesting observation is that when this toluene solution was cooled to 25° C., once again poly-1b gave a positively signed Cotton effect albeit with lower intensity compared to the original one at 25° C. This reveals that the chiroptical properties of helical poly-1b can be reversible switched around 40° C. without racemizing the polymer. The decrease in the intensity is due to slow racemization during the entire thermal process.
Keeping in mind the fact of slow racemization in toluene at 80° C., we further performed the heating-cooling cycles of poly-1b in toluene in the temperature range of 25° C. and 60° C. As expected, no significant racemization was observed. Poly-1b shows absolutely reversible chiroptical switching in the four thermal cycles as we conducted. FIG. 11 displays the CD and UV-visible spectra of poly-1b in toluene in the first two heating-cooling cycles.
FIG. 12 shows the variable temperature CD and UV-visible spectra of poly-1b in chloroform. When the temperature was raised from 25° C. to 60° C., slight decrease in the UV-visible absorption was observed. However, the g abs -values remained constant. FIG. 13 shows the variable temperature CD spectra of poly-1b in tetrahydrofuran (THF). Slight increase in the absolute g abs -values was observed.
Interestingly, poly-1b shows negative Cotton effects in chloroform and THF at all temperatures. These CD spectra resemble that of poly-1b in toluene at 60° C., but are of opposite in sign, compared to that of poly-1b in toluene at 25° C. This indicates the solvent-driven chiroptical switching. FIG. 14 , which shows the solvent-composition dependence of the g abs -values of poly-1b, clearly demonstrates the chiroptical inversion driven by the change in solvent composition between toluene and THF. The chiroptical inversion occurs around 10% content of THF.
Without wishing to be bound to any particular theory of the present invention, FIG. 15 shows the possible molecular motions leading to the full racemization of poly-1b. They are the N—C bond rotations (φ) in the backbone, N—C AR bond rotations (θ) in the side chains, and the imine configuration interconversions (ω). φ is related to the torsion angle of the main chains, which determines the helical screw sense and the helical pitches. The helical inversion barrier of poly-1b is unknown, though we attempted to calculate it theoretically using polymer-consistent-force-field (pcff). The barrier for a structural analogue of polyguanidines, polyisocyanates, was estimated as 12.5 kcal/mol by an empirical force field (Lifson, S. et al. Macromolecules 1992, 25, 4142). Considering the stiffer backbone of the polyguanidine, it is reasonable to assume that the helical inversion barrier of poly-1b is greater than 12.5 kcal/mol. Pcff calculations reveal a limited rotation between N—C Ar (0<θ<90°) because of the great bulkiness of anthracene groups, indicating that the energy for the free rotations are extremely high but a low energy for the limited reorientation (wagging) of the anthracence rings. The barrier of imine configuration interconversions in small molecules is in the range of 20-26 kcal/mol (coalescence temperatures in the range of 50-180° C.) (Jennings, W. B.; Boyd, D. R. J. Am. Chem. Soc. 1972, 94, 7187). Thus, the energy barrier in poly-1b is probably in the sequence of ΔE(ω)>ΔE(φ)>ΔE(θ). The full racemization of poly-1b occurring at +80° C. takes more than 100 h, and probably results from contributions by all three of these processes. Three mechanisms are possible to explain this interesting chiroptical switching phenomenon: helix inversions, imine inversions and/or rotations around the N-anthracene bonds. Of the three, partial rotations (wagging) around the N-anthracene bonds are the lowest energy process. Compared to the time-consuming (100 h) and energy-demanding (+80° C.) full racemization process, the reversible chiroptical inversion occurs quickly (less than 1 min) by thermo-driven at the lower temperature of +38.5° C. in toluene and by changes in solvent polarity, implying that the imine configuration inversion and the helix inversion in poly-1a are not involved in this reversible chiroptical switching process. The blue-red shift in UV-visible and CD absorptions above and below the chiroptical switching temperature, however, suggest that the directions of the anthracence rings cooperatively switch relative to the helix director (i.e., wagging in θ around the N—C Ar bond). The helical pitches in these various states may also vary in this process. Hence, although small contributions from helical reversals and imine inversions cannot be ruled out, we believe that changes in the helical pitches and the directions of the transition dipole moments of anthracence may lead to this chiroptical switching phenomenon (Tinoco, I. J. Chim. Phys. 1968, 65, 91). The clear reversible switching mechanisms are under study.
Concluding Remarks We have synthesized a series of chiral binaphthyl titanium complexes for use in helix-sense-selective polymerizations. Among them, chiral titanium complex R-3 exists as a crystallographic C 2 dimer in solid but a monomer in solution at room temperature. Application of R-3 in the helix-sense-selective polymerization of achiral carbodiimide 1 yielded a well-defined regioregular, stereoregular poly-1b with a relatively narrow PDI of 2.7. Poly-1b was found to undergo dramatic reversible chiroptical switching that is extremely sensitive and can be driven by heat and solvent polarity. Chiroptical switching occurs at 38.5° C. in toluene and around 10% THF content in mixed THF/toluene at 25° C. This is the first example of chiroptical switching occurring in a helical polymer possessing no chiral moieties in the polymer chains, and may prove useful in lowcost optical memory and switching applications. The reversible chiroptical switching occurs at substantially lower energy than racemization (>100 h, +80° C.).
Experimental Section
General considerations. The 1 H and 13 C NMR spectra were recorded on a Mercury 300 or 400 spectrometers (300 or 400 MHz for 1 H, 75.0 or 100 MHz for 13 C). Chemical shifts are reported in δ (ppm) relative to tetramethylsilane as internal standard. Infrared spectra were acquired on a JASCO FT/IR-410 or a Mattson Genesis II FT/IR spectrometer. Wavenumbers in cm −1 are reported for characteristic peaks. Relative molecular weights and molecular weight distributions were determined with polystyrene standards by gel permeation chromatography (GPC) at room temperature using chloroform as solvent (1.0 ml/min), two MIXED-C columns (300×7.5 mm, Polymer Laboratories), and a JASCO differential refractometer RI-1530. UV-visible/CD spectra were recorded on a JASCO J-600 spectropolarimeter. A NESLAB RTE-210 circulating water bath was used to vary the temperatures of the samples. The path length of cell is 10 mm. UV-visible spectra were recorded on a JASCO V-550 spectrophotometer. Optical rotations were recorded on a JASCO P-1010 polarimeter. A NESLAB RTE-140 circulating water bath was used to vary the temperatures of the samples. Sample concentration is 1 g/L (c=0.1 g/100 ml). The path length of cell is 50 mm. Molecular mechanics calculations were performed using the Molecular Simulation Inc., Discover 3 module, Ver. 4.00, on Silicon Graphics Indigo II XZ using the MSI pcff force field. For this calculation, the MSI built-in functions of simple-minimization were used with setup parameters which included 1.00 for the final convergency.
All manipulations involving titanium complexes were carried out in an MBraun UNILab drybox under a nitrogen atmosphere. Ti(OEt) 4 , Ti(O-i-Pr) 4 , and Ti(O-t-Bu) 4 were distilled under vacuum, and stored in a dry box. Anhydrous solvents were passed through columns packed with Q5 catalysts and molecular sieves prior to use. Benzene-d6 and methylene chloride-d 2 were dried over CaH 2 , vacuum-transferred, degassed by repeated freeze-pump-thaw cycles, and stored over 4 Å molecular sieves. A.C.S. spectrophotometric grade solvents (Aldrich) were used for optical measurements.
Ligands L2-L6 were synthesized according to literatures (Tsang, W. C. P. et al. Organometallics 2001, 20, 5658; Maruoka, K. et al. Bull. Chem. Soc. Jpn. 1988, 61, 2975; Ooi, T. et al. J. Am. Chem. Soc. 2003, 125, 5139; van der Linden, A. et al. J. Am. Chem. Soc. 1995, 117, 3008). A typical experimental procedure for synthesizing titanium complexes is described for the reaction of L2 with Ti(O-t-Bu) 4 . Addition of Ti(O-t-Bu) 4 (1.7333 g, 5.09 mmol) to the stirred solution of L2 (2.2620 g, 5.09 mmol) in toluene (10 ml) gave a light yellow transparent solution. After it was stirred for 6 h at room temperature in a dry box, the solution was transferred to a Schlenk flask. Toluene and the resulting t-BuOH were removed off completely in vacuo at 50° C. overnight. Pure R-3 was obtained by recrystallization from pentane at −35° C. 13 C NMR (100 MHz, C6D6, 25° C.) d 158.92, 133.79, 132.76, 131.35, 127.85, 126.15, 124.82, 121.01, 118.80, 88.60, 32.13, 26.71.
The syntheses of carbodiimides and polyguanidines were described previously (Tang, H.-Z. et al. J. Am. Chem. Soc. 2004, 126, 3722; Tian, G. et al. J. Am. Chem. Soc. 2004, 126, 4082) poly-1b: 1 H NMR (400 MHz, CDCl 3 ) δ 7.77 (br), 7.68 (br), 7.13 (br), 6.81 (br), 6.69 (br), 6.37 (br), 5.66 (br), 3.89 (br), 2.32 (br), 1.60 (br), 1.30 (br), 1.10 (br), 0.90 (br), 0.29 (br), −0.21 (br), −0.71 (br), −1.31 (br). 13 C NMR (100 MHz, CDCl3) δ 148.5, 142.1, 131.7 (overlapped), 131.0 (overlapped), 128.4 (overlapped), 127.8 (overlapped), 125.0 (overlapped), 124.5 (overlapped), 121.7 (overlapped), 113.6 (overlapped), 48.3, 31.9, 29.8 (overlapped), 29.4 (overlapped), 2705 (overlapped), 22.7, 14.1. IR: 1642 (s, guanidine stretching). Elemental analysis: C, 84.05; H, 9.88; N, 5.90 (theory, C 33 H 46 N 2 . 1/20C 4 H 10 O, assuming the end groups are t-Bu- and H—); C, 83.58; H, 10.06; N, 5.90 (found).
The foregoing is illustrative of the present invention, and is not to be construed as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein.
|
A polycarbodiimide polymer that is reversibly switchable between two distinct optical orientations is described. The polymer is useful in forming devices such as filters, storage media, actuators, and displays. Methods of making and using such polymers are also described.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The application is a continuation-in-part of U.S. application Ser. No. 10/915,129 filed on Aug. 10, 2004, which claims the benefit of U.S. Provisional Application No. 60/494,420 filed on Aug. 11, 2003, which is incorporated herein by reference
BACKGROUND
[0002] For many years, it has been demonstrated that tobacco use is harmful, whether from cigarette or cigar smoking or tobacco chewing. Cured tobacco is known to contain a number of nitrosamines, including the harmful carcinogens N′-nitrosonomicotine (NNN) and 4-(N-nitrosomethylamino)-1-(3-pyridyl)-1-butanone (NNK). Cigarette smoke is known to cause lung and other cancers as well as have other deleterious effects on the body, e.g., skin, teeth, etc. In addition, chewing tobacco is known to cause lip, mouth, and throat cancers, among others. Despite this knowledge, individuals continue to use tobacco products and many become addicted to these products. Accordingly, there have been many attempts at products and methods to assist cigarette smokers and other tobacco users to quit tobacco use.
[0003] Certain substitute products incorporate some amount of tobacco along with other ingredients, essentially cutting the amount of harmful tobacco in each dose. Other chewing tobacco substitutes are in the form of leafy materials that emulate the feel of tobacco; however, these products do not contain nicotine or any similar chemical. As a result, these substitutes do not have any mechanism for breaking the chemical addiction.
[0004] In contrast, current nicotine-containing replacement products are generally aimed at cigarette users. These products are only in gum, lozenge, or tablet form and deliver nicotine through oral ingestion. The gum is a mixture of nicotine polacrilex, gum, flavorants, and aspartame. The lozenge is configured with similar ingredients to those of the gum, but in lozenge form. The tablets are compressed tobacco, with other natural ingredients. The tablets are to be chewed and swallowed, thereby giving the user the desired nicotine.
[0005] There is a need for a tobacco-free chewing tobacco substitute that is used and feels like chewing tobacco products and contains some amount of nicotine.
BRIEF DESCRIPTION OF THE INVENTION
[0006] The invention is a chewing tobacco substitute made from natural leaves and additives which simulate the taste and consistency of chewing tobacco to which nicotine polacrilex or cotinine is added. The invention allows those addicted to chewing tobacco to chew and receive nicotine without incurring the other harmful side effects of tobacco. In one embodiment of the invention the product is provided with varying levels of nicotine
DETAILED DESCRIPTION OF THE INVENTION
[0007] The tobacco-free blends of the present invention combine a leaf-like ingredient, such as tea, peppermint, cabbage, and other plant leaves, with a moisturizer, an alkaline chemical to adjust the ph balance of the blend, and a type of nicotine that can be absorbed through the mouth. Additional additives may also be used, such as natural and artificial flavorants to create flavors and smells that emulate moist tobacco products. The blend may have the same taste as chewing tobacco, or may have some other pleasing taste such as peppermint or orange.
[0008] The leaf-like material is used to provide a product that has the same look and feel as tobacco. This is an important aspect of the invention since addiction to chewing tobacco is both a physiological addiction to nicotine, as well as a psychological addiction to the act of chewing the chewing tobacco. The invention satisfies this psychological addiction by providing a product that looks and feels and can be chewed and expectorated in the same way as chewing tobacco. In one preferred embodiment, the flavor and smell of tobacco are also simulated thereby further meeting the psychological needs of the user. While the inventor has found one effective leaf (or combination of leaves) to be tea leaves with mint leaves (such as spearmint or peppermint), all of the following natural materials could potentially be used:
bak choy cabbage leave chrysanthemum leaves collard leaves maple leaves mint leaves nasturtium leaves Oriental greens petunia leaves pansy leaves salvia leaves spearmint leaves spinach leaves sugar cane tannecetum leaves viola leaves
Any other type of material, whether natural or man-made could be that provides a feel similar to tobacco. While herbal leaves are readily used with the invention other parts of plants such as roots, stems and cane may also be used, when properly shredded and processed, in place of or in combination with such leaves. These leaf-like materials may be used separately or in combinations.
[0009] Some type of alkaline chemical is also added to the mixture so that the mixture has a ph level between 5.0 and 7.0, and preferably between 6.0 and 6.5. Nicotine is best absorbed in the mouth at ph level between 6.0 and 6.5. The leaf-like ingredients above typically are acidic and have a ph level below 6.0 and some cases below 5.0. Therefore, the alkaline (i.e. base) chemical is added to enhance the absorption of nicotine through the mouth. Preferable, the alkaline chemical should be non-toxic. Calcium carbonate, sodium bicarbonate, sodium carbonate, ammonium bicarbonate, potassium citrate, sodium citrate and citric acid are satisfactory alkaline chemicals. Other alkaline chemicals that are safe for human ingestion may also be used.
[0010] Importantly, a nicotine compound capable of being absorbed through the mouth is also added to the mixture. Nicotine is best absorbed in the mouth through in the area between the gum and cheek. Nicotine polacrilex is used as a nicotine additive in the current invention. Any other type of nicotine additive capable of being absorbed through the mouth, whether now known or hereinafter invented, may also be used and is considered to be within the scope of the invention. This blending of nicotine allows users to continue enjoying the gratifying effects of nicotine, while avoiding the dangerous aspects of tobacco-based products, such as the known carcinogens. The present invention can incorporate any nicotine derivative, analog, or variant that is safe for oral contact and has a similar mechanism of action to naturally occurring nicotine found in tobacco products.
[0011] The present invention may be distributed as a line of nicotine-reduced products, including, a line of products beginning with levels similar to that of chewing tobacco and stepping the user down through versions with gradually reduced nicotine content. The controlled amounts of nicotine also enable tobacco users to wean themselves off of tobacco and nicotine products altogether. In other words, the blends of the present invention can be used as a tobacco-free alternative to moist tobacco or as a mechanism for gradually ceasing use of tobacco and nicotine products, i.e., stepping down the levels of nicotine.
[0012] Preferably, a moisturizer is added to the leaf-like ingredient to give it the same degree of moisturizer as chewing tobacco. A moisturizer is desirable since some of the leaf-like materials above are not intrinsically as moist as tobacco leaves, and further because the process of curing, drying, cutting and processing the leaves, as with tobacco, removes most of the moisture. As in the production of regular chewing tobacco, a moisturizer is added to the processed leave to give the product a moist and pleasing look and feel. Glycerin has been found to be useful as a moisturizer, although the invention is not intended to be limited to any particular type of moisturizer. Indeed any non-toxic moisturizer can be used.
[0013] Other common additives may be used in the mixture as well to enhance its flavor or smell or to act as a preservative. In one embodiment potassium sorbate is used as a preservative. Such additives are well known in the food and drug industry and will not be further described herein but are meant to be within the scope of the invention.
[0014] The compositions of the present invention are intended for the snuff and loose leaf tobacco user. The compositions are created to look, feel, and taste like tobacco-based products. The compositions are designed to be a moist loose leafed or finely cut leaf product that are placed between the gum and cheek allowing nicotine to be absorbed by the gum and cheek membranes. The moisture from the moist blend is typically expectorated. Preferably, there is no tobacco whatsoever contained in these compositions. However, in some embodiments, a small amount of tobacco may be included in order to enhance the tobacco flavor and feel of the product. In some embodiments of the invention the mixture may be contained in a pores pouch. As used herein “chewing tobacco substitute” is also meant to include snuff substitute and such pouches.
[0015] Unlike the nicotine replacement products currently available, the compositions of the present invention are substantially in the form of the tobacco products that they are replacing, i.e., loose, leafy form. This should ease the transition to these compositions as the activity of the user (i.e., “dipping” and expectorating) is nearly identical. In addition, nicotine is administered through the cheek and gum and not necessarily from ingestion or inhalation. This allows nicotine uptake without contact with the digestive system; this can prevent irritation or other possible harmful effects to the stomach or other organs. In addition, the compositions of the present invention can allow those with conditions affecting the digestive system who would not normally be able to ingest nicotine to use a nicotine-containing substitute.
[0016] In one embodiment the following amounts of chemicals are added per 34 grams of leaf (or other tobacco substitute) product:
(1) 0.1 to 1 g of nicotine polacrilex, or other forms of ingestible nicotine; (2) 0.1 to 1 g of sodium bicarbonate, sodium carbonate, calcium carbonate or ammonium bicarbonate; and (3) 0.5 to 2 grams of glycerin.
[0020] In one example for preparing the compositions, the herbaceous material first goes through a curing process, in which it is heated and dried. It is then hydrated in an aqueous solution containing water, natural and artificial flavorings, and potassium sorbate. After the hydration process, glycerin, sodium bicarbonate, sodium carbonate and/or ammonium carbonate, and nicotine polacrilex or other forms of ingestible nicotine are mixed with the product. The sodium bicarbonate/carbonate is added to create the proper pH levels for free nicotine release.
[0021] In another embodiment cotinine, is used as the nicotine replacement instead of nicotine polacrilex as described above. Cotinine is a chemical derivative of nicotine which results after the human body has broken down nicotine. It is also know in the art to produce cotinine in the laboratory. The following amounts of chemicals are added per 34 grams of leaf (or other tobacco substitute) product:
(1) 0.01 to 1 g of cotinine, or other forms of ingestible nicotine; (2) 0.1 to 1 g of sodium bicarbonate, sodium carbonate, calcium carbonate or ammonium bicarbonate; and (3) 0.5 to 2 grams of glycerin.
[0025] While illustrated and described above with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, the present invention is directed to a leafy tobacco substitute containing nicotine, and a method of making the substitute, and various modifications may be made in the details within the scope and range of equivalents of the description and without departing from the spirit of the invention.
|
The invention is a chewing tobacco substitute made from natural leaves and additives which simulate the taste and consistency of chewing tobacco to which a nicotine compound is added. The invention allows those addicted to chewing tobacco to chew and receive nicotine without incurring the other harmful side effects of tobacco. In one embodiment of the invention the product is provided with varying levels of nicotine.
| 0
|
FIELD OF THE INVENTION
The present invention relates generally to the field of illumination, and, more particularly, to a submersible color light. Although the present invention is subject to a wide range of applications, it is especially suited for use in a pool lighting system, and will be particularly described in that context.
BACKGROUND OF THE INVENTION
Pool lights illuminate the water at night for the safety of swimmers and for aesthetic purposes. The illumination emanates from underwater lights affixed to the wall of the pool. As used herein, a pool is used generically to refer to a container for holding water or other liquids. Examples of such containers are recreational swimming pools, spas, and aquariums.
To enhance the aesthetics, some current underwater pool lights use a transparent color filter or shade affixed to the front of the lens of the pool light to filter the light emanating from the lens of the pool light and thus add color to the pool. The color filters come in a variety of colors but only one of these color filters can be affixed to the pool light at a given time. Thus, the color of the pool stays at that particular color that the color filter passes. In order to change the color of the pool, the color filter must be removed from the pool light and a different color filter installed across the lens of the pool light.
As a alternative to these fixed colored filters, a system has been devised whereby a rotating wheel having filters of several colors is provided, such as the system disclosed in U.S. Pat. No. 6,002,216 and incorporated herein by reference. In this arrangement, white light is provided from a single source to at least one fiber optic lens through an optical fiber. Colored light is emitted from each fiber optic lens by passing white light through the color filter wheel which is selectively rotated by a motor in the illuminator. The color of light emitted by multiple illuminators is synchronized by independent circuitry within each illuminator that responds to digital signals in the form of manually interrupted supply current.
However, fiber optic underwater illumination systems have several limitations that lead to the need for the present invention. The first is that their performance is relative to the skill of the installer. Only a well-trained technician is capable of installing a fiber optic system that can adequately illuminate a swimming pool. The availability of qualified training is limited thus the availability of trained installers is limited. Rushed fiber termination or fiber termination performed by an untrained installer can result in more than a 30% decrease in fiber optic system performance and can ultimately result in a costly failure of the total fiber optic system.
The second disadvantage of underwater fiber optic illumination is the limited amount of light delivered to the pool. This results from the light attenuation over distance that is inherent in the fibers' composition and the inefficiencies of focusing available light into the optical fiber at the light source.
A further drawback of fiber optic underwater illumination is in the possibility of retrofitting the millions of existing pools having traditional submersible incandescent lighting fixtures. The feasibility of installing adequately sized fiber optic cable in the existing conduits is limited. These conduits are commonly ½ inch in diameter and are rarely over one inch in diameter. The minimum conduit diameter to carry a single fiber optic cable capable of delivering minimally acceptable light to a pool is one inch and the recommended size is 1½ inches.
An additional limitation of fiber optic systems is the additional cost of the materials and professional installation.
The alternative to colored fiber optic systems, providing colored lenses to submersible incandescent lighting fixtures, can be troublesome as well. These fixtures can be supplied with a colored glass lens to deliver that specific color to the pool. These colored glass lenses are typically limited to how richly they can color the light because the darker (or richer) the lens color, the more light in the form of heat that is trapped in the lens and the fixture. As the lens becomes too hot by absorbing too much light it can break due to thermal expansion or due to the differences in thermal expansion on the hot interior surface of the glass and the cool exterior surface that is in contact with the water. Further, as a result less light is emitted and it may be insufficient to illuminate the pool.
As an alternative to glass lenses, snap on or twist lock plastic colored lenses can be installed over an existing clear glass lens for a considerably simpler method to changing the color of the pool lighting. This method still requires physically lying or kneeling on the edge of the pool an reaching below the water to remove the existing plastic lens and then reaching again into the water to install the next colored plastic lens. Economical transparent colored plastics are also inefficient light transmitters reducing the amount of colored light reaching the pool.
A need therefore exists for pool lights that can easily replace existing self-contained, incandescent lighting fixtures, but having synchronized color wheels without the additional cost of installing fiber optic cables and other drawbacks associated with fiber optic underwater illumination systems. Further, a need exists for colored lenses to be used with incandescent fixtures that do not trap excessive amounts of light and heat.
SUMMARY OF THE INVENTION
The present invention, which tends to address these needs, resides in a pool lighting system. The pool lighting system described herein provides advantages over known pool lighting systems in that it is less difficult and less costly to install than existing pool lighting systems that can provide a variety of synchronized colors to the pool water and can be easily retrofitted to existing incandescent lighting systems.
According to the present invention, each lighting fixture of the pool lighting system comprises a color wheel and an incandescent lamp, wherein the lighting fixture places the color wheel at a predetermined position after a predetermined time subsequent to an alternating-current (AC) source of power being applied to the lighting fixture.
Further, according to the present invention, an underwater lighting fixture includes a lamp housing which is adapted to be installed in a lamp receiving recess in the wall of a swimming pool. The housing has an interior cavity, an open mouth defined by a rim, and a rear opening. A plate is mounted within the housing and is transverse to a longitudinal axis of the housing. The plate has a pair of diametrically opposed openings. A pair of incandescent lamps are positioned at each of the plate openings on one side of the plate and each lamp is provided with a reflector directed toward its plate opening. Secondary reflectors are positioned on the other side of the plate so that the reflectors have mouths at one end which are directed toward the plate openings. Each secondary reflector has a portal at its other end which is directed toward the mouth of the housing. A color wheel which is mounted for rotation in the housing about the longitudinal axis of the housing. The color wheel has a plurality of radial dichroic filter segments which are arranged so that identically colored segments are diametrically opposed on the wheel. The wheel is driven by a motor to sequentially position successive filter segments over each reflector portal. A transparent cover is sealed to the open mouth of the housing and an electrical supply conduit extends through a fluid seal in the rear housing opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a submersible lighting fixture mounted in a pool wall;
FIG. 2 is a cross-sectional view, the plane of the section being indicated by the line 2 — 2 in FIG. 1;
FIG. 2 a is a cross-sectional view, the plane of the section being indicated by the line 2 a — 2 a in FIG. 2;
FIG. 3 is a perspective view of a submersible lighting fixture shown with its transparent cover removed;
FIG. 4 is a fragmentary perspective view of the submersible lighting fixture shown with its transparent cover and color wheel removed;
FIG. 5 is a back plan view of the color wheel of the submersible lighting fixture;
FIG. 6 is a detail of the submersible lighting fixture illustrating the alignment of a sensor and a magnet disposed therein;
FIG. 6 a is a detail of the engagement between a worm gear and a ring gear in the present lighting fixture;
FIG. 6 b is a detail of the engagement between a conventional worm gear and a ring gear; and
FIG. 7 is an electrical schematic of a synchronizer circuit of the lighting fixture.
DETAILED DESCRIPTION OF THE INVENTION
As shown in the drawings, and with particular reference to FIGS. 1 and 2, the present invention is embodied in a submersible incandescent lighting fixture 10 comprising a housing 12 having an open mouth 15 and defining a cavity 15 a with a rear opening 15 b. A component tray 14 is mounted on the housing 12 . The lighting fixture 10 is adapted to be mounted in a recess 11 in a wall 13 of a pool. A power cord 16 extends from the housing 12 through the opening 15 b and is sealed by a grommet 15 c to provide power to the lighting fixture 10 .
Referring to FIG. 2, to provide light to a pool, the lighting fixture 10 further comprises two lamps 18 with integral dichroic-coated glass reflectors 19 having axial grooves 19 a therein and two secondary reflectors 20 mounted to a copper plate 22 , the plate 22 being mounted to the housing 12 and having a pair of diametrically opposed openings 22 a and 22 b. The secondary reflectors 20 extend through two circular passages 24 provided in the tray 14 . The secondary reflectors 20 are provided with circular portals 23 to allow the passage of light emanating from the lamps 18 . The portals 23 are relatively small in area compared to the openings 22 a and 22 b and bottom openings 20 a and 20 b in the secondary reflectors 20 are relatively large in area compared to the openings 22 a and 22 b.
The contact areas between the lamps 18 , a copper plate retainer 25 , the copper plate 22 , and the metal housing 12 allow heat generated by the lamps 18 to be efficiently transferred to the housing 12 and dissipated into the pool water. Thus, the lighting fixture operates at a cooler temperature and the life of its components, including the lamps 18 , is increased.
Referring to FIG. 4, the tray 14 is further provided with a center post 26 and a sensor guide 28 . Affixed to the tray 14 is a printed circuit board 30 , a driver mechanism 32 , and a sensor 34 extending from the circuit board 30 and disposed within the sensor guide 28 .
Referring now to FIGS. 3-6, a color wheel 36 is mounted on center post 26 . The color wheel 36 comprises a ring gear 38 , a magnet 40 , and three pairs of dichroic glass filters 42 , 44 and 46 , as best shown in FIG. 5 . The color wheel 36 is disposed in front of the lamps 18 so that light emitted by the lamps 18 when energized, passes through the color wheel 36 . Dichroic filters are used, as opposed to colored glass or other types of filters, because they allow the greatest amount of light to pass through, reducing the amount of light absorbed as heat and providing more intense colors. Except for the magnet 40 and filters 42 , 44 and 46 , all of the components of the color wheel 36 are made from a transparent, colorless material so as not to interfere with the emission of light from the lighting fixture 10 .
The driver mechanism 32 is comprised of a stepper motor 48 and a worm gear 50 that rotate the color wheel 36 through a connection to the ring gear 38 , a best shown by FIG. 3 and FIG. 5 . Such a connection eliminates the need for a shaft connecting the color wheel 36 to the stepper motor 48 , as in U.S. Pat. No. 6,002,216. Such a shaft would require tedious realignment each time a burned-out lamp needed to be replaced. The use of the worm gear 50 and ring gear 38 allow the entire color wheel drive train to be contained in front of the lamps
Referring now to FIGS. 6 a and 6 b, a conventional worm gear 50 ′ and ring gear 38 ′ engagement is shown in FIG. 6 b. In this arrangement, it is necessary for the worm gear 50 ′ to be precisely aligned to a line 50 a ′ being parallel to a line 38 a ′ being tangent to the ring gear 38 ′ at the point of engagement. In this conventional design, if the worm 50 ′ is angularly misaligned, a tooth 50 b ′ of the worm gear 50 ′ may be unable to freely move within the space between teeth 38 b ′ of the ring gear 38 ′. The present invention, in order to solve this problem of gear binding, provides the worm gear 50 with a slightly undercut tooth 50 b, as shown in FIG. 6 a. As will be appreciated by one of skill in the art, this undercut tooth 50 b allows for a certain amount of angular misalignment, φ, between the longitudinal center-line 50 a of the worm gear 50 and a line 38 a being tangent to the ring gear 38 at the point of engagement, without any binding occurring.
Referring again to FIGS. 3-6, as the color wheel 36 is rotated, the pairs of filters 42 , 44 and 46 pass sequentially in front of the lamps 18 , filtering the light emanating from the lamps 18 . The filtered light is transmitted to the pool through a lens or transparent cover 60 mounted to the front of the housing.
The pairs of filters 42 , 44 and 46 allow the passage of a specific wavelength of light: green, blue and red/magenta, respectively. A pair of openings 51 are also provided on the color wheel 36 to allow for the passage of white light. When a combination of two adjacent filters of different colors, or a filter and an opening 51 , are simultaneously positioned over a single lamp 18 , the light emitted from the lighting fixture 10 has the appearance of being a mixture between the two colors being passed through, the particular hue being determined by the relative proportions of light passing through each filter or opening 51 . For example, the blue filter 44 and red/magenta filter 46 could be combined to produce light at nearly any hue of purple. The filters 42 , 44 and 46 are sequentially arranged in spectral order, with green 42 isolated from red/magenta 46 . Thus, rotation of the color wheel 36 gives the appearance of a subtle, nearly indistinguishable transition from one hue to the next.
It should be noted that the portals 23 provided between the lamps 18 and the color wheel 36 serve a variety of purposes. The portals 23 limit the light that is emitted to the area with the greatest flux density (the primary focus spot), minimizing the size of the dichroic filters 42 , 44 and 46 and the color wheel 36 and thus reducing the cost and overall size of the lighting fixture 10 . Additionally, it is necessary to mask the light emitted so that it does not pass through unintended adjacent filters. As will be appreciated by one of ordinary skill in the art, dichroic filters require light to strike them in a generally perpendicular fashion in order to produce predictable results. The farther in either direction from perpendicular that light strikes a dichroic filter, the greater the variance from the desired hue will the light be that passes through. Thus, the small size of the portals 23 is necessary to prevent scattered light from striking the dichroic filters at shallow angles and tainting the desired hue.
In the present embodiment the lamps 18 utilized are 75-watt, 12-volt lamps having integral reflectors. The lamps 18 are selected to have optimal characteristics, such that a sufficient amount of light can be generated but the lamps still have an acceptable life and efficiency. The filters 42 , 44 and 46 and the openings 51 are arranged with bilateral symmetry on the wheel 36 , such that the same filter/opening combination and proportion appears in front of each lamp 18 at any given moment.
To further enhance the efficiency of the lighting fixture 10 , the use of secondary reflectors 20 allows much of the light that does not directly pass from one of the lamps 18 through the corresponding portal 23 to be reflected back into the primary reflector 19 and finally out through the portal 23 . Thus, the secondary reflectors 20 take otherwise wasted light that is outside the primary focus spot and reflect it back to the primary reflectors 19 where it is then reflected forward to the useable primary focus spot.
Referring now to FIG. 6, the color wheel 36 is shown rotated such that the magnet 40 is aligned with the sensor 34 . This alignment provides a magnetic indexing point, such that the sensor 34 is responsive to the position of the color wheel 36 and provides a reference position pulse indicating the color wheel is at a predetermined position when the magnet 40 passes over the sensor 34 . The sensor 34 is a readily available magnetic field detector that generates a reference position pulse when in close proximity to the magnetic field generated by magnet 40 .
Referring again to FIG. 2, the lighting fixture 10 is provided with an integral transformer 52 that converts alternating current line voltage into power suitable for the circuit board 30 and the stepper motor 48 . The integral transformer 52 allows the lighting fixture 10 to easily replace existing 120 volt light fixtures with little effort and it avoids many of the problems associated with connecting a plurality of low voltage lighting devices to a single transformer, including the risk of overloading the transformer. Additionally, the integral transformer 52 allows the use of 12-volt lamps, since present technology limits viable, bright, compact, long-life lamps with integral reflectors to low voltage. A thermally conductive resin 54 secures the transformer 52 to the housing 12 and transfers thermal energy therebetween which is eventually dissipated by the housing 12 into the pool water.
The interior of the cavity 15 a is sealed from fluid by the lens or transparent cover 60 and a sealing grommet 62 . The grommet 62 is seated in a peripheral lip 64 of the housing 12 and is covered by a trim seal ring 66 . The seal ring 66 has a plurality of depending hooks 68 which are pivotally connected to the ring 66 and which receive an annular tensioning wire 70 . The wire is tensioned by a tensioning bolt (not shown) which, upon tightening, draws the hooks into contact with the lip 64 to compress the grommet 62 . The sealed housing 12 is retained in the recess 11 by a screw 72 located at the top of the housing 12 , as mounted in the recess 11 , and by a tab 74 located at the bottom of the housing 12 . The interior of the recess is flooded with water for cooling purposes by providing a plurality of openings 76 in the seal ring 66 . The colored or white light admitted through the color wheel is further dispersed by a lens texture 60 a molded into the cover 60 .
A synchronization circuit is-provided on the circuit board 30 . The circuit operates in a way that allows multiple light fixtures 10 to be synchronized without the need for additional wiring between units.
In the present invention, the synchronization circuit uses the 60 Hz alternating current supply voltage to generate a master pulse. Thus, the same master pulse is generated by every lighting fixture that is connected to the same power source. Accordingly, there are no slave units and no need for wiring from a master unit to slave unit in order to transmit the master reference signal to each slave unit.
The synchronization circuits are controlled by timed interruptions in the alternating current supply voltage. Each power interruption is used as a reference point by the synchronization circuits allowing all of the color wheels to be synchronized and the same accent color from each of the light fixtures to be provided to the pool water.
The synchronization circuit of each light fixture synchronizes the color wheel by controlling the driver mechanism to place the color wheel at a predetermined position subsequent to the alternating-current source of power being interrupted in a predetermined sequence. This assures that the color wheels are synchronized.
After a predetermined time, the synchronization circuits begin stepping the motors that rotate the color wheel. If the power to the light-fixtures is applied at the same instant, then each color wheel will begin stepping at the exact same time and the wheels will step at the same rate, being determined by the sine waves of the alternating—current source of power. Thus, the color wheels remain synchronized.
Referring to FIG. 7, which is an electrical scheme of the present embodiment of a synchronizer circuit 100 according to the present invention, the synchronizer circuit 100 includes a power supply circuit 120 , a filter 140 , a control circuit 160 , an index point sensing circuit 180 , and a low-impedance output driver circuit 200 .
A parts list for the synchronizer circuit 100 follows:
Reference
Part Value
Part Number
Manufacturer
C1
47 μF/35 V
ECE-B1VFS470
Panasonic
C2
100 μF/16 V
ECE-A1CFS101
Panasonic
C3
220 μF/10 V
ECE-A1AFS221
Panasonic
C4
1 nF
ECU-V1H102KBM
Panasonic
D1, D2, D5, D6
—
DL4002
Microsemi
D3
—
DL4148
Microsemi
D4
—
SMB5817MS
Microsemi
L1
330 μH
5800-331
J.W. Miller
R1
2.2 Ω
—
—
R2, R3, R7
68 kΩ
ERJ-6GEYJ683
Panasonic
R4
4.7 kΩ
ERJ-6GEYJ472
Panasonic
R5, R6
22 Ω
—
—
U1
—
LM2574N-005
Motorola
U2, U6
—
TPS2813D
Texas Instruments
U3
—
A3144LU
Allegro
U4
—
PIC12C508-04I/P
Microchip
U5
—
MC33164P-3
Motorola
The power supply circuit 120 receives the alternating current supply voltage from the integral transformer 52 and provides a regulated 5 volt output 122 . In this particular embodiment, power supply 120 comprises a bridge rectifier including diodes D 1 , D 2 , D 5 , and D 6 , capacitor C 1 , and resistor R 1 . The rectified signal is provided to a step-down voltage regulator 126 that, in conjunction with diode D 4 , inductor L 1 and capacitor C 2 , regulates the output voltage to 5 V and filters unwanted frequency components of the regulated 5 V output 122 . When the alternating current supply voltage is not applied to the transformer, the output 122 goes to 0 volts. An uninterrupted 5 volt output 128 is also provided which continues to supply power for approximately 4 seconds, depending upon the load, after the alternating current supply voltage is interrupted. This power is stored in capacitor C 3 and when the supply power is interrupted the capacitor C 3 provides a limited supply of current at the output 128 . Diode D 3 is provided to prevent capacitor D 3 from being discharged by the power supply circuit 120 .
The filter 140 prevents unwanted high-frequency components of the alternating current supply voltage applied to it from passing to the control circuit 160 . The filter 140 comprises resistor R 2 and capacitor C 4 in a low-pass filter configuration. In addition, resistors R 2 and R 3 arranged in a voltage divider configuration reduce the voltage of the alternating current supply voltage passed to the control circuit 160 .
The index point sensing circuit 180 comprises the magnetic sensor 34 and resistor R 7 . When the magnetic index point 40 on the color wheel 36 is aligned with the sensor 34 , the sensor 34 outputs a logical “0” to input GP 2 of the microcontroller 170 ; otherwise GP 2 remains at 5 V. or logical “1”. One of skill in the art will appreciate that resistor R 7 is required for the present application of sensor 34 because sensor 34 has an open collector output. To this end, the resistor would normally connect the open collector output of sensor 34 to a positive 5 V supply to pull the output up. However, to prevent the sensor 34 from drawing power from microcontroller 170 when the alternating current supply voltage is interrupted, node GP 1 on the microcontroller 170 is programmed to provide 5 V to the resistor R 7 only when supply voltage is present.
The control circuit 160 comprises a reset circuit 162 and a microcontroller 170 . Reset circuit 162 provides a reset signal on its output that assists in resetting the microcontroller 170 when the alternating current supply-voltage is initially applied to the light fixture 10 . Reset circuit 162 comprises undervoltage sensor U 5 and resistor R 4 .
The low-impedance output driver circuit 200 comprises two dual high-speed MOSFET drivers U 2 and U 6 . The outputs of U 2 and U 6 are coupled to two coils, A and B, of the stepper motor 48 and provide sufficient current, in response to outputs from the microcontroller 170 , for driving the motor 48 . Power is provided to U 2 and U 6 from the 5 volt output 122 .
Coupled to the reset circuit 162 , the filter 140 , and the driver circuit 200 is the microcontroller 170 . The microcontroller 170 receives the reset signal provided by the reset circuit 162 , the alternating current supply voltage filtered by the filter 140 , and an index signal from the index point sensing circuit 180 . In response to these inputs, the microcontroller 170 provides control signals at outputs GP 4 and GP 5 in the form of a grey code to driver circuit 200 . The alternating current provided by filter 140 provides an input signal 190 for the microcontroller 170 . The microcontroller 170 is preprogrammed to provide control signals according to the following scheme.
In the initial state of the synchronizer circuit 100 there is no alternating current applied from the transformer 52 and no current stored in capacitor C 3 . When power is applied, the microcontroller 170 is placed in “state 0” and no control signals are provided to the driver circuit 200 , and thus the color wheel 36 remains stationary. To control the input signal 190 , a user must interrupt power provided to the transformer 52 . However, power must be reapplied within 4 seconds or capacitor C 3 will completely discharge, bringing the 5 volt output 128 to 0 volts and causing the reset circuit 162 to return the microcontroller 170 to “state 0. ” From “state 0, ” when input signal 190 is sequentially interrupted and reengaged (within 4 seconds), the microcontroller 70 is advanced to “state 1.”
Once placed in “state 1” the microcontroller 70 generates cycling outputs at GP 4 and GP 5 causing the driver circuit 200 to step the stepper motor 48 very quickly (“fast stepping”) until the microcontroller 170 receives a logical “0” input from the sensing circuit 180 . This positive input is caused by the alignment of the index point 40 with the magnetic sensor 34 . Once they are aligned, the controller waits for a predetermined period of time, t, and then the microcontroller 170 advances to “state 2. ” This predetermined period of time, t, allows any other lighting fixtures that are being synchronized using the same power source to become aligned, so that all of the lighting fixtures. The predetermined time, t, is selected in this embodiment to be twenty-one seconds, the time required for a full revolution of the color wheel during fast stepping of the motor 48 , twenty seconds, plus an additional second to account for the possibility of error. This is the longest possible time it should take to return the color wheel to alignment of the index point 40 with the sensor 34 .
In “state 2” the microcontroller generates slowly cycling outputs at GP 4 and GP 5 causing the driver circuit 200 to step the stepper motor 48 slowly (slow stepping), resulting in the color wheel 38 to rotate its color filters 42 , 44 and 46 slowly past the lamps 18 , which will allow a user time to view each hue produced and make a selection. This slow stepping continues indefinitely until the input signal 190 is interrupted. From “state 2, ” when the input signal 190 is sequentially interrupted and reengaged (within 4 seconds), the microcontroller 170 returns to “state 0, ” and the color wheel 38 stops rotating. In this way, a user can choose a desired hue of light and cause the light fixture to halt.
The following table summarizes the control scheme described above:
State
Output
Wait for
and then
0
none (stopped)
“off” then “on”
go to “state 1”
1
fast stepping to
a predetermined
go to “state 2”
index point and then stop
period of time from
last “on”
2
slow stepping
“off” then “on”
go to “state 0”
As mentioned above, if at any time the power to transformer 52 is interrupted for longer than 4 seconds, the 5 volt output 128 will go to 0 volts and when reengaged, the microcontroller 170 will be reset to “state 0”. Thus, a user may select a position for the color wheels of one or more lighting fixtures that produces a desired hue of light and then turn off the lights at the source. When the source power is restored, the color wheels will remain stationary and the light will remain the chosen hue. Likewise, an unintentional interruption of source power, such as a power outage, will not cause the selected hue to change.
It should be appreciated that multiple light fixtures will step at precisely the same rate as long as they are connected to the same source of power. This is because the microcontroller 170 generates output signals at GP 4 and GP 5 that step a grey code to the driver circuit 200 once for every N sine wave transitions of the alternating current supply voltage. N is a number determined by the microcontroller 170 depending upon how quickly the stepper motor 48 must be advanced. For fast stepping N=1, which causes the color wheel 36 to make one full rotation every twenty seconds. For slow stepping N=6, causing the color wheel 36 to make one full rotation in 120 seconds.
Further, when synchronizing multiple light fixtures, one fixture may become misaligned with respect to the others if it its power is independently interrupted for some reason or if there is mechanical slippage. For this reason, a master reference pulse is generated by the microcontroller 170 by counting the number of alternating current transitions (120 transitions per second for a 60 Hz supply) after current is initially applied and generating a pulse every 120 seconds or 14,400 transitions, which is the normal (slow stepping) full rotation period. To correct the synchronization, the master reference pulse is compared to an index pulse received from the sensor 34 . The index pulse is generated every time the output of the sensor 34 is a logical “0”, indicating that the magnetic index point 40 is aligned with the sensor 34 .
If the master reference pulse is generated before the index pulse, then the microcontroller 170 determines that the color wheel 36 is lagging behind and the microcontroller 170 then begins to cause the motor to begin fast stepping until the index pulse is received from the sensor 34 . Since the fast stepping is 6 times faster than the slow stepping, the lag time will then be reduced by a factor of 6 for every complete rotation of the color wheel 36 .
If the index pulse is received before the master reference pulse is generated, then the microcontroller 170 determines that the color wheel 36 is ahead in its rotation and the microcontroller causes the color wheel 36 to stop rotating until the master reference pulse is generated. When the color wheel 36 resumes its rotation, it will be correctly aligned with the master reference pulse.
It should also be appreciated that, to conserve power, the sensor 34 and the driver circuit 200 are supplied power by 5 volt output 122 , instead of output 128 , so that when no power is being supplied by transformer 54 to power supply circuit 120 , the sensor 34 and the driver circuit 200 do not unnecessarily draw power from the capacitor C 3 and exhaust the limited supply of current from the capacitor C 3 too quickly.
|
An underwater lighting fixture adapted for installation in a lamp receiving recess in the wall of a swimming pool. The fixture includes a lamp housing having a pair of reflector-mounted incandescent lamps mounted therein. A plate having a pair of a apertures is mounted in the housing with the apertures mounted in alignment with the lamps. A pair of secondary reflectors are mounted to face the plate apertures and are provided with light-transmitting portals. A color wheel having dichroic filter segments is mounted so that identically colored pairs of segments pass the portals when the color wheel is driven by a motor. The motor is controlled by a circuit by disconnecting power to an input of the circuit, reconnecting power to the input to control the motor to move at a first speed. The control circuit stops the motor when the driven element reaches an index position. After the step of reconnecting power and after a predetermined period of time, the control circuit controls the motor to move the driven element at a second speed.
| 5
|
RELATED APPLICATIONS
[0001] The present application claims benefit to provisional U.S. Patent Application Serial No. 60/341,407 entitled “Electromechanical Locking Mechanism”, filed Dec. 14, 2001. The entire disclosure of this application No. 60/341,407 is incorporated by reference herein in its entirety for all purposes.
BACKGROUND
[0002] The present invention is intended as an improvement to pop out handle locks used typically in vending machines and utilized to lockingly engage the door to the main chamber of the machine.
[0003] In a typical application, a pop out handle system, the door contains a lock mechanism, which includes a pop out handle, actuated by an appropriate key which is exposed to the outer portion of the door. The interior portion of the lock mechanism includes a threaded stud, which extends toward the main chamber of the machine and is typically adapted to be screw threaded into a stud receiving fixture, securely mounted to the inside portion of the main chamber.
[0004] To unlock the pop out handle lock, and operator inserts the proper key into the lock placed inside the pop out handle, which actuates the handle to pop towards the user. The handle is then turned counterclockwise, which unscrews the lock stud from the internal locking fixture.
[0005] In order to lock the door to the main chamber, the operator reverses the procedure, such that the door is closed and the stud is oriented in linear alignment with the internal locking fixture (which usually contains a threaded nut), then the handle is rotated clockwise, resulting in engaging the stud into the locking fixture. When the thread is fully engaged, the operator depresses the handle into the recess provided by the machine and the depressed position is maintained by the engagement of a locking bolt.
[0006] The current design requires significant effort and time to be spent by the person who is filling the vending machine (routeman) when the door is being opened and closed. There is no record of who entered the machine and when the machine was entered. The machine is easily compromised by anyone who has duplicated a key, which is an easy task. If it has been determined that a key had been stolen, or duplicated, there is significant effort, time and expense involved in re-keying the lock.
SUMMARY OF THE INVENTION
[0007] The present invention is a motorized lock, mounted to the inside of a vending machine door or the cabinet. It is intended to decrease the amount of time required to lock the machine by providing a motorized draw-in feature which will pull the door tight and lock it. This draw-in feature is completely automatic. Further, the present invention allows for quick entry of the vending machine, which is actuated by the routeman showing an electronic key. The control electronics for the lock are capable of a large number of different keys being used to gain entry to the vending machine, and will remember an “audit trail”. The “audit trail” consists of the key that gained access, the date and the time of access. A significant history can be developed, limited only by the size of the memory chips in the controller.
[0008] According to the present invention, a gear motor is attached to a slotted link, which pulls a locking hook which hooks a u-bolt, or a headed bolt, which closes the vending machine door. The gear motor is under the control of a microprocessor based circuit which employs three switches for feedback.
[0009] The operation of the lock is as follows. For purposes of this description, the starting point will be with the locking hook and the door open with the routeman filling the machine. To begin the close cycle, the routeman swings the door such that it is in close proximity to the main chamber of the machine. This action closes a feedback switch, S 3 , which sends a signal to the control circuit which turns the motor on. S 3 is a plunger type switch, located in the main chamber of the machine such that the door plunges the switch when the door closes. The motor is connected to a multifunction cam wheel which, in turn, is connected to a slotted link, which, in turn, is connected to the spring loaded locking hook. The starting of the motor begins to rotate the locking hook. The locking hook “hooks” a u-bolt, or headed bolt, which is attached to the main chamber of the vending machine. The locking hook is shaped such that it draws the u-bolt in as it rotates, bringing the door closer to the main chamber. The locking hook is provided with six teeth which are engaged by a ratchet mechanism as the hook rotates. This continues until the door gasket between the door and the main chamber is compressed, and two additional feedback switches, S 1 and S 2 close. These switches close due to actuation by two cam surfaces on the multi function wheel. In this condition, the machine is completely sealed and locked. The ratchet mechanism is seated behind the last locking hook tooth, which is held solidly in place by a loaded extension spring between the locking hook and the main housing.
[0010] When the routeman wants to gain access to the inside of the machine, an electronic key is needed. Each electronic key is provided with a unique electronic serial number and a unique password. Each password is unique to each machine, so a plurality of passwords are stored in each key. The routeman places the electronic key on the key reader and it is read by the control circuit. The control circuit then decodes the key number, which is encrypted, and checks it against its internal database. If the key number is in the data base, the control circuit then electronically reads the password assigned to that machine. If the passwords match, the key is deemed valid. The password is then changed for the next access, and the new password is loaded into the key and is remembered in nonvolatile memory in the control circuit.
[0011] The motor is then turned on, which rotates the multifunction wheel. One of cams on the wheel engage a ratchet release lever, which pushes the ratchet off of the last tooth of the locking hook, causing the locking hook to pop open, as the loaded locking hook extension spring brings the locking hook open. This causes the vending machine door to open slightly. The wheel continues to rotate until feedback switch S 1 opens. In this position, the locking hook is completely free to rotate allowing the routeman to open the vending machine door fully. S 3 opens when the door opens and the motor again begins to rotate the multifunction wheel. The cam surface that was engaging the ratchet release lever travels past the lever, which releases the ratchet. Another cam surface on the multifunction wheel then pushes the ratchet down to engage the first tooth of the locking hook. The wheel continues to rotate until feedback switch S 2 opens. At this time, the ratchet is engaged into the locking hook, such that if the door was closed, the u-bolt, or headed bolt, would hit the locking hook. The link that connects the multifunction wheel to the locking hook is provided with a slot on the wheel end. This slot allows the locking hook to advance before the motor turns on. If the u-bolt, or headed bolt, hits the locking hook it will cause it to rotate slightly, advancing the ratchet to the second tooth. At that time, the follower attached to the wheel travels down the slot in the link. The harder the door was closed, the further the locking hook would rotate, advancing the ratchet further. This feature is very important, since it allows latching of the door without electricity. When the motor turns on (due to S 3 being plunged), the follower, attached to the multifunction wheel, first travels to the end of the slot on the link. The follower then pulls the link, which rotates the locking hook about the locking hook fulcrum to close and seal the door. If power was lost during a vending machine fill operation and the routeman slammed the door shut, the controller would, upon power up, see that S 3 was closed and S 1 and S 2 were both open. This condition would be a vending machine with the door closed and the multifunction wheel in a position where the locking hook was not fully drawn closed. As such, the controller would automatically turn on the motor to advance the wheel until S 1 and S 2 were closed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is an upper right perspective of the present invention.
[0013] [0013]FIG. 2 is the left-side view of the lock of FIG. 1.
[0014] [0014]FIG. 3 is similar to FIG. 2 except the left mounting plate has been removed. The locking hook is completely open and the ratchet is engaged.
[0015] [0015]FIG. 4 is similar to FIG. 3 except the u-bolt is pushing the locking hook closed, moving the ratchet.
[0016] [0016]FIG. 5 is similar to FIG. 3 except the locking hook is fully closed and the ratchet is engaged into the last tooth of the locking hook.
[0017] [0017]FIG. 6 is similar to FIG. 5 except the ratchet release lever is pushing the ratchet off of the last tooth.
[0018] [0018]FIG. 7 is a functional block diagram of the control system.
[0019] [0019]FIG. 8 is a timing diagram, illustrating the various operating modes of the system.
DETAILED DESCRIPTION
[0020] Turning first to FIG. 1, reference numeral 1 designates the gear motor, which includes a motor 3 and a gear box 2 . The gear motor is coupled, through a linkage mechanism, to drive locking hook 4 , which engages and pulls in u-bolt 35 .
[0021] This u-bolt 35 could be substituted for a headed bolt and the locking hook 4 could be substituted for a claw shaped device which would grab the headed bolt around the head and pull it in.
[0022] Turning now to FIG. 2, the left side view of the lock is illustrated. The output shaft 2 a of the gearbox 1 is coupled to multifunction wheel 25 with key 34 . The multifunction wheel 25 rotates, moving motor pull point 8 in a counterclockwise fashion (in this view). As the motor pull point moves, it pulls link 5 by cam follower 8 A sliding up slot 6 which is integral to link 5 . When the end of slot 6 is reached, link 5 begins to move in an upwardly fashion, rotating locking hook 4 about locking hook fulcrum 10 . The locking hook 4 is pulled at locking hook pull point 7 which travels in slot 9 . As the locking hook 4 rotates, it pulls u-bolt (or headed bolt) 35 towards the lock assembly.
[0023] The gear motor 1 is attached to mounting plate 11 by motor mount screws 13 A,B,C,D. Mounting plate 11 has a corresponding mounting plate (not shown) on the inside of locking hook 4 . The two mounting plates 11 are further held together by assembly screws 12 A,B,D,E.
[0024] Turning now to FIG. 3, the left side view is again illustrated, this time with mounting plate 11 removed. This figure illustrates the inner workings of the feedback switches and the multifunction wheel. The multifunction wheel 25 is composed of feedback switch cam surfaces 23 and 24 . Cam surfaces 23 A,B are integral to cam surface 23 , and cam surfaces 24 A,B are integral to cam surface 24 . As the wheel 25 rotates, it brings ascending cam surfaces 23 A and 24 A into contact with feedback switches 21 and 22 respectively. When this contact is made, the switches are electrically closed. As the wheel 25 continues to rotate, the risen sections of cam surfaces 23 and 24 keep feedback switches 21 and 22 closed until descending cam surfaces 23 B and 24 B release and therefore electrically open the feedback switches. The feedback switches 21 and 22 are provided with rollers to minimize wear.
[0025] As link 5 pulls on locking hook 4 , causing it to rotate, spring 14 begins to stretch and charge (increasing its potential energy). Locking hook spring 14 is mounted on one end to mounting plate 11 with screw 16 , and on the other end to locking hook 4 with screw 15 . This spring is used with the release operation described in FIG. 6.
[0026] Turning now to FIG. 4 the ratchet action is illustrated. As locking hook 4 rotates, it is engaged by ratchet assembly 37 at teeth 28 , 29 , 30 , 31 , 32 , 33 . These teeth are provided with a ratchet side 28 A, 29 A, 30 A, 31 A, 32 A and 33 A respectively and a locking side 28 B, 29 B, 30 B, 31 B, 32 B, and 33 B respectively. Ratchet assembly 37 is provided with a ratchet side 37 A and a lock side 37 B. The ratchet assembly 37 , rotates within ratchet guide 27 . Ratchet guide 27 is made up of two ratchet edges 27 A and 27 C and two lock edges 27 B and 27 D. Ratchet guide 27 is integral to both sides of mounting plate 11 .
[0027] Illustrated in FIG. 4 is tooth 28 ratcheting the ratchet 37 . The ratchet side of tooth 28 , 28 A, is contacting ratchet assembly 37 its the ratchet surface 37 A. This causes ratchet 37 to rotate freely within the ratchet guide 27 inside openings created by edges 27 A and 27 C. Ratchet 37 is biased in the clockwise direction within ratchet guide 27 by ratchet spring 18 . Ratchet spring 18 is mounted to mount plate 11 by screw assembly 17 and to the ratchet at screw assembly 19 . When the ratchet surface 37 A reaches the end of 28 A it is pulled by ratchet spring 18 to the side of tooth 28 's locking side 28 B. This occurs due to the end of surface 28 A and charged ratchet spring 18 , pulling ratchet edge 37 A into contact with tooth 29 's ratchet edge 29 A. This repeats until ratchet edge 37 B is seated behind tooth 33 B, as illustrated in FIG. 5.
[0028] Turning to FIG. 5 the fully locked state, described above, is illustrated. Once the locking hook's tooth surface 33 B is engaged by ratchet surface 37 B, it is not possible to open the locking hook, due primarily to the multifunction wheel 25 having surface 36 in contact with ratchet 37 (aside from the tooth engagement). This engagement also makes the assembly act like a deadbolt, that is, it is not able to open until the opening formed by cam profiles 36 A and 36 B in the multifunction wheel is in line with the ratchet.
[0029] Turning now to FIG. 6, the opening state is illustrated. As multifunction wheel 25 continues to rotate, an opening in cam surface 36 beginning with descending edge 36 A and ending with ascending edge 36 B allows the ratchet assembly's surface 37 B to be pushed off of the last tooth surface 33 B.
[0030] The multifunction wheel 25 is additionally provided with release lever cam surface 26 which incorporates ascending surface 26 A. As wheel 25 rotates, it brings ascending ratchet release cam surface 26 A into contact with ratchet release lever 20 at surface 20 A. When ratchet release cam surface 26 A hits ratchet release lever 20 it causes it to rotate clockwise about screw and bushing assembly 38 . As the release lever 20 rotates, integral surface 20 B pushes on ratchet assembly 37 at ratchet spring holder 19 causing it to move in the upward direction. It is now able to move in this direction because cam surface 36 is now past the descending surface 36 A which allows the ratchet assembly to move up. The ratchet assembly 37 moves up until the end of its ratchet surface 37 B is clear of the last locking tooth 33 B on the locking hook 4 . Now, the locking hook is released and it is able to rotate freely about locking hook fulcrum 10 , and charged spring 18 pulls it in the counterclockwise direction until the latch hook is fully open.
[0031] [0031]FIG. 7 illustrates the block diagram of the electrical system. The power supply 43 can be any conventional supply, for this embodiment it is a 120VAC/24VDC 2 amp supply. The supply 43 powers the microprocessor based control circuit 40 . The control circuit 40 reads the feedback switches 21 , 22 , 41 and the user credential input system 42 . The credential system can be any type of electronic access control credential including RF, IR, Magstripe cards, Smart cards, etc. but for this embodiment it is a Dallas semiconductor I-Button. These keys are provided with internal memory, capable of remembering each vending machine's encrypted password as well as an encrypted key number. As described earlier, the machine's password changes each time the key is used.
[0032] When the microprocessor based control circuit 40 reads an I-button through the user credential input system 42 it first decrypts the serial number of the key. The control circuit then checks the non-volatile memory to see if that key has access to the lock. If that key is in memory, it then reads and decrypts the password from the key. If the password matches the password stored in non volatile memory, corresponding to the key number, then the key is deemed valid.
[0033] A new password is generated, encrypted and stored in the key and in nonvolatile memory in the control board.
[0034] At this point, the optional solenoid driven latch 44 is opened. This latch is used in a different area of the door as the present invention to provide a more secure lock. The solenoid plunger is a simple bolt mounted inside a solenoid that engages a hole in the main chamber of the vending machine. The gear motor 3 is then energized to open the lock. Complete electrical details on a lock open and close cycle are described below under FIG. 8. Finally, the vending machine access is stored in nonvolatile memory. The entire history of accesses can be accessed through the user information output system 45 . This output system could employ another Dallas semiconductor I-button, a laptop computer, a palm pilot etc. This system has the ability to read the prior accesses along with the date and time.
[0035] Turning now to the timing diagram in FIG. 8. This diagram illustrates the states of the feedback switches 21 , 22 , 41 and the locking hook 4 with respect to the state of the system electronics and the vending machine.
[0036] Again, for purposes of this illustration, the starting point will be with the latch and the door open, with the routeman filling the machine, time event 50 . In this state, motor 3 is off, feedback switches 1 , 2 , and 3 ( 21 , 22 , 41 ) are open and the locking hook 4 has the ratchet 37 on tooth 1 ( 28 ). In this state the microprocessor is waiting for the vending machine door to be closed, which will close switch 3 ( 41 ). This event occurs at time 51 at event 56 . When the switch closes, the control circuit turns on the motor 3 , to advance the multifunction wheel 25 which moves link 5 , which rotates locking hook 4 as fully described above. The motor continues to run until the locking hook advances past teeth 2 , 3 , 4 , 5 , and 6 ( 28 , 29 , 30 , 31 , 32 , 33 )(events 57 A,B,C,D,E) and switches 1 ( 21 ) and 2 ( 22 ) close, events 58 A, 58 B, time 52 . In this state, the vending machine door is fully closed, the door is sealed shut, and the microprocessor is waiting for a user credential to be shown and validated, which occurs at time 53 . After the microprocessor validates the credential, the control circuit 40 again turns on the motor 3 . Very soon after the motor is turned on, the ratchet 37 is pulled off the locking hook 4 and the locking hook 4 is released at event 59 . The motor 3 remains energized until switch 1 ( 21 ) opens, event 60 , time 54 . In this state, the microprocessor is waiting for the vending machine door to be pulled open. The locking hook 4 is completely free, as the ratchet 37 is pulled completely out of the way of all of the hook's teeth ( 28 , 29 , 30 , 31 , 21 , 33 ). When the door is pulled open, switch 3 ( 41 ) is opened, event 61 , time 55 . At this time, the control circuit 40 turns on the motor 3 which causes surface 36 B to push the ratchet back down onto tooth 1 ( 28 ), event 62 . The motor 3 stays on until switch 2 ( 22 ) opens, event 63 , time 49 . This sequence then repeats itself.
|
A locking mechanism is provided. The locking mechanism includes a mounting plate that carries a locking hook. The locking hook is pivotal with respect to the mounting plate and may be pivoted from an unlocked position to a locked position. A motor is in communication with a locking hook, and is capable of causing the locking hook to be pivoted to the locked position. The locking mechanism may be opened by use of an electronic key, and may contain electronics capable of recording the date and time a particular key was used to open the locking mechanism. Also, the locking mechanism may be capable of being locked without the use of the motor when the motor is disabled due to power disruption or other circumstances.
| 4
|
BACKGROUND OF THE INVENTION
The digestion of titaniferous materials with sulfuric acid is one of the two processes to produce titanium pigment. The raw materials used in the sulfate process are essentially ilmenite ores and titaniferous slags produced by electric furnace smelting of ilmenite ores. Ilmenite ores are composed principally of iorn oxides (Fe++, Fe+++) and titanium oxide. Pure ilmenite can be represented by the formula FeTiO 3 . Of course, natural ores do not correspond exactly to this formula. The major sources of ilmenite ores are Allard Lake Ore, Australian beach sands and Richards Bay beach sands.
In the sulfuric acid digestion of ilmenite ores, the ilmenite (FeTiO 3 ) is reacted with sulfuric acid to produce FeSO 4 , TiOSO 4 and Ti(SO 4 ) 2 . Most of the FeSO 4 is removed as crystals and the liquor is boiled and seeded which precipitates TiO 2 and regenerates H 2 SO 4 .
When ilmenite is digested with sulfuric acid, the resulting cake after water leaching yields a liquor containing some ferric sulfate which must be later reduced into ferrous sulfate by reaction with metallic iron. This step is necessary in order to avoid any precipitation of iron oxide and other impurities such as vanadium oxide with the titanium dioxide during the hydrolysis stage.
When titaniferous slag is the raw material for digestion, the sulfate liquor normally contains no ferric sulfate but it contains some reduced titanium. Ti +3 is present, generally in concentrations of about 3-6 g/l for a titanium concentration of 220-240 g/l expressed as TiO 2 . If some ferric ions are present, scrap iron is added to get a reduced solution containing some Ti +3 as is the case for treating ilmenite. If Ti +3 , expressed as TiO 2 exceeds 6 g/l, the excess Ti +3 has to be oxidized to avoid losses of titanium as Ti +3 does not hydrolyse.
Certain ores such as Allard Lake ores (Quebec, Canada) and Richards Bay ore (South Africa) are processed more economically by first smelting the ore with carbon, coal, etc. The process takes place in an electric furnace wherein the ore is liquefied and a substantial part of the iron content thereof is reduced to the molten elementary state. The titaniferous phase floats on this iron and is tapped therefrom into molds, in which it is partly cooled. The products of this process are metallic iron and a slag much richer in TiO 2 . The slag produced by the foregoing smelting process when Allard Lake ores are treated is called Sorelslag. This slag and similar slags are treated by the sulfate process described above to recover TiO 2 .
Sorelslag upon digestion normally results in the retention of 3-6 g/l of Ti +3 in the sulfate liquor. Slight variations occur from time to time as in all commercial operations and slight adjustments have to be made sometimes either by reduction with scrap iron or oxidation with chemicals. These chemicals might be nitrates, hydrogen peroxide, etc.
As stated above, the Ti +3 level of Sorelslag is 3-6 g/l. However, with higher grade ilmenites such as beach sand ilmenite from Richards Bay, a higher TiO 2 slag is obtained in the smelting operation along with a much higher reduced titanium content in the slag. Such a slag will digest properly but will consistently yield a sulfate solution after digestion with a higher Ti +3 content than the desired (6 g/l). Oxidation with an oxidizing chemical such as sodium nitrate will be required.
Another method to oxidize the excess Ti +3 content is to digest a mixture of slag and ilmenite (containing ferric oxide) or ferric oxide (U.S. Pat. No. 2,953,434). Such mixtures yield ferric sulfate by reacting with sulfuric acid. During the dissolution of the cake, Fe +3 ions react with Ti +3 ions to yield Fe +2 and Ti +4 . It is possible to digest ilmenite and slag separately and later mix the resulting sulfate liquors in the proper proportions. The disadvantage of this method, however, is that it produces more iron sulfate thus aggravating pollution problems.
U.S. Pat. No. 2,990,250 involves the selective preoxidation of the slag, which method requires treating the finely ground slag at carefully controlled temperatures to avoid the conversion of the slag into an insoluble material (U.S. Pat. No. 2,715,501).
U.S. Pat. Nos. 2,589,909 and 2,589,910 suggest the oxidation of Ti +3 by aeration during the baking of the sulfate cake. This requires blowing hot air in order to avoid a rapid cooling of the cake.
U.S. Pat. No. 2,850,357 uses a carbonaceous material (coal, coke, carbonized carboxyhydrate) as a catalyst promoting the oxidizing properties of sulfuric acid at high temperature. The disadvantage is that the method needs a very finely divided substance uniformly mixed with the slag which is relatively difficult to realize in commercial operation.
SUMMARY OF THE INVENTION
The present invention used lignins, an inexpensive by-product of the pulp and paper industry, in conjunction with sulfuric acid in the digestion process. The lignins promote the oxidizing properties of sulfuric acid even when added in very small quantities in the acid-slag mixture and allows the conversion of Ti +3 into Ti +4 during the digestion process.
DESCRIPTION OF THE PREFERRED EMBODIMENT
At the outset the process is described in its broadest overall aspects with a more detailed description following. In its most basic terms the present invention is a process in which a lignin and sulfuric acid are used to treat TiO 2 containing slag. The composition of the slag treatable by the present process is as follows:
______________________________________TiO.sub.2 70-90Ti.sub.2 O.sub.3 (as TiO.sub.2) 10-35Fe (Total) 5-15Al.sub.2 O.sub.3 1-6CaO 0-3MgO 4-6Mno 0-2SiO.sub.2 1-7V.sub.2 O.sub.5 0-1Cr.sub.2 O.sub.3 0-1______________________________________
As used throughout this specification and claims the term lignin is, after cellulose, the principal constituent of the woody structure of higher plants. About one-quarter of dry wood consists of lignin, in part deposited in the xylem cell walls and in part located in the intercellular spaces, where it may constitute as much as 70% of the solid materials present. Its function in nature is to act as a cementing agent to bind the matrix of cellulose fibers together into a rigid woody structure. Since woody plants are so widespread, lignin is second only to cellulose as the most abundant organic chemical product.
Always closely associated with cellulose, a large proportion, if not all, of the lignin is chemically bound to the plant polysaccharides. Its exact chemical structure both in wood and when separated from other wood substances is not yet known. Much is known about the structure of isolated lignins, however. The lignin, isolated from coniferous trees, is thought to be a polymeric substance, resulting from an enzymically induced oxidation (dehydrogenation) of coniferyl alcohol. Several functional groupings, such as hydroxyl, methoxyl, and carbonyl, have been identified in the lignin polymer. There are probably many lignins, the properties and composition of each depending on the source and method of isolation.
The commercial lignin products are by-products of the wood and cellulose industries. The largest source of lignin products is, of course, the paper industry.
The sulfite process for producing pulp can lead to products (lignins) which consist of lignosulfonic acids, or various lignosulfonates. These are commonly referred to in the trade as lignin sulfonic acids, and lignin sulfonates, but the terms lignosulfonic acid and lignosulfonate are used by Chemical Abstracts. Such products are useable in the present invention.
Lignins that can be obtained from the spent liquors of the sulfate and soda processes are known as alkali lignins. They may be designated as sulfate lignins or soda lignins and are also useable in the process of the present invention. Commercial lignin products useable in the present process are set forth in Table I below.
TABLE I__________________________________________________________________________North American Companies Active in Sales of Lignin Products Trade name of Commodity main lignin from which ligninCompany product Source of lignin is a by-product__________________________________________________________________________Marathon Division ofAmerican Can Co. Marasperse mixed wood sulfite pulpCrown Zellerbach Corp. Orzan mixed wood sulfite pulpKimberly Clark Corp. Additive A mixed wood sulfite pulpGeorgia Pacific Corp. Lignosite mixed wood sulfite pulpConsolidated PaperCorp., Ltd. Stapel mixed wood sulfite pulpOntario Paper Co., Ltd. mixed wood sulfite pulpRayonier, Inc. Raylig mixed wood sulfite pulpRayonier, Inc. Rayflo bark sulfite pulpLignosol Chemicals, Ltd. Lignosol mixed wood sulfite pulpRoberson Process Co. Goulac mixed wood sulfite pulpInternational Paper Co. Binderene mixed wood sulfite pulpPacific Lumber Co. Palcotan redwood bark lumber PalconateLake States Yeast andChemical Division, St. RegisPaper Co. Toranil mixed wood sulfite pulpWeyerhaeuser Co. Weychem bark lumber, sulfite Silvacon and sulfate pulpWest Virginia Pulp &Paper Co. Indulin mixed wood sulfate pulpQuaker Oats Co. Furafil cereal residues furfuralGoetz Bros. Sansalo importerArthur C. Trask Co. Peritan importer__________________________________________________________________________
In general, an amount of lignin equal to about 0.05-0.4% of the weight of acid is used to treat slag in accordance with the present invention. As used throughout this specification and claims all percentages are by weight. Table II shows the proportions of constituents in greater detail.
TABLE II______________________________________Effect of Lignosol Additions on RBIT Slag Digestion Acid Ti.sup.+3 / Decom- Yield Ti.sub.T % posed % % Remark______________________________________Standard 90% Acid 24.3 0.10 93.0Acid/slag = 1.80 21.1 0.08 93.5 100 cc/min ofBaking 200° C., 2h air for 2 hrs during dissolu- tionLignosolin acid0.063% 10.6 0.46 93.80.125% 4.5 0.54 94.20.19% 1.9 0.50 93.40.25% -0.4 1.31 94.00.25% 2.4 1.21 93.10.31% 0.9 1.44 94.00.50% 0.3 1.96 93.3 Slower dissolu- tion rate0.625% 1.3 2.19 91.8 Slower dissolu- tion rateLignosol in dis-solution slurry0.31%(of acid weight) 16.1 0.04 93.5 100 cc/min of air for 2 hrs.0.31% 13.8 0.04 92.2 55 cc/min of air for 4 hrs lower flow because of foamingNo lignosol 14.6 0.12 93.2 55 cc/min of air for 4 hrs.______________________________________ Negative values for Ti.sup.+3 indicate Fe.sup.+3 is present.
In general the present invention utilizes the parameters set forth in U.S. Pat. No. 2,850,357 by Meyers et al. entitled "Digestion of Titanium Dioxide Slags", the teachings of which are incorporated herein by reference with the exception that lignin is substituted for the finely divided carbonaceous material of that patent.
The following non-limiting examples will illustrate the practice of the invention.
EXAMPLE 1
200 g of a titaniferous slag of composition as shown in Table I and ground to 99% -325 mesh, was mixed with 220 cc of 90% sulfuric acid (acid:slag ratio 1:1.8) in a pyrex reaction vessel with a 4 neck cap.
TABLE III______________________________________SLAG COMPOSITION IN %Equivalent TiO.sub.2 Ti.sub.2 O.sub.3 (as TiO.sub.2) FeO______________________________________85.5 27.9 10.4______________________________________
A stainless steel stirrer with a hollow shaft was inserted in the central neck in a teflon gasket and connected to a small motor to agitate the digestion slurry. A thermocouple was placed in the hollow shaft of the stirrer. The slurry was rapidly preheated to 100° C. with a heating-plate to initiate or set off the reaction. Then a heating mantle was substituted for the hot plate and the mantle temperature controlled to follow the digestor temperature in order to compensate for the heat losses from the vessel. The maximum temperature reached by the reaction was 200° C. accompanied by solidification of the reaction mixture which was indicated by stoppage of the stirrer. This occurs about 15 minutes after initiation of the reaction. The set-up was then dismantled and the reaction kettle placed in an oven at 200° C. After 2 hours baking the vessel was cooled down to room temperature. The cake was broken down, crushed and leached with 800 cc of 10% sulfuric acid solution for 2 hours at 65° C. The slurry was filtered.
The solid residue was washed with dilute sulfuric acid which was added to the liquor, the volume of which was adjusted at one liter.
The Ti +3 concentration in the liquor was 37.2 g/l (expressed as TiO 2 ). The digestion yield was 93.1%.
EXAMPLE 2
200 g of the same slag as above has been treated in the same way as in Example 1, except that 0.38 g of a calcium lignosulfite (lignosol) as a 25% aqueous solution was added initially to the acid.
The final sulfate liquor contained 3.1 g/l of Ti +3 expressed as TiO 2 . The digestion yield was 93.48%.
The primary purpose of the present invention is to treat titaniferous slags. However, it is possible to mix up to 20% ilmenite ores with such slag prior to treatment by the present process.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
The invention relates to the sulfuric digestion of titaniferous slags and more specifically to a method to decrease the reduced titanium concentration in the resulting sulfate liquor. The process uses lignin products to assist in the oxidation of the Ti +3 content of the slag.
| 2
|
This application is a continuation of Ser. No. 08/786,325 filed Jan. 23, 1997, now U.S. Pat. No. 5,746,334.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to techniques for arranging and supporting modular, cooperating components such as, for example but not limitation, computing equipment, audio equipment, and video equipment.
2. Description of the Prior Art
Recent rapid advances in the computing industries have been driven largely by a reduction in the price of both processing power and computer memory. One result in the increased availability of inexpensive computing equipment is a tremendous increase in consumer demand for modular computing equipment, such as computers, computer displays, printers, and peripheral devices such as tape back-up devices and CD ROM devices. There appears to be an increased integration of computing equipment with traditional audio-visual entertainment devices, such as tuners, amplifiers, equalizers, video cassette recorders, laser discs, CD audio players, CD video players, and display screens of all types.
The computing equipment, audio equipment, and video equipment is still rather expensive and delicate, so conventional cabinet work is frequently utilized for supporting these modular components in the safest possible manner. However, the increased integration of computing equipment, audio equipment, and video equipment necessarily requires increased electrical connectivity between such devices, and it is not uncommon for an operator to frequently reconfigure devices to accomplish a particular short-term goal with such modular equipment. Traditional equipment supporting furniture does not allow easy access to all sides of the modular equipment, in particular the back portions of the modular equipment, and thus frustrates operator-initiated attempts to reconfigure the modular components for a particular purpose. However, since the modular components are still relatively expensive, exposing them to unnecessary risk of damage is generally not considered to be an acceptable risk when compared to the temporal needs of a particular operator.
A need exists for a support apparatus for utilization with modular cooperating components, such as computing equipment, audio equipment, and video equipment, which enhances the overall coordinated functionality of these components without unnecessarily exposing the modular components to risk of damage.
SUMMARY OF THE INVENTION
It is one objective of the present invention to provide an apparatus for supporting modular and cooperating components which includes a base member, a vertical support pole extending upward from the base member, at least one bushing concentrically engaging the vertical support pole at a particular axial location, at least one support arm extending radially outward from the bushing, and at least one support surface secured to the support arms in a position substantially orthogonal to the support pole, which minimizes the space requirements for supporting modular and cooperating components, particularly in an office environment. The support apparatus according to the present invention increases the functionality of the modular and cooperating components without exposing the modular and cooperating components to unnecessary risk of harm.
More particularly, the present invention is directed to an apparatus for supporting modular and cooperating components. The apparatus includes a base member which engages a flooring surface. In the preferred embodiment of the present invention, this base member includes a sleeve member, and a plurality of leg members secured to the sleeve member for engaging the flooring surface and maintaining the sleeve member in a substantially vertical position. Preferably, the plurality of leg members of the base member are disposed orthogonally to one another. A plurality of optional leg member configurations are provided in accordance with the present invention. In one configuration, two leg members are provided and are angularly spaced apart approximately 90°. This configuration is particularly useful for placement of the support apparatus of the present invention in or about workspace corners, such as corners provided in modular office cubicles, or the corners provided by office equipment such as desks. In another configuration, three leg members are provided over a range of approximately 180°, with each leg angularly spaced approximately 90° from the adjacent leg. In this configuration, the support apparatus of the present invention can be positioned in office spaces which are defined by a wall or other linear constraint. This configuration is particularly useful for placement of the modular and cooperating components in a central location relative to a workspace such as a desk. In a third configuration, the plurality of leg members are spaced angularly equidistant about a 360° area. In this configuration, the support apparatus of the present invention can be placed in "open" office spaces, since support is provided in all directions.
In accordance with the present invention, the base member further includes a fastener seat which is secured to an inner surface of the sleeve member. The fastener seat is adapted for engaging a substantially vertical support pole and maintaining it in a substantially fixed position relative to the base member. More particularly, in the preferred embodiment of the present invention, the fastener seat includes at least one inclined seating surface which engages a lowermost portion of the substantially vertical support pole, and which allows the weight of the substantially vertical support pole to urge portions of the vertical support pole into fixed engagement with a portion of the inner surface of the sleeve member. Still more particularly, the seat member includes an apex portion which is maintained in a distal position relative to the inner surface. The fastener seat further includes a plurality of downwardly sloping edges which extend from the apex to the inner surface. During assembly and operation, gravity biases the substantially vertical support pole both downwardly and inwardly along the downwardly sloping edges until the vertical support pole comes into contact with the inner surface. In the preferred embodiment of the present invention, the fastener seat operates to fix the position of the substantially vertical support pole in position relative to the base member in five out of six degrees of freedom. The substantially vertical support pole can still be rotated relative to the base member. A locking key is provided to engage the substantially vertical support pole and prevent rotation relative to the base member. More particularly, at least one latching cavity is provided on the exterior surface of the vertical support pole. The sleeve member of the base member includes at least one key-feed port extending therethrough, which can be aligned with the at least one latching cavity of the vertical support pole. A portion of the locking key is passed through a particular key-feed port and engages a particular one of the latching cavities. In the preferred embodiment of the present invention, the locking key includes an externally threaded portion which engages an internally threaded portion of the key-feed port, thus securing the locking key in position relative to the base member.
The preferred embodiment of the support apparatus of the present invention further includes at least one bushing, which concentrically engages the substantially vertical support pole at a particular axial location. Preferably, a plurality of bushings are provided, each disposed at a particular axial location relative to the substantially vertical support pole. Each bushing is rotatable relative to the vertical support pole, but preferably over a predetermined rotation range. In the preferred embodiment of the present invention, the rotation range allowed by a particular bushing matches the particular base configuration. For a base configuration which includes two legs which provide support over a 90° range, the modular and cooperating components should be maintained intermediate the legs to maximize stability. For a three leg configuration, where the legs span a range of 180°, it is acceptable to allow the modular and cooperating components to be arranged in any rotational orientation over the 180° range. Finally, for a base configuration with four or more legs, which provide support over a range of 360°, any angular orientation is allowed.
Preferably, each bushing includes a hub portion which includes a central bore for concentrically receiving the vertical support pole, a hub pin for maintaining the hub portion in a fixed axial position relative to the vertical support pole, and a bushing insert which is carried within the hub portion, and which includes a particular contoured portion which defines the range of rotation of the particular bushing relative to the base member. More particularly, the bushing insert is adapted to be positioned within the hub portion in a particular orientation. The lowermost portion of the bushing insert extends outwardly of the bushing, and is contoured to provide a surface which slidably engages the hub pin over the predetermined range of rotation. Typically, the region which slidably engages the hub pin is defined by stop members. This contoured configuration is typically referred to as "castellation".
In the preferred embodiment of the present invention, the hub pin includes an eyelet portion which is adapted for receiving and securing conductors which extend between the modular and cooperating components. The hub pin also includes a load bearing portion (preferably the shaft portion of an eye-bolt) for engaging the lowermost portion of the hub, and in particular the bushing insert. The hub pin and hub portion engagement serves two functions simultaneously. First, it prevents downward axial displacement of the bushing. Second, it limits the range of rotation depending upon the particular configuration of the base member, as was discussed above. The hub pin thus simultaneously serves three important functions in the present invention.
In the preferred embodiment of the present invention, a plurality of bushing station ports are provided which extend through the vertical support pole, and which define a plurality of possible axial positions for engagement of bushings. In accordance with the present invention, the orientation of the bushing station ports corresponds to the particular base member provided. In other words, bushing station ports are provided at particular positions which ensure that the modular and cooperating components are maintained within the range of support provided by the particular leg configuration of the base member.
In the preferred embodiment of the present invention, the hub pin is externally threaded at the end opposite the eye portion. A hub pin retainer member is provided, which includes an internally threaded portion, which couples to the hub pin and prevents inadvertent removal of the hub pin.
The support apparatus of the present invention further includes at least one support surface, each of which is secured to a corresponding cantilevered support arm which extends radially outward from a particular bushing. Preferably, the support arms are orthogonal to the substantially vertical support pole. Loads are applied normal to the support surface and associated support arm. Preferably, the support surfaces are positioned substantially orthogonal to the support pole and are adapted for receiving and supporting the modular and cooperating component's particular axial and angular positions relative to the base member and the substantially vertical support pole
In the preferred embodiment of the present invention, each particular support surface is pivotally coupled to a selected support arm. Preferably, this support surface comprises a single piece of relatively low profile but sturdy material, such as an aluminum sheet. The pivotal coupling between the support surface and the support arm preferably comprises a coupling bore which extends through the support surface at a central location, and a coupling pin which extends to the coupling bore and which serves to secure the support surface to the support arm. This coupling allows for full 360° rotation of the support surface, to allow any orientation of the modular components that is required by the operator. In the preferred embodiment of the present invention, a locking member is provided for fixing the rotational orientation of the support surface relative to the support arm. Additionally, male and female mating members are provided between the support surface and the support arm for slightly impeding rotational movement, and especially for impeding vibration-induced rotational movement, which is frequently present during the operation of such components as impact printers.
Additional objectives, features and advantages of the present invention will be apparent with reference to the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of one embodiment of the support apparatus of the present invention;
FIG. 2 depicts the support apparatus of FIG. 1, supporting modular computing equipment;
FIG. 3 is a detail and cut-away view of the base portion of the support apparatus which is depicted in FIG. 1;
FIGS. 4a and 4b are fragmentary detail views of a portion of the support apparatus depicted in FIG. 1, depicting a base portion and interconnecting support pole;
FIG. 5 is a longitudinal section view of the base portion of the support apparatus which is depicted in FIGS. 3, 4a, 4b, and 6, as seen along section line B--B of FIG. 6;
FIG. 6 is a cross-section view of the base portion of the support apparatus which is depicted in FIGS. 3, 4a, 4b, and 5, as seen along section A--A of FIG. 5;
FIGS. 7a, 7b, 7c, 8a, 8b, 9a, and 9b depict alternative base members for use in the support apparatus of the present invention;
FIG. 10 is a depiction of the castellation the support bushing of FIGS. 11, 12, and 13, which define the range of rotation of the support arm;
FIG. 11 is a detail view of an arm bushing which couples a support arm to the support pole in the support apparatus depicted in FIG. 1, seen in cross-section;
FIG. 12 is a perspective and fragmentary view of the support bushing, support arm, and support pole which are depicted in FIG. 11;
FIG. 13 is a longitudinal section view of the support bushing and support pole as seen along section line C--C of FIG. 11;
FIGS. 14a, 14b, and 14c depict the utilization of the castellation of the support bushing to provide a restricted range of movement of the associated support arm;
FIGS. 15a and 15b depict another utilization of the castellation of the support bushing to provide at least a pair of fixed positions of the associated support arm;
FIG. 16 depicts the utilization of no castellation on the support bushing to provide an unlimited range of movement of the associated support arm;
FIGS. 17a, 17b, and 17c depict the utilization of an eye bolt fastener to secure electrical cables which run between the various modular components of the computing equipment;
FIG. 18 is a detail view of a portion of FIG. 1, depicting a coupling of a support arm and a support shelf of the support apparatus;
FIG. 19 is a cross-section view of the detail view of FIG. 18 of FIG. 20;
FIG. 20 is a view from the bottom of the detail view of FIG. 18;
FIG. 21 is a fragmentary perspective view of a leveler utilized on the legs of the support apparatus according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of one embodiment of support apparatus 11 of the present invention. As is depicted therein, support apparatus 11 includes base member 13 which is adapted for engaging a flooring surface 15 and a substantially vertical support pole 17. A plurality of bushings 19, 21, 23, each concentrically engage vertical support pole 17 at a particular axial location. A plurality of support arms 25, 27, 29 extend radially outward from bushings 19, 21, 23 at particular orientations relative to one another, and a plurality of support surfaces 31, 33, 35 are secured to the support arms 25, 27, 29, respectively, and are positioned substantially orthogonal to the vertical support pole and adapted for receiving and supporting modular and cooperating components at particular axial and angular positions relative to base member 13 and vertical support pole 17.
FIG. 2 depicts support apparatus 11 of FIG. 1, supporting modular computing equipment. As is shown, printer 37 is disposed on support surface 31 at a particular axial and angular position relative to base member 13 and vertical support pole 17. Central processing unit and associated mass memories 39 are supported by support surface 35 in a particular and angular position relative to base member 13 and vertical support pole 17. Monitor 41 is supported by support surface 33 at a particular axial and angular position relative to base member 13 and vertical support pole 17. Cabling 43 extends between the modular and cooperating components which make up the data processing system depicted in FIG. 2. The present invention is not intended to be limited for utilization in supporting components of a data processing system, and is intended to support all types of modular and cooperating components, including audio components and video components. The present invention may be utilized to support a combination of computing, audio, and video components in a particular location, with subgroupings of these components comprising cooperating components, and with not all of the components cooperating together.
FIG. 3 is a detail and cut-away view of base member 13 of FIGS. 1 and 2. As is shown, base member 13 includes sleeve member 49 and a plurality of leg members 45, 47 which are secured to sleeve member 49 and adapted for engaging flooring surface 15 (in FIG. 1) and maintaining sleeve member 49 in a vertical position. In the embodiment of FIG. 3, leg members 45, 47 are disposed orthogonally relative to one another. In this configuration, support apparatus 11 is adapted to maintain the modular and cooperating components within the 90° region spanned by leg members 45, 47. In alternative embodiments which will be discussed below, alternative arrangements are discussed for providing a broader region for placement of the modular and cooperating components.
In FIG. 3, fastener seat 51 is also depicted. As is shown, the sleeve member 49 defines an interior cylindrical surface 53 and an exterior cylindrical surface 55. The fastener seat is secured to the interior cylindrical surface 53 and is adapted for engaging vertical support pole 17 and substantially fixing its position relative to base member 13. More particularly, fastener seat 51 includes at least one incline seating surface 57 which engages a lowermost portion of vertical support pole 17, and which allows the weight of vertical support pole 17 to urge it into substantially fixed engagement with a portion of interior cylindrical surface 53 of sleeve member 49. In the preferred embodiment of the present invention, fastener seat 51 includes apex portion 59 which is disposed in a distal position relative to interior cylindrical surface 53, and further includes a plurality of downwardly sloping edges which extend from apex 59 to interior cylindrical surface 53. During assembly operation, gravity biases support pole 17 downwardly and inwardly along the plurality of downwardly sloping edges until vertical support pole 17 contacts interior cylindrical surface 53. In this particular embodiment, fastener seat 51 substantially fixes the position of vertical support pole 17 in five out of the six degrees of freedom. Only freedom to rotate relative to fastener seat 51 remains.
FIG. 5 provides a section view of the base member 13 of support apparatus 11 which is depicted in FIGS. 3, 4a, 4b, and 6 as seen along section line B--B of FIG. 6. FIG. 6 is a cross-section view of base member 13 of support apparatus 11 which is depicted in FIGS. 3, 4a, 4b, and 5, as seen along section line A--A of FIG. 5. As is shown in these figures, apex portion 59 is disposed a substantial distance away from interior cylindrical surface 53. Fastener seat 51 includes downwardly sloping edges 61, 63 which extend from apex portion 59 to interior cylindrical surface 53. During assembly, vertical support pole 17 is placed within the bore defined by interior cylindrical surface 53, and lowered in position relative to fastener seat 51. The lowermost portion 65 of vertical support pole 17 engages downwardly sloping edges 61, 63, and is urged into contact with interior cylindrical surface 53. Note in both FIGS. 5 and 6 that a substantial clearance exists between vertical support pole 17 and interior cylindrical surface 53. Nevertheless, fastener seat 51 is sufficient to fix the position of vertical support pole 17 in five out of six degrees of freedom, with the sole remaining degree of freedom comprising rotation of vertical support pole 17 relative to base member 13.
In order to prevent rotation of vertical support pole 17, and to ensure proper alignment of vertical support pole 17 relative to base member 13, another fastening mechanism is provided, which will be explained with reference to FIGS. 4a, 4b, 5, and 6. As is shown in these figures, latching cavities 67, 69 are provided in the exterior surface of vertical support member 17 at particular angular orientations relative to support holes 71 which are utilized to secure bushings in position relative to vertical support pole 17 (and which will be discussed in detail further below). As is shown best in FIGS. 4a and 4b, latching cavity 69 is disposed directly beneath support holes 71, while latching cavity 67 is disposed 90° away from latching cavity 69. These particular orientations ensure that the modular and cooperating components which are to be supported by support apparatus 11 are maintained within the 90° region which is spanned by leg members 45, 47 of base member 13.
Also, as is shown in these figures, sleeve member 49 includes key-feed port 73 which extends therethrough, and which is adapted with internal threads for coupling with external threads on a portion of locking key 75 which is adapted to engage either latching cavity 67 or latching cavity 69, depending upon the operator selection of the particular orientation. As is shown in these figures, locking key 75 includes an unthreaded tip portion 77 which is appropriately sized to fully engage and mate with latching cavities 67, 69. The larger-diameter exteriorly threaded portion 79 is adapted in size to mate with the internal threads on key-feed port 73.
FIGS. 7a, 7b, 7c, 8a, 8b, 9a, and 9b depict alternative base member 13 configurations which provide different acceptable ranges of rotation for the angular and axial placement of the modular and cooperating components, and illustrate, in simplified form, the relationship between a pin 81, which is utilized to secure a bushing in position relative to vertical support pole 17 and base member 13. FIGS. 7a, 7b, and 7c depict one embodiment of base member 13 which includes leg members 45, 47, which are disposed over a range of approximately 90°, and which is especially useful in positioning the modular and cooperating components in or about a corner, such as that depicted in FIGS. 7b and 7c. In FIG. 7b, support apparatus 11 is depicted in a position within a corner of modular office furniture, which is typically identified as office "cubicles". As is shown, vertical support pole 17 extends through circular port 99 in work table 97 which is oriented within a corner of cubicle 101. As is shown, leg members 45, 47 of base member 13 are oriented in alignment with the orthogonal components of cubicle 101. Also note that support platforms 103, 105 are disposed in angular positions within the 90° range spanned by leg members 45, 47. In this configuration, the load of the modular and cooperating components which are placed upon support surfaces 103, 105 exert thrust and bending forces upon vertical support member 17, which transfers the load through sleeve member 49 and leg members 45, 47 to flooring 107. FIG. 7c depicts support apparatus 11 positioned to straddle corner 109 of desk 111 in a manner which orients support surfaces 103, 105 in useful positions relative to desk 111, but within the 90° range spanned by leg members 45, 47.
FIGS. 8a and 8b depict an alternative base member 13 configuration which utilizes three leg members 83, 85, 87 which span a 180° range, and thus which provide a broader region for the angular placement of the modular and cooperating components which are suspended from vertical support pole 17. Since this configuration provides a 180° range of angular placement of the modular and cooperating components, it is particularly useful in alignment of the modular and cooperating components along a linear office component, such as an office wall, or intermediate office equipment, such as desk 111 and an office wall, which is depicted in FIG. 8b. As is shown, leg 85 extends forward into the leg space provided within desk 111. Support surfaces 103, 105 are conveniently located in positions relative to desk 111, and can be rotated through the full 180° range of available positions, as required by the workers immediate needs.
FIGS. 9a and 9b depict yet another alternative configuration for base member 13 which includes leg members 89, 91, 93, and 95, thus providing a full 360° of rotation freedom for the modular and cooperating components which are carried by support apparatus 11. This orientation is particularly useful in open areas such as that depicted in FIG. 9b, where one may desire to rotate the particular modular and cooperating components about fully, such as may be required in the drafting table configuration depicted in FIG. 9b. As is shown, support surfaces 103, 104, 105 may be rotated to allow one or more individuals access to the particular modular components during particular drafting operations.
While the particular orientation of the latching cavities and the key-feed port determine the angular orientation of vertical support pole 17 relative to base member 13, the rotational freedom of the modular and cooperating components supported by the various support surfaces determined by the functional components of the bushing members which circumferentially engage vertical support pole 17 at particular axial locations, as will now be described with particular reference to FIGS. 10, 11, 12, and 13. As is shown in these figures, bushing 121 includes hub portion 115 which includes a central cylindrical bore 114 which is adapted to receive vertical support pole 17. As is shown in these figures, hub portion 115 is secured to support arm 117 which extends radially outward therefrom. Bushing 121 further includes hub pin 119 which includes an eyelet portion 123, a load bearing portion 125, and an externally threaded fastening portion which is adapted to mate with an internally threaded hub pin retainer member 129 which prevents the inadvertent or accidental removal of hub pin 119 from vertical support pole 17. As is best depicted in FIGS. 17a and 17b, eyelet portion 123 of hub pin 121 is utilized to secure conductors which extend between the various modular and cooperating components in a secure position relative to vertical support pole 17. Returning now to FIG. 13, load-bearing portion 125 of hub pin 119 is utilized to maintain hub portion 115 in a fixed axial position relative to vertical support pole 17. Also, as is best depicted in FIG. 13, externally threaded fastening portion of hub pin 119 engages hub pin retainer member 129 to prevent hub pin 119 from being inadvertently removed from vertical support pole 17. As is best depicted in FIG. 13, a plurality of axially positioning holes, such as holes 133, 135 of FIG. 13 are adapted in size to receive load bearing portion 125 of hub pin 119. In this configuration, hub portion 115 bears down upon load bearing portion 125 of hub pin 119.
In the preferred embodiment of the present invention, bushing 121 further includes a bushing insert 137 which is preferably formed of plastic, and which includes a radially reduced portion 139 which is adapted to slide inward of hub portion 115 and be disposed in the space between vertical support pole 17 and interior cylindrical surface 114 of hub 115, and radially enlarged and contoured lower portion 141. A female mating notch 143 is provided on the lower lip of hub portion 115, while a male mating notch 145 is provided on the radially-enlarged contoured portion of bushing insert 137. When these male and female mating portions are aligned, bushing insert 141 is in its proper alignment relative to hub portion 115. In FIG. 10, bushing insert 137 is depicted slightly retracted from the interior cylindrical bore 114 of hub portion 115 of bushing 121; however, in the view of FIG. 12, the male and female portions are depicted as mating, thus indicating a proper orientation of bushing insert 131 relative to hub portion 115. As is best shown in FIG. 12, radially-enlarged contoured portion 139 of bushing insert 137 includes a range limiting portion 147 for slidably engaging hub pin 119 over a preselected acceptable range of rotation, with the range limiting portion being defined between stop members, such as stop members 149, 151 of FIG. 12 which prevent further rotation of bushing 121.
The one possible configurations are best depicted in the views of FIGS. 14a, 14b, 14c, 15a, 15b, and 16. The views of FIGS. 14a, 14b, 14c, depict hub pin 119 cooperating with castellations or range limiting portions 147 in lower enlarged portion 139 of bushing insert 137. FIGS. 14a through 14c illustrate range limiting portions 147 arranged to provide a 30° range of motion. FIG. 14a illustrates support arm 117 at a 30° orientation relative to vertical support pole 17. In this 30° position, hub pin 119 abuts the end walls of range limiting portions 147 in lower portion 139 of bushing insert 137. FIG. 14b illustrates support arm 117 in an intermediate position in which hub pin 119 is intermediate the end walls of range limiting portion 147. FIG. 14c illustrates support arm 117 in a 60° position in which hub pin 119 abuts the end walls of range limiting portions 147 opposite from those abutted in the 30° position illustrated in FIG. 14a. Thus, FIGS. 14a through 14c illustrate a pattern of crenellations or range limiting portions 147 that restrict movement of support arm 117 to a 30° range of motion.
FIGS. 15a and 15b represent an embodiment of the present invention in which lower end 139 of bushing insert 137 is provided with two pairs of crenellations or range limiting portions 147 that are dimensioned to be coextensive with the diameter of hub pin 119. Thus, two fixed positions of support arm 117, a 150° position and a 30° position are selectable, depending on which pair of range limiting portions 147 engage hub pin 119. In this arrangement, support arm 117 is not freely movable but occupies one of two fixed positions defined by range limiting portions 147. Of course, any number of fixed positions may be selected, limited only by the ability to provide lower end 139 of bushing insert 137 with range limiting portions 147.
FIG. 16 depicts an arrangement in which lower end 139 of bushing insert 137 is smooth and provided with no range limiting portions. Thus, the arrangement illustrated in FIG. 16 provides for unrestricted movement of support arm 117 a full 360° around vertical support member 17. In this arrangement, hub pin 119 serves only to maintain bushing 121 in a selected axial or vertical position relative to vertical support member 17.
FIGS. 14a through 16 illustrate various arrangements in which movement of support arm 117 about vertical support member 17. In the preferred embodiment of the present invention, the range of motion of support arm 117 should be restricted to equal to or less than the included angle between the legs of base member 13 to prevent tipping of the support apparatus due to unbalanced loads. In the case of the two leg embodiment of FIGS. 7a, 7b and 7c, the range of motion would be restricted to equal to or less than 90°. In the three leg embodiment of FIGS. 8a and 8b, the range of motion should be restricted to 180°. In the four leg embodiment illustrated in FIGS. 9a and 9b, the range of motion need not be restricted at all.
FIGS. 17a, 17b, and 17c illustrate the utility of eye portion 123 of hub pin 119 in securing cables 131, cords, and the like of equipment supported by the apparatus according to the present invention. As shown in FIG. 17b, cords 131 can be secured within eye portion 123 of support hub pin 119 to prevent tangling and catching of cables 131 on other equipment or the apparatus itself. FIG. 17c illustrates an alternative arrangement in which the cords are first bundled utilizing a sheathing member 131a prior to securing the cables in the hook portions of hub pins 119.
FIGS. 18, 19, and 20 depict support surface 201, support arm 203, and pivotal coupling 211 which includes externally threaded bolt 205, internally threaded sleeve 207 with beveled seating head 209, beveled seating washer 213, and locking member 215. A coupling bore 217 is provided in a central location in support surface 201. In the preferred embodiment of the present invention, support surface 201 comprises a low profile sturdy material, such as an aluminum plate. Internally threaded sleeve 207 is placed into bore 219 of support arm 203. Externally threaded bolt 205 serves as a coupling pin for securing support surface 201 to support arm 203 in a manner which allows 360° of rotation for support surface 201 relative to support arm 203. Locking member 205 is provided with a knob component and an internally threaded bore for engaging externally threaded bolt 205 and fixing the position of support surface 201 relative to support arm 203. Locking member 215 may be loosened or tightened depending upon the operator's desires for repositioning of the modular component supported by support surface 201. Since only a very unobtrusive bolt head 221 of externally threaded bolt 205 extends outward from support surface 201, the coupling mechanism 211 does not interfere with, or impede the operation of, the modular and cooperating component which is carried and supported by support surface 201. Since coupling bore 217 is disposed in a central location within support surface 201, an advantageous load bearing configuration is obtained so that pure bending forces are applied through support surface 201 to support arm 203 through a region of support surface 201 which substantially coincides with the center of gravity of the modular and cooperating component which is carried by support surface 201.
The male and female mating members defined by beveled head 209 and beveled washer 213 provide a means for slightly impeding the rotational movement of support surface 201 relative to support arm 203, which is especially useful in impeding vibration-induced rotational movement of support surface 201 relative to support arm 203 in response to highly kinetic equipment, such as impact printers. This male and female mating configuration allows for infinite rotational adjustability without presenting rotational instability.
FIG. 21 is a fragmentary section view illustrating a leveler for use with the legs (45, 47, 83, 85, 87, 89, 91, 93, and 95 in FIGS. 7a through 9b) to permit leveling of the support apparatus according to the present invention. Leveler 45a consists of a footed attachment which is secured by a threaded portion 45b to leg 45. By rotating foot 45a, its protrusion from bottom of leg 45 can be varied permitting leveling of the support apparatus according to the present invention. Each of the legs of the support apparatus according to the present invention preferably is provided with a leveler as illustrated in FIG. 21.
While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
|
An apparatus for supporting modular and cooperating components which includes a base member, a vertical support pole extending upward from the base member, at least one bushing concentrically engaging the vertical support pole at a particular axial location, at least one support arm extending radially outward from the bushing, and at least one support surface secured to the support arms in a position substantially orthogonal to the support pole, which minimizes the space requirements for supporting modular and cooperating components, particularly in an office environment. The support apparatus according to the present invention increases the functionality of the modular and cooperating components without exposing the modular and cooperating components to unnecessary risk of harm.
| 0
|
BACKGROUND OF THE INVENTION
A number of common physical, mental and psychological disorders have been associated with states of psychoneuroses or anxiety. Such states typically result in feelings of apprehension, uncertainty or fear, without apparent stimulus or objectively out of proportion to any apparent cause, and may be associated with physiological changes such as tachycardia, sweating and tremors. Furthermore, an extreme state of anxiety is a common consequence of withdrawal from substances capable of inducing drug dependence, such as alcohol, nicotine and cocaine. In use, such substances produce an anxiolytic effect. However, their chronic use is accompanied by a state of dependence. The sudden interruption of these substances may even exacerbate the initial anxiety, making withdrawal from the substances extremely difficult.
The benzodiazepine-type drugs customarily used in the treatment of anxiety have the disadvantage of inducing, on cessation of treatment, an exacerbation of the anxiety and, therefore, do not constitute effective therapy, for instance, for drug addicts undergoing withdrawal. Accordingly, chemical compounds that can relieve states of psychoneuroses or anxiety have been sought for use as pharmaceutical agents in the treatment of patients. In particular, there has been a need for anxiolytic agents that relieve the anxiety of withdrawal from addictive drug substances.
Schizophrenia is an imbalance that encompasses any of a group of severe emotional disorders, usually of psychotic proportions, characterized by misinterpretation and retreat from reality, delusions, hallucinations, ambivalence, inappropriate affect, and withdrawn, bizarre, or regressive behavior. Accordingly, chemical compounds that can relieve the anxiety characteristic of psychotic disorders such as schizophrenia have also been sought for use as pharmaceutical agents in the treatment of patients.
The present theory of the physiopathology of schizophrenia is that an augmented dopaminergic activity in the medial temporal lobes of the brain is responsible for the dopamine induced hyperactivity characteristic of this disorder. Thus, the antipsychotic drugs currently in use are antidopaminergics.
SUMMARY OF THE INVENTION
The present invention concerns pharmaceutical uses of the compound N-[2-(diethylamino)-ethyl]-2-methoxy-4-[(1H-4,5-dihydro-2-imidazolyl)-amino]-5-chlorobenzamide, represented by the following chemical structure: ##STR1## or any of the pharmaceutically acceptable salts thereof (herein referred to as "The Compound").
The Compound, and methods for its preparation, are described in French Patent No. 2592042 and U.S. Pat. No. 4,835,172, issued May 30, 1989, the disclosures of which are incorporated herein by references, as an activator of the central nervous system and antidepressant. The antidepressant activity has been confirmed by Porsolt's test, a conventional and known protocol well-accepted in the art.
In addition to such properties, it has now been found that The Compound possesses anxiolytic and antipsychotic properties.
The Compound has been shown to be a potent anxiolytic agent in standard laboratory animals. This has been demonstrated by the two-compartment (dark and light) box test in the mouse, by observation of "social" behavior of the rat and by the human confrontation test in the marmoset. Furthermore, The Compound relieves the anxiety of withdrawal from substances capable of inducing drug dependence without causing the anxiety-generating effects manifested on the cessation of chronic treatment with conventional anxiolytic agents of the benzodiazepine-type.
As a psychotropic agent, The Compound is distinguished from other methoxybenzamide compounds by the fact that it does not possess antidopaminergic properties. Thus, The Compound is not a neuroleptic in the usual sense of the term, as it is not bound to the D 1 -D 2 dopaminergic receptors. It is inactive in the behavior tests customarily performed to test neuroleptics. These results do not suggest that The Compound is an antipsychotic agent. However, the tests conducted have demonstrated that The Compound does suppress the hyperactivity induced by dopamine perfused in the brain of the rat, more specifically in the nucleus accumbens, thus indicating a utility in the treatment of psychotic disorders such as schizophrenia.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1D illustrate graphically the anxiolytic activity of The Compound when administered subcutaneously in the mouse using the 2-compartment box test;
FIGS. 2A-2D illustrate graphically the anxiolytic activity of The Compound when administered orally in the mouse using the 2-compartment box test;
FIG. 3 illustrates graphically the anxiolytic action of The Compound in a social behavior model in the rat;
FIGS. 4A and 4B illustrate graphically the anxiolytic action of The Compound in the marmoset confronted with human presence;
FIGS. 5A-5D illustrate graphically the antagonism to anxiety generated by withdrawal from alcohol by The Compound;
FIGS. 6A-6D illustrate graphically the antagonism to anxiety generated by withdrawal from nicotine by The Compound;
FIGS. 7A-7D illustrate graphically the antagonism to anxiety generated by withdrawal from cocaine by The Compound;
FIGS. 8A-8D illustrate graphically the effect of withdrawal after chronic treatment with a benzodiazepine in the mouse using the 2-compartment box test;
FIGS. 9A-9D illustrate graphically the effect of withdrawal after chronic treatment with The Compound in the mouse using the 2-compartment box test; and
FIGS. 10A and 10B illustrate graphically the antagonism by The Compound to the hyperactivity induced by dopamine perfused bilaterally in the nucleus accumbens of the rat.
DETAILED DESCRIPTION OF THE INVENTION
A very thorough study of The Compound in standard laboratory animals has demonstrated that it possesses unexpected properties. The protocols used and the test results obtained are described hereinafter.
TWO-COMPARTMENT BOX TEST IN THE MOUSE
This test is based on a natural aversion of mice to light. The apparatus used is a box containing two compartments, one of which is dark (labeled "black compartment" in the figures) and the other illuminated (labeled "white compartment" in the figures). The apparatus is designed to allow the animal to choose between staying in either of the two compartments. Under normal conditions, the mice avoid light and remain especially in the dark compartment. Under the influence of an anxiolytic agent, however, exploration of the illuminated compartment predominates.
The test consists of placing each mouse in the center of the illuminated compartment and observing the animal's behavior by video system for 5 minutes. The number of exploratory rearings and the number of displacements (the crossing of lines traced on the floor of each compartment constitute "passages") are then recorded for each compartment.
An anxiolytic effect induced by a drug such as diazepam is characterized by an increase in the number of exploratory rearings and in the number of passages into the illuminated compartment.
According to the results shown in FIGS. 1A-2D, The Compound exerts an anxiolytic effect in this test which is manifested at 0.001 mg/kg subcutaneously and 0.1 mg/kg orally by a significant increase in the number of exploratory rearings and displacements into the illuminated compartment.
"SOCIAL" BEHAVIOR TEST IN THE RAT
This test consists of observing by video system the behavior of 2 rats, coming from different cages, brought into each other's presence for 10 minutes in a brightly illuminated box.
The "social" behavior of each animal is assessed by measurement of the duration of different activities: smelling the partner, leaping over the partner, grooming, genital exploration and shadowing of the partner. Under the anxiety-generating influence of light, such behavior tends to be maintained at a reduced level.
The administration of anxiolytic substances such as benzodiazepines tends to lift that effect with, consequently, an enhancement of social behavior.
According to the results shown in FIG. 3, The Compound enhances social behavior in a statistically significant manner after the subcutaneous administration of a minimal dose of 0.0001 mg/kg.
ANXIETY TEST IN THE MARMOSET
In the marmoset, the presence of an unknown experimentor standing 60 cm from the animal's cage triggers anxiety, which is manifested by a series of aggressive postures and the animal's retreat to the back of the cage.
The administration of an anxiolytic substance like diazepam, for example, reduces the animal's anxiety and one observes a diminution of the number of aggressive postures as well as an increase in the time spent in front of the cage facing the experimentor.
The Compound likewise reduces anxiety. According to the results shown in FIGS. 4A and 4B, the anxiolytic effect is manifested subcutaneously at from 0.000001 mg/kg by a significant diminution in the number of aggressive postures and a significant increase in the time spent in front of the cage.
ANXIETY INDUCED BY WITHDRAWAL
Mice rendered dependent by the repeated administration of various substances undergo withdrawal upon cessation of treatment. The anxiety induced by such withdrawal is objectively represented, as previously described, by the two-compartment box test.
In general, the administration of substances inducing dependence diminishes the animal's "anxiety state" which is expressed by an increase in the number of rearings and passages into the illuminated compartment. On withdrawal, one encounters an exacerbation of the animal's anxiety with a consequent increase in the number of rearings and passages into the dark compartment which exceed the values observed before administration of the substance.
The test consists of administering the substance to be tested on withdrawal until the day of the two-compartment box test. The increase in the number of passages and rearings in the illuminated compartment is the criterion of effectiveness of the substance on withdrawal-induced anxiety. The Compound has reduced the anxiety induced by withdrawal of alcohol, nicotine and cocaine in this test.
ALCOHOL DEPENDENCE
Mice rendered alcohol-dependent by the addition of 8% alcohol to the drinking water for 14 days undergo withdrawal and are tested 48 hours after the start of withdrawal; i.e., the time when maximum anxiety-generating effects are manifested.
According to the results shown in FIGS. 5A-5D, the subcutaneous administration of 1 mg/kg/day of The Compound for 48 hours after withdrawal significantly increases the number of passages and of rearings in the illuminated compartment by comparison with the untreated withdrawn animals.
NICOTINE DEPENDENCE
Mice rendered nicotine-dependent by the intraperitoneal administration of 0.1 mg/kg twice-daily of nicotine for 14 days undergo withdrawal and are tested 48 hours after the start of withdrawal; i.e., the time when maximum anxiety-generating effects are manifested.
According to the results shown in FIGS. 6A-6B, the subcutaneous administration of 1 mg/kg/day of The Compound for 48 hours after withdrawal significantly increases the number of passages and of rearings in the illuminated compartment by comparison with the untreated withdrawn animals.
COCAINE DEPENDENCE
Mice rendered cocaine-dependent by the administration of 1 mg/kg twice-daily for 14 days undergo withdrawal and are tested 8 hours after the start of withdrawal; i.e., the time when maximum anxiety-generating effects are manifested. According to the results shown in FIGS. 7A-7D, the subcutaneous administration at the start of withdrawal of 1 mg/kg of The Compound significantly increases the number of passages and of rearings in the illuminated compartment by comparison with the untreated withdrawn animals.
INVESTIGATION OF WITHDRAWAL ANXIETY GENERATED WITH THE COMPOUND EMPLOYED IN THE METHODS OF THE INVENTION, COMPARED TO THAT INDUCED BY BENZODIAZEPINES
Some substances, such as benzodiazepines, induce a dependence after chronic use, which is one of the disadvantages of therapy with such substances. As reflected by the results shown in FIGS. 8A-8D, the chronic administration of a benzodiazepine for 7 days entails after the cessation of treatment a recrudescence of anxiety, objectively manifested by an increased number of rearings and of passages into the dark compartment.
According to the results shown in FIGS. 9A-9D, the chronic subcutaneous administration of The Compound at a dose of 1 mg/kg twice-daily for 7 days does not induce anxiety within 8, 48 or 96 hours after the cessation of treatment. On the other hand, it is observed that the anxiolytic effect of The Compound is maintained after withdrawal, as the rearings and passages into the illuminated compartment remain significantly greater than those of the controls 8 and 48 hours after withdrawal, before returning to the control values in 96 hours.
HYPERACTIVITY INDUCED BY PERFUSION OF DOPAMINE INTO THE NUCLEUS ACCUMBENS IN THE RAT
One of the factors mentioned to explain the genesis of schizophrenia is a cerebral dopaminergic hyperactivity. The suppression of such hyperactivity, as with neuroleptics, would make possible an improvement of the psychotic state.
In the hyperactivity test in the rat, dopamine is perfused by the intracerebral route into the nucleus accumbens by means of osmotic minipumps at a dose of 24 μg/24 hours for 13 days. The spontaneous motor activity of the rats placed in individual cages is measured by means of photoelectric cells. The results are expressed in the number of interruptions of light beams corresponding to the photoelectric cells (passage of the animal).
On the administration of dopamine, an increase of locomotor activity of the animals is observed, manifested by two peaks in hyperactivity toward the 3rd and 9th days. The standard neuroleptics prevent occurrence of that hyperactivity when they are administered during the period of perfusion.
According to the results shown in FIGS. 10A and 10B, the subcutaneous administration of The Compound at a dose of 0.01 mg/kg twice-daily prevents occurrence of the hyperactivity normally induced by the perfusion of dopamine.
The foregoing tests demonstrate the anxiolytic and antipsychotic activity of The Compound and its utility for the treatment of various anxiety states, as well for the treatment of certain psychotic states. Furthermore, the test results evidence the usefulness of The Compound in facilitating withdrawal from substances and medications capable of creating drug dependence by forestalling the anxiety generated by their interruption.
Thus, The Compound may be administered in therapeutically effective amounts to patients including lower animals and humans.
The Compound can be administered in any number of conventional pharmaceutical forms including, but not limited to, tablets, capsules, pills, syrups, injectable solutions or other dosage forms intended for oral, parenteral or any other conventional pharmaceutical administration, in combination with solid or liquid excipients. Substances which are inert relative to The Compound can be used in these preparations, such as lactose, magnesium stearate, starch, talc, cellulose, levilite, alkali metal lauryl-sulphates, saccharose and other vehicles commonly employed in pharmaceutical preparations.
By way of illustration only, The Compound may be formulated in tablet dosage form as shown below. As the formulation is provided for illustrative purposes only, it is understood that the invention is not restricted or limited thereto, as the scope of the invention is defined and restricted or limited solely as set forth in the appended claims.
______________________________________N-[2-(diethylamino)-ethyl]-2- 100 mgmethoxy-4-[(1-H-4,5-dihydro-2-imidazolyl)-amino]-5-chlorobenzamidedried starch 20 mglactose 100 mgmethylcellulose 1500 cps 1.5 mglevilite 10 mgmagnesium stearate 4 mg______________________________________
|
Anxiolytic and antipsychotic treatment is provided to patients by administering therapeutically effective amounts of N-[2-(diethylamino)-ethyl]-2-methoxy-4-[(1-H-4,5-dihydro-2-immidazolyl)-amino]-5-chlorobenzamide, or a pharmaceutically acceptable salt thereof.
| 8
|
BACKGROUND OF THE INVENTION
[0001] In hydrocarbon reforming, a hydrocarbon feedstock and steam is reacted catalytically in a reformer furnace to form a synthesis gas comprised of hydrogen, carbon monoxide, and carbon dioxide. The reforming furnace is a critical component of hydrogen production facilities and plants which use synthesis gas to produce methanol and ammonia, and can account for almost half of the operating costs and energy expenditures of such installations.
[0002] A reforming furnace typically contains a fired radiant section, a transition section, and a convection section. Tubes filled with a reforming catalyst (e.g., nickel on an alumina support) are disposed in the radiant section. A hydrocarbon feedstock and steam is fed through and reformed in the tubes. Combustion of a conventional fuel in the radiant section produces a hot flue gas which heats the tubes and provides the thermal energy necessary for the endothermic reforming reaction. The transition section receives hot flue gas from the radiant section and passes it to the convection section. One or more heating coils disposed in the convection section may be used for different preheat purposes, including preheating the hydrocarbon feedstock and steam before that feed stream is reformed in the radiant section catalyst tubes. Flue gas from the transition section heats the convection section coils.
[0003] The overall efficiency of a reforming furnace is determined by the absorbed heat duty of the radiant section catalyst tubes. In general, greater catalyst tube heat duties require increased temperatures and firing rates in the radiant section. Operating the radiant section in this way requires increased maintenance and shortens the radiant section's useful life. Increasing the heat duty provided by the radiant section can also lead to coke formation in the radiant section catalyst tubes.
[0004] Maximizing the temperature of the hydrocarbon feedstock and steam at the inlet of the radiant section catalyst tubes (the “preheat temperature”) improves reformer efficiency. At higher preheat temperatures, the reforming reaction is initiated closer to the inlet of the catalyst tubes, which improves the efficiency of the reforming reaction.
[0005] FIG. 1 illustrates a conventional reforming process in which a mixed feed 1 comprising a hydrocarbon feedstock and steam is preheated in the convection section 2 of the reformer 10 . Preheated mixed feed 3 then flows through catalyst-filled tubes 4 located in radiant section 5 . Synthesis gas product stream 6 is collected at the other end of the tubes and is supplied to a customer after additional purification. A conventional reforming process such as that illustrated in FIG. 1 can only achieve a preheat temperature of around 500° C. to around 600° C. due to the risk of carbon formation from the heavy hydrocarbons present in the feedstock.
[0006] A reduction in radiant section heat load can be achieved by reforming at least the hydrocarbon feedstock heavy hydrocarbons in a prereformer prior to feeding the mixed feed through the radiant section catalyst tubes. This approach is illustrated in FIG. 2 and in U.S. Pat. No. 5,264,202. Referring to FIG. 2 , a mixed feed 1 of a hydrocarbon feedstock and steam is preheated in convection section 2 of reformer 10 and is then fed to prereformer 7 . Prereformer effluent stream 3 may be heated to a reheat temperature of around 680 ° C in convection section 2 prior to being fed to the inlet of radiant section catalyst tubes 4 .
[0007] FIG. 3 illustrates a variant of the process of FIG. 2 in which a prereformer is positioned within the reformer convection section. In the process illustrated in FIG. 3 , a mixed feed comprising a hydrocarbon feedstock and steam is fed to prereformer 1 which is positioned in and heated to a reheat temperature by convection section 2 of reformer 10 . The prereformed mixed feed is then fed at the reheat temperature to radiant section catalyst tubes 4 . Prereforming within a convection/transition section prereformer is also described in U.S. Pat. No. 6,818,028. In general, prereforming proves useful for reforming a natural gas feed as a means to reduce steam generation or primary reformer duty and in instances where the conversion from one feedstock to another is required.
[0008] The preheat and prereforming process designs described above prove unsuitable for expanding the production capacity of an existing reformer above around 25% of existing capacity because they are constrained by the energy available in the flue gas, radiant section firing duty, convection section space limitations, and overall plant heat balance.
[0009] Exposure to reformer section radiant heat and variation in radiant section flue gas temperature make it difficult to regulate the reheat temperature of the effluent stream from a prereformer located in a reformer convection section as well.
[0010] Installation of a prereformer in the transition section of an existing reformer is very expensive; the reformer must be taken off-line, thereby disrupting the output of all associated facilities. Limited space in the convection section often precludes installation of an adequately-sized prereformer. Further, the convection section coil design may interfere with the positioning of the prereformer in the convection section.
[0011] These problems can be compounded by the fact that heat in the flue gas coming from the reformer radiant section may be inadequate to heat both the convection section coils and the prereformer. In such cases, installing a prereformer in the convection section could disrupt the energy balance of the reformer and all associated plants. Major changes to all of the convection coils downstream of the prereformer might also be required.
[0012] Accordingly, the need exists for a cost-effective process which expands the production capacity of an existing reformer through preheat and prereforming without disrupting the output or energy balance of the either the reformer or any associated plant.
BRIEF SUMMARY OF THE INVENTION
[0013] The invention provides a process for generating a hydrogen-containing product gas in a reformer comprising a radiant section, a plurality of reforming catalyst-filled tubes disposed in the radiant section, a transition section, and a convection section, the process comprising:
(a) firing the reformer radiant section to generate a flue gas which passes from the radiant section, through the transition section, and to the convection section and which heats the radiant section catalyst-filled tubes and the convection section; (b) feeding a mixed feed stream comprising a hydrocarbon feedstock and steam through the convection section to yield a preheated mixed feed stream; (c) feeding the preheated mixed feed stream to a prereformer which adiabatically prereforms the preheated mixed feed stream and generates a prereformed and preheated mixed feed stream; (d) feeding the prereformed and preheated mixed feed stream to an independent heater which heats the prereformed and preheated mixed feed stream to a reheat temperature; and (e) feeding the preheated and prereformed mixed feed stream at the reheat temperature through the radiant section catalyst-filled tubes, thereby generating a hydrogen-containing product gas, wherein (1) the prereformer is configured to receive the preheated mixed feed stream from the reformer convection section and to feed the prereformed and preheated mixed feed stream to the independent heater; (2) the independent heater is configured to receive the prereformed and preheated mixed feed stream from the prereformer and to feed the preheated and prereformed mixed feed stream at the reheat temperature to the inlet of the radiant section catalyst tubes; and (3) neither the prereformer nor the independent heater are located within the reformer.
[0020] In another embodiment, the invention provides a process for increasing the hydrogen production capacity of a reformer comprised of a radiant section, a plurality of reforming catalyst-filled tubes disposed in the radiant section, a transition section, and a convection section comprising one or more coils, the process comprising:
(a) providing a prereformer which is configured to receive a preheated mixed feed stream comprising a hydrocarbon feedstock and steam from the reformer convection section and which adiabatically prereforms the preheated mixed feed stream and generates a prereformed and preheated mixed feed stream; and (b) providing an independent heater which: (i) is configured to receive the prereformed and preheated mixed feed stream from the prereformer, (ii) heats the prereformed and preheated mixed feed stream to a reheat temperature without causing local overheating of heat exchange surfaces (e.g., independent heater reheat coils) or carbon formation on surfaces contacted by the preheated mixed feed stream (e.g., inside a heater reheat coil), and which (iii) feeds the prereformed and preheated mixed feed stream at the reheat temperature to the inlet of the plurality of reforming catalyst-filled tubes disposed in the reformer radiant section, wherein (1) the reformer radiant section is fired to generate a flue gas which passes from the radiant section, through the transition section, and to the convection section and which heats the radiant section catalyst-filled tubes and the one or more convection section coils; (2) a mixed feed stream comprising a hydrocarbon feedstock and steam is fed through and heated in the convection section to yield the preheated mixed feed stream; (3) feeding the preheated and prereformed mixed feed stream through the radiant section catalyst-filled tubes generates a hydrogen-containing product gas; and (4) the prereformer and independent heater are not contained within the reformer.
[0027] In a preferred embodiment of the invention, the prereformed and preheated mixed feed stream is heated from about 400° C. to a reheat temperature of between about 650° C. to about 700° C. in the independent heater.
[0028] In another preferred embodiment of the invention, the independent heater is a fired heater.
[0029] In a particularly preferred embodiment, the reformer is a steam-methane reformer (SMR), the hydrocarbon feedstock is natural gas, the independent heater is a fired heater, the prereformer effluent reheat temperature is between about 650° C. to about 700° C., and the hydrogen-containing product gas is synthesis gas which is recovered and purified. Existing prereformers or independent heaters which are located outside of an operating reformer can be reconfigured in accordance with the instant invention to increase the hydrogen-containing product gas production capacity of the reformer and overall hydrogen production of an associated plant.
[0030] Processes of the invention facilitate the expansion of the hydrogen-containing product gas production capacity of an existing reformer and/or an associated plant (conceivably by around 25% to around 60%) without disrupting the output or energy balance of either the reformer or any associated plant. Implementation of processes of the invention is not constrained by reformer convection section size or coil configuration. Substantially uniform reheat temperatures are achieved by processes of the invention because the prereformer effluent reheat coil is not exposed to a non-uniform heating environment, e.g., reformer radiant section flames. Positioning the prereformer and independent heater outside of the reformer achieves uniform temperature control of the reformer feed; does not interfere with reformer heat duty; and eliminates carbon formation on heat exchange surfaces such as fired heater heating coils while reheating prereformed feed to the reformer to temperatures of as high as around 700° C.
[0031] The independent heater used in the invention may be adjusted to vary reheat temperature, e.g., in response to variations in process conditions and product demand. A lower reheat temperature of the prereformer effluent stream may be maintained if the reformer's rate of production of hydrogen-containing product gas is reduced and a higher reheat temperature may be maintained if a greater rate of production of hydrogen-containing product gas is required. The independent heater may be relatively small and may have a substantially smaller heat duty compared to the reformer. Therefore, the rate of production of hydrogen-containing product gas can be varied in a matter of hours.
[0032] Another advantage offered by processes of the instant invention is that when the independent heater is taken off-line, e.g., for purposes of servicing, the prereformer effluent may be fed directly to the reformer radiant section catalyst tubes, thereby avoiding a complete shut-down of reformer operation.
[0033] Further, because of all of the aforementioned advantages, processes of the instant invention prove particularly useful in optimizing the incremental expansion of hydrogen production networks.
[0034] These and other aspects of the invention are described further in the following detailed description of the invention.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0035] FIG. 1 illustrates a conventional reforming process, as described above.
[0036] FIG. 2 illustrates a conventional reforming process that employs adiabatic prereforming, as described above.
[0037] FIG. 3 illustrates a conventional reforming process that employs convection section prereforming, as described above.
[0038] FIG. 4 illustrates one embodiment of a process of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The following definitions apply unless indicated otherwise.
[0040] A “hydrocarbon feedstock” includes any hydrocarbon-containing stream which can be reacted chemically to produce a hydrogen-containing product gas. Hydrocarbon feedstocks include but are not limited to light hydrocarbons such as natural gas, naphtha, and refinery offgases, and high molecular weight liquids or solid carbonaceous materials. “Reforming” and “reacting hydrocarbon feedstock chemically to produce a hydrogen-containing product gas” include but are not limited to: steam reforming of light hydrocarbons (primarily natural gas, naphtha, and refinery offgases); dry reforming; the partial oxidation of carbon-containing feedstocks (ranging from natural gas to high molecular weight liquid or solid carbonaceous materials); non-oxidative catalytic decomposition; and autothermal reforming of light hydrocarbon feed (which combines features of both partial oxidation and steam reforming in a single reactor).
[0041] Steam reforming is a preferred reforming process. In steam reforming, a hydrocarbon and steam mixture reacts in the presence of a catalyst to form hydrogen, carbon monoxide and carbon dioxide. Since the reforming reaction is strongly endothermic, heat must be supplied to the reactant mixture, e.g., by heating the tubes in a furnace or reformer. The amount of reforming achieved depends on the temperature of the gas leaving the catalyst.
[0042] “Hydrogen-containing product gas” is produced by reforming a hydrocarbon feedstock, as defined above. Hydrogen-containing product gas (e.g., synthesis gas) produced by processes of the invention can be separated to yield a substantially pure hydrogen product by separation apparatus and processes that are well-known to those of ordinary skill in the art.
[0043] “Reformers” used in the processes of the invention include but are not limited to conventional steam methane reformers and modular steam reformers, including Modular Partition Reformers (MPR's) such as those described in commonly-owned U.S. Pat. No. 6,793,700 ('700 Patent) and U.S. patent application Ser. No. 10/746,577, the complete disclosures of which are hereby incorporated by reference.
[0044] One embodiment of a MPR that is disclosed in the '700 Patent and that can be used in processes of the invention includes: a combustion chamber, a convection chamber in fluid communication with the combustion chamber, at least one burner disposed in the combustion chamber, and a reaction chamber. The combustion chamber has a first end and a second end opposite the first end. The convection chamber has a first end and a second opposite the first end, the first end of the convection chamber being adjacent the second end of the combustion chamber. The at least one burner is disposed in the combustion chamber and is adapted to combust a fuel, thereby generating a flow of a flue gas from the combustion chamber to the convection chamber, the flue gas having a sensible heat. The reaction chamber has a first part and a second part in fluid communication with the first part. A substantial portion of the first part is disposed in the combustion chamber and a substantial portion of the second part is disposed in the convection chamber. The second part is a tube-in-tube having an annular portion between an inner tubular portion and an outer tubular portion surrounding the inner tubular portion. The apparatus also includes a means for flowing a first mixed-feed through the first part of the reaction chamber, and a means for flowing a second mixed-feed through the annular portion of the second part of the reaction chamber counter-currently with the flow of the flue gas in the convection chamber.
[0045] MPR's disclosed in the '700 Patent can combine combustion and convection chambers in one compact unit that can be built in the shop and serve as a modular unit, so that several units can be added with relatively simple connections in the field to achieve or to expand synthesis gas production capacity.
[0046] One embodiment of a MPR disclosed in U.S. patent application Ser. No. 10/746,577 which can be used in processes of the invention includes a vessel having at least one partition wall disposed in the vessel. The at least one partition wall divides the vessel into a plurality of chambers, including at least one combustion chamber and at least one convection chamber. Each of the chambers has a first end and a second end opposite the first end. At least one burner is disposed in the combustion chamber. The burner is adapted to combust a fuel, thereby generating a flue gas having sensible heat. The apparatus also includes communication means between the combustion chamber and the convection chamber whereby at least a portion of the flue gas flows from the combustion chamber to the convection chamber at a first location adjacent the first end of the convection chamber. The apparatus also includes transfer means whereby at least a portion of the flue gas flows to a second location in the convection chamber adjacent the second end of the convection chamber. The apparatus also includes multiple reaction chambers, including a first reaction chamber and a second reaction chamber. A substantial portion of the first reaction chamber is disposed in the combustion chamber, and a substantial portion of the second reaction chamber is disposed in the convection chamber.
[0047] MPR's disclosed in U.S. patent application Ser. No. 10/746,577 are in the form of a compact unit that may be built in the shop and may be used as a modular unit in a configuration where several units set side-by-side are connected with simple connections at a field site to achieve or to expand synthesis gas production capacity.
[0048] “Prereformers” used in processes of the invention are adiabatic prereformers which can comprise an insulated vessel filled with a prereforming catalyst. Other types of useful adiabatic prereformers are well-known to those of ordinary skill in the art and can be also be used in the invention.
[0049] Reforming and prereforming catalysts used in processes of the invention can be the same or different and include but are not limited to metallic catalysts such as structured or unstructured metallic catalysts, e.g., structured or unstructured nickel reforming catalysts Conventional steam-methane reforming and prereforming catalysts such as nickel-alumina, nickel-magnesium alumina and the noble metal catalysts can also be used in steam-methane reforming embodiments of the invention.
[0050] In certain embodiments, reformer catalyst tubes have an inside diameter of at least about 125 mm, the pressure drop through the reformer catalyst tubes is less than about 0.1 MPa, the catalyst in the catalyst-filled tubes preferably has a substantially uniform size distribution, and the catalyst in the reformer catalyst-filled tubes preferably has a nickel content from about 15 to about 20 weight percent and is optionally promoted with potassium. Other useful reforming and prereforming catalysts are well-known to those of ordinary skill in the art and can be used in the invention.
[0051] An “associated plant” means any facility that receives or uses hydrogen-containing product gas produced by a reformer.
[0052] A “mixed feed stream comprising a hydrocarbon feedstock and steam” typically is comprised of mixture of natural gas with steam, mixture of vaporized naphtha with steam, mixture of refinery off gases with steam, or combination of those hydrocarbons with steam
[0053] A “prereformed and preheated mixed feed stream” typically is comprised of hydrogen, carbon monoxide, carbon dioxide, water, as well as methane and nitrogen.
[0054] “Conventional fuels” include “hydrocarbon feedstock” as defined herein, as well as other hydrogen or hydrocarbon containing fuels.
[0055] “Independent heaters” used in processes of the invention can include any means of heating the prereformer effluent, including but not limited to convective, electrical, and other heating means. The independent heater preferably employs heating elements, e.g., pipes or coils, which reheat the prereformer effluent at a substantially constant reheat temperature. Achieving a uniform reheat temperature minimizes carbon deposition in the prereformer effluent stream.
[0056] Well-known infrastructure (e.g., pipes, valves, compressors, etc.) can be used to: (1) configure the prereformer to receive the preheated mixed feed stream from the reformer convection section and to feed the prereformed and preheated mixed feed stream to the independent heater; (2) configure the independent heater to receive the prereformed and preheated mixed feed stream from the prereformer and to feed the preheated and prereformed mixed feed stream at the reheat temperature to the inlet of the radiant section catalyst tubes; and (3) to recover and optionally purify the hydrogen-containing product gas from the radiant section catalyst tubes.
[0057] “Control means” can be associated, e.g., with the reformer, prereformer, and independent heater used in processes of the invention. The control means can perform a variety of functions, including regulation and optimization of the amount of hydrocarbon feedstock and steam in the mixed feed stream, the mixed feed preheat temperature, and the reheat temperature.
[0058] Control means can include computer systems comprising central processing units (CPU's) for processing data related to network parameters (e.g., hydrocarbon feedstock flow rates and hydrogen-containing product gas production and consumption rates), associated memory media including floppy disks or compact discs (CD's) which may store program instructions for CPU's, one or more display devices such as monitors, one or more alphanumeric input devices such as a keyboard, and one or more directional input devices such as a mouse. Computer systems used in control means can include a computational system memory such as DRAM, SRAM, EDO DRAM, SDRAM, DDR SDRAM, or Rambus RAM, or a non-volatile memory such as a magnetic media (e.g., a hard drive) or optical storage. The memory medium preferably stores a software program or programs for event-triggered transaction processing. The software program(s) may be implemented in any of various ways, including procedure-based techniques, component-based techniques, and/or object-oriented techniques, among others.
[0059] Control means can include instrumentation for: (1) monitoring analog input data relating to process parameters (e.g., hydrocarbon feedstock flow rates and hydrogen-containing product gas production rates); (2) converting such analog input data to CPU input digital signals for CPU processing and generation of CPU digital output signals; and (3) converting CPU digital output signals to analog signals that vary process parameters such as hydrocarbon feedstock flow rates and preheat and reheat temperatures in accordance with CPU digital output signals. Thus, control means can provide real-time, feedback control of process operation.
[0060] In a preferred embodiment, the independent heater is a fired heater having a combustion section which generates a flue gas which is passed to a fired heater convection section. One or more heating coils may be positioned in the fired heater convection section in manner which avoids direct exposure of the coils to the radiation heat from the fired heater combustion section. The fired heater flue gas temperature may be controlled by varying the number and/or duty of fired heater combustion section firing elements (e.g., burners) and by using, e.g., 180% to about 280% of a stoichiometric amount of air. Such a firing system provides substantial temperature control of the fired heater flue gas temperature in proximity to the fired heater convection section coils. The temperature of the flue gas in proximity to the fired heater convection section heating coils may be held slightly above that required for prereformer effluent stream reheat.
[0061] In still another embodiment, the combustion air used to fire the reformer radiant section is preheated in the independent heater.
[0062] Generating a flue gas in the fired heater combustion section through combustion of a conventional fuel with excess air eliminates high temperature gradients between the fired heater flue gas and reheated prereformer effluent and minimizes the differential between the prereformer effluent reheat temperature and fired heater convection section coil metal peak temperatures. This minimizes the risk of carbon formation on the fired heater convection section coils and enables a high reheat temperature for the prereformer effluent stream.
[0063] In another embodiment, the fired heater convection section contains rows of convection coils configured in a split design, with the first several rows of the coils arranged to channel fired heater flue gas co-currently with the prereformer effluent stream to reduce the coil's metal peak temperatures.
[0064] In preferred embodiments, the prereformed and preheated mixed feed stream is heated from about 370° C. to a reheat temperature of about 700° C. in the independent heater, and is most preferably heated from about 400° C. -500° C. to a reheat temperature of about 680° C.
[0065] FIG. 4 illustrates one embodiment of a process of the instant invention. Referring to FIG. 4 , mixed feed stream 1 comprising a hydrocarbon feedstock and steam is preheated in convection section 2 of reformer 10 . An adiabatically prereformed and preheated mixed feed stream is then generated by feeding the preheated mixed feed stream 1 through prereformer 7 .
[0066] The prereformed and preheated mixed feed stream is then heated to a reheat temperature by independent heater 8 . As indicated by dashed line 1 a, preheated mixed feed stream 1 may also be preheated prior to prereforming using independent heater 8 . Prereformed and preheated mixed feed stream 3 is then fed at the reheat temperature to the inlet of a plurality of reforming catalyst-filled tubes 4 disposed in radiant section 5 of reformer 10 , thereby generating a hydrogen-rich synthesis gas 6 which is recovered and optionally purified through the use of processes and apparatus that are well-known to those of ordinary skill in the art.
[0067] The invention is illustrated further in the following non-limiting example.
EXAMPLE 1
[0068] An optimized steam reforming process of the instant invention was modeled based on the use of an independent fired heater which heats an adiabatically prereformed and preheated mixed feed described in Table 1 below to a reheat temperature of around 650° C.
[0069] The fired heater is designed with a separate combustion chamber which operates on natural gas fuel with an excess air of 130% above stoichiometry (corresponding to 11.2% (wet) oxygen in the fired heater flue gas). A reheat coil is located in the fired heater convective section and is not exposed directly to the fired heater combustion chamber radiant heat. The temperature of the flue gas at the coil inlet is 990° C. The reheat coil has nine rows of 2″ tubes; the first two rows of tubes are configured in a co-current arrangement with the flue gas flow to reduce peak temperatures, and the remaining seven rows are configured in a counter-current arrangement with the flue gas. The inner gas film temperature at the first and hottest tube row of the coil is 690° C., which ensures than no carbon formation can occur on the internal heat exchange surface. The corresponding maximum (peak) metal temperature is 733° C. and the bulk gas temperature at the first row exit is 505° C. The first five rows of the coil are designed based on the use of bare tubes; finned tubes are used for the last four rows of the coil to extend surface area at the part of the coil with lower flue gas temperatures.
TABLE 1 PREREFORMER EFFLUENT STREAM (Inlet to the Fired Heater reheat coil) COMPOSITION COMPONENTS kmol/hr % mol. H2 21.42 7.9% C1 59.11 21.8% CO 0.11 0.0% CO2 6.79 2.5% N2 0.25 0.1% H2O 183.17 67.6% TOTAL 270.84 100.0% Pressure, 24.6 Bara Temperature ° C. 453
[0070] Although illustrated and described herein with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention.
|
The invention provides a process which facilitates high incremental capacity expansion of existing syngas-based plants by providing an adiabatic prereformer and an independent heater which is configured to (1) receive a prereformed and preheated mixed feed stream from the prereformer, (2) heat the prereformed and preheated mixed feed stream to a reheat temperature of as high as around 700° C. without local overheating of heat exchange surfaces and without the risk of carbon formation (on, e.g., fired heater heating coils), and which (3) feeds the prereformed and preheated mixed feed stream at the reheat temperature to the inlet of reformer radiant section catalyst tubes, wherein the prereformer and independent heater are not contained within the reformer.
| 1
|
BACKGROUND OF THE INVENTION
[0001] Vitamin K controls the formation of prothrombin, factor VII, factor IX, and factor X by acting as a substrate for the enzyme γ-glutamyl carboxylase. This enzyme catalyzes the addition of carbon dioxide to the γ-carbon of protein-bound glutamic acid in the gla regions of the coagulation factors.
[0002] Coumarin anticoagulants, which include warfarin and dicumarol (dicoumarol), prevent the reduction of vitamin K epoxides in the liver microsomes and induce a state of vitamin K deficiency. A side effect of such anticoagulants is hemorrhage. If hemorrhage does occur, there is a need for a substance to inhibit the coumarin anticoagulant-induced bleeding.
DESCRIPTION OF THE INVENTION
[0003] The present invention fills this need by administering factor XIII to patients afflicted with bleeding due to a coumarin anticoagulant-induced vitamin K deficiency. Factor XIII can be administered alone or in conjunction with cryoprecipitate or fresh frozen plasma, generally two units or plasma. Vitamin K can also be administered at an initial dose of 5 to 10 mg, generally subcutaneously. The administration of factor XIII can be applied prophylactically or at the time of a bleeding episode.
[0004] Factor XIII, also known as fibrin-stabilizing factor, circulates in the plasma at a concentration of 20 μg/ml. The protein exists in plasma as a tetramer comprised of two A subunits and two B subunits. Each subunit has a molecular weight of 83,000 Da, and the complete protein has a molecular weight of approximately 330,000 Da. Factor XIII catalyzes the cross-linkage between the γ-glutamyl and ε-lysyl groups of different fibrin strands. The catalytic activity of factor XIII resides in the A subunits. The B subunits act as carriers for the A subunits in plasma factor XIII. Recombinant factor XIII can be produced according to the process described in European Patent No. 0 268 772 B1. The level of factor XIII in the plasma can be increased by administering a factor XIII concentrate, derived from human placenta or plasma, called FIBROGAMMIN® (Aventis Corp.) or by administration of recombinant factor XIII. When recombinant factor XIII is used, only the ‘A 2 ’homodimer is generally administered without the ‘B 2 ’ subunit.
[0005] Administration of factor XIII to a subject is generally done intravenously. When administering therapeutic proteins by injection, the administration may be by continuous infusion or by single or multiple boluses. A pharmaceutical composition comprising factor XIII can be formulated according to known methods to prepare pharmaceutically useful compositions, whereby the therapeutic proteins are combined in a mixture with a pharmaceutically acceptable carrier. A composition is said to be a “pharmaceutically acceptable carrier” if its administration can be tolerated by a recipient patient. A suitable pharmaceutical composition of factor XIII will contain 1 mM EDTA, 10 mM Glycine, 2% sucrose in water. An alternative formulation will be a factor XIII composition containing 20 mM histidine, 3% wt/volume sucrose, 2 mM glycine and 0.01% wt/vol. polysorbate, pH 8.
[0006] Other suitable carriers are well known to those in the art. See, for example, Gennaro (ed.), Remington's Pharmaceutical Sciences, 19th Edition (Mack Publishing Company 1995).
[0007] The levels of factor XIII in an individual can be determined by assays well known in the art such as the BERICHROM® F XIII assay (Dade Behring Marburgh GmbH, Marburg, Germany). The normal adult has an average of about 45 ml of plasma per kg of body weight. Each liter of blood has 1000 units (U) of factor XIII. The amount of factor XIII administered should be enough to bring an individual's level of factor XIII in the plasma to at least 100% of normal plasma or preferably 1-5% above normal. A dose of 0.45 U/kg would raise the level of factor XIII by about 1% compared to normal. One unit of factor XIII is about 10 μg of recombinant factor XIII, which contains only the dimerized A subunit. Thus, to raise the level of factor XIII by 1%, one would administer about 4.5 μg of the A2 subunit per kilogram weight of the individual. So to raise the level 30% of normal, one would administer 13.5 U/kg. For a 75 kg individual this would be about 1,012.5 U. Some patients may have consumptive coagulopathies that involve factor XIII losses. In such cases, a higher dosing (e.g., 1-2 U/kg-%) or multiple dosing of factor XIII (e.g., 1-2 U/kg-%-day) may be required.
|
Use of factor XIII for treating coumarin-induced hemorrhage or bleeding. The coumarin may be warfarin or dicoumarol. A patient having coumarin-induced bleeding is treated with factor XIII alone or in conjunction with vitamin K.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Application No. 61/554,187 filed Nov. 1, 2011, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of reconfigurable structures and, more particularly, reconfigurable multivibrator electronic devices. As an underling principle, this invention uses the dynamical richness of nonlinear (chaotic) systems to provide different alternatives or embodiments of multivibrators. Where a nonlinear oscillator circuit, a simple input circuit, and a comparator function (output circuit) are made to operate in astable, monostable or bistable mode.
BACKGROUND OF INVENTION
[0003] Chaos in known to be useful. In fact, under certain conditions, it is a desirable feature of systems and circuits. The dynamical richness of chaotic behavior has significant potential applications to real-world problems, including secure communications, persistent excitation, information processing and incryption, to mention but a few (Ott, 2002 “Chaos in Dynamical Systems (Cambridge University Press, UK); Strogatz, S. H. 2001 “Nonlinear Dynamics, and Chaos: with applications to physics, biology, chemistry, and engineering (Westview Press, USA)); Tam et al., 2007 “Communications with Chaos: Multiple access techniques and performance (Elsevier Science Press, Great Britain)). In particular, the present invention uses chaos theory to design a reconfigurable multivibrator element in order to have different configurations in an all-in-one circuit.
[0004] A multivibrator circuit is a simple two-state system that has only one of three possible configurations, these are:
[0005] (i) Astable multivibrator, in this configuration, both states of the system are unstable. As a consequence, the output of the circuit spends a given amount of time in one state, and then in the other, moving back and forth from one to the other in a continuously repeated cycle. Usually, this configuration is used to generate sequences and pulses with a given frequency and width, see for example patents JP53085479, U.S. Pat. No. 4,191,927.
[0006] (ii) Monostable multivibrator, in this configuration, one state of the circuit is stable while the other is unstable. As such, the system may spend some time in the unstable state, but eventually will move into the stable state and remain there afterwards. This configuration can be used, for instance, to define a time-period of activity measured from an event, for example in JP57044768, U.S. Pat. No. 4,430,682 monostable multivibrators are used in motor timing.
[0007] (iii) Bistable multivibrator, in this configuration both states are stable. This implies that the circuit remains in its current state, until being forced to change to the other by an external event or input. A multivibrator system in bistable configuration can be used as a fundamental building block of a register or memory device, for example in U.S. Pat. Nos. 4,081,840 and 4,191,927, a bistable multivibrator in used as part of a switching device.
[0008] There is great interest in developing new working paradigms to complement and even replace current statically configurable architectures. One of the newest ideas is chaos computing which focuses on the development of devices with dynamic logic architecture and employs nonlinear or chaotic elements in logic operations. Application of chaos computing requires the development of dynamic logic gates (also called logic cells) that are able to change their response according to threshold reference signals and offset signals in order to produce different logic gates. These dynamic logic gates would support development of logic chips for next generation computers. Current inventions related to logic gates that exploit features of nonlinear dynamic systems through their electronic implementations are, for example, U.S. Pat. Nos. 8,091,062, 7,973,566, 7,924,059, 7,863,937, 7,415,683, 7,096,437, 7,453,285, 7,925,814, 7,925,131 and US patent application 2010/0219858. These inventions make use of chaotic computing architectures based on nonlinear elements, while the present invention discloses reconfigurable multivibrator using a nonlinear oscillator.
[0009] Reconfigurable structures based on chaos have been investigated for a long time, with significant results, such as: [Cafagna, D. & Grassi, G. 2005. “Chaos-based computation via Chua's circuit: Parallel computing with application to the SR flip-flop,” Int. Symp. Sign. Circuits Syst. 2, 749-752.] where the chaotic Chua's circuit use it to obtain two logic gates from two state variables, from those chaos-based logic they implemented two NOR gates and build a standard flip-flop device. Alternative realizations of chaos-based logic gate have been reported [Sinha, S. & Ditto, W. 1998 “Dynamics based computations,” Phys. Rev. Lett. 81, 2156-2159; Murali K., Sudeshna S. 2003 “Experimental realization of chaos control by thresholding”, Physical Review E., vol. 68, Jul. 14, 2003; Campos-Cantón E., J. G. Barajas-Ramírez, G. Solís-Perales, R. Femat, 2010, “Multiscroll attractors by switching systems”. CHAOS, 20: 013116]. With these logic gates is possible to build just a static bistable multivibrator.
[0010] Different methods for the construction of multivibrators have been disclosed, for example U.S. Pat. Nos. 6,281,732, 4,301,427, and GB1416931 describe constructions of astable, monostable and bistable multivibrators based on stabilized amplifiers, mosfets and inverters. However, unlike the present invention these multivibrators have fixed configurations, without the possibility of reconfiguration. In many applications of multivibrators more than one configuration is required, for example in devices for measurement and control of temperature, acoustic, and motor timing (see patents U.S. Pat. No. 4,081,840, U.S. Pat. No. 7,310,82, JP53085479). In these inventions it is compulsory to combine more than one multivibrator configuration. The reconfigurable multivibrator provided in the present invention discloses a single device to obtain an all-in-one multivibrator configuration (monostable, astable, and bistable).
SUMMARY OF THE INVENTION
[0011] The instant application discloses and claims a dynamically reconfigurable multivibrator element, comprising: an input block coupled to a nonlinear chaotic system with a control input that adjust the parameters in order to change a desirable multivibrator configuration and coupled to an output block; wherein the nonlinear chaotic system is a Piecewise-linear (PWL) chaotic system and wherein the output block comprises at least one comparator circuit.
[0012] In said dynamically reconfigurable multivibrator element the adjustment of the parameters allows to get the three different multivibrator configurations, astable, bistable and monostable. Furthermore, wherein the dynamically reconfigurable multivibrator element is set to bistable configuration becomes the embodiment of a full SR flip-flop. wherein the full SR flip-flop accepts all the logic inputs (S,R): (0,0), (0,1), (1,0) and (1,1) and responds as (Q n+1 ): Q n , 0, 1, and Q n , respectively.
[0013] Also, said dynamically reconfigurable multivibrator element, when is set to astable configuration becomes the embodiment of a pulse generator with irregular period when the nonlinear element is oscillating chaotically or regular pulses when is oscillating into a limit cycle.
[0014] In a further embodiment, said dynamically reconfigurable multivibrator element, when is set to monostable configuration becomes unstable in the state logic zero and stable in the state logic one.
[0015] As a particular embodiment said dynamically reconfigurable multivibrator element, comprises an input block, a piecewise-linear (PWL) chaotic system with a control input that adjusts the parameters in order to change a desirable multivibrator configuration, and an output block with at least one comparator circuit.
[0000] Also, it is described an claimed a SR flip-flop device, comprising the above mentioned dynamically reconfigurable multivibrator elements.
[0016] Finally a pulse generator device is described, comprising the above disclosed dynamically reconfigurable multivibrator elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a block diagram of a reconfigurable dynamic multivibrator device using an input circuit, a nonlinear oscillator and comparator function in the output circuit.
[0018] FIG. 2 is a circuit schematic of the reconfigurable multivibrator device of FIG. 1 according to one embodiment of the present invention; The elements 202 , 204 , 206 , 208 , 210 , 212 , 214 , 216 , 218 , 220 , 222 , 224 , 226 , 228 , 230 , 232 and 234 constitute the input block, the output block is comprised by the elements 236 , 238 , 240 , 242 , 244 and 246 , and the nonlinear oscillator is made up by the elements 248 , 250 , 252 , 254 , 256 , 258 , 260 , 262 , 264 , 266 , 268 , 270 , 272 , 274 , 276 , 278 and 280 .
[0019] FIG. 3 is a series of timing graph illustrating timing sequences of implementations of a representative bistable multivibrator configuration formed in accordance with the inventive arrangements disclosed herein that generates a full RS flip-flop.
[0020] FIG. 4 is a series of timing graph illustrating timing sequences of implementations of an astable multivibrator configuration formed in accordance with the arrangements by using the dynamically reconfigurable multivibrator element disclosed in the instant invention.
[0021] FIG. 5 is a series of timing graph illustrating timing sequences of implementations of a representative monostable multivibrator configuration formed in accordance with the inventive arrangements disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The instant invention comprises a dynamically reconfigurable multivibrator element based on nonlinear (chaotic) dynamics which through a parameter modulating control specially designed to operate as one of the three multivibrator configurations, namely, astable, monostable or bistable multivibrator circuits. The advantage of the element is that a single device (all-in-one) is capable of carrying out the three configurations without additional multivibrator elements.
[0023] As for the scope of the invention, the term element should be understood as a circuit that can be incorporated to a larger system, device or circuit suitable for the purposes of the invention.
[0024] The invention comprises nonlinear dynamics of a Piecewise Linear (PWL) system used to provide the three different multivibrator configurations. Structurally PWL systems are very simple, consisting of linear descriptions for each partition of their phase space. This simplicity makes them particularly well-suited for electronic implementations, e.g. via operational amplifiers. On the other hand, they can produce dynamical behaviors that range from stable fixed points to multiscroll chaotic attractors. As described in [Campos-Cantón E., J. G. Barajas-Ramírez, G. Solís-Perales, R. Femat, 2010, “Multiscroll attractors by switching systems”. CHAOS, 20: 013116], different dynamical regimes can be imposed on the solutions of a PWL system by properly tuning the system's parameters. In this way, an analogy between the three multivibrator configurations and the dynamical regimes of a PWL system can be obtained as follows:
[0025] (i) Astable Multivibrator.
[0026] By applying parameter modulation control, a PWL system can be made to have a double-scroll chaotic attractor with a basin of attraction covering its entire domain. By associating to each scroll a different output state, as the trajectories of the system move along the chaotic attractor, the output state will continuously switch from one output state to the other, which corresponds to the behavior of an astable multivibrator. It is noteworthy that since the transitions between the output states occurs as the trajectory moves along the chaotic attractor, the transitions will occur at irregular times and not with a fixed period.
[0027] (ii) Monostable Multivibrator.
[0028] A controlled PWL system can be made to have a single-scroll chaotic attractor for its entire domain. By dividing the domain along the center axis with the single-scroll attractor contained in one side, it is possible to associate an output state to the empty part of the domain and the other output state to the single-scroll attractor. Then, as the trajectories move from the empty half of the domain towards the single-scroll attractor, the output state will be at one value for a while, and when the trajectory reaches the attractor, the output will switch to the other state and remain at that value from that moment on. In this way, the monostable multivibrator behavior is obtained from a PWL system via chaos control.
[0029] (iii) Bistable Multivibrator.
[0030] Under appropriate parameter modulating control a PWL system can be made to have two different stable single-scroll attractors located each side of the center axis of the domain. When there are two stable chaotic attractors and it is possible to generate only one of them by means of changing the initial conditions, it is said that the system exhibits bistable chaos. In this case the trajectories will follow only one of the attractors according to their initial conditions. That is, in bistable chaos, each attractor has its own distinct basin of attraction. Then, associating each output state to the basins of attraction of each single-scroll chaotic attractor, if an initial condition is set to one of the attractors the output state will remain at that value from that moment on. However, if the initial condition is set to the opposite side, the other output state will be shown from that moment onwards. As such, the behavior of the bistable multivibrator is obtained from the controlled PWL system.
[0031] Thus, the present invention provides a reconfigurable multivibrator that can be configured to function as any of a variety of different multivibrators such as a bistable multivibrator, a monostable multivibrator and an astable multivibrator. The functionality of the reconfigurable multivibrator can be altered by changing one or more parameters to the nonlinear oscillator. The reconfigurable multivibrator can function, for example, as one type of multivibrator, such as a bistable multivibrator, and during operation be instructed to begin operating or functioning as another type of multivibrator, such as an astable multivibrator or monostable multivibrator or combinations thereof. Applications are illustrated herein below by designing a circuit that functions as a pulse generator and a full S-R flip flop device based on the all-in-one reconfigurable multivibrator element.
[0032] Table I below illustrates a truth table of basic operations. For example, column 3 illustrates the function of a bistable multivibrator given inputs (S,R), column 4 shows the function of an astable multivibrator given inputs (S,R), and column 5 shows the function of a monostable multivibrator given inputs (S,R).
[0000]
TABLE 1
1
2
3
4
5
S
R
Bistable Q n
Astable Q n
Monostable Q n
0
0
Q n−1
Free running
Free running
0
1
0
Not allowed
Not allowed
1
0
1
Not allowed
Not allowed
1
1
Q n−1
Free running
Free running
[0033] FIG. 1 is a schematic diagram illustrating a high level circuit architecture 100 for a reconfigurable multivibrator in accordance with the present invention. Therefore, this FIG. 1 discloses the essential technical characteristic of the invention, and should be taken as the main principle of the same. As shown, the reconfigurable multivibrator can include a nonlinear oscillator 110 , a parameters controller 112 , an input circuit 106 , and an output circuit 116 . The parameters controller provides a tuning of parameters that change the stability of the nonlinear oscillator. The input block can receive the inputs signals S 102 and R 104 , when S and R are equal the signal 108 is null but when they are different then signal 108 forced the nonlinear oscillator 110 . The output block 116 receives the signal 114 which is compared with a reference signal in order to generate a logic zero or logic one that are given as the output Q 118 .
[0034] The operation of the nonlinear oscillator 110 according to the present invention can be described by the mathematical model as follows:
[0000]
(
x
.
1
x
.
2
x
.
3
)
=
(
∝
(
x
2
-
x
1
-
f
(
x
1
)
)
x
1
-
x
2
+
x
3
-
β
x
2
+
γ
x
3
)
[0035] where f(x 1 ) is a nonlinear negative resistor which is described as
[0000]
f
(
x
1
)
=
{
b
1
x
1
-
c
1
,
if
x
1
>
1
;
a
x
1
,
if
x
1
≤
1
;
b
2
x
1
+
c
2
,
if
x
1
<
-
1
;
[0036] with c i =b i −a, i=1, 2. Thus, the nonlinear oscillator 110 can be implemented as a three dimensional Chua's system. Given a dynamics ({dot over (x)} 1 , {dot over (x)} 2 , {dot over (x)} 3 ) T corresponding to a physical device, the values of parameters and initial state satisfying the conditions derived from the truth table to be implemented must be determined. Still, those skilled in the art will recognize that other functions also can be used, including, but not limited to, discrete time chaotic functions.
EXAMPLES
[0037] As a preferred embodiment, that should be taken as a work example but not limiting the scope of the invention, FIG. 2 represents schematic diagram illustrating an exemplary circuit implementation of the dynamically reconfigurable multivibrator element 100 depicted in FIG. 1 . The operation of the input block according to the present invention may be described as follows: there are two inputs 202 (S) and 204 (R) that are introduced to the system by the resistors 214 (R 209 ) and 206 (R 206 ). The input 204 (R) is passed through inverting amplifier given by the operational amplifier 210 (U 2 ) and the resistor 206 (R 6 ) and 208 (R 7 ). The output of the operational amplifier 216 (U 3 ) is the voltage 262 (V 1 ) which is added with the input signal 202 (S) and the output of operational amplifier 210 (−R) through the resistors 212 (R 8 ), 214 (R 9 ), 218 (R 10 ) and 220 (R 11 ) and the operational amplifier 222 (U 4 ) by means of inverting adder. Thus the output of 222 (V a ) is R−S−V 1 ( 204 - 202 - 262 ) due to all the values of the resistor of the input block are equal to 1 kΩ, except for the resistor 234 (R 14 ), which is set to 100 kΩ. The voltage 224 (V a ) is passed through the inverting amplifier given by the resistors 226 (R 12 ) and 228 (R 13 ), and the operational amplifier 230 (U 5 ), generating the voltage 232 (V n ). The voltage 232 (V n ) is given by V 1 +S−R, always that the inputs 202 and 204 are equal (S=R) the voltage 232 (V n ) is equal to the voltage 262 (V 1 ) and the current through the resistor 234 (R 14 ) is zero.
[0038] The operation of the output block according to the present invention may be described as follows: the input voltage for this block is 262 (V 1 ) that is passed through a buffer 236 (U 6 ) and after a low pass filter comprising resistor 238 (R 15 ) and the capacitor 240 (C 3 ), this signal is passed by a buffer 242 (U 7 ) and a comparator 244 (U 8 ), generating the output signal 246 (Q).
[0039] The nonlinear oscillator has the following relationship between the electronic components in FIG. 2 and the parameters of the mathematical model are:
[0000]
∝
=
C
2
C
1
,
β
=
C
2
R
0
2
L
,
γ
=
C
2
R
0
r
L
,
a
=
-
R
0
R
2
R
1
R
3
,
b
1
=
-
R
0
R
2
R
1
R
3
+
R
0
R
4
,
b
2
=
-
R
0
R
2
R
1
R
3
+
R
0
R
5
,
[0040] where the capacitor 260 C 1 =100 nF, the capacitor 254 C 2 =1 μF, the inductor 250 L=67.1 mH with internal resistance 248 r=2.57Ω, the resistors 270 (R 2 ) and 268 (R 3 ) equal to 220Ω. The resistors 258 (R 0 ), 272 (R 1 ), 276 (R 4 ) and 280 (R 5 ) are 5 kΩ potentiometers. The potentiometer 258 R 0 is tuned to 1003Ω the others according to the Table 2. The parameter b 1 is active when the diode 274 D 1 is forward bias voltage and the parameter b 2 is active when the diode 278 D 2 is forward bias voltage
[0000]
TABLE 2
Bistable
Astable
Monostable
R 1 tune to
884 Ω
825 Ω
884 Ω
R 4 tune to
4.062 kΩ
3.058 kΩ
4.062 kΩ
R 5 tune to
4.062 kΩ
3.058 kΩ
3.515 kΩ
[0041] The bistable form of multivibrator illustrated in FIG. 2 is controlled by the inputs according to the table 1 and the potentiometers 272 (R 1 ), 276 (R 4 ) and 280 (R 5 ) tune according to the table 2.
[0042] When the dynamically multivibrator element is configured as bistable, it becomes part, for example, of a full SR flip-flop device. Thus, FIG. 3 is a series of timing graph illustrating timing sequences of implementations of a representative bistable multivibrator configuration formed in accordance with the arrangements disclosed in an specific embodiment of the invention, which generates a full SR flip-flop. The timing sequences of the exemplary bistable multivibrator implementation, from top to bottom, represent: (1) first input S; (2) second input R; and (3) the output Q.
[0043] An advantage of the bistable form of the multivibrator according to the present invention is that all the entries are allowed, i.e., the system is determined for a particular entry (S, R)=(1,1); as is shown in the table 1.
[0044] The astable form of multivibrator illustrated in FIG. 2 is free-running when the potentiometers 272 (R 1 ), 276 (R 4 ) and 280 (R 5 ) are tuned according to the table 2, and the inputs are set at zero volts.
[0045] When the dynamically multivibrator element is configured as astable, it becomes part of a, for example, a noise generator. Therefore, FIG. 4 is a series of timing graph illustrating timing sequences of implementations of a representative astable multivibrator configuration formed in accordance with a particular example of the dynamically reconfigurable multivibrator element of the instant invention. This multivibrator generates an aperiodic rectangular output wave and also can generate periodic rectangular output wave. The input circuitry can be omitted, since the astable multivibrator is shown in a free-running form, so the line form the resistor 234 to the node 262 (V 1 ) can be shut off.
[0046] An advantage of the astable form of the multivibrator according to the present invention provides for equal rise and fall times on the square wave, as well as symmetrical on and off periods. Furthermore, due to its nonlinear dynamics and the possibility to produce chaos is possible to generate irregular or chaotic square wave that can be used as a noise generator.
[0047] The monostable form of multivibrator illustrated in FIG. 2 is free-running when the potentiometers 272 (R 1 ), 276 (R 4 ) and 280 (R 5 ) are tuned according to Table 2, and the inputs are set at zero volts.
[0048] In such monostable configuration, FIG. 5 represents a series of timing graph illustrating timing sequences of implementations of a representative monostable multivibrator configuration formed according to the dynamically reconfigurable multivibrator element disclosed above.
[0049] As a consequence, one multivibrator, a set of multivibrators, or all of the multivibrators within the system can change functionality according to data provided as in Table 2, which parameters can change according to the application of the dynamically reconfigurable multivibrator element using an example that has incorporated specific analog components. Those skilled in the art will recognize that such components have been provided for purposes of illustration only. Therefore, any variety of different components, whether functional equivalents, variants, or alternatives of the analog components or of the higher level components (i.e. of FIG. 1 ) disclosed herein, can be used and are within the scope of the invention. As such, the invention is not limited to the use of a particular component or set of components.
[0050] In light of the above description, a dynamically reconfigurable multivibrator element is designed by adding modulation parameters which modify the stability properties of the linear subsystems. Because the chaos generation is exploited, the multivibrator element incorporates dynamical features onto the a logic-gate architecture.
[0051] Thus, the proposed dynamical logic structure is more adaptable than static logic-gates, as it is reconfigurable by parametric modulation. The reconfiguration allows us to achieve distinct tasks with the same circuit. that is, the proposed architecture might serve as a component of general purpose computing devices with a flexible structure. As a consequence of the parametric modulation, diverse scrolls are generated or inhibited around the equilibrium points of the continuously connected sections of the nonlinear (chaotic) system (such as the PWL system).
|
A reconfigurable element based on nonlinear (chaotic) dynamics is adapted to implement the three different multivibrator configurations. A nonlinear dynamical system, under parameter modulating control, operates as a tunable oscillator with different dynamical regimes which in turn provide the different multivibrator configurations (monostable, astable, and bistable). The reconfigurable multivibrator is realized as a tunable circuit which includes an input stage for receiving at least one input voltage signal and an output stage that produces a digital two-level electric output signal. The all-in-one reconfigurable multivibrator device consisting of a nonlinear oscillator circuit electrically coupled to the input/output circuitry is used in at least, but not limited to three basic applications, namely, an irregular width pulse generator, a rising flank trigger and a full RS flip-flop device.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to catheters having inflatable balloons and in particular to a balloon catheter wherein the balloon is fabric reinforced.
2. Background of the Prior Art
Catheters having inflatable balloons affixed thereto are used in a variety of applications. One application for a balloon catheter is as a dilator for blood vessels which have been partially or entirely blocked by deposits on the inside wall of the blood vessel. The catheter is introduced into the affected blood vessel and the deflated balloon is maneuvered into the blocked area. By inflating the balloon, the deposits are compressed against the wall of the blood vessel, thereby opening the blood vessel to blood flow.
Because of the danger of over dilating and thereby bursting the blood vessel, it is preferred that the balloon be reinforced so that it can expand only to a predetermined maximum diameter regardless of the interior pressure applied. One balloon catheter which is so reinforced is described in British Pat. No. 1,566,674 to Hanecka and Olbert. The Hanecka balloon is reinforced by a woven synthetic fabric wherein the filaments of the fabric extend along helices of opposite sense. As stated in the patent, such a reinforced balloon shortens in length with an increase in diameter. Therefore, to prevent folds in the balloon when it is deflated, the Hanecka device employs two coaxial tubes, one slidable within the other, for lengthening the balloon when it is deflated and permitting shortening of the balloon as it is inflated. One disadvantage of such a balloon catheter is that the structure requires components or parts which are movable relative to one another.
The present invention provides a reinforced inflatable balloon which is smooth in its deflated state, yet expands in diameter without decreasing in length.
SUMMARY OF THE INVENTION
A balloon catheter includes a catheter tube having an expandable and collapsible balloon attached thereto. Means are provided for connecting the balloon to an external source of pressurized fluid. The balloon includes an impervious elastic wall for retaining pressure therein, the balloon being reinforced by a knitted fabric layer to limit the maximum expanded diameter of the balloon.
It is an object of the present invention to provide an improved balloon catheter which is reinforced to limit its maximum expanded diameter, yet which has a smooth configuration in both its contracted and expanded states.
It is another object to provide a balloon catheter as described above with a minimum of moving parts.
Further objects and advantages will become apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a balloon catheter constructed in accordance with the present invention.
FIG. 2 is an enlarged view of the balloon of the balloon catheter of FIG. 1, with portions shown in longitudinal section.
FIG. 3 is an enlarged cross sectional view of the inner member of the balloon catheter of FIG. 1 taken along the line 3--3 of FIG. 2.
FIG. 4 is an enlarged view of the knitted fabric reinforcement layer of the balloon of the balloon catheter of FIG. 1., shown in its expanded state.
FIG. 5 is an enlarged longitudinal sectional view of the Y-fitting of the balloon catheter of FIG. 1.
FIG. 6 is a side elevational view of an alternative embodiment of a balloon catheter constructed in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in particular to FIGS. 1 and 2, there is illustrated a balloon catheter 10 including a catheter tube 11 made of radiopaque flexible urethane tubing. Attached to the distal end portion of catheter tube 11 is an inflatable and collapsible balloon 12, which is shown in greater detail in FIG. 2. Disposed coaxially within catheter tube 11 and balloon 12 is a flexible inner member 13. FIG. 3 shows a cross sectional view of inner member 13, which includes an interior eccentrically located lumen 14 and a longitudinal groove 15. Groove 15 aids in providing a longitudinal passageway between inner member 13 and catheter tube 11 for the passage of fluid therethrough for inflating balloon 12, as described below.
Referring to FIG. 2, it can be seen that inner member 13 extends beyond the distal end 16 of catheter tube 11. Attached to the distal end 18 of inner member 13 is a hollow open tapered plastic tip 19. Lumen 14 is in communication with opening 17 in tip 19. Affixed within the distal end 16 of catheter tube 11 and extending therefrom is a thin-walled stainless steel sleeve 20. Balloon 12 is disposed coaxially about inner member 13 between sleeve 20 and tip 19, defining an annular balloon chamber 21. Balloon 12 includes a three layer wall, the inner layer 22 being an elastic impervious urethane membrane for retaining pressure within balloon chamber 21, the middle layer 23 being a knitted fabric tube, and the outer layer 24 being an elastic impervious urethane membrane, the ends of which are tapered at points 25 and 26 to a smooth transition with the outer surfaces of plastic tip 19 and catheter tube 11. Inner layer 22 and middle layer 23 are secured to portion 28 of tip 19 by tiedown thread 29 which is wound tightly about middle layer 23. Similarly, inner layer 22 and middle layer 23 are secured to sleeve 20 by tiedown thread 30. Outer layer 24 is preferably formed by dipping partially completed balloon 12, including inner layer 22 and middle layer 23, into a liquid urethane solution. Radiopaque marker bands 31 and 32 are disposed about inner member 13 proximate the ends of the inflatable portion of the balloon to aid in the placement of the balloon at the desired location within a blood vessel.
Referring to FIG. 4, there is shown in detail the configuration of a portion of knitted middle layer 23 in an expanded state. Middle layer 23 is knitted as a tube from a single yarn strand arranged generally in a helix, with each turn of the helix comprising a successive row of knitting. Machines for knitting tube shaped fabric are commercially available, with the number of needles varying depending on the size of tube being knitted. The prototype embodiment described herein was knitted on a craft or hobby type machine to which a few needles and an electric motor were added. Preferably, during fabrication of balloon 12, middle layer 23 is knitted over preformed inner layer 22. As is characteristic of knitted fabric, each row is configured as a series of periodically spaced loops, with each loop in each row passing through an adjacent loop in the next preceding row. To illustrate this knit stitch, one row 35 in FIG. 4 is shown darker. Row 35 includes a series of loops, such as loops 36, 37 and 38, each of which passes through loops 36', 37' and 38', respectively, of the next preceding row.
The yarn strand 39 of which middle layer 23 is knitted is comprised of multiple plies or filaments. In the preferred embodiment, the yarn strand is comprised of two parallel twisted plies, one ply 39A being strong and inelastic for limiting the maximum expanded diameter of the balloon, and the other ply 39B being elastic for contracting the balloon when inflation pressure is absent. Preferably, the strong inelastic ply is made of Kevlar, a DuPont product, although it can also be made of other known natural or synthetic fibers, such as Dacron, but with a decrease in the bursting strength of the balloon. The elastic ply is preferably made of a material known by the trade name Spandex.
Middle layer 23 is knitted loosely with the Spandex plies being stretched during knitting so that after the tube is knitted, the Spandex strands contract and collapse middle layer 23 into its normal configuration. Thereafter, when balloon 12 is expanded, knitted middle layer 23 expands in diameter until all of the loops are pulled taut (as shown in FIG. 4), at which point knitted layer 23 will expand no further because of the inelastic nature of the Kevlar plies. If additional inflation pressure be applied after balloon 12 reaches its predetermined maximum diameter, no further increase in diameter will be observed unless the pressure is so great that the tension in the yarn exceeds the tensile strength of the Kevlar plies, at which point the balloon would burst. Of course, in the normal use of the present device it would never be inflated to the point of bursting because of the harm that would result to the patient. The physician will realize when the balloon is fully inflated because the pressure of the inflating fluid will begin to rise sharply at that point. It is to be understood that the ratio of maximum to minimum diameter of balloon 12 is determined primarily by how loosely middle layer 23 is originally knitted.
One advantage of a balloon reinforced with a knitted fabric over prior known fabric reinforced balloons is in the expansion and contraction characteristics. Prior known balloons reinforced with a braided or woven fabric tube are unable to expand in diameter without correspondingly decreasing in length. However, a balloon reinforced with the knitted fabric tube described herein is capable of expanding three-dimensionally such that an increase in diameter does not require a decrease in length of the balloon. Consequently, balloon catheter 10 is constructed so that inner member 13 and catheter tube 11 are fixed against relative longitudinal displacement. Balloon 12 is therefore of fixed length. When balloon 12 is collapsed, the fabric of middle layer 23 contracts uniformly such that in the normal unexpanded state the balloon walls are smooth and free from folds and wrinkles.
Referring to FIGS. 1 and 5, there is shown attached to the proximal end portion of catheter 10 a Y-fitting 27 having a main portion 33 and a side branch 34. Bore 43A in main portion 33 communicates with bore 43B in side branch 34. Side branch 34 is terminated in a female Luer lock connector 42 in communication with bore 43B. Disposed within bore 43A is a stainless steel cannula sleeve 40 having a side aperture 41 in alignment with bore 43B of side branch 34. Inner member 13 is disposed within cannula sleeve 40 such that groove 15 is aligned with side aperture 41 and bore 43B. Groove 15 aids in providing a continuous longitudinal passageway from bore 43B to annular balloon chamber 21. Cannula sleeve 40 extends beyond main portion 33 at both ends. The proximal end 44 of catheter tube 11 is expanded to frictionally fit over end 45 of cannula sleeve 40, with proximal end 44 extending within bore 43A. Cap 46 is threadedly received over end portion 47 of Y-fitting 27 with O-ring 48 compressed between cap 46 and end portion 47. O-ring 48 when compressed forms a pressure seal between catheter tube 11 and end portion 47 of Y-fitting 27. Heat shrink tubing 49 is shrunk over extension 50 of cap 46 and the proximal end portion 44 of catheter tube 11 to provide structural reinforcement and further sealing.
At the proximal end 53 of main portion 33 is a secondary catheter tube 54 attached in a manner similar to the attachment of catheter tube 11 to end 47. Referring to FIG. 1, the proximal end of tube 54 is terminated in a cap 55 having a female Luer lock connector 56 in communication with lumen 14 of inner member 13. Inner member 13 and secondary catheter tube 54 are sealed together within cap 55 to prevent relative longitudinal displacement between them.
In its normal configuration, balloon 12 is only slightly greater in diameter than catheter tube 11. In this configuration, the outer surface of balloon 12 is smooth, thus facilitating placement of the balloon within a blood vessel with a minimum of trauma. After balloon 12 has been positioned in the desired location, it is inflated by introducing a saline solution under pressure at the proximal end of catheter 10 through Luer lock connector 42 of side branch 34 such that it flows through bore 43B and aperture 41, and through the longitudinal passageway between catheter tube 11 and inner member 13 (aided by groove 15) into annular balloon chamber 21. Balloon 12 then expands to its predetermined maximum diameter.
Lumen 14 within inner member 13 is externally accessible through Luer lock connector 56 at the proximal end of the catheter assembly, and provides a continuous passageway to the distal opening 17 beyond balloon 12. This passageway is completely independent of the inflation state of balloon 12 and may be used for the introduction of drugs or radiopaque dye into the blood stream.
Referring to FIG. 6, there is illustrated an alternative embodiment of the present invention. Balloon catheter 60 includes a hollow radiopaque urethane catheter tube 61 which is closed at distal end 62. Attached to the proximal end of catheter tube 61 is a female Luer lock connector 63 in communication with the bore of catheter tube 61. Disposed coaxially about the distal end portion of catheter tube 61 is a balloon 64 which is attached and sealed to catheter tube 61 at points 65 and 66 by means similar to that used to secure balloon 12 to tip 19 and sleeve 20 in the previously described embodiment. Likewise, balloon 64 is a three-layer knitted fabric reinforced balloon similar to balloon 12. In the present embodiment, the catheter tube has only one fluid passageway which communicates with the interior of balloon 64 via apertures 67 in catheter tube 61. Balloon 61 can be inflated by pressurized saline solution introduced into catheter tube 61 through Luer lock connector 63.
While particular embodiments of the invention have been illustrated and described in detail in the drawings and foregoing description, it is to be understood that this description is made only by way of example and not as a limitation to the scope of the invention which is claimed below.
|
A balloon catheter having an expandable and collapsible elastic balloon is shown, wherein the balloon is reinforced by knitted fabric such that the balloon can not expand beyond a predetermined diameter regardless of the internal pressure applied to the balloon. The knitted construction permits the balloon to expand in diameter without shortening in length, and permits the balloon to collapse smoothly without folds and wrinkles.
| 0
|
BACKGROUND
[0001] 1. Field of Invention
[0002] This invention relates to medicine and dentistry, specifically to desensitization of tissues required in association with traumas.
[0003] 2. Description of Prior Art
[0004] In medicine and dentistry, tissues are frequently subjected to traumas, such as periodontal ligament injections, intraosseous injections, general tissue injections, drawing blood, glucose tests, biopsies, lancing abscesses, and so on. Typically the tissues involved are the skin or mucosa epithelial and subepithelial tissues. However, the periosteum, and other tissues may also be involved.
[0005] For the descriptions herein, an instrument causing any trauma is called a sharp, and traumas are called punctures. Sharps include needles, aspirators, scalpels, biopsy punches, biopsy brushes, intraosseous perforators, lancets, and so on.
[0006] There are several methods of desensitizing tissues prior to puncture. These methods include the use of topical chemical anesthetics, Transcutaneous Electrical Nerve Stimulation (TENS), pressure, vibration, cooling, and so on.
[0007] A first method of desensitizing involves applying and removing the desensitizing means from the puncture area immediately prior to the puncture. Examples include the use of DentiPatch (Noven) anesthetic patches, pressing ice or a cold instrument to directly cool the site, and devices of U.S. Pat. Nos. 5,639,238, 5,839,895, 5,873,844 and US Pat Appl 2006/0217636. With anesthetic patches, substantial time is required. With the ice or cold instruments, the method is somewhat awkward.
[0008] A second method of desensitizing involves applying cold, vibration, pressure, or other desensitizing means along one side of the puncturing site immediately prior and during the puncture. Examples include pressing on the tissues with a blunt instrument during the puncture, such as a dental mirror handle or a Pressure Anesthesia Device (U.S. Pat. No. 5,171,225).
[0009] A third method of desensitizing involves applying pressure to tissues substantially surrounding the puncture area immediately prior to and during the puncture. For example, pressure is maintained on the tissues with a Palatal Anesthesia Device (U.S. Pat. No. 5,088,925) while inserting a needle into the central lumen of the device.
[0010] A fourth method of desensitizing involves applying negative pressure to tissues prior and during puncture (U.S. Pat. No. 2,945,496).
[0011] A fifth method involves cooling the puncture area prior to puncturing the tissues. A first cooling method involves directing a vapocoolant aerosol spray onto the puncture area prior to a puncture. An example is Freeze aerosol spray (Hagar Worldwide). To avoid frostbite, only moderately cold vapocoolants may be used when spraying directly onto the tissues. A second cooling method involves applying the cold side of a Peltier electrode to the puncture area prior to a puncture.
[0012] A sixth method involves placing TENS electrodes near the puncture area and applying current during the puncture (U.S. Pat. No. 5,496,363).
[0013] A seventh method of desensitizing involves vibrating the sharp during the puncture (U.S. Pat. Nos. 5,401,242, 5,647,851). For example, a VibraJect (VibraJect LLC) is connected to vibrate a syringe during an injection to activate a pain-gate response (U.S. Pat. No. 6,602,229).
[0014] An eighth method of desensitizing involves vibrating the tissues adjacent to the puncture area (U.S. Pat. Nos. 2,258,857, 3,620,209, 6,231,531, & EP1535572).
[0015] A ninth method of desensitizing involves applying topical anesthetic gels or liquids to the tissue for a substantial time, and puncturing the tissue through the residual anesthetics.
[0016] A tenth method of desensitizing involves stretching the puncture area (US Pat Appl 2006/0211982).
[0017] An eleventh method of desensitizing involves pinching the skin surrounding the puncture area (EP1535572)
[0018] A twelfth method of desensitizing involves applying heat to the puncture area prior and during the puncture (US Pat Appl 2006/0217636).
[0019] A thirteenth method of desensitizing involves applying cold to a puncture area prior and during the puncture with a non-absorbent surface (US Pat Appl 2006/0106363).
[0020] The above tissue desensitization methods suffer from one or more of a number of disadvantages:
(a) Pain control achieved is slight to moderate (b) Method requires excessive time (c) Method is awkward
SUMMARY OF THE INVENTION
[0024] The invention is a method and device for reducing pain associated with sharps used to puncture tissues, as well as for saving time.
[0025] In a typical embodiment, the device comprises an injector handpiece desensitizing system, similar to the self-contained intraosseous injection systems. The system desensitizes the tissue surface with vibrations and/or cooling, and then injects a medicament with a hollow drill bit, such as a local anesthetic.
[0026] The part of the system that desensitizes the tissues with vibrations and cooling is called the topical press. Cooling and vibrating of tissues are both known to reduce nerve-pain transmission.
[0027] In addition, vibrations can increase the rate of diffusion of a medicament into the tissues. For the purposes of this discussion, it can be assumed that a topical press can vibrate tissues, cool tissues, or both vibrate and cool tissues, unless called a vibrating press or a cooling press.
[0028] In another embodiment, the device comprises a needle device desensitizing system with a connected topical press. In another embodiment, a needle device is used with a topical press that comprises a separate brace for vibrating limbs.
[0029] For use with non-mechanized sharps like syringes and glucose lancets, topical presses are connected to separate instruments.
OBJECTS AND ADVANTAGES
[0030] Accordingly, several objects and advantages of my invention and process are to provide pain control for tissue puncture:
(a) at a high comfort level (b) without substantial tissue damage (d) using a simple method (e) rapidly
[0035] Further objects and advantages are to tissue provide pain control of short duration, so that the tissue sensation is normal soon after the procedure. Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
DRAWING FIGURES
[0036] In the drawings, closely related figures have the same number, but different alphabetic suffixes.
[0037] FIG. 1 is a perspective view of a drill injector with a slotted topical press-head detail.
[0038] FIG. 2 is a perspective view of a drill injector bit.
[0039] FIG. 3 is a cutaway view of a drill injector and topical press.
[0040] FIGS. 4A to 4E show embodiments of a topical presses.
[0041] FIG. 4A is a perspective view of a disc press.
[0042] FIG. 4B is a perspective view of a segmented topical press.
[0043] FIG. 4C is a cross-section view of a sharp cap.
[0044] FIG. 4D is a cross-section detail of a sharp cap lock.
[0045] FIG. 4E is a perspective view of a sharp tip press.
[0046] FIGS. 5A to 5E show embodiments of topical press covers.
[0047] FIG. 5A is a top view of a slotted cover for a slotted press.
[0048] FIG. 5B is a top view of a full cover for covering a receiver press.
[0049] FIG. 5C is a perspective view of a slot pad for covering the tissue side of a slotted press.
[0050] FIG. 5D is a perspective view of a full pad for covering the tissue side of a receiver press.
[0051] FIG. 5E is a perspective view of a lumen pad for covering the tissue side of a receiver press.
[0052] FIG. 5F is a perspective view of a bandage cover for covering a topical press.
[0053] FIG. 6 is a cross-sectional view of an injection device.
[0054] FIGS. 7A and 7B show embodiments of a brace press.
[0055] FIG. 7A is a perspective view of a brace press.
[0056] FIG. 7B is a perspective view of a segmented brace press.
[0057] FIGS. 8A to 8C show handheld topical presses.
[0058] FIG. 8A is a perspective view of a massager press.
[0059] FIG. 8B is a perspective view of a hand instrument topical press with a vibrator
[0060] FIG. 8C is a perspective view of a hand instrument topical press.
REFERENCE NUMERALS IN DRAWINGS
[0061]
[0000]
10
sharp
12
injector
14
handpiece
16
slot
18
actuator
20
bit
22
flutes
24
shank
26
groove
28
flat
30
tube
32
bore
34
orifice
36
shoulder
38
disc
40
receiver
42
segment press
44
cap
46
absorbent
48
barrel
50
first position lock
52
third position lock
54
male lock ring
56
tip press
58
slot cover
60
full cover
62
slot pad
64
adhesive
66
full pad
68
lumen pad
70
bandage
72
spot
74
stack
76
backing
78
needle device
80
brace
82
access
84
anchor
86
segment brace
88
massager
90
handle
DESCRIPTION
FIGS. 1 to 8
[0062] According to one aspect, the invention provides methods for puncturing tissues with a sharp.
[0063] A first tissue puncture method for injecting medicament into the periodontal ligament of a tooth comprises the steps of puncturing the tissues by drilling into the ligament with a drill bit having a central bore, injecting medicament through the bore and into the ligament, and removing the bit from the ligament.
[0064] It is preferred that a vibrating and/or cooling topical press desensitizes the tissues prior to an initial puncture. The topical press vibrations are generally in a frequency range of 2 Hz to 200 Hz, but the preferred frequency is between 25 Hz and 45 Hz. The topical press may be cooled by exposure to cold liquids, gasses, or solids, such as cold air in a freezer, refrigerated beads, water cooled to +0.5° C., propylene glycol cooled below 0° C., CO 2 ice, aerosolized CO 2 ice crystals, refrigerants, vapocoolant aerosols, and so on. Suitable vapocoolants have a boiling point between +15° C. and −100° C., with preferred boiling points between +5° C. and −30° C., such as 1,1,1,2-tetrafluoroethane, dichlorotetrafluoroethane, 1,1,1,2,3,3,3-heptafluoropropane, 1,1,1,3,3,3-hexafluoropropane, vapocoolant blends, and so on.
[0065] It is preferred that medicament is pumped through the bore while the bit is drilling into the ligament to substantially prevent clogging of the bore with debris.
[0066] A second tissue puncture method comprises the steps of supporting a sharp with respect to a topical press, vibrating and/or cooling a tissue puncture area with a topical press, or cover thereof, puncturing the tissues with a sharp at a puncture point within the vibrating and/or cooled puncture area, and withdrawing the sharp from the puncture point.
[0067] A third tissue puncture method comprises the steps of supporting a sharp with respect to a topical press, the topical press having a receiving surface having an opening therethrough for passage of the sharp, directly vibrating and/or cooling a tissue puncture point with the topical press or cover thereof, puncturing the vibrating and/or cooling tissues at the puncture point with a sharp, and withdrawing the sharp from the tissues.
[0068] A fourth tissue puncture method comprises the steps of supporting a sharp with respect to a topical press surface or cover thereof, directly vibrating and/or cooling a tissue puncture point with the topical press or cover thereof, puncturing the topical press surface or cover thereof, puncturing the vibrating and/or cooling tissue puncture point with a sharp, and withdrawing the sharp from the tissues.
[0069] A fifth tissue puncture method comprises the steps of directly vibrating and/or cooling a tissue puncture point, puncturing the vibrating and/or cooling the tissue puncture point with a sharp, and withdrawing the sharp from the tissues.
[0070] A sixth tissue puncture method comprises the steps of vibrating a tissue area which substantially encompasses a puncture point, puncturing the vibrating tissue area at the puncture point with a sharp, and withdrawing the sharp from the puncture point.
[0071] A seventh tissue puncture method comprises the steps of cooling a tissue area which substantially encompasses a puncture point utilizing an coolant-absorbent surface, puncturing the cooling puncture point with a sharp, and withdrawing the sharp from the puncture point.
[0072] A eighth tissue puncture method comprises the steps of cooling a tissue puncture area with a cold topical press or cover thereof, inserting a sharp into and through the topical press and into the cooling tissues of the puncture area, and withdrawing the sharp from the tissues.
[0073] For the purposes of this discussion, in general, a sharp used to puncture the tissues is called a sharp 10 , including needles, intra-osseous anesthesia drills, lancets, and so on.
[0074] According to another aspect of the invention, there is provided a sharp for injecting the periodontal ligament of a tooth, injector 12 , as shown in FIG. 1 . Injector 12 is a type of sharp 10 . Injector 12 is shown connected to a motorized injector handpiece, handpiece 14 , of the type shown in US Pat Appl 2006/0106363. A type of topical press, slot 16 , is shown connected to handpiece 14 for desensitizing the tissues for injector 12 . Slot 16 is a disc-shaped topical press configured with a slot open to the perimeter.
[0075] It is preferred that slot 16 is supported with respect to handpiece 14 by a resiliency means. The resiliency means applies pressure on slot 16 away from handpiece 14 and over a limited distance. An example of a resiliency means is a spring, and elastic part, and so on. As such, after slot 16 contacts a puncture area, handpiece 14 may advance toward the tissues by compressing the resiliency means.
[0076] Also shown is a cooling and/or vibrating means, actuator 18 for cooling and/or vibrating any topical press, such as slot 16 . For handpiece 14 , it is preferred that actuator 18 is an offset-weight vibrator with linkage to the handpiece 14 motor. However, actuator 18 may have a dedicated motor and power source. It is preferred that actuator 18 is located in the proximity of the topical press. However, actuator 18 may be located in proximity to the motor, or other locations.
[0077] In the preferred embodiment of injector 12 , the distal portion of injector 12 comprises a bit, bit 20 , for penetrating into the ligament, as shown in FIG. 2 . The surface of bit 20 is substantially covered with spiraling serrations, flutes 22 . Bit 20 is tapered from a sharp point at the distal tip to the widest point proximal to a cylindrical shank, shank 24 . Toward the proximal end of shank 24 is a groove, groove 26 , and a drive facet, flat 28 , for engaging the drive mechanism of handpiece 14 . On the proximal end of shank 24 is a hollow tube, tube 30 , for connecting to a medicament source. Tube 30 has a central bore, bore 32 . Bore 32 extends continuously from the proximal tip of tube 30 through shank 24 , and through at least a portion of bit 20 . An orifice, orifice 34 , communicates from the surface of bit 20 to bore 32 .
[0078] It is preferred that bore 32 ends at orifice 34 a given distance from the distal tip of bit 20 so that bit 20 has a solid core in the tip portion to reduce the risk of fracture. However, bore 32 may extend to the distal tip of bit 20 . It is preferred that bit 20 is comprised of nickel-titanium alloy, and has a taper between 0.02 and 0.04. However, bit 20 can be of greater or lesser taper, and may be comprised of other materials.
[0079] It is preferred that a non-fluted area of enlarged diameter, shoulder 36 , is located at the junction of shank 24 and bit 20 . In use, bit 20 penetrates the tissue to the level of shoulder 36 , and shoulder 36 presses against the gingiva to provide a fluid seal against backpressure leakage of injected medicament from the ligament puncture.
[0080] It is preferred that the medicament is onboard handpiece 14 . However, the medicament may be located remotely from handpiece 14 . It is preferred that medicament is pumped by handpiece 14 by an automatic pump mechanism. However, a manual pump may be used.
[0081] FIG. 3 shows a slot 16 desensitizing the tissues and an injector 12 penetrated into the periodontal ligament of a tooth. Shoulder 36 is shown pressing into the tissues to form a seal to fluid backpressure. An actuator 18 is connected to handpiece 14 . The connection of slot 16 to handpiece 14 has slidingly permitted handpiece 14 to move closer to slot 16 as injector 12 penetrates the ligament.
[0082] FIGS. 4A to 4F shows embodiments of the topical press. In general, a topical press comprises at least a structural surface, called a tissue surface, configured to contact the surface of the tissues, wherein the topical press may be vibrated and/or cooled while in contact with the tissues to desensitize the tissues.
[0083] The topical press may comprise a single unitary press, or may comprise multiple segments. The preferred overall geometrical shape of a topical press varies with the application, such as straight segments, curved segments, a disc, a slotted disc, and so on.
[0084] It is preferred that the topical press tissue surface is smooth and convex. However the tissue surface may be substantially flat, concave, irregular, corrugated, porous, fibrous, and so on. It is preferred that the topical press is comprised of stainless steel. However, the topical press may be comprised of other metals, plastic, composites, ceramic, elastomers, wood, absorbent material, fibrous material, fibrous material at least partly impregnated with a hardener, fibrous material on a hard backing material, any combination of a fibrous material and another material, and so on.
[0085] FIG. 4A shows a disc-shaped topical press, disc 38 , having an open passage, receiver 40 , to receive the entry of a sharp 10 into the tissues beyond. In FIG. 4A , receiver 40 is funnel-shaped.
[0086] FIG. 4B shows a segmented topical press, segment press 42 , comprised of adjacent segments for contacting the tissues. It is preferred that the segment press 42 segments have a simple connection to actuator 18 . However, the segment press 42 segments may be connected to actuator 18 by a tunable vibratory phase means. As such, the vibrations of either segment may be tuned to be in or out of phase relative to the other segment to influence tissue desensitization.
[0087] FIG. 4C shows a topical press configured as a cap for a sharp 10 , cap 44 . Sharp 10 is able to pass through the distal end of cap 44 to puncture the tissues. The distal end of cap 44 is penetrable by sharp 10 , such as by sharp 10 penetrating a thin area of cap 44 , by penetrating a fibrous area of cap 44 , by penetrating a porous area of cap 44 , by entering a pre-existing minimally-sized receiver 40 in cap 44 , by pushing open a small flap, and so on.
[0088] It is preferred that at least the exterior surface of the distal end of cap 44 is comprised of an absorbent material, absorbent 46 , which is absorbent of coolants, such as a gauze, felt, other fibrous materials, porous materials, and so on.
[0089] For a cap 44 associated with a syringe, it is preferred that the syringe barrel, barrel 48 , is stored in a first position with respect to cap 44 . Barrel 48 may telescope into cap 44 , thereby causing sharp 10 to penetrate the tip of cap 44 , extend distally from cap 44 , and thereby penetrate the tissues to a second position. Barrel 48 may be telescopically withdrawn from cap 44 , thereby withdrawing sharp 10 from the tissues and retracting sharp 10 entirely into cap 44 , and cap 44 locks into barrel 48 in a sharp-retracted third position. With cap 44 locked into barrel 48 , sharp 10 cannot be moved distally again. However, cap 44 may be elastically compressible between an advancing barrel 48 and the tissues, and elastically reboundable as the barrel 48 withdraws so as to cover sharp 10 , and so on.
[0090] It is preferred that cap 44 remain in contact with the tissues until after sharp 10 is entirely withdrawn into cap 44 . As such, the procedure can be completed without sharp 10 being exposed to the user or the patient. In addition, cap 44 facilitates containment of bodily fluids, such as droplets that may be released as sharp 10 withdraws from the tissues.
[0091] It is preferred that cap 44 has a locking mechanism with barrel 48 , first position lock 50 , and third position lock 52 . A male lock component, male lock ring 54 , is at the distal end of barrel 48 . First position lock 50 is a female locking portion that permits male lock ring 54 to release and slide toward distal end of cap 44 , such that sharp 10 protrudes through cap 44 and into the tissues at the second position for barrel 48 . When the barrel is retracted and moving in a proximal direction, male lock ring 54 slides past first position lock 50 , and expands into third position lock 52 . The inclined plane of female third position lock 52 mates with the plane of male lock ring 54 , preventing the release of male lock ring 54 either proximally or distally. Cap 44 is shown releasably locked with the first position lock 50 engaged with barrel 48 .
[0092] FIG. 4D shows a cap 44 after retracting sharp 10 through receiver 40 and into cap 44 . Cap 44 has slid over first position lock 50 , and is non-releasably locked with barrel 48 in third position lock 52 . The inclined plane of female third position lock 52 mates with male lock ring 54 , preventing the release of male lock ring 54 either proximally or distally. Absorbent 46 shows at the end of cap 44 .
[0093] FIG. 4E shows a topical press configured for connecting to the tip of a sharp 10 , a tip press 56 . The receiver 40 of tip press 56 is configured to securely connect to the sharp 10 tip, such as by having a cylindrical configuration with a lumen of specified diameter, an elongated cylindrical lumen where the cylinder protrudes substantially above the surface, or a similar lumen. Tip press 56 may also comprise a protective cover for sharp 10 . Absorbent 46 covers the distal end of tip press 56 .
[0094] It is preferred that tip press 56 provides a degree of resistance to sharp 10 penetration. As such, when sharp 10 is pushed toward the tissues, tip press 56 is first pressed onto the tissue surface prior to sharp 10 pushing through tip press 56 and into the tissues. Configurations of receiver 40 which provide penetration resistance include a lumen of a specific diameter, a lumen with a diameter constriction, a cone with a central lumen, a cone having visualization slits in the side that are open to a central lumen, an area of receiver 40 that is sufficiently thin to be penetrable by a sharp 10 , and so on. For a tip press 56 with a penetrable thin area, an open lumen is not formed until after the sharp 10 penetrates receiver 40 to form a lumen.
[0095] For some applications, it is preferred that at least a portion of the topical press is covered by a cover. FIGS. 5A to 5D show preferred covers for the topical press. It is preferred that covers are comprised of an absorptive, fibrous material. However, the cover may be comprised of plastic, metal, or composites, and so on, and may be arranged in strands, sheets, mesh, foil, fabric, and so on.
[0096] A cover fitted to cover slot 16 , slot cover 58 , is shown in FIG. 5A . Slot cover 58 facilitates visualization of the sharp 10 , and permits removal of the topical press from the mouth prior to removal of the sharp 10 .
[0097] FIG. 5B shows a full cover, full cover 60 , for covering a topical press, such as disc 38 . It is preferred that full cover 60 has no central lumen. However, full cover 60 may have a lumen that aligns with receiver 40 of disc 38 , or a lumen may be made by the user before or after placement on disc 38 . Full cover 60 may also be used to cover slot 16 to combine advantages of both. As such, full cover 60 may be used to vibrate and/or cool a puncture point, yet slot 16 can be withdrawn from sharp 10 by sliding out of full cover 60 while full cover 60 remains punctured by sharp 10 .
[0098] FIG. 5C shows a cover configured to cover only the tissue side of slot 16 , slot pad 62 . Slot pad 62 is comprised of absorbent materials such as woven material, felts, fibrous material, porous materials, mesh, and so on. Slot pad 62 facilitates visualization of the sharp 10 , and permits removal of slot 16 from the puncture area at anytime. It is preferred that slot pad 62 is connected to slot 16 by an adhesive coating, adhesive 64 . However, slot pad 62 may connect with molded snaps that grasp the edges of the slot or the outer perimeter of slot 16 , and so on.
[0099] A cover which covers only the tissue side of disc 38 , full pad 66 , is shown in FIG. 5D . Full pad 66 is comprised of absorbent materials that permit penetration of a sharp 10 through full pad 66 and into the tissues, such as woven material, felt, fibrous material, foil, sheets, mesh, and so on. It is preferred that full pad 66 is connected to segment press 42 by adhesive 64 . However, full pad 66 may connect with molded snaps that grasp the edges of the receiver 40 lumen or the outer perimeter of segment press 42 , and so on. Full pad 66 may also simultaneously connect to the separate bars of segment press 42 .
[0100] FIG. 5E shows a pad with a central lumen, lumen pad 68 , connected to disc 38 . The central lumen of lumen pad 68 may be aligned with receiver 40 when connected to disc 38 . It is preferred that lumen pad 68 is connected to disc 38 by adhesive 64 . However, lumen pad 68 may connect with molded snaps that grasp the edges of the lumen or the outer perimeter of disc 38 , and so on.
[0101] FIG. 5F shows a topical press cover designed to remain over an extraoral puncture area after withdrawal of sharp 10 , bandage 70 . Bandage 70 has a first side and a second side, wherein the first side contacts the tissues, called the tissue side, and the second side is away from the tissues, called the top side. A substantial portion of the tissue side is coated with adhesive 64 to facilitate adhesion to the tissues prior, during, and after the puncture.
[0102] It is preferred that bandage 70 has at least one adhesive-coated area on the top side, spot 72 , so as to facilitate adhesion of a bandage 70 to the topical press. It is further preferred that a multiplicity of spots 72 are spaced along the top side perimeter. When a bandage 70 having adhesive 64 and spots 72 are adhered to the topical press is pressed into contact with the tissues, the topical press is thereby transferred to the tissue and adhered to the tissue.
[0103] The topical press vibrates the tissues with a higher efficiency than substantially planar vibrators. As the topical press depresses the tissue surface, it nests into the tissue due to a relatively small footprint, thereby engaging the tissue. The topical press vibrations therefore push, pull and massage the tissue, rather than simply sliding or rapping on the surface.
[0104] When bandage 70 adheres the topical press to the tissues, the vibration efficiency is further enhanced. Adhered bandage 70 adhesively connects the topical press to the tissues, such that the topical press connectedly vibrates the tissues. Further, when bandage 70 physically contacts the tissue over the actual puncture point, the puncture point is vibrated directly, in addition to vibrating the tissue area surrounding the puncture point.
[0105] It is preferred that bandages 38 are supplied in a convenience stack, stack 74 , also shown in FIG. 5F . To mount a bandage 70 onto a topical press, the topical press is pressed onto spots 72 of the top bandage 70 of stack 74 . Spots 72 adhere to the topical press, and bandage 70 is thereby pulled away from stack 74 when the topical press is withdrawn.
[0106] It is preferred that adhesive 64 is removably covered with an adhesion-resistant backing, backing 76 . Backing 76 minimizes adhesion between individual bandages 70 in stack 74 . Backing 76 therefore increases the likelihood that bandage 70 will pull away from stack 74 when the topical press is withdrawn. Backing 76 is removed immediately prior to puncturing the tissues, thereby exposing adhesive 64 . However, adhesion between individual bandages 70 in stack 74 may be minimized without backing 76 , such as by providing a bandage 70 having an adhesion-resistant top side similar to backing 76 .
[0107] As such, bandages 70 have a multiplicity of functions. Bandages 70 form a contamination barrier between the tissues and the topical press, facilitate vibrating the tissues at a puncture area, enhance tissue vibration pain-gate effect, wipe body fluids from the withdrawing sharp 10 , and can remain as a dressing over the puncture area.
[0108] Bandages 70 may be connected to the topical press by means other than spots 72 , such as by utilizing vacuum ports in the topical press, spikes to impale bandage 70 , tiny barbs to engage small pores on the top side of bandage 70 , a spring-clip, and so on.
[0109] When full cover 60 , full pad 66 , or bandages 70 , cover a topical press, they physically contact the tissue at the actual puncture point. As such, when vibrated and/or cooled, full cover 60 , full pad 66 , or bandages 70 , directly vibrate and/or cool the tissues of the puncture point, in addition to vibrating the tissues of the surrounding puncture area.
[0110] FIG. 6 shows a mechanized injector, needle device 78 . After a user activates a switch or triggering mechanism, needle device 78 moves a needle sharp 10 from a first retracted position to a second tissue-penetrating position, injects a medicament through needle sharp 10 , and returns needle sharp 10 to a third retracted position. The third position may coincide with the first position. Examples of similar mechanized puncture devices include automatic syringes, automatic glucose lancets, and so on, as shown in US Pat Appl 2002/0082522, and U.S. Pat. Nos. 6,454,743, 6,099,503, and 5,035,704.
[0111] FIGS. 7A and 7B show topical presses which are useful with mechanized puncture devices, such as needle device 78 , but are also useful with traditional manual syringes, manual glucose lancets, and so on.
[0112] FIG. 7A shows a topical press for contacting a bodily surface, brace 80 , having an open access for sharps, access 82 , and a connected actuator 18 . It is preferred that brace 80 is configured to fit closely against a limb, such as an arm, leg, fingertip, and so on, such that the limb nests into brace 80 . It is preferred that brace 80 has a detachable connection, anchor 84 , to a stable object, such as a chair, wall, pole, tree, and so on. It is further preferred that the position of brace 80 is adjustable in at least one dimension, such as by moving it along anchor 84 , by sliding, ratcheting, clipping, and so on.
[0113] FIG. 7B shows another embodiment of a brace press, segment brace 86 , connected to actuator 18 and anchor 84 . Segment brace 86 is similar to brace 80 , but is a set of two separate braces.
[0114] Sharp 10 has access to the tissues in the variable area between the brace segments. It is preferred that actuator 18 is capable of vibrating the brace segments in or out of phase with respect to one another, such as by incorporating dedicated actuators 18 .
[0115] FIGS. 8A to 8C show handheld topical presses.
[0116] FIG. 8A shows a handheld vibrating topical press, massager 88 for use with manually operated sharps 10 , such traditional syringes, lancets, and so on. Massager 88 is connected to a handle, handle 90 , and an actuator 18 . Actuator 18 vibrates and/or cools massager 88 . It is preferred that massager 88 , as well as handle 90 , and actuator 18 have a coordinated appearance resembling a child's toy, so as to reduce children's fear. The toy shown in FIG. 8A shows a slot 16 configured as an animal's paws.
[0117] For intraoral use, smaller topical presses are required. FIG. 8B shows a topical press with an actuator 18 connected to handle 90 , for vibrating and/or cooling intraoral tissues. It is preferred that actuator 18 is nondetachably connected to handle 90 . However actuator 18 may be detachably connected to handle 90 .
[0118] A coolant actuator 18 is comprised of a refrigeration system. An example of a coolant actuator 18 comprises a contained vapocoolant, an intake valve, a release valve, and a tubing to full pad 66 on disc 38 , wherein opening the valve releases vapocoolant onto full pad 66 , thereby cooling full pad 66 . However, a coolant actuator 18 may comprise a small refrigeration compressor and fan system, or intake and release valves for externally supplied liquid or gas coolants from a remote refrigeration system, and so on.
[0119] FIG. 8C shows an intraoral topical press hand instrument having a handle 90 connected to disc 38 .
[0120] It is preferred that the opposite end of handle 90 is connected to an instrument that is different than disc 38 , such as a mouth mirror. However, handle 90 may be connected to a second disc 38 , such as a disc 38 set at an angle different from a first disc 38 , or any other instrument.
[0121] From the description above, a number of advantages of the topical press become evident:
(a) The topical press is able to substantially reduce tissue sensitivity to control pain (a) It is simple to use (b) The topical press is time efficient (c) The topical press can decrease patient apprehension
OPERATION
FIGS. 1 - 8
[0126] By using the topical press of the invention, it is now possible, surprisingly, to achieve substantial reduction in puncture discomfort within seconds.
[0127] The process offers the advantage that the user can now puncture the tissues simply and economically.
[0128] In a further embodiment of the invention, there are multiple applications of the method for desensitizing the tissues with a topical press and puncturing with a sharp 10 .
EXAMPLE 1
[0129] For a periodontal ligament injection, a user selects a handpiece 14 having an injector 12 and a slot 16 with an absorbent surface, as shown in FIG. 1 . A local anesthetic cartridge is loaded into the medicament chamber. Actuator 18 is turned on to vibrate slot 16 . A refrigerant is applied to the surface of slot 16 . A few seconds are allowed to elapse until the slot 16 surface appears frosty.
[0130] Slot 16 is inserted into the gingival sulcus of a tooth and pressed against the tissue puncture area by partly compressing the resiliency means of handpiece 14 . Handpiece 14 rotates injector 12 , and anesthetic is pumped from the anesthetic cartridge, into tube 30 , into bore, and flowing out orifice 34 . By further compressing the resiliency means, handpiece 14 is advanced toward the tissues until rotating injector 12 punctures the tissues.
[0131] Anesthetic is pumped under pressure from orifice 34 and into the ligament space as injector 12 penetrates the ligament. The anesthetic flow anesthetizes the tissues and prevents debris from entering into orifice 34 . Anesthetic continues to flow as injector 12 advances into the ligament. Injector 12 tends to seal the tissue hole created by the advancing injector 12 , thereby creating a backpressure of anesthetic. The backpressure causes the anesthetic to flow distally from orifice 34 toward the distal tip of injector 12 , and into the ligament.
[0132] Injector 12 is advanced until shoulder 36 seats into the sulcus, as shown in FIG. 3 . Shoulder 36 further seals the puncture hole to fluid backpressure, and facilitates diffusion of anesthetic toward the tooth apex. A sufficient volume of anesthetic is pumped into the ligament so as to diffuse through the cortical plate, into the medullary bone, and to the apex of the tooth. Injector 12 is counter-rotated out of the puncture site. Handpiece 14 is removed from the area.
EXAMPLE 2
[0133] For an injection, a user selects a needle device 78 having an actuator 18 , as shown in FIG. 6 .
[0134] Needle device 78 has a segment press 42 , as shown in FIG. 4B . A disposable syringe having a needle sharp 10 is preloaded with a medicament is placed in needle device 78 . Needle device 78 is oriented perpendicularly over a skin puncture area and segment press 42 is pressed into contact with the skin.
[0135] Needle device 78 is turned on. Actuator 18 begins to vibrate segment press 42 , and segment press 42 vibrates the skin of the puncture area. Sharp 10 is moved toward the skin, and penetrates the vibrating tissue injection site between the vibrating segments of segment press 42 to a preset depth. Needle device 78 injects the medicament. After the injection is complete, sharp 10 is withdrawn from the tissues and actuator 18 turns off. Needle device 78 is lifted from the skin.
EXAMPLE 3
[0136] For an injection, a user selects a needle device 78 and a segmented brace 86 topical press. Actuator 18 is connected to both segments. Segmented brace 86 and needle device 78 are connected to a chair utilizing anchor 84 , as shown in FIG. 7B .
[0137] A disposable syringe with a needle sharp 10 is preloaded with a medicament and placed in needle device 78 . The patient is seated in the chair with shoulder bared. The position of segmented brace 86 is adjusted to the patient's height by sliding segmented brace 86 along anchor 84 . The patient's shoulder is nested into of segmented brace 86 .
[0138] Actuator 18 and needle device 78 are turned on. Actuator 18 vibrates the two segments of segmented brace 86 , which vibrates the skin of the puncture area. Needle device 78 moves sharp 10 toward the shoulder. Sharp 10 penetrates the vibrating puncture point between the vibrating segments of segmented brace 86 to a preset depth. Needle device 78 injects the medicament.
[0139] After the injection is complete, sharp 10 is withdrawn from the tissues and actuator 18 turns off.
EXAMPLE 4
[0140] For an injection, a user selects a needle device 78 having an actuator 18 , and a disc 38 , as shown in FIG. 4A . A syringe with a needle sharp 10 is preloaded with a medicament and placed in needle device 78 . The user presses needle device 78 perpendicularly onto adhesive spots 72 of a bandage 70 at the top of stack 74 , as shown in FIG. 5F , such that spots 72 adhere to disc 38 . As the user withdraws needle device 78 from stack 74 , adhered spots 72 lifts the top bandage 70 with its backing 76 away from stack 74 . As such, bandage 70 covers disc 38 , thereby preventing direct contact of disc 38 with the skin during use. Backing 76 is removed from adhesive 64 of bandage 70 , exposing adhesive 64 .
[0141] Needle device 78 is oriented perpendicularly to the surface of the skin. Needle device 78 is pressed onto the skin so that disc 38 contacts the skin with bandage 70 interposed. Adhesive 64 adheres bandage 70 to the skin.
[0142] Needle device 78 is turned on. Actuator 18 begins to vibrate disc 38 and bandage 70 , which in turn vibrates the skin and the puncture area. Sharp 10 moves toward the skin, penetrating bandage 70 and the vibrating tissue at the puncture point. Needle device 78 injects the medicament.
[0143] Actuator 18 turns off, the needle is withdrawn from the tissues, through bandage 70 , through disc 38 , and up into needle device 78 . Needle device 78 is lifted from the skin. As needle device 78 is lifted from the skin, the adhesion of bandage 70 to the skin is greater than the adhesion of spots 72 to disc 38 . Therefore bandage 70 pulls away from disc 38 , and remains adhered to the skin.
EXAMPLE 5
[0144] For an injection, a user selects a needle device 78 having an actuator 18 , a preloaded syringe, and a cap 44 , as shown in FIG. 4C . An absorbent surface of cap 44 is sprayed with a refrigerant. Needle device 78 is oriented perpendicularly over a tissues puncture area and cap 44 is pressed into contact with the tissues.
[0145] Needle device 78 is turned on. Actuator 18 vibrates cap 44 , and cap 44 vibrates the tissues of the puncture area. The refrigerant spray cools the tissue. Needle device 78 releases first position lock 50 by pushing the syringe barrel and the sharp 10 needle telescopically into cap 44 . Sharp 10 penetrates the distal end of cap 44 and punctures the tissues to a preset depth at the second position. Needle device 78 stabilizes the barrel at the second position, and pushes the syringe plunger until the medicament is injected.
[0146] Needle device 78 telescopically withdraws the barrel from cap 44 , and withdraws sharp 10 from the tissues until sharp 10 is retracted entirely into cap 44 . As sharp 10 is fully retracted, the male component of the lock slides over first position lock 50 , and expands into third position lock 52 , thereby locking cap 44 into the barrel in the sharp-retracted position. Cap 44 cannot be moved distally again, as shown in FIG. 4D . Actuator 18 turns off. Needle device 78 is lifted from the tissues.
EXAMPLE 6
[0147] A user selects a tip press 56 having a tissue side covered with absorbent fibers, as shown in FIG. 4E . A sharp 10 is inserted into receiver 40 of tip press 56 until it encounters a thin sheet occluding the lumen, whereupon the insertion is halted. Sharp 10 does not protrude from the tissue side of tip press 56 . A vapocoolant is sprayed onto the absorbent tissue side of tip press 56 . After a few seconds the absorbent side appears frosty. Frosty tip press 56 is carried on sharp 10 to the puncture site, and is held against the tissues for a few seconds to cool the tissues. Sharp 10 is pushed through the thin occluding sheet, emerges from tip press 56 , and punctures the tissues. The procedure is completed, such as an injection, and then sharp 10 and tip press 56 are removed from the tissues.
EXAMPLE 7
[0148] User selects a topical press massager 88 with the outer appearance of a puppy with front paws extended forward, as shown in FIG. 8A . Actuator 18 is turned on to vibrate primarily the front paws. The vibrating front paws are placed on the skin of a child to desensitize the skin with vibrations. The appearance of massager 88 partly allays the child's fears. A sharp 10 is used to puncture the skin, such as a manual syringe, and is removed.
EXAMPLE 8
[0149] A topical press hand instrument having a disc 38 on a first end and a mirror on a second end is frequently used by a user as a mouth mirror, as shown in FIG. 8C . Prior to a palatal injection, an adhesive full pad 66 is removed from a backing paper and adhered to the tissue side of a disc 38 , as shown in FIG. 5D . A vapocoolant is sprayed onto full pad 66 . After a few seconds, the surface of full pad 66 appears frosty. Full pad 66 is firmly held against the tissues for a few seconds to cool the tissues, thereby reducing tissue sensitivity. A sharp 10 needle is inserted through receiver 40 , through full pad 66 , and into the tissues. A few drops of local anesthetic are deposited. The topical press is lifted from the tissues by sliding disc 38 with full pad 66 up the sharp 10 needle shaft toward the hub. After depositing additional local anesthesia, the user removes the sharp 10 needle and the topical press from the mouth.
EXAMPLE 9
[0150] A user selects a topical press hand instrument having a slot 16 . A slot cover 58 is stretched snugly over slot 16 , as shown in FIG. 5A . A vapocoolant is sprayed onto slot cover 58 . After a few seconds, the surface of slot cover 58 appears frosty. Slot 16 with frosty slot cover 58 is firmly held against the tissues for a few seconds to cool the tissues. A sharp 10 is inserted through slot 16 and into the tissues. After a few seconds, the user pulls slot 16 away from the inserted sharp 10 , and withdraws the topical press from the mouth. After the procedure, sharp 10 is removed from the tissues, and from the mouth.
EXAMPLE 10
[0151] A topical press having a metal disc 38 , as shown in FIG. 8B , is stored on a frozen block, such as ice. The cold topical press and frozen block are removed from the freezer and placed within reach of the user. The user turns on vibrating actuator 18 , and firmly holds the cold disc 38 against an oral puncture area to simultaneously cool and vibrate the tissues. A sharp 10 penetrates the tissues through receiver 40 . Sharp 10 is removed from the tissues. Sharp 10 and the topical press are removed from the mouth.
SUMMARY, RAMIFICATIONS AND SCOPE
[0152] Accordingly, the reader will see that the topical press of this invention is able to substantially control pain associated with minor tissue trauma and punctures. Furthermore, the topical press and method have the additional advantages in that it permits pain control in just a few seconds.
[0153] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention and process, but as merely providing illustrations of some of the presently preferred embodiments of this invention.
[0154] For a first example, needle device 78 is shown with needle sharps 10 . However, it can be adapted for use with other sharps 10 .
[0155] For a second example, handpiece 14 can be improved to include a computerized medicament pump, battery power, a vibrator for injector 12 , an onboard coolant system for the topical press, and so on.
[0156] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
|
A method and device for controlling the pain of a periodontal ligament injection, and other minor medical and dental procedures. The device desensitizes the tissues utilizing cold, vibration, or both. The method is useful for injections, small biopsies, intraosseous drilling, blood sampling, and so on.
| 0
|
GOVERNMENT RIGHTS
[0001] This invention was made with Government support under Contract R01 DK063158 awarded by the National Institutes of Health. The Government has certain rights in this invention.
[0002] Cytochrome P450 enzymes are a heme-containing family that play central roles in oxidative, peroxidative and reductive metabolism of numerous endogenous and exogenous compounds, including many pharmaceutical agents. Substances known to be metabolized by P450 enzymes include steroids, bile acids, fatty acids, prostaglandins, leukotrienes, biogenic amines, retinoids, lipid hydroperoxides, phytoalexins, pharmaceuticals, environmental chemicals and pollutants. P450 substrates also include natural plant products involved in flavor, odor, flower color, and the response to wounding. P450 enzymes and other drug-metabolizing enzymes maintain steady-state levels of endogenous ligands involved in ligand-modulated transcription of genes effecting growth, apoptosis, differentiation, cellular homeostasis, and neuroendocrine functions. The metabolism of foreign chemicals by P450 enzymes can produce toxic metabolites, some of which have been implicated as agents responsible for birth defects and tumor initiation and progression.
[0003] The CYP3A subclass catalyzes a remarkable number of oxidation reactions of clinically important drugs such as quinidine, warfarin, erythromycin, cyclosporin A, midazolam, lidocain, nifedipine, and dapsone. Current estimates are that more than 60% of clinically used drugs are metabolized by the CYP3A4 enzyme, including such major drug classes as calcium channel blockers, immunosuppressants, macrolide antibiotics and anticancer drugs.
[0004] In addition to the liver, the P450s are expressed appreciably in the small intestinal mucosa, lung, kidney, brain, olfactory mucosa, and skin. Of these tissues, the intestinal mucosa is the most important extrahepatic site of drug biotransformation. As a consequence, the potential exists for substantial presystemic metabolism and thus an enhanced reduction in bioavailability as a drug passes, sequentially, through the small intestine and liver. See Lang et al. (1996) Clin Pharmacol Ther 59:41-46; Kolars et al. (1992) J. Clin. Invest. 90:1871-1878, herein specifically incorporated by reference.
[0005] As in the liver, CYP3A is the most abundant P450 subfamily expressed in the small intestine, with an average (or median) specific content representing from 50 to 70% of spectrally determined P450 content. Like hepatic CYP3A, enteric CYP3A is localized in a single cell type, specifically, within the mature absorptive columnar epithelial cells (enterocytes) that largely compose the mucosal lining. Enteric microsomal CYP3A content, as well as associated catalytic activity, is generally highest in the proximal region and then declines sharply toward the distal ileum.
[0006] Although the total mass of CYP3A in the entire small intestine has been estimated to be ˜1% of that in the liver, human studies have demonstrated that enteric CYP3A can contribute significantly, and in some cases equally with hepatic CYP3A, to the overall first-pass metabolism of several drugs, particularly those are absorbed by the transcellular route. An advantage of CYP3A activity as a biomarker for enteropathy is the rapidity with which CYP3A activity can change. For example, as little as 7 days of treatment with rifampin, a known inducer of CYP3A4, can result in a >5-fold increase in enzyme activity in the small intestine (Kolars, et al, vide supra). Similarly, grapefruit juice, a known downregulator of CYP3A4, reduces the small bowel epithelial concentration of this enzyme by >2-fold in as little as 6 days (Lown, et al., J. Clin. Invest. 99, 2545, 1997). Thus, it is possible to minimize the duration of illness in patients in whom disease must be induced for diagnostic or related purposes.
[0007] A number of disease conditions involve enterocytes. For example, in 1953, it was first recognized that ingestion of gluten, a common dietary protein present in wheat, barley and rye causes disease in sensitive individuals. Gluten is a complex mixture of glutamine- and proline-rich glutenin and gliadin molecules, which is thought to be responsible for disease induction. Ingestion of such proteins by sensitive individuals produces flattening of the normally luxurious, rug-like, epithelial lining of the small intestine known to be responsible for efficient and extensive terminal digestion of peptides and other nutrients.
[0008] Clinical symptoms of Celiac Sprue include fatigue, chronic diarrhea, malabsorption of nutrients, weight loss, abdominal distension, anemia, as well as a substantially enhanced risk for the development of osteoporosis and intestinal malignancies (lymphoma and carcinoma). The disease has an incidence of approximately 1 in 200 in most populations. Although no non-dietary therapy has been approved thus far for the treatment of Celiac Sprue, several efforts are under way to develop oral enzyme therapies (hereafter referred to as “glutenases”) that accelerate the digestion, detoxification and assimilation of proteolytically resistant, immunotoxic gluten peptides in the celiac patient's gastrointestinal tract. Other types of drugs are also being considered for treatment of celiac sprue.
[0009] A related disease is dermatitis herpetiformis, which is a chronic eruption characterized by clusters of intensely pruritic vesicles, papules, and urticaria-like lesions. IgA deposits occur in almost all normal-appearing and perilesional skin. Asymptomatic gluten-sensitive enteropathy is found in 75 to 90% of patients and in some of their relatives. Onset is usually gradual. Itching and burning are severe, and scratching often obscures the primary lesions with eczematization of nearby skin, leading to an erroneous diagnosis of eczema. Strict adherence to a gluten-free diet for prolonged periods may control the disease in some patients, obviating or reducing the requirement for drug therapy. Dapsone, sulfapyridine and colchicines are sometimes prescribed for relief of itching, although the underlying disease is unaffected by these drugs. Given the close relationship between Celiac Sprue and dermatitis herpetiformis pathogenesis, the above-mentioned therapies are also expected to be useful for the treatment of dermatitis herpetiformis.
[0010] There is an urgent need for the development of sensitive, specific and non-invasive biomarkers for assessing drug efficacy in the treatment of patients with enteropathic diseases such as Celiac Sprue. The ideal biomarker would not only facilitate clinical trials of drug candidates, but would also find utility in disease management of patients who are prescribed such medications. Current diagnostic methods for Celiac Sprue, such as ELISA-based methods in which either anti-gliadin or anti-tTG antibodies in the patient's serum are detected or T cell methods in which cell proliferation or γ-IFN secretion is measured upon stimulation with gliadin, are unsuitable for this purpose. Antibody tests are unsuitable because patients must be exposed to relatively high doses of gluten over extended durations before they seroconvert. T cell proliferation assays are more sensitive, but they require invasive procedures (e.g. withdrawal of a small intestinal biopsy or relatively large quantities of blood to harvest adequate numbers of peripheral blood mononuclear cells) and are deemed to be too expensive for routine use. The present invention addresses this emerging but unmet medical need.
SUMMARY OF THE INVENTION
[0011] Methods are provided for diagnosis and clinical monitoring of enteropathic disease, which diseases include, without limitation, celiac sprue, Crohn's disease and irritable bowel syndrome. In some embodiments, the methods of the invention are used in determining the efficacy of a therapy for treatment of an enteropathic disease, either at an individual level, or in the analysis of a group of patients, e.g. in a clinical trial format. Such embodiments typically involve the comparison of two or more time points for a patient or group of patients. The patient status is expected to differ between the two time points as the result of administration of a therapeutic agent, therapeutic regimen, or challenge with a disease-inducing agent to a patient undergoing treatment. The response of a patient with an enteropathic disease to therapy is assessed by detecting the ability of the patient to metabolize an orally administered CYP3A substrate. The patient metabolism may be monitored in a variety of ways. Conveniently, the appearance of a metabolite of the CYP3A substrate is detected in a patient sample over a period of time following oral administration, e.g. in urine, plasma, breath, saliva, etc. The CYP3A substrate is optionally labeled, e.g. with an isotopic, fluorescent, etc. label.
[0012] Various formats may be used in the pharmacokinetic analysis. In some embodiments, a patient sample is obtained prior to treatment, as a control, and compared to samples from the same patient following treatment. In other embodiments, the CYP3A function is assessed over long periods of time to monitor patient status.
DETAILED DESCRIPTION
[0013] Enteropathic disease is clinically monitored by measuring the pharmacokinetic behavior of substances that are primarily metabolized by CYP3A cytochromes. In preferred embodiments such substances are orally administered, as a solution, enteric formulation, etc.
[0014] The pharmacokinetics of an orally administered drug CYP3A substrate is monitored as a non-invasive surrogate for enteropathy. Certain xenobiotic cytochrome P450 enzymes, such as CYP3A4, are highly active in enterocytes as well as liver cells (Kolars, 1992). However, in contrast to the liver, where the expression level is relatively constant, CYP3A4 levels can fluctuate significantly in the small bowel. For example, CYP3A4 is abundant in enterocytes near villous tips but not near the crypts (Kolars, 1992; Lang, 1996; Johnson, 2001), suggesting that CYP3A4 activity correlates with enterocyte maturity.
[0015] Dietary gluten is known to induce abnormal enterocyte morphology and physiology in celiac patients (Kagnoff, 2007). Consequently, celiac patients with active disease have decreased CYP3A protein and activity levels in their small intestine, both of which recover to normal after introduction of a gluten-free diet (Lang, 1996; Johnson, 2001). Thus, drug efficacy in celiac patients is conveniently monitored using intestinal CYP3A4 activity as a surrogate for gluten-induced enteropathy.
DEFINITIONS
[0016] As used herein, the term “therapeutic drug” or “therapeutic regimen” refers to an agent used in the treatment or prevention of a disease or condition, particularly an enteropathic condition for the purposes of the present invention. Of interest are clinical trials using such therapies, and monitoring of patients undergoing such therapy.
[0017] In some embodiments, the therapy involves treatment of celiac sprue patients with glutenase. In other embodiments, the therapy involves treatment of celiac sprue patients with a transglutaminase inhibitor. Assessment of treatment may utilize a gluten challenge. In some embodiments, 1-14 days of a moderate dose (at least about 1 g/day, at least about 5 g/day, at least about 10 g/day, or more) of oral gluten is utilized for this for this purpose. Patients may be control patients that have not been treated, or patients subject to a clinical regimen of interest, e.g. dietary restriction of gluten, treatment with transglutaminase inhibitor, treatment with glutenase, and the like.
[0018] A “patient,” as used herein, describes an organism, including mammals, from which samples are collected in accordance with the present invention. Mammalian species that benefit from the disclosed systems and methods for therapeutic drug monitoring include, and are not limited to, apes, chimpanzees, orangutans, humans, monkeys; and domesticated animals (e.g., pets) such as dogs, cats, mice, rats, guinea pigs, and hamsters.
[0019] The term “pharmacokinetics,” refers to the mathematical characterization of interactions between normal physiological processes and a therapeutic drug over time (i.e., body effect on drug). Certain physiological processes (absorption, distribution, metabolism, and elimination) will affect the ability of a drug to provide a desired therapeutic effect in a patient. Knowledge of a drug's pharmacokinetics aids in interpreting drug blood stream concentration and is useful in determining pharmacologically effective drug dosages
[0020] The terms “cytochrome P450” and “CYP” are meant to refer to a large family (often called a “superfamily”) of hemoprotein enzymes capable of metabolizing xenobiotics such as drugs, carcinogens, and environmental pollutants, as well as endobiotics such as steroids, fatty acids, and prostaglandins. As used herein, these terms are meant to encompass all members of the CYP superfamily. In some embodiments, these terms refer to CYPs of human origin.
[0021] All isoenzymes, or isoforms, within the CYP superfamily are contemplated to fall within the terms “cytochrome P450” and “CYP” as used herein. Particularly contemplated CYP isoforms include, but are not limited to, members of the CYP1A, CYP2B, CYP2C, CYP2D, CYP2E, and CYP3A families, as these isoforms have been identified as those most commonly responsible for the metabolism of drugs in humans.
[0022] CYP3A substrate. As used herein, the term refers to a compound that is enzymatically transformed by CYP3A into a different compound, or metabolite. For the purposes of the present invention, it is desirable for the primary metabolite or metabolites to be detectably different than the substrate. It is additionally desirable that the substrate by orally administered, and that it by absorbed in the gut.
[0023] A number of commercially available drugs are metabolized by CYP3A4 and may find use in the methods of the invention. Substrates of interest include, without limitation, those set forth in Table 1, with their primary metabolite(s).
[0000]
TABLE 1
Substrate
Primary Metabolite(s)
cyclosporine A
AM9 1 AM1 1 AM4N 1
Midazolam
1′-hydroxymidazolam, 4-hydroxymidozalam
Triazolam
1′-hydroxytriazolam, 4-hydroxytriazalam
lovastatin
(β)-hydroxy acid form
Simvastatin
3′-hydroxy simvastatin, 6′-exomethylene
simvastatin, 3′,5′-dihydrodiol
simvastatin, simvastatin (β)-hydroxy acid
Terfenadine
azacyclonol and terfenadine alcohol
[0024] In some embodiments of the invention, midazolam is the CYP3A substrate. Midazolam exhibits large and relatively reproducible clearance rate changes in humans, most of which can be attributed to changes in enteric metabolism (Thummel et al. (1996) Clin. Pharm Therap. 59:491; Gorski et al. (1998) Clin. Pharm Therap. 64:133; Paine et al. Clin. Pharm Therap. 60:14-24; Chung et al. (2006) Pharmacokinetics & Drug Disposition 79:350, each herein incorporated by reference). Thus, by monitoring C max , AUC or clearance rate of a single dose of midazolam, e.g. if midozalam is administered following a gluten challenge in the presence of drug or placebo, during long term treatment of a celiac patient, etc., the efficacy of the treatment is assessed. In humans, midazolam is primarily eliminated from the body by metabolism to 1′-hydroxymidazolam and 4-hydroxymidazolam by enzymes in the 3A subfamily of cytochrome P450, and less than 1% of the dose is excreted unchanged in the urine. Midazolam clearance and the 1′-hydroxymidazolam to midazolam plasma ratio after intravenous administration have proved to be effective indices of CYP3A activity in liver biopsies. Following oral administration, midazolam is useful in assessing enterocyte CYP3A function.
[0025] An alternative CYP3A4 substrate is oral simvastatin, the bioavailability of which is more dependent on intestinal metabolism than midazolam. Changes in intestinal CYP3A4 activity can be monitored with simvastatin by measuring serum concentration of the drug 1-2 hours post-dose, which reasonably approximates the Cmax of the drug. The advantage of a reliable single time-point measure of intestinal CYP3A4 activity is that a finger-stick or urine test can be used for long-term monitoring of compliance to a gluten-free diet or adherence to drug regimen.
[0026] The term “patient sample” or “sample” as used herein refers to a sample from an animal, most preferably a human, seeking diagnosis or treatment of a disease, e.g. an enteropathic disease. Samples of the present invention include, without limitation, urine, saliva, breath, and blood, including derivatives of blood, e.g. plasma, serum, etc.
[0027] Sample analysis. Patient samples are analyzed to determine the metabolism of a CYP3A substrate, usually an orally administered CYP3A substrate. Sample may be quantitatively analyzed for the presence of the substrate and/or its metabolites by any suitable assay, which are well-known in the art. Methods of analysis include liquid chromatography-mass spectroscopy (see Kanazawa et al. (2004) J. Chromatography 1031:213-218, Gorski et al., supra.); HPLC; ion-monitoring gas chromatography/mass spectroscopy (see Paine et al., supra.); gas chromatography; semiconductive gas sensors; immunoassays; mass spectrometers (including proton transfer reaction mass spectrometry), infrared (IR) or ultraviolet (UV) or visible or fluorescence spectrophotometers (i.e., non-dispersive infrared spectrometer); binding assays involving aptamers or engineered proteins etc.
[0028] In other embodiments, competitive binding immunoassays can be used to test a bodily fluid sample for the presence of the substrate or metabolites. Immunoassay tests may include an absorbent, fibrous strip having one or more reagents incorporated at specific zones on the strip. The bodily fluid sample is deposited on the strip and by capillary action the sample will migrate along the strip, entering specific reagent zones in which a chemical reaction may take place. At least one reagent is included which manifests a detectable response, for example a color change, in the presence of a minimal amount of a signaling agent of interest.
[0029] In some embodiments, the biological sample is patient breath. Sensors that can analyze a patient's exhaled breath components to detect, quantify, and/or trend concentrations of compounds in exhaled breath, can be correlated to the compound concentration in the patient's body, in particular in blood. A sensor can be selected from a variety of systems that have been developed for use in collecting and monitoring exhaled breath components, particularly specific gases. For example, the sensor of the subject invention can be selected from those described in U.S. Pat. Nos. 6,010,459; 5,081,871; 5,042,501; 4,202,352; 5,971,937, and 4,734,777. Further, sensor systems having computerized data analysis components can also be used in the subject invention (i.e., U.S. Pat. No. 4,796,639).
[0030] In other embodiments, the biological sample is patient urine. The concentration of the compound and its metabolites can be monitored in a 6-hour urine collection. In cases where any of these concentrations show a good correlation to the plasma AUC of the compound, a urine test can be developed for CYP3A activity using this biomarker.
[0031] Conditions of interest for monitoring methods of the present invention include a variety of enteropathic conditions, particularly chronic conditions. In some embodiments of the invention, a patient is diagnosed as having an enteropathic condition, for which treatment is contemplated. The patient may be initially tested for enteric CYP3A activity prior to treatment, in order to establish a baseline level of activity. Alternatively, the patient may be released from a treatment regimen for a period of time sufficient to induce an enteropathic state, in which state the patient is tested for enteric CYP3A activity in order to establish a baseline level of activity. Enteropathic conditions of interest include, without limitation, Celiac Sprue, herpetiformis dermatitis, irritable bowel syndrome (IBS); and Crohn's Disease.
[0032] Celiac sprue is an immunologically mediated disease in genetically susceptible individuals caused by intolerance to gluten, resulting in mucosal inflammation, which causes malabsorption. Symptoms usually include diarrhea and abdominal discomfort. Onset is generally in childhood but may occur later. No typical presentation exists. Some patients are asymptomatic or only have signs of nutritional deficiency. Others have significant GI symptoms.
[0033] Celiac sprue can present in infancy and childhood after introduction of cereals into the diet. The child has failure to thrive, apathy, anorexia, pallor, generalized hypotonia, abdominal distention, and muscle wasting. Stools are soft, bulky, clay-colored, and offensive. Older children may present with anemia or failure to grow normally. In adults, lassitude, weakness, and anorexia are most common. Mild and intermittent diarrhea is sometimes the presenting symptom. Steatorrhea ranges from mild to severe (7 to 50 g fat/day). Some patients have weight loss, rarely enough to become underweight. Anemia, glossitis, angular stomatitis, and aphthous ulcers are usually seen in these patients. Manifestations of vitamin D and Ca deficiencies (eg, osteomalacia, osteopenia, osteoporosis) are common. Both men and women may have reduced fertility.
[0034] The diagnosis is suspected clinically and by laboratory abnormalities suggestive of malabsorption. Family incidence is a valuable clue. Celiac sprue should be strongly considered in a patient with iron deficiency without obvious GI bleeding. Confirmation usually involves a small-bowel biopsy from the second portion of the duodenum. Findings include lack or shortening of villi (villous atrophy), increased intraepithelial cells, and crypt hyperplasia. Because biopsy results may be non-specific, serologic markers can aid diagnosis. Anti-gliadin antibody (AGA) and anti-endomysial antibody (EMA, an antibody against an intestinal connective tissue protein) in combination have a positive and negative predictive value of nearly 100%. These markers can also be used to screen populations with high prevalence of celiac sprue, including 1st-degree relatives of affected patients and patients with diseases that occur at a greater frequency in association with celiac sprue. If either test is positive, the patient may have a diagnostic small-bowel biopsy performed. If both are negative, celiac sprue is unlikely. Other laboratory abnormalities often occur and may be sought. These include anemia (iron-deficiency anemia in children and folate-deficiency anemia in adults); low albumin, Ca, K, and Na; and elevated alkaline phosphatase and PT. Malabsorption tests are sometimes performed, although they are not specific for celiac sprue. If performed, common findings include steatorrhea of 10 to 40 g/day and abnormal D-xylose and (in severe ileal disease) Schilling tests.
[0035] Conventional treatment is gluten-free diet (avoiding foods containing wheat, rye, or barley). Gluten is so widely used that a patient needs a detailed list of foods to avoid. Patients are encouraged to consult a dietitian and join a celiac support group. The response to a gluten-free diet is usually rapid, and symptoms resolve in 1 to 2 months. Ingesting even small amounts of food containing gluten may prevent remission or induce disease.
[0036] Complications include refractory sprue, collagenous sprue, and the development of intestinal lymphomas. Intestinal lymphomas affect 6 to 8% of patients with celiac sprue, usually presenting in the patient's 50s. The incidence of other GI malignancies (eg, carcinoma of the esophagus or oropharynx, small-bowel adenocarcinoma) increases. Adherence to a gluten-free diet can significantly reduce the risk of malignancy.
[0037] Dermatitis herpetiformis is a chronic eruption characterized by clusters of intensely pruritic vesicles, papules, and urticaria-like lesions. The cause is autoimmune. Diagnosis is by skin biopsy with direct immunofluorescence testing. Treatment is usually with dapsone or sulfapyridine.
[0038] This disease usually presents in patients 30 to 40 yr old and is rare in blacks and East Asians. It is an autoimmune disease. Celiac sprue is present in 75 to 90% of dermatitis herpetiformis patients and in some of their relatives, but it is asymptomatic in most cases. The incidence of thyroid disease is also increased. Iodides may exacerbate the disease, even when symptoms are well controlled. The term “herpetiformis” refers to the clustered appearance of the lesions rather than a relationship to herpesvirus.
[0039] Patients may have skin biopsy of a lesion and adjacent normal-appearing skin. IgA deposition in the dermal papillary tips is usually present and important for diagnosis. Patients should be evaluated for celiac sprue.
[0040] Strict adherence to a gluten-free diet for prolonged periods (eg, 6 to 12 mo) controls the disease in some patients, obviating or reducing the need for drug therapy. When drugs are needed, dapsone may provide symptomatic improvement. It is started at 50 mg po once/day, increased to bid or tid (or a once/day dose of 100 mg); this usually dramatically relieves symptoms, including itching, within 1 to 3 days; if so, that dose is continued. If no improvement occurs, the dose can be increased every week, up to 100 mg qid. Most patients can be maintained on 50 to 150 mg/day, and some require as little as 25 mg/wk. Although less effective, sulfapyridine may be used as an alternative for those who cannot tolerate dapsone. Initial oral dosage is 500 mg bid, increasing by 1 g/day q 1 to 2 wk until disease is controlled. Maintenance dosage varies from 500 mg twice/wk to 1000 mg once/day. Colchicine is another treatment option. Treatment continues until lesions resolve.
[0041] Crohn's Disease (Regional Enteritis; Granulomatous Ileitis or Ileocolitis) is a chronic transmural inflammatory disease that usually affects the distal ileum and colon but may occur in any part of the GI tract. Symptoms include diarrhea and abdominal pain. Abscesses, internal and external fistulas, and bowel obstruction may arise. Extraintestinal symptoms, particularly arthritis, may occur. Diagnosis is by colonoscopy and barium contrast studies. Treatment is with 5-aminosalicylic acid, corticosteroids, immunomodulators, anticytokines, antibiotics, and often surgery.
[0042] The most common initial presentation is chronic diarrhea with abdominal pain, fever, anorexia, and weight loss. The abdomen is tender, and a mass or fullness may be palpable. Gross rectal bleeding is unusual except in isolated colonic disease, which may manifest similarly to ulcerative colitis. Some patients present with an acute abdomen that simulates acute appendicitis or intestinal obstruction. About 33% of patients have perianal disease (especially fissures and fistulas), which is sometimes the most prominent or even initial complaint. In children, extraintestinal manifestations frequently predominate over GI symptoms; arthritis, fever of unknown origin, anemia, or growth retardation may be a presenting symptom, whereas abdominal pain or diarrhea may be absent.
[0043] With recurrent disease, symptoms vary. Pain is most common and occurs with both simple recurrence and abscess formation. Patients with severe flare-up or abscess are likely to have marked tenderness, guarding, rebound, and a general toxic appearance. Stenotic segments may cause bowel obstruction, with colicky pain, distention, obstipation, and vomiting. Adhesions from previous surgery also may produce bowel obstruction, which begins rapidly, without the prodrome of fever, pain, and malaise typical of obstruction due to a Crohn's disease flare-up. An enterovesical fistula may produce air bubbles in the urine (pneumaturia). Draining cutaneous fistulas may occur. Free perforation into the peritoneal cavity is unusual.
[0044] Crohn's disease should be suspected in a patient with inflammatory or obstructive symptoms or in a patient without prominent GI symptoms but with perianal fistulas or abscesses or with otherwise unexplained arthritis, erythema nodosum, fever, anemia, or (in a child) stunted growth. A family history of Crohn's disease also increases the index of suspicion. Patients presenting with an acute abdomen (either initially or on relapse) should have flat and upright abdominal x-rays and an abdominal CT scan. These studies demonstrate obstruction, abscesses or fistulas, and other possible causes of an acute abdomen (eg, appendicitis). Ultrasound may better delineate gynecologic pathology in women with lower abdominal and pelvic pain.
[0045] If initial presentation is less acute, an upper GI series with small-bowel follow-through and spot films of the terminal ileum is preferred over conventional CT. However, newer techniques of CT enterography, which combines high-resolution CT with large volumes of ingested contrast, are becoming the procedures of choice in some centers. These imaging studies are virtually diagnostic if they show characteristic strictures or fistulas with accompanying separation of bowel loops. If findings are questionable, CT enteroclysis or video capsule enteroscopy may show superficial aphthous and linear ulcers. Barium enema x-ray may be used if symptoms appear predominantly colonic (eg, diarrhea) and may show reflux of barium into the terminal ileum with irregularity, nodularity, stiffness, wall thickening, and a narrowed lumen. Differential diagnoses in patients with similar x-ray findings include cancer of the cecum, ileal carcinoid, lymphosarcoma, systemic vasculitis, radiation enteritis, ileocecal TB, and ameboma.
[0046] Established Crohn's disease is rarely cured but is characterized by intermittent exacerbations and remissions. Some patients suffer severe disease with frequent, debilitating periods of pain. However, with judicious medical therapy and, where appropriate, surgical therapy, most patients function well and adapt successfully. Disease-related mortality is very low. GI cancer, including cancer of the colon and small bowel, is the leading cause of excess Crohn's disease-related mortality.
[0047] 5-Aminosalicylic acid (5-ASA, mesalamine) is commonly used as first-line treatment, although its benefits for small-bowel disease are modest at best. Antibiotics are considered a first-line agent by some clinicians, or they may be reserved for patients not responding to 4 wk of 5-ASA; their use is strictly empiric. With any of these drugs, 8 to 16 wk of treatment may be required. Patients with more severe disease may require corticosteroids, either oral or parenteral, depending on severity of symptoms and frequency of vomiting. Patients not responding to corticosteroids, or those whose doses cannot be tapered, should receive azathioprine, or possibly methotrexate. 6-mercaptopurine is preferred by some as a second-line agent after corticosteroids, and even as a first-line agent in preference to corticosteroids, but it is contraindicated in active uncontrolled infection.
[0048] Irritable bowel syndrome consists of recurring upper and lower GI symptoms, including variable degrees of abdominal pain, constipation or diarrhea, and abdominal bloating. Diagnosis is clinical. Treatment is generally symptomatic, consisting of dietary management and drugs, including anticholinergics and agents active at serotonin receptors.
[0049] There are no consistent motility abnormalities. Some patients have an abnormal gastro-colonic reflex, with delayed, prolonged colonic activity. There may be reduced gastric emptying or disordered jejunal motility. Some patients have no demonstrable abnormalities, and in those that do, the abnormalities may not correlate with symptoms. Small-bowel transit varies: sometimes the proximal small bowel appears to be hyperreactive to food or parasympathomimetic drugs. Intraluminal pressure studies of the sigmoid show that functional constipation can occur with hyperreactive haustral segmentation (ie, increased frequency and amplitude of contractions). In contrast, diarrhea is associated with diminished motor function. Thus strong contractions can, at times, accelerate or delay transit.
[0050] Hypersensitivity to normal amounts of intraluminal distention and heightened perception of pain in the presence of normal quantity of intestinal gas exist. Pain seems to be caused by abnormally strong contractions of the intestinal smooth muscle or by increased sensitivity of the intestine to distention. Hypersensitivity to the hormones gastrin and cholecystokinin may also be present. However, hormonal fluctuations do not correlate with symptoms. Meals of high caloric density may increase the magnitude and frequency of myoelectrical activity and gastric motility. Fat ingestion may cause a delayed peak of motor activity, which can be exaggerated in IBS. The first few days of menstruation can lead to transiently elevated prostaglandin E2, resulting in increased pain and diarrhea, probably by the release of prostaglandins.
[0051] Two major clinical types of IBS have been described. In constipation-predominant IBS, most patients have pain over at least one area of the colon and periods of constipation alternating with a more normal stool frequency. Stool often contains clear or white mucus. Pain is either colicky, coming in bouts, or a continuous dull ache; it may be relieved by a bowel movement. Eating commonly triggers symptoms. Bloating, flatulence, nausea, dyspepsia, and pyrosis can also occur.
[0052] Diarrhea-predominant IBS is characterized by precipitous diarrhea that occurs immediately on rising or during or immediately after eating, especially rapid eating. Nocturnal diarrhea is unusual. Pain, bloating, and rectal urgency are common, and incontinence may occur. Painless diarrhea is not typical.
[0053] Diagnosis is based on characteristic bowel patterns, time and character of pain, and exclusion of other disease processes through physical examination and routine diagnostic tests. Diagnostic testing should be more intensive when “red flags” are present: older age, weight loss, rectal bleeding, vomiting. Proctosigmoidoscopy with a flexible fiberoptic instrument should be performed. Introduction of the sigmoidoscope and air insufflation frequently trigger bowel spasm and pain. The mucosal and vascular patterns in IBS usually appear normal. Colonoscopy is preferred for patients >40 with a change in bowel habits, particularly those with no previous IBS symptoms, to exclude colonic polyps and tumors. In patients with chronic diarrhea, particularly older women, mucosal biopsy can rule out possible microscopic colitis.
METHODS OF THE INVENTION
[0054] The ability of an individual to metabolize a CYP3A substrate via an intestinal route is analyzed by administering an oral dose of a CYP3A substrate to an individual suffering from an enteropathic disorder, and quantitating the presence of the CYP3A substrate and/or its metabolite(s) in at least one patient sample.
[0055] In some embodiments, the method comprises identifying a patient as having an enteropathic disorder, e.g. by criteria described above for specific disease conditions; administering an oral dose of a CYP3A substrate to an individual identified as having an enteropathic disorder, and quantitating the presence of the CYP3A substrate and/or its metabolite(s) in at least one patient sample.
[0056] Patient samples include a variety of bodily fluids in which the CYP3A substrate and/or metabolites will be present, e.g. blood and derivatives thereof, urine, saliva, breath, etc. The samples will be taken prior to administration of the substrate, and at suitable time points following administration, e.g. at 15 minutes, 30 minutes, 1 hour, 1.5 hours, 2 hours, 2.5 hours, 3 hours, 4 hours, 6 hours, etc., following administration.
[0057] In some preferred embodiments, the methods of the invention are used in determining the efficacy of a therapy for treatment of an enteropathic disease, either at an individual level, or in the analysis of a group of patients, e.g. in a clinical trial format. Such embodiments typically involve the comparison of two time points for a patient or group of patients. The patient status is expected to differ between the two time points as the result of a therapeutic agent, therapeutic regimen, or disease challenge to a patient undergoing treatment.
[0058] Examples of formats for such embodiments may include, without limitation, testing enteric CYP3A metabolism at two or more time points, where a first time point is a diagnosed but untreated patient; and a second or additional time point(s) is a patient treated with a candidate therapeutic agent or regimen. An additional time point may include a patient treated with a candidate therapeutic agent or regimen, and challenged for the disease, particularly for celiac sprue and/or dermatitis herpetiformis, which may be challenged with administration of gluten.
[0059] In another format, a first time point is a diagnosed patient in disease remission, e.g. as ascertained by current clinical criteria, as a result of a candidate therapeutic agent or regimen. A second or additional time point(s) is a patient treated with a candidate therapeutic agent or regimen, and challenged with a disease-inducing agent, particularly for celiac sprue and/or dermatitis herpetiformis, which may be challenged with administration of gluten.
[0060] In such clinical trial formats, each set of time points may correspond to a single patient, to a patient group, e.g. a cohort group, or to a mixture of individual and group data. Additional control data may also be included in such clinical trial formats, e.g. a placebo group, a disease-free group, and the like, as are known in the art. Formats of interest include crossover studies, randomized, double-blind, placebo-controlled, parallel group trial is also capable of testing drug efficacy, and the like. See, for example, Clinical Trials: A Methodologic Perspective Second Edition, S. Piantadosi, Wiley-Interscience; 2005, ISBN-13: 978-0471727811; and Design and Analysis of Clinical Trials: Concepts and Methodologies, S. Chow and J. Liu, Wiley-Interscience; 2003; ISBN-13: 978-0471249856, each herein specifically incorporated by reference.
[0061] Specific clinical trials of interest include analysis of therapeutic agents for the treatment of celiac sprue and/or dermatitis herpetiformis, where a patient is identified as having celiac sprue by conventional clinical indicia. For example, in celiac sprue a daily dose of 5-10 g gluten (equivalent to 2-3 slices of bread) for two weeks can induce malabsorption, as measured by a 72-hour quantitative fecal fat collection or a D-xylose urinary test (Pyle, 2005), providing for a means to challenge the efficacy of a treatment.
[0062] In one embodiment, a blinded crossover clinical trial format is utilized. A patient alternates for a set period of time, e.g. one week, two weeks, three weeks, or from around about 7-14 days, or around about 10 days, between a test drug and placebo, with a 4-8 week washout period. The patient is challenged with gluten during both alternating time periods with around about 1 g gluten, about 5 g. gluten, about 10 g. gluten, or more, usually not more than about 25 g gluten daily. Subjects are tested with a CYP3A substrate, as described above, at the beginning and end of each alternating time period. Care is taken to ensure that subjects are not consuming other drugs or food items (e.g. grapefruit juice) that are known CYP3A4 inhibitors for an appropriate duration before the CYP3A substrate tests. The duration of gluten challenge may be about 1, about 3, about 5, about 7, about 10 days, about 14 days, because changes in the enterocytes at the villous tips are usually one of the earliest consequences of gluten exposure. By decreasing the duration of the gluten challenge or the magnitude of the daily gluten dose, adverse symptoms can be minimized.
[0063] In another embodiment a randomized, double-blind, placebo-controlled, parallel group trial is used to test drug efficacy. In one embodiment, individuals identified as having celiac sprue, who are on a gluten-free diet, undergo three sequential treatment periods, each of 1-14 day durations. Subjects will be assessed with the CYP3A substrate at entry and at the end of each treatment period. During the entire study, subjects will consume regular gluten-free meals plus drug or placebo as indicated. During the first treatment period (run-in), all subjects will receive placebo. During the second treatment period, the subjects will be randomized into drug or placebo groups. During the third treatment period, subjects will remain on the same (drug or placebo) treatment as in the second period. In addition, all subjects will receive 1-5 g gluten with each meal. Drugs that are effective will show a statistically lower frequency of relapse in the treatment arm versus placebo arm of the study.
[0064] In all such methods, the CYP3A substrate is administered at a dose that is sufficient to monitor the metabolism over time, which will vary with the specific substrate that is selected. Where the substrate is midazolam, the dose may be at least about 0.5 mg, at least about 1 mg, at least about 2 mg at least about 4 mg, at least about 5 mg, at least about 7.5 mg, and not more than about 10 mg.
[0065] The substrate may be administered in any conventional formulation, e.g. solution, suspension, tablets, powders, granules or capsules, for example, with conventional additives, such as lactose, mannitol, corn starch or potato starch; with binders, such as crystalline cellulose, cellulose derivatives, acacia, corn starch or gelatins; with disintegrators, such as corn starch, potato starch or sodium carboxymethylcellulose; with lubricants, such as talc or magnesium stearate; and if desired, with diluents, buffering agents, moistening agents, preservatives and flavoring agents.
[0066] In one embodiment of the invention, the oral formulations comprise enteric coatings, so that the active agent is delivered to the intestinal tract. Such formulations are created by coating a solid dosage form with a film of a polymer that is insoluble in acid environments, and soluble in basic environments. Exemplary films are cellulose acetate phthalate, polyvinyl acetate phthalate, hydroxypropyl methylcellulose phthalate and hydroxypropyl methylcellulose acetate succinate, methacrylate copolymers, and cellulose acetate phthalate. Other enteric formulations comprise engineered polymer microspheres made of biologically erodable polymers, which display strong adhesive interactions with gastrointestinal mucus and cellular linings and can traverse both the mucosal absorptive epithelium and the follicle-associated epithelium covering the lymphoid tissue of Peyer's patches. The polymers maintain contact with intestinal epithelium for extended periods of time and actually penetrate it, through and between cells. See, for example, Mathiowitz et al. (1997) Nature 386 (6623): 410-414. Drug delivery systems can also utilize a core of superporous hydrogels (SPH) and SPH composite (SPHC), as described by Dorkoosh et al. (2001) J Control Release 71(3):307-18.
Databases of Pharmacokinetic Analyses
[0067] Also provided are databases of pharmacokinetic analyses. Such databases will typically comprise analysis profiles of various individuals following a clinical protocol of interest etc., where such profiles are further described below.
[0068] The profiles and databases thereof may be provided in a variety of media to facilitate their use. “Media” refers to a manufacture that contains the expression profile information of the present invention. The databases of the present invention can be recorded on computer readable media, e.g. any medium that can be read and accessed directly by a computer. Such media include, but are not limited to: magnetic storage media, such as floppy discs, hard disc storage medium, and magnetic tape; optical storage media such as CD-ROM; electrical storage media such as RAM and ROM; and hybrids of these categories such as magnetic/optical storage media. One of skill in the art can readily appreciate how any of the presently known computer readable mediums can be used to create a manufacture comprising a recording of the present database information. “Recorded” refers to a process for storing information on computer readable medium, using any such methods as known in the art. Any convenient data storage structure may be chosen, based on the means used to access the stored information. A variety of data processor programs and formats can be used for storage, e.g. word processing text file, database format, etc.
[0069] As used herein, “a computer-based system” refers to the hardware means, software means, and data storage means used to analyze the information of the present invention. The minimum hardware of the computer-based systems of the present invention comprises a central processing unit (CPU), input means, output means, and data storage means. A skilled artisan can readily appreciate that any one of the currently available computer-based system are suitable for use in the present invention. The data storage means may comprise any manufacture comprising a recording of the present information as described above, or a memory access means that can access such a manufacture.
[0070] A variety of structural formats for the input and output means can be used to input and output the information in the computer-based systems of the present invention. Such presentation provides a skilled artisan with a ranking of similarities and identifies the degree of similarity contained in the test expression profile.
Reagents and Kits
[0071] Also provided are reagents and kits thereof for practicing one or more of the above-described methods. The subject reagents and kits thereof may vary greatly. Reagents of interest include reagents specifically designed for use in production of the above described analysis. Kits may include a CYP3A substrate, reagents for analysis of the substrate and/or metabolites, and such containers as are required for sample collection.
[0072] The kits may further include a software package for statistical analysis of one or more phenotypes. In addition to the above components, the subject kits will further include instructions for practicing the subject methods. These instructions may be present in the subject kits in a variety of forms, one or more of which may be present in the kit. One form in which these instructions may be present is as printed information on a suitable medium or substrate, e.g., a piece or pieces of paper on which the information is printed, in the packaging of the kit, in a package insert, etc. Yet another means would be a computer readable medium, e.g., diskette, CD, etc., on which the information has been recorded. Yet another means that may be present is a website address which may be used via the internet to access the information at a removed site. Any convenient means may be present in the kits.
[0073] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the present invention, and are not intended to limit the scope of the invention or to represent that the experiments below are all or the only experiments performed. Efforts have been made to ensure accuracy with respect to numbers used (e.g., amounts, temperature, and the like), but some experimental errors and deviations may be present. Unless indicated otherwise, parts are parts by weight, molecular weight is weight average molecular weight, temperature is in degrees Centigrade, and pressure is at or near atmospheric.
Example 1
Material and Methods
[0074] Subjects. After institutional review board approval, eight healthy adult volunteers and eight adult celiac sprue patients with diagnosed ongoing intestinal malabsorption are selected. After the initial baseline testing, celiac patients are treated with glutenase for a length of time sufficient to alleviate symptoms of malabsorption, and are then retested as done for the initial baseline analysis.
[0075] Study design. After the subjects fast overnight, an intravenous catheter is placed in one forearm of each subject for the withdrawal of blood. Before receiving the dose of midazolam, each subject empties his or her bladder, and a baseline blood sample is obtained. Each subject receives 4.0 mg midazolam orally as a solution. Blood samples are obtained 5, 15, 30, and 45 minutes and 1, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, and 24 hours after drug administration. Serum is obtained and frozen at −20° C. until analysis. Urine is collected during the intervals 0 to 2, 2 to 4, 4 to 6, 6 to 12, and 12 to 24 hours after the dose and frozen at −20° C. until analysis. Midazolam-induced sleep time is determined as the interval between the time the subject is no longer able to be aroused by mild auditory stimuli and the time that the subject remains awake and aware in response to mild auditory stimuli. A mild auditory stimulus is defined as speaking in a normal conversational voice.
[0076] Sample analysis. Serum samples are processed with use of a liquid-liquid extraction technique and quantified after derivatization with gas chromatography-mass spectrometry (Hewlett-Packard 597 1 mass selective detector and 5890A gas chromatograph) as described by Thummel et al. (1994) J. Pharmacol. Exp. Ther. 271:549-546, herein specifically incorporated by reference. Monitored ions include 310, and 398, which are used to quantify levels of midazolam, and 1′-hydroxymidazolam. Diazepam and temazepam are used as the internal standards for parent and metabolite, respectively, and the monitored ions are 256 and 357, respectively, after derivitization with N-methyl-N-t-butyldimethylsilyl trifluoroacetamide containing 1% t-butyldimethylchlorosilane (Regis Technologies, Morton Grove, Ill.)
[0077] The assay is used to routinely measure midazolam and metabolite concentrations of 1 ng/ml. Urine samples are processed as described after deconjugation with P-glucuronidase (Sigma Chemical Co., St. Louis, Mo.). The midazolam concentration in the infused solution is estimated by HPLC (see Gorski et al. (1994) Biochem Pharmacol 47:1643-1657, herein specifically incorporated by reference). Serum samples are processed through a liquid-liquid extraction method.
[0078] Pharmacokinetic analysis. Standard model independent methods are used to determine the pharmacokinetic parameters of interest. The terminal elimination rate constant (p) is determined by linear regression. The elimination half-life (t½) is determined as t½=0.693/β. The maximum concentration and time to reach the maximum concentration are determined by visual inspection of the data. The area under the concentration-time curve (AUC from zero to final detectable midazolam serum concentration) after oral administration is determined by a combination of linear and logarithmic trapezoidal methods with extrapolation to infinity.
[0079] The efficacy of treatment for celiac sprue patients is assessed by determining the decrease in enteric CYP3A metabolism of midazolam. An effective glutenase will protect a patient from gluten-induced enteropathy; consequently, the t½ and AUC for midazolam will remain unchanged before and after gluten challenge. In contrast, the placebo will result in gluten-induced enteropathy; consequently, the t½ and AUC for midazolam will increase after gluten challenge as compared to corresponding values before gluten challenge.
Example 2
[0080] Administration of midazolam and sample analysis is performed as described above.
[0081] Patients are identified as having celiac sprue by conventional clinical indicia.
[0082] The clinical efficacy of a prolyl endopeptidase from Aspergillus niger (Stepniak, et al. Am. J. Physiol. GI Liver Physiol. 291, 621-629, 2006) is evaluated as follows. Clinically diagnosed adult celiac patients who are on a gluten-free diet are enrolled in the study and are divided into two groups. Each subject in the clinical trial undergoes three sequential treatment periods of 1-14 day duration. CYP3A metabolism of each subject is assessed at entry and at the end of each treatment period.
[0083] During the entire study, subjects consume regular gluten-free meals plus one dose of glutenase or placebo with breakfast, lunch and dinner. The dose range of the glutenase to be tested for clinical efficacy is 0.2-10 mg/kg. During the first (run-in) period, all subjects receive placebo glutenase. It is anticipated that the intestinal health of a subset of subjects will improve due to greater dietary vigilance on their part. During the second period, the subjects are randomized into active or placebo glutenase groups. This period is designed to establish whether the intestinal health of subjects taking active glutenase improves as a result of its ability to detoxify background levels of gluten in a celiac patient's diet. During the third period, subjects will remain on the same (drug or placebo) treatment as in the second period. In addition, all subjects receive 0.5-3 g gluten with each meal in the form of an appropriate test article (e.g., a cookie or a slice or bread). The efficacy of the glutenase treatment is primarily assessed based on the results of this treatment period.
[0084] A statistically significant result is based on midazolam AUC and clearance rate measurements. An increase in AUC and a decrease in clearance rate imply that the celiac condition has worsened as a result of exposure to toxic gluten peptides. This is observed at the end of the third treatment period in subjects who are dosed with placebo glutenase. A statistically unchanged AUC and clearance rate are indicative of gluten detoxification by the oral glutenase. This is observed at the end of the third treatment period in subjects who are dosed with active glutenase. In subjects who initiate the clinical trial with evidence of active disease, a decrease in AUC and increase in clearance rate may be observed at the end of the second period relative to the end of the first period. A two-fold or higher change in AUC or clearance between the two cohorts is anticipated for statistical significance.
Example 3
[0085] An alternate method for assessing the efficacy of the prolyl endopeptidase from Aspergillus niger involves a double-blind, placebo controlled crossover clinical trial. The principal advantage of this trial format is that each patient serves as his/her own control. Clinically diagnosed adult celiac patients whose disease is in remission (as judged by a normal small bowel biopsy, seronegativity, and a 72-hour fecal fat measurement within the normal range) are enrolled in the study.
[0086] Each subject in the clinical trial undergoes two treatment periods of 1-14 day durations separated by a 4-8 week washout. CYP3A metabolism of each subject is assessed at entry and at the end of each treatment period. During each of the two treatment periods, subjects receive 0.5-3 g gluten with each meal in the form of an appropriate test article. Each subject receives active glutenase and placebo glutenase alternately in the two treatment periods; the order of dosing is randomly assigned. The dose range of the glutenase to be tested for clinical efficacy is 0.2-10 mg/kg.
[0087] A statistically significant result is based on midazolam AUC and clearance rate measurements. An increase in AUC and a decrease in clearance rate imply that the celiac condition has worsened as a result of exposure to toxic gluten peptides. This is observed at the end of the placebo glutenase treatment period. A statistically unchanged AUC and clearance rate are indicative of gluten detoxification by the oral glutenase. This is observed at the end of the active glutenase treatment period.
Example 4
[0088] An alternate glutenase therapy is a two-enzyme glutenase comprised of protease EP-B2 from barley and peptidase SC PEP from Sphingomonas capsulata (Gass, et al., Gastroenterology 133, 472-480, 2007). The clinical efficacy of this enzyme is tested via a clinical trial, as in Example 2 or Example 3 above. In one embodiment, glutenase doses in the range of 0.2-10 mg/kg, with the two proteins present in a 1:1 mass ratio, are tested for efficacy by the methods of the invention.
Example 5
[0089] An alternate drug candidate for celiac sprue is the intestinal permeability inhibitor, AT1001 (Paterson, et al. Aliment. Pharmacol. Ther. 26, 757-766, 2007). The clinical efficacy of this drug is tested via a clinical trial, as in Example 2 or Example 3 above. In one embodiment, the doses in the range of 5 to 50 mg/kg (tid, with meals) are tested for efficacy by the methods of the invention.
Example 6
Material and Methods
[0090] Subjects. After institutional review board approval, eight healthy adult volunteers and eight adult celiac sprue patients with diagnosed ongoing intestinal malabsorption are selected. After the initial baseline testing, celiac patients are treated with glutenase for a length of time sufficient to alleviate symptoms of malabsorption, and are then retested as done for the initial baseline analysis.
[0091] Study design. After the subjects fast overnight, an intravenous catheter is placed in one forearm of each subject for the withdrawal of blood. Before receiving the dose of midazolam, each subject empties his or her bladder, and a baseline blood sample is obtained. Each subject receives from 20 to 100 mg simvastatin orally as a solution. Blood samples are obtained 5, 15, 30, and 45 minutes and 1, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, and 24 hours after drug administration. Serum is obtained and frozen at −20° C. until analysis. Urine is collected during the intervals 0 to 2, 2 to 4, 4 to 6, 6 to 12, and 12 to 24 hours after the dose and frozen at −20° C. until analysis.
[0092] Sample analysis. Serum samples are processed with use of a liquid-liquid extraction technique and quantified after derivatization with gas chromatography-mass spectrometry (Hewlett-Packard 597 1 mass selective detector and 5890A gas chromatograph) as described by Thummel et al. (1994) J. Pharmacol. Exp. Ther. 271:549-546, herein specifically incorporated by reference. Simvastatin, 3′-hydroxy simvastatin, 6′-exomethylene simvastatin, 3′,5′-dihydrodiol simvastatin, and/or simvastatin (β)-hydroxy acid are monitored.
[0093] The assay is used to routinely measure simvastatin and metabolite concentrations of 1 ng/ml. Urine samples are processed as described after deconjugation with P-glucuronidase (Sigma Chemical Co., St. Louis, Mo.). The simvastatin concentration in the infused solution is estimated by HPLC (see Gorski et al. (1994) Biochem Pharmacol 47:1643-1657, herein specifically incorporated by reference). Serum samples are processed through a liquid-liquid extraction method.
[0094] Pharmacokinetic analysis. Standard model independent methods are used to determine the pharmacokinetic parameters of interest. The terminal elimination rate constant (p) is determined by linear regression. The elimination half-life (t½) is determined as t½=0.693/β. The maximum concentration and time to reach the maximum concentration are determined by visual inspection of the data. The area under the concentration-time curve (AUC from zero to final detectable simvastatin serum concentration) after oral administration is determined by a combination of linear and logarithmic trapezoidal methods with extrapolation to infinity. The Cmax is determined.
[0095] The efficacy of treatment for celiac sprue patients is assessed by determining the decrease in enteric CYP3A metabolism of simvastatin. An effective glutenase will protect a patient from gluten-induced enteropathy; consequently, the t½ and AUC for simvastatin will remain unchanged before and after gluten challenge. In contrast, the placebo will result in gluten-induced enteropathy; consequently, the t½ and AUC for simvastatin will increase after gluten challenge as compared to corresponding values before gluten challenge.
Example 7
[0096] Administration of simvastatin and sample analysis is performed as described above.
[0097] Patients are identified as having celiac sprue by conventional clinical indicia.
[0098] The clinical efficacy of a prolyl endopeptidase from Aspergillus niger (Stepniak, et al. Am. J. Physiol. GI Liver Physiol. 291, 621-629, 2006) is evaluated as follows. Clinically diagnosed adult celiac patients who are on a gluten-free diet are enrolled in the study and are divided into two groups. Each subject in the clinical trial undergoes three sequential treatment periods of 1-14 day duration. CYP3A metabolism of each subject is assessed at entry and at the end of each treatment period.
[0099] During the entire study, subjects consume regular gluten-free meals plus one dose of glutenase or placebo with breakfast, lunch and dinner. The dose range of the glutenase to be tested for clinical efficacy is 0.2-10 mg/kg. During the first (run-in) period, all subjects receive placebo glutenase. It is anticipated that the intestinal health of a subset of subjects will improve due to greater dietary vigilance on their part. During the second period, the subjects are randomized into active or placebo glutenase groups. This period is designed to establish whether the intestinal health of subjects taking active glutenase improves as a result of its ability to detoxify background levels of gluten in a celiac patient's diet. During the third period, subjects will remain on the same (drug or placebo) treatment as in the second period. In addition, all subjects receive 0.5-3 g gluten with each meal in the form of an appropriate test article (e.g., a cookie or a slice or bread). The efficacy of the glutenase treatment is primarily assessed based on the results of this treatment period.
[0100] A statistically significant result is based on simvastatin AUC, Cmax, and clearance rate measurements. An increase in AUC and a decrease in clearance rate imply that the celiac condition has worsened as a result of exposure to toxic gluten peptides. This is observed at the end of the third treatment period in subjects who are dosed with placebo glutenase. A statistically unchanged AUC and clearance rate are indicative of gluten detoxification by the oral glutenase. This is observed at the end of the third treatment period in subjects who are dosed with active glutenase. In subjects who initiate the clinical trial with evidence of active disease, a decrease in AUC and increase in clearance rate may be observed at the end of the second period relative to the end of the first period. A two-fold or higher change in AUC or clearance between the two cohorts is anticipated for statistical significance.
Example 8
[0101] An alternate method for assessing the efficacy of the prolyl endopeptidase from Aspergillus niger involves a double-blind, placebo controlled crossover clinical trial. The principal advantage of this trial format is that each patient serves as his/her own control. Clinically diagnosed adult celiac patients whose disease is in remission (as judged by a normal small bowel biopsy, seronegativity, and a 72-hour fecal fat measurement within the normal range) are enrolled in the study.
[0102] Each subject in the clinical trial undergoes two treatment periods of 1-14 day durations separated by a 4-8 week washout. CYP3A metabolism of each subject is assessed at entry and at the end of each treatment period. During each of the two treatment periods, subjects receive 0.5-3 g gluten with each meal in the form of an appropriate test article. Each subject receives active glutenase and placebo glutenase alternately in the two treatment periods; the order of dosing is randomly assigned. The dose range of the glutenase to be tested for clinical efficacy is 0.2-10 mg/kg.
[0103] A statistically significant result is based on simvastatin AUC, Cmax, and clearance rate measurements. An increase in AUC and a decrease in clearance rate imply that the celiac condition has worsened as a result of exposure to toxic gluten peptides. This is observed at the end of the placebo glutenase treatment period. A statistically unchanged AUC and clearance rate are indicative of gluten detoxification by the oral glutenase. This is observed at the end of the active glutenase treatment period.
Example 9
[0104] An alternate glutenase therapy is a two-enzyme glutenase comprised of protease EP-B2 from barley and peptidase SC PEP from Sphingomonas capsulata (Gass, et al., Gastroenterology 133, 472-480, 2007). The clinical efficacy of this enzyme is tested via a clinical trial, as in Example 7 or Example 8 above. In one embodiment, glutenase doses in the range of 0.2-10 mg/kg, with the two proteins present in a 1:1 mass ratio, are tested for efficacy by the methods of the invention.
Example 10
[0105] An alternate drug candidate for celiac sprue is the intestinal permeability inhibitor, AT1001 (Paterson, et al. Aliment. Pharmacol. Ther. 26, 757-766, 2007). The clinical efficacy of this drug is tested via a clinical trial, as in Example 7 or Example 8 above. In one embodiment, the doses in the range of 5 to 50 mg/kg (tid, with meals) are tested for efficacy by the methods of the invention.
[0106] These and other diagnostic methods of the invention can be practiced using the methods provided by the invention.
[0107] All publications, patents, and patent applications cited in this specification are herein incorporated by reference as if each individual publication, patent, or patent application were specifically and individually indicated to be incorporated by reference.
[0108] The present invention has been described in terms of particular embodiments found or proposed by the inventor to comprise preferred modes for the practice of the invention. It will be appreciated by those of skill in the art that, in light of the present disclosure, numerous modifications and changes can be made in the particular embodiments exemplified without departing from the intended scope of the invention. Moreover, due to biological functional equivalency considerations, changes can be made in methods, structures, and compounds without affecting the biological action in kind or amount. All such modifications are intended to be included within the scope of the appended claims.
|
The response of a patient with an enteropathic disease to therapy, particularly a candidate therapy in a clinical trial setting, is assessed by detecting the ability of the patient to metabolize an orally administered CYP3A substrate. The CYP3A metabolism may be monitored in a variety of ways. Conveniently, the appearance of a metabolite of the CYP3A substrate is detected in a patient sample over a period of time following oral administration, e.g. in urine, plasma, breath, saliva, etc. The CYP3A substrate is optionally labeled, e.g. with an isotopic, fluorescent, etc. label.
| 6
|
CROSS-REFERENCE To RELATED APPLICATIONS
[0001] This application claims priority to commonly owned U.S. Provisional Patent Application No. 62/281,056 filed Jan. 20, 2016; which is hereby incorporated by reference herein for all purposes.
TECHNICAL FIELD
[0002] The present disclosure relates to synchronous serial interfaces, and in particular to a time-triggered communication channel in a synchronous network.
BACKGROUND
[0003] Serial interfaces using either a synchronous protocol are well known in the art. For example, an SPI or I 2 C interface bus uses two bus lines to separately transmit a clock signal and associated data signals. These type of interfaces are synchronous because the data is transmitted synchronous to the clock signal. Generally, such interfaces are more robust than asynchronous interfaces and allow for higher transmission rates.
[0004] Media Oriented Systems Transport (MOST®) is a high-speed multimedia network technology optimized by the automotive industry. It can be used for applications inside or outside the car. The serial MOST® bus uses a ring topology and synchronous data communication to transport audio, video, voice and data signals via plastic optical fiber (POF) (MOST25, MOST150) or electrical conductor (MOST50, MOST150) physical layers.
[0005] The MOST® specification defines the physical and the data link layer as well as all seven layers of the ISO/OSI-Model of data communication. Standardized interfaces simplify the MOST® protocol integration in multimedia devices. For the system developer, MOST® is primarily a protocol definition. It provides the user with a standardized interface (API) to access device functionality. The communication functionality is provided by driver software known as MOST® Network Services. MOST® Network Services include Basic Layer System Services (Layer 3, 4, 5) and Application Socket Services (Layer 6). They process the MOST® protocol between a MOST® Network Interface Controller (NIC), which is based on the physical layer, and the API (Layer 7).
[0006] The Automotive industry is looking for alternatives to the FlexRay communications protocol, which has a bandwidth of approximately 10-20 Mbps, and is looking to MOST® as an alternative. The channel complements MOST® to become a fully featured and cost-effective solution. There exists a need for a highly deterministic communication channel in MOST® networks.
SUMMARY
[0007] Systems and method for a time-triggered communication channel in a synchronous network are disclosed. The systems and methods may include communicating in a repeated cycle wherein each of the plurality of nodes has a dedicated slot, wherein a cycle comprises n subsequent slots, and wherein each slot comprises a plurality of frames, defining a centralized schedule that associates each node to an associated slot comprising a start frame and an end frame, and transmitting by each node only during the associated slot comprising said start frame.
[0008] According to various embodiments, a transmission method in a synchronous network transmitting periodic frames is disclosed. In the synchronous network, each frame includes a plurality of channels, and the network includes a plurality of nodes. The method may include communicating in a repeated cycle wherein each of the plurality of nodes has a dedicated slot, wherein a cycle comprises n subsequent slots, and wherein each slot comprises a plurality of frames, defining a centralized schedule that associates each node to an associated slot comprising a start frame and an end frame, and transmitting by each node only during the associated slot comprising said start frame.
[0009] In some embodiments, the systems and methods may also include a master node that defines the schedule, the master node being one of the plurality of nodes. In some embodiments, the schedule is distributed to the plurality of nodes in an out-of-band communication. The schedule may be static, and/or the schedule may be configurable.
[0010] In some embodiments, each node may be associated with multiple slots within the repeated cycle. In alternative embodiments, one or more of the slots may be of different sizes. In further embodiments, a cycle length may be configurable. In still further embodiments, a slot may include at least one unused frame. In such embodiments, the unused frame may follow after the end frame of a slot. In alternative embodiments, wherein a slot includes a plurality of unused frames, any unused frames may follow after the end frame of a slot.
[0011] In various embodiments, the systems and methods may also include a synchronous network for transmitting periodic frames, wherein each frame comprises a plurality of channels. The synchronous network may include a plurality of nodes communicatively coupled to one another, and a master node. In such embodiments, each of the plurality of nodes may be operable to communicate in a repeated cycle, each of the plurality of nodes may have a dedicated slot, a cycle includes n subsequent slots, each slot includes a plurality of frames, the master node may be operable to define a centralized schedule that associates each of the plurality of nodes to an associated slot comprising a start frame and an end frame, and each of the plurality of nodes may be operable to transmit only during the associated slot comprising said start frame.
[0012] In various embodiments, the systems and methods may also include a synchronous network for transmitting periodic frames, wherein each frame comprises a plurality of channels. The synchronous network may include a plurality of nodes communicatively coupled to one another and a participating node operable to receive a centralized schedule from a master node, wherein the centralized schedule associates each of the plurality of nodes to an associated slot comprising a start frame and an end frame. The network may be configured such that each of the plurality of nodes is operable to communicate in a repeated cycle, each of the plurality of nodes has a dedicated slot, a cycle comprises n subsequent slots, each slot comprises a plurality of frames, and the participating node may be operable to transmit only during the associated slot comprising said start frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates an example high-level diagram of a communication network in which the time-triggered communication channel may be deployed, in accordance with certain embodiments of the present disclosure;
[0014] FIG. 2 illustrates an example network communication frame, in accordance with certain embodiments of the present disclosure;
[0015] FIG. 3 illustrates an example communication cycle for communicating data between nodes over a time-triggered synchronous communication channel, in accordance with certain embodiments of the present disclosure;
[0016] FIG. 4 illustrates an example cycle detailing an example frame assignment, in accordance with certain embodiments of the present disclosure; and
[0017] FIG. 5 illustrates an example system schedule for scheduling a time-triggered synchronous communication channel, in accordance with certain embodiments of the present disclosure.
DETAILED DESCRIPTION
[0018] According to various embodiments, a communication channel can be provided for a synchronous network where all communication is pre-scheduled and transmitters are allowed to transmit on the channel based on a frame count.
[0019] According to various embodiment, the solution is intended for a synchronous network with a single master node that generates a bit clock. For the purposes of this disclosure, a “synchronous network” may refer to any appropriate communication network in which data is sent synchronously with a clock signal. For example, the MOST communication protocol describes a synchronous network.
[0020] FIG. 1 illustrates an example high-level diagram 10 of a communication network in which the time-triggered communication channel may be deployed, in accordance with certain embodiments of the present disclosure. In some embodiments, diagram 10 illustrates a plurality of nodes 12 , 14 , 16 interconnected with one another. For the purposes of this disclosure, a “node” may refer to any appropriate communication device operable to electronically communicate with one or more other nodes. For example, a node may be a microprocessor, microcontroller, or other electronic device. Although a particular network topology is illustrated to aid in understanding, one of ordinary skill in the art would recognize that others would be available without departing from the scope of the present disclosure. With reference to the present disclosure, any appropriate topology instituting an appropriate synchronous network would suffice.
[0021] FIG. 2 illustrates an example network communication frame 100 , in accordance with certain embodiments of the present disclosure. In some embodiments, frame 100 may include a plurality of channels 102 - 10 . For example, frame 100 may include a plurality of administrative channels, asynchronous channels, synchronous channels, isochronous channels, time-triggered channels, and/or unallocated channels. In the illustrative example of frame 100 , a MOST frame is depicted. Such a frame may be sent approximately every 20.8 microseconds with a 48-kHz clock. In this configuration, a frame may be approximately 384 bytes. The allocation of channels within frame 100 may be driven by the performance characteristics of a particular configuration. For example, frame 100 may include administrative channels 102 , asynchronous channels 104 , synchronous channels 106 , isochronous channels 108 , and/or time-triggered channels 110 , in addition to unallocated channels. Although a certain clock speed, frame length, frame frequency, channel distribution, etc. are illustrated for the purposes of aiding understanding, different configurations would be available to one of ordinary skill in the art without departing from the scope of the present disclosure.
[0022] In some embodiments, information appropriate to be transmitted over a time-triggered communication channel may be carried in one or more time-triggered channels 110 . In some embodiments, each frame 100 may have an assigned frame number, as described in more detail below. Communication from a particular node in a communication system may be broken up in order to be communicated over a plurality of frames 100 .
[0023] FIG. 3 illustrates an example communication cycle 300 for communicating data between nodes over a time-triggered synchronous communication channel, in accordance with certain embodiments of the present disclosure. In some embodiments, cycle 300 may include a plurality of slots 302 , 304 , 306 , 308 , 310 , 312 , 314 . For the purposes of this disclosure, a “slot” refers to a portion of a network cycle that is dedicated to at least a portion of a communication from a particular node. A node may have multiple slots within a cycle. In some embodiments, the cycle length may be configurable. By assigning a node to a slot, each node knows where it is in the communication schedule by knowing its assigned frame number(s). Synchronization of scheduling is described in more detail below.
[0024] In the illustrative example of cycle 300 , slots 302 , 308 may be assigned to a first node, slot 304 to a second node, slot 306 to a third node, slot 310 to a fourth node, etc. To aid in understanding, slots 312 , 314 are illustrated in order to demonstrate that more than the referenced number of slots may be available within any particular network cycle.
[0025] As referenced above, each slot may be of a different size. In some embodiments, the size of a slot may be associated with the number of frames 100 associated with a particular slot. FIG. 4 illustrates an example cycle 300 detailing an example frame assignment, in accordance with certain embodiments of the present disclosure.
[0026] In some embodiments, example cycle 300 may include first frame assignment 402 , second frame assignment 404 , and third frame assignment 406 . In some embodiments, each frame assignment is separated by an unused frame. Although, for the purposes of illustration, the unused frame is depicted as occurring at the end of each frame assignment, different configurations would be possible without departing from the scope of the present disclosure.
[0027] In some embodiments, first frame assignment 402 may be associated with, for example, a first slot (and accordingly, a first node). In the illustrative example, the first slot includes seven frames, although more, fewer, or different frames may be present without departing from the scope of the present disclosure. Second frame assignment 404 may be associated with, for example, a second slot (and accordingly, a second node). In the illustrative example, the second slot includes five frames, although more, fewer, or different frames may be present without departing from the scope of the present disclosure. Third frame assignment 406 may be associated with, for example, a third slot (and accordingly, a third node). In the illustrative example, the third slot includes nine frames, although more, fewer, or different frames may be present without departing from the scope of the present disclosure.
[0028] In some embodiments, as described in more detail above with reference to FIG. 2 , each frame within a slot may be assigned a number. Further, each frame within a cycle may be assigned a number. With each frame assigned a number and each frame assigned a slot, a master node may establish a synchronous schedule for all slots. FIG. 5 illustrates an example system schedule 500 for scheduling a time-triggered synchronous communication channel, in accordance with certain embodiments of the present disclosure.
[0029] In some embodiments, communication on the channel may be done in a repeating cycle where nodes have predetermined slots to transmit in. A slot may be divided over a number of frames. To identify the frame the master node may output either a global frame number or the channel may have the count embedded within the frame bytes. In each cycle the frame count for the channel restarts from 0; if a global count is used it is either masked or nodes keep an internal count based on a common starting frame.
[0030] In some embodiments, a system integrator that may be part of a master node (e.g., node 12 ) may set up the schedule for the whole system and distribute this schedule to participating nodes (e.g., nodes 14 , 16 ). Each node may then set up an access table which determines in what frames that node may transmit. In some embodiments, the master node may distribute the schedule out-of-band (e.g., over the Control Channel on MOST®). The illustrated schedule is static, but one of ordinary skill in the art would recognize that it could be easily switched.
[0031] For example, example master schedule 500 may include master schedule 502 and participating node schedule 504 . In some embodiments, master schedule 502 may include a plurality of frame, slot, and node assignments. In the illustrative example, slot one, frame zero is assigned to node 1 ; slot two, frame eight is assigned to node four, slot three, frame thirteen is assigned to node seven; slot four, frame twenty-two is assigned to node one; and slot five, frame thirty is assigned to node three. Thus, the master schedule includes a time-triggered, synchronous communication schedule for each node. The schedule may then be distributed. For example, participating node schedule 504 illustrates an example schedule for participating “node one.” This node (e.g., that referred to as a “first node” in the examples above) has two assigned frames in two different slots: slot one, frame zero; and slot four, frame twenty-two.
[0032] A channel for pre-scheduled and time-triggered communication within a synchronous network (MOST®) can be provided which is predictable, highly deterministic and has a low latency. Such a channel in a MOST® system can be used for mission critical communication, like periodic sensor data and control loops.
[0033] Thus is disclosed a system and method for a time-triggered communication channel in a synchronous network. The systems and methods provide for the following advantages: It shares physical medium with other MOST® channels: synchronous, isochronous and asynchronous. It reduces cabling. It is flexible and scalable: bandwidth, slot sizes, cycle time and partitioning. It provides for a centrally distributed schedule. The network is synchronized, no need for low-level clock synchronization. The frame number synchronizes the schedule.
|
Systems and method for a time-triggered communication channel in a synchronous network are disclosed. The systems and methods may include communicating in a repeated cycle wherein each of the plurality of nodes has a dedicated slot, wherein a cycle comprises n subsequent slots, and wherein each slot comprises a plurality of frames, defining a centralized schedule that associates each node to an associated slot comprising a start frame and an end frame, and transmitting by each node only during the associated slot comprising said start frame.
| 7
|
TECHNICAL FIELD
[0001] The present invention relates to a method for the preparation of a silica slurry in water. It specifically relates to such a method to be applied in the context of making a slurry of silica in particular silica gel, to be used for coating formulations particularly for offset papers. It furthermore relates to methods for making coating formulations using such a silica slurry, and to papers coated with such a coating formulation.
BACKGROUND OF THE INVENTION
[0002] In the field of sheet fed offset printing it is desirable to be able to further process a freshly printed sheet as quickly as possible, while at the same time still allowing the printing inks to settle in and on the surface of the paper in a way such that the desired print gloss and the desired resolution can be achieved. Relevant in this context are on the one hand the physical ink drying process, which is connected with the actual absorption of the ink vehicles into an image receptive coating, e.g. by means of pores or a special system of fine pores provided therein. On the other hand there is the so-called chemical drying of the ink, which is connected with solidification of the ink in the surface and on the surface of the ink receptive layer, which normally takes place due to an oxidative cross-linking (oxygen involved) of cross linkable constituents of the inks. This chemical drying process can on the one hand also be assisted by IR-irradiation, it may however also be sped up by adding specific chemicals to the inks which catalytically support the cross-linking process. The more efficient the physical drying during the first moments after the application of the ink, the quicker and more efficient the chemical drying takes place.
[0003] Nowadays typically times until reprinting and converting times in the range of several hours (typical values until reprinting for standard print layout: about 1-2 h; typical values until converting for standard print layout: 12-14 h; matt papers are more critical than glossy papers in these respects), which is a severe disadvantage of the present ink and/or paper technology, since it slows down the printing processes and makes intermediate storage necessary. Today shorter times are possible if for example electron beam curing or UV irradiation is used after the printing step, but for both applications special inks and special equipment is required involving high costs and additional difficulties in the printing process and afterwards.
[0004] One possible way to decrease the typical printing times in offset printing processes has been described in a recent publication EP-A-1 743 976. In this document it is proposed to use particulate silica not as a main constituent of the coating formulation (top coating and/or undercoat) in order to decrease the drying time in offset printing processes. The particulate silica mentioned there is stated to include compounds commonly referred to as silica sol, as well as colloidal silica and fumed silica, and preferably also amorphous silica gel as well as precipitated silica. Substantially shortened drying times and times until converting is possible, can be achieved.
[0005] One problem associated with the use of silica as a pigment is the fact that in particular if silica gel is used, it is essential to bring the initially powdery raw material into a water dispersion together with the further pigments which form part of the coating formulation. To do that the powdery raw material (silica gel or precipitated silica) is at first dispersed in water (if need be with addition of dispersants), and since the silica has a very particular powder and surface structure (high surface area and moderate wettability, low bulk density, high capability of liquid uptake), which actually leads to the beneficial printing properties, this dispersion process is time-consuming and leads to a silica slurry with a rather low solids content. For example, the powder has the tendency to swim on top of the mixing tank and it is difficult to actually bring the powder below the surface. Furthermore it forms clusters with a wetted surface and a dry core. To break up these clusters necessitates a high intake of mechanical agitation energy over a long time span. So usually special dispersion plants are necessary to actually bring silica gel into such a slurry state. Furthermore, a silica slurry prepared in such a process is not very stable and cannot be stored for a long time, and bringing it into a proper state after having been stored beyond a certain time limit is very difficult if not impossible. This preprepared silica slurry is therefore quite quickly subsequently introduced into the coating formulation making process, so subsequently the further pigments (usually calcium carbonate, kaoline, clay, possibly also (solid or hollow) plastic pigments), these further pigments finally making up the main constituent of the coating formulation, are added, usually also as a preprepared slurry together with the necessary additional constituents like binders and further additives (like brightener, rheology modifiers etc.). Furthermore only low solids contents can be achieved when using this method, leading to long drying times in the papermaking process.
SUMMARY OF THE INVENTION
[0006] The objective of the present invention is therefore to provide a method for making coating formulations comprising silica, in particular comprising silica gel or precipitated silica. Specifically, an improved method for the preparation of a silica slurry in water to be used as a constituent of a coating formulation for a paper comprising precipitated silica and/or silica gel as well as at least one further fine particulate pigment, in particular for an offset paper, shall be given.
[0007] The present invention achieves the above problem by proposing a method, which includes, in the sequence as given, the steps of a) making or providing a dispersion of the at least one further fine particulate pigment in water, b) adding the silica in dry powdery form to that dispersion.
[0008] It should be noted that the same is equivalently possible if one uses a dispersion as made in step a) as starting material and then in one single step the method is carried out as step b).
[0009] One of the key features of the invention is therefore the finding that it is surprisingly and unexpectedly possible and very beneficial to reverse or rather change the classical order of first making a silica slurry and then adding this slurry to a slurry comprising the further pigments.
[0010] As a matter of fact, it was recognised that a high dispersion energy has to be introduced into the system (mixing energy in the dispersion plant) for making a silica dispersion for the reasons already outlined above. Indeed, for making a silica slurry in water, even if dispersants are added for making a silica slurry in water, heavy stirring is necessary for at least 4 to 8 hours, and the silica slurry obtained in such a dispersion process when then finally used for making the final coating formulation leads to coating formulations with a rather low solids content. This was always accepted as one of the drawbacks of making coating formulations with precipitated silica or silica gel in particular.
[0011] Unexpectedly however it was now found that if in a first step one makes a dispersion of a further pigment present in the final coating formulation (or if equivalently one uses such a dispersion as starting material) and then adds the silica in powdery form to this dispersion, surprisingly the dispersion process is exceedingly more efficient.
[0012] On the one hand it is possible to disperse more silica gel or precipitated silica into the dispersion, and on the other hand the energy required for dispersing the silica gel or the precipitated silica and correspondingly the time for the dispersion process can be reduced dramatically.
[0013] At present an explanation for this is that the further pigment already present in the dispersion acts as a dispersion aid, most likely in the sense that the pigment particles of the further pigments act like stirring aids almost on a mechanical level.
[0014] Using the proposed method, the time for making a silica slurry can be reduced to an hour or less (reduction of approximately 80%!), and furthermore higher solid contents can be achieved, this under conditions, where silica is present in the slurry in an amount making up at least 5 weight % (dry weight) of the total pigment in the slurry (which means that the rest of the pigment in the slurry, e.g. the calcium carbonate pigment, makes up 95 weight %), preferably under conditions, where silica is present in the slurry in an amount making up above than or equal to 8 or 10 weight % of the total pigment in the slurry, preferably in the range of 8-15 weight %. Under these conditions it is now possible to raise the solids content of the silica slurry resulting from the process or of the final coating formulation to a value of above than or equal to 65%, which is, using the conventional process, simply impossible.
[0015] This higher solids content leads to shorter drying times on the machine since less water has to be removed from the coating after application of the coating formulation. In turn this allows to run the paper machine faster leading to a higher paper production speed. Furthermore, the high solids content leads to a better quality and a better coating coverage since there is less water penetration leading, among other advantages, to a higher gloss in particular in case of glossy papers.
[0016] Furthermore such as silica slurry which already comprises further pigments is unexpectedly storable for much longer times, typically for at least for 20 days, than a slurry comprising silica only, eventually with dispersants.
[0017] Generally the present method is suitable and optimised for making coating formulations as described and claimed in the above-mentioned EP-A-1743976. Correspondingly therefore, the content of this document is explicitly included into this disclosure as concerns the composition of formulations and the characteristics of the constituents thereof.
[0018] The proposed method provides a silica slurry which can subsequently be introduced into the coating formulation making process. In this case, the resulting silica (gel) slurry serves as a starting material for the coating formulation making process, during which then eventually further pigments are introduced, brighteners, the binders etc.
[0019] On the other hand it is also possible to incorporate the proposed method into the coating formulation making process. It is for example possible to introduce the silica as proposed here directly into the dispersion tank of the coating formulation making unit of the paper machine, by for example pneumatically blowing the silica powder into this dispersion tank in which there is also a dispersion with a further pigment present.
[0020] In a first preferred embodiment of the present invention, the silica is an amorphous silica gel. Making dispersions of amorphous silica gel is particularly difficult, and it was found that in particular for this situation the present methods is most suitable. This holds particularly true, if the silica gel to be dispersed has an internal pore volume above 0.5 ml/g, preferably above 1.0 ml/g, even more preferred above or equal to 1.5 or 2.0 ml/g. Equally or alternatively this holds true if the silica gel used has a surface area in the range of 200-1000 m 2 /g, preferably in the range of 250-800 m 2 /g, even more preferably in the range of 200-400 m 2 /g. Equally or alternatively, it holds true if the silica gel has a particle size in the range of 0.1-5 μm, preferably in the range of 0.3-4 μm, particularly in the range of 0.3-1 μm or in the range of 3-4 μm.
[0021] As already mentioned above, the further pigment acts as a dispersion aid as it provides kinetic energy in the dispersion at a particulate level. To achieve this effect the dispersion of the further pigment is preferably rather heavily loaded with such particulate pigment. Preferably therefore, the further fine particulate pigment(s) are present after step a) in a dispersion with a solids content above 50%, preferably above 60%, even more preferably in the range of 70 to 80%.
[0022] A further preferred embodiment of the method is characterised in that the further fine particulate pigment(s) are selected from the group of: calcium carbonate, kaoline, clay, plastic pigment, or a mixture thereof. Preferred is calcium carbonate, so preferably the further fine particulate pigment used in or provided as step a) essentially consists of calcium carbonate, preferably with a particle size distribution such that 50% of the particles are smaller than 1 μm, even more preferably with a particle size distribution such that 50% of the particles are smaller than 0.5 μm, and most preferably with a particle size distribution such that 50% of the particles are smaller than 0.4 μm. If the final coating formulation comprises still further pigments, either of completely different type or calcium carbonate with a different particle distribution, these can also be added after the making of the silica slurry.
[0023] Preferably, prior to step a) additionally a dispersant is used, preferably a polyacrylate and/or polyphosphate dispersant or other dispersants currently available for dispersing pigments in water.
[0024] It should be pointed out that preferably the proposed method for making a silica slurry is carried out in the absence of binder for the final coating formulation. So in step a) essentially no binder of the final coating formulation is present yet, and the binder is only added after the preparation of the silica slurry. Indeed, the proposed silica slurry can be used as a preprepared constituent of a final coating formulation, which can be stored for a comparably long time. The final coating formulation can then be made by adding further pigments, additives, binders, etc shortly before applying the coating formulation to the substrate, which can be for example a standard on coated or precoated (e.g. with sizing layer) substrate.
[0025] According to a further preferred embodiment prior to step a) additionally an alkaline is added, preferably to adjust the pH at the end of step a) to be above 7, even more preferably in the range of pH=7.5-8.7 (target value typically pH˜8.2), wherein preferably sodium hydroxide solution is used as alkaline to this end. The adjustment of the pH to these values is particularly important if calcium carbonate is used as pigment since if the pH props to values too low, gas formation starts to initiate.
[0026] As a matter of fact, cluster formation can efficiently be prevented if in a very first and initial step water is provided comprising dispersant as well as alkaline, and subsequently a slurry comprising the further pigment is introduced into the system.
[0027] A specific preferred embodiment of the present invention is characterised in that in step a) water making up typically 20-50 or 20-40 weight-% of the weight of the total final wet coating formulation is introduced into a mixing tank, if need be preceded, accompanied or followed by introduction of dispersants and/or alkaline, followed by the addition of (typically a main part) of the calcium carbonate pigment part of the final coating formulation. The amount of calcium carbonate added in step a preferably such that in the total final dry coating formulation its content is the range of 50-95 weight-%, even more preferably in the range of 70-90 weight-% of the total final dry coating formulation, and then this slurry is agitated until the formation of an essentially homogeneous dispersion has taken place Subsequently step b) is carried out.
[0028] According to a preferred embodiment the silica is essentially continuously or intermittently continuously added to the dispersion in step b). Preferably, the addition takes place in an essentially continuous manner, by blowing silica powder in essentially dry state into the pigment dispersion made in step a). Preferably therefore, the silica (gel) powder is introduced into the system using pneumatic assistance. This means that e.g. pressurised air is used for providing a stream of air mixed with silica particles as homogeneously as possible for the introduction into the dispersion (“blowing in”). This is for example possible by providing a pipe with pressurised air with an inlet for powder leading to a mixing of powder and air and the air thus carries the powder into the dispersion plant. In order to avoid problems with powder in the surrounding atmosphere of the dispersion plant, it is advantageous to provide corresponding injection valves for the powder/air mixture in and/or close to the top cover of the dispersion tank. The speed of adding the silica powder can be adjusted by monitoring the agitator in the dispersion plant. Efficient control of the addition can be effected if the speed of addition is adjusted such that the agitator in the mixing tank is able to continuously maintain a mixing speed well above zero or above a certain minimum value.
[0029] For the preparation of the above-mentioned preprepared silica slurry to be subsequently used for making of the coating formulation it is possible to supplement the silica slurry made in step b) by some additional water in order to adjust the final solids content and to agitate the system some more to achieve a homogeneous system. Generally, it is possible to achieve a final solids content of the silica slurry is in the range of 40-70%, preferably in the range of 50-70%, even more preferably in the range of 60-65%.
[0030] As already mentioned above, the proposed method provides a method for making a preprepared silica slurry. The final coating formulation is typically only made in a subsequent step, so preferably after step b) eventually additional pigments (for example coarser calcium carbonate pigments kaoline, clay or the like, typically not making up more than 5-20 weight % of the final dry weight of the coating, as well as further additives are added Binder is, as already outlined above, only added for making up the final coating formulation later so after the making of the silica slurry. Typically the binder is added such as to lead finally to a dry weight of the final drive coating formulation in the range of 5-20, preferably 7-12, parts in dry weight.
[0031] As already outlined above, typically, particularly for offset coating applications, the silica content in the slurry and in the final coating formulation is below the content of further pigment. Preferably therefore in step b) silica gel is added in an amount such that in the final coating formulation 3-20 parts, preferably 8-12 parts in dry weight is present.
[0032] The present invention furthermore relates to a silica slurry made in accordance with the above methods, as well as to a method for making a coating formulation, which is characterised in that a preprepared silica slurry is made using a method as given above is used. It furthermore relates to a coating formulation made using such a method. Last but not least it relates to a coated paper, preferably a coated offset printing paper, comprising at least one coating layer on at least one side made by using such a coating formulation.
[0033] Further embodiments of the present invention are outlined in the dependent claims.
SHORT DESCRIPTION OF THE FIGURES
[0034] In the accompanying drawings preferred embodiments of the invention are shown in which:
[0035] FIG. 1 is a schematic view of a dispersion plant with two mixing tanks for use in the context of the present invention; and
[0036] FIG. 2 a) is a schematic view of a dispersion plant with one mixing tank for use in the context of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Referring to the drawings and the specific examples, which are for the purpose of illustrating the present preferred embodiments of the invention and not for the purpose of limiting the same, FIG. 1 shows a dispersion plant 1 comprising a primary mixing tank 2 and a secondary mixing tank 3 . In both mixing tanks agitators 4 and 5 are provided, each of them driven by a motor M. The agitators are preferably agitators with a high dispersive action, as they are known for disbursing pigments in water. They can for example be located near the bottom of the tank. The primary mixing tank is the actual dispersion tank, while the secondary mixing tank is usually called the circulation tank.
[0038] The two mixing tanks are interconnected via two conduits 6 and 7 which allowed to circulate the liquid in the two containers 2 and 3 on the one hand assisted by the two agitators 4 and 5 , but specifically by means of the pump 8 (so called cyclisation vat).
[0039] In the setup according to FIG. 1 water and possible additional chemicals (dispersants in particular) are added to the primary mixing tank in a first step ( 1 in circle). Calcium carbonate is added as a slurry in a second step to the secondary mixing tank 3 , which can take place either subsequently or at the same time as the first step ( 2 in circle). In the actual second method step as detailed above subsequently then the silica gel is added by blowing in the powder into the primary mixing tank.
[0040] A different setup is given in FIG. 2 , here there is only one single container 11 with one single agitator 4 . As one can see from the figure, the above three different additions of constituents take place into that one single container.
[0041] The silica slurry produced in such a dispersion plant is therefore made in accordance with the present invention in that the silica powder is introduced into a ready pigment slurry (usually calcium carbonate slurry), which as a result allows to have silica pigment in a coating formulation with a solids content of 65% which is usual for coating formulations, and which beforehand could not be achieved with silica slurries, in particular with silica gel slurries.
[0042] As mentioned above, in an initial step, dispersant, typically a polyacrylate or polyphosphate dispersant, as well as an appropriate amount of alkaline (typically sodium hydroxide) to adjust the pH and to a value of 8.2 is provided together with water in the above step 1 in FIGS. 1 and 2 . The water together with the water content in the calcium carbonate slurry introduced into the system in step 2 makes up approximately 30% of the total water amount in the slurry. In the next step ( 2 in circle in FIGS. 1 and 2 ) the calcium carbonate is introduced, typically in slurry form. This leads to a dispersion of approximately 70-80% solids content. This dispersion is agitated for some time until no clusters are present any more.
[0043] Subsequently (step 3 in circle in FIGS. 1 and 2 ) the silica powder (in essentially dry state) is introduced. This is effected by blowing the silica powder, for example the product SYLOID C803 or Sylojet 701A or 703A from Grace into the tank 2 or 11 , respectively. The introduction of this powder takes place rather slowly, and it can be adjusted depending on the power of the dispersion aggregate. One simple way to control the addition is to monitor the behaviour of the agitators 4 and 5 . If these agitators start to either become exceedingly slow or to even stop, the addition or rather blowing in of silica powder should be reduced or even stopped temporarily.
[0044] In a subsequent step, it is possible to add further water in order to adjust the final desired solids content, for example to a value of 65%. Usually after this additional water introduction it is advantageous if the system is stirred some more time (e.g. up to 30 minutes).
[0045] Total dispersion time using this method is approximately 1 hour. As a comparison, dispersion times for making a silica slurry in water, in which there is no additional further pigment present yet, takes at least 4 to 8 hours. Dispersion time can thus be reduced by about 80%.
[0046] In contrast to the silica slurries according to the state-of-the-art which are provided in water (usually in combination with dispersants) a silica slurry with further pigmentmade in accordance with the present invention can be stored over a long time. Storage times of at least 20 days are easily possible. Typically a conventional silica slurry in water only can only be stored for a few days.
[0047] Such a silica slurry can then be used for the making of the actual coating formulation in the coating aggregate of the paper machine. To this end, further pigment are added, additives like for example brighteners, rheology modifiers etc, as well as, importantly, the binder.
[0048] Specifically, it is for example possible to produce a silica slurry with silica gel (Syloid C803) and a calcium carbonate with a fine particle structure (e.g. CC90), wherein silica gel is added such that in the final coating formulation a dry content of 10% is achieved, and wherein the fine calcium carbonate is added such that in the final coating formulation a dry content of 80% is achieved. This slurry can then be stored. Subsequently, in the actual coating formulation making process just before applying the coating to the substrate, further pigment is added (for example a more coarse calcium carbonate of the type CC60 or a plastic pigment) as well as binder.
[0049] The solids content which can be achieved using this method is much higher than if for the making of the coating formulation a silica slurry in water without further pigment is used. As a matter of fact, in the final coating formulation the achievable solids content is approximately 5% higher than if a preprepared conventional silica slurry in water is used.
LIST OF REFERENCE NUMERALS
[0000]
1 dispersion plant
2 primary mixing tank
3 secondary mixing tank
4 agitator in 2
5 agitator in 3
6 first circulation conduit
7 second circulation conduit
8 pump
9 opening for introduction of further pigments into secondary mixing tank
10 opening for introduction of silica pigments into primary mixing tank
11 single mixing tank
M motor for agitator
|
A method for the preparation of a silica slurry in water is described. The proposed silica slurry can be advantageously used as a constituent of a coating formulation for a paper comprising precipitated silica and/or silica gel as well as at least one further fine particulate pigment, in particular for an offset paper. The method includes, in the given sequence, the steps a) making a dispersion of the at least one further fine particulate pigment in water, b) adding the silica in dry powdery form to that dispersion.
| 3
|
FIELD OF THE INVENTION
The present invention relates to dryers in papermaking machinery in general, and to single tier dryers in particular.
BACKGROUND OF THE INVENTION
In the paper manufacturing industry, a critical factor controlling the production of a cost effective paper product is the ability to rapidly and efficiently dry the paper stock. The plant must be able to cost effectively remove water in order to produce a paper product having a workable moisture content.
Upon entering the headbox of the papermaking plant, the paper stock is released onto a rapidly moving forming wire. Excess water filters through the forming wire and the paper fibers interlace with one another thereby forming a paper mat on the forming wire or screen. The formed paper web is carried on the screen through a series of rolls which smooth out the web and press out excess water.
At the end of the forming wire, the paper web is transferred to a dryer fabric which conveys the web around a series of steam heated dryer drums. Upon contact with the heated dryer drums, excess water in the web is evaporated which reduces the moisture content in the web to the desired level.
In order to reduce operating and capital costs, paper manufacturers have steadily increased production rates. During the standard drying process, the dryer fabric and web can travel at a speed of 4,000 feet per minute. Early drying schemes utilized a row of upper drying drums aligned above a row of lower drying drums and the web was conveyed around successive drying drums in a serpentine manner. As the web was transferred from an upper drum to a successive lower drum, it passed through a gap of open draw in which the web was not in contact with the dryer fabric. This open draw presented problems at high production speeds because the unsupported web often fluttered and sometimes broke, forcing paper production to stop.
In an attempt to minimize shutdowns, a single continuous flexible support dryer design was developed. The web was supported by a single flexible dryer fabric. Although this scheme used the same upper and lower rows of drying drums, it avoided the problems associated with the open draw by having the web remain in constant contact with the dryer fabric. While this new scheme reduced web fluttering and breakage, it created two different problems. First, due to the high web and dryer fabric speeds, the rapidly moving felt causes a high pressure area at the nip where the dryer fabric and web initially contact each drying drum. This localized high pressure, combined with inertial effects, causes the web to separate from the dryer fabric causing wrinkling and, in severe cases, breakage of the web. Second, by the nature of the configuration of the single continuous support dryer design, the dryer fabric was located between the lower dryer drum surfaces and the web. Because of its interior location, the dryer fabric insulates the web from the heat of the lower drying drums, thereby reducing drying efficiency for the lower drums.
Several configurations have been designed to solve the problems associated with the single dryer fabric continuous dryers. Known configurations include replacing lower dryer drums with unheated vacuum rolls, with unheated grooved rolls, or with unheated rolls having exterior vacuum sources. These configurations prevent pressure build-up at the nip where the dryer fabric and web contact the roll surface and save energy because they are not heated. However, because the configurations have only one level of drying drums, they occupy a large floor area of the paper manufacturing facility. This problem is intensified by the fact that single rolls, due to the small angle of web wrap on the dryers, are unable to utilize the maximum surface drying area of the upper drying drums. Also, the lack of open draw space and failure of these configurations to completely control air flow in the pocket above each roll minimizes the ability of utilizing air caps as a method of increasing drying efficiency. Finally, the cost of a vacuum roll, due to the high cost of drilling a multitude of vacuum draw holes in, is approximates the cost of a full-sized heated drying drum.
What is needed is an economical paper drying apparatus that maximizes the angle of web wrap on the dryer while completely controlling air flow in the pocket above each roll, and which eliminates disruptive localized pressure at the nips and allows the use of air caps in order to increase drying efficiency.
SUMMARY OF THE INVENTION
The dryer of this invention employs a vacuum chamber interposed below and between first and second heated dryer rolls. The vacuum chamber has two sides and a top which overlies two grooved reversing rolls. The vacuum chamber controls all flow of air in the gap between and below the dryer rolls. The dryer-fabric-backed paper web passes from the first dryer roll around the reversing rolls and up to the second dryer roll. The dryer fabric seals the vacuum chamber, and air is drawn therefrom. The two rolls within the chamber permit a greater fraction of the dryer roll surfaces to be maintained in contact with the web. Furthermore, the chamber permits a vacuum to be drawn on two rolls as well as three sections of web which are not engaged with rolls by a single vacuum source for significant cost savings.
It is an object of the present invention to provide a paper drying apparatus that completely controls air flow in the pocket between successive dryers in order to eliminate flapping of the web and to enable the use of air caps in combination with high permeability dryer fabric.
It is another object of the present invention to provide a compact paper drying machine.
It is a further object of the present invention to provide a paper drying apparatus of increased efficiency which utilizes a greater fraction of dryer roll surface for paper drying.
It is an additional object of the present invention to provide a cost-effective paper drying machine which does not require vacuum rolls and which utilizes a minimal number of drying drums.
It is also an object of the present invention to provide a paper drying machine that has an area of open draw which enables the effective use of air caps in the drying process.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-elevational view of a prior art two tier continuous single dryer-fabric dryer configuration.
FIG. 2 is a side-elevational view of a prior art single tier continuous dryer-fabric dryer configuration.
FIG. 3 is a side-elevational view of the paper drying apparatus of this invention with arrows indicating direction of rotation.
FIG. 4 is an isometric view of the apparatus of FIG. 3, with arrows indicating the direction of roll rotation.
FIG. 5 is a fragmentary isometric view, with web partly broken away, of the paper drying apparatus of FIG. 3, showing the vacuum chamber transfer rolls enclosed therein.
FIG. 6 is an isometric view of the vacuum chamber of FIG. 5.
FIG. 7 is a cross-sectional view of the apparatus of FIG. 3 taken along section line 7--7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to FIGS. 1-7, wherein like numbers refer to similar parts, a paper drying apparatus 20 is shown in FIGS. 3-4. The paper drying apparatus 20 dries a continuous web 22 of wet paper formed during an earlier stage of the papermaking process through the use of a rapidly moving forming wire (not shown). The web 22 of wet paper is transferred from the forming wire after the former, through a press, and thence to a dryer fabric 24 which conveys the web 22 over a first dryer roll 26, under two reversing rolls 110, 114 within a vacuum chamber 30, and over a second dryer roll 28 in a serpentine configuration. The dryer rolls 26, 28 are internally steam heated and dry the web 22 to the desired moisture content. The reversing rolls 110, 114 are preferably grooved.
A prior art two tier continuous single dryer-fabric dryer 32 is shown in FIG. 1. The single dryer-fabric dryer 32 has a tier of upper dryer rolls 34 and a tier of lower dryer rolls 36. In operation, a dryer fabric 38 conveying a contiguous paper web 40 wraps around a first upper dryer roll 42 with the paper web 40 beneath the dryer fabric 38 and in contact with the first upper dryer roll 42. From the first upper dryer roll 42, the dryer fabric 38 extends downward and wraps around a first lower dryer roll 44 in such a manner that the dryer fabric is confined between the paper web 40 and the first lower dryer roll 44. After wrapping around the first lower dryer roll 44, the dryer fabric 38 extends upward and wraps around a second upper dryer roll 46 with the paper web 40 located beneath the dryer fabric 38 and in contact with the second upper dryer roll 46. Thereafter, the dryer fabric 38 and contiguous paper web 40 consecutively extend to and wrap around a second lower dryer roll 48 and a third upper dryer roll 50 in the same serpentine manner described above.
Because the dryer fabric 38 is located between the paper web 40 and the lower dryer rolls 44, 48 the dryer fabric 38 insulates heat transfer from the rolls 44, 48 and reduces the drying efficiency of the lower dryer rolls 44, 48. Also, the rapidly moving dryer fabric 38 may cause a buildup of air pressure at nip points 52, adjacent to where the dryer fabric 38 initially contacts the lower dryer rolls 44, 48. This localized air pressure forces the paper web 40 to separate from the dryer fabric 38 causing wrinkling and, in extreme cases, breakage, of the web 40.
A prior art single tier continuous dryer fabric dryer configuration 54 is shown in FIG. 2. The configuration 54 has a first dryer roll 56 spaced from a second dryer roll 58. The first dryer roll 56 is rotatably mounted lengthwise about a first central axis 60. The second dryer roll 58 is rotatably mounted lengthwise about a second central axis 62. The first central axis 60 and the second central axis 62 are parallel and are located in the same horizontal plane. A vacuum roll 64 is rotatably mounted lengthwise about a third central axis 66. The vacuum roll 64 is parallel to the dryer rolls 56, 58 and is centered in the paper travel direction between the first central axis 60 and the second central axis 62. A dryer fabric 68 conveying a contiguous paper web 70 is transferred in a serpentine route over the first dryer roll 56, under the vacuum roll 64 and over the second dryer roll 58.
Because the vacuum roll 64 is centered between the dryer rolls 56, 58 the configuration 54 does not maximize the drying potential of the dryer rolls 56, 58. The arrow 72 indicates the angle of wrap of the web about the dryer roll in a single vacuum roll configuration 54. The arrow 74 indicates the angle of wrap which is left unused by the configuration 54.
Another characteristic of the single vacuum roll configuration 54 is that the position of the vacuum roll 64 creates a short first open draw 76 and a short second open draw 78 located between the first dryer roll 56 and the vacuum roll 64 and between the vacuum roll 64 and the second dryer roll 58, respectively. Because the open draws 76, 78 have limited surface area and limited accessibility, the use of air caps to enhance drying is not feasible.
The paper drying apparatus 20 of the present invention, shown in FIG. 3, provides for a greater angle of wrap than the prior art dryer 54 in a single tier configuration. The drying apparatus 20 has a first cylindrical dryer roll 26 which is rotatably mounted about a first central axis 80. Separated from the first dryer roll 26 by an open gap 82 is a second cylindrical dryer roll 28 which is rotatably mounted about a second central axis 84. The first central axis 80 and the second central axis 84 are parallel and are located within the same generally horizontal plane. Both the first dryer roll 26 and the second dryer roll 28 are heated internally by steam supplied by an external source.
A vacuum chamber 30 is formed by a rigid metal structure located beneath the gap 82 between the first dryer roll 26 and the second dryer roll 28. As shown in FIG. 6, the vacuum chamber 30 is formed by a metal cover 31 which is sealed against the moving dryer fabric 24 to define an internal volume on which reduced pressure is drawn. The cover 31 is comprised of two side plates 98, 100, which are joined by a top plate 106. Each side plate 98, 100, has two clearance openings 118 which are smaller in diameter than the grooved reversing rolls 110, 114 which are rotatably mounted within the vacuum chamber 30. The openings 118 provide clearance for the sideward extension of the shafts (not shown) on which the rolls 110, 114 are mounted. The side plates 98, 100 oppose each other and are perpendicular to the central axes 80, 84 of the dryer rolls. A hole 102 is cut through the side plate 100 which allows for the drawing of a vacuum on the vacuum chamber 30 by an external vacuum means (not shown). Each side plate 98, 100, has an upper segment 105 which extends above the grooved rolls 110, 114, and a downwardly extending tab 107 which blocks escape of air to the sides of the grooved rolls. A lower horizontal edge 103 of the tab 107 engages with the dryer fabric 24 as it passes between the two grooved rolls 110, 114. Stiffening ribs 104 project inwardly from the interior perimeter of the side plates 98, 100 to prevent excessive deflection of the plates by application of the vacuum.
Two inclined flanges 108 extend from the top plate 106 between the side plates 98, 100. Each inclined flange 108 extends upward from the top plate 106 and inward toward the center of the top plate 106 thereby forming an acute angle with the top plate 106.
As shown in FIG. 3, the first grooved roll 110 is rotatably mounted within the vacuum chamber 30 about a first roll axis 112. The second grooved roll 114 is rotatably mounted about a second roll axis 116. The first roll axis 112 and the second roll axis 116 are parallel to the central axes 80, 84 of the dryer rolls. A plurality of circumferential grooves 120 are spaced uniformly along the length of the grooved rolls 110, 114. The grooves 120 permit a vacuum to be drawn from the surfaces of the rolls 110, 114 which are engaged with the dryer fabric 24 by applying a vacuum to the exposed roll surfaces within the vacuum chamber 30.
As shown in FIG. 3, the first roll axis 112 is aligned frontwardly of a first vertical plane 122 which is tangent to the first dryer roll 26. The second roll axis 116 is aligned rearwardly of a second vertical plane 124 which is tangent to the second dryer roll 28.
As shown in FIGS. 3, and 7, the vacuum chamber bottom is enclosed by a dryer fabric 24 conveying a contiguous paper web 22. The dryer fabric 24 and paper web 22 wrap around the first grooved roll 110, extend across the vacuum chamber bottom and then wrap around the second grooved roll 114 thereby sealing the vacuum chamber bottom.
In operation, as shown in FIGS. 3 and 4, the continuous dryer fabric 24 and web 22 wrap around the first dryer roll 26 with the paper web 22 engaged against the heated surface of the dryer roll 26 and backed by the dryer fabric 24. The dryer fabric 24 and web 22 extend downwardly and frontwardly from the first dryer roll to wrap around the first grooved roll 110. As the dryer fabric 24 and web 22 extend downward, the dryer fabric 24 comes in close proximity to the inclined flange 108 which extends from the cover 31 and forms a seal with it. The dryer fabric 24 is traveling at high speeds as it engages the first grooved roll 110, and will tend to carry with it a quantity of air resulting in a localized region of high pressure. The vacuum chamber 30, however, draws away the air on the dryer fabric between the front flange 108 and the line of initial contact or first nip 126. Furthermore, at the first nip 126, the air is drawn from the grooves in the first grooved roll 110. By removing this air from the dryer fabric, fluttering of the web is prevented. The dryer fabric 24 and web 22 extend between the first grooved roll 110 and the second grooved roll 114 along the lower horizontal edge 103 of the cover 31. The low pressure region created in the vacuum chamber 30 draws the dryer fabric and web upwardly, and prevents fluttering of the web across this draw 134.
Localized pressure caused by the rapidly moving dryer fabric 24 at a second nip point 128 where the dryer fabric 24 initially contacts the second roll 114 is released through the circumferential grooves 120 in the second roll 114 with the aid of the vacuum means within the vacuum chamber 30. The dryer fabric 24 and web 22 extend upwardly and frontwardly from the second grooved roll 114. The dryer fabric 24 comes in close proximity to the inclined flange 108 on the rear of the cover top plate 106, thereby sealing the rear edge of the vacuum chamber 30. Finally the dryer fabric 24 and web 22 wrap around the second dryer roll 28 with the web 22 between the dryer fabric 24 and the second dryer roll 28.
Typically, the dryer fabric and web will proceed from the second dryer roll 28 to another pair of dryer rolls and a vacuum chamber, where the process will be repeated until the paper has achieved the desired level of dryness.
The use of two grooved rolls 110, 114, with the first grooved roll axis 112 located to the left of the first vertical plane 122 tangent to the first dryer roll 26, and the second grooved roll axis 116 located to the right of the second vertical plane 124 tangent to the second dryer roll 28, causes the web 22 to contact a larger portion of each dryer roll 26, 28 than would be possible through the use of a single roll. In other words, the distance between the grooved rolls is greater than the distance between the dryer rolls, such that the paper and dryer fabric are wrapped onto portions of the dryer rolls below a plane which passes through the axes of the dryer rolls. For example, a comparison of FIG. 2 and FIG. 3 shows that the two-roll design 20 uses a larger portion of the each dryer roll 26, 28. In FIG. 2, the single tier continuous dryer-fabric dryer roll 54 with a 24-inch vacuum roll 64 and 72-inch dryer rolls 56, 58 obtains an angle of wrap equal to 221 degrees as shown by arrow 130. In comparison, FIG. 3 shows that the paper drying apparatus 20 of this invention, with 84-inch dryer rolls 26, 28 and 32-inch grooved rolls 110, 114, obtains an angle of wrap equal to 272 degrees as shown by arrow 132.
By making more efficient use of dryer rolls, the length of the entire drying apparatus is reduced. The increase in efficiency and decrease in machine length is even more apparent when the two-roll configuration 20 of this invention is used in combination with larger dryer roll sizes. For example, modeling indicates that a conventional single tier dryer configuration 54 as shown in FIG. 2 with six-foot diameter dryer rolls requires 30 dryer rolls and a length of 195 feet in order to dry the web 70 to the desired moisture content. In contrast, the two-grooved-transfer-roll design 20 as shown in FIG. 3, when utilized with eight-foot diameter dryer rolls, requires 20 dryer rolls and 170 feet in length in order to dry the web 22 to the desired moisture content. Besides the reduction in length, the dryer configuration 20 reduces initial capital expenditures for construction by requiring fewer dryer rolls.
In addition to the cost benefits of fewer dryer rolls, significant cost advantages are realized in the utilization of a single vacuum chamber in preference to one or more vacuum rolls. Vacuum rolls, which require a multiplicity of drilled holes in the roll surface to provide air channels, are much more costly to fabricate than a grooved roll. The present invention provides a single tier dryer installation with no unsupported draws and without the need for any vacuum rolls.
The two-roll configuration 20 creates a length of draw 134 between the two rolls 110, 114. The length of draw 134 allows for the easy installation of air caps (not shown) which blow hot air through the web 22. The use of air caps increases vapor flashing thereby increasing drying rates.
The vacuum chamber 30 provides restraint to the web 22 and controls all air flow in the gap 82 between the first dryer roll 26 and the second dryer roll 28. By controlling air flow in the gap 82, sheet flutter of the web 22 is eliminated and greater running speeds are obtainable. Additionally, because the vacuum chamber 30 controls air flow in the gap 82, high permeability blanket dryer fabric can be utilized to enhance drying rates when used in combination with air caps.
It should be understood that the assembly of dryer rolls and vacuum chamber may be provided within an extended line of dryer rolls, and that dryers having different dimension rolls may also be formed.
It should also be understood that the diameter of the dryer rolls may be varied. Further the diameter of the reversing rolls may be varied. Additionally other types of rolls may be substituted for the grooved reversing rolls. The dryer apparatus may also employ blind-drilled rolls, plain rolls, perforated rolls, or a combination of roll types.
Furthermore, although the grooved rolls have been illustrated and described as being positioned below the dryer rolls, it should be understood that the paper web as it progresses through the dryer section of a papermaking machine will alternatively be wrapped around upper dryer rolls to dry one side of the web, and lower dryer rolls, to dry the other side of the web. Hence in some cases the grooved rolls will be positioned above the dryer rolls, and the vacuum chamber thus beneath the paper web.
It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces all such modified forms thereof as come within the scope of the following claims.
|
The dryer of this invention employs a vacuum chamber interposed below and between first and second heated dryer rolls. The vacuum chamber has two sides and a top which overlies two grooved reversing rolls. The vacuum chamber controls all flow of air in the gap between and below the dryer rolls. The dryer-fabric-backed paper web passes from the first dryer roll around the reversing rolls and up to the second dryer roll. The dryer fabric seals the vacuum chamber, and air is drawn therefrom. The provision of the grooved rolls permits a greater wrap of the felt around the dryers and the application of vacuum to hold the web against the felt during movement of the web between the dryers and the grooved rolls and between the grooved rolls.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Application claims priority from U.S. Provisional Patent Application No. 61/223,647 that was filed Jul. 7, 2009 and from U.S. Provisional Patent Application No. 61/254,567 that was filed Oct. 23, 2009, which applications are expressly incorporated by reference herein for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to integrated circuits and more particularly to controlling the code that can be executed on microprocessors using a combination of hardware and software command filters.
[0004] 2. Description of Related Art
[0005] Related art is drawn from two fields: software that implements or controls data flow into or out of a microprocessor-driven system under security protocols or policies and hardware implemented as network firewall protection.
BRIEF SUMMARY OF THE INVENTION
[0006] Certain embodiments of the present invention comprise systems and methods applicable to integrated circuits including microprocessors, including microprocessors used in personal computers, workstations, servers, networking devices, telecommunications devices, encryption hardware, mechanized vehicles of all types, and any device with the capability of storing, transporting, or processing of data and data control system applications. According to certain aspects of the invention, a processor may not run unauthorized and/or undesired code that could impair or compromise either the integrity of the data or function of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a block diagram illustrating a command filter matrix according to certain aspects of the invention.
[0008] FIG. 2 depicts a signal transport filter mechanism according to certain aspects of the invention.
[0009] FIG. 3 is a simplified drawing depicting one example of an embodiment according to certain aspects of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Embodiments of the present invention will now be described in detail with reference to the drawings, which are provided as illustrative examples so as to enable those skilled in the art to practice the invention. Notably, the figures and examples below are not meant to limit the scope of the present invention to a single embodiment, but other embodiments are possible by way of interchange of some or all of the described or illustrated elements. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to same or like parts. Where certain elements of these embodiments can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present invention will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the invention. In the present specification, an embodiment showing a singular component should not be considered limiting; rather, the invention is intended to encompass other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, applicants do not intend for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present invention encompasses present and future known equivalents to the components referred to herein by way of illustration.
[0011] For the purposes of this description, a command filter matrix is understood to mean a proprietary hardware device that may be embodied in a memory cell matrix encoded and configured by a trusted source. For the purposes of this description, malicious hardware is understood to mean a functionality that is embedded in external (to the microprocessor) peripheral devices, integrated circuits or memory devices and considered potentially harmful. For the purposes of this description, hardware exploitation malware (“malware”) is understood to mean software components, such as computer viruses, which are designed to exploit unauthorized run-time capabilities of an electronic data processing environment.
[0012] Certain embodiments of the present invention comprise systems and methods applicable to integrated circuits including microprocessors, including microprocessors used in personal computers, workstations, servers, networking devices, telecommunications devices, encryption hardware, mechanized vehicles of all types, and any device with the capability of storing, transporting, or processing of data and data control system applications. According to certain aspects of the invention, a command filter matrix comprising a trusted-source filtering element that prevents a processor from running unauthorized and/or undesired code that could impair or compromise either the integrity of the data or function of the system.
[0013] Certain embodiments of the invention provide systems, methods, processes, circuits and tools to assure that only trusted commands and instructions are executed by a microprocessor. According to certain aspects of the invention, a universal solution may be employed to assure that malicious hardware content, present in unknown hardware and software system resources, is prevented from entering, controlling or compromising any system under control of the microprocessor or related integrated circuit.
[0014] With reference to FIG. 1 , certain embodiments provide a proprietary in-line hardware device 12 that creates a trusted-source filter for microprocessor 10 or integrated circuit code execution. Trusted source filter 12 may comprise layered control elements, including, for example, a layer 1 JTAG and control element 120 and a layer 2 hyper transport element 122 . In one example, trusted source filter 12 is inserted between microprocessor 10 and a socket 14 provided on motherboard 16 . In another example, a lightweight, lower profiled embodiment is achieved by embedding the command filter matrix within the Socket itself, thus eliminating elevation growth.
[0015] Referring also to FIG. 2 , a two-layer detection and protection scheme can be implemented on an integrated circuit, which is designated herein as the command filter matrix chip (CFM) 12 . The CFM 12 is typically embedded into a hardware construct wherein the signal input is a microprocessor and the signal output is engaged into the normal socket 14 or direct interconnect to motherboard 16 where the microprocessor 10 is normally inserted or connected, thus providing a physical standoff barrier to the normal interconnect. Signals originating from the microprocessor 10 are diverted into CFM 12 for parsing. The CFM 12 can comprise memory cells capable of being externally programmed from a trusted hardware source. According to certain aspects of the invention, the memory cells are programmed as a command filter matrix 12 that parses instructions, commands, data fetches and memory destination addresses originating from the microprocessor 10 . Based on the image programmed by the trusted hardware source device, the CFM 12 will only allow trusted instructions, commands, data fetches and memory destination addresses to be transported as output signals. This transport filter mechanism is illustrated in FIG. 2 .
[0016] CFM 12 can be implemented in two independent modules 120 and 122 that interdict microprocessor signals from different code execution partitions of the microprocessor 10 . As illustrated, JTAG/Debug and Control module 120 and a HyperTransport Interface module 122 may be employed. The CFM 12 can be configured as a filter matrix to selectively restrict transportation of signals across the filter interface to patterns that match a limited pattern set 24 . Accordingly, the filter interface can serve to aggressively defend the microprocessor 10 and its associated system from external malicious attack and control.
[0017] With reference to FIGS. 1 and 3 , one example of a system according to certain aspects of the invention is embodied within a physical body constructed to house an assembly comprising a printed wire board (PWB) 16 , one or more integrated circuits, such as microprocessor 10 , and any necessary electrical interconnect to provide signal, voltage, and control functionality. the one or more integrated circuits can be affixed to the PWB 16 to provide support, signal, and voltage interconnect as well as physical and structural integrity. Integrated circuits may come in many different design formats which accomplish the prescribed or desired functions.
[0018] In the example depicted in FIG. 3 , a microprocessor adapter assembly 30 is selected to support the target microprocessor 10 . Adapter assembly 30 may comprise a chip adapter 302 that performs one or more functions including, for example, routing and mapping signals between microprocessor 10 and CFM 304 or CFM adapter body 306 , interception of signals and/or spoofing, replacing or simulating intercepted signals or otherwise missing signals. Adapter assembly 30 can assure secure interconnect of required signals to the one or more integrated circuits. The assembly 30 may be sealed with, for example, a solid curing polymer or epoxy. In at least some embodiments, the microprocessor 10 maybe mounted to the adapter assembly 30 prior to sealing, thereby providing a secured microprocessor 32 .
[0019] The integrated circuit can be connected to an external trusted source hardware device for configuring, adaptation, test and/or for programming purposes. Connection to a trusted source may be provided through proprietary or standard connections such as JTAG and, in some embodiments, connection may be made through microprocessor interface, typically using a coded sequence. Trusted source programming localizes the universal device 304 to a microprocessor-specific (CFM) device. The CFM 304 may contain external reporting functionality and capability. However, the reporting function cannot typically be accessed by externally addressable memory and the reporting capability is incorporated in the device by ASIC etch.
[0020] In certain embodiments, the CFM 304 denies access to any out-of-bounds hardware attempting to connect to unassigned pins, factory test and configuration pins and other non-specified functions on the microprocessor 10 . CFM 12 is positioned between the microprocessor 10 and the socket 14 wherein the functional run-time authorized data paths are correctly aligned. The CFM 12 can have a secondary configuration wherein the CFM 12 is manufactured as part of socket 14 , and mounted permanently onto the circuit board 16 , where it receives the microprocessor 10 .
Additional Descriptions of Certain Aspects of the Invention
[0021] The foregoing descriptions of the invention are intended to be illustrative and not limiting. For example, those skilled in the art will appreciate that the invention can be practiced with various combinations of the functionalities and capabilities described above, and can include fewer or additional components than described above. Certain additional aspects and features of the invention are further set forth below, and can be obtained using the functionalities and components described in more detail above, as will be appreciated by those skilled in the art after being taught by the present disclosure.
[0022] Certain embodiments of the invention provide a secured semiconductor integrated circuit. Some of these embodiments comprise an interconnect configured to intercept signals transmitted between an integrated circuit device and a circuit board. Some of these embodiments comprise a command filter matrix configured to receive the intercepted signals and to selectively transmit the intercepted signals to the circuit board or the integrated circuit device. In some of these embodiments, the command filter matrix is configured by a trusted source. In some of these embodiments, the command filter maintains a set of associations between instructions and data according to characteristics of a target microprocessor device. In some of these embodiments, the command filter maintains a set of associations between instructions, data and characteristics of a target microprocessor device. In some of these embodiments, the command filter matrix transmits only intercepted signals that match entries in the set of associations maintained by the command filter matrix.
[0023] In some of these embodiments, the trusted source configures the command filter matrix using a secure process. In some of these embodiments, the command filter matrix hardware comprises a hardware memory matrix. In some of these embodiments, the hardware memory matrix is configured to operate as a code comparator. In some of these embodiments, the selective transmission of the intercepted signals is controlled by the code comparator. In some of these embodiments, the command filter matrix blocks transmission of intercepted signals that conform to a pattern indicative of malware. In some of these embodiments, the command filter matrix is configured to block malware from being executed by the microprocessor. In some of these embodiments, the command filter matrix and the interconnect are embodied in a socket adapted to receive the microprocessor. In some of these embodiments, the command filter matrix and the interconnect are embodied in a component configured for insertion between the microprocessor and a socket adapted to receive the microprocessor.
[0024] Certain embodiments of the invention provide a method for controlling semiconductor devices. In some of these embodiments, the method comprises providing a command filter matrix between a microprocessor and a circuit board. In some of these embodiments, the method comprises redirecting signals transmitted between the microprocessor and the circuit board to the command filter matrix. In some of these embodiments, the command filter matrix is configured to receive an address from the microprocessor. In some of these embodiments, the command filter matrix is configured to determine if the address is a valid program-instruction address. In some of these embodiments, the command filter matrix is configured to permit a program instruction to be fetched from the address if the address is a valid program-instruction address. In some of these embodiments, the command filter matrix is configured to redirect the microprocessor to a different address if the address is an invalid program-instruction address. In some of these embodiments, the validity of the program-instruction address is determined based on set of signal patterns maintained by the filter matrix. In some of these embodiments, the program instruction includes a request for data from a data address. In some of these embodiments, the command filter matrix is configured to determine whether the program instruction is one of a group of instructions permitted to request the data from the data address. In some of these embodiments, the command filter matrix is configured to permit the data to be retrieved from the data address when the program instruction is one of the group of instructions permitted to request the data from the data address. In some of these embodiments, the command filter matrix is configured to prevent the data from being retrieved from the data address when the program instruction is not included in the group of instructions permitted to request the data from the data address. In some of these embodiments, responsive to determining if the address is a valid program-instruction address, the command filter matrix is configured to redirect one or more input signals of the microprocessor to corresponding buffers selected based on the validity of the program-instruction address. In some of these embodiments, responsive to determining if the address is a valid program-instruction address, the command filter matrix is configured to redirect one or more output signals of the microprocessor to corresponding buffers selected based on the validity of the program-instruction address.
[0025] Certain embodiments of the invention provide devices including semiconductor devices. Some of these embodiments comprise an interconnect configured to intercept signals transmitted from a microprocessor provided in an integrated circuit device to a socket configured to receive the integrated circuit. Some of these embodiments comprise a command filter matrix configured to receive the intercepted signals and to selectively transmit certain of the intercepted signals to the socket. In some of these embodiments, the command filter matrix is configured using a secured configuration process. In some of these embodiments, the secured configuration provides a set of associations to the command filter matrix. In some of these embodiments, the set of associations identifies patterns of signals corresponding to instructions and data associated with the microprocessor. In some of these embodiments, the command filter matrix transmits only intercepted signals that match a pattern of signals identified by the set of associations in the command filter matrix. In some of these embodiments, the command filter matrix is configured by a trusted source. In some of these embodiments, the command filter matrix hardware comprises a code comparator. In some of these embodiments, the code comparator is configured to identify a plurality of valid program instructions from the pattern of signals. In some of these embodiments, the plurality of valid program instructions includes instructions permitted to request data from predetermined data addresses. In some of these embodiments, the plurality of valid program instructions includes instructions located at one or more addresses.
[0026] Certain embodiments of the invention provide a semiconductor integrated circuit. Some of these embodiments comprise a command filter matrix arranged so that it may only be programmed by a secure process and arranged to store associations between instructions and data according to requirements resulting from specification of a target microprocessor device. In some of these embodiments, the secure process is arranged to program the command filter matrix from a trusted source. In some of these embodiments, the hardware mechanism comprises a hardware memory matrix programmable as a code comparator. In some of these embodiments, the input and output of signals is controlled by the logical output of the code comparator. In some of these embodiments, hardware and embedded logic functions deny Hardware Exploitation Malware from entering the processing core.
[0027] Certain embodiments of the invention provide security process and methods used in semiconductor devices. Some of these embodiments provide an ability to fetch a program instruction from an actual address via a virtual address. Some of these embodiments comprise determining whether the actual address is a valid program-instruction address. Some of these embodiments comprise fetching the program instruction from the actual address if the actual address is a valid program-instruction address; and generating a go/no-go determination. In some of these embodiments, the program instruction includes a request for data from a data address. Some of these embodiments comprise determining whether the program instruction is within a group of instructions allowed to request the data. Some of these embodiments comprise retrieving the data from the data address if the program instruction is within the group of instructions; and generating a go/no-go determination. Some of these embodiments provide an ability to switch or shunt input and output signals to specific input and output buffers according to the logical output of the go/no-go determination.
[0028] Although the present invention has been described with reference to specific exemplary embodiments, it will be evident to one of ordinary skill in the art that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
|
A semiconductor integrated circuit includes a hardware mechanism arranged to ensure that associations between instructions and data are enforced so that a processor cannot execute an instruction that is not authorized. A Command Filter Matrix stores entries comprising instructions and associated data memory ranges. A hardware arrangement denies command execution if the CPU attempts to make a data fetch from an instruction that is outside the range associated with data in the Command Filter Matrix. The Command Filter Matrix may be implemented in a Field Programmable Gate Array such that the memory cell content is pre-programmed with entrusted code by a separate trusted hardware source. In this way, an operating system may function normally but only execute trusted instructions, commands and memory operations. The Command Filter Matrix also contains external write-only capability to enable external monitoring of performance.
| 6
|
CROSS-REFERENCE TO RELATED PATENT APPLICATION
This application is the National Stage entry of PCT/US2008/055962 filed Mar. 5, 2008 and claims the benefit of provisional patent application No. 60/904,999, filed Mar. 5, 2007, having the title “Method of local electro-magnetic field enhancement of terahertz (THz) radiation and related system” the disclosure of which is incorporated herein by reference, as though recited in full.
FIELD OF THE INVENTION
The invention relates to elector-magnetic field enhancement of terahertz radiation in sub wavelength regions and Improved Coupling of radiation to materials through the Use of the discontinuity edge effect and more particularly to the use of slots in materials such as semiconductors and metals for use in THz sensors.
BACKGROUND OF THE INVENTION
At terahertz (THz) frequencies, electromagnetic (EM) fields can be absorbed by optically active internal vibrations of molecules. The capability of THz spectroscopy to detect directly the low-frequency vibrations of weak bonds, including but not limited to hydrogen bonds, is unique in providing information quite different from the visible or IR spectroscopic characterization. This uniqueness opens a large number of applications for THz vibrational spectroscopy in areas such as biomedicine, pharmaceutical analysis, real time monitoring of biological processes, detecting and identification of harmful biological species. A significant advantage of THz spectroscopy is that it is nondestructive to living species. Since each molecule has its own specific internal vibrations, this process can be used to fingerprint, characterize and identify a broad range of molecules. Very recently a THz spectroscopy technique for structural characterization of DNA, proteins and other bio-polymers in diluted solutions was developed by taking advantage of the lower water absorption in the sub-THz vs. IR and far IR regions [1-3].
However, several primary problems impede the development of THz spectroscopy of biological molecules and the application of this technique for characterization, detection, and discrimination between species as well as for the development of new devices for monitoring biological processes. The first problem is that the THz coupling to molecules is not very strong, resulting in poor sensitivity to molecular vibrations. The second problem is low spatial resolution due to the long wavelength of THz radiation (3 mm at 0.1 THz) and diffraction limitation. Thus, the spatial resolution is limited to several mm in the spectral range of 10-30 cm −1 . This spectral range below 1 THz is especially attractive for practical applications because of low disturbance from the absorption by water or other solvents. In order to increase the sensitivity and reliability of THz fingerprinting techniques, coupling of incident THz radiation to biological or chemical molecules has to be enhanced.
The enhancement of the electric field was demonstrated long ago in optical diffraction by perfect metallic screens. Diffraction by a single slit in a perfect metallic screen was considered by Sommerfield [7]. He studied a case of the incident electromagnetic waves being normal to the screen and proved that the electric field is divergent at the edges of the slit if the incident electric field is perpendicular to the edges. Periodic slot arrays are other possible candidates for increasing the sensitivity. Such arrays were previously used for THz bandpass filters fabricated from lossy metal films deposited on dielectric membranes [8]. Experimental work on enhanced transmission are mostly available at optical and near-infrared frequencies for metallic periodic structures (gratings [9-12] and hole arrays [13-15]). Recently, it has been shown that waveguide resonance and diffraction are the main factors contributing to enhanced transmission of narrow slot subwavelength metallic gratings [12]. The phenomenon of extraordinary optical transmission (transmission efficiency exceeding unity when normalized to the surface of the holes) through hole arrays, first experimentally observed in Ag in 300 nm-1500 nm range [13-14], has been attributed to the resonant tunneling of surface plasmons [14-19] through thin films. Recently, similar studies were conducted in the THz range with hole arrays in films made of metals (Ag-coated stainless steel [20], Al-coated Si wafers [21]) and doped semiconductors (Si [22] and InSb [23]), and also with metallic slot arrays [24] using the perfect conductor approximation).
SUMMARY OF THE INVENTION
The present invention relates to a method and related system to enhance the local electro-magnetic field of THz radiation in sub wavelength regions and to improve the coupling of THz radiation with bio- and chemical materials through the use of the discontinuity edge effects in propagation of radiation in semiconductor or metal slots for application in THz sensors with the spatial resolution much below the diffraction limit.
The electro-magnetic field distribution inside slot or hole arrays was not investigated previously in terahertz range. It has now been found that transmission properties of subwavelength slot arrays are fundamentally different from arrays of holes, since unlike hole arrays, a slot array can support propagating waveguide modes. Thus, increased transmission and local electric field enhancement for transverse magnetic (TM) wave incidence can be obtained through careful choice of materials and design of periodic slot array structures. It has now been found that the enhancement of the THz electro-magnetic field extends across the slots and reaches peak values at the edges because of discontinuity effects. This highly intense localized peak of THz radiation is used in sensors to dramatically improve their spatial resolution and magnify the sensitivity.
An aspect of various embodiments of the present invention may comprise, but not be limited thereto, a novel method and related system to the fundamental problem of improving THz coupling to bio-molecules, explosives, and other materials of interest that have been deposited near the discontinuity edges of a slot or a periodic grating fabricated from semiconductor materials or metals, while simultaneously improving special resolution [4-6]. The improved coupling and spatial resolution are both based on the local EM field and power enhancement near the discontinuity edges with respect to the incident field in structures of slots in a doped semiconductor or metal film or multilayer structures that support modes which locally enhance EM fields. The enhancement mechanism is purely due to the diffraction or discontinuity edge effects in propagation of Terahertz (THz) radiation in subwavelength rectangular slot or periodic structures. It should be noted that theories are provided for background and a full understanding of the technology and not by way of limitation.
The mechanism of coupling of TM polarized THz radiation to the periodic thin film structure consisting of a doped semiconductor with rectangular slot arrays using InSb, Si and gold films are described herein by way of example and not by way of limitation. Transmission properties of subwavelength slot arrays are fundamentally different from arrays of holes, since unlike hole arrays, a slot array can support propagating waveguide modes. Thus, increased transmission and local electric field enhancement for TM incidence can be obtained through careful choice of materials and design of periodic slot array structures. The enhancement of the THz electro-magnetic field extends across the slots and reaches peak values at the edges because of discontinuity effects.
The vector of the electric field E is directed perpendicular to the slots. This approach leads to a new mechanism for sub-wavelength THz imaging sensing with sub-micron spatial resolution.
This method of local enhancement has been discovered using a rigorous mathematical solution of Maxwell's equations for doped semiconductor and metal structures with sub wavelength one dimensional slot arrays subjected to THz radiation. Using InSb as an example, an EM field enhancement of over 30 near the slot edges translates into a 1000 fold increase in power.
The “edge effect” at sub-THz frequencies caused by the effects of the discontinuity of the present invention, is a very important new result that guides the novel device design. In one embodiment, the bio- or chemical material is embedded in the regions of the slot edges where the EM field enhancement is generated. Other modifications include semiconductor or metal films and multilayer structures with slots of different periodicity and geometry with bio- or chemical material embedded at locations of EM field enhancement. The bio- or chemical material can also be delivered to the slots using microfluidic channels. The enhanced coupling to biological or chemical material inside the chip at particular frequencies within THz gap (approximately 0.1-10 THz) results in more significant changes to the transmitted and reflected spectra that can be applied to enhance the sensitivity and selectivity of bio- and chemical detection.
One example of an important practical application of this invention is the development of a simple, all optical, appertureless, subwavelength transmission THz sensor with the spatial resolution much below the diffraction limit and integrated with a microfluidic channel chip for a sample material. The imaging mechanism of the present invention, integrated with a “lab-on-a chip” device, is the heart of a sub-wavelength THz microscopic sensor.
An aspect of the present invention is a grating structure with optimized periodic sub-wavelength geometries and integrated with a microfluidic chip for bio material analyte.
Another aspect of the present invention is an inexpensive microfluidic chip made from plastic and integrated with a thin film grating to dramatically enhance sensitivity and spatial resolution. In such an instrument, the other crucial component is a miniature detector assembly with micron size antenna mounted on the translation stage to probe the spatial distribution of a THz signal in a near field configuration.
A further aspect of this invention is an integration of these central components of a proposed sensor with a THz source through the optical focusing system.
The instrument is capable of collecting THz-frequency signatures from microscopic biological or chemical molecules. The upper frequency limit of practical application of discovered mechanism for the local EM field enhancement is determined by the condition d<λ, where λ is the wavelength of radiation and d is the structure periodicity.
The prototype of a miniature THz detector consisting of a Schottky diode integrated with a circuit and a sub-micron beam lead probe has been designed and fabricated. The integration of the detector assembly with the translation stage has been designed. The periodic slots structure has been fabricated using the photolithographic process and electroplating. The microfabrication processes have been optimized to obtain high sharpness at the edge of the slots. The technology to fabricate and characterize microfluidic channels for biological molecules was also demonstrated.
This novel detection platform can be applied to, but not limited thereto, the development of a new class of resonant, highly sensitive and selective portable bio- and chemical devices for biochemical, medical and military applications.
Some exemplary novel aspects that may be associated with various embodiments of the present invention method and system may comprise, but not limited thereto, the following:
The method of detection the spectroscopic signatures of bio-molecules or other materials of interest, such as explosives, using the local EM field enhancement with respect to the incident field within semiconductor or metallic slot or hole arrays. This enhancement leads to increased coupling of EM radiation in the THz spectral range to materials of interest and, therefore, results in dramatic improvements to the sensitivity, selectivity, reliability and spatial resolution of THz detection systems.
(2) Criteria for optimizing the selection of materials and properties appropriate for the local distribution of THz radiation suitable for the method as (1).
(3) Design of a periodic structure of slots to support a set of THz modes that locally enhance EM fields for the method as (1).
(4) Application of the periodic structure of slots to locally enhance THz coupling to biological, explosive, or other materials of interest in solid or fluidic form, with the material immobilized on the surface, trapped at slot edges, or scanned across a microfluidic chamber.
(5) Application of the periodic structure of slots scanned the slots across the material sample to enhance local coupling and thereby improve the chemical resolution and sensitivity of the detector to THz imaging.
(6) Application of the periodic structure of slots to detectors that include miniaturized THz near-field sensing.
(7) Application of the collimated beam of a polarized THz radiation to illuminate a structure from rectangular slots in a thin metallic or doped semiconductor film.
(8) Developing a grating structure with optimized periodic sub-wavelength geometries.
(9) Integration of THz radiation with an inexpensive (disposable) microfluidic chip containing sample materials in aqueous or biological native state, made from plastic or other materials transparent in the THz range.
(10) Application of the thin film slot grating integrated with the microfluidic channel with the sample material to be tested where it is illuminated with the terahertz energy.
(11) Integration of THz radiation with a microfluidic network of channels of nanoscale thickness for purposes of washing, sorting and pre-concentration of samples to permit real-time THz detection and characterization at improved sensitivities.
(12) Application of the integrated THz micro-detector assembly that is composed of three essential parts, i.e. a micron/sub-micron probe (antenna) that is connected to a miniature detector and control circuit with the corresponding impedance matching network to achieve the precise detection of the electric field in the near-field configuration.
(13) Application of mounting the detector assembly on the stage, which can provide precise (with resolution less than 1 μm) scanning over the sample under test along XYZ direction with nanometer accuracy controlled by the control circuit.
(14) Application of microscopic device for precise positioning of a micron probe in close vicinity of a slot structure outdoing interface.
(15) Alternatively, application of an electric (capacitive) mechanism for precise positioning of a micron probe in close vicinity of a slot structure outdoing interface.
(16) Application of reduced amount of material for characterization.
(17) Application of a linear array of miniature detectors integrated with scanning mechanism for a THz imaging.
The invention is illustrated by the example structure consisting of a one-dimensional array of rectangular slots with the period less than the wave length of applied EM radiation in a thin doped InSb film with a free electron concentration of 1.1×10 16 cm −3 . This is not to be construed in any way as imposing limitations upon the scope of the invention. Structures with slot arrays or hole arrays of different periodicity and different geometry can be used as well. Different materials such as semiconductor films or metallic films can be used separately or in combinations as in multilayer structures.
Applications might include simple microscopic sensors for detecting traces of particular material at the nanograms level in a solid form or in dilute solutions in water or other analytes; microscopic sensors combined with microfluidic channels for monitoring biological processes; microscopic sensors with linear detectors array and two dimensional scanning as THz imaging instruments.
It should be understood that resort may be had to various other embodiments, modifications, and equivalents to the embodiments of the invention described herein which, after reading the description of the invention herein, may suggest themselves to those skilled in the art without departing from the scope and spirit of the present invention.
In accordance with an embodiment of the invention, an enhanced THz coupling to molecules is achieved by depositing a test material near the discontinuity edges of a slotted member, enhancing the THz radiation by transmitting THz radiation, having a vector directed perpendicular to the slots of the slotted member and illuminating molecules of the test material with the enhanced THz radiation transmitted through these slots. This method results in producing an increased coupling of EM radiation in the THz spectral range to the material.
In accordance with another embodiment of the invention the enhanced THz radiation is an EM field of terahertz radiation in a submicron region, and the THz vibration absorption by the test material is analyzed. The molecules can comprise bio-molecules, organic molecules, or an explosive.
In accordance with a further embodiment of the invention the slotted member is selected from the group comprising doped semiconductors, metal films, and multilayer structures that support modes that locally enhanced EM fields, and near field sensing of THz radiation from the molecules. Increased coupling and spatial resolution are both based on the local EM field and power enhancement near the discontinuity edges with respect to the incident field in slotted structures.
In accordance with a further embodiment of the invention an EM field enhancement is generated at the edges of the slots and a bio- or chemical material is embedded at the location of the EM field enhancement. THz radiation is transmitted through the slots and bio- or chemical material at the location of EM field enhancement and the near field THz radiation that has been transmitted through the slots and has illuminated said bio- or chemical material at the location of EM field enhancement is then sensed. The transmission of THz radiation through the slots increases the degree of the coupling of EM radiation in the THz spectral range to materials of interest by transmitting THz radiation through an array of openings, to detect the spectroscopic signatures of said bio- or chemical material. Near field scanning with a THz antenna, of transmitted radiation of the slotted member from sample material near the discontinuity edges can be used.
In accordance with a still further embodiment of the invention the increase in coupling of EM radiation in the THz spectral range to weak bonds in molecules, is achieved by depositing a material of biological or chemical molecules near the discontinuity edges of slots of a slotted member, and transmitting THz radiation through the slots and illuminating the molecules with the transmitted THz radiation. The slots are periodic structures with the coupling increase being due to the diffraction or discontinuity edge effects in propagation of THz radiation in subwavelength rectangular slots of the slotted member, which is fabricated from semiconductor materials, metals, or combinations thereof. The near field THz radiation is transmitted through said slots and said bio- or chemical material which can be selected from the group comprising explosives, toxic materials, living organisms and pharmaceuticals, is then sensed.
In accordance with a further embodiment of the invention the changes of dielectric properties of bio-materials in biophysical processes, is monitored. The property is selected from the group comprising denaturation of DNA, folding-unfolding of proteins, and structural conformational changes of biomolecules in interactions with drugs. A GHz signal is generated and the GHz radiation converted to THz radiation with a frequency multiplier. The THz radiation is collimated for transmission through the slots and illumination of the molecules with the transmitted THz radiation. An EM field enhancement is generated at the edges of the slots, selectively detecting enhanced THz transmitted through the bio-materials at the slot edges. The selectively detected enhanced THz radiation is monitored to determine changes of dielectric properties of bio-materials in biophysical processes.
In accordance with a further embodiment of the invention an all-optical, apertureless instrument, free of mechanical tips or probes to contact testing material is used for analysis. The instrument comprises a slotted member, a source of THz radiation, and an analyte material embedded at least at the edges of the slots of the slotted member. The analyte material is molecules in dilute solutions with the molecules selected from the group comprising monolayers of biological material and cancer cells.
In accordance with a further embodiment of the invention an integrated THz micro-detector assembly comprises a sub-micron probe connected to a miniature bolometer detector and control circuit with a corresponding impedance matching network and is used to achieve the precise detection of the electric field in the near-field configuration. The sub-micron probe is mounted on a stage and positioned for near field scanning, with a resolution of less than 1 nm, over the sample under test along XYZ direction with nanometer accuracy controlled by said control circuit. Preferably the sub-micron probe is positioned within 2 microns of the sample.
In accordance with a further embodiment of the invention the coupling of THz radiation to molecules in the analyte sample is increased by using a slotted member, consisting of an array of rectangular slots or elongated holes, positioned between said source of EM radiation in the THz spectral range and the materials of interest. The slotted member can be an array of spaced strips of metal, semiconductors, or layers thereof and selected from the group comprising thin InSb thin film, thin Si thin film and a thin Au thin film and combinations thereof.
In accordance with a further embodiment of the invention a device for sub-wavelength THz imaging sensing with sub-micron spatial resolution consists of means for generating THz radiation, a slotted structure with slots of a predetermined periodicity and geometry, a translation stage, a miniature detector assembly and at least one THz radiation sensor. The detector assembly is a chip about 1 mm wide and 1.5 mm long having a beam lead micro-tip with a length of about 60μ. long, a tip length of about 15 μm, a tip width of about 15 μm, and a tip of about 0.6 μm. The detector further has a micron size antenna mounted on the translation stage, to probe the spatial distribution of a THz signal in a near field configuration. The THz radiation sensor(s) are positioned to receive THz radiation from the slots. The slotted structure can be a one-dimensional array of rectangular, or elongated, slots with a periodicity of less than the wave length of applied EM radiation in a doped InSb thin film. A fluidic member having microfluidic channels, delivers bio- or chemical material to the slots through the microfluidic channels. The microfluidic chamber comprises a network of micro-channels of nanoscale thickness, and means for at least one of washing, sorting and pre-concentration of samples to attain real-time THz detection at improved sensitivities. The micro-channels can be about 5-50 μm wide, 1 μm deep, 1-2 μm long, and are in a 10-50 μm substrate of polydimethylsiloxane (PDMS) or polymethylmethacrylate (PMMA), or other material, that is transparent to THz radiation.
In a further embodiment of the invention an optical device, such as a THz microscope, comprises an apertureless, subwavelength transmission THz sensor with the spatial resolution substantially below the diffraction limit and having a source of THz radiation, a slotted member with substantially rectangular or elliptical slots of a predetermined periodicity and geometry, at least one THz radiation sensor positioned to receive near field THz radiation transmitted through said slots at the slot edges and means to optically focus the THz radiation through the analyte. An EM field enhancement is generated at the edges of the slots, with a bio- or chemical material embedded at the location of EM field enhancement. An integrated microfluidic channel chip, comprises a network of channels of nanoscale thickness, delivers a sample material to the slotted member. The slots have a width less than the wavelength of the THz radiation and a length greater than the wavelength of the THz radiation and d<μ, where μ is the wavelength of radiation and d is spacing from the distal edge of one slot to the proximal edge of the next slot. Means are provided to collimate and polarize the THz radiation and the THz radiation can be a collimated beam of a polarized radiation and illuminates an analyte through rectangular slots in a thin metallic or doped semiconductor film. The analyte materials are in solid or fluidic form, and are embedded on the surface of the slotted member, trapped at slot edges, embedded in slots, or scanned across a microfluidic chamber. An integrated THz microdetector assembly comprising a micron/sub-micron probe connected to a miniature detector and control circuit, said control circuit having a corresponding impendence matching network to achieve the precise detection of the electric field in the near-field configuration can be incorporated. The micro-detector assembly, a linear array of miniature detectors integrated with said scanning mechanism for THz imaging of analytes, is mounted on a stage member to provide precise scanning, with resolution less than 1 nm, over the sample under test along XYZ direction with nanometer accuracy controlled by the control circuit.
In a another embodiment of the invention a monitoring system for monitoring changes of dielectric properties of materials comprises a THz source, with a GHz signal generator, a frequency multiplier, and a power supply for said source; at least one collimating member; a periodic slot chip; a detector assembly chip and a motorized XYZ stage with controller. The detector assembly chip is mounted on a stage for XYZ movement with respect to said periodic slot chip, for detecting and monitoring THz radiation that is transmitted through slots in the periodic slot chip.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . The periodic rectangular slot array structure. The axes and the structure parameters (d—spacing, s—slot width, h—film thickness) are shown. The vector of electric field is in the x direction perpendicular to the slot.
FIG. 2 . Electric field enhancement,
E x i E 0 ,
as a function of a coordinate x (μm) across a slot for the structure parameters d=381 μm, s=55 μm, h=4 μm and for the wavelength λ=714 μm. Note the majority of the enhancement takes place at the slot edges i.e. around (−s/2) and (s/2).
FIG. 3 . THz power, (E x /E o ) 2 , enhancement as a function of a coordinate x (m) across a slot for the structure with the same parameters as in FIG. 2 at two frequencies 14 cm −1 (the wavelength=714 m) and 24 cm −1 .
FIG. 4 . The edge effect for two components of electric field E x and E z ,
FIG. 5 . Plot of maximum electric field enhancement,
E x i E 0 ( max . ) ,
at the incident interface and around slot edges as a function of a slot width, s, with d=381 m, and =714 m, for different h values (h=12 m, 6 m and 4 m).
FIG. 6 . Far field transmission, |t|, as a function of d/ for different values of a slot width, s. Here d=381 μm, h=12 μm.
FIG. 7A . The edge effect in periodic structures made of a Si film: d=251 μm, s=95 μm, and h=4 μm, and of a gold film.
FIG. 7B . The edge effect in periodic structures made of a Si film d=251 μm, s=36 μm, and h=4 μm.
FIG. 8 . A diagrammatic illustration of a THz microscopic sensor.
FIG. 9 . The periodic slot structure made of gold on the silicon wafer fabricated using the photolithographic process and electroplating. The yellow parts are gold and the dark parts are air slots of 55 μm. The similar periodic structure was fabricated on a quartz substrate and using polydimethylsiloxane polymer substrate.
FIG. 10 . A SEM picture of one gold slot. The edge extrude is 0.5 μm.
FIG. 11A . Concept of integrated probe with Schottky diode detector.
FIG. 11B . Prototype sensor circuit with planar probe. The position for the diode detector between the probe and lowpass filter is indicated.
FIG. 12 . Beam lead structures fabricated on an ultra-thin (5 μm thick) silicon chip.
FIG. 13 . The electrical field distribution along the cross section of one slot with and without the detecting probe present. The distance between the probe and the slot surface is 1 μm.
FIG. 14 . Array of detectors for operation at 1.6 THz. The spacing between adjacent elements is 40 μm and the substrate material is quartz [28].
FIG. 15 . Miniature detectors (nanometer-scale bolometer) integrated with planar antennas for operation at 600 GHz [29].
FIG. 16 . A preferred embodiment for applying the periodic slots to increase the THz coupling to molecules across the sample area, through the use of a piezo-stage to scan the light exiting the slot edges across the samples and place the detector in close proximity to the slots and sample. A detector assembly is combined with a sample or microfluidic channel (5-50 μm wide, 1 μm deep, 1-2 cm long, with a 10-50 μm backing support to enable handing) filled with biomaterials. A 2-5 μm Au edge layer is patterned on the top edge of channel. Not in scale.
FIG. 17 . Example of assembly for integrating periodic microfluidic structure with translatable miniaturized detectors (not in scale) for monitoring changes of THz dielectric properties of bio-materials in solutions.
FIG. 18A . Side-view of the proposed sample cell with 1-10 um thickness for biological material.
FIG. 18B . Schematic top view of fluidic system with multiple inlets to affect local chemical changes to biomolecule conformation and its integration to terahertz (THz) optics and detection.
FIG. 19A . Sub-THz transmission spectra of a single stranded and double stranded Salmon DNA. The sensor can be tuned to either of frequencies 12.7 cm −1 , 16 cm −1 , or 22.3 cm −1 where spectral features differences are observed [30];
FIG. 19B . Lysozyme unfolded with a GuHCl and thermo-unfolded. Lysozyme sample unfolded with GuHCl are in substantially unfolding state in which little persists secondary or tertiary structure and eliminates refolding process in unfolded lysozyme.
FIG. 20 . The schematic layout for the experimental system.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
As employed herein, the term “slots” is inclusive of a structure having a linear array of thin opaque strips, a structure in which slots are formed in a solid material, and slits or slots having a periodic spacing and suspended on a solid matrix. The term slots is inclusive of hole and gratings. The geometry of slots includes:
a closed curve, the intersection of a right circular cone (see cone) and a plane that is not parallel to the base, the axis, or an element of the cone. It may be defined as the path of a point moving in a plane so that the ratio of its distances from a fixed point (the focus) and a fixed straight line (the directrix) is a constant less than one. Any such path has this same property with . . .
elongated slot, such as, a flattened circle: a two-dimensional shape like a stretched circle with slightly longer flatter sides
ii—egg shape: something shaped like an egg or a flattened circle
iii—oval—a closed plane curve resulting from the intersection of a circular cone and a plane that is non-parallel to the plane of the base of cone the cutting completely through it; “the sums of the distances from the foci to any point on an ellipse is constant”.
Ellipse:
A conic section whose plane is not parallel to the axis, base, or generatrix of the intersected cone.
The locus of points for which the sum of the distances from each point to two fixed points is equal.
A four sided polygon having opposing sides equal to each other but not equal to their adjacent sides.
An elongated square or rectangle.
A rectangle with rounded corners
viii—an elongated parallelogram—a quadrilateral whose opposite sides are both parallel and equal in length to each other but not equal in length to adjacent sides
DESCRIPTION
An aspect of various embodiments of the present invention comprises, but is not limited thereto, a method and related system for detection of the THz spectroscopic signatures of bio-molecules or other materials of interest, such as explosives, in 0.1-3 THz range that is based on the local EM field enhancement with respect to the incident field in structures with slot or slot arrays fabricated using semiconductor or metallic films or multilayer structures. This enhancement leads to an increased coupling of EM radiation in the THz spectral range to materials of interest and, therefore, results in dramatic improvements to the sensitivity, selectivity, reliability and spatial resolution of THz detection systems.
A prototypical embodiment of this application to deliver the enhanced coupling of THz radiation with bio- or chemical materials is through periodic structures of sub wavelength slots in semiconductor or metallic films. In the THz region, interaction between radiation and metals is quite different from higher frequency regions due to the change in material dielectric properties. In the visible and near-IR regions, where frequencies are only slightly less than plasma frequency, the permittivity is predominantly real and negative (for example, at wavelength 1 μm, ∈ Au =−51.4+j1.6), and metals are reflective. On the contrary, as the frequency is lowered to the THz range, the real part continues to be negative and large, but the dissipative imaginary part becomes larger, and hence metals are very conducting and absorbing (at wavelength 500 μm, ∈ Au =−5.5×10 4 +j8.5×10 5 ). Therefore, to reduce radiation losses, it is preferable to substitute metals with doped semiconductors with plasma frequencies in the low THz range. InSb with high electron mobility and low effective mass is most suited for this purpose, but still has a substantial absorbing imaginary part compared to the real component. In the semiconductor structure with periodic gratings, the material properties are periodic functions of coordinates as well. The absorbing component in semiconductors (InSb and Si) requires the assumption of a small film thickness, which makes the semiconductor skin depth at both semiconductor-air interfaces larger than half the film thickness throughout the frequency range of interest. This renders the surface impedance boundary conditions for perfect conductors [32,33] to be unsuitable for semiconductor structures. On the other hand, in contrast with the behavior of metals in short wavelength ranges, the Fourier expansion method for field diffracted from gratings [9] can be applied in the THz region for InSb and Si films, since the imaginary permittivity component damps the Gibbs oscillations [34]. The Fourier expansion of the electro-magnetic fields and the permittivity were used to solve the terahertz transmission/absorption/reflection problem and to calculate the total distribution of the electro-magnetic field in the system. At the same time, the Fourier expansion method is unsuitable for Au owing to its dielectric properties. However since the skin depth for Au is small compared to thickness, surface impedance boundary conditions can be used. Even in this case, the perfect conducting walls approximation [35] for fields inside slots is employed since the thickness assumed is very small compared to the wavelength. Using a rigorous theoretical model of the enhancement effect derived from the numerical solution of Maxwell's equations for semiconductor based periodic structures with one dimensional slot arrays in 0.3-0.75 THz range [described originally in Refs.5,6], the “edge effect”, a localization of EM field that can be used to implement novel bio- and chemical sensors, was discovered. Maxwell's equations with appropriate boundary conditions on interfaces were solved with the frequency-dependent permittivity of the doped semiconductor. For polar materials like InSb, the frequency dependence of the relative permittivity, ∈(ω), includes terms describing the interaction of light with free carriers (Drude model) and with the optical phonons.
EXAMPLE
An aspect of various embodiments of the present invention can comprise a structure suitable for sensing applications, as illustrated in FIG. 1 . The structure includes a structure 102 having a subwavelength array of slots 104 with the periodicity in the x-direction and extending in the y-direction. The z-direction is perpendicular to the plane of incidence. Since the structural geometry is not altered in the y-direction, it would suffice to analyze a one-dimensional periodic slot structure as shown in FIG. 1 with spacing (or periodicity) denoted by (d), the slot width by (s) and the thickness of the film by (h). The structure is considered to be illuminated at normal TM incidence 106 .
FIG. 2 shows the electric field amplitude (with incident field normalized to unity) at the interface of incidence, as a function of position with a slot width (s) of 55 μm, periodicity (d) of 381 μm, height (h) of 4 μm. The simulation frequency is chosen to be 420 GHz (wavenumber of 14 cm −1 ) because absorption peaks of interest for many biological molecules have been shown to occur in this region. The enhancement of the field intensity at this frequency was obtained at all points in the slots. The half-power peak field near the slot edges occurs over a sub-micron region (˜500 nm). In practice, most of the field is confined to the edges (i.e. sharp regions) of the conducting medium. The maximum power enhancement is approximately 1100 and also occurs for a slot height of 4 μm. The enhancement persists across the slots, decreasing slightly from the incident interface to the outgoing (transmission) interface. It cannot be attributed to a surface plasmon mode because the plasmon matching condition is not applicable for permittivities with substantial imaginary parts.
Using InSb as an example, it has been shown that the 30-fold EM field enhancement within the sub-micron region of the slot edges, translates into a 1000 fold increase in power ( FIGS. 2 and 3 ). This “edge effect” at sub-THz frequencies caused by discontinuity effects is an important new result that can be applied to guide designs for enhanced THz coupling, as described below. The EM field enhancement at other points inside the slot, away from the edges is smaller, on the order of 3-5 fold. The enhancement of the amplitude of the electric field with respect to the incident field is demonstrated in FIG. 2 where the relative x-component of the electric field amplitude is plotted as a function of a coordinate across the slot, x, with s=55 μm and h=4 μm, for radiation with the frequency of 14 cm −1 . The electric field enhancement occurred within the sub-micron region around the slot edges i.e. at discontinuities as illustrated in FIG. 2 . Practically most of the fields were confined to the edges i.e. sharp regions of the conducting medium. The enhancement at the edges is an order of magnitude higher than at the other points within the slot. The maximum field enhancement is 33.3 at the incident interface and 31.8 at the outgoing interface for h=4 μm. For h=6 μm, these values are 27.7 and 25 respectively and for h=12 μm, 20.5 and 14.7 respectively. The half power width around the slot edges was ˜500 nm with maximum power enhancement ˜1100 for the h=4 μm case. This region did not change much for the other h values. The enhancement exists across the slots, slightly decreasing from the incident interface to the outgoing interface. The decay into the metallic region is more abrupt than into free space as expected, as seen in FIG. 3 , and around the edges is approximately proportional to
x - 1 3 ,
consistent with edge effects.
FIG. 3 illustrates the basic concept of an instrument of the present invention. FIG. 3 shows THz power, (E x /E o ) 2 , enhancement as a function of a coordinate x (μm) across a slot for the structure with the same parameters as in FIG. 2 at two frequencies 14 cm −1 (the wavelength λ=714 μm) and 24 cm −1 . It is seen that an imaging sensor is capable of measuring the THz response as well as resolving spatial features of samples under the test with a micron-submicron resolution. The instrument employs a terahertz source radiation that is collimated using optical components. The THz radiation is directed at a thin film slot grating integrated with a microfluidic channel with the sample material to be measured where the sample is illuminated with the terahertz energy. An integrated THz micro-detector assembly is composed of three essential parts, i.e. a sub-micron probe (antenna) that is connected to a miniature bolometer detector (for example, Schottky-diode), and control circuit with the corresponding impedance matching network to achieve the precise detection of the electric field in the near-field configuration. The detector assembly with a micro probe is mounted on the stage, which provides precise scanning, with a resolution of less than 1 μm, over the sample under test along XYZ direction with nanometer accuracy controlled by the control circuit.
The technology for fabricating the miniature detector with micron size antenna to affectively couple with THz radiation transmitted through the slit is disclosed in publications noted herein as 26 and 27.
FIG. 4 compares the enhancement of two electric field components, E x and E z , that are perpendicular and along the direction of the incident radiation. The enhancement at the slot edge as a function of a slot width is plotted in FIG. 5 for three different thickness. The calculated far field transmission through the structure is plotted in FIG. 6 as a function of a periodicity, d/λ, for different slot widths. The “edge effect” at sub-THz frequencies for two other materials (silicon and gold) is demonstrated in FIGS. 7A and 7B . The effect is significantly less than for InSb structure, however these materials still can be used due to technological advances. In all these cases, a sub micron narrow THz beam along the edge is a local, highly intense radiation source for probing biological and other material properties using near field configuration for specific microscopic sensing and imaging instruments in the THz range.
The invention is illustrated by the example structure consisting of a one-dimensional array of rectangular slots with the period less than the wave length λ of applied EM radiation, which contains small quantities of biological material embedded in the nano-size regions of the edges where enhancements of radiation in the THz gap are observed. This array is made of a thin-doped InSb film with a free electron concentration of 1.1×10 16 cm −3 fabricated on a substrate transparent for THz radiation. This is not to be construed in any way as imposing limitations upon the scope of the invention. Structures with slot arrays or hole arrays of different periodicity and different geometry can be used as well. Different materials such as semiconductor films or metallic films can be used separately or in combinations as in multilayer structures.
It should be understood that resort can be had to various other embodiments, modifications, and equivalents to the embodiments of the invention described herein which, after reading the description of the invention herein, can suggest themselves to those skilled in the art without departing from the scope and spirit of the present invention.
FIG. 8 shows an embodiment of the present invention for the application of the periodic array of semiconductor slots to enhance THz coupling to materials of interest for THz sensing and imaging. The basic concept of the instrument is an imaging instrument capable of measuring the THz spectral response as well as resolving spatial features of samples under test with submicron resolution. The design consists of three parts:
A supporting plate from plastic or quartz onto which a periodic slots structure is bonded or electroplated that also comprise materials sample chamber;
A miniaturized THz detector assembly which can be adjusted with a movable stage so that sub micron probe(s) of detector(s) are within ˜1 μm of the plane where the THz radiation exiting the slots. The preferable miniaturized THz detector is a Schottky micro-diode from Virginia Diode Inc., Charlottesville, Va., integrated with a coupling circuit and a nano-probe (antenna); and a motorized movable stage with controller that provides sub micron steps.
A terahertz source is collimated using standard optical components onto the sample material that is induced into channels of a microfluidic periodic structure integrated with a thin film periodic slot grating. The detector assembly with a micro probe is mounted to an XYZ nanopositioner and is scanned over the sample under test. High-resolution piezoelectric positioners with nanometer accuracy and travel ranges up to 1 cm are commercially available and can be used for probe placement and positional control.
In this configuration, the rectangular slots of a periodic structure are concurrently used as channels for the sample material and the materials or molecules of interest can be immobilized on the surface of the film structure or trapped at the slot edges.
In another embodiment, these two functional elements can be separated. Small quantities of biological material are embedded in the nano-size regions of the edges where enhancements of radiation in the THz gap are observed. Very small amount of material would be enough for detection using this approach. The detector probes (antennas) can be scanned in two perpendicular directions across the sample chamber and sample material to improve sensitivity and selectivity of THz sensing or to generate a 2 D THz imaging.
Such application modes provide a new class of devices using bio- or chemical fluidic chips combined with near field THz detectors.
The effect of local near field enhancement of electromagnetic field is used to maximize the coupling of terahertz radiation to both biological and chemical molecules. The new process for coupling provides dramatic improvements in spatial resolution, sensitivity, reliability, and selectivity of terahertz detection systems. The imaging mechanism of the present invention is appertureless, all optical, and utilizes low THz frequency range radiation to achieve a spatial resolution well below the diffraction limit.
This new detection platform can produce a new class of resonant, highly sensitive and selective portable bio and chemical devices for uses in many different applications. By interacting the THz vibration absorption modes from organic or biological molecules with a locally enhanced EM field of terahertz radiation in a sub-micron region, the developed imaging mechanism:
Is capable of sub wavelength spatial resolution, ideally 10 3 orders less than the radiation wavelength. Is an all-optical instrument, with no required mechanical tips or probes to contact testing material. Requires no apertures. Can allow for spectral selectivity. Can test biological monolayers, and molecules in dilute solutions.
The applications of terahertz frequencies for identification and detection uses is virtually almost endless, ranging from military and transportation detection devices to real time drug development monitoring of anti-bacterial or anti-viral drugs.
Some Examples:
New imaging mechanism integrated with a “lab-on-a chip” device for sub-wavelength THz spectroscopic microscope.
Water quality monitoring.
Monitoring Biological Processes
Real time monitoring of drug-bacteria cell wall interaction in drug development.
Rapid tissue testing for skin cancer diagnostics
Portable bio-material structure testing devices.
The research work included sensor modeling and design, fabrication of a beam lead antenna and a diode integrated with a circuit, and demonstrated the successful implementation of the imaging mechanism of the present invention. All elements of a THz detector assembly to measure the electrical field distribution around the periodic slots were modeled and fabricated and the detector assembly was completed and tested.
The periodic slots structure of FIG. 9 , indicated generally as 900 , was made of gold thin film on silicon wafers and quartz using the photolithographic process and electroplating. The key challenge associated with the fabrication of the slot arrays 902 is to obtain a high degree of sharpness at the edges of slots due to the fact that the enhancement of electrical field is in a micron region. The microfabrication processes have been optimized to obtain high sharpness at the edge 1002 of the slots 1006 , as shown in FIG. 10 . The edge extrude of 0.2-0.5 μm has been attained.
The key function of the THz micro-sensor is to detect the electrical field in the vicinities of the slot edges where the enhanced coupling occurs. In other word, the THz micro-sensor system is responsible to detect the near field distribution of radiation transmitted through the biological or other materials of interest that are located around the edges of the slots. Since the electrical field enhancement is only available in a region of several microns, the sub-micron sharp probe (antenna) 1102 of FIG. 11 , is required for the sensing of the transmitted electrical field through biological sample in order to obtain high sensitivity and spatial resolution. Thus, it is crucial to provide an integrated THz sensor detector with high-sensitivity and sub-micron spatial resolution for subwavelength THz spectroscopy.
One example of such a sensor is a miniature sensing device which incorporates a room-temperature detector, Schottky micro-diode 1112 , integrated with a coupling circuit and a nano-probe 1108 , (also referred to as an antenna) mounted on a silicon substrate 1102 , as shown in FIG. 11A . Other types of miniature detectors can be used as well.
The zero biased Schottky diode 1112 , which in this example incorporates GaAs islands, transforms the input THz radiation coupled from the sharp beam lead probe 1108 tip to the output dc voltage. The magnitude of the output dc voltage is proportional to the input power of the THz radiation. In FIG. 11 b , a low pass filter 1120 and the RF choke 1126 , are the components for blocking the high frequency radiation for the measurement of the dc voltage across the diode 1112 . Thin (50 μm) fused quartz material is chosen as the substrate 1102 for the detector circuit to minimize the possible surface mode excitation. The detector assembly chip in this example is 1 mm wide and 1.5 mm long. As illustrated in FIG. 12 the beam lead micro-tip 1200 has a length of about is ˜60 μm long, as indicated by arrow 1204 , has a tip length of about 15 μm as indicated by arrows 1206 , a tip width of about 15 μm as indicated by arrow 1202 , and a tip 1208 of about 0.64 μm. Other types of miniature detectors that produce the same results as the detector set forth above can be used as well.
A sharp coupling device can modify the original electrical field distribution produced by the slots structure. Thus, the size of the coupling device and the distance between the coupling device and the slots has to be designed and optimized in order to obtain the balance between measurement and disturbance of the local electrical field around the periodic slots, while being a physically realizable tip geometry. The local electrical field enhancement at the edge of slot is confirmed by our electrical field simulation work using the commercial full-wave solver. From FIG. 13 it is seen that although the beam lead antenna disturbs the electric field distribution, the enhancement effect near slot edges is preserved.
Another aspect of the research was fabrication and characterization of sample or microfluidic chambers. To apply the local enhancement of THz coupling, the bio- or chemical material can be immobilized on the surface, trapped at slot edges, or scanned across a microfluidic chamber. The materials of interest can be in solid or fluidic form. Microfluidic channels were fabricated using polydimethylsiloxane (PDMS) as the polymeric material onto which channels were micromolded. Inexpensive disposable periodic Lab-on-chip structures can be used for enhanced THz coupling and detection.
The slots can be scanned across the material sample to enhance local coupling and thereby improve the chemical resolution and sensitivity of the detector to THz imaging. The linear array of several integrated THz sensor detectors can be designed and fabricated to provide the capability for a two-dimensional imaging. One of possible solutions for realization a proposed imaging technology is to use a linear detector array of micron/sub-micron size detector elements with a coupling structure, antenna, at each element to probe several slots. Only short distance movement of the detector assembly over the slot width will be required in this case.
FIGS. 14 and 15 demonstrate the existing capabilities to fabricate a Schottky diode or bolometer detector array with the spacing between elements ˜40 μm [27,28]. FIG. 15 illustrates an array section 1500 including low band pass filters 1504 and slot ring antennas 1502 , and an HEB superconducting bridge 1506 .
FIG. 16 shows (not in scale) an example of a detector assembly 1606 combined with a sample or microfluidic channel 1612 (5-50 μm wide, 1 μm deep, 1-2 cm long), with a 10-50 μm transparent substrate, that is, a backing support 1610 to enable handing, is filled with bio-material 1604 . In this embodiment a 2-5 μm Au edge layer 1602 is patterned on the top of channel structure, although other semiconductors as taught herein can be used. A movable stage with an XYZ controller 1608 is placed at one end of the channel 1612 . As can be seen, linear polarized THz radiation 1614 is presented at right angles to the substrate 1610 .
The precise control of the THz sensor position, especially of the sensing probe, has to be implemented in order to enable the sensor to approach near the surface of a sample and to scan along the plane of the periodic structure. Long focused optical components can be utilized for precise location of sensing antennas at the distance of about 1-3 μm from the sampling material. Electric (for example, capacitive) sensors can be used as well.
The disclosed detection system can include variety of miniaturized THz near-field sensors as listed above. Another application of the invention is monitoring changes of dielectric properties of bio-materials in biophysical processes, for example, denaturation of DNA, folding-unfolding of proteins, structural conformational changes of biomolecules in interactions with drags, and monitoring other processes for a broad bio-medical and pharmaceutical research.
FIG. 17 illustrates a detection device 1700 wherein the THz illumination 1701 is applied from the top down. A plate of quartz 1710 has InSb 1712 bonded to the plate 1710 effectively forming slots 1714 . The mid-plate 1720 contains the fluidic cells 1722 with an inlet and outlet. The mid-plate 1720 is adjacent to the quartz bottom plate 1730 that contains a translatable piezo stage with THz detectors. The near field detectors can be less than 0.1 μm from the fluidic cells.
FIGS. 18A and 18B are illustrative arrangements for the microfluidic cells. In FIG. 18A the cell 1800 has an inlet 1802 that is connected to an outlet 1804 by channel 1808 . In FIG. 18B the biomolecules enter the cell at inlet 1 ( 1842 ) and the reagent at inlet 2 ( 1840 ) and are mixed at the joining point 1830 . The biomolecules are moved into the trapping region 1836 where they are exposed to THz radiation 1832 . A THz detector receives the resulting radiation 1834 . The biomolecules then move to the outlet 1838 . The cell can be used for real time monitoring of processes.
FIG. 19 demonstrates the dramatic difference in transmission spectra of a single and double-stranded DNA that can be used in the proposed monitors. FIG. 19 a shows similar possibilities for monitoring conformational change of proteins.
FIG. 20 shows the schematic layout for the experimental system.
The System Composes of
THz source (GHz signal generator 2010 , frequency multiplier 2008 and power supply 2006 for the source);
collimating devices 2012 (an off-axis parabolic mirror 2012 and an hemispheric silicon lens);
horn 2012 ;
periodic slot chip 2014 combined with microfluidic cell and mounted on the planar surface of silicon lens 2024 ;
detector assembly chip 2016 (beam lead probe, transmission line, Schottky diode and detector circuit);
motorized XYZ stage with controller 2022 ;
the dc voltage measurement device (i.e. a lock-in amplifier) 2002 , and
controlling computer 2004 .
The THz radiation required to illuminate the periodic structure is generated by multiplying the low frequency radiation using a frequency multiplier (36 times) as can be obtained from a source such as Virginia Diodes Inc., of Charlottesville Va. System path loss is minimized by using reflectors (rather than lens) as well as an anti-refection coating on the surface of the hemispherical lens. The lens assembly is mounted to a platen. The integrated THz antenna is scanning transmitted beam over the sample material put into a microfluidic channel using precision XYZ positioners.
Some exemplary products and services that various embodiments of the present invention method and system may be utilized for may comprise, but not limited thereto, the following:
Transportation security:
Portable scanners to detect explosive residues or bio hazards on clothing, bags, in vehicles, in trains, metro stations, airports, on board of ships, on bridges, in tunnels.
Public Safety:
Portable scanners to detect explosive residues or bio hazards in public areas, buildings.
Quality of water monitoring.
Military
Compact remote sensors to detect explosives or bio hazards that can be installed as stand alone devices, as well as on buildings, structures, put on unmanned airplanes, unmanned land vehicles.
Light weight battlefield detectors that can be carried by soldiers.
Drug Development:
Detectors for real-time monitoring of drug-bacteria cell wall interaction, for testing the effectiveness of bacteria or virus destruction by drugs under development.
Medicine
Rapid tissue testing, cell testing for skin cancer diagnostics.
Biomaterial Applications
Portable devices for biomaterial structure testing.
The following publications as listed below and throughout this document are hereby incorporated herein by reference in their entirety.
[1] T. Globus, D. Woolard, M. Bykhovskaia, B. Gelmont, L. Werbos, and A. Samuels, Int. J. of High Speed Electron. Syst. 13, 903 (2003). [2] T. Globus, D. Woolard, T. W. Crowe, T. Khromova, B. Gelmont, and J Hesler, J. Phys. D: App. Phys. 39, 3405 (2006). [3] A. Bykhovski, T. Globus, T. Khromova, B. Gelmont, and D. Woolard, Proc. SPIE 6212, 62120H (2006). [4] Proposal submitted to DARPA, Solicitation Number: BAA06-19, “Terahertz characterization for real time control protein conformation.” T. Globus, Pl. Jul. 11, 2006. [5]. R. Parthasarathy, A. Bykhovski, Boris Gelmont, T. Globus, N. Swami, D. Woolard, “Enhanced coupling of subterahertz radiation with semiconductor periodic slot arrays”, Phys. Rev. Lett., 98 (15), 153906 (2007). [6]. B. Gelmont, R. Parthasarathy, T. Globus, A. Bykhovski, and N. Swami, “Terahertz (THz) Electromagnetic Field Enhancement in Periodic Subwavelength Structures”, The 2007 Nanoelectronic Devices for Defense & Security (NANO-DDS) Conference Presentation, Washington D.C., June 2007, submitted to the IEEE Sensors Journal Special Issue. [7]. A. Sommerfeld, Optics. Academic Press Inc., New York, 1954. [8]. M. E. McDonald, A. Alexanian, R. A York, Z. Popovic, and E. N. Grossman, “Spectral Ttransmittance of Lossy Printed Resonant-Grid Terahertz Bandpass Filters”, IEEE Trans. on Microwave Theory and Techniques , vol. 48, pp. 712-718, April 2000. [9 ]. Electromagnetic Theory of Gratings edited by R. Petit, Springer-Verlag, Berlin Heidelberg, 1980. [10]. Sheng, R. S Stepleman, and P. N. Sanda, “Exact eigenfunctions for square-wave gratings: Application to diffraction and surface-plasmon calculations”, Phys. Rev. B, vol. 26, pp. 2907-2916, 1982. [11]. H. E. Went, A. P. Hibbins, J. R. Sambles, C. R. Lawrence, and A. P. Crick, “Selective transmission through very deep zero-order metallic gratings at microwave frequencies”, App. Phys. Lett, vol. 77, pp. 2789-279, 2000. [12]. Q. Cao, and P. Lalanne, “Negative Role of Surface Plasmons in the Transmission of Metallic Gratings with Very Narrow Slits”, Phys. Rev. Lett , vol. 88, pp. 057403-01-04, 2004. [13]. T. W. Ebbesen, H. J. Lezec, H. F. Ghaemi, T. Thio, and P. A. Wolff, “Extraordinary optical transmission through sub-wavelength hole arrays”, Nature , vol. 391, pp. 667-669, 1998. [14]. H. F. Ghaemi, T. Thio, D. E. Grupp, T. W. Ebbesen, and H. J. Lezec, “Surface plasmons enhance optical transmission through subwavelength holes”, Phys. Rev. B , vol. 58, pp. 6779-6782, 1998. [15]. T. Thio, H. F. Ghaemi, H. J. Lezec, P. A. Wolff, and T. W. Ebbesen, “Surface-plasmon-enhanced transmission through hole arrays in Cr films”, J. Opt. Soc. Am B, vol. 16, pp. 1743-1748, 1999. [16] E. Popov, M. Neviere, S. Enoch, and R. Reinisch, “Theory of light transmission through subwavelength hole arrays”, Phys. Rev. B, vol. 62, pp. 16100-16108, 2000. [17]. L. Martin-Moreno, F. J. Garcia-Vidal, H. J. Lezec, K. M. Pellerin, T. Thio, J. B. Pendry, and T. W. Ebbesen, “Theory of Extraordinary Optical Transmission through Subwavelength Hole Arrays”, Phys. Rev. Lett , vol. 86, pp. 1114-1117, 2001. [18]. A. Darmanyan, and A. V. Zayats, “Light tunneling via surface plasmon polariton states and the enhanced transmission of periodically nanostructured metal films”, Phys. Rev. B , vol. 67, pp. 035424-1-7, 2003. [19]. S. H. Chang, and S. K. Gray, “Surface plasmon generation and light transmission by isolated nanoholes and arrays of nanoholes in thin metal films”, Opt. Exp ., vol. 13, pp. 3150-3165, 2005. [20]. H. Cao, and A. Nahata, “Resonantly enhanced transmission of terahertz radiation through a periodic array of subwavelength apertures”, Opt. Exp ., vol. 12, pp. 1004-1010, 2004. [21]. D. Qu, D. Grischkowsky, and W. Zhang, “Terahertz transmission properties of thin, subwavelength metallic hole arrays”, Opt. Lett ., vol. 29, pp. 896-898, 2004. [22]. J. Gomez Rivas, C. Schotsch, P. Haring Bolivar, and H. Kurz, “Enhanced transmission of THz radiation through subwavelength holes”, Phys. Rev. B , vol. 68, pp. 201306-1-4, 2003. [23]. J. Gomez Rivas, C. Janke, P. Haring Bolivar, and H. Kurz, “Transmission of THz radiation through InSb gratings of subwavelength apertures”, Opt. Exp ., vol. 13, pp. 847-859, 2005. [24]. J. W. Lee, M. A. Seo, D. J. Park, S. C. Jeoung, Q. H. Park, Ch. Lienau, and D. S. Kim, “Terahertz transparency at Fabry-Perot resonances of periodic slit arrays in a metal plate: experiment and theory”, Opt. Exp ., vol. 14, pp. 12637-12643, 2006. [25]. E. Popov, S. Enoch, G. Tayeb, M. Neviere, B. Gralak, and N. Bonod, “Enhanced transmission due to non-plasmon resonances in one- and two-dimensional gratings”, App. Opt ., vol. 43, pp. 999-1008, 2004. [26]. VIBRATESS, LLC. ARO SBIR Phase I Final Report “Spectroscopic Imaging Technology for THz Biosensor Integrated with a Lab-on-Chip Platform”, Contract #: W911 NF-07-C-0055, December-2007. [27]. Interim Report for the UVA-Keck Project “Terahertz Spectroscopy of Biological Molecules:Developing THz prototype spectrometer for bio-medical research” for the period of January 2006-December 2007. [28]. D. S. Kurtz, J. L. Hesler, J. B. Hacker, T. W. Crowe, D. B. Rutledge, and R. M. Weikle, II, “Submillimeter Wave Sideband Generation using a Planar Diode Array”; IEEE MTT-S Internat. MicrowaveSymposium Digest, vol. 3, pp. 1903-1906, Baltimore, Md., June 1998. [29]. L. Liu, H. Xu, Q. Xiao, A. W. Lichtenberger, and R. M. Weikle, II, “Performance at 585 GHz of a Slot RingAntenna Coupled Niobium HEB Mixer Element for Imaging Applications”; Proceedings of the Joint 30th International Conf. On Infrared And Millimeter Waves and the 13th International Conference On Terahertz Electronics, Williamsburg, Va., pp. 265-266, September 2005. [30]. T. Globus, A. Bykhovski, B. Gelmont, R. M. Weikle, J. O. Jensen, W. R. Loerop, “Enhanced Spectroscopy Signatures of Biological Molecules and Organisms in the Low THz Range”. The 2007 Scientific Conference on Chemical & Biological Defense Research, Timonium, Md., 13-15 Nov. 2007. [31]. T. Globus, T. Khromova, R. Lobo, D. Woolard, N. Swami, and E. Fernandez, “THz characterization of lysozyme at different conformations”, Proceedings of SPIE, “Terahertz for Military and Security Applications”, v. 5790, p. 54-65, Defense and Security Symposium, Orlando, Fla., 28-29 Mar., 2005. 32. J. A. Porto, F. J. Garcia-Vidal, and J. B. Pendry, “Transmission Resonances on Metallic Gratings with Very Narrow Slits”, Phys. Rev. Lett, vol. 83, pp. 2845-2848, 1999. 33. F. J. Garcia-Vidal, and L. Martin-Moreno, “Transmission and focusing of light in one-dimensional periodically nanostructured metals”, Phys. Rev. B, vol. 66, pp. 155412-1-10, 2002. 34. G. B. Arfken, and H. J. Weber, Mathematical Methods for Physicists Academic Press, San Diego, Calif., 4 th ed, Chaps. 14, p. 836, 1995. 35. A. Wirgin, T. Lopez-Rios, “Can surface-enhanced Raman scattering be caused by waveguide resonances”, Opt. Commun., vol. 48, pp. 416-420, 1984.
It should be appreciated that aspects of various embodiments of the present invention method and system may be implemented with the method and system disclosed in the following, the disclosures of which are incorporated herein by reference, as though recited in full:
U.S. Pat. No. 6,977,767 Plasmonic nanophotonics methods, materials, and apparatuses; U.S. Pat. No. 7,170,085 Frequency selective terahertz radiation detector; and U.S. Pat. Application Publication No. 2005/0230705 A1 to Taylor, Geoff W.
|
A method and apparatus for enhanced THz radiation coupling to molecules, includes the steps of depositing a test material near the discontinuity edges of a slotted member, and enhancing the THz radiation by transmitting THz radiation through the slots. The molecules of the test material are illuminated by the enhanced THz radiation that has been transmitted through the slots, thereby producing an increased coupling of EM radiation in the THz spectral range to said material. The molecules can be bio-molecules, explosive materials, or species of organisms. The slotted member can be a semiconductor film, a metallic film, in particular InSb, or layers thereof. THz detectors sense near field THz radiation that has been transmitted through said slots and the test material.
| 6
|
[0001] This application claims the benefit of the Provisional application No. 60/323,824 filed Sep. 21, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to fire suppression systems, in general, and more specifically to a fire suppression system and a plurality of aerosol generators for dispensing a fire suppressant material, that is substantially void of an ozone depleting material, promptly into the affected storage area, and a solid propellant container preferably for use therein.
[0003] It is of paramount importance to detect a fire in an unattended, storage area or enclosed storage compartment at an early stage of progression so that it may be suppressed before spreading to other compartments or areas adjacent or in close proximity to the affected storage area or compartment. This detection and suppression of fires becomes even more critical when the storage compartment is located in a vehicle that is operated in an environment isolated from conventional fire fighting personnel and equipment, like a cargo hold of an aircraft, for example. Current aircraft fire suppressant systems include a gaseous material, like Halon® 1301, that is compressed in one or more containers at central locations on the aircraft and distributed through piping to the various cargo holds in the aircraft. When a fire is detected in a cargo hold, an appropriate valve or valves in the piping system is or are activated to release the Halon fire suppressant material into the cargo hold in which fire was detected. The released Halon material is intended to blanket or flood the cargo hold and put out the fire. Heretofore, this has been considered an adequate system.
[0004] However, the Halon material of the current systems contains an ozone depleting material which may leak from the storage compartment and into the environment upon being activated to suppress a fire. Most nations of the world prefer banning this material to avoid its harmful effects on the environment. Also, Halon produces toxic products when activated by flame. Accordingly, there is a strong desire to find an alternate material to Halon and a suitable fire suppressant system for dispensing it as needed.
[0005] For cargo holds of aircraft, a fire in the hold indication requires not only a dispensing of the fire suppressant material, but also a prompt landing of the aircraft at the nearest airport. The aircraft will then remain out of service until clean up is completed and the aircraft is certified to fly again. This unscheduled servicing of the aircraft is very costly to the airlines and inconveniences the passengers thereof. The problem is that some activations of the fire suppressant system result from false alarms of the fire detection system, i.e. caused by a perceived fire condition that is something other than an actual fire. Thus, the costs and inconveniences incurred as a result of the dispensing of the fire suppressant material under false alarm conditions could have been avoided with a more accurate and reliable fire detection system.
[0006] The present invention intends to overcome the drawbacks of the current fire detection and suppressant systems and to offer a system which detects a fire accurately and reliably, generates a fire indication and provides for a quick dispensing of a fire suppressant, which does not include substantially an ozone depleting material, focused within the storage compartment in which the fire is detected.
SUMMARY OF THE INVENTION
[0007] In accordance with one aspect of the present invention, a solid propellant container for exhausting a fire suppressant aerosol comprises: a housing having at least one open side and including a multiplicity of orifices for exhausting the fire suppressant aerosol; a solid propellant disposed inside of the housing; at least one cover mounted to the housing to seal correspondingly the at least one open side thereof; an ignition material coupled to the solid propellant for igniting the solid propellant to produce the fire suppressant aerosol; and at least one baffle integral to the housing to capture non-usable effluent.
[0008] In accordance with another aspect of the present invention, a fire suppression system for a substantially enclosed area comprises: a plurality of solid propellant aerosol generators disposed about the enclosed area for exhausting a fire suppressant aerosol that is substantially void of an ozone depleting material into the enclosed area, each aerosol generator including an ignition element for igniting the solid propellant thereof; and a fire control unit, each ignition element of the aerosol generators being coupled to the fire control unit which is operative to ignite the solid propellant of at least one aerosol generator utilizing the ignition element thereof to exhaust fire suppressant aerosol into the enclosed area.
[0009] In accordance with yet another aspect of the present invention, a fire suppression system for a plurality of substantially enclosed areas comprises: a plurality of solid propellant aerosol generators disposed about each enclosed area of the plurality for exhausting a fire suppressant aerosol that is substantially void of an ozone depleting material into at least one enclosed area, each aerosol generator including an ignition element for igniting the solid propellant thereof; and a fire control unit for each enclosed area of the plurality, each fire control unit being coupled to the ignition elements of the aerosol generators of the corresponding enclosed area and is operative to ignite the solid propellant of at least one aerosol generator of the corresponding enclosed area utilizing the ignition element thereof to exhaust fire suppressant aerosol into the corresponding enclosed area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a sketch of a fire detection and suppression system for use in a storage compartment suitable for embodying the principles of the present invention.
[0011] [0011]FIGS. 2 and 3 are top and bottom isometric views of an exemplary aerosol generator assembly suitable for use in the embodiment of FIG. 1.
[0012] [0012]FIGS. 4 and 5 are bottom and top isometric views of an exemplary aerosol generator assembly compartment mounting suitable for use in the embodiment of FIG. 1.
[0013] [0013]FIG. 6 is a block diagram schematic of an exemplary fire detector unit suitable for use in the embodiment of FIG. 1.
[0014] [0014]FIG. 7 is a block diagram schematic of an exemplary imager unit suitable for use in the embodiment of FIG. 1.
[0015] [0015]FIG. 8 is a block diagram schematic of an overall fire detection system suitable for use in the application of an aircraft.
[0016] [0016]FIG. 9 is a block diagram schematic of an exemplary fire suppression system suitable for use in the application of an aircraft.
[0017] [0017]FIG. 10 is an isometric view of an exemplary aerosol generator illustrating exhaust ports thereof suitable for use in the embodiment of FIG. 1.
[0018] [0018]FIG. 11 is an expanded view assembly illustration of the aerosol generator of FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
[0019] A sketch of a fire detection and suppression system for use at a storage area or compartment suitable for embodying the principles of the present invention is shown in cross-sectional view in FIG. 1. Referring to FIG. 1, a storage compartment 10 which may be a cargo hold, bay or compartment of an aircraft, for example, is divided into a plurality of detection zones or cavities 12 , 14 and 16 as delineated by dashed lines 18 and 20 . It is understood that an aircraft may have more than one cargo compartment and the embodiment depicted in FIG. 1 is merely exemplary of each such compartment. It is intended that each of the cargo compartments 10 include one or more aerosol generators for generating a fire suppressant material. In the present embodiment, a plurality of hermetically sealed, aerosol generators depicted by blocks 22 and 24 , which may be solid propellant in ultra-low pressure aerosol generators, for example, are disposed at a ceiling portion 26 of the cargo compartment 10 above vented openings 28 and 30 as will be described in greater detail herein below.
[0020] In the present embodiment, the propellant of the plurality of aerosol generators 22 and 24 produces upon ignition an aerosol that is principally potassium bromide. The gaseous products are principally water, carbon dioxide and nitrogen. For aircraft applications, each of the aerosol generators 22 and 24 has a large orifice instead of the conventional sonic nozzles. As a result, the internal pressure during the discharge period is approximately 10 psig. During storage and normal flight the pressure inside the generator is the normal change in pressure that occurs in any hermetically sealed container that is subjected to changes in ambient conditions.
[0021] Test results of aerosol generators of the solid propellant type are shown in Table 1 below. The concept that is used for Extended Twin Operations (ETOPS) up to 540 minutes is to expend a series of aerosol generators of 3½ lbs each for each 2000 cubic feet. This would create the functional equivalent of an 8% Halon 1301 system. At 30 minutes, the concentration would be reduced to the functional equivalent of 4½% Halon 1301. At that point, another aerosol generator may be expended every 30 minutes. Different quantities of aerosol generators may be used based upon the size of the cargo bay. It is understood that the size and number of the generators for a cargo compartment may be modified based on the size of the compartment and the specific application.
TABLE 1 Requirements Of Present Embodiment vs. Halon in 2000 Cubic Feet Suppression Design 30 Minute Threshold Minimum initial Release Fuel Fire 3.5 pounds 4.6 pounds 9.2 pounds Bulk Load Test <2.5 pounds <2.5 pounds <2.5 pounds Container Test 3.5 pounds 4.6 pounds 9.2 pounds Aerosol Can 4.6 pounds Test Halon 25 pounds = 33 pounds = 66 pounds = requirement 3% of Halon 4% of Halon 8% of Halon
[0022] An exemplary hermetically sealed, aerosol generator 22 , 24 with multiple outlets 25 for use in the present embodiment is shown in the isometric sketch of FIG. 10. The aerosol generator 22 , 24 may employ the same or similar initiator that has been used in the US Air Force's ejection seats for many years which has a history of both reliability and safety. Its ignition element consists of two independent 1-watt/1-ohm bridge wires or squibs, for example. The aerosol generator 22 , 24 for use in the present embodiment will be described in greater detail herein below in connection with the break away assembly illustration of FIG. 11.
[0023] In the top view of FIG. 2 and bottom view of FIG. 3, the sealed container 22 , 24 is shown mounted to a base 32 by supporting straps 34 and 36 , for example. The bottom of the base 32 which has a plurality of openings 38 and 40 may be mounted to the ceiling 26 over vented portions 28 and 30 thereof to permit passage of the aerosol and gaseous fire suppressant products released or exhausted from the aerosol generator via outlets 25 out through the vents 28 and 30 and into the compartment 10 .
[0024] The present example employs four aerosol generators located in two places 22 , 24 for compartment 10 which are shown in bottom view in FIG. 4 and top view in FIG. 5. As shown in FIGS. 4 and 5, in the present embodiment, each of the four aerosol generators 42 , 44 , 46 and 48 is installed with its base over a respectively corresponding vented portion 50 , 52 , 54 , 56 of the ceiling 26 . Accordingly, when initiated, each of the aerosol generators will generate and release its aerosol and gaseous fire suppressant products through the openings in its respective base and vented portion of the ceiling into the compartment 10 .
[0025] With the present embodiment, the attainment of 240 or 540 minutes or longer of fire suppressant discharge is a function of how many aerosol generators are used for a compartment. It is expected that the suppression level will be reached in an empty compartment in less than 10 seconds, for example. This time may be reduced in a filled compartment. Aerosol tests demonstrated that the fire suppressant generated by the aerosol generators is effective for fuel/air explosives also. In addition, the use of independent aerosol generator systems for each cargo compartment further improved the system's effectiveness. For a more detailed description of solid propellant aerosol generators of the type contemplated for the present embodiment, reference is made to the U.S. Pat. No. 5,861,106, issued Jan. 19, 1999, and entitled “Compositions and Methods For Suppressing Flame” which is incorporated by reference herein. This patent is assigned to Universal Propulsion Company, Inc. which is the same assignee and/or a wholly-owned subsidiary of the parent company of the assignee of the instant application. A divisional application of the referenced '106 patent was later issued as U.S. Pat. No. 6,019,177 on Feb. 1, 2000 having the same ownership as its parent '106 patent.
[0026] Referring back to FIG. 1, as explained above, each cargo compartment 10 may be broken into a plurality of detection zones 12 , 14 and 16 . The number of zones in each cargo compartment will be determined after sufficient testing and analysis in order to comply with the application requirements, like a one minute response time, for example. The present embodiment includes multiple fire detectors distributed throughout each cargo compartment 10 with each fire detector including a variety of fire detection sensors. For example, there may be two fire detectors installed in each zone 12 , 14 and 16 in a dual-loop system. The two fire detectors in each zone may be mounted next to each other, inside pans located above the cargo compartment ceiling 26 , like fire detectors 60 a and 60 b for zone 12 , fire detectors 62 a and 62 b for zone 14 and 64 a and 64 b for zone 16 , for example. In the present embodiment, each of the fire detectors 60 a , 60 b , 62 a , 62 b , 64 a and 64 b may contain three different fire detection sensors: a smoke detector, a carbon monoxide (CO) gas detector, and hydrogen (H 2 ) gas detector as will be described in greater detail herein below. While in the present application a specific combination of fire detection sensors is being used in a fire detector, it is understood that in other applications or storage areas, different combinations of sensors may be used just as well.
[0027] In addition, at least one IR imager may be disposed at each cargo compartment 10 for fire detection confirmation, but it is understood that in some applications imagers may not be needed. In the present embodiment, two IR imagers 66 a and 66 b may be mounted in opposite top corners of the compartment 10 , preferably behind a protective shield, in the dual-loop system. This mounting location will keep each imager out of the actual compartment and free from damage. Each imager 66 a and 66 b may include a wide-angle lens so that when aimed towards the center or bottom center of the compartment 10 , for example, the angle of acceptance of the combination of two imagers will permit a clear view of the entire cargo compartment including across the ceiling and down the side walls adjacent the imager mounting. It is intended for the combination of imagers to detect any hot cargo along the top of the compartment, heat rise from cargo located below the top, and heat reflections from the compartment walls. Each fire detector 60 a , 60 b , 62 a , 62 b , 64 a and 64 b and IR imagers 66 a and 66 b will include self-contained electronics for determining independently whether or not it considers a fire to be present and generates a signal indicative thereof as will be described in greater detail herein below.
[0028] All fire detectors and IR imagers of each cargo compartment 10 may be connected in a dual-loop system via a controller area network (CAN) bus 70 to cargo fire detection control unit (CFDCU) as will be described in more detail in connection with the block diagram schematic of FIG. 8. The location of the CFDCU may be based on the particular application or aircraft, for example. A suitable location for mounting the CFDCU in an aircraft is at the main avionics bay equipment rack.
[0029] A block diagram schematic of an exemplary fire detector unit suitable for use in the present embodiment is shown in FIG. 6. Referring to FIG. 6, all of the sensors used for fire detection are disposed in a detection chamber 72 which includes a smoke detector 74 , a carbon monoxide (CO) sensor 76 , and a hydrogen (H 2 ) sensor 78 , for example. The smoke detector 74 may be a photoelectric device that has been and is currently being used extensively in such applications as aircraft cargo bays, and laboratory, cabin, and electronic bays, for example. The smoke detector 74 incorporates several design features which greatly improves system operational reliability and performance, like free convection design which maximizes natural flow of the smoke through the detection chamber, computer designed detector labyrinth which minimizes effects of external and reflected light, chamber screen which prevents large particles from entering the detector labyrinth, use of solid state optical components which minimizes size, weight, and power consumption while increasing reliability and operational life, provides accurate and stable performance over years of operation, and offers an immunity to shock and vibration, and isolated electronics which complete environmental isolation of the detection electronics from the contaminated smoke detection chamber.
[0030] More specifically, in the smoke detector, a light emitting diode (LED) 80 and photoelectric sensor (photo diode) 82 are mounted in an optical block within the labyrinth such that the sensor 82 receives very little light normally. The labyrinth surfaces may be computer designed such that very little light from the LED 80 is reflected onto the sensor, even when the surfaces are coated with particles and contamination build-up. The LED 80 may be driven by an oscillating signal 86 that is synchronized with a photodiode detection signal 88 generated by the photodiode 82 in order to maximize both LED emission levels and detection and/or noise rejection. The smoke detector 74 may also include built-in test (BIT), like another LED 84 which is used as a test light source. The test LED 84 may be driven by a test signal 90 that may be also synchronized with the photodiode detection signal 88 generated by the photodiode 82 in order to better effect a test of the proper operation of the smoke detector 74 .
[0031] Chemical sensors 76 and 78 may be each integrated on and/or in a respective semiconductor chip of the micro-electromechanical system (MEMS)-based variety for monitoring and detecting gases which are the by-products of combustion, like CO and H 2 , for example. The semiconductor chips of the chemical sensors 76 and 78 may be each mounted in a respective container, like a TO-8 can, for example, which are disposed within the smoke detection chamber 72 . The TO-8 cans include a screened top surface to allow gases in the environment to enter the can and come in contact with the semiconductor chip which measures the CO or H 2 content in the environment.
[0032] More specifically, in the present embodiment, the semiconductor chip of the CO sensor 76 uses a multilayer MEMS structure. A glass layer for thermal isolation is printed between a ruthenium oxide (RuO 2 ) heater and an alumina substrate. A pair of gold electrodes for the heater is formed on a thermal insulator. A tin oxide (SnO 2 ) gas sensing layer is printed on an electrical insulation layer which covers the heater. A pair of gold electrodes for measuring sensor resistance or conductivity is formed on the electrical insulator for connecting to the leads of the TO-8 can. Activated charcoal is included in the area between the internal and external covers of the TO-8 can to reduce the effect of noise gases. In the presence of CO, the conductivity of sensor 76 increases depending on the gas concentration in the environment. The CO sensor 76 generates a signal 92 which is representative of the CO content in the environment detected thereby. It may also include BIT for the testing of proper operation thereof. This type of CO sensor displayed good selectivity to carbon monoxide.
[0033] In addition, the semiconductor chip of the H 2 sensor 78 in the present embodiment comprises a tin dioxide (SnO 2 ) semiconductor that has low conductivity in clean air. In the presence of H 2 , the sensor's conductivity increases depending on the gas concentration in the air. The H 2 sensor 78 generates a signal 94 which is representative of the H 2 content in the environment detected thereby. It may also include BIT for the testing of proper operation thereof. Integral heaters and temperature sensors within both the CO and H 2 sensors, 76 and 78 , respectively, stabilize their performance over the operating temperature and humidity ranges and permit self-testing thereof. For a more detailed description of such MEMS-based chemical sensors reference is made to the co-pending patent application bearing Ser. No. 09/940,408, filed on Aug. 27, 2001 and entitled “A Method of Self-Testing A Semiconductor Chemical Gas Sensor Including An Embedded Temperature Sensor” which is incorporated by reference herein. This application is assigned to Rosemount Aerospace Inc. which is the same assignee and/or a wholly-owned subsidiary of the parent company of the assignee of the instant application.
[0034] Each fire detector also includes fire detector electronics 100 which may comprise solid-state components to increase reliability, and reduce power consumption, size and weight. The heart of the electronics section 100 for the present embodiment is a single-chip, highly-integrated conventional 8-bit microcontroller 102 , for example, and includes a CAN bus controller 104 , a programmable read only memory (ROM), a random access memory (RAM), multiple timers (all not shown), multi-channel analog-to-digital converter (ADC) 106 , and serial and parallel 1 / 0 ports (also not shown).The three sensor signals (smoke 88 , CO 92 , and H 2 94 ) may be amplified by amplifiers 108 , 110 and 112 , respectively, and fed into inputs of the microcontroller's ADC 106 . Programmed software routines of the microcontroller 102 will control the selection/sampling, digitization and storage of the amplified signals 88 , 92 and 94 and may compensate each signal for temperature effects and compare each signal to a predetermined alarm detection threshold. In the present embodiment, an alarm condition is determined to be present by the programmed software routine if all three sensor signals are above their respective detection threshold. A signal representative of this alarm condition is transmitted along with a digitally coded fire detection source identification tag to the CFDCU over the CAN bus 70 using the CAN controller 104 and a CAN transceiver 114 .
[0035] Using preprogrammed software routines, the microcontroller 102 may perform the following primary control functions for the fire detector: monitoring the smoke detector photo diode signal 88 , which varies with smoke concentration; monitoring the CO and H 2 sensor conductivity signals 92 and 94 , which varies with their respective gas concentration; identifying a fire alarm condition, based on the monitored sensor signals; receiving and transmitting signals over the CAN bus 70 via controller 104 and transceiver 114 ; generating discrete ALARM and FAULT output signals 130 and 132 via gate circuits 134 and 36 , respectively; monitoring the discrete TEST input signal 124 via gate 138 ; performing built-in-test functions as will be described in greater detail herebelow; and generating supply voltages from a VDC power input via power supply circuit 122 .
[0036] In addition, the microcontroller 102 communicates with a non-volatile memory 116 which may be a serial EEPROM (electrically erasable programmable read only memory), for example, that stores predetermined data like sensor calibration data and maintenance data, and data received from the CAN bus, for example. The microcontroller 102 also may have a serial output data bus 118 that is used for maintenance purposes. This bus 118 is accessible when the detector is under maintenance and is not intended to be used during normal field operation. It may be used to monitor system performance and read detector failure history for troubleshooting purposes, for example. All inputs and outputs to the fire detector are filtered and transient protected to make the detector immune to noise, radio frequency (RF) fields, electrostatic discharge (ESD), power supply transients, and lightning. In addition, the filtering minimizes RF energy emissions.
[0037] Each fire detector may have BIT capabilities to improve field maintainability. The built-in-test will perform a complete checkout of the detector operation to insure that it detects failures to a minimum confidence level, like 95%, for example. In the present embodiment, each fire detector may perform three types of BIT: power-up, continuous, and initiated. Power-up BIT will be performed once at power-up and will typically comprise the following tests: memory test, watchdog circuit verification, microcontroller operation test (including analog-to-digital converter operation), LED and photo diode operation of the smoke detector 74 , smoke detector threshold verification, proper operation of the chemical sensors 76 and 78 , and interface verification of the CAN bus 70 . Continuous BIT testing may be performed on a continuous basis and will typically comprise the following tests: LED operation, Watchdog and Power supply ( 122 ) voltage monitor using the electronics of block 120 , and sensor input range reasonableness. Initiated BIT testing may be initiated and performed when directed by a discrete TEST Detector input signal 124 or by a CAN bus command received by the CAN transceiver 114 and CAN controller 104 and will typically perform the same tests as Power-up BIT.
[0038] A block diagram schematic of an exemplary IR imager suitable for use in the fire detection system of the present embodiment is shown in FIG. 7. Referring to FIG. 7, each imager is based on infrared focal plane array technology. A focal plane infrared imaging array 140 detects optical wavelengths in the far infrared region, like on the order of 8-12 microns, for example. Thermal imaging is done at around 8-12 microns since room temperature objects emit radiation in these wavelengths. The exact field-of-view of a wide-angle, fixed-focus lens of the IR imager will be optimized based on the imager's mounting location as described in connection with the embodiment of FIG. 1. Each imager 66 a and 66 b is connected to and controlled by the CAN bus 70 . Each imager may output a video signal 142 to the aircraft cockpit in the standard NTSC format. Similar to the fire detectors, the imagers may operate in both “Remote Mode” and “Autonomous Mode”, as commanded by the CAN bus 70 .
[0039] The imager's infrared focal plane array (FPA) 140 may be an uncooled microbolometer with 320 by 240 pixel resolution, for example, and may have an integral temperature sensor and thermoelectric temperature control. Each imager may include a conventional digital signal processor (DSP) 144 for use in real-time, digital signal image processing. A field programmable gate array (FPGA) 146 may be programmed with logic to control imager components and interfaces to the aircraft, including the FPA 140 , a temperature controller, analog-to-digital converters, memory, and video encoder 148 . Similar to the fire detectors, the FPGA 146 of the imagers may accept a discrete test input signal 150 and output both an alarm signal 152 and a fault signal 154 via circuits 153 and 155 , respectively. The DSP 144 is preprogrammed with software routines and algorithms to perform the video image processing and to interface with the CAN bus via a CAN bus controller and transceiver 156 .
[0040] The FPGA 146 may be programmed to command the FPA 140 to read an image frame and digitize and store in a RAM 158 the IR information or temperature of each FPA image picture element or pixel. The FPGA 146 may also be programmed to notify the DSP 144 via signal lines 160 when a complete image frame is captured. The DSP 144 is preprogrammed to read the pixel information of each new image frame from the RAM 158 . The DSP 144 is also programmed with fire detection algorithms to process the pixel information of each frame to look for indications of flame growth, hotspots, and flicker. These algorithms include predetermined criteria through which to measure such indications over time to detect a fire condition. When a fire condition is detected, the imager will output over the CAN bus an alarm signal along with a digitally coded source tag and the discrete alarm output 152 . The algorithms for image signal processing may compensate for environmental concerns such as vibration (camera movement), temperature variation, altitude, and fogging, for example. Also, brightness and contrast of the images generated by the FPA 140 may be controller by a controller 162 prior to the image being stored in the RAM 158 .
[0041] In addition, the imager may have BIT capabilities similar to the fire detectors to improve field maintainability. The built-in-tests of the imager may perform a complete checkout of its operations to insure that it detects failures to a minimum confidence level, like around 95%, for example. Each imager 66 a and 66 b may perform three types of BIT: power-up, continuous, and initiated. Power-up BIT may be performed once at power-up and will typically consist of the following: memory test, watchdog circuit and power supply ( 164 ) voltage monitor verification via block 166 , DSP operation test, analog-to-digital converter operation test, FPA operation test, and CAN bus interface verification, for example. Continuous BIT may be performed on a continuous basis and will typically consist of the following tests: watchdog, power supply voltage monitor, and input signal range reasonableness. Initiated BIT may be performed when directed by the discrete TEST Detector input signal 150 or by a CAN bus command and will typically perform the same tests as Power-up BIT. Also, upon power up, the FPGA 146 may be programmed from a boot PROM 170 and the DSP may be programmed from a boot EEPROM 172 , for example.
[0042] A block diagram schematic of an exemplary overall fire detection system for use in the present embodiment is shown in FIG. 8. In the example of FIG. 8, the application includes three cargo compartments, namely: a forward or FWD cargo compartment, and AFT cargo compartment, and a BULK cargo compartment. As described above, each of these compartments are divided into a plurality of n sensor zones or cavities #1, #2, . . . , #n and in each cavity there are disposed a pair of fire detectors F/D A and F/D B. Each of the compartments also include two IR imagers A and B disposed in opposite corners of the ceilings thereof to view the overall space of the compartment in each case. Alarm condition signals generated by the fire detectors and IR imagers of the various compartments are transmitted to the CFDCU over a dual loop bus, CAN bus A and CAN bus B. In addition, IR video signals from the IR imagers are conducted over individual signal lines to a video selection switch of the CFDCU which selects one of the IR video signals for display on a cockpit video display.
[0043] In the present embodiment, the CFDCU may contain two identical, isolated alarm detection channels A and B. Each channel A and B will independently analyze the inputs from the fire Detectors and IR imagers of each cargo compartment FWD, AFT and BULK received from both buses CAN bus A and CAN bus B and determine a true fire alarm and compartment source location thereof. A “true” fire condition may be detected by all types of detectors of a compartment, therefore, a fire alarm condition will only be generated if both: (1) the smoke and/or chemical sensors detect the presence of a fire, and (2) the IR imager confirms the condition or vice versa. If only one sensor detects fire, the alarm will not be activated. This AND-type logic will minimize false alarms. This alarm condition information may be sent to a cabin intercommunication data system (CIDC) over data buses, CIDS bus A and CIDS bus B and to other locations based on the particular application. Besides the CAN bus interface, each fire detector and IR imager will have discrete Alarm and Fault outputs, and a discrete Test input as described herein above in connection with the embodiments of FIGS. 6 and 7. As required, each component may operate in either a “Remote Mode” or “Autonomous Mode”.
[0044] As shown in the block diagram schematic embodiment of FIG. 8, the Cargo Fire Detection Control Unit (CFDCU) interfaces with all cargo fire detection and suppression apparatus on an aircraft, including the fire detectors and IR imagers of each compartment, the Cockpit Video Display, and the CIDS. It will be shown later in connection with the embodiment of FIG. 9 that the CFDCU also interfaces with the fire suppression aerosol generator canisters, and a Cockpit Fire Suppression Switch Panel. Accordingly, the CFDCU provides all system logic and test/fault isolation capabilities. It processes the fire detector and IR Imager signals input thereto to determine a fire condition and provides fire indication to the cockpit based on embedded logic. Test functions provide an indication of the operational status of each individual fire detector and IR imager to the cockpit and aircraft maintenance systems.
[0045] More specifically, the CFDCU incorporates two identical channels that are physically and electrically isolated from each other. In the present embodiment, each channel A and B is powered by separate power supplies. Each channel contains the necessary circuitry for processing Alarm and Fault signals from each fire detector and IR imager of the storage compartments of the aircraft. Partitioning is such that all fire detectors and IR imagers in both loops A and B of the system interface to both channels via dual CAN busses to achieve the dual loop functionality and full redundancy for optimum dispatch reliability. The CFDCU acts as the bus controller for the two CAN busses that interface with the fire detectors and IR imagers. Upon determining a fire indication in the same zone of a compartment by both loops A and B, the CFDCU sends signals to the CIDS over the data buses, for eventual transmission to the cockpit that a fire condition is detected. The CFDCU may also control the video selector switch to send an IR video image of the affected cargo compartment to the cockpit video display to allow the compartment to be viewed by the flight crew.
[0046] A block diagram schematic of an exemplary overall fire suppression system suitable for use in the present embodiment is shown in FIG. 9. As shown in FIG. 9, Squib fire controllers in the CFDCU also monitor and control the operation of the fire suppression canisters, #1, #2, . . . #n in the various compartments of the aircraft through use of squib activation signals Squib # 1 -A, Squib # 1 -B, . . . , Squib #n-A and Squib #n-B, respectively. Upon receipt of a discrete input from a fire suppression discharge switch on the Cockpit Fire Suppression Switch Panel, the respective squib fire controller fires the initiater in the suppressant canisters, as required. Verification that the initiaters have fired is sent to the cockpit via the CIDS as shown in FIG. 8. The CFDCU may include BIT capabilities to improve field maintainability. These capabilities may include the performance of a complete checkout of the operation of CFDCU to insure that it detects failures to a minimum confidence level of on the order of 95%, for example.
[0047] More specifically. the CFDCU may perform three types of BIT: power-up, continuous, and initiated. Power-up BIT will be performed once at power-up and will typically consist of the following tests: memory test, watchdog circuit verification, microcontroller operation test, fire detector operation, IR imager operation, fire suppressant canister operation, and CAN bus interface verification, for example. Continuous BIT may be performed on a continuous basis and will typically consist of the following tests: watchdog and power supply voltage monitor, and input signal range reasonableness. Initiated BIT may be performed when directed by a discrete TEST Detector input or by a bus command and will typically perform the same tests as Power-up BIT.
[0048] The exemplary aerosol generators 22 , 24 of the present embodiment will now be described in greater detail in connection with the break away assembly illustration of FIG. 11. The assembly is small enough to mount in unusable spaces in the storage compartment, e.g. cargo hold of an aircraft, and provides an ignition source for the propellant and a structure for dispensing hot aerosol while protecting the adjoining mounting structure of the aircraft, for example, from the hot aerosol. A modular assembly of the aerosol generator supports and protects the fire suppressant propellant during shipping, handling and use by a tubular housing 180 . The modular design also allows the assembly to be used on various sized and shaped compartment or cargo holds by choosing the number of assemblies for each size. This assembly may be mountable within the space between the ceiling of the cargo hold and the floor of the cabin compartment as described in connection with the embodiment of FIG. 1. In the assembly, the propellant may be supported by sheet metal baffles that capture non-usable effluent and force the hot aerosol to flow through the assembly allowing them to cool before being directed into the cargo hold through several exhaust orifices or ports 25 . These ports 25 are closed by a hermetic seal, which provides the dual purpose of protecting the propellant from the environment as well as the environment from the propellant. An integral igniter is included in the assembly, which meets a 1-watt, 1-amp no-fire requirement.
[0049] Referring to FIG. 11, more specifically, the assembly comprises a substantially square tube or housing 180 which may have dimensions of approximately 19″ in length and 4″ by 4″ square, for example. The tube 180 supports the rest of the assembly. Several holes are stamped in one wall of the tube or housing 180 to provide mounting for mating parts and ports 25 that are used to direct the fire suppressant aerosol into the cargo hold. Two extruded propellants 182 which may be approximately 3⅓ pounds, for example, are mounted flat to surfaces of two sheet metal baffles 184 , respectively. The baffles 184 are in turn mounted vertically within the square aerosol generator such that a gap between the top of the baffles 184 and the inside of the tube 180 exists to allow the hot aerosol to flow over the baffles 184 and out the ports 25 in the tube. Two additional baffles 186 cover the sides of the tubular housing 180 . The baffles also capture non-useful effluent. One side of the assembly is closed with a snap-on cap 187 which has a port 188 to secure a through bulkhead electrical connector 190 . The other side of the assembly is also closed with another snap-on end cap 192 . Inside the assembly attached to a face of each of the propellants 182 is a strip of ignition material that is ignited by an igniter. The electrical leads of the igniter are connected to the through bulkhead electrical connector in order to provide the ignition current to the igniter.
[0050] While the present invention has been described herein above in connection with a storage compartment of an aircraft, there is no intended limitation thereof to such an application. In fact, the present invention and all aspects thereof could be used in many different applications, storage areas and compartments without deviating from the broad principles thereof. Accordingly, the present invention should not be limited in any way, shape or form to any specific embodiment or application, but rather construed in breadth and broad scope in accordance with the recitation of the claims appended hereto.
|
A fire suppression system for a substantially enclosed area comprises: a plurality of solid propellant aerosol generators disposed about the enclosed area for exhausting a fire suppressant aerosol that is substantially void of an ozone depleting material into the enclosed area. Each aerosol generator including an ignition element for igniting the solid propellant thereof. Each ignition element of the aerosol generators being coupled to a fire control unit which is operative to ignite the solid propellant of at least one aerosol generator utilizing the ignition element thereof to exhaust fire suppressant aerosol into the enclosed area. Each aerosol generator preferably includes a container which comprises: a housing including an orifice for exhausting the fire suppressant aerosol; a solid propellant disposed inside of the housing; at least one cover mounted to the housing to seal correspondingly at least one open side thereof; an ignition material coupled to the solid propellant for igniting the solid propellant to produce the fire suppressant aerosol; and at least one baffle disposed integral to the housing to capture non-usable effluent.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. provisional application 61/408,920 filed Nov. 1, 2010 hereby incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates generally to cheese processing equipment and in particular to a cutting machine for extruded string cheese.
String cheese is normally produced by extruding an Italian-style or “pasta filata” cheese, such as mozzarella, that has a grain structure producing string-like fibers. A “rope” of semi-molten extruded cheese is cut into short segments then cooled in a brine solution.
U.S. Pat. No. 4,759,704, describes a machine for extruding and cutting string cheese in which the cheese is extruded vertically downward toward a trip lever that activates a cutter, producing segments of the desired length. U.S. Pat. No. 4,902,523 describes a machine for extruding and cutting string cheese in which multiple sensors monitor horizontally extruded cheese ropes to trigger independent cutters at the appropriate lengths.
SUMMARY OF THE INVENTION
The present inventor has identified a substantial variation in the weight and volume of string cheese segments produced by current commercial machines believed to be inherent in length-based metering systems working on a semi-molten material. The present invention provides an improved cutting system for extruded string cheese that greatly reduces the variation among cut segments by constraining the semi-molten extruded cheese, before cutting, within a controlled volume provided by a sleeve and piston. By so constraining the semi-molten cheese, significantly greater uniformity in weight and volume is provided.
Specifically, the present invention provides apparatus and corresponding method for producing sections of extruded cheese employing a series of tubular sleeves having first ends adapted to receive cheese from an extruder. A series of pistons fit slidably within corresponding tubular sleeves, the pistons having first ends contacting cheese filling the tubular sleeves from the extruder and second ends moving in a direction of extrusion as the tubular sleeves are filled with cheese. A blocking element stops movement of the pistons when the tubular sleeves are filled with cheese to a predetermined volume and an ejector operates upon a filling of the tubular sleeves to the predetermined volume to eject cheese from the tubular sleeves.
It is thus one feature of at least one embodiment of the invention to provide an accurate method of providing uniform string cheese segments that addresses inherent inaccuracies of free-length measurement of a semi-molten material and the difficulty of weight measurement of a partially extruded rope.
The ejector may provide an actuator moving the second ends of the pistons counter the direction of extrusion to eject cheese from the first ends of the tubular sleeves.
It is thus one feature of at least one embodiment of the invention to provide a simplified mechanism that may employ a reciprocating piston motion for constraining then ejecting cheese segments.
The apparatus may provide a set of ports receiving cheese from the extruder and positioned between the extruder and the first ends of the series of tubular sleeves and the tubular sleeves may be mounted for reciprocation between a first and second position with respect to the ports in a direction substantially perpendicular to the axis so that a first set of tubular sleeves may align with ports in the first position and a different, second set of tubular sleeves may align with the ports in the second position. The ejector may operate to move the second ends of the pistons of the first set of tubular sleeves against the direction of extrusion for the first set of tubular sleeves when the tubular sleeves are in the second position and to move the second ends of the pistons of the second set of tubular sleeves against the direction of extrusion when the tubular sleeves are in the first position.
It is thus one feature of at least one embodiment of the invention to permit substantially continuous extrusion of the cheese through the use of two sets of tubular sleeves that may be alternately filled and ejected.
The interface between the ports and the tubular sleeves may provide a shearing of cheese extending between the ports and some tubular sleeves when the tubular sleeves move in the direction perpendicular to the axis between the first and second positions.
It is thus one feature of at least one embodiment of the invention to incorporate the cutting process into a movement of the tubes to further simplify the mechanism.
The ports may be spaced in a direction perpendicular to the axis at twice the distance of spacing of the tubular sleeves perpendicular to the axis and the ejector may provide an axially traveling ejector surface having spaced blocking elements contacting only every other piston.
It is thus one feature of at least one embodiment of the invention to provide an ejector that may interfere with the piston stops in a compact mechanism.
The direction of extrusion may be substantially horizontal and the ports may be separated by a distance no less than a diameter of a tubular sleeve and provide downwardly opening channels therebetween allowing cheese ejected from the first ends of the tubular sleeves to drop downward therefrom.
It is thus one feature of at least one embodiment of the invention to permit a gravity-assisted ejection of cut cheese segments in a compact mechanism employing a reciprocating piston motion.
The ports may be second ends of forming tubes having first ends receiving cheese from the extruder and further including a mixer positioned between the extruder and the forming tubes providing first and second cheese input ports. The forming tubes may be mounted for rotation about axes of the forming tubes to impart a spiral pattern to an interface between first and second cheese received from the first and second cheese input ports into the forming tubes.
It is thus one feature of at least one embodiment of the invention to permit decorative spiraling of the cheese segments in a system that provides for controlled volume and weight of the segments.
The tubular sleeves may be in adjacent parallel configuration and the apparatus may further include a sensor system detecting positions of the pistons indicating that multiple of the tubular sleeves are filled with cheese to the predetermined volumes to trigger the ejector.
It is thus one feature of at least one embodiment of the invention to provide controlled back pressure on the extruded cheese by delaying the injector stage until each of the tubes is filled to ensure complete filling of each of the tubular sleeves.
The sensor system may be an optical beam interrupted by movable elements moving out of occlusion with the optical beam by each piston when a corresponding tubular sleeve is filled with cheese to the predetermined volume.
It is thus one feature of at least one embodiment of the invention to provide a simple and robust sensing system suitable for a food-manufacturing environment.
The tubular sleeves may be bores in a block of a fluorocarbon polymer.
It is thus one feature of at least one embodiment of the invention to provide a simple readily cleaned structure for constraining and releasing semi-molten extruded cheese.
These particular features and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is an exploded perspective view of the string cheese cutting apparatus per the present invention showing various components as controlled by a programmable controller or the like to provide for extrusion of cheese through forming tubes into a shuttle block having a precisely dimensioned bore and contained pistons;
FIG. 2 is a perspective detail view of the forming tubes of FIG. 1 showing a rotating mechanism to provide for a spiral decoration of the cheese;
FIG. 3 is a top plan cross-section through the shuttle block of FIG. 1 with the contained pistons in a first position before receipt of cheese;
FIG. 4 is a figure similar to that of FIG. 3 showing the extrusion of cheese into alternate bores in the shuttle block;
FIG. 5 is a fragmentary detail view of a stop assembly and ejector bar used for constraining the extension of the pistons and sensing that all pistons are fully extended for the alternate bores, and further for pressing inward on the pistons to eject the cheese from the alternate bores of the shuttle block when the shuttle block is in an ejection position for those bores;
FIG. 6 is a figure similar to that of FIG. 4 showing the shuttle block in a second ejection position for ejection of the extruded cheese from the alternate bores; and
FIG. 7 is a fragmentary detail of FIG. 6 showing the ejection of the cheese in between the forming tubes while permitting filling of new bores in the shuttle block now aligned with the forming tubes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , a string cheese cutting apparatus 10 of the present invention may receive prepared pasta filata cheese along a horizontal axis 12 as indicated by an arrow into a funneling hopper 14 . The pasta filata cheese may be provided by conventional kneading equipment of a type known in the art that develops the grain structure characteristic of these cheese types.
The funneling hopper 14 may also receive a contrasting cheese 22 or other similar foodstuff. The contrasting cheese 22 may, for example, coat the upper surface of a planar slab 16 of the pasta filata in a thin colored layer 26 across the upper surface of the planar slab 16 . The funneling hopper 14 may further have various ports 20 receiving and outputting heating water to maintain the planar slab 16 and colored layer 26 at a proper consistency for extrusion.
The combined height of the planar slab 16 and colored layer 26 will approximate the cross-sectional dimension of the desired string cheese segments being produced and the horizontal width of the planar slab 16 and colored layer 26 will have a width greater than a combined cross-sectional dimension of the number of simultaneous extrusions being performed.
An exit port of the hopper 14 may deliver the combined planar slab 16 and colored layer 26 to a shaper die 31 fitting over the exit port. The shaper die 31 may divide the combined planar slabs 16 and colored layer 26 into adjacent square cross-sections defined by square entrance openings of the shaper die 31 . Each of these square openings funnels to a circular hole 33 having a cross-section matching that of the ultimately produced string cheese and permitting extrusion of the cheese into a cylindrical shape.
Cheese extruded through the holes 33 passes through bearings 37 held by a bearing block 35 (as will be described below) and is received by corresponding forming tubes 28 in a forming assembly 27 and having ends fitting within the bearings 37 . Each of the forming tubes 28 is mounted parallel to the axis 12 and arrayed across the horizontal width of the combined planar slab 16 and colored layer 26 and aligned with holes 33 in the shaper die 31 . Generally the forming tubes 28 are spaced horizontally by slightly more than twice their width to provide a gap between each forming tube 28 slightly larger than the outer diameter of a forming tube 28 . These gaps will provide an exit path for extruded cheese as will be described below.
First, open ends of the forming tubes 28 pass through a support plate 30 that abuts the bearing block 35 which in turn is aligned with the exposed planar face of the shaper die 31 . Second, opposite open exit ends of the forming tubes 28 pass through a slide plate 32 displaced from but parallel to the support plate 30 , as will be described below. The slide plate 32 includes apertures or cutouts 34 aligned with the gaps between the forming tubes 28 to provide openings between the openings of the forming tubes 28 for ejection of cheese as will be described. The forming tubes 28 are mounted to rotate about their respective axes within the support plate 30 and the slide plate 32 .
Referring to FIGS. 1 and 2 , the first ends of the forming tubes 28 extending through the support plate 30 are received by correspondingly sized bores of spur gears 36 which are around the outer diameter of ends of the forming tubes 28 and attached thereto. The forming tubes 28 extend slightly through the spur gears 36 to provide a support lip 39 that may be received by the bearings 37 of the bearing block 35 described above to support the forming tubes 28 for rotation. The spur gears 36 inter-engage so that each forming tube 28 rotates in unison with the others in alternate counter-cyclic directions 38 . An idler gear 40 communicates between one spur gear 36 and a corresponding drive gear 42 on a motor 44 permitting rotation of these forming tubes 28 during the extrusion by the motor 44 . This rotation will produce a spiraling of the colored layer 26 and the planar slab 16 in the manner of a barber pole.
The motor 44 may be controlled by a control system 46 , for example, a programmable logic controller executing a stored program for operating the string cheese cutting apparatus 10 the structure of which will be understood from the following description. The control system 46 may include a user console 48 for the entry of data or control parameters according to techniques well known in the art.
It should be understood that the above-described spiraling mechanism is optional and required only if the spiral form is desired.
Referring again to FIG. 1 , the slide plate 32 may smoothly abut a leading edge of a shuttle block 50 . The shuttle block 50 , for example, may be formed of machined Teflon and a spring biased to ride against the trailing face of the slide plate 32 as it reciprocates back and forth in a horizontal direction 52 with respect to the slide plate 32 between the first and second positions. The spring biasing may be accomplished, for example, by air cylinders operating under control of the predetermined pressure.
The reciprocation of the shuttle block 50 may be controlled by an actuator 54 , such as an air cylinder and valve, also under control of a stored program in control system 46 .
The shuttle block 50 includes multiple bores 56 numbering twice the number of the forming tubes 28 and having half the horizontal spacing. In this way, in the first position, a first set of alternate bores 56 are aligned with the forming tubes 28 and a second set of bores 56 between the first set are aligned with cutouts 34 . Conversely, in the second position, the second set of bores 56 is aligned with the openings of the forming tubes 28 and the first set of bores is aligned with cutouts 34 .
Each of the bores 56 may receive a mold plug 58 being a cylindrical metal rod having a diameter closely fitting with the inner diameter of the bores 56 to form a piston-like structure there in. Trailing ends of the mold plugs 58 provide for stop heads 59 limiting insertion of the mold plugs 58 into the bores 56 . In one embodiment, the mold plugs 58 excluding the stop heads 59 may have a length substantially equal to the axial length of the bores 56 . As cheese is extruded through the forming tubes 28 , the cheese will fill alternate bores 56 (depending on the position of the shuttle block 50 ) and push outward against a leading face of the corresponding mold plugs 58 .
The rearward movement of the mold plugs 58 is arrested before the mold plugs are fully disengaged from the bores 56 by stop pins 60 (to be described in more detail below) aligned only with every other mold plug 58 in those bores 56 receiving cheese from a forming tube 28 . A castellated ejection pusher 62 provides upward extending projections 64 positioned between stop pins 60 and, after the shuttle block 50 shifts, may be used to push the extended mold plugs 58 back into the bores 56 of the shuttle block 50 by the agency of an actuator 66 also controlled by control system 46 .
Referring now to FIG. 3 , the operation of the string cheese cutting apparatus 10 may start, for example, with the shuttle block 50 in a leftmost position with respect to the tube assembly 27 with mold plugs 58 a , 58 c , 58 e , and 58 g (and their corresponding bores 56 ) aligned with forming tubes 28 to receive cheese therefrom.
Referring now to FIG. 4 , as cheese 70 is received into the bores 56 associated with the mold plugs 58 a , 58 c , 58 e , and 58 g , those mold plugs travel backward displaced by the cheese 70 . Generally, the mold plugs 58 will move at different rates because of an inherent uneven pressure in the extrusion process such as contributes in the prior art to inconsistent product weights.
Referring now momentarily to FIG. 5 , each of the stop pins 60 may be mounted on a corresponding pivoting tab 72 that may pivot about a horizontal axis perpendicular to axis 12 backward within the gaps between projections 64 of the ejection pusher 62 . This pivoting proceeds until the stop pins 60 are vertical and abut a stop plate 74 . As the tabs 72 pivot backward they raise opaque flags 80 whose weight generally causes the stop pins 60 to be displaced forward before they contact the mold plugs 58 . When the opaque flags 80 are in the lowered position they align along a horizontal axis of light beam 82 to block a light beam between a light transmitter 86 and light receiver 88 . The light receiver 88 is connected to the control system 46 to detect when all of the flags 80 have been raised indicating that all of the mold plugs 58 are fully extended and the corresponding mold tabs 72 abut the stop plate 74 . At this point of equal extension, the pressure in each of the bores 56 equalizes and the volumes (and weight) of cheese in each of the bores 56 is substantially equal. With the flags 80 fully raised out of the light beam 82 , a signal is provided to the control system 46 to slide the shuttle block 50 leftward.
As shown in FIG. 6 , this leftward sliding of the shuttle block 50 moves the bores 56 of mold plugs 58 b , 58 d , 58 f , and 58 h into alignment with forming tubes 28 and the bores 56 of mold plugs 58 a , 58 c , 58 e , and 58 g into alignment with the cutouts 34 (shown in FIG. 1 ) providing a shearing action between the leading edge of the shuttle block 50 and the abutting surface of the slide plate 32 cutting the cheese 70 within the bores of mold plugs 58 a , 58 c , 58 e , and 58 g cleanly to length. This movement moves the mold plugs 58 a , 58 c , 58 e , and 58 g off of the stop pins 60 and into alignment with the projections 64 of the ejection pusher 62 . The ejection pusher 62 may then be moved inward by the actuator 66 , shown in FIG. 1 , by the control system 46 using a simple delay timer from the motion of the shuttle block 50 .
Referring to FIG. 7 , the inward motion of the ejection pusher 62 ejects the cheese 70 in the bores 56 of mold plugs 58 a , 58 c , 58 e , and 58 g backward toward the extruder. Then the cheese 70 , as cut to length, may pass in between the forming tubes 28 of the assembly 27 through the cutouts 34 in the slide plate 32 shown in FIG. 1 . Cheese sticks of precise length and volume may then drop downward, for example, into chilled brine or onto a carrier.
During this ejection process, the alternate bores, for example, associated with mold plugs 58 b , 58 d , 58 f , and 58 h may be simultaneously filled from forming tubes 28 providing a substantially continuous process. In this way back-and-forth motion of the shuttle block 50 and the motion of the ejection pusher 62 may provide for a steady stream of precisely formed cheese sticks.
Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
References to “a controller” and “a processor” can be understood to include one or more controllers or processors that can communicate in a stand-alone and/or a distributed environment(s), and can thus be configured to communicate via wired or wireless communications with other processors, where such one or more processor can be configured to operate on one or more processor-controlled devices that can be similar or different devices. Furthermore, references to memory, unless otherwise specified, can include one or more processor-readable and accessible memory elements and/or components that can be internal to the processor-controlled device, external to the processor-controlled device, and can be accessed via a wired or wireless network.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. All of the publications described herein, including patents and non-patent publications, are hereby incorporated herein by reference in their entireties.
|
A string cheese-forming machine provides for extrusion of cheese into control volumes, for example, implemented with tubes each movably blocked with a piston having a stop. Complete filling of each tube is detected before ejection of the cheese from the tubes is undertaken, thereby ensuring consistent product volume and weight.
| 0
|
RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application No. 61/729,914, filed Nov. 26, 2012, titled “Cosmetic Applicator,” the content of which is hereby incorporated by reference in its entirety.
FIELD
[0002] The present disclosure relates generally to a product dispensing apparatus and, more particularly, to a product dispensing apparatus comprising a container, a cap, an elongate stem, and a wiper element configured to prevent a rotational movement of the elongate stem when cap is screwed onto the container.
BACKGROUND
[0003] It is important in the cosmetic industry to provide an applicator for products which not only applies the product easily, but also avoids excess product from being dispensed onto the applicator prior to application.
[0004] Prior art applicators typically have a stem that has a cross-sectional shape that is round or circular, so that when the cap to which the applicator stem is attached is unthreaded or unscrewed from the vial or container containing the product, the stem will twist through a wiper in the vial, wiping excess product off from the stem.
[0005] However, the rounded styles of the stems of such applicators are not desirable. There remains a need in the art for an applicator which has more flexibility in size and style.
SUMMARY
[0006] The present disclosure is directed to an applicator having an elongate stem that does not does not twist or rotate when the applicator is unscrewed from its container. In certain embodiments the applicator stem of the present disclosure is orientated such that the wiper in the vial holds the stem in place, while the inner cap or handle can spin about the stem when the inner cap is being unscrewed from or screwed onto the container. The inner cap or handle enables the stem to be axially pushed or pulled through a wiper element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present disclosure will be more readily understood from the detailed description of examples presented below considered in conjunction with the attached drawings, of which:
[0008] FIG. 1 shows a front view of an example applicator.
[0009] FIG. 2 shows a cross-section view of an example applicator.
[0010] FIG. 3 shows an exploded view of an example applicator.
[0011] FIG. 4 shows a top view of an embodiment an applicator.
[0012] FIG. 5 shows a bottom view of an embodiment of an applicator.
[0013] FIG. 6 shows a front view of an embodiment of an applicator.
[0014] FIG. 7 shows a side view of an embodiment of an applicator.
[0015] FIG. 7A shows a front view of an embodiment of an applicator
[0016] FIG. 7B shows a side view of an embodiment of an applicator.
[0017] FIG. 7C shows a perspective view of an embodiment of an applicator.
[0018] FIG. 8 shows a perspective view of an embodiment of an applicator.
[0019] FIG. 9 shows a top view of an embodiment of an applicator.
[0020] FIG. 10 shows a side view of an embodiment of an applicator.
[0021] FIG. 11 shows a perspective view of an embodiment of an applicator.
[0022] FIG. 12 shows a bottom view of an embodiment of an applicator.
[0023] FIG. 12A shows a front view of an embodiment of an applicator.
[0024] FIG. 12B shows a side view of an embodiment of an applicator.
[0025] FIG. 13 shows a front view of an embodiment of an applicator.
[0026] FIG. 14 shows a side view of an embodiment of an applicator.
[0027] FIG. 15 shows a rear view of an embodiment of an applicator.
[0028] FIG. 16 shows a perspective view of an embodiment of an applicator.
DETAILED DESCRIPTION
[0029] Examples of the present disclosure are directed to an apparatus and method for an applicator. In the following description, numerous details are set forth. It will be apparent, however, to one skilled in the art, that the present disclosure may be practiced without some or all of these specific details.
[0030] FIG. 1 shows a front view of an example applicator 100 . The cosmetic applicator 100 comprises an outer cap 102 , an applicator arrangement comprising an applicator stem, also referred to herein as an elongate stem 110 and an applicator element 112 , and a container 106 for containing a product 108 . In an embodiment the elongate stem 110 comprises a metal, a plastic, a ceramic, a glass, or any combination thereof. The product 108 can be any type of a cosmetic, including but not limited to cosmetics to apply to the face, eye, and nail area such as, lip gloss, eye liner, mascara, a concealer, a blemish control material, a nail polish or nail hardener, and the like. The product 108 can be a liquid, a semi-solid material, a solution, a suspension, a powder, a cream, or an ointment. The product 108 can be a therapeutic product, a fragrance, or a consumer product such as paint.
[0031] FIG. 2 shows a cross-section view of the example applicator 100 . The applicator 100 as shown in FIG. 2 illustrates the outer cap 102 , the container 106 , and the product 108 . In an embodiment, the container 106 comprises a container threaded portion 116 which is externally threaded around a cylindrically shaped sidewall defining an opening of the container 106 . In an embodiment, the container 106 comprises a metal, a plastic, a ceramic, a glass, or any combination thereof.
[0032] The applicator 100 of FIG. 2 also comprises an applicator arrangement comprising the elongate stem 110 coupled to the applicator element 112 at a distal end and coupled to the handle (inner cap) 104 at a proximal end. In an embodiment, the elongate stem 110 can be substantially flat. In an embodiment, the elongate stem 110 can be a non-circular stem such as an ovoid, oval, or a polygon. In an embodiment, the handle (inner cap) 104 comprises an inner cap threaded portion 114 which is internally threaded and dimensioned for cooperated threaded engagement with the container threaded portion 116 . In an embodiment, the proximal end of the elongate stem 110 comprises a plurality of snap fasteners 122 configured to form a coupling of the proximal end of the elongate stem 110 to the handle (inner cap) 104 . In an embodiment, the elongate stem 110 and the handle (inner cap) 104 are unitary. In an embodiment, the snap fasteners 122 enable the handle (inner cap) 104 to spin or rotate about the elongate stem 110 when the handle (inner cap) 104 is being unscrewed from or screwed onto the container 106 . In an embodiment, the snap fasteners 122 enable the handle (inner cap) 104 , coupled to the elongate stem 110 , to be axially pushed or pulled through a wiper element 118 . The wiper element 118 is configured to remove or wipe excess product 108 from the elongate stem 110 and applicator element 112 when the elongate stem 110 and applicator element 112 is dipped into the container 106 in order to pick up the product 108 and then withdrawn from the container 106 in order to apply the product 108 for its intended use. In an embodiment, the wiper element 118 and the container 106 are unitary.
[0033] In an embodiment, the wiper element 118 comprises a cup shaped body that can be inserted or mounted into the cylindrically shaped sidewall defining the opening of the container 106 . In an embodiment, the wiper element 118 is constructed from a hard plastic, or from a flexible material such as rubber or synthetic rubber or the like. In an embodiment, the wiper element 118 comprises a metal, a plastic, a ceramic, a glass, or any combination thereof. In an embodiment, the wiper element 118 comprises a passage to permit or allow the elongate stem 110 and the applicator element 112 to slide through the passage.
[0034] In an embodiment, the outer cap 102 is a removable outer cap that engages the container 106 or the elongate stem 110 . In an embodiment, the outer cap 102 is a removable outer cap that engages the handle (inner cap) 104 . FIG. 3 shows an exploded view of the example applicator 100 . The applicator 100 comprises an outer cap 102 , an applicator arrangement comprising the elongate stem 110 comprising a sealing element 126 and snap fasteners 122 coupled to the handle (inner cap) 104 at a proximal end and the elongate stem 110 coupled to the applicator element 112 at a distal end and, the elongate stem 110 , a wiper element 118 comprising guide ribs 124 and a peripheral lip 128 , and a container 106 for containing a product 108 , the container 106 comprising a container threaded portion 116 . In an embodiment, the sealing element 126 is configured to form a contact seal with the peripheral lip 128 when the handle (inner cap) 104 is screwed onto the container threaded portion 116 of the container 106 . In an embodiment, the contact seal that is formed by the contact between the peripheral lip 128 and the sealing element 126 contains the product 108 within the applicator 100 . In an embodiment, the dimensions of the passage 126 substantially conform to the cross-section perimeter of the elongate stem 110 .
[0035] FIG. 4 shows a top view of an embodiment the applicator 100 . A top view of the elongate stem 110 shows an example of the relative position and placement of the snap fasteners 122 with respect to the top portion of the sealing element 126 .
[0036] FIG. 5 shows a bottom view of an embodiment of the applicator 100 . A bottom view of the elongate stem 110 shows an example of the relative position and placement of the applicator element 112 with respect to the bottom portion of the sealing element 126 .
[0037] FIG. 6 shows a front view of an embodiment of the applicator 100 . The elongate stem 110 comprises a sealing element 126 and a plurality of snap fasteners 122 at a proximal end.
[0038] FIG. 7 shows a side view of an embodiment of the applicator 100 in which the elongate stem 110 comprises a sealing element 126 and a plurality of snap fasteners 122 at a proximal end.
[0039] FIG. 7A shows a front view of an embodiment of the applicator 100 in which the elongate stem 110 comprises a sealing element 126 . In an embodiment, the sealing element 126 may be substantially cone shaped and substantially conforms to the cone shaped wiper element 118 as illustrated below in FIGS. 12A and 12B .
[0040] FIG. 7B shows a side view of an embodiment of the applicator 100 in which the elongate stem 110 comprises a sealing element 126 . In an embodiment, the sealing element 126 may be substantially cone shaped and substantially conforms to the cone shaped wiper element 118 as illustrated below in FIGS. 12A and 12B .
[0041] FIG. 7C shows a perspective view of an embodiment of the applicator 100 in which the elongate stem 110 comprises a cone shaped sealing element 126 .
[0042] FIG. 8 shows a perspective view of an embodiment of an applicator 100 in which the elongate stem 110 comprises a sealing element 126 and a plurality of snap fasteners 122 at a proximal end.
[0043] FIG. 9 shows a top view of an embodiment of the applicator 100 . A top view of the wiper element 118 shows the peripheral lip 128 for providing a seal when in contact with the bottom portion of the sealing element 126 of the elongate stem 110 . In an embodiment, a substantially cone shaped wiper element 118 provides a seal when in contact with the substantially cone shaped sealing element 128 as illustrated in FIGS. 7A , 7 B, and 7 C.
[0044] FIG. 9 also shows the passage 126 for allowing the elongate stem 110 and the applicator element 112 to slide through the passage while wiping excess product 108 from the elongate stem 110 and applicator element 112 when the elongate stem 110 and applicator element 112 is withdrawn from the container 106 . In an embodiment, the dimensions of the passage 126 substantially conform to the cross-section perimeter of the elongate stem 110 . In an embodiment, the wiper element 118 comprises a plurality of guide ribs 124 along a sidewall of the wiper element 118 . The dimensions of the guide ribs 124 can substantially conform to that of the elongate stem 110 to guide the elongate stem 110 while being inserted into the container 106 . In an embodiment, the guide ribs 124 are also configured to restrain and prevent the elongate stem 110 from rotating when the handle (inner cap) 104 is being screwed into or unscrewed from the container 106 . In an embodiment, the guide ribs 124 are also configured to align the elongate stem 110 as it is placed into the container 106 .
[0045] FIG. 10 shows a side view of an embodiment of the applicator 100 . A side view of the wiper element 118 shows that the shape of the wiper element can be in the form of a cup. The shape of the wiper element 118 as shown in FIG. 10 can substantially conform to the cylindrically shaped sidewall defining the opening of the container 106 .
[0046] FIG. 11 shows a perspective view of an embodiment of the applicator 100 in which the wiper element 118 comprises the guide ribs 124 and the peripheral lip 128 .
[0047] FIG. 12 shows a bottom view of an embodiment of the applicator 100 in which the wiper element 118 comprises the passage 126 and the peripheral lip 128 .
[0048] FIG. 12A shows a front view of an embodiment of the applicator 100 in which the wiper element 118 is cone shaped and substantially conforms to the cone shaped sealing element 128 as illustrated in FIGS. 7A , 7 B, and 7 C.
[0049] FIG. 12B shows a side view of an embodiment of the applicator 100 in which the wiper element 118 is cone shaped and substantially conforms to the cone shaped sealing element 128 as illustrated in FIGS. 7A , 7 B, and 7 C.
[0050] FIG. 13 shows a front view of an embodiment of the applicator 100 in which the front portion of the applicator element 112 comprises a layer of a first material. In an embodiment, the applicator element 112 is capable of absorbing a liquid or semi-solid product. In an embodiment, the applicator element 112 is capable of adsorbing a liquid or semi-solid product. In an embodiment, the applicator element 112 is an absorbent material or an adsorbent material. In an embodiment, the applicator element 112 comprises a fabric. In an embodiment, the applicator element 112 is a brush, a rollerball or a doe foot applicator.
[0051] FIG. 14 shows a side view of an embodiment of the applicator 100 in which the applicator element 112 has a concave shape for the product 108 .
[0052] FIG. 15 shows a rear view of an embodiment of the applicator 100 in which the rear portion of the applicator element 112 comprises a layer of a second material.
[0053] FIG. 16 shows a perspective view of an embodiment of the applicator 100 .
[0054] One having ordinary skill in the art will appreciate that the size, shape and placement of such structures may be varied depending on the particular application. Apart from the functional aspects the structures provide, they also provide a novel decorative element. One having ordinary skill in the art will appreciate the decorative possibilities such shapes present.
[0055] The foregoing description, for purposes of explanation, has been described with reference to specific examples. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The examples were chosen and described in order to best explain the principles of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure and various examples with various modifications as may be suited to the particular use contemplated.
|
An applicator apparatus comprising a container comprising an opening, a wiper element coupled to the container, the wiper element comprising a passage, a non-circular applicator stem removably coupled to the container, the applicator stem configured to be slidably engaged in the passage of the wiper element such that rotational movement of the applicator stem is minimized.
| 0
|
FIELD OF INVENTION
The present invention relates to solar cell technology and in particular to maximum power tracking converters. The present invention has particular but not exclusive application for use in vehicles that are at least in part electrically powered by solar cells. Reference to solar powered vehicles is by means of example only and the present invention has application in other areas.
BACKGROUND OF THE INVENTION
A solar cell is a device able to convert incident light to electrical power. Many solar cells are typically grouped to form an array of solar cells. To collect the electrical power from the solar cells, groups of cells are either directly connected in series or in parallel. Where the cells are connected in series, they must have identical currents but if the cells are connected in parallel they must operate with identical voltages. An individual cell will produce maximum power at a unique cell voltage and current which will vary from cell to cell. The combination of voltage and current that allows a cell to produce its maximum power is termed the maximum power point. The maximum power point varies with cell illumination and temperature. Connection of the cells in series forces cells to have identical current while connection in parallel forces cells to have identical voltage. Direct connection in series or parallel results in failure to collect all the available electrical power from the solar cells in the array and at least some of the cells will operate at a condition other than at their maximum power points.
To obtain the maximum available power from a group of solar cells connected in an array or sub-array, a maximum power tracking device is used. Maximum power tracking devices are DC to DC power converters that allow an array or sub-array to operate at their maximum power point. A DC to DC converter can transform a power input at a certain voltage and current to be transformed to a DC power output at a differing voltage and current. A key feature of all maximum power trackers is a control device that determines the point of maximum power for the connected solar cells and acts to adjust the DC to DC converter performance to adjust the cell voltage or current to extract the maximum available power.
However there are a number of problems or disadvantages associated with the use of a single maximum power device to control the voltage or current of an array or sub-array of solar cells.
Where solar cells are used to power vehicles, the vehicles are usually aerodynamically designed with curved surfaces and also have limited surface area in which to mount the solar cells. Consequently arrays of cells are mounted on the curved surfaces but the variation of the angle of incidence of light on the different cells within the array on the curved surface causes variation in the available optical power. Furthermore, cells in an array may be subjected to variable light levels due to shadowing by foreign objects such as trees and buildings between the cell and the source of illumination.
Because of differences in optical illumination, cell temperatures may vary within arrays causing some cells to be hotter than other cells. Arrays may be cooled partially by air flow or by the use of a cooling fluid in an illumination concentrator system. These mechanisms however may not provide uniform cooling to all cells.
The available power from each cell within an array will vary due to the variations in illumination and temperature. In these cases, the maximum power conditions of different cells within the array will differ at any one point of time. Furthermore the maximum power conditions of some cells within the array will vary differently over time compared with others. As well these variations are not predictable. In addition changes to the maximum power conditions of cells can vary rapidly thereby requiring a relatively quick response time.
Currently maximum power tracking devices are directly electrically connected to an array of solar cells. A single maximum power tracking device is currently used to control the available power from an array of between ten to several hundred cells.
OBJECT OF THE INVENTION
It is an object of the present invention to provide an alternate maximum power tracking device that overcomes at least in part one or more of the above mentioned problems or disadvantages.
SUMMARY OF THE INVENTION
The present invention arises from the realization that each cell at any one particular time point will have a unique maximum power point defined by a specific cell voltage and specific current at which the cell will produce its maximum available power. Furthermore the invention was developed from the realization that it is not possible for every cell in an array to operate at its maximum power point if the array is formed by the direct electrical interconnection of cells. With this in mind and taking advantage of recent advances in low voltage electronics, maximum power tracking devices for very small groups of directly connected cells or for single solar cells were developed to provide a solution to optimizing the electrical power from the array.
In one aspect the present invention broadly resides in a system for providing power from solar cells including
one or more solar generators wherein each of said solar generators has one to nine solar cells;
a maximum power tracker operatively associated with each solar generator, each of said maximum power tracker includes a buck type DC/DC converter without an output inductor, each of said maximum power trackers are operatively connected in series with each other;
an inductor operatively connected to the series connected maximum power trackers; and
means for providing electrical power from the inductor to load means, wherein each of said maximum power trackers is controlled so that the operatively associated solar generator operates at its maximum power point to extract maximum available power.
The maximum power tracker preferably includes an energy storage capacitor and a control means for adjusting the buck type DC/DC converter duty cycle so that a connected solar generator operates at its maximum power point.
Preferably the control means makes observations of solar generator voltage, and observations of the change in energy storage capacitor voltage during the buck converter switch off time and observations of the duration of the buck converter switch off time to infer solar generator power to adjust the buck converter duty cycle to extract maximum power from the connected solar generator.
In one preferred embodiment, the switching operations of the DC/DC converter are synchronized in frequency by the use of a synchronizing signal.
Preferably each solar generator includes one solar cell. Preferably each solar generator includes one solar cell and each solar cell is connected to its own dedicated maximum power tracker so that the tracker responds to its connected solar cell.
Preferably the system uses a single inductor.
Load means includes devices that use or store the electrical power.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the present invention can be more readily understood and put into practical effect, reference will now be made to the accompanying drawings wherein:
FIG. 1 is a diagrammatic view of a simplified Buck type DC/DC converter with solar generator and load;
FIG. 2 is a diagrammatic view of an alternative embodiment of a simplified Buck type DC/DC converter with solar generator and load;
FIG. 3 is a diagrammatic view of a solar generator with a Buck type DC/DC converter without an inductor;
FIG. 4 is a diagrammatic view of an alternative embodiment of a solar generator with a Buck type DC/DC converter without an inductor;
FIG. 5 is a diagrammatic view of the interconnection of a plurality of Buck type DC/DC converters without inductors, corresponding plurality of solar generators, one inductor and a load; and
FIG. 6 is a diagrammatic view of a preferred embodiment of the single cell MPPT converter;
FIG. 7 is a graphical representation of the control signals and gate signals for MOSFETs;
FIG. 8 is a graphical representation of a no load 2 kHz waveforms, top MOSFET gate waveform; top MOSFET gate drive referred to ground, bottom MOSFET gate waveform to ground, output terminal to ground (from top to bottom);
FIG. 9 is a graphical representation of an unloaded 20 kHz waveforms, Traces top to bottom, output terminal, bottom MOSFET gate, top MOSFET gate, all referred to ground;
FIG. 10 is a graphical representation of a loaded 20 kHz waveforms, traces top to bottom, output terminal, bottom MOSFET gate, top MOSFET gate, all referred to ground;
FIG. 11 is a graphical representation of input voltage, current and power at 10 kHz (from top to bottom);
FIG. 12 is a graphical representation of output current, voltage and power at 10 kHz (from top to bottom);
FIG. 13 is a table of equipment for efficiency measurement; and
FIG. 14 is a table of converter efficiency at different frequencies.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1 there is shown a simplified buck type DC/DC converter 10 connected to a solar generator 11 and load 12 . The solar generator 11 can be a solar cell or several cells. The buck type DC/DC converter 10 includes a capacitor 13 which serves as an energy storage element, a controlled switching device 14 , a diode or a controlled device acting as a synchronous rectifier 15 and an output inductor 16 . An alternative arrangement for the buck type DC/DC converter 10 is shown in FIG. 2 .
A buck type DC/DC converter can be controlled to operate the solar generator at its maximum power point while producing an adjustable level of output current. The solar generator and maximum power tracker will be referred to as a solar generator/MPPT. Many solar generators/MPPT can be series connected. Each DC/DC converter will then have an identical output current but they can be individually controlled to allow each solar generator to operate at their maximum power point.
A conventional buck converter uses an output inductor to provide energy storage that is necessary for current filtering. An important feature of this invention is that the many inductors would normally be required, one for each solar generator/MPPT, and this can be replaced by a single inductor which will perform the energy storage and filtering function for many series connected solar generator/MPPT. The MPPT device can be produced as an inductor free device.
FIG. 3 shows an inductorless DC/DC buck converter with a solar generator while FIG. 4 shows an alternate embodiment.
Many solar generators/MPPT devices that utilize inductor free DC/DC buck converters can be series connected with a single inductor to supply power to an electrical load. The series connection of the solar generators/MPPT devices forces each inductorless DC/DC buck converter to supply an identical output current. Each converter operates with a constant current load.
The controlled switching device operates alternates between an open and closed state. The average portion of time that the switch is closed is the switch duty cycle. Closure of the controlled switching device causes the load current to be supplied from the solar generator and the energy storage capacitor. When the controlled switch is open, the load current transfers to the diode or synchronous rectifier device while the solar generator current replenishes the charge within energy storage capacitor.
The duty cycle of the controlled switching device will determine the average current withdrawn from the energy storage capacitor. The energy storage capacitor will adjust its voltage in response to the difference in the current supplied by the solar generator and the current withdrawn to by the controlled switch. The switching device will be controlled by a device that adjusts the controlled switch duty cycle to maintain the solar generator voltage at the maximum power point.
With respect to FIG. 5 there is shown a solar generator 20 connected to a capacitor 21 , diode 22 and control switch 23 . The capacitor 21 , diode 22 and control switch 23 forms the inductorless DC/DC converter 24 . Several solar generators 20 are connected in series via their dedicated inductorless DC/DC converters 24 . Each solar generator 20 has its own inductorless DC/DC converters 24 . After the last inductorless DC/DC converters 24 , there is an inductor 25 to filter the current prior to reaching the load 26 . The inductor 25 can be smaller in terms of magnetic energy shortage measured as ½ LI 2 , where L is the inductance value in Henry and I is the inductor current, in Amperes, than the total combined set of inductors that are normally used with each buck DC/DC converter. The use of a smaller inductor and only one inductor reduces cost and weight and increases the efficiency in providing maximum power from the solar cells. In the preferred embodiment the solar generator consists of a solar generator which is a single high performance solar cell.
With reference to FIG. 6 , there is shown a DC to DC converter 30 in the formed by MOSFETs Q 1 and Q 2 ( 31 and 32 respectively), and the energy storage capacitor 33 . No filter inductor is required. In this preferred embodiment MOSFET Q 1 ( 31 ) is a synchronous rectifier implementation of the diode device and MOSFET Q 2 ( 32 ) is the buck converter controlled switch element. In the preferred embodiment the output terminals of the solar generator/MPPT device are the drain terminal of Q 1 , point X and the junction of the source terminal of Q 1 and the drain terminal of Q 2 , point Y.
The control element of the maximum power device is a microprocessor. In this preferred embodiment, an ultra-low power Texas Instruments MSP430 microprocessor 34 which is capable of operation at a supply voltage of 1.8V. This allows direct operation from a dual junction cell which typically produces 2V. If other cell types are used with lower cell voltages, a power conditioning device may be required to develop a higher voltage supply to allow the control element to be operated from a single cell. For example, silicon cells typically produce 0.4V and a voltage boosting converter would be required to generate a voltage high enough to operate a microprocessor control element.
An alternate embodiment is possible where the solar generator/MPPT device output terminals are the junction of Q 1 and Q 2 , point Y, and the source of Q 2 . In this case Q 1 is the controlled switch element and Q 2 is the diode element implemented as a synchronous rectifier.
The gate drive voltage for the MOSFETS Q 1 and Q 2 is derived by charge pump circuit. In the preferred implementation a multiple stage charge pump circuit formed by diodes D 1 to D 4 , devices 35 - 38 , and their associated capacitors 39 - 42 .
The MOSFETS Q 1 and Q 2 are driven by a gate driver circuit. In the preferred embodiment a comparator, 43 , forms the driver circuit. As this circuit delivers a higher gate to source voltage to device Q 2 than Q 1 , Q 2 achieves a lower turn on resistance. In the preferred embodiment Q 2 is the controlled switching device as this arrangement minimises power losses.
Resistors 44 and 45 form a voltage divider network which is used to perform voltage observations of solar generator voltage using a analogue to digital converter within the microprocessor 34 . An important feature of the maximum power tracking method is the measurement of cell voltage magnitude, the and measurement of the change in cell voltage during periods when the controlled switch, 32 , is open and the measurement of the time that the controlled switch is open to infer cell power. This may be used as an input to a maximum power tracking method that will control the DC-DC converter duty cycle to allow the solar generator to operate at maximum power.
In order to secure high efficiency in the solar generator/MPPT, low switching frequencies are preferred. In the preferred embodiment switching frequencies will be below 20 kHz. At very low switching frequencies the ripple voltage on capacitor C 1 will increase. The voltage ripple will cause the cell to deviate from its maximum power point. An optimum switching frequency range will exist. In the preferred embodiments the switching frequency will be adjusted to maximise the energy delivered by the solar generator/MPPT.
A plurality of solar generator/MPPT may be configured within a large array to switch at the same frequency and with a relative phase relationship that provides improved cancellation of switching frequency voltage components in the output voltage waveforms of the solar generator/MPPT combinations. This allows a smaller inductor to provide filtering of the load current. Such synchronisation may be provided by auxiliary timing signals that are distributed within an array or by other means.
In some embodiments the solar generator/MPPT devices within an array may not switch at the same frequency. The combined output voltage of large number of asynchronously switching series connected buck converters will follow a binomial distribution. The average output voltage of the group of n solar generator/MPPT devices, with an input voltage V in and a duty cycle d, increases linearly with n while the switching ripple or the distortion voltage, V dist , rises as √n.
V dist =V in √{square root over ( n ( d−d 2 ))} (1)
Likewise the average volt second area, A, for a shared filter inductor follows an √n relationship.
A
=
n
V
i
n
f
(
d
-
d
2
)
(
2
)
In a non synchronized embodiment, a larger inductor is required than in an optimally synchronized embodiment. The required inductor is still significantly smaller than the combined plurality of inductors that would be required for conventional buck converters.
A prototype converter was developed to first examine the conversion efficiency of the DC to DC converter stage and its suitability for use with a dual junction single solar cell, with an approximate maximum power point at 2V and 300 mA. For these tests the MSP340 was programmed to drive the charge pump circuitry and to operate the buck converter stage at a fixed 50% duty ratio. The experimental circuit is as in FIG. 6 . A fixed 2V input source voltage was applied and a load consisting of a 2 500 μH inductor and a 1.6Ω resistor was applied. A dead-time of 0.8 μS is inserted in each turn-on and turn-off transient to prevent MOSFETs shoot through conduction events.
As gate charging loss was a significant loss contributor, a range of operating frequencies was trialled. FIG. 7 shows the control waveforms at 20 kHz. The waveforms show the dead times between the top and bottom signals at turn-on and turn-off. All waveforms in this figure are ground referred. The measured no load loss in this condition was 6 mW which is approximately twice the expected figure. The gate drive loss is fully developed at no load and we may have additional loss in the charge pump circuitry. FIG. 8 shows gate waveforms at 2 kHz but a differential measurement is made of V gs1 to show the lowering of the gate source voltage to approximately 4V due to elevation of the source at the device turn-on.
The waveforms at 20 kHz without load are shown in FIG. 9 . Note that the load connection is across terminals X and Y. The lower MOSFET has the higher gate drive voltage and a lower R dson . FIG. 10 shows the loaded waveforms. Note the conduction of the MOSFET inverse diodes in the dead time as seen by the 2 μS wide peaks on the leading and trailing pulse top edges on the top trace. The transfer of current to these diodes generates an additional conduction loss of 24 mW which reduces efficiency at higher frequencies.
Given circuit losses are around a few percentage points of rating, precise voltage and current measurements are needed if power measurements are used to determine efficiency. A complication is that the output is inductorless and both the output voltage and current contain significant switching frequency components. It is likely that a significant amount of power is transferred to the combined R-L load at frequencies other than DC.
In order to determine the efficiency of this converter, a new high end oscilloscope was used to measure the input and output power. The internal math function was employed to obtain the instantaneous power from the current and voltage, the mean value of which indicates the average power. The current probe was carefully calibrated before each current measurement, to minimise measurement errors. FIG. 13 shows the details of the equipment used in a table format. FIGS. 11 and 12 show the input and output voltages, current and power. The mean value of measured power is displayed at the right column of the figures.
The efficiencies of the converter obtained are shown in a table in FIG. 14 . It is seen that the measured efficiency is slightly lower than estimated especially at higher frequencies. One reason is the loss during the dead-time. The on-state voltage drop of the diode is much higher than the MOSFET, and therefore reduces the efficiency of the converter. At 10 kHz the dead time loss accounts for 12 mW of the observed 30 mW. The results do confirm that the circuit is capable of achieving high efficiencies especially if the switching frequency is low.
Variations
It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth.
Throughout the description and claims this specification the word “comprise” and variations of that word such as “comprises” and “comprising”, are not intended to exclude other additives, components, integers or steps.
|
A system for providing power from solar cells where each cell or cell array is allowed to produce its maximum available power and converted by its own DC/DC converter. In one form the system includes: one or more solar generators, each of which has at least one solar cell; a maximum power tracker operatively associated with each solar generator, where the maximum power tracker includes a buck type DC/DC converter without an output inductor, and the maximum power trackers of the solar generators are operatively connected in series with each other; and an inductor operatively connected to the series connected maximum power trackers.
| 8
|
FIELD OF THE INVENTION
[0001] The present invention relates to improved methods and apparatus involving the integrated use of Automated External Defibrillators (AEDs) and cardiopulmonary resuscitation (CPR). Specifically, this invention relates to AEDs and methods that quickly and reliably determine the presence of a shockable cardiac rhythm in a cardiac arrest victim during a resuscitation attempt such that minimal delay between CPR and delivery of a defibrillation shock is made possible.
BACKGROUND OF THE INVENTION
[0002] Cardiac arrest is widely-understood to be a substantial public health problem and a leading cause of death in most areas of the world. Each year in the U.S. and Canada, approximately 350,000 people suffer a cardiac arrest and receive attempted resuscitation. Accordingly, the medical community has long sought ways to more successfully treat cardiac arrest victims through CPR and application of defibrillation shocks to rapidly restore a normal heart rhythm to persons experiencing this type of event. AEDs were first developed decades ago to help treat incidents of cardiac arrest. Since their creation, AEDs have become prevalent in public locales such as offices, shopping centers, stadiums, and other areas of high pedestrian traffic. AEDs empower citizens to provide medical help during cardiac emergencies in public places where help was previously unavailable in the crucial early stages of a cardiac event.
[0003] Fully automated external defibrillators capable of accurately detecting ventricular arrhythmia and non-shockable supraventricular arrhythmia, such as those described in U.S. Pat. No. 5,474,574 to Payne et al., have been developed to treat unattended patients. These devices treat victims suffering from ventricular arrhythmias and have high sensitivity and specificity in detecting shockable arrhythmias in real-time. Further, AEDs have been developed to serve as diagnostic monitoring devices that can automatically provide therapy in hospital settings, as exhibited in U.S. Pat. No. 6,658,290 to Lin et al.
[0004] Despite advances in AED technology, many current AEDs are not fully functional in implementing the current medically suggested methods of integrated CPR and AED use. Most of the AEDs available today attempt to classify ventricular rhythms and distinguish between shockable ventricular rhythms and all other rhythms that are non-shockable. This detection and analysis of ventricular rhythms provides some real-time analysis of ECG waveforms. However, the functionality, accuracy and speed of a particular AED heavily depends on the algorithms and hardware utilized for analysis of ECG waveforms. In many implementations, the algorithms used in AEDs depend on heart rate calculations and a variety of morphology features derived from ECG waveforms, like ECG waveform factor and irregularity as disclosed in U.S. Pat. No. 5,474,574 to Payne et al. and U.S. Pat. No. 6,480,734 to Zhang et al. Further, in order to provide sufficient processing capability, current AEDs commonly embed the algorithms and control logic into microcontrollers.
[0005] As advances have taken place in the field of AEDs, there have been significant medical advancements in the understanding of human physiology and how it relates to medical care as well. These advancements in medical research have lead to the development of new protocols and standard operating procedures in dealing with incidents of physical trauma. For example, in public access protocols for defibrillation, recent guidelines have emphasized the need for the use of both CPR and AEDs and suggested an inclusive approach involving defibrillation integrated with CPR.
[0006] Along with its advantages, integrated use of CPR with defibrillation can, however, negatively impact the operation of an AED as chest compressions and relaxations are known to introduce significant motion artifacts in an ECG recording. During and after CPR, where a rescuer is instructed to apply chest compressions and relaxations at a prescribed rate of approximately 100 cycles per minute, the ability to obtain clean signal data from the patient can be challenging.
[0007] In addition to the difficulty of obtaining a clean ECG signal, the importance of doing this quickly has recently been highlighted as the current AHA Guidelines emphasize the importance of minimizing interruptions between CPR and defibrillation. The guidelines state, “[d]efibrillation outcome is improved if interruptions (for rhythm assessment, defibrillation, or advanced care) in chest compressions are kept to a minimum”, and “[m]inimizing the interval between stopping chest compressions and delivering a shock (ie, minimizing the preshock pause) improves the chances of shock success and patient survival.” See Circulation 2010, 122: S678, S641.
[0008] Some past AEDs implement an algorithm that requires an extended period of clean ECG signal data during a rescue to classify a sensed ventricular rhythm as shockable. Some prior art disclosures requiring a clean signal also discuss carrying out an initial assessment of ECG when CPR is ongoing, before relying on a temporary stoppage in CPR to acquire and perform an ECG analysis. Moreover, much of the recent scholarship in this area involves using tools which enable the entire analysis of ECG to take place while CPR is ongoing such that little or no stoppage of CPR is required. Accordingly, numerous techniques for identifying and filtering CPR artifacts for the purpose of ECG signal analysis have been proposed. However, many of these methods and analysis techniques have limitations or raise concerns related to providing appropriate care, especially in view of the newest AHA guidelines.
[0009] Accordingly, improved methods and apparatus for quickly assessing shockable cardiac rhythms which minimize any time periods between CPR and delivery of a defibrillation shock by an AED are desired.
SUMMARY OF THE INVENTION
[0010] Various embodiments of the present invention can overcome the problems of the prior art by providing a method and device to rapidly, but accurately, determine and verify the presence of a shockable cardiac rhythm to minimize delay between CPR and delivery of a defibrillation shock by a rescuer.
[0011] In one embodiment, an automated external defibrillator (AED) is provided. This AED includes an ECG sensor that obtains an ECG signal corresponding to patient heart activity and a prompting device that provides cardiopulmonary resuscitation (CPR) instructions. Further, the AED also has a control system including a microprocessor programmed to run two rhythm analysis algorithms after instructions to terminate CPR have been provided. The two rhythm analysis algorithms analyze segments of the ECG signal for recognizing the presence of a shockable rhythm. One of the two rhythm analysis algorithms provides a delayed start shockable rhythm verification algorithm. The AED additionally includes a therapy generation circuit for treating the shockable rhythm with a defibrillation pulse in response to the control system determining the presence of a shockable rhythm.
[0012] In another embodiment according to the present invention, an AED is disclosed. The AED includes an ECG sensor that obtains an ECG signal corresponding to patient heart activity. The AED also includes a prompting device for providing CPR instructions. The AED further includes a control system including a microprocessor in which the control system is adapted to determine the presence of a shockable a cardiac rhythm in a first segment of the ECG signal using a first algorithm. The control system is further adapted to determine the presence of a shockable cardiac rhythm in a second segment of the ECG signal using a second verification algorithm. The first algorithm and second verification algorithms run in parallel and analyze segments of the ECG signal. In this embodiment, the first segment begins when instructions to cease CPR are given. Thereafter, the second segment begins after a short number of seconds. The AED of this embodiment further includes a power generation circuit for providing power for a defibrillation pulse that may be used to treat shockable rhythms and a pulse delivery circuit.
[0013] According to an embodiment of the present invention, an automated external defibrillator is provided for reducing the delay between termination of cardiopulmonary resuscitation and administration of a defibrillating shock. The AED includes an ECG sensor that obtains an ECG signal corresponding to patient heart activity and a processor. The processor runs multiple rhythm analysis algorithms that each independently determine the presence of a shockable rhythm based segments of the ECG signal with different start times following cardiopulmonary resuscitation in order to verify the presence of a shockable rhythm.
[0014] Another embodiment according to the present invention, includes a method for delivering a defibrillation shock with an automated external defibrillator (AED). The method includes charging an AED during cardiopulmonary resuscitation (CPR), prompting a break in CPR with a prompting device of the AED, and analyzing a first segment of patient ECG data immediately following CPR with a first algorithm to determine if the ECG data has an initial shockable classification. The method also includes monitoring the ECG data with the first algorithm after the initial shockable classification to verify that the shockable classification remains consistent. The method further includes analyzing a second segment of the ECG data with a delayed start time compared to the first segment of ECG data with a second verification algorithm while the first algorithm is concurrently analyzing and monitoring ECG data to obtain an independent rhythm classification. The method also includes the step of comparing using the rhythm classification of the second algorithm with the classification of the first algorithm to provide resuscitation advice.
[0015] Yet another embodiment includes a method for reducing the delay between termination of cardiopulmonary resuscitation and administration of a defibrillating shock with an AED. This method includes the steps of initiating CPR, charging the AED, and prompting a break in CPR, analyzing a first set of ECG data immediately following CPR with a first algorithm to determine if the ECG data has a shockable rhythm classification. The method also includes the steps of analyzing a second set of ECG data obtained with a delayed start with respect to the first set of ECG data to determine if the ECG data has a shockable rhythm classification, and comparing the classification of the first set of ECG data and the second set of ECG data to determine whether a defibrillation shock should be delivered by the AED.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] 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:
[0017] FIG. 1 illustrates generally an example of a cardiac arrest victim being treated with CPR and an AED, according to an embodiment of the invention.
[0018] FIG. 2 illustrates generally an example of a schematic drawing of the hardware of an AED, according to an embodiment of the invention.
[0019] FIG. 3 illustrates generally a flowchart of the operation steps of the AED rhythm analysis according to an embodiment of the invention.
[0020] FIG. 4 illustrates generally a chart setting forth an example timeline of rhythm assessment and AED operation with a successful match of rhythm assessment in algorithms generally run in parallel.
[0021] FIG. 5 illustrates generally a chart setting forth an example timeline of rhythm assessment and AED operation which does not include a successful match of rhythm assessment in generally parallel algorithms.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The invention may be embodied in other specific forms without departing from the essential attributes thereof, therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive.
[0023] In various embodiments of this invention an apparatus and method are disclosed for rapidly and reliably evaluating an ECG signal from a patient such that minimal delay between CPR and delivery of a defibrillation shock is made possible. FIG. 1 depicts a cardiac arrest victim who is undergoing a resuscitation attempt and is being treated with an AED and CPR. The AED 100 is shown with electrode pads 104 and 106 coupled to the patient's chest and the rescuer 108 is shown in position for rapidly providing chest compressions to the patient 110 .
[0024] The AHA currently recommends that all rescuers, regardless of training, should provide chest compressions to all cardiac arrest victims, and that chest compressions should be the initial CPR action for all victims regardless of age. CPR typically improves a victim's chance of survival by providing critical blood circulation in the heart and brain.
[0025] Often, CPR alone will be insufficient to reverse cardiac arrest in a patient. In these cases, an AED 100 may be used to deliver an impulse of high amplitude current to a patient's heart to restore it to normal cardiac rhythm. However, there are many different types of heart rhythms, only some of which are considered shockable. The primary shockable rhythms are ventricular fibrillation (VF), ventricular tachycardia (VT), and ventricular flutter. Non-shockable rhythms may include bradycardias, electro-mechanical dissociation, idio-ventricular rhythms, and normal heart rhythms.
[0026] In order to determine if a rhythm is shockable, AEDs analyze ECG data to classify the type of rhythm the patient is experiencing. Specifically, a pair of AED electrodes 104 and 106 are positioned on the patient's chest, as shown in FIG. 1 , to obtain an ECG signal. Next, the ECG signal is analyzed by the AED and if the cardiac rhythm is deemed shockable, a defibrillation pulse is delivered to the patient.
[0027] AEDs relying upon such an ECG analysis may be considered semi-automatic or fully-automatic. In general, semiautomatic defibrillators require a user to press a button to deliver the actual defibrillating shock, compared to fully-automatic defibrillators that can deliver therapy without such an input of the user. Various embodiments of the present invention can work with either automatic and/or semi-automatic AEDs.
[0028] In FIG. 1 , the AED 100 is shown coupled to a pair of electrodes 104 and 106 located on the patient's chest 110 . The AED 100 is equipped with a central compartment having a hinged lid 112 to house the electrode pads 104 and 106 when the defibrillator is not in use. The lid 112 is shown in an open configuration in FIG. 1 and accordingly, is ready for use. In one embodiment, opening this lid 112 activates the AED 100 and begins sending prompts to the user. Prompts may include voice prompts from speaker 114 and visual prompts from the display 116 .
[0029] FIG. 2 illustrates generally a block diagram of the hardware of an AED 200 implementing the improved shocking algorithms according to one embodiment of the invention. A digital microprocessor-based control system 202 is used for controlling the overall operation of AED 200 . The electrical control system 202 further includes an impedance measuring circuit for testing the interconnection and operability of electrodes 204 and 206 . Control system 202 includes a processor 208 interfaced to program memory 210 , data memory 212 , event memory 214 and real time clock 216 . The operating program executed by processor 208 is stored in program memory 210 . Electrical power is provided by the battery 218 and is connected to power generation circuit 220 .
[0030] Power generation circuit 220 is also connected to power control unit 222 , lid switch 224 , watch dog timer 226 , real time clock 216 and processor 208 . A data communication port 228 is coupled to processor 208 for data transfer. In certain embodiments, the data transfer may be performed utilizing a serial port, usb port, firewire, wireless such as 802.11x or 3G, radio and the like. Rescue switch 230 , maintenance indicator 232 , diagnostic display panel 234 , the voice circuit 236 and audible alarm 238 are also connected to processor 208 . Voice circuit 236 is connected to speaker 240 . In various embodiments, rescue light switch 242 and a visual display 244 is connected to the processor 208 to provide additional operation information.
[0031] In certain embodiments, the AED will have a processor 208 and a co-processor 246 . The co-processor 246 may be the rhythm analysis algorithm implemented in hardware and operably connected to the processor over a high-speed data bus. In various embodiments, the processor 218 and co-processor 246 are on the same silicon and may be implemented in a multi-core processor. Alternatively, the processor 208 and co-processor may be implemented as part of a multi-processor or even networked processor arrangement. In these embodiments, the processor 208 offloads some of the calculations to the co-processor thus optimizing the processing of the sensed signals from the electrodes 204 and 206 . In other embodiments, the processor 208 is optimized with specific instructions or optimizations to execute calculations. Thus, processor 210 may execute calculations in fewer clock cycles and while commanding fewer hardware resources. In other embodiments, the logic and algorithm of the control system 202 may be implemented in logic, either hardware in the form of an ASIC or a combination in the form of an FPGA, or the like.
[0032] High voltage generation circuit 248 is also connected to and controlled by processor 208 . High voltage generation circuit 248 may contain semiconductor switches (not shown) and a plurality of capacitors (not shown). In various embodiments, connectors 250 , 252 link the high voltage generation circuit 248 to electrodes 204 and 206 . Note that the high voltage circuit here is battery powered and is of high power.
[0033] Impedance measuring circuit 254 is connected to both connector 250 and real time clock 216 . Impedance measuring circuit 254 is interfaced to real time clock through analog-to-digital (A/D) converter 256 . Another impedance measuring circuit 258 may be connected to connector 250 and real time clock 216 and interfaced to processor 208 through analog-to-digital (A/D) converter 256 . A CPR device 260 may optionally be connected to the processor 208 and real time clock 216 through connector 252 and A/D converter 256 . The CPR device 260 may be a chest compression detection device or a manual, automatic, or semi-automatic mechanical chest compression device. Additional detailed discussions of some AED designs can be found in U.S. Pat. Pub. No. 2011/0105930 and U.S. Pat. Nos. 5,474,574, 5,645,571, 5,749,902, 5,792,190, 5,797,969, 5,919,212, 5,999,493, 6,083,246, 6,246,907, 6,263,238, 6,289,243, 6,658,290, 6,993,386, each of which is hereby incorporated by reference.
[0034] The methods and systems utilized by embodiments of the present invention generally consist of employing two instances of rhythm analysis algorithms 300 and 301 that operate in parallel for assessment and verification in an AED or similar cardiac resuscitation device (like the one depicted in FIG. 2 , for example) so as to improve the time to deliver therapy. The first rhythm analysis algorithm 300 operates immediately, with little or no initial hold-off period from the AED's instruction to cease CPR. The second algorithm is a verification algorithm and default therapy recommendation algorithm. The second rhythm analysis verification algorithm 301 operates after a delayed start as a verification algorithm. Specifically, the second rhythm analysis verification algorithm 301 starts operating after a hold-off period that is designed to reduce the impact of CPR artifacts on rhythm analysis. The defibrillator will advise shock if after an initial learning period, the first instance of rhythm analysis 300 indicates the presence of the same shockable rhythm throughout and the rhythm classification from the second rhythm analysis verification algorithm 301 coincides with that of the first classification from the first rhythm analysis algorithm 300 . If the rhythm classifications do not match, the second rhythm analysis verification algorithm 301 is allowed to complete a full analysis and monitoring period and the classification resulting from that second algorithm 301 is used to determine the classification as well as any subsequent protocol advice for rescue.
[0035] FIG. 3 sets forth a more detailed flowchart describing the operational steps of an AED which utilizes a rhythm analysis coordinating two algorithms directed at segments with different start points for analysis of an ECG signal to quickly arrive at a cardiac rhythm classification and to verify assessments of shockable status.
[0036] Specifically, operation of the AED 100 with one embodiment of the rhythm analysis algorithm first charges the AED capacitors with the internal battery during CPR, as set forth at numeral 302 . This charge may be triggered in a variety of ways. In some embodiments, charging may occur simply by activating the AED 100 by opening its cover, turning it on, or other similar method. In other preferred embodiments, charging only will occur if a previous analysis has found a shockable rhythm so that the operating life of the battery is not negatively impacted in a substantial way by such pre-charging. Next, at an appropriate point during CPR, the AED 100 provides a voice prompt indicating that the user 108 should stop CPR, as represented by numeral 304 . Immediately following the voice prompt either a momentary analysis holdoff period or no holdoff period at all is provided, as represented at 306 . This preliminary analysis holdoff period only lasts for around one second in various embodiments. Next, a first (or primary) rhythm analysis algorithm (RAA) engine (the first rhythm analysis algorithm 300 engine) is started at 308 and is analyzed at 310 . The analyze period for this algorithm may last for about four seconds in some embodiments. The first rhythm analysis algorithm 300 follows the analyze period with an operation at 312 in which a shockable decision is reached and monitored for a short length of time. In some embodiments, this shockable decision and monitoring phase lasts for around five seconds. A determination is then made at 314 if a consistent classification of a shockable rhythm has remained throughout the monitoring phase. While the first rhythm analysis algorithm 300 is being carried out, a second rhythm analysis verification algorithm 301 operates simultaneously in a parallel evaluation of ECG rhythm data. This second (or secondary) rhythm analysis verification algorithm 301 begins with an analysis holdoff period 316 which starts as the first rhythm analysis operation 310 begins. Next, the second rhythm analysis verification algorithm 301 starts when the holdoff period completes at 318 . By delaying the start of the second rhythm analysis verification algorithm 301 , data artifacts and disturbances that might impact signal integrity or the ability to obtain a clean signal are greatly reduced, but without reliance on any filtering of the ECG signal. The second rhythm analysis algorithm 301 then enters an analyze phase 320 . This analyze period 320 may last for five seconds, for example, in some embodiments. At the end of this period, a determination is made at 322 classifying the rhythm as shockable or non-shockable.
[0037] Next, if the rhythm is deemed shockable by the second algorithm 301 and the first algorithm 300 gave a consistent classification indicating a shockable rhythm throughout the monitoring period, a shock is issued, at step 324 . In the case that either the first algorithm 300 was not consistently classified as shockable throughout the monitoring period or the second algorithm 301 classification was not shockable, the second algorithm classification is continued at 326 . The second algorithm is then classified as shockable or non-shockable throughout a continued period of monitoring and analysis at 328 . If the classification is shockable, a defibrillation shock is issued at 330 . If the rhythm is not classified as shockable, no shock is delivered and further CPR or rescue protocol prompts or recommendations are provided, at 332 .
[0038] For purposes of this disclosure, the first rhythm analysis algorithm may also be understood as the primary rhythm analysis algorithm and the second rhythm analysis verification algorithm may also be understood as the secondary rhythm analysis algorithm or the second rhythm analysis algorithm in various embodiments. In certain embodiments, each of the rhythm analysis algorithms can be understood to be modified versions of the RHYTHMx® software algorithm of Cardiac Science Corporation. Note that this method may make use of existing rhythm analysis algorithms in current AEDs or be part of completely updated algorithms used to control AED operation in various embodiments.
[0039] Use of two independent rhythm analysis algorithms for a shockable assessment and verification process is a useful and advantageous alternative over past prior art techniques. For example, alternative windowing techniques have been used throughout the prior art which restrict therapy decision-making to assessments of contiguous windows which are further subjected to a voting process to enhance consistency. This windowing technique has been modified somewhat in other disclosures to use overlapping windows of data for speeding up this assessment. One signal analysis technique that models overlapping windows and +has been know for decades for doing so is referred to as Welch's method although other similar techniques exist. Welch's method essentially teaches reduction in noise signals, like ECG signals, using spectral density estimation. The method is based on the concept of using periodogram spectrum estimates which are the result of converting a signal from the time domain to the frequency domain. Basically, a signal is split up into overlapping segments that are windowed and a Fourier transform operation is used to provide an array of power measurements vs. frequency bin. This overlapping in Welch's technique is deemed useful as it reduces problems at the boundaries between windows but provides a different computational methodology for approaching the problem of speeding up a rhythm assessment and specifically dealing with problematic post CPR signals. See U.S. Pat. No. 7,463,922.
[0040] The current disclosure does not use such a windowing technique, and instead approaches the problem in a different way using a targeted assessment and verification process. It has been found that use of the currently disclosed, non-windowing process, that makes use of two entirely separate algorithms and verification process, allows one to better rapidly assess and verify the shock assessment. The methods discussed in the current application both make use of the period immediately following CPR and yet take into account the potential noise inaccuracies of this period, in a way that windowing data by past techniques does not contemplate.
[0041] FIG. 4 depicts the rhythm analysis process in an alternate timeline format. Specifically, FIG. 4 is a chart 400 setting forth an example timeline of rhythm assessment and AED operation with an initial match of rhythm assessment in the generally parallel rhythm analysis algorithm 300 and the rhythm analysis verification algorithm 301 . In this example, an ECG signal is analyzed and a defibrillation shock is delivered within ten seconds of CPR.
[0042] The first timeline section 402 represents a ten second period of charging that occurs while CPR is performed. The end of the first timeline segment 402 corresponds to commencement of a voice prompt of the AED that occurs at 404 . This voice prompt at 404 instructs the rescuer to stop CPR and not to touch the victim. Specifically, the voice prompt states, “Do Not Touch Patient! Analyzing Heart Rhythm.”
[0043] The prompt to cease CPR also coincides with the start of an analysis period 406 by the first rhythm analysis algorithm 300 . This period of analysis 406 could last for five seconds, as depicted in the chart, or for another suitable alternative time period. The first second of this analysis period 406 can include a brief hold-off period, such as a one second delay in some embodiments as well. During the analysis period 406 , ECG data is acquired and analyzed with respect to the shockability of the heart activity data presented. This is followed by an analysis and monitoring period 408 . This period begins with an assessment of the cardiac condition of ECG data indicating that either a shockable or non-shockable cardiac rhythm is present. This assessment is then continued to be analyzed and monitored over the period 408 to ensure that a consistent shockable or non-shockable assessment is made throughout this time period.
[0044] Concurrently with the analysis period 406 , the second rhythm analysis verification algorithm 301 carries out an initial hold-off period 410 . This hold-off period 410 may last four to five seconds in some embodiments, for example. The hold-off period 410 is useful, in that, it avoids signals immediately following CPR and any potential impact of data artifacts and disturbances on signal integrity or on the ability to obtain a clean signal. The hold-off period 410 many culminate in a short learn period 412 in some embodiments in which ECG data is obtained. Once the hold-off period 410 is complete, acquired ECG data is evaluated by the second rhythm analysis verification algorithm 301 during an analyze period 414 to determine if a shockable or non-shockable rhythm exists. After a short time in the analyze period 414 (five seconds in some embodiments) a shockable rhythm determination is made which is compared to the determination made and monitored by the first rhythm analysis algorithm 300 during the concurrent period 408 .
[0045] FIG. 4 illustrates an instance in which the classification during the analyze and monitor period 408 is “shockable” and the assessment after the first seconds of the analyze period 414 is also “shockable”. Because both of these classifications match, instructions to deliver a shock are immediately provided by the AED control circuit. Such a quick shock decision is accordingly made possible because this method increases confidence in early rhythm classifications that may be determined soon after CPR.
[0046] FIG. 5 is a chart 500 setting forth an example timeline of rhythm assessment and AED operation which does not include an initial match of rhythm assessment in the parallel algorithms. Here, either the period 508 did not maintain a consistent “shockable” classification or the second rhythm analysis verification algorithm 301 revealed a non-shockable cardiac rhythm. In this situation, the rhythm analysis algorithm 301 completes the analysis period 514 and requests therapy based upon the classification determined by rhythm analysis algorithm 301 alone.
[0047] A further set of voice prompts from the AED are depicted in FIGS. 4 and 5 . These further voice prompts occur following the instructions given not to touch the patient at 404 . Specifically, the subsequent voice prompts 416 will announce “Preparing Shock. Move Away From The Patient!”
[0048] With respect to battery charging, this charging is designed to continue during a period 418 partially common to the analyze and hold-off periods 406 , 408 , 410 , 412 and 414 . However, the battery charge is short enough to be ready for defibrillation pulse delivery before an early shock decision can be made. Fast charging batteries are possible in some embodiments as well, which could complete charging is much less time than depicted in FIGS. 4 and 5 .
[0049] It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with an enabling disclosure for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention as set forth in the appended claims and the legal equivalents thereof.
[0050] The embodiments above are intended to be illustrative and not limiting. Additional embodiments are within the claims. Although the present invention has been described with reference to particular embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
[0051] Various modifications to the invention may be apparent to one of skill in the art upon reading this disclosure. For example, persons of ordinary skill in the relevant art will recognize that the various features described for the different embodiments of the invention can be suitably combined, un-combined, and re-combined with other features, alone, or in different combinations, within the spirit of the invention. Likewise, the various features described above should all be regarded as example embodiments, rather than limitations to the scope or spirit of the invention. Therefore, the above is not contemplated to limit the scope of the present invention.
[0052] For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.
|
An automated external defibrillator (AED) and methods for reducing the delay between termination of cardiopulmonary resuscitation (CPR) and administration of a defibrillating shock, among other disclosed apparatus and methods. In one embodiment, the AED includes an ECG sensor that obtains an ECG signal corresponding to patient heart activity and a prompting device that provides instructions regarding cardiopulmonary resuscitation. The AED also has a control system including a microprocessor programmed to run two rhythm analysis algorithms after instructions to terminate CPR. The two rhythm analysis algorithms analyze segments of the ECG signal for recognizing the presence of a shockable rhythm, with one algorithm having a delayed start relative to the other algorithm. The AED additionally includes a therapy generation circuit for treating the shockable rhythm with a defibrillation pulse in response to the control system determining the presence of a shockable rhythm.
| 0
|
FIELD OF THE INVENTION
[0001] The present invention relates to rail crossings and turnouts and more specifically to an improved frog particularly suitable for mine use.
BACKGROUND OF THE INVENTION
[0002] Rail crossings and turnouts are points where two sets of track cross. The center part of the crossing is sometimes referred to as a frog. Frogs can be cast or fabricated. For heavy use, frogs are sometimes formed from a durable steel such as manganese to increase resistance to wear and impact. Manganese frogs are a standard part of the mining, tunneling and railroad industry.
[0003] The rails connecting the switch rails to the frog are called closure rails. A frog has a toe end connected to the closure rail and a heel end at the end of a frog furthest from the switch. The frog point is the area where the running edges of two crossing rails come together. The frog has wing rails, which are two small rails at the heel end of the frog running essentially parallel to the wheel path along each side of the frog point. The wing rails support the wheel of the train car as the wheel crosses the gap at the frog point. The wing rails and the point define an X-shaped pair of grooves or flangeways. The flangeway is a channel that allows the wheel flange of the car to pass. The flangeway allows the wheel flange to maintain continuous contact with the inner surfaces of the frog through the intersection of the rails.
[0004] In order to properly guide a passing car over the frog, a guard-rail is typically placed on the opposite rail. A short rail is placed inside of and parallel to the stock rail opposite the point that the wheels pass through the frog.
[0005] The width of the frog is called its spread. Different sized frogs are used for rails making various angled turns. Frogs are generally identified by a frog number, which corresponds to the ratio of the length to the sum of heel and toe spreads. Conventional frogs have standard dimensions according to the frog number. Larger numbered frogs are generally used for larger turn radii.
[0006] The mining industry presents challenges for rail crossings. Modern mining cars are longer than their predecessors are. Most mine car wheels are fixed and do not turn. Due to the tight curves in the rails in mining operations, the wheels of these longer rail cars cannot follow the turns easily and easily derail when passing through a frog. As the leading wheels of the car move through the frog to the secondary rail, the car is turned in a different direction from that of the original rail. The fixed rear wheels of the car are pushed to the outside of the turn. In an existing frog, the rear wheel may jump the frog and derail the car. Where cars derail, damage may occur to the car and or the load in the car and the impact of the train car wheels on the frog generates early failure of the crossing.
[0007] Wing rails and guard rails have been used in an attempt to prevent derailing; however, no frog exists that adequately prevents derailing of longer fixed-wheel cars, such as those used in mines. A need exists for a frog having the ability to maintain the rear wheels of a car and successfully transfer the car through a turnout or crossover on a track. A need exists for a frog with a flangeway having an adequate width and angle to allow the wheel of a train car riding the wing rail across the intersection to stay in contact with the frog until it is supported by the secondary rail.
SUMMARY OF THE INVENTION
[0008] The present invention addresses these needs and relates to an improved frog having flared segments in each of two opposite flangeways. The improved frog varies in size and turn radius corresponding generally to known frog numbers. Although the frog's dimensions vary by frog number, the ending width of the flangeway is proportionally greater than a corresponding ending flangeway width of a conventional frog.
[0009] The frog has an upper surface for supporting a rail car wheel. The flared flangeway comprises a channel that allows a wheel flange of a railway car to pass through the frog. A segment of the flangeway angles away from a point section at a greater angle than that of similar segments of conventional frog flangeways. In an embodiment, the segment's ending width is approximately 3.5 times greater than the beginning width.
[0010] Each segment tapers outwardly from a center line of the frog to form a generally triangular perimeter. Together the segments form a generally triangular perimeter. In an embodiment, the angle of the segment wall forms about a 25 degree or about a 30 degree angle with the center line or the point wall. The segments together form about a 50 degree to about a 60 degree angle. In an embodiment having a frog number of ______, the ending width of each channel is approximately 5.5 inches.
[0011] The present invention's construction comprises walls that are thicker than corresponding walls of conventional frogs. In comparison to conventional frogs, the present invention comprises additional steel in cavities to increase strength and durability. In an embodiment, the frog is unitarily formed of steel, preferably manganese.
[0012] The present invention comprises a method for providing an improved rail way frog comprising forming the frog into a predetermined shape having a predetermined length and a predetermined width with thicker walls than corresponding walls of conventional frogs. The improved frog of the present invention is formed with opposite flangeway channels having an ending width greater than a corresponding ending width of a channel in a conventional frog.
[0013] These improvements offer enhanced performance over conventional frogs, resulting in a savings of time and expense by rail operators and owners, particularly mines owners and their employees.
[0014] Features, aspects, advantages and objects presented and accomplished by the present invention will become apparent and or be more fully understood with reference to the following description and detailed drawings of preferred and exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a top view of the frog;
[0016] FIG. 2 is a cross sectional side view of the frog;
[0017] FIG. 3 depicts cross-sectional views of the frog at various points in connection with the rail; and
[0018] FIG. 4 is a perspective view of the frog.
DETAILED DESCRIPTION OF THE INVENTION
[0019] As shown in FIG. 1 , the frog comprises substantially mirrored portions extending from a centered horizontal line. The frog comprising a toe end 100 and a heel end 110 . The toe end 100 comprises toe end connectors 120 , 121 that connect the frog to a first set of tracks, and the heel end 110 comprises heel end connectors 122 , 123 that connect the frog to a second set of tracks. The far ends 124 , 125 of each of the toe end connectors 120 , 121 are farther apart than the near ends 126 , 127 of each toe end connector 120 , 121 . The near ends 126 , 127 of the toe end connectors 120 , 121 converge to a set distance at the throat 130 of the frog. A toe ramp 140 extends from a middle portion of the toe end connectors 120 , 121 to the throat 130 of the frog. The toe ramp 140 extends between the toe end connectors 120 , 121 from near the bottom of each inside wall of each toe end: connector 120 , 121 to the throat 130 . The end of the toe ramp 140 at the throat 130 is in a higher plane than the end of the toe ramp 140 at the middle portion of the toe end connectors 120 , 121 .
[0020] The frog comprises a left wing rail 150 and a right wing rail 160 that generally mirror each other and extend from the throat 130 . The distance between the throat ends 151 , 161 of the wing rails 150 , 160 is less that the distance of the opposite ends 152 , 162 of the wing rails 150 , 160 .
[0021] The toe ramp 140 cooperates with flangeways 170 , 180 . The flangeways 170 , 180 are joined prior to point 185 and formed from the sides of the wing rails 150 , 160 . The flangeways 170 , 180 diverge after the point 185 and each extend outwardly toward the heel end 110 . A point section 190 extends between flangeways 170 , 180 . Lateral side walls of the point section 190 form each flangeway's second wall 191 , 192 . The point section 190 is essentially triangular shaped and terminates at the heel end connector near ends 128 a , 128 b . Each heel end connector near end 128 a , 128 b is closer to the other than each heel end connector far end 129 a , 129 b.
[0022] The flangeways 170 , 180 angle outward as compared to each other. Ends of a flangeway first segment 171 , 181 at the throat 130 are closer in proximity to each other than the segment opposite end. The first segment wing rail side wall 178 , 188 and the point side wall 191 , 192 are approximately parallel to each other. A second flangeway segment 173 , 183 has a second segment wing rail side wall 179 , 189 at a greater angle to that of the side wall of the first flangeway segment 171 , 181 in reference to the point side wall 191 , 192 . In an embodiment, the angle of the second segment side wall 179 , 189 to the point side wall 191 , 192 is approximately 25 degrees to approximately 30 degrees. In a preferred embodiment, each second flangeway segment wing rail side wall 179 , 189 angles from the respective point side wall 191 , 192 at about a 28 degree angle. In an embodiment, the segment side walls 179 , 189 form about a 50 degree to about a 60 degree angle to each other. In a preferred embodiment, the angle formed by the second segments is about a 56 degree angle.
[0023] In an embodiment, a flangeway second segment end 172 , 182 width is approximately 3 to 4 times greater than a beginning width closest to first segment. In a preferred embodiment, the width of each flangeway end 172 , 182 is about 3.5 times greater than end closest to the first segment.
[0024] One skilled in the art would readily understand that the size and angles of the present invention vary to conform to the pattern and dimensional details of the rail and the radius of the curve. The present invention varies in size, generally corresponding to the size of conventional frogs based on frog numbers.
[0025] In FIG. 2 and FIG. 3 , only one side of the frog is shown, however, one skilled in the art would readily understand that mirror images of the figures would describe the other half of the frog. As shown in FIG. 2 , the upper surface 200 of the frog is essentially flat. The general slope of the toe ramp 140 is illustrated in FIG. 2 . The flangeways 170 , 180 are also ramped downward toward the heel end 110 and deep enough to provide sufficient clearance to allow the flange of a wheel of a car to pass without contacting the bottom of the frog.
[0026] FIG. 3 depicts cross-sectional views of the frog as it conforms to the rails. Only one half of the frog is shown, however, one skilled in the art would readily understand that mirror images of the figures would describe the other half of the frog. FIG. 3A depicts the frog in relation to the rail at the toe end connectors 120 , 121 . The frog is secured to the rail by means 310 of bolting, riveting, fastening, welding, and the like. FIG. 3B depicts the the ramp 140 in relation to the rail. The frog is secured 320 to the rail in a similar fashion as in FIG. 3A at this sector. FIG. 3C depicts the side wall of the ramp 140 in cooperation with the throat 130 and wing rails 150 , 160 .
[0027] FIG. 3D depicts the wing flangeway 170 , 180 , in conjunction with the wing rail 150 , 160 and the point section 190 at the flangeway first segment 171 , 181 . FIG. 3F shows the relationship of the improved frog to the second rail at the heel end connector far end 129 a , 129 b just prior to the connection to the second rail. The heel end connector 122 , 123 is secured 330 , 340 (see FIG. 4 ) to the second rail by means of bolting, riveting, fastening, welding, and the like.
[0028] The improved frog of the present invention is cast of steel, preferably, manganese steel. As depicted in FIGS. 3 A-F, the wall thickness of the improved frog is thicker than conventional frogs. As shown in FIGS. 3E and 3F , the structure of present invention from about the heel end connector near end 128 a , 128 b to about the point 185 of the frog is not hollowed as found in conventional frogs, but is solid steel. In an embodiment, the walls are about ⅝ inch to about ¾ inch thick. The thicker walls of the improved frog add durability and strength. Manganese steel is used to increase tolerance for impact and work load imposed by the wheels of the cars of the train traversing the frog. In an embodiment, the present invention is formed from manganese poured into a casting shaped to provide the flared flangeways, reinforced sections and other features of the improved frog.
[0029] The frog of the present invention is formed such that wheel load is borne at least in part by the rail ties. The thickness of the walls of the at the heel end connector 122 , 123 adds stability at the point of re-contact of the wheel of the train car to the second rail. As a consequence of these improvements, the frog supports heavier loads and lasts longer than conventional frogs.
[0030] The following example is provided to further describe the invention. One skilled in the art would readily understand that the example would similarly apply to a right hand turn, switch, other crossing, and the like.
EXAMPLE 1
[0031] In this example, a train car traveling on a first track is switched to a track that is a left turn from the direction of the first track. As the train car is moved from the first track to the second track, the front wheels of the car traverse the frog and change the direction of the car to the direction of the second track. As the fixed rear wheels of the car enter the turnout, the right hand wheel engages the frog. As shown in FIG. 4 , the wheel is supported by the wing rail 160 as the wheel passes the gap at the throat 130 between the toe end connector 121 and the point 185 . The flange of the wheel may optionally ride up all or part of the toe ramp 140 to enter the throat 130 . As the car continues, the flange of the wheel travels flangeway 150 . At the flangeway second segment 173 , the wheel is supported by the point section 190 and the wheel flange brushes the flangeway wing rail wall 177 allowing the wheel supported by the point section 190 to move sufficiently toward the wing rail to allow the wheel opposite the frog wheel to maintain contact with the stock rail. The wheel re-engages the rail at the heel end connector 122 . The force exerted from the frog wheel on the stock rail wheel is eased by the width and the angle of the second segment of the flangeway 173 . By offsetting the force, the frog wheel is not pushed out of the frog and the train car stays on the rail through the turn.
[0032] The frog optionally works in conjunction with conventional guard railings that work on the wheel opposite the frog wheel to further aid in the prevention of derailings.
[0033] The thickness of the walls, the additional steel, and the wide flared flangeways of the present invention have greatly improved performance over conventional frogs, resulting in a savings of time and expense.
[0034] One skilled in the art will understand that the description of the present invention herein is presented for purposes of illustration and that the design of the present invention should not be restricted to only one configuration or purpose, but rather may be of any configuration or purpose which essentially accomplishes the same effect.
[0035] The foregoing descriptions of specific embodiments and examples of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. It will be understood that the invention is intended to cover alternatives, modifications and equivalents. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0036] 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 present invention relates to an improved railway frog having opposite side flangeways, each flangeway comprising a channel with an ending width greater than a corresponding channel width of a conventional frog. The improved frog further comprising a segment with an outside wall angle greater than a corresponding segment wall angle of a conventional frog.
| 4
|
FIELD OF THE INVENTION
[0001] The present invention relates to a game controlling method, and more particularly, to an interactive game controlling method for use in a touch panel device medium.
DESCRIPTION OF THE RELATED ART
[0002] With the development of touch control technology, it is nowadays possible to use it in many application fields. For example, the touch screens have been broadly equipped not only on gigantic public equipments like automatic teller machines (ATMs) and Karaokes but also on personal consumer products, such as personal digital asistants (PDAs), Smart-phones and personal computers (PCs). Taking advantage of the touch control technology, touch games have become so popular though they have only appeared for a few years. The rising of touch games depends on some strong points. For example, touch games are more intuitive, user-friendly in its touch operation than the conventional video games. These advantages make touch games be in great demand.
[0003] It should be noted that the design and development of touch games, in contrast to those of the conventional video games, are particularly focused on the mode of touch operation. The mode of touch operation is the decisive factor of the playability of touch games, and this is particularly true for the games to be played on a PDA or a smart-phone. Player's movements in a baseball game, for example, may be designed to define a sliding movement as a command of pitching a ball and a single tapping operation as a command of swinging the bat. In some cases, touch games are designed to display a row of virtual control buttons adapted to be selectively pressed by the user. More preferably, the mode of touch operation can be adjusted with different hardware specifications.
[0004] FIG. 1 shows a current method for controlling a first-person shooter game (FPS). In a FPS gaming process, players are required to control the character and change visual angles to search the enemy at the same time. For example, a common FPS is typically controlled by a handgrip or by a keyboard and a computer mouse, so that a player can give complicated instructions by the respective fingers of right and left hands. This operation logic is normally passed along when a FPS is transplanted from a computer to a smart-phone and a PDA. Therefore, a movement controlling button 81 is displayed on the lower left of the touch panel 8 , and the visual angle controlling button 82 is displayed on the lower right. When the character controlled by the player encounters an enemy 83 , the player, in the hope of aiming the enemy 83 as shown in FIG. 2 , could use the visual angle controlling button 82 to change the visual angle until the enemy 83 enters the shooting area 84 in the center of the screen, and then press the zooming button 85 to enlarge the image and press the fire button 86 to shoot forwards.
[0005] A problem would occur when the player holds the touch panel with both hands. The player has to hold the touch panel with four fingers each hand, only leaving two thumbs to control more than two virtual buttons. It means that the visual angle controlling button 82 , the zooming button 85 and the fire button 86 cannot be pressed at same time. For example, when the player relocates the enemy 83 within the shooting area 84 upon pressing the visual angle controlling button 82 as shown in FIG. 2 , the player need to move the thumb of right hand to press the fire button 86 . This finger movement, however, would give a chance to the enemy 83 to run out of the shooting area 84 at this moment. If it is the case, the player would have to repeat the previous step to re-catch the enemy 83 . The enemy 83 will run out of shooting area 84 again and again if this problem has not solved. The design of virtual buttons described above places the player in a hurry-scurry state. Besides, the space of a Smartphone screen is not board enough. It gets worse when the player put their thumbs in two sides of the screen. Such being the case, the practical size of the images of the game is typically designed to be much smaller than the size of a Smartphone screen. In contrast, it's easier for a player to player the game when using a computer with a keyboard and a computer mouse or using an arcade game machine with a handgrip.
[0006] Therefore, when a touch game requires a player to control multiple serially arranged virtual buttons by two thumbs, it is impossible for the player to input multiple commands, such as searching enemies, aiming the target and shooting, in a short period of time. On the one hand, the operational accuracy of the player is limited by the design of virtual buttons, making the game interface unfriendly to the player. Meanwhile, the player cannot thoroughly enjoy the game due to the limitation of operability, reducing the playability of the game. Therefore, there is a need for a game controlling method that is capable of providing greater operability of the touch control games and allow multiple complicated commands, thus greatly improving the control convenience for players.
[0007] In view of the drawbacks described above, the invention provides a game controlling method, which is adapted to detect and identify the number of one or more initial points of a touch and sense the motion of the touch. The interactive game includes a virtual hot zone, and an interactive program will be executed in response to a finger tapping on the virtual hot zone. These technical features allow the manufacturers of touch games to develop games that are easier-to-operate and friendly to the players, and can be played by inexperienced game players. It also allows sending multiple complicated commands, which further improves the playability of the game. The game controlling method proposed in this invention can resolve the aforementioned problems encountered by the conventional touch games played on touch panels.
SUMMARY OF THE INVENTION
[0008] The first aspect of this invention is to provide an interactive game controlling method for use in a touch panel device medium, so as to impart the touch panel device medium an improved convenience of game operations.
[0009] The second aspect of this invention is to provide an interactive game controlling method that improves the game operation mode by performing a movement in a direction opposite to the direction to which the touch is moving.
[0010] The third aspect of this invention is to provide an interactive game controlling method, by which multiple commands may be so integrated as to be executed consecutively in a short period of time, thereby increasing the delicacy of the game.
[0011] The fourth aspect of this invention is to provide an interactive game controlling method for use in a touch panel device medium without using any virtual buttons, thereby maximizing the visual area of the panel.
[0012] The invention provides an interactive game controlling method for use in a touch panel device medium comprising a touch panel device provided with a plurality of cells and a processor device, wherein the touch panel device is adapted to detect and identify the number of one or more initial points of a touch and sensing the subsequent motion of the touch; and wherein the interactive game includes a virtual hot zone, a virtual display range and at least one self-acting virtual object displayed on the touch panel device, and wherein an interactive program that allows a user to interact with the at least one self-acting virtual object in the virtual hot zone is executed in response to a finger tapping on the virtual hot zone, the interactive game controlling method comprising the steps of: a) receiving a touch and sensing the motion of the touch; b) moving the virtual display range where the at least one self-acting virtual object is included in a direction opposite to the direction to which the touch is moving; and c) executing the interactive program to allow the user to interact with the at least one self-acting virtual object when the at least one self-acting virtual object is relocated to the virtual hot zone and the virtual hot zone receives a change in state of touch.
[0013] According to the technical features disclosed herein, the invention executes the designated programs corresponding to the respective changes in finger touch on the touch screen. By doing so, it allows the player to hold the game medium with one hand while controlling multiple complicated commands with the other hand, so as to improve the convenience of the game operations, keep the fun in gaming, make the game interface more friendly to the player, and further facilitate the game designer to develop more highly operational games.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above and other objects, features and effects of the invention will become apparent with reference to the following description of the preferred embodiments taken in conjunction with the accompanying drawings, in which:
[0015] FIGS. 1-2 are schematic diagrams of a conventional FPS displayed on the touch panel;
[0016] FIG. 3 is a schematic diagram of a FPS displayed on the touch panel according to the first preferred embodiment of the invention;
[0017] FIG. 4 is a flowchart of the interactive game controlling method according to the first preferred embodiment of the invention;
[0018] FIGS. 5-6 are schematic diagrams of a FPS displayed on the touch panel according to the first preferred embodiment of the invention;
[0019] FIGS. 7-9 are schematic diagrams of a FPS displayed on the touch panel according to the second preferred embodiment of the invention;
[0020] FIG. 10 is a schematic diagram showing the step of zooming-in and zooming-out according to the third preferred embodiment of the invention;
[0021] FIG. 11 is a schematic diagram showing the step of getting target locked-on according to the fourth preferred embodiment of the invention; and
[0022] FIG. 12 is a schematic diagram showing the application of the present invention to a role-playing game according to the fifth preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The foregoing and other features and advantages of 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, wherein similar numerals designate like parts.
[0024] As shown in FIG. 3 , the touch panel device medium, in which the interactive game controlling method according to the invention is to be used, includes a conventional touch panel device 8 and a processor device (not shown) provided in the touch panel device 8 . The touch panel device 8 comprises multiple pixels to make up images on the screen and is adapted to detect and identify the number of finger touches and the state and speed of finger motions on the touch panel device 8 and then transmit the received signals to the processor device. The received signals are computed in the processor device and then presented in the form of images and/or audio information in accordance with the executed program, which are adapted for the user to watch or identify. According to this embodiment, the interactive game controlling method is illustrated as a first-person shooter game (FPS) as shown in FIG. 3 . For the purpose of convenience in illustration, an area in the touch panel device is defined to be a virtual display range 12 , and a visual hot zone is demonstrated as a foresight of a gun at the center of FIG. 3 and illustrated herein as a virtual shooting zone 13 . Any virtual figure that is displayed on the touch panel device without controlled by the user is defined as a self-acting virtual object 11 .
[0025] Now referring the flow chart shown in FIG. 4 , the touch panel device 8 initially receives a finger touch in Step 401 . In this embodiment, the touch panel device 8 detects and identifies the number of the initial points of the finger touch and senses the subsequent motion of the finger touch. In Step 402 , when the touch panel device 8 identifies that the finger touch has one initial touch point and the subsequent motion of the finger touch is a finger dragging motion, the virtual display range 12 is moved in a direction opposite to the direction to which the finger dragging motion is advancing.
[0026] Afterwards, when the touch panel device 8 displays the self-acting virtual object 11 , namely, an enemy character, at top-left of the gaming image as shown in FIG. 5 , and the virtual shooting zone 13 is shown at the center of gaming image, the player may want to relocate the enemy character within the virtual shooting zone 13 to expose the enemy character under his/her gun fire. Unlike the conventional video games where the player has to turn gun muzzle to aim at the enemy character, the method according to this embodiment allows the player to touch the enemy character with a finger and then drag the enemy character right-downwardly as indicated by the solid arrow to relocate it within the virtual shooting zone 13 . That is to say, the finger dragging motion inputs a vector 21 for dragging the enemy character into the virtual shooting zone 13 , by which the processor device generates an opposite vector having an equal magnitude (as indicated by the dashed arrow). The opposite vector controls the rotation and movement of the visual angle of the gaming image, so that the virtual display range 12 is moved left-upwardly in an opposite direction of the vector 21 , whereby the self-acting virtual object 11 located in the virtual display range 12 looks as if it is shifted right-downwardly.
[0027] The following step 403 is shown in FIG. 6 . When the self-acting virtual object 11 is placed at the virtual shooting zone 13 , the player could tap on the virtual shooting zone 13 , which is located at the center of touch panel device 8 , to open fire. The processor device activates an interactive firearm firing program when the virtual shooting zone 13 senses the finger tapping and, therefore, receives a change in state of touch. In Step 404 , the player interacts with the self-acting virtual object 11 by activating the firearm firing program to open fire at the virtual shooting zone 13 . Finally, in Step 405 , the damage to the self-acting virtual object 11 is calculated based on the region tapped by the finger. For example, there would cause minor damage to the enemy if the player only attacks the enemy's limb. On the contrary, the enemy would be one hit killed if player attacks the enemy's vital point. Meanwhile, the displayed status of the virtual object is changed based on the damage.
[0028] It is apparent to those who have ordinary skill in the art that the change in state of touch described above is not limited to the finger tapping on the virtual shooting zone 13 after the enemy character enters the virtual shooting zone 13 , but also includes stopping the finger dragging motion after the enemy character is moved into the virtual shooting zone 13 and removing the finger from the touch panel device, which is defined herein as a release of the finger dragging motion. Therefore, the state of touch is illustrated to be a finger dragging motion according to the second preferred embodiment of the invention as shown in FIG. 7 . In the case where the player doesn't release the finger dragging motion immediately after the enemy character is dragged within the virtual shooting zone 13 by the vector 22 , the enemy would be able to escape right upwards following a path 111 as indicated by the dotted line. In this case, the player may relocate the enemy character to the center of gaming image by inputting a vector 23 which is opposite to the direction which the enemy character is escaping along the path 111 . As shown in FIG. 9 , when the enemy is relocated within the virtual shooting zone, the player may fire at the virtual shooting zone by releasing the finger dragging motion within the virtual shooting zone while changing the visual angle.
[0029] As such, when the player drags the enemy character to the virtual shooting zone with a finger and then removes the finger from the touch panel device, the processor device moves and shifts the virtual display range in a direction opposite to the finger dragging direction to track the enemy character and immediately activates the firearm firing program to open fire at the enemy character now relocated within the virtual shooting zone in response to the removal of the finger from the touch panel device. By virtue of the technical features described above, the command of moving the virtual shooting zone is integrated with the command of opening fire, thereby simplifying the operation. In short, taking advantage of the simplified operation mode, the present invention not only improves the convenience of changing the visual angle of the gaming image, but also realizes an integrated operation of changing the visual angle of the gaming image and firing at the virtual shooting zone. Therefore, the present invention greatly facilitates the diversity and convenience in game controlling.
[0030] Some conventional video games provide a virtual button for the player to adjust the visual field. As described above, the addition of the virtual bottom could result in an operational burden to the player. According to the third preferred embodiment of the invention shown in FIG. 10 , in the case where the player touches the touch panel device with two fingers concurrently, the touch panel device detects and identifies a two-point touch which is distinct from a one-point touch. When the player touches the enemy character with two fingers and subsequently moves the two fingers toward a certain direction along the surface of the touch panel device while sliding the two fingers away from each other to increase an interval therebetween, the finger movement generates two motion vectors 24 , 25 , whereby the virtual display range is zoomed-in and the enemy character is relocated at the midpoint of the end points of the two vectors 24 , 25 using one-half of the sum vector of the two vectors 24 , 25 as a motion vector for relocating the enemy character. Due to the three vectors, the player may enlarge the size of the enemy character while dragging it to a certain spot simultaneously. Meanwhile, the processor device is programmed to open fire when the enemy character is relocated within the virtual shooting zone. Accordingly, the embodiment disclosed herein integrates the command of zooming-in the virtual display range, the command of relocating the enemy character and the command of opening fire.
[0031] Furthermore, according to the fourth preferred embodiment of the invention as shown in FIG. 11 , the invention comprises an automatic lock-on function. That is to say, when the self-acting virtual object 11 enters the virtual shooting zone, the player could input a lock-on command by, for example, drawing a circle surrounding the self-acting virtual object 11 , so that the self-acting virtual object 11 is locked-on in the virtual shooting zone, allowing the virtual shooting zone and the virtual display range to intimately follow up the movement of the self-acting virtual object 11 . As the self-acting virtual object 11 is locked on, the player can take his time to perform other actions. For example, the player can switch his weapon from one to another, and then calmly taps on the self-acting virtual object 11 to annihilate it.
[0032] It should be noted that the concept of the present invention is not limited for use in a shooting game and is also applicable to a role-playing games (abbreviated as R.P.G.) as described below, in which the virtual hot zone is a virtual conversation area. According to the fifth preferred embodiment of the invention shown in FIG. 12 , the character 3 controlled by the player may be locked-on to track the movement of a non-player character 6 (NPC 6 ). During the period of locked-on, the player can focus on management of the dialog box 7 which shows the dialogue with NPC. The invention can also be used when the player finds a treasure chest or a gate. In this case, the treasure chest and the gate each functions as a self-acting virtual object adapted to be opened up when dragged to a central spot of the gaming image.
[0033] By virtue of moving the virtual display range in a direction opposite to the direction to which the finger dragging motion is advancing as a means to track the self-acting virtual object in combination with performing a change in state of touch, such as a finger-tapping and a release of finger dragging motion, on the virtual hot zone, the invention generates a variety of virtual activities on a touch panel device by executing predetermined processing programs corresponding to the respective virtual activities, without using multiple complicated commands. Therefore, in the light of the technical features disclosed herein, the gaming operation becomes more easily than the conventional video games and simply requires changing touch points and touch state to accurately realize a variety of virtual activities. It doesn't need to keep one eye on many things, the player would not fall into the situation of multitasking when playing the game. In this way, it reduces the operational complexity of the game.
[0034] It should be noted that the visual hot zone can be displayed elsewhere besides at the center of the touch panel device, such as at a lower central spot, at a left central spot or at a right central spot of the touch panel device, depending on design need. It is unnecessary for the visual hot zone to be shown in the form of a circle or other geometric shapes, as long as the player can clearly know where it is according to the game instructions.
[0035] In summary, the interactive game controlling method disclosed herein provides different operation modes responsive to different numbers of touch points and touch motions. As a result, the player doesn't have to concern about the state of each operation command at all times. On one hand, it makes the game more user-friendly and easy-to-play. On the other hand, the player doesn't have to carry out every operation by himself, but leaves some commands to be executed by the processor device. In this way, the player could focus on the command control in other aspects, so as to lower the complexity of the game. The invention goes out of the boundary of the virtual buttons, thus facilitating the use of the medium space and expanding the visual area of the screen. The invention is also applicable to laptop computers, smart phones, portable game stations and so on.
[0036] While the invention has been described with reference to the preferred embodiments above, it should be recognized that the preferred embodiments are given for the purpose of illustration only and are not intended to limit the scope of the present invention and that various modifications and changes, which will be apparent to those skilled in the relevant art, may be made without departing from the spirit and scope of the invention.
|
The present invention relates to an interactive game controlling method for use in a touch panel device medium. The game includes a virtual hot zone, a virtual display range, at least one self-acting virtual object displayed on the touch panel device. An interactive program that allows users to interact with the virtual object in the virtual hot zone is executed in response to a finger tapping on the virtual hot zone. The method includes the steps of: a) receiving a touch and sensing the motion of the touch; b) moving the virtual display range where the virtual object is included in a direction opposite to the direction which the touch is moving; c) executing the interactive program to allow the user to interact with the virtual object when the virtual object is relocated is to the virtual hot zone and the virtual hot zone receives a change in state of touch.
| 0
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a video signal recording apparatus which records, along with a video signal, some data signals relative to the video signal on recording means such as a recording medium.
[0003] 2. Description of the Related Art
[0004] The conventional apparatus for recording and/or reproducing a plurality of data signals on and from a recording medium along with a video signal has been arranged to put the video signal and the data signals in a superimposed state confirmable on a monitor and to record them in that state on the recording medium in response to some recording trigger signal.
[0005] However, with the conventional apparatus arranged in this manner to have the data signals superimposed on the video signal for confirmation on the monitor, the video signal displayed on the monitor in recording it is hidden by the data signal over an excessively wide area on the monitor in cases where the data signals are to be recorded in many different kinds. This has presented a problem.
SUMMARY OF THE INVENTION
[0006] It is a first object of this invention to provide a video signal recording apparatus which is arranged to be free from the above stated problem of the prior art.
[0007] It is a second object of this invention to provide a video signal recording apparatus which is arranged to have a recording video signal adequately confirmable on a monitor.
[0008] To attain this object, a video signal recording apparatus arrange to have a video signal and data signals relative to the video signal recorded together on a recording medium comprises: first means for supplying a monitor with the data signal in a state of being superimposed on the video signal; second means for supplying the monitor with the data signal not in a state of being superimposed on the video signal; and selection means for selectively causing the first or second means to operate. The selection means is arranged such that the second means is caused to operate in case where a video signal to be recorded would be excessively hidden by the data signals, so that the video signal to be recorded can be always adequately confirmed on the monitor.
[0009] It is another object of this invention to provide an apparatus which is of the kind recording and reproducing a video signal together with a plurality of data signals related to the video signal on and from recording means and is arranged to permit adequate confirmation of the video signal on a monitor when the plurality of data signals are reproduced and supplied to the monitor along with the video signal.
[0010] Under this object, a recording and/or reproducing apparatus arranged as a preferred embodiment of this invention to record and reproduce a video signal together with a plurality of data signals related to the video signal on and from a recording medium comprises: selecting means for determining whether at least some of the data signals is to be set or not; and control means for varying, according to selection made by the selecting means, the position of the data signal in which the data signal is to be displayed in a state of superimposed on the video signal during a reproducing operation.
[0011] It is a further object of this invention to provide a reproducing apparatus which facilitates observation of reproduced data signals on a monitor in reviewing recorded data signals by reproducing them.
[0012] It is a further object of this invention to provide a recording apparatus which is of the kind recording a video signal and data signals related to the video signal together on a recording medium and is arranged to permit recording on the medium with adequate timing while reviewing the video signal on a monitor and to permit confirmation of the recording through the monitor.
[0013] Under that object, a recording apparatus which is arranged as another preferred embodiment of this invention to display on a monitor the execution of a video signal recording operation on a recording medium comprises: means for supplying the monitor with a video signal to be recorded; means for generating a trigger signal for causing the video signal to be recorded; means for supplying the monitor with the video signal by at least partially varying the video signal to have the monitor display that the video signal is recorded.
[0014] It is a still further object of this invention to provide a recording apparatus arranged to enable the operator to correctly and adequately set data signals in setting the data signals which are to be recorded along with a video signal.
[0015] These and further objects and features of this invention will become apparent from the following detailed description of embodiments thereof taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a block diagram showing the arrangement of an embodiment of this invention.
[0017] [0017]FIG. 2 shows combinations of the switching positions of switches SW 2 to SW 5 shown in FIG. 1.
[0018] [0018]FIG. 3 is a front view showing an apparatus arranged as the same embodiment.
[0019] [0019]FIG. 4 is a front view of a remote control device to be used in combination with the same apparatus.
[0020] FIGS. 5 to 20 , 23 , 25 to 27 and 29 to 31 are flow charts showing the operation of a CPU 40 .
[0021] FIGS. 21 ( a ) to 21 ( c ), 22 ( a ) to 22 ( b ) and 24 are illustrations of ID signals to be displayed on a monitor.
[0022] FIGS. 28 ( a ) to 28 ( c ) are illustrations of a flow of operation shown in FIG. 27.
[0023] [0023]FIG. 32 is an illustration of signals generated from an erasion signal generator 85 shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In an embodiment described below, this invention is applied to a recording and/or reproducing apparatus which is of the kind arranged to record and/or reproduce a still picture video signal on or from a disc shaped recording medium, i.e. a disc-shaped magnetic sheet. However, it should be noted that the application of this invention is not limited by the kind of recording mediums, as described below.
[0025] Hereinafter, the embodiment of the invention will be described in the following order. Furthermore, the correspondence of the various items with the figures is as follows:
[0026] Arrangement of the embodiment . . . FIGS. 1 to 4 .
[0027] Main flow . . . FIGS. 5, 6A and 6 B.
[0028] Subroutine (F) . . . FIG. 7 (contents: renewal of track feed speed).
[0029] Subroutines (D) and (E) . . . FIGS. 8A, 8B and 8 C (contents: track UP and track DOWN).
[0030] Subroutines (J) and (B) . . . FIG. 9 (contents: field/frame selection).
[0031] Subroutine (C) . . . FIG. 10 (contents: PB mode setting).
[0032] Subroutine (G) . . . FIG. 11 (contents: interval time setting).
[0033] Subroutine (N) . . . FIG. 12 (contents: REC operation).
[0034] Subroutine (H) . . . FIG. 13 (contents: program setting mode).
[0035] Subroutine (I) . . . FIG. 15 (contents: program setting process).
[0036] Subroutines (K), (M) and (O) . . . FIGS. 16 to 18 (contents: interval reproduction and programed reproduction).
[0037] Subroutine (R) . . . FIG. 19 (contents: ID setting).
[0038] Subroutine (Q) . . . FIGS. 20 to 22 ( b ) (contents: ID display).
[0039] Subroutines (S), (T) and (U) . . . FIGS. 23 to 26 (contents: year, month, day setting as ID).
[0040] Subroutine (V) . . . FIGS. 27 to 30 ( b ) (contents: erasing operation).
[0041] Subroutine (W) . . . FIG. 31 (contents: all track erasing operation).
Arrangement of the Embodiment
[0042] [0042]FIG. 1 shows the arrangement of the embodiment in a block diagram. The magnetic sheet 1 has the positions of video signal recording or reproducing tracks and the track pitch predetermined thereon. These tracks are concentrically formed. In the case of a frame video signal which has one field portion of the video signal recorded in one track, one-field video signals recorded in two adjacent tracks jointly form one frame video signal. The magnetic sheet 1 is obtained in a state of having been placed within a jacket which is not shown. The jacket 1 is provided with an erroneous erasion preventing claw. An erasing action can be prevented by breaking off the claw beforehand in the same manner as in the case of an audio cassette. A DC motor 2 is arranged to cause the magnetic sheet 1 to rotate at a constant speed. In-line type heads 3 - 1 and 3 - 2 are arranged to have access to two adjacent tracks. The head 3 - 1 is having access to the track on the outer circumferential side of the magnetic sheet 1 and the head 3 - 2 to the other track on the inner circumferential side. A magnetic head shifting device 4 is arranged to shift the positions of the magnetic heads 3 - 1 and 3 - 2 to bring them to the tracks formed on the magnetic sheet 1 . An innermost track detection switch 5 shifts from an OFF state to an ON state when the magnetic head 3 - 2 has access to the innermost track on the magnetic sheet 1 and then produces a low level signal which is supplied to a microcomputer (hereinafter referred to as CPU) 40 . A reproduction amplifier 6 is arranged to amplify signals detected by the magnetic heads 3 - 1 and 3 - 2 . A level detector 7 is arranged to detect a mean level value of the output signal of the reproduction amplifier 6 . A comparator 8 is arranged to detect whether the output of the level detector 7 is higher than a threshold value set at a reference voltage source which is not shown. A demodulation circuit 9 is arranged to demodulate the output signal of the reproduction amplifier 6 . A ½H delay circuit 10 is arranged to delay the output of the demodulation circuit 9 as much as ½horizontal scanning period (hereinafter referred to as ½H). A synchronizing signal separation circuit 11 is arranged to separate synchronizing signals such as a horizontal synchronizing signal Hsync and a vertical synchronizing signal Vsync, etc. from the output of the demodulation circuit 9 . A data demodulator 12 is arranged to detect a predetermined data signal from the output of the reproduction amplifier 6 and to demodulate the data signal according to the timing of the synchronizing signal separated by the separation circuit 11 . The data signal can be set as desired in 11 digits by the operator. This signal permits discrimination of the kind of information recorded in the track. For example, it permits making a discrimination between a field video signal and a frame video signal or represents an year, a month and a day set by the operator. The data signal is recorded in a predetermined position relative to the synchronizing signal of the track and is within a frequency band lower than the video signal. The demodulation circuit 9 and the data demodulator 12 are separately arranged for the following reason: The video signal recorded on the magnetic sheet 1 is frequency modulated. Whereas, for the data signals other than the video signal, a DPSK (differential phase shift keying) modulation method which differs from the frequency modulation is employed. While the demodulation circuit 9 is arranged to frequency demodulate, the data demodulator 12 is arranged to DPSK demodulate.
[0043] A monitor 13 is arranged to permit observation of a reproduced video signal. A printer 13 ′ is connected to the apparatus for the purpose of printing the video signal. The printer 13 ′ is arranged to begin to operate when the level of a signal coming to a start signal input terminal becomes high and to make the level of a busy signal output terminal low while it is in operation. A modulator 14 is arranged, contrarily to the data demodulator 12 , to DPSK modulate data produced from the CPU 40 and to supply a recording amplifier 16 with data which is modulated at timing according to the synchronizing signals Hsync and Vsync separated by a synchronizing signal separation circuit 17 from the video signal coming to a video signal input terminal 18 .
[0044] A recording signal processing circuit 15 is arranged to perform frequency modulation and other processes necessary for recording on the video signal coming via the input terminal 18 and to supply its output to the recording amplifier 16 . A reference signal generator 19 is arranged to generate accurate reference pulses (60 Hz) required for rotating the magnetic sheet 1 and an erasing AC signal. A magnetized piece 20 is provided on the magnetic sheet 1 . As will be further described later, the magnetized piece 20 produces a signal which is used in performing rotation control over a DC motor 2 in synchronism with the reference signal produced from the reference signal generator 19 . A PG coil 21 is arranged for detecting the signal from the magnetized piece 20 when the magnetic sheet 1 is rotated by the DC motor 2 .
[0045] A wave form shaping circuit 22 is arranged to shape the wave form of a signal produced from the PG coil 21 . The output of the wave form shaping circuit 22 is supplied to the CPU 40 and a motor control circuit 23 .
[0046] The motor control circuit 23 is arranged to control the rotation of the DC motor 2 . The rotation of the DC motor 2 is controlled in such a manner that the synchronizing signal Vsync from the synchronizing signal separation circuit 17 or the signal produced from the reference signal generator 19 and the signal produced from the magnetized piece 20 provided on the magnetic sheet 1 are always in a predetermined phasic relation to each other. For example, the rotation of the motor 2 is controlled to keep the phases of the two deviating by 7 H from each other. When the magnetic heads 3 - 1 and 3 - 2 are performing a recording action, a switch SW 1 is shifted beforehand to its connecting position on the side of the synchronizing signal separation circuit 17 . Then, the rotation of the DC motor 2 is controlled on the basis of the signal Vsync and a signal supplied from the wave form shaping circuit 22 , i.e., a signal coming from the magnetized piece 20 provided on the magnetic sheet 1 . In case of reproduction by the magnetic heads 3 - 1 and 3 - 2 , the connecting position of the switch SW 1 is shifted beforehand for the reference signal generator 19 . In this instance, the rotation of the DC motor 2 is controlled on the basis of the reference signal from the generator 19 and the signal produced from the magnetized piece 20 and coming via the wave form shaping circuit 22 .
[0047] A driver 23 ′ is arrange to drive a stepping motor 24 according to a signal produced from the CPU 40 for the purpose of controlling the position of the heads 3 - 1 and 3 - 2 . The stepping motor 24 is thus arranged to shift the position of the heads 3 - 1 and 3 - 2 via the above stated head shifting device 4 . A display circuit 25 is arranged to be driven by a signal from the CPU 40 . The display circuit 25 is composed of display elements including, as shown in FIG. 3, seven-segment display elements which are arranged to display a number assigned to the track to which the head 3 - 1 has access in a two-place number and a speed at which the head is being shifted; a PB (play back) LED arranged to display a reproduction mode; a REC (recording) LED arranged to display a recording mode; a FRAME LED arranged to display a frame mode; and a FIELD LED arranged to display a field mode. A ROM 26 stores the program of the CPU 40 . A RAM 27 is arranged to temporarily store the data of the CPU 40 . A timer 28 is arranged to be driven by the CPU 40 . A crystal oscillator 29 is arranged to generate reference clock pulses for the CPU 40 . A detecting circuit 80 is connected to photo-couplers 81 and 82 which form a detection switch for detecting whether the magnetic sheet 1 is inserted in the apparatus. Elements 83 and 84 and a switch SW 6 are provided for displaying at the monitor 13 and a printer 13 ′ a data signal (hereinafter referred to as ID signal) indicative of information on the year, the month, the day, etc. set as desired by the operator. More specifically, a synchronizing signal separation circuit 83 is arranged similarly to the synchronizing signal separation circuit 17 to separte synchronizing signals Vsync and Hsync from the video signal coming via a switch SW 5 which is provided for adjustment of the timing of a data character to be generated. A character generator 84 is arranged to generate a character corresponding to data in synchronism with the synchronizing signals Vsync and Hsync separated by the circuit 83 . In case where the ID signal is to be displayed in a state of being superimposed on the video signal at the monitor 13 or the printer 13 ′, the CPU 40 produces a control signal to turn on the switch SW 6 . Then an adder 86 applies the synchronizing signals and the ID signal to the video signal to have the character displayed in a specific position on the monitor 13 or the printer 13 ′.
[0048] An erase signal generator 85 is arranged to erase a signal recorded in any desired track on the magnetic sheet 1 . An AC current to be used for erasion is obtained from a reference signal generator 19 . The erase signal generator 85 generates an attenuation signal which is composed of, for example, a constant amplitude period T 1 and an ensuing attenuating period T 2 as shown in FIG. 32. The circuit 85 is connected to the recording amplifier 16 . The wave form of the attenuation signal is arranged to be suitable for magnetic recording medium. However, any other suitable wave form is of course usable even if the medium is a magnetic recording medium.
[0049] A switch SW 1 is arranged to have its connecting position shifted by a signal from a control circuit 30 which is driven by a signal from the CPU 40 . The switch SW 1 connects the synchronizing signal separation circuit 17 to the motor control circuit 23 when a recording mode indicating signal is received from the CPU 40 while the synchronizing signal Hsync is produced from the synchronizing signal separation circuit 17 . The switch SW 1 connects the reference signal generator 19 to the motor control circuit 23 when a reproducing mode indicating signal is received from the CPU 40 or when the signal Hsync is not produced from the synchronizing signal separation circuit 17 or when the apparatus is in an erasing mode. A switch SW 2 shifts its connecting position on the basis of a signal from the CPU 40 . The switch SW 2 has a position in which the head 3 - 1 is connected to the recording amplifier 16 ; a position connecting the head 3 - 1 to the reproduction amplifier 6 ; and an intermediate position connecting the head neither to the recording amplifier 16 nor to the reproduction amplifier 6 . A switch SW 3 operates on the basis of a signal from the CPU 40 to shift its position among a position connecting the head 3 - 2 to the recording amplifier 16 , another position connecting the same head to the reproduction amplifier 6 and an intermediate position connecting the same head neither to the recording amplifier 16 nor to the reproduction amplifier 6 . A switch SW 4 is also operated by the CPU 40 to shift its position as follows: In reproducing a frame video signal from the magnetic sheet 1 using both the heads 3 - 1 and 3 - 2 , the position of the switch is shifted upward as viewed on FIG. 1 thus connecting them to the demodulation circuit 9 . In reproducing a field video signal using only the head 3 - 1 , the switch SW 4 shifts between the upward shifted position and a downward shifted position. In other words, in that instance, the switch SW 4 connects the head alternately to the demodulation circuit 9 and the ½H delay circuit 10 for every field. A switch SW 5 is driven by the CPU 40 to connect the monitor 13 to the video signal input terminal 18 for recording and to the switch SW 4 for reproduction.
[0050] As mentioned in the foregoing, the video signal recorded or reproduced on and from the magnetic sheet 1 is sometimes a field video signal consisting of only one field or sometimes a frame video signal consisting of a pair of fields. The change-over of the connecting positions of the switches SW 2 , SW 3 , SW 4 and SW 5 for the field video signal and the frame video signal is as described below with reference to FIG. 2, which shows in combination the change-over states of the switches SW 2 , SW 3 , SW 4 and SW 5 :
[0051] In the field reproduction, the switch SW 2 connects the head 3 - 1 to the reproduction amplifier 6 . The switch SW 3 is in the intermediate position thus connecting the head 3 - 2 neither to the reproduction amplifier 6 nor to the recording amplifier 16 . The switch SW 4 allows a signal supplied from the demodulation circuit 9 to be supplied directly to the monitor 13 in the case of an odd number field and to be supplied via the ½H delay circuit 10 to the monitor 13 if the field is an even number field. The position of the switch SW 4 thus changes from one position over to the other every time the field changes. This prevents occurrence of a skew distortion.
[0052] In frame reproduction, the switch SW 2 connects the head 3 - 1 to the reproduction amplifier 6 for an odd number field and shifts to the intermediate position thereof for an even number field. The switch SW 3 is in the intermediate position thereof for an odd number field and connects the head 3 - 2 to the reproduction amplifier 6 for an even number field. Therefore, in the case of frame reproduction, the signal of either the head 3 - 1 or the head 3 - 2 is alternately supplied to the reproduction amplifier 6 for every field. In this instance, the position of the switch SW 4 is shifted upward to allow the signal of the demodulation circuit 9 to be supplied directly to the monitor 13 .
[0053] In either case of field reproduction or frame reproduction, the switch SW 5 is driven to connect the monitor 13 to the switch SW 4 .
[0054] In field recording, the switch SW 2 connects the head 3 - 1 to the recording amplifier 16 and the switch SW 3 shifts to its intermediate position. Therefore, recording is performed by the head 3 - 1 in that instance.
[0055] Further, in frame recording, the switch SW 2 connects the head 3 - 1 to the recording amplifier 16 for an odd number field and takes its intermediate position for an even number field. The switch SW 3 takes its intermediate position for an odd number field and connects the head 3 - 2 to the recording amplifier 16 for an even number field. The combination of the positions of these switches for the heads 3 - 1 and 3 - 2 may be reversed for frame recording. In either case of field or frame recording, the switch SW 5 shifts its position to connect the monitor 13 to the video signal input terminal 18 to enable the operator to observe the video signal to be recorded. Meanwhile, in any of these cases, the switch SW 4 can be in any position thereof.
[0056] The operation of the embodiment in an erasing mode is as follows: Under an erasion standby condition which will be described later, the switch SW 1 has its connecting position on its side for a reference signal generator 19 and the switch SW 5 on its upper side as viewed on FIG. 1. In other words, they are in exactly the same state as in the case of the reproduction mode. In the case of field erasion for erasing the record of, for example, only the track being reproduced by the magnetic head 3 - 1 , the embodiment operates as follows: In this case, the CPU 40 produces a control signal to shift the position of the switch SW 2 to its side for the recording amplifier 16 and that of the switch SW 3 to its intermediate position. An erasion signal trigger pulse is supplied from the CPU 40 to the erase signal generator 85 . As a result, an erasion signal is applied only to the head 3 - 1 .
[0057] In the event of frame erasion for simultaneously erasing the records of tracks to which the heads 3 - 1 and 3 - 2 have access, the embodiment operates as follows: The CPU 40 produces a control signal to shifts the switches SW 2 and SW 3 to their positions on the side of the recording amplifier 16 for allowing the erasion signal to be applied simultaneously to the heads 3 - 1 and 3 - 2 . Then, the erasion signal is generated in response to a trigger pulse produced from the CPU 40 and is allowed to flow to both the heads via the recording amplifier 16 .
[0058] In this specific embodiment, the field erasion is arranged to be performed by means of the head 3 - 1 . In case that the other head 3 - 2 is to be used for that purpose instead of the head 3 - 1 , the switch control must be changed to shift the switch SW 2 to its intermediate position and the switch SW 3 to its position on the side of the recording amplifier 16 .
[0059] Next, the switches 51 to 79 shown in FIG. 1 are arranged as described in the following with reference to FIGS. 3 and 4 which are showing the appearance of this embodiment: FIG. 3 is a front view of the apparatus and FIG. 4 a front view of a remote control device. The switches 51 to 79 shown in FIG. 1 are divided into groups including a group of switches shown in FIG. 3, a group provided on the remote control device of FIG. 4 and a group disposed in both the apparatus of FIG. 3 and the remote control device of FIG. 4. In FIGS. 1 to 4 , the switches performing the same functions are indicated by the same reference numerals. Among the switches shown in FIG. 3, those disposed only on the remote control device of FIG. 4 are shown in the circuit arrangement of FIG. 1 as connected through lines to the CPU 40 for the sake of illustration. In actuality, however, each of signals generated by operating the switches disposed on the remote control device is converted into infrared rays by the remote control device and is supplied to the CPU 40 via a remote control light receiving part 45 which is provided on the apparatus shown in FIG. 3.
[0060] The switches 51 to 79 may be arranged in various manners and their arrangement is not limited to the arrangement of this embodiment.
[0061] Referring to FIGS. 1 to 4 , these illustrations include a power supply switch 41 ; a sot 42 for inserting the magnetic sheet 1 ; an ejection button 43 which is arranged to automatically eject the magnetic sheet 1 when it is turned on with the magnetic sheet 1 in the inserted state; the above stated PB LED and REC LED 44 A and 44 B; the remote control light receiving part 45 which is arranged to receive the signal of the remote control device shown in FIG. 4; an interval mode display LED 46 which lights up when an interval reproduction mode is selected; a display LED 48 which is arranged to show selection of field reproduction or recording or selection or frame reproduction or recording; the above stated two-place seven-segment LED 25 ; and LEDs 50 A, 50 B and 50 C arranged to display the operated states of a programed reproduction setting switch 58 , an interval time setting switch 57 and a programed track setting switch 62 respectively.
[0062] A REC mode setting switch 51 is arranged to set a recording mode and to find whether the head is having access to a recorded track or non-recorded track. With this switch 51 turned on, when a track to which the head has access has some existing record, the REC LED makes a flickering display to show an unrecordable state of the track. The head mentioned here is the head 3 - 1 in the case of field recording and is at least one of the heads 3 - 1 and 3 - 2 in the case of frame recording. When the track has no existing record, or when the control circuit 30 has detected that a video signal is not supplied, the REC LED lights up to show the recordable state of the track in question.
[0063] A REC switch 52 is arranged to determine timing for recording operation. With a recording mode selected by means of the REC mode setting switch 51 , the recording operation is performed on the magnetic sheet 1 when this switch 52 is turned on. In case that a continuous recording mode has been selected by means of a track feed speed setting switch 56 , a continuous recording operation is performed with the use of the heads 3 - 1 and 3 - 2 being automatically changed from one head over to the other as long as this switch 52 remains in an ON state. A PB (play back) mode setting switch 53 is arranged to set the apparatus in a reproduction mode. When the switch 53 turns on, the PB LED lights up to show the selection of the reproduction mode. A track UP switch 54 is arranged to cause the driver 23 ′ to rotate the stepping motor 24 when the switch 54 is operated. Then, the rotation of the stepping motor 24 causes the head shifting device 4 to shift the heads 3 - 1 and 3 - 2 from one track to another track located on the inner side of the magnetic sheet 1 . Further, in case that frame recording or frame reproduction has been selected by means of a field/frame setting switch 59 , the heads 3 - 1 and 3 - 2 are shifted to an extent corresponding to two tracks respectively every time the track UP switch 54 is turned on. In that event, the seven-segment LED 25 displays a two-track shifted track number instead of a one-track shifted track number. In the event of selection of field recording or field reproduction, the heads 3 - 1 and 3 - 2 are shifted inward to an extent corresponding to one track when the track UP switch 54 is turned on. Then, the seven-segment LED 25 display a one-track shifted track number. Further, when the heads 3 - 1 and 3 - 2 are shifted by the operation of the track UP switch 54 after selection of the recording mode, if the track to which the head 3 - 1 or 3 - 2 has access has existing records therein, the REC LED 44 B makes a flickering display. A track DOWN switch 55 is arranged to shift the heads 3 - 1 and 3 - 2 in the direction of the outer circumference of the magnetic sheet (outward) instead of its inner circumference (inward).
[0064] The switch 55 is arranged in a manner similar to the track UP switch 54 . When the switch 55 is operated with frame recording or frame reproduction selected, the seven-segment LED 25 displays a two-track-shifted track number instead of a one-track-shifted track number. In case that the switch 55 is operated with field recording or field reproduction selected, the heads are shifted by one track at a time and a one-track-shifted track number is displayed. Further, in the same manner as in the case of the track UP switch 54 , when the heads 3 - 1 and 3 - 2 are shifted by the operation of the track DOWN switch 55 in the recording mode, the REC LED 44 B makes a flickering display as necessary showing that the tracks to which the heads 3 - 1 and 3 - 2 gained access have existing records therein.
[0065] A track feed speed setting switch 56 is arranged to make a selection between a recording or reproducing operation to be performed with the positions of the heads automatically and continuously shifted and a recording or reproducing operation to be performed with the head shifted in a noncontinuous manner and is also arranged to set a track feeding speed to determine how often recording or reproduction is to be performed per sec in the event of the continuous operation.
[0066] When the switch 56 is turned on from an OFF state by pushing it once, the seven-segment LED 25 comes to display a track feeding speed instead of a track number. If, under this condition, the track feed speed setting switch 56 is again turned on within a predetermined period of time counted by the timer 28 , the seven-segment LED 25 cyclically makes displays every time the switch 56 is turned on including, for example, a display of “2” indicating continuous recording or reproduction of two picture planes per sec; a display of “5” indicating continuous recording or reproduction of five picture planes per sec; and a display of “10” indicating continuous recording or reproduction of 10 picture planes per sec or makes a display of “0” indicating recording or reproduction of a single picture plane. Further, with the switch 56 turned on after it has been turned off to cause the seven-segment LED 25 to display a track feeding speed in place of a track number, if after that the switch 56 is not turned on again before expiration of the predetermined time counted by the timer 28 , the display by the LED 25 comes back from the display of the track feeding speed to the normal track number display.
[0067] In case that the track feeding speed is changed by the switch 56 while the frame image recording mode has been already selected by the field/frame setting switch 59 and the REC mode setting switch 51 , selection of continuous recording of ten picture planes per sec becomes impossible.
[0068] An interval time setting switch 57 is provided for setting a relatively long interval time in a continuous reproducing operation and also for setting a track feeding interval time in the event of a programed reproduction mode set by means of a programed track setting switch 58 which will be described later. The interval time is set by means of the switches 63 to 72 of the ten-key switch arrangement before the lapse of 10 sec after the switch 57 is turned on. In the event that a switch other than the ten key switches 63 to 72 is turned on after the interval time setting switch 57 is turned on, the interval time setting is automatically cancelled. A programed reproduction setting switch 58 is provided for setting the programed reproduction mode. This mode is set by programing beforehand a sequence in which tracks are to be reproduced and is continuously performed at intervals of a length of time set by means of the interval time setting switch 57 .
[0069] In designating the sequence of reproducing tracks, the programed reproduction mode is first set by turning the switch 58 on. Next, the track UP and track DOWN switches 54 and 55 are operated to shift the track access positions of them and to have the video signal of a desired track reproduced on the monitor 13 for confirmation. While performing this confirmation process, a programed track setting switch 62 is turned on to store the track number of each track confirmed by the monitor 13 . The field/frame setting switch 59 is arranged such that change-over takes place from the field-recording or -reproduction mode to the frame-recording or -reproduction mode and vice versa every time this switch 59 turns on.
[0070] In the event that the continuous recording mode has been set for 10 picture planes per sec by means of the REC mode setting switch 51 and the track feed speed setting switch 56 , the track feeding speed is automatically changed to a continuous recording mode for five picture planes per sec when frame recording is selected by the field/frame setting switch 59 , because:
[0071] In the case of frame recording, unlike field recording, the heads 3 - 1 and 3 - 2 must be shifted to an extent corresponding to two tracks at a time. In the event of recording 10 picture planes per sec, therefore, the heads must be shifted to a total extent corresponding to 20 tracks per sec, i.e., two tracks per {fraction (4/60)}sec taking a time for recording a video signal into consideration. However, it is difficult to carry out such a high speed head shift. In this particular embodiment of this invention, therefore, continuous frame recording for 10 picture planes per sec is inhibited.
[0072] A start switch 60 is provided for continuous reproduction with intervals or programed reproduction. When the start switch 60 is turned on in the interval reproduction mode, reproduction is performed on the tracks one after another beginning with the first track at intervals set by the interval time setting switch 57 and the ten-key switches 63 to 72 , and programed reproduction begins with programed reproduction selected.
[0073] A stop switch 61 is provided for bringing to a stop the reproducing operation started by the start switch 60 . In case that the stop switch 61 is turned on during programed reproduction, the programed reproduction is brought to a stop with the track which is then under the reproducing operation left in that state. A reference numeral 62 denotes the program track setting switch which is mentioned in the foregoing.
[0074] A switch 73 is provided for selection as to whether an ID signal setting action is to be allowed to begin in the recording mode and as to whether the contents of the ID signal are to be displayed in the event of the reproduction mode. In other words, in the recording mode, there obtains an ID signal setting mode with this switch 73 turned on. In the reproduction mode, the switch 73 permits selection as to whether the contents of the ID signal is to be displayed. In case where a date is to be set as the ID signal with the ID signal setting mode selected by the switch 73 , switches 74 , 75 and 76 are used. The switch 74 turns on when the year is set. The switch 75 turns on when the month is set. The switch 76 turns on when the day is set. In FIG. 1, these switches 74 , 75 and 76 are expediently shown for the sake of illustration independently of the above stated switches 57 , 58 and 62 . In the case of this embodiment, however, the switches 58 , 57 and 62 are arranged to perform combined functions as the switches 74 , 75 and 76 as shown in FIG. 4 which shows a remote control device. In other words, since the interval time setting action by the switch 57 , the program setting action by the switch 58 and the program track setting action by the switch 62 are to be performed independently of the year, month and day setting actions on the ID signal, the embodiment is arranged to reduce the number of switches for improvement in the operability and reliability of the apparatus.
[0075] The combined use of the switches are not limited to the above stated arrangement but various different combinations are conceivable and acceptable.
[0076] An erasion standby switch 77 is arranged to be used for temporarily bringing the apparatus into a standby state for erasion in erasing information recorded on the magnetic sheet 1 . An erasing switch 78 is provided for having an erasing action performed in the erasion standby state. An all track erasion standby switch 79 is arranged to be used in bringing the apparatus into a mode of erasing information recorded in all the tracks.
[0077] In erasing the information recorded on the sheet 1 , the erasion standby state obtains with the switch 77 first turned on. Under this condition, the apparatus is automatically set into the reproduction mode. Therefore, while the apparatus is in the erasion standby state, i.e. before carrying out the erasion, the images recorded in the erasing tracks can be confirmed on the monitor 13 or the printer 13 ′. Further, under the standby condition, the numbers of tracks to be erased can be continuously designated by operating the ten-key switches 63 - 72 . After that, when the erasing switch 78 is turned on, at least one of the heads 3 - 1 and 3 - 2 is connected to the recording amplifier 16 . Then, the erasion signal generator 85 produces an erasion signal as shown in FIG. 32. In response to this signal, information recorded in the applicable track is erased. Further, information recorded in all the tracks can be automatically erased by turning on the erasing switch 78 after the all track erasion standby switch 79 is turned on.
[0078] The embodiment of this invention operates as described below with reference to flow charts shown in FIGS. 5 to 20 , 23 and 25 to 27 .
[0079] Main Flow:
[0080] When the power supply switch 41 shown in FIG. 3 is pushed in, the power supply to the apparatus shown in FIG. 1 turns on. Electric energy begins to be supplied to each of applicable circuit parts.
[0081] Step # 1 : With the power supply thus switched on, registers I and S, etc. which will be described later with reference to FIG. 15 are reset to “0”. A PB (play-back) mode flag is set. Then, the track feeding speed is initially set for two picture planes per sec and the interval time at three seconds. In other words, the continuous reproduction mode is automatically set when the power supply is switched on. Step # 2 : A check is made to see if a jacket having the magnetic sheet 1 is inserted. If so, the flow of operation proceeds to a step # 3 . If not, it comes to a step # 4 skipping the step # 3 . Step # 3 : With the jacket having the magnetic sheet 1 found to be inserted at the step # 2 , the DC motor 3 is driven. Step # 4 : A check is made to see if the head 3 - 1 has gained access to the 50th track by detecting whether the switch 5 shown in FIG. 1 is in an ON state. If the heads are found to have gained access to the 50th track, the flow of operation comes to a step # 6 . If not, the flow branches out to a step # 5 to drive the stepping motor 24 shown in FIG. 1 to bring the head 3 - 1 to the 50th track by repeating the loop of steps # 4 and # 5 . Step # 6 : With the head 3 - 1 having gained access to the 50th track, the flow of operation comes to this step to set a register N at a value of 50 for having access to a memory (RAM 27 ). Step # 7 : A check is made for the driving operation of the DC motor 2 . With the above stated jacket inserted, the DC motor 2 has been caused to drive the magnetic sheet 1 by the step # 3 . In this event, the flow of operation proceeds to a step # 8 to set a field flag. If the jacket is not inserted, the DC motor 2 has not been operated as the step # 3 has been skipped. In that event, therefore, the flow of operation comes back to the step # 2 to see whether the jacket is inserted or not.
[0082] Step # 8 : The field flag is set if the DC motor 4 is found to be performing a driving operation at the step # 7 . Accordingly, the field mode indicating LED 44 A which is shown in FIG. 3 lights up to show the field mode. In other words, in the case of this embodiment, the field mode is automatically selected with the power supply switched on and the jacket inserted. Step # 9 : The output of the level detector 7 shown in FIG. 1 is detected to find whether the track accessed by the head 3 - 1 is recorded or nonrecorded. The output level of the level detector 7 becomes high if the accessed track has already been recorded. In that event, the flow of operation proceeds to a step # 10 . If the output level of the level detector 7 is low, the flow of operation comes to a step # 16 . Let us here first described the step # 16 . Step # 16 : Data “0000” is set at an address N of the memory. The data “0000” indicates that the track corresponding to this particular address is nonrecorded (has no previous or exsisting record).
[0083] The flow of operation at a step # 10 and subsequent steps is as follows:
[0084] Step # 10 : With the output of the level detector 7 having been found to be at a high level at the step # 9 , a signal recorded in the track is reproduced. Then, an ID (identification) signal is taken in from the data demodulator 12 . Step # 11 : The content of the ID signal is detected to discriminate the video signal recorded in the track between a field video signal and a frame video signal. If it is a field video signal, the flow of operation shifts to a step # 15 . If it is a frame video signal, the flow proceeds to a step # 12 . Step # 12 : The video signal recorded in the track accessed by the head 3 - 1 is checked to find whether the signal is recorded in the inner side track of the frame video signal or in the outer side track thereof. The flow of operation comes to a step # 14 if the track is located on the inner side or proceeds to a step # 13 if it is located on the outer side. Step # 13 : With the video signal of the track accessed by the head 3 - 1 found to be in the outer track of the frame video signal, the address N of the memory is set at “0011”. In case that the flow of operation comes from the step # 1 to this step for the first time, the address N has been set 50 at the step # 6 . Step # 14 : In the event of the inner track of the frame video signal, the address N of the memory is set at “0010”. Step # 17 : The head 3 - 1 is shifted to a first track. Then, if a state of N=1 is detected, the flow of operation comes to a step # 20 . If not, the flow of operation proceeds to a step # 18 . Step # 18 : With the state of N=1 not detected at the step # 17 , the head 3 - 1 is shifted outward to an extent corresponding to one track pitch. Step # 19 : With the head 3 - 1 shifted outward at the step # 18 , 1 is subtracted from the value N to renew it. Step # 20 : With the state of N=1 detected at the step # 17 indicating that the head 3 - 1 has gained access to the first track which is located outermost on the magnetic sheet, when information on the presence or absence of any record there is set at the memory, the data of the address N, i.e. the first address, of the memory is read out. If the data is “0011” thus indicating that the first track is the outer side track of two tracks forming a frame video signal, the flow of operation proceeds to a step # 21 . If not, the flow of operation comes to a step # 23 . Step # 21 : With the first track having been found at the step # 20 to be the outer track of the two tracks forming a frame video signal, the data of an address N+1, i.e. a second address of the memory is read out. If the data is “0010” thus indicating that a second track is the inner track of the two tracks forming the frame video signal, the flow of operation proceeds to a step # 22 . Step # 22 : With the frame video signal having been found to be recorded in the first and second tracks, the field flag which is set at the step # 8 is cleared to change the field mode over to a frame mode. The field/frame display LED 48 which is shown in FIG. 3 lights up to show the frame mode. Steps # 23 and # 24 : The register N showing the above stated memory address is displayed by the two-place seven segment LED 25 shown in FIGS. 1 and 3. This display enables the operator to know the track number to which the head 3 - 1 has gained access. Upon completion of this step, the flow of operation jumps to another flow (A), which is as shown in FIGS. 6A and 6B.
[0085] Step #A- 1 : A check is made to see if the REC mode setting switch 51 is in an ON state. If so, the flow of operation calls a subroutine (B) to set the recording mode. If not, the flow proceeds to a step #A- 2 . Step #A- 2 : A check is made to see if the REC switch 52 has been turned on. If so, a subroutine (N) is called. If not, the flow proceeds to a step #A- 3 . Step #A- 3 : A check is made to find if the PB mode setting switch 53 has been turned on. If so, a subroutine (C) is called. If not, the flow proceeds to a step #A- 4 . Step #A- 4 : If the track UP switch 54 is turned on, the flow of operation calls a subroutine (D). If the switch 54 is not turned on, the flow proceeds to a step #A- 5 . Step #A- 5 : If the track DOWN switch 55 is turned on, the flow of operation calls a subroutine (E). If not, it proceeds to a step #A- 6 . Step #A- 6 : If the track feed speed setting switch 56 is turned on, the flow of operation calls a subroutine (F). If not, it proceeds to a step #A- 7 . Step #A- 7 : If the interval time setting switch 57 has been turned on, the flow of operation calls a subroutine (G). If not, it proceeds to a step #A- 8 . Step #A- 8 : If the program setting switch 58 has been turned on, the flow of operation calls a subroutine (H). If not, it proceeds to a step #A- 9 . Step #A- 9 : If the program track setting switch 62 has been turned on, the flow of operation calls a subroutine (I). If not, it proceeds to a step #A- 10 . Step #A- 10 : If the field/frame setting switch 59 has been turned on, the flow of operation calls a subroutine (J). If not, it proceeds to a step #A- 11 . Step #A- 11 : If the start switch 60 has been turned on, the flow of operation calls a subroutine (K). If not, it proceeds to a step #A- 12 . Step #A- 12 : If the stop switch 61 has been turned on, a subroutine (M) is called. If not, the flow of operation proceeds to a step #A- 13 . Step #A- 13 : If a jacket detection switch (corresponding to the detection circuit 80 of FIG. 1) has been turned on, the flow of operation jumps to a subroutine (L). If not, it proceeds to a step #A- 14 .
[0086] Step #A- 14 : A programed reproduction mode flag and a programed reproduction in-process flag are cleared.
[0087] Step #A- 15 : A subroutine (R) is called if any one of the ten-key switches 63 - 72 is in an ON state. If not, the operation proceeds to a step #A- 16 . Step #A- 16 : If the ID switch 73 is in an ON state, a subroutine (Q) is called. If not, the operation proceeds to a step #A- 17 . Step #A- 17 : If the year setting switch 74 is in an ON state, a subroutine (S) is called. If not, the operation proceeds to a step #A- 18 . Step #A- 18 : If the month setting switch 75 is in an ON state, a subroutine (T) is called. If not, the operation proceeds to a step #A- 19 . Step #A- 19 : If the day setting switch 76 is in an ON state, a subroutine (U) is called. If not, the operation proceeds to a step #A- 20 . Step #A- 20 : If the erasion standby switch 77 is in an ON state, a subroutine (V) is called. If not, the operation proceeds to a step #A- 21 . Step #A- 21 : If the all track erasion standby switch 79 is in an ON state, a subroutine (W) is called. If not, the operation comes to the step #A- 13 .
[0088] After the head 3 - 1 is allowed to gain access to the first track on the magnetic sheet with the flow of operation carried out as shown in FIG. 5, the operation jumps to the flow (A) shown in FIGS. 6A and 6B. The flow (A) of operation is repeatedly performed while checking the switches shown in FIGS. 1, 3 and 4 for their states until the state of each of these switches comes to change over to the other state. A subroutine corresponding to each of these operated switches is called.
[0089] Subroutine (F):
[0090] The subroutine (F) which is called when the track feed speed setting switch 56 is turned on is as described below with reference to FIG. 7:
[0091] [0091]FIG. 7 is a flow chart showing the subroutine (F) to be carried out when the switch 56 which is provided for changing a track feeding speed. Steps #F- 1 and #F- 2 : A setting value of track feeding speed is read out from the memory. The setting value thus read out is set at a track number displaying buffer which is not shown. Therefore, a track feeding speed is displayed at the two-place, seven-segment LED 25 shown in FIG. 3. When the flow of operation comes to the step #F- 1 , a track feeding speed has been set at a value for two picture planes per sec and the LED 25 displays “2” accordingly. Step #F- 3 : If the track feeding speed setting switch 56 is in an ON state, the flow of operation respectively performs the step #F- 3 . If not, the flow of operation comes to a step #F- 4 .
[0092] As mentioned in the foregoing, the two-place, seven-segment LED 15 is arranged to change its track number display over to a track feeding speed display when the track feed speed setting switch 56 turns on for once. After that, when the switch 56 again turns on, the track feeding speed is changed over to another value. The step #F- 3 is arranged to have the track feeding speed changed when the switch 56 comes again to turn on after it is turned off from the initial turned-on state as mentioned above.
[0093] Steps #F- 4 to #F- 7 : With the display by the two-place, seven-segment LED 25 of FIG. 3 changed from the track number display over to the track feed speed display by turning on the track feed speed setting switch 56 , if the switch 56 or any other switch is not turned on before the lapse of a predetermined period of time (two seconds) after the change-over, the track feeding speed setting action is cancelled through these steps #F- 4 to #F- 7 . When the track feed speed setting switch 56 is turned on before the lapse of the predetermined period of time (two seconds) after the start of time count by the timer 1 , the flow of operation comes from the step #F- 7 to a step #F- 10 . If the switch is turned on after completion of the time count by the timer 1 or when another switch is turned on, the flow of operation proceeds from the step #F- 6 to a step #F- 8 . Step #F- 8 : The count value of the timer 1 is cleared. Step #F- 9 : Contrarily to the step #F- 1 , the display by the two-place, seven-segment LED 25 is brought back to the track number display. Step F- 10 : The count value of the timer 1 is cleared. Step F- 11 : A check is made to find if the set value of the track feeding speed is for a single performance, which means that the head is shifted after one performance of recording or reproduction to an extent corresponding to one track in the field mode or to an extent corresponding to two tracks and then the recording or reproduction comes to a stop in the frame mode. The flow of operation proceeds to a step #F- 12 in the case of a single performance or comes to a step #F- 13 if the set value is not for a single performance. Further, after the power supply switch 41 is turned on, the track feeding speed has been set for two picture planes per sec at the step # 1 before the flow of operation comes to this step. Step #F- 12 : In the event of the track feed speed setting value for a single performance, the set value is changed to a value for two picture planes per sec and then the flow of operation comes back to the step #F- 1 . Then, the renewed track feed speed is displayed and the above stated steps #F- 3 to #F- 7 are performed. Step #F- 13 : A check is made to find if the track feed speed setting value is for two picture planes per sec. If so, the flow of operation proceeds to a step #F- 14 . If not, the flow comes to a step #F- 15 . Step #F- 14 : The track feed speed setting value is changed to a value for five picture planes per sec. The flow of operation then comes back to the step #F- 1 . The renewed track feed speed value is displayed and the steps #F- 3 to #F- 7 are carried out.
[0094] Step #F- 15 : A check is made to find if the track feed speed setting value is for five picture planes per sec. If so, the flow of operation proceeds to a step #F- 16 . If the set value is found not for five picture planes per sec but for ten picture planes per sec, the flow of operation comes to a step #F- 17 . Step #F- 16 : A check is made to find if the PB mode flag is set indicating that the reproduction mode has already been set. If so, the flow of operation comes to a step #F- 18 . If not, it comes to a step #F- 19 . Step #F- 17 : The track feed speed setting value is changed to a value for a single performance and the flow of operation comes back to the step #F- 1 . A new track feed speed value thus set is displayed and the steps #F- 3 to #F- 7 are carried out. Step #F- 18 : In a continuous reproduction mode, field reproduction is performed irrespective as to whether the video signal recorded in the tracks of the magnetic sheet 1 is a field video signal or a frame video signal. In this instance, the track feed speed setting value is changed to a value for ten picture planes per sec and then the flow of operation comes back to the step #F- 1 . Step #F- 19 : A check is made to see if the field flag is set thus indicating the field recording mode with the track feed speed set for ten picture planes per sec. If so, the flow of operation branches out to a step #F- 18 . If not, the flow comes to the step #F- 17 to change the track feed speed setting value to a value for a single performance.
[0095] In the subroutine (F) described above, the two-place, seven-segment LED 25 displays the track feed speed when the track feed speed setting switch 56 is turned on. Then, after that, the track feeding speed can be changed by again turning the switch 56 on within a predetermined period of time (two seconds). The range of selectable track feeding speeds includes the following three speeds in the frame recording mode: A speed for a single performance, a speed for two picture planes per sec and a speed for five picture planes per sec. In a mode other than the frame recording mode, the selectable track feeding speed range includes the following four speeds: A speed for a single performance, a speed for two picture planes per sec, a speed for five picture planes per sec and a speed for ten picture planes per sec. The selectable speed range depends on the track shifting capability of the arrangement including the device for shifting the heads 3 - 1 and 3 - 2 , etc. shown in FIG. 1. Therefore, the range of selectable track feeding speed is set at a suitable range according to the track shifting capability.
[0096] Subroutines (D) and (E):
[0097] Referring now to FIGS. 8A, 8B and 8 C, the subroutines (D) and (E) which are to be called out when the track UP switch 54 or the track DOWN switch 55 is turned on during the process of the subroutine (A) shown in FIGS. 6A and 6B are as follows:
[0098] The flow of operation to be performed when the track UP switch 54 is turned on is first described. Step #D- 1 : When the flow of operation comes to this step, the register N is checked to see if it is at a value 50 for the purpose of finding whether the track to which the head 3 - 1 has gained access is the innermost track of the magnetic sheet. If the register N is found not at 50, the flow of operation proceeds to a step #D- 2 . If it is found to be at 50, the flow comes to a step #D- 34 . Step #D- 2 : A check is made to find if the PB mode flag has been set thus indicating the reproduction mode. If so, the flow of operation comes to a step #D- 8 . If not, the flow proceeds to a step #D- 3 . Step #D- 3 : A check is made to see if the address N+1 of the memory is at “0000” thus indicating that a No. N+1 track contains no record. If so, the flow of operation proceeds to a step #D- 4 . If not, the flow branches out to a step #D- 7 . Step #D- 4 : With the No. N+1 track having been found to be not recorded at the step #D- 3 , a check is made to see if the field flag is set. If so, the flow of operation comes to a step #D- 6 . If not, the flow proceeds to a step #D- 5 . Step #D- 5 : With the field flag found not set at the step #D- 4 thus indicating the frame mode, a check is made to see if the content of the memory at an address N+2 is at “0000” thus indicating that the No. N+2 track of the magnetic sheet has no existing record (unrecorded). If so, the flow of operation proceeds to a step #D- 6 . If not, it comes to a step #D- 7 .
[0099] With the steps #D- 3 to #D- 5 carried out, the flow of operation comes to the step #D- 6 if two consecutive tracks are both unrecorded in the case of the frame mode. If one of the two tracks is recorded, the flow of operation comes to the step #D- 7 .
[0100] Step #D- 6 : The flow of operation comes to this step when a track accessed by the head 3 - 1 in the field mode or a track accessed by the head 3 - 1 and a track which is accessed by the head 3 - 2 and is located on the inner side of the former in the case of the frame mode are unrecorded and are recordable. In this case, the REC LED 44 B shown in FIG. 3 lights up. Step #D- 7 : Contrarily to the step #D- 6 , if the tracks accessed by the heads 3 - 1 and 3 - 2 are recorded and unrecordable, the REC LED 44 B shown in FIG. 3 is caused to blink (flicker) to inform the operator of the unrecordable state of the track. Step #D- 8 : With the PB mode flag found to have been set at the step #D- 2 , the field flag is set. This step #D- 8 will be further described later along with further steps #D- 9 , #D- 10 and #D- 13 . Step #D- 9 : A check is made to see if the address N of the memory is at “0011” indicating that a track being accessed by the head 3 - 1 is one of two tracks located on the outer side as mentioned in the description of the step # 13 . If so, the flow of operation proceeds to the step #D- 10 . If not, it comes to the step #D- 13 . Step #D- 10 : A check is made to see if the address N+1 of the memory is at “0010” thus indicating that a track being accessed by the head 3 - 2 is one of two tracks located on the inner side. If so, the flow of operation proceeds to a step #D- 11 . If not, it comes to the step #D- 13 .
[0101] In case that one of two frame video signal forming tracks which is located on the inner side is either erased or has a video signal newly recorded after erasing, even if a track accessed by the head 3 - 1 is located on the outer side of the two tracks forming the frame video signal, another track accessed by the other head 3 - 2 might not be one of the two tracks which is located on the inner side. In that event therefore, in shifting the heads 3 - 1 and 3 - 2 inward, these heads must be shifted only to an extent of one track instead of two for erasing or for reproducing the video signal newly recorded after erasing. However, under the condition of having the heads 3 - 1 and 3 - 2 shifted inward to the extent of only one track, the tracks being accessed by these heads are not always having a frame video signal recorded therein. These tracks might have different field video signals recorded therein. In the latter case, if the field flag is in a reset state, the two different field video signals would be reproduced as a frame video signal. This embodiment solves that problem by the provision of the step #D- 8 mentioned in the foregoing. In other words, the field flag is set to obtain the field mode before these heads are shifted inward as mentioned above. Therefore, the possibility of having completely different field video signals reproduced as a frame video signal can be eliminated.
[0102] Step #D- 11 : A check is made to see if the register N is at 49. If so, the flow of operation comes to a step #D- 13 . If not, it comes to a step #D- 12 . Step #D- 12 : With a frame video signal recorded in two adjacent tracks accessed by the heads 3 - 1 and 3 - 2 , the flow of operation comes to this step. Under this condition, if the track UP switch 54 is turned on, the driver 23 is operated to have the heads 3 - 1 and 3 - 2 shifted to the extent of just one track at this step. Following that, at the step #D- 13 , the heads 3 - 1 and 3 - 2 are further shifted to the extent of one track. Meanwhile the content of the register N is renewed and changed by one every time the heads 3 - 1 and 3 - 2 are thus shifted. Step #D- 13 : The heads 3 - 1 and 3 - 2 are shifted to the extent of one track in the same manner as in the preceding step #D- 12 . Step #D- 14 : The two place, seven-segment LED 25 shown in FIG. 3 is caused to display the content of the register N in the same manner as in the step # 23 .
[0103] Since the step #D- 14 is subsequent to the steps #D- 12 and #D- 13 in this embodiment, the track number displayed by the LED 25 is changed by two at a time when a frame video signal is recorded in the tracks to which the heads 3 - 1 and 3 - 2 gain access. In case that a field video signal is recorded, the track number display of the LED 25 is changed by one at a time. Therefore, the display shows which of the field and frame video signals is recorded on the magnetic sheet 1 .
[0104] Further, if this step is provided also in between the steps #D- 12 and #D- 13 , the track number display of the LED 25 is renewed and changed by one at a time in response to the closing of the track UP switch 54 even in cases where a frame video signal is recorded in two adjacent tracks accessed by the heads 3 - 1 and 3 - 2 .
[0105] Step #D- 15 : A check is made to see if the PB mode flag is set. If so, the flow of operation comes to a step #D- 15 - 1 . If not, it comes to a step #D- 19 .
[0106] Step #D- 15 - 1 : At this stop, the CPU 40 takes the reproduced ID signal produced from the data demodulator 12 into the RAM 27 . The flow of operation then proceeds to a step #D- 15 - 2 . Step #D- 15 - 2 : A check is made to find if the apparatus is in the mode in which the ID signal is superimposed on the video signal for monitoring. The details of this mode will be later described with reference to FIG. 20. If the apparatus is in that mode, the operation proceeds to a step #D- 15 - 3 . If not, it comes to a step #D- 15 - 4 . Step #D- 15 - 3 : Since the apparatus is in the mode of having the ID signal monitored in the state of being superimposed on the video signal when the flow of operation comes to this step, the CPU 40 reads out the reproduced ID signal from the RAM 27 and causes the character generator 84 to generate a character pattern. Then, the character pattern is displayed on the monitor 13 in a state of superimposed on the video signal. The flow then proceeds to the step #D- 15 - 4 . In other words, at this point of time, an ID data signal recorded in the track presently accessed by the head is displayed on the monitor 13 . Step #D- 15 - 4 : If the automatic track feeding flag is not set, the flow comes to a step #D- 20 . If the flag is set, the flow branches off to a step #D- 16 . Step #D- 16 : A check is made to see if the address N of the memory is at “0011” thus indicating that the track accessed by the head 3 - 1 is the outer side track of two tracks having a frame video signal recorded. The content of the address N corresponds to the number assigned to the track to which the head 3 - 1 has gained access as repeatedly mentioned in foregoing. If the content of the address N is found to be “0011”, the flow of operation proceeds to a step #D- 17 . If not, the flow branches out to a step #D- 19 . Step #D- 17 : A check is made to find if the content of the address N+1 of the memory is “0010” thus indicating that the head 3 - 1 has gained access to the inner side track of two adjacent tracks in which a frame video signal is recorded. If so, the flow of operation proceeds to a step #D- 18 . If not, it branches out to the step #D- 19 .
[0107] Step #D- 18 : When the flow of operation comes to this step through the steps #D- 16 and #D- 17 , a frame video signal is recorded in two adjacent tracks to which the heads 3 - 1 and 3 - 2 has gained access after a shift of their positions. Therefore, the field flag which has been set at the step #D- 8 is cleared to obtain a frame reproducing mode. Further, this step is carried out only in case that the automatic track feeding flag is set. (If this flag is not set, the flow branches off from the step #D- 15 - 4 to the step #D- 20 . In that event, field reproduction is performed as the field flag is left in the state of being set at the step #D- 8 ). Step #D- 19 : A check is made to see if an automatic track feed flag is set. If so, the flow of operation proceeds to a step #D- 20 . If not, the flow comes back from this subroutine (RTS). The automatic track feed flag is arranged to be set in another subroutine (K). This flag is arranged to enable the flow of operation to pull out from the subroutine (D) or from another subroutine (E) when the subroutine (D) or (E) is called during execution of a program for repeating a reproducing action while automatically feeding the tracks.
[0108] Step #D- 20 : A track feed speed setting value is taken in from the memory. Step #D- 21 : a check is made to see if the track feed speed setting value is for a single performance. If so, the flow of operation comes to a step #D- 34 . If not, it proceeds to a step #D- 22 . Step #D- 22 : A check is made to see if the track feed speed setting value is for two picture planes per sec. If so, the flow of operation proceeds to a step #D- 23 . If not, it comes to a step #D- 24 . Step #D- 23 : A wait timer register which is disposed within the CPU 40 is set at 28. Step #D- 24 : A check is made to see if the track feed speed setting value is for five picture planes per sec. If so, the flow of operation proceeds to a step #D- 25 . If not, it comes to a step #D- 26 . Step #D- 25 : The wait timer register is set at 10. Step #D- 26 : In case that the track feed speed setting value is for ten picture planes per sec, the flow of operation comes to this step. The wait timer register is set at 4. Further, the wait timer register the value of which is set at the above stated steps #D- 23 , #D- 25 and #D- 26 is arranged to control the track feeding speed. The content of the timer register is arranged to be decreased every time the magnetic sheet 1 is caused to make one turn by the DC motor 2 at step #D- 31 and #D- 32 which will be described later. Step #D- 27 : A check is made to see if the REC-in-process flag is set. If so, the flow of operation proceeds to a step #D- 28 . If not, it branches out to a step #D- 31 . The REC-in-process flag is arranged to be set in a subroutine (N). When the subroutine (D) is called out while a program of repetitively performing a recording action by automatically feeding tracks is in process, this flag gives a period of time necessary for recording by setting a length of time at the wait timer register when the subroutine (D) is called and by subtracting 2 or 5 from the content of the register at a step #D- 29 or #D- 30 . In other words, the REC-in-process flag is provided for the purpose of determining a timing for recording in a predetermined position on the magnetic sheet 1 a signal which is obtained by detecting the rotating state of the magnetic sheet 1 from the PG coil 21 and also for recording the signal on the magnetic sheet 1 .
[0109] Steps #D- 28 , #D- 29 and #D- 30 : The field flag is checked to find if it has been set. If so, 2 is subtracted from the content of the wait timer register. If not, 5 is subtracted from the content of the register. In this instance, the wait timer register is set at 4 if the track feeding speed is set for ten picture planes per sec. However, such setting is possible only for the field mode. Therefore, in that event, the wait timer register never has 5 subtracted from its content.
[0110] Step #D- 31 : A check is made to see if pulses are produced from the reference signal generator 19 shown in FIG. 1. If so, the flow of operation proceeds to a step #D- 32 . If not, it repeats the step #D- 31 . Step #D- 32 : One is subtracted from the content of the wait timer register. Step #D- 33 : A check is made to see if the content of the wait timer register has become 0. If so, the flow of operation comes to a step #D- 34 . If not, it comes to the step #D- 31 .
[0111] At the steps #D- 32 and #D- 33 , the wait timer register and the reference signal generator 19 are used as a timer for controlling the track feeding speed. Compared with a method of forming a timer by performing subtraction from the content of the wait timer register according to the output of the wave form shaping circuit 22 which is arranged to shape the wave form of the output of the PG coil 21 , the method of the steps #D- 32 and #D- 33 permits a more stable and accurate time counting action, because: While the output of the PG coil 21 is likely to include some error resulting from unevenness of rotation of the magnetic sheet 1 , the output of the reference signal generator 19 is substantially free from such error. Further, in the event of reproduction or recording with intervals, the DC motor 2 is preferably stopped from rotating during the interval time. In that event, the method of performing subtraction from the wait timer register according to the output of the wave form shaping circuit 22 is incapable of including the interval time. Whereas, in accordance with the method of this embodiment, the time counting action can be stably carried out even in that event.
[0112] Step #D- 34 : A check is made to see if the REC-in-process flag has been set. If so, the flow of operation comes back to the program (RTS) carried on before calling the subroutine (D). If not, it comes to a step #D- 35 . Step #D- 35 : A check is made for the ON state of the track UP switch 54 . If the switch 54 is found to be on, the flow of operation comes to the step #D- 1 to have the track access position of the heads 3 - 1 and 3 - 2 shifted inward. If not, the flow of operation comes to a step #D- 36 . Step #D- 36 : A check is made for the ON state of the track DOWN switch 55 . If the switch 55 is on, the flow of operation shifts to a step #D- 37 of the subroutine (E) for shifting outward the track access position of the heads 3 - 1 and 3 - 2 . If not, the flow branches to a step #D- 37 .
[0113] Step #D- 37 : If the PB mode flag is set, the flow of operation proceeds to a step #D- 38 . If not, it comes back to the program in which the subroutine (D) is called. Steps #D- 38 , #D- 39 and #D- 40 : Like in the case of the steps D- 16 , #D- 17 and #D- 18 , the field flag is cleared for frame reproduction in the event of a frame recorded video signal. After that, the flow comes back to the program in which the subroutine (D) is called.
[0114] In the example described, above, the value set at the wait timer is not changed at the steps #D- 23 , #D- 25 and #D- 26 irrespective as to whether or not the flow of operation passes through the step #D- 12 in the PB mode. Therefore, in the case of passing through the step #D- 12 , the track feeding speed delays as much as a length of time required for feeding one track. However, this problem can be solved with the track feeding speed adjusted for this delay by subtracting the same length of time from the value set at the wait timer in the event of passing through the step #D- 12 .
[0115] Subroutine (E):
[0116] The subroutine (E) which is to be carried out when the track DOWN switch 55 is turned on is as described in the following: In the subroutine (E), steps #E- 1 to #E- 13 are similar to the steps #D- 1 to #D- 13 and therefore the details of these steps are omitted here. In the subroutine (E), when the track DOWN switch 55 is turned on, the register N is checked for a state of N=1 at the step #E- 1 , for example, for shifting outward the track access position of the heads 3 - 1 and 3 - 2 . At the step #E- 9 , a check is made to find if a memory address N−1 is at “0010” thus indicating the inner side track of two tracks forming a frame video signal. At the step #E- 10 , a check is made to find if a memory address N−2 is at “0011” indicating the outer side track of the two tracks forming the frame video signal. At the step #E- 11 , a check is made for a state of N=2. At the steps E- 12 and #E- 13 , the heads 3 - 1 and 3 - 2 are shifted outward to the extent of one track.
[0117] Subroutines (J) and (B):
[0118] Referring to FIG. 9, the subroutines (J) and (B) which are to be called when the field/frame selection switch 59 and the REC mode setting switch 51 are turned on are as described below:
[0119] Step #J- 1 : When the field/frame selection switch 59 is found to be turned on at the step #A- 10 shown in FIG. 6A, the flow of operation comes to the step #J- 1 . At this step, if the field flag is set, the flow of operation proceeds to a step #J- 2 . If not, it branches out to a step #J- 4 . Step #J- 2 : With the field flag found to be set at the step #J- 1 , the flag is cleared at the step #J- 2 . Step #J- 3 : A check is made to see if the PB mode flag is set. If so, the flow of operation comes to a step #J- 8 . If not, it branches out to a step #J- 5 .
[0120] Step #J- 4 : With the field flag found not set at the step #J- 1 , the field flag is set at the step #J- 4 .
[0121] When the field flag is cleared at the step #J- 2 in the recording mode with the PB mode not set, there obtains a frame recording mode. Then, as mentioned in the description of the subroutines (D), (E) and (F), continuous recording at a speed for ten picture planes per sec is impossible. Therefore, in the subroutine (J), if the track feed speed has been set for ten picture planes per sec at the time of change-over from the field mode to the frame mode, the change-over must be inhibited. In view of that, this embodiment is arranged to have the track feed speed setting value automatically changed at steps #J- 6 and #J- 7 to a speed for five picture planes per sec if it has been set at a speed for ten picture planes per sec.
[0122] Step #J- 5 : Data of a track feed speed setting value is taken into the CPU 40 . Step #J- 6 : If the track feed speed setting value taken in at the step #J- 5 is for ten picture planes per sec, the flow of operation proceeds to a step #J- 7 . If not, it branches out to a step #J- 8 . Step #J- 7 : The track feed speed setting value is changed to a value for five picture planes per sec. Step #J- 8 : This step is repeated as long as the field/frame selection switch 59 is kept in an ON state. When the switch 59 turns off, the flow of operation comes back to the step #A- 1 of FIG. 6A.
[0123] The subroutine (B) which is called when the REC mode setting switch 51 is turned on is as described below:
[0124] Step #B- 1 : When the REC mode setting switch 51 is found to have turned on at the step #A- 1 of FIG. 6A, the flow of operation comes to this step #B- 1 . Then, the light of the PB LED 44 A is put out and the PB mode flag is cleared. Steps #B- 2 , #B- 3 , #B- 4 , #B- 5 and #B- 6 : These five steps are similar to the steps #D- 3 to #D- 7 respectively and, therefore, omitted from description given here.
[0125] Step #B- 5 - 1 : The CPU 40 controls the character generator 84 to cause it to suspend its character generating action. Step #B- 5 - 2 : A check is made to see if there obtains the ID signal setting mode. If so, the flow proceeds to a step #B- 5 - 3 . If not, it comes to a step #B- 6 ′. Step #B- 5 - 3 : The CPU 40 reads out the set ID signal from the RAM 27 and causes the character generator 84 to generate a character pattern. As a result, the ID signal is displayed on the monitor 13 in a state of being superimposed on the video signal. Following that, the flow of operation proceeds to the step #B- 6 ′.
[0126] Step #B- 6 ′: This step is repeated as long as the REC mode setting switch 51 is kept in an ON state. The flow of operation proceeds to a step #B- 7 when the switch 51 is turned off. Step #B- 7 : With the REC mode setting switch 51 having been turned off, a check is made to find if the field flag is set. If so, the flow of operation comes back to the step #A- 1 of FIG. 6A. If not, it jumps to the step #J- 5 of the subroutine (J). Then, if the track feed speed setting value is for ten picture planes per sec, the set value is automatically changed to a speed for five picture planes per sec by carrying out the steps #J- 6 to #J- 8 . Therefore, in the event of a frame mode with the REC mode set by the REC mode setting switch 51 , the track feed speed setting value is limited to a speed for five picture planes per sec.
[0127] Subroutine (C):
[0128] Referring to FIG. 10, the subroutine (C) which is to be called when the PB mode setting switch 53 is turned on is as described below:
[0129] Step #C- 1 : The flow of operation branches out to this step upon detection of that the PB mode setting switch 53 is turned on at the step #A- 3 of FIG. 6A. At the step #C- 1 , the REC LED 44 is turned off and the field flag is temporarily set. In case that the frame recording mode has been set by resetting the field flag with the PB mode flag cleared while different field video signals are recorded in two tracks accessed by the heads 3 - 1 and 3 - 2 , the different field video signals would be reproduced in an interlaced state if a reproducing action is immediately performed on the tracks accessed by the heads 3 - 1 and 3 - 2 when the PB mode setting switch 53 is found to have turned on. The step #C- 1 is provided for preventing this inconvenience.
[0130] Step #C- 2 : A check is made to see if an applicable memory address is at “0011” thus indicating that the head 3 - 1 has gained access to a track which is one of two tracks having a frame video signal recorded therein and is located on the outer side of the other. If so, the flow of operation proceeds to a step #C- 3 . If not, it branches out to a step #C- 5 .
[0131] Step #C- 3 : A check is made to see if a memory address N+1 is at “0010” thus indicating that a track to which the head 3 - 2 has gained access is one of the two frame signal recorded tracks and is located on the inner side. If so, the flow of operation proceeds to a step #C- 4 . If not, it branches out to the step #C- 5 .
[0132] Step #C- 4 : The flow of operation comes to this step upon detection of that a frame video signal is recorded in two adjacent tracks to which the heads 3 - 1 and 3 - 2 have gained access in the steps #C- 2 and #C- 3 . A field flag is cleared and the frame mode is set.
[0133] Step #C- 5 : The PB LED 44 A shown in FIG. 3 lights up. The PB mode flag is set. A reproducing action begins.
[0134] Step #C- 5 - 1 : The CPU 40 causes the character generator 84 to suspend its character generating action. The CPU 40 also stores at the RAM 27 the ID signal data demodulated by the data demodulator 12 . Step #C- 5 - 2 : A check is made to see if there obtains a mode of displaying the ID signal. If so, the flow of operation proceeds to a step #C- 5 - 3 . It not, it comes to a step #C- 6 . Step #C- 5 - 3 : The CPU 40 reads out the ID data demodulated by the data demodulator 12 and causes the character generator 84 to generate a character pattern. Therefore, the ID data is displayed on the monitor 13 in a state of being superimposed on the reproduced video signal. The flow then proceeds to the step #C- 6 .
[0135] Step #C- 6 : In the event of a continuous ON state of the PB mode setting switch 53 , this step is repeated. the flow of operation comes back to the step #A- 1 through the step #A- 14 of FIG. 6A when the switch 53 is turned off.
[0136] Subroutine (G):
[0137] The subroutine (G) which is to be called out when the interval time setting switch 57 is turned on is as described below with reference to FIG. 11. At the step #G- 0 of the subroutine (G), the timer T′ is first initialized and an interval time Ti is displayed at the 7-segment LED 25 .
[0138] Step #G- 1 : The timer T′ is initialized to zero with the interval time setting switch 57 having been found to be turned on at the step #A- 7 of FIG. 6A before the flow of operation comes to this step #G- 1 . Then, if the ten-key switch arrangement 63 - 72 is turned on, the flow proceeds to a step #G- 2 . If not, it branches out to a step #G- 3 .
[0139] Step #G- 2 : The interval time Ti is changed to another interval time value Ti set by the ten-key switch arrangement 63 - 72 .
[0140] Step #G- 3 : A check is made to find if any switch other than the ten-key switch arrangement 63 - 72 is turned on. If so, the flow of operation proceeds to a step #G- 4 . If not, it branches to a step #G- 5 .
[0141] Step #G- 4 : A check is made for the ON state of the interval time setting switch 57 . If the switch 57 is found on, the flow of operation comes to the step #G- 1 . If not, it branches to the step #A- 1 shown in FIG. 6A.
[0142] Step #G- 5 : The value of the timer T′ is increased by one and the flow of operation shifts to a step #G- 6 after one second. The timer T′ is arranged to be incremented every sec by one. No addition is performed before the lapse of one sec.
[0143] Step #G- 6 : The timer T′ is checked to find if it is at a value 10. If so, the flow of operation comes to the step #A- 1 of FIG. 6A. If not, it comes to the step #G- 1 to repeat the loop of steps #G- 1 , #G- 3 , #G- 5 and #G- 6 . When the value of the timer T′ becomes 10, the flow comes back to the step #A- 1 . Therefore, in the subroutine (G), if no other switch turns on in ten seconds after the interval time setting switch 57 is turned on, the flow of operation comes back to the step #A- 1 of FIG. 6A and the interval time setting is cancelled.
[0144] While the subroutine (G) is in the process of execution, the interval time Ti is of course displayed at the 7-segment LED 25 . However, this display comes to a stop when the flow of operation comes back to the step #A- 1 from the step #G- 6 .
[0145] Further, with the interval time Ti set at “0” in the subroutine (G), there obtains an external trigger mode in which, for example, the embodiment is connected to an external device such as a printer as will be described later as a reproducing action in a subroutine (K).
[0146] Subroutine (N):
[0147] Referring now to FIG. 12, a subroutine (N) which is called when the REC switch 52 is turned on is arranged as follows:
[0148] Step #N- 1 : The flow of operation comes to this step when the ON state of the REC switch 52 is detected at the step #A- 2 of FIG. 6A. A check is made for the cleared state of the PB mode flag. If the flag is not cleared thus indicating the existence of the reproduction mode, the flow comes back to the step #A- 14 of FIG. 6A (RTS). If the flag is found to have been cleared, it proceeds to a step #N- 2 . Therefore, if the REC (recording) mode is not set, no recording action is performed even if the REC switch 52 is on.
[0149] Step #N- 2 : A check is made for “0000” of the memory address N which indicates that the head 3 - 1 has gained access to an unrecorded track. If the track accessed is found recorded, the flow of operation comes back to the step #A- 14 of FIG. 6A. If the track is unrecorded, the flow comes to a step #N- 3 .
[0150] Step #N- 3 : A check is made to see if the field flag is set. If so, the flow of operation comes to a step #N- 5 . If not, it proceeds to a step #N- 4 .
[0151] Step #N- 4 : The flow of operation comes to this step when the frame recording mode has been set. At this step, a check is made to find if the address N+1 of the memory is at “0000” thus indicating that the track accessed by the head 3 - 2 is unrecorded. If the track is not unrecorded, the flow of operation comes back to the step #A- 14 of FIG. 6A. If the track is unrecorded, the REC LED 44 B has been flickering. In the case of the unrecorded track, the flow branches out to a step #N- 6 .
[0152] Step #N- 5 : the head 3 - 1 records one field portion of the video signal in one track on the magnetic sheet 1 . Then, the switch SW 6 shown in FIG. 1 is turned off and the output of the character generator 84 ceases to appear on the monitor 13 . Meanwhile, “0001” is set at the memory address N. Step #N- 6 : In case that the flow of operation comes to this step, the apparatus is in the frame recording mode. Therefore, the heads 3 - 1 and 3 - 2 respectively record one-field portions of the video signal in two tracks on the magnetic sheet 1 . Then, “0011” is set at the memory address N and “0010” at the memory address N+1. The switch SW 6 is turned off in the same manner as in the case of the step #N- 5 . Following this, the stepping motor 24 is driven to shift inward the heads 3 - 1 and 3 - 2 to an extent corresponding to one track width.
[0153] In executing the steps #N- 5 and #N- 6 , the switches SW 2 to SW 5 are driven as described in the foregoing with reference to FIG. 2. Further, in performing a recording operation at the step #N- 6 , the CPU 40 reads out the set ID data from the RAM 27 and supplies it to the data modulator 14 . The data modulator 14 modulates the ID data into a DPSK signal. The modulated ID data is supplied to the recording amplifier 16 and is then recorded in a state of being superimposed on the video signal. However, in the event of an ID data display mode which will be described later with reference to FIG. 21( c ), the ID data (signal) is not recorded. In that instance, however, the data provided for indicating whether the track is on the inner side or on the outer side of a frame is simply recorded together with the video signal. Further, even in a display mode as shown in FIG. 21( a ) or 21 ( b ), the ID data signal is not displayed on the monitor 13 with the switch SW 6 kept in an OFF state during the recording operation performed by executing the steps #N- 5 and #N- 6 .
[0154] Step #N- 7 : The recording-in-process flag is set. Then, the switch SW 6 of FIG. 1 turns on.
[0155] With the steps #N- 1 to #N- 7 executed, the set ID data is produced by the character generator 84 and is superimposed on the video signal. When it is supplied to the monitor 13 , the character signal which is produced only during the execution of recording is cut off by the switch SW 6 of FIG. 1 and then the character disappears. The monitor 13 again displays the ID data when the switch SW 6 is turned on at the step #N- 7 .
[0156] Step #N- 8 : The subroutine (D) is called. If the head 3 - 1 has access to a track other than the 50th track, the flow of operation shifts from the steps #D- 1 and #D- 2 to the step #D- 3 . Then, the flow shifts from the step #D- 3 to the step #D- 13 to shift the heads 3 - 1 and 3 - 2 inward to the extent of one track. In the case of the frame recording mode, the heads 3 - 1 and 3 - 2 have already been shifted inward to the extent of one track at the step #N- 6 . In that case, therefore, the head 3 - 1 comes to gain access to a track located next to the track recorded at the step #N- 6 although the embodiment is in the frame recording mode. In the event that the tracks to be used for recording by the heads 3 - 1 and 3 - 2 already have existing records, the REC LED 44 B which is shown in FIG. 3 make a blinking display to give a warning to the operator. After that, the flow of operation branches from the step #D- 15 to the step #D- 19 and then from the step #D- 19 to the steps #D- 20 to #D- 34 to carry out these steps. More specifically, in case that the track feed speed setting value is for a single performance, the flow branches from the step #D- 21 to the step #D- 34 . Then, in accordance with the REC-in-process flag which has been set at the step #N- 7 , the flow comes back to the step #N- 9 . In case that the track feed speed for two picture planes per sec or five picture planes per sec has been set, subtraction is made from the value of the wait timer register as much as a period of time required for recording at the step #D- 28 . With the value of the wait timer register down counted, when the value of the register becomes zero, the flow of operation comes back from the step #D- 33 via the step #D- 34 to the step #N- 9 according to the REC-in-process flag set at the step #N- 7 in the same manner as mentioned above.
[0157] Step #N- 9 : The REC-in-process flag is cleared.
[0158] Step #N- 10 : The step is similar to the step #D- 20 . Data of the track feed speed setting value is taken in from the memory.
[0159] Step #N- 11 : If the track feed speed setting value is for a single performance, the flow of operation comes to a step #N- 12 . If not, it comes back to the step #A- 14 shown in FIG. 6A.
[0160] Step #N- 12 : With the track feed speed set for the single performance, if the REC switch 52 is in an ON state, this step is repeated to prevent recording from being performed by repeating this step to have the subroutine (N) carried out.
[0161] In case that the track feed speed is set at a value not for the single performance and that the REC switch 52 is in an ON state, the flow comes from the step #N- 11 via the step #A- 14 to the step #A- 1 . Then, at the step #A- 2 , the subroutine (N) is called out to carry out the above subroutine. Thus, as long as the REC switch 52 remains in the ON state, recording is continuously performed at the set track feed speed. If the REC switch 52 is in an OFF state, the flow of operation comes from the step #N- 12 to the steps #A- 14 , #A- 1 and #A- 2 . However, the continuous recording comes to an end at the step #A- 2 without calling the subroutine (N).
[0162] Subroutine (H):
[0163] Referring to FIG. 13, a subroutine (H) which is called when the program setting switch 58 is turned on is arranged as described below:
[0164] Step #H- 1 : When the program setting switch 58 is found to have been turned on at the step #A- 8 of FIG. 6A, the flow of operation comes to this step. A check is made to find if the PB mode flag has been set. If so, the flow proceeds to a step #H- 2 . If not, it comes back to the step #A- 1 of FIG. 6A (RTS). This step #H- 1 is provided for inhibiting program setting in the recording mode. In this embodiment, the reproduction mode must be selected before setting a program. Then, program setting is performed while confirming on a monitor the video signal recorded in the magnetic sheet 1 .
[0165] The change-over to the reproducing mode can be automatically effected by automatically setting the PB mode flag when the program setting switch 58 is turned on. In that instance, a step is provided in a manner similar to the step shown in the subroutine (C), that is, the step #H- 1 is replaced with a step “call (C)” for calling the subroutine (C).
[0166] Step #H- 2 : During the process of programed reproduction using a programed track memory which is arranged to store a program as shown in FIG. 14, the content of a register I showing an address of the programed track number at which the number of a track to be next reproduced is changed to zero.
[0167] Step #H- 3 : A programed reproduction mode flag which indicates selection of the programed reproduction mode is set. The flow then comes back to the step #A- 1 .
[0168] Subroutine (I):
[0169] [0169]FIG. 15 is a flow chart showing a subroutine (I) which is to be called when the programed track setting switch 62 is turned on after the programed reproduction mode is set by the subroutine (H).
[0170] Step #I- 1 : A check is made to see if the programed reproduction mode flag has been set. If so, the flow of operation proceeds to a step #I- 2 . If not, it branches out to the step #A- 1 . Therefore, with the programed reproduction mode not set by the program setting switch 58 , no program setting action is performed even when the programed track setting switch 62 is operated.
[0171] Step #I- 2 : a register S which is initially set at a state of S=0 when the power supply is switched on at the step # 1 indicates the foremost address storing the program of the above stated programed track memory. At the step #I- 2 , data which is the same as the content of the register S is written into a register M.
[0172] Step #I- 3 : The data of the programed track memory stored at the register M is stored at an address which is larger by one than the above stated address. In other words, the tracks number indicating data stored at the programed track memory is stored at another address which is larger by one than the address storing the data.
[0173] Step #I- 4 : A value obtained by adding one to the content of the register M is written into a register I.
[0174] Step #I- 5 : One is subtracted from the content of the register M.
[0175] Step #I- 6 : A check is made as to whether or not the content of the register M is not greater than zero. If it is found zero or less than zero, the flow proceeds to a step #I- 7 . If it is found greater than zero, it branches out to the step #I- 3 .
[0176] The loop of steps #I- 3 to #I- 6 are repeated until the content of the register becomes zero. When it becomes zero, all the data stored at the addresses of the programed track memory are respectively transferred to addresses larger by one. Therefore, when the flow comes from the step #I- 6 to a step #I- 7 after repeating the loop of steps, no data is stored at the address 1 of the programed track memory.
[0177] Step #I- 7 : The number of a track to which the head 3 - 1 has access is stored at the address 1 of the programed track memory. Therefore, with the programed track setting switch 62 turned on, the number of a track having the recorded video signal thereof being reproduced by the head 3 - 1 is programed.
[0178] Step #I- 8 : One is added to the content of the register S. With this step performed, the foremost address (the largest address) of data of the programed track memory shifted by execution of the loop of steps #I- 3 to #I- 6 is always stored at the register S.
[0179] Step #I- 9 : This step is repeated while the programed track setting switch 62 is in an ON state. When the switch 62 turns off, the flow of operation comes back to the step #A- 1 .
[0180] In case that the operator further proceeds with program setting, the track UP switch 54 or the track DOWN switch 55 is turned o to change the tracks to which the heads 3 - 1 and 3 - 2 are to be shifted. When reproduction is made from a desired track, program setting can be accomplished by turning on the programed track setting switch 62 while confirming a picture thus reproduced.
[0181] The data stored at each of addresses of the programed track memory shown in FIG. 14 comes to be stored at a larger address one by one every time the programed track setting switch 62 is turned on. During the process of program setting, the registers S and I have exactly the same content as each other.
[0182] With a program set by turning on the program setting switch 58 and the programed track setting switch 62 , the program is reproduced by a program reproducing operation. Programs for execution of the programed reproduction and an interval reproducing operation which is carried out by reproducing records at set intervals one after another from recorded tracks accessed by the heads 3 - 1 are as described below with reference to FIGS. 16 to 18 :
[0183] Subroutine (K):
[0184] [0184]FIG. 16 shows a subroutine (K) which is called when the start switch 60 is turned on. The subroutine (K) consists of the following steps:
[0185] Step #K- 1 : With the start switch 60 found to have turned on at the step #A- 11 of FIG. 6A, the flow of operation comes to this step to make a check to see if the PB mode flag has been set. If not, the flow comes to the step #A- 1 . If the flag is set, the flow comes to a step #K- 2 . In this embodiment, therefore, neither interval reproduction nor programed reproduction are possible if the reproduction mode is not set. Therefore, interval reproduction or program reproduction can be prevented from being accidentally started even if the start switch 60 is turned on by mistake when the embodiment is in the recording mode. This arrangement, however, may be changed to permit starting interval reproduction or programed reproduction immediately by just turning on the start switch 60 without setting the reproduction mode set beforehand. In the case of that modification, the step #K- 1 is replaced with a step similar to the step #C- 5 .
[0186] Step #K- 2 : A check is made to see if the programed reproduction mode flag has been set. If so, the flow proceeds to a step #K- 3 . If not, it branches to a step #K- 4 . In the case that the programed reproduction mode flag is not set, i.e. in carrying out interval reproduction, the flow of operation takes place in the following manner:
[0187] Step #K- 4 : A check is made to see if the address N of the memory is at “0000” indicating that the head 3 - 1 has gained access to an unrecorded track. If so, the flow of operation comes to a step #K- 6 . If not, it proceeds to a step #K- 5 . In the case that the track accessed by the head 3 - 1 is not recorded, the flow of operation from the step #K- 6 is as follows:
[0188] In the embodiment described below, if the track accessed by the head 3 - 1 is not the 49th nor 50th track, only recorded tracks are reproduced one after another beginning with the accessed track. If the track is either the 49th or 50th track, recorded tracks are reproduced beginning with the first track. However, this arrangement can be changed to have the reproduction of recorded tracks begin always from the first track by inserting an additional step of driving the stepping motor 24 to cause the head 3 - 1 to gain access to the first track in between the steps #K- 2 and #K- 4 .
[0189] This arrangement is highly advantageous in carrying out a look-up operation by automatic interval reproduction starting with the first track one after another in the event that the head 3 - 1 has access to a track other than the first track.
[0190] Step #K- 6 : An automatic track feeding flag is set indicating that an interval reproducing operation is in process.
[0191] Step #K- 7 : A check is made to see if the field flag has been set. If so, the flow of operation proceeds to a step #K- 8 . If not, it branches to a step #K- 9 .
[0192] Step #K- 8 : The register N is checked to find if it is at 50 thus indicating that the track accessed by the head 3 - 1 is the innermost track. If so, the flow of operation comes to a step #K- 10 . If not, it comes to a step #K- 11 .
[0193] Step #K- 9 : The register N is checked to find if it is at 49 thus indicating that the track accessed by the head 3 - 1 is in the innermost position but one. If so, the flow proceeds to the step #K- 10 . If not, it comes to the step #K- 11 .
[0194] Step #K- 10 : The interval time Ti which is set by execution of the subroutine (G) is checked to find if it is at “0” thus indicating a mode in which the head 3 - 1 is to be shifted in accordance with a preset program in response to an external trigger signal as will be described later. If the interval time Ti is set at “0” because of that mode, the flow branches out to the step #A- 1 . If not, it comes to a step #K- 12 .
[0195] Step #K- 11 : The subroutine (D) is called to execute steps #D- 1 to #D- 18 . The PB mode flag is set when the subroutine (D) is called during the execution of the subroutine (K). Therefore, the flow of operation branches from the step #D- 2 to the step #D- 9 . Then, the heads 3 - 1 and 3 - 2 are shifted inward to an extent of two tracks at steps #D- 12 and #D- 13 if a track located more inward by one track than the track accessed by the head 3 - 1 is found to be the inner side track of the two tracks having a frame video signal recorded therein and if the head 3 - 1 is not having access to the 49th track at the step #K- 4 . If not, the heads 3 - 1 and 3 - 2 are shifted inward to an extent of only one track at the step #D- 13 . Further, if a frame video signal is recorded in the tracks accessed by the heads 3 - 1 and 3 - 2 , the field flag is cleared and the flow of operation shifts from the step #D- 19 to a step #K- 14 .
[0196] Step #K- 12 : The subroutine (E) is called. The steps #E- 1 to #E- 13 and #D- 14 to #D- 19 are carried out. In case that a frame video signal is found at the step #K- 4 to be recorded in two tracks located adjacent to and on the outer side of a track accessed by the head 3 - 1 , the heads 3 - 1 and 3 - 2 are shifted outward to the extent of two tracks at steps #E- 12 and #E- 13 . With the exception of this case, the heads are shifted outward to the extent of only one track. Further, like in the case of the step #K- 11 , if a frame video signal is recorded in the tracks accessed by the heads 3 - 1 and 3 - 2 , the field flag is cleared and the flow shifts from the step #D- 19 to a step #K- 13 .
[0197] Step #K- 13 : The content of the register N is checked to see if it is 1 thus indicating that the track accessed by the head 3 - 1 is the outermost track. If so, the flow proceeds to a step #K- 14 . If not, it branches out to the step #K- 12 . Therefore, in case that the flow of operation branches to the step #K- 12 from the step #K- 8 or #K- 9 with the head 3 - 1 gaining access to the 49th or 50th track, the steps #K- 12 and #K- 13 are repeated to bring the head 3 - 1 to the first track.
[0198] Step #K- 14 : The automatic track feeding flag is cleared.
[0199] As mentioned above, when the flow of operation comes from the step #K- 4 to the step #K- 5 with the steps #K- 4 to #K-= 14 carried out, the head 3 - 1 comes to have access to a track having a video signal recorded therein. All the tracks having no video signal recorded therein are skipped over and substantially not reproduced.
[0200] Further, when the flow comes from the step #K- 4 to the step #K- 5 with the steps #K- 4 to #K- 14 executed, if a frame video signal is recorded in two tracks accessed by the heads 3 - 1 and 3 - 2 , the filed flag has been cleared at the step #D- 18 of the subroutine (D). In that event, therefore, a frame reproduction mode is automatically set. Further, if a field video signals are recorded in tracks accessed by the heads 3 - 1 and 3 - 2 , a field reproduction mode is automatically set. In the event of interval reproduction, therefore, the embodiment is automatically set in the optimum reproduction mode according to the manner in which the video signal is recorded.
[0201] Step #K- 5 : The interval time Ti set by the subroutine (G) is taken into the CPU 40 from the memory.
[0202] Step #K- 15 : A check is made to see if the interval time Ti is at “0” in a manner similar to the step #K- 10 . If so, the flow branches out to a step #K- 17 ′. If not, it comes to a step #K- 16 . Assuming that no external trigger mode is set in this case, the flow of operation at the step #K- 16 and steps ensuing it is as follows:
[0203] Step #K- 16 : The timer 1 begins to count time. The flow comes to a step #K- 18 .
[0204] Step #K- 18 : A check is made to see if the timer 1 has counted one second. If so, the flow proceeds to a step #K- 19 . If not, the flow branches out to a step #K- 20 .
[0205] Step #K- 20 : A check is made to see if the stop switch 61 is in an ON state. If so, the flow branches out to the step #A- 1 . If not, it comes to a step #K- 21 . When the flow branches to the step #A- 1 , the steps #A- 1 to #A- 12 are executed. Therefore, when the stop switch 61 is turned on under a normal condition, the flow calls a subroutine (M) at the step #A- 12 .
[0206] Subroutine (M):
[0207] The subroutine (M) is as described below with reference to FIG. 17:
[0208] Step #M- 1 : A check is made to see if the programed reproduction mode flag is set. If not, the flow comes to the step #A- 14 . If the flag is set, the flow proceeds to a step #M- 2 .
[0209] Step #M- 2 : A check is made to see if a programed reproduction-in-process flag is set. If so, the flow proceeds to a step #M- 3 . If not, it branches out to a step #M- 4 .
[0210] Step #M- 3 : The content of the register I is equalized with that of the register S.
[0211] Step #M- 4 : The content of the register S is shifted to zero. Then, the step #M- 3 is executed.
[0212] Further details of the subroutine (M) will be described later along with the programed reproduction mode. The flow of operation at a step #K- 21 and steps ensuing it is as follows:
[0213] Step #K- 21 : A check is made to see if the track UP switch 54 is on. If the switch is found to be on, the subroutine (D) is called to shift the heads 3 - 1 and 3 - 2 inward. If not, the flow proceeds to a step #K- 22 .
[0214] Step #K- 22 : The track DOWN switch 55 is checked to see if it is on. If it is, the subroutine (E) is called to shift the heads 3 - 1 and 3 - 2 outward. If not, the flow of operation branches out to the step #K- 18 .
[0215] Step #K- 19 : One is subtracted from the interval time Ti taken in from the memory.
[0216] Step #K- 23 : If the interval time Ti is zero, the flow proceeds to a step #K- 24 . If not, the flow branches to the step #K- 16 .
[0217] During interval reproduction, images recorded in tracks neighboring the tracks under the reproducing operation thus can be reproduced by turning on the track UP switch 54 and the track DOWN switch 55 with the above stated steps #K- 15 to #K- 23 carried out. In that instance, the track to be reproduced at the track feeding speed set by the subroutine (F) can be automatically renewed from one track to another by keeping the switch 54 or 55 in its ON state. Therefore, an image preceding by several picture planes can be readily reproduced during the interval reproduction.
[0218] Further, in reproducing the images recorded in the tracks neighboring the track under the reproducing operation by turning on the track UP switch 54 and the track DOWN switch 55 , if the reproducing operation is performed for the remaining period of the interval time Ti of the track under the reproducing operation, the flow of operation according to the arrangement of this embodiment shifts from the step #K- 23 to the step #K- 24 to renew the reproducing track. However, this arrangement may be changed to reset the interval time Ti to enable the operator to observe the image renewed by the switch 54 or 55 for a predetermined period of time without fail by allowing the flow of operation to jump to the step #K- 5 as indicated by a broken line in FIG. 16.
[0219] Step #K- 24 : At the time of renewal of the reproducing track after the end of the interval time Ti, a check is made to see if the programed reproduction mode has been set. If so, the flow branches to the step #K- 3 . If not, it branches to the step #K- 6 .
[0220] Subroutine (O):
[0221] [0221]FIG. 18 shows a subroutine (O) which is called when the programed reproduction mode flag is found to be set at the step #K- 2 . The subroutine (O) is as described below with reference to FIG. 18:
[0222] Step #O- 1 : The register S is checked to see if its content is “0”. If so, the flow comes to the step #A- 1 . If not, it proceeds to a step #O- 2 . As mentioned in the foregoing, the foremost address of the programed track memory at which a program is set is stored at the register S. When the content of the register S is “0”, it indicates that no program is stored. In this instance, therefore, the flow of operation comes back to the subroutine (A).
[0223] Step #O- 2 : A check is made to see if the content of the register I is “0”. If so, the flow proceeds to a step #O- 3 . If not, the flow branches out to a step #O- 5 .
[0224] As mentioned in the foregoing, the address of the track memory storing the number of a track to be next reproduced during the execution of programed reproduction is stored at the register I. during the programed reproduction, one is subtracted from the register I every time one step of programed reproduction is performed, as described in a step #O- 14 . Therefore, the fact that the flow comes to the step #O- 2 and the register I is found to be at “0” does not indicate that the register S is at “0” with a program set but indicates completion of execution of one round of steps of programed reproduction. In other words, with the programed reproduction having been performed for once, the flow of operation comes to a step #O- 3 . If the programed reproduction is still in process, the flow branches to a step #O- 5 .
[0225] Step #O- 3 : The interval time Ti set by the subroutine (G) is taken in. A check is made to see if the interval time Ti is at “0”. If so, the flow comes back to the step #A- 1 to complete the programed reproduction.
[0226] Therefore, in the external trigger mode which is set with the interval time set at “0”, a program reproducing operation comes to a stop upon completion of execution of one round of the programed reproduction.
[0227] In the case of normal programed reproduction for which the interval time Ti is set at a value other than “0”, the flow shifts to a step #O- 4 .
[0228] Step #O- 4 : The content of the register S is written into the register I. Then, the programed action is resumed.
[0229] Step #O- 5 : The data (I) of an address of the programed track memory which is set at the register I (indicating data written in an address set at the register I of the programed track memory by parenthesizing I) is read out.
[0230] Step #O- 6 : The data (I) is subtracted from the content of the register N indicating the number of a track to which the head 3 - 1 presently gains access. If the result of subtraction is not less than “0”, the flow comes to a step #O- 9 . If it is less than “0”, the flow comes to a step #O- 7 .
[0231] Step #O- 7 : The field flag is set for the purpose of inhibiting the heads from being shifted in the frame mode in the same manner as in the case of the step #D- 8 .
[0232] Step #O- 8 : The heads 3 - 1 and 3 - 2 are shifted outward to an extent corresponding to one track.
[0233] Step #O- 9 : A check is made to see if the number of a track to which the head 3 - 1 has access as indicated by the register N is equal to the data (I). If so, the flow comes to a step #O- 11 . If not and the data (I) is larger, the flow comes to a step #O- 10 .
[0234] Step #O- 10 : The heads 3 - 1 and 3 - 2 are shifted inward to the extent corresponding to one track.
[0235] Steps #O- 11 , #O- 12 and #O- 13 : These steps are similar to the steps #D- 16 , #D- 17 and #D- 18 . Either frame reproduction or field reproduction is automatically performed according to whether the video signal recorded by these steps is a frame video signal or field video signal.
[0236] Further, the head 3 - 1 is controlled by repeating the steps #O- 6 to #O- 10 to have access to track programed at the programed track memory.
[0237] Steps #O- 14 : One is subtracted from the register I.
[0238] Step #O- 15 : A programed reproduction-in-process flag is set. With this step performed, the flow can be branched by making a check at the step #K- 24 to see if the program reproduction mode flag is set. Next, the flow jumps to the step #K- 5 .
[0239] Therefore, when the subroutine (O) is called at the step #K- 2 , a check is first made for an actual set state of a reproduction program. Further, a check is made to see if the external trigger mode has been set. If the external trigger mode is found to have been set, the program is executed only for once. With the exception of this, the programed reproduction is performed in a repeating manner.
[0240] The flow of operation in the external trigger mode is as follows: In this instance, the flow branches from the step #K- 15 to a step #K- 17 ′.
[0241] Step #K- 17 ′: A check is made to find whether a printer connected to the embodiment as an external device is busy (performing a printing action). If so, the flow of operation comes to the step #A- 1 . If not, it branches out to a step #K- 18 ′.
[0242] Step #K- 18 ′: A print start signal is sent to the printer. The print start signal can be sent by making high the signal level of a terminal connected to the printer.
[0243] Step #K- 19 ′: There obtains a wait state for 150 m.sec.
[0244] Step #K- 20 ′: If the printer is busy, the flow of operation comes to a step #K- 21 ′. If not, the flow branches out to a step #K- 24 .
[0245] Step #K- 21 ′: The stop switch 61 is checked for an ON state thereof. If not, the flow comes to the step #K- 20 ′. If the switch 61 is found to be turned on, the flow comes back to the step #A- 1 .
[0246] If the printer which is connected as an external device is found busy in executing the steps #K- 17 ′ to #K- 21 ′, the flow of operation comes back to the step #A- 1 as mentioned above. In that instance, the flow shown in FIG. 16 is repeated until another switch is turned on. During this repeating process, when the start switch 60 is again turned on, the above stated flow of operation is repeated to carry out the step #K- 17 ′.
[0247] In case that the printer is not connected as an external device, a terminal which is arranged to receive a signal from the busy signal output terminal of the printer 13 ′ as shown in FIG. 1 opens to have a high level there. This causes the flow of operation to come back to repeat the above stated flow. Therefore, in the event that no external device such as the printer is connected although the external trigger mode is set, the record of the tracks to which the heads 3 - 1 and 3 - 2 have access is continuously reproduced and the reproducing tracks are not renewed.
[0248] Further, with the printer connected as an external device, if the printer is not busy and the flow proceeds from the step #K- 17 ′ to the step #K- 18 ′ a printer start action begins when the wait time of 150 m.sec of the step #K- 19 ′ elapses after a print start signal is applied to the printer. Then, when the printer thus becomes busy, the steps #K- 20 ′ and #K- 21 ′ are repeated until either the action of the printer comes to an end or the stop switch 61 is turned on. When the action of the printer comes to an end, the flow branches from the step K- 20 ′ to a step #K- 24 . At this step, a check is made to find if the programed reproduction mode has been set. If so, the flow branches to the step #K- 3 . If not, it branches to the step #K- 6 . Further, in case that the stop switch 61 is turned on, the flow of operation is performed in the same manner as described in the foregoing.
[0249] When the external trigger mode is selected in the programed reproduction mode, programed reproduction is performed and comes to a stop at the end of one performance of reproduction as mentioned at the step #O- 3 in the foregoing.
[0250] In accordance with the arrangement of this embodiment, even in case that the programed reproduction mode is not set while the external trigger mode has been selected, the provision of the step #K- 10 brings a reproducing operation to a stop when the records of the tracks are reproduced one after another for once from the tracks accessed by the heads 3 - 1 and 3 - 2 to the last track. Therefore, in the external trigger mode, reproduction comes to a stop irrespective as to whether the programed reproduction is set or not set. Therefore, with a printer used as an external triggering device, printing is performed only once.
[0251] In cases other than the external trigger mode, after reproduction is performed once in the predetermined sequence, reproduction is again performed from the beginning irrespective as to whether the programed reproduction mode is set or not set. Therefore, with the exception of the external trigger mode, the so-called endless reproduction can be performed as the reproduction is thus arranged to be repeated in the predetermined sequence.
[0252] While the printer is described by way of example as an external triggering device usable in combination with the embodiment, the external device is not limited to a printer but may be a device having an electrically transmitting function or a device for processing a reproduced signal.
[0253] Subroutine (R):
[0254] In case that the ID signal is to be set, the flow of operation is performed in the following manner:
[0255] In the subroutine (A), when some of the ten-key switches 63 to 72 is turned on, the flow of operation branches off to the subroutine (R) which is as shown in FIG. 19.
[0256] Step #R- 1 : If the PB mode flag is set, the flow branches off to a step #R- 10 and comes back to the flow of the subroutine (A). With the exception of the recording mode, therefore, substantially nothing is performed in this subroutine even with any of the ten-key switches turned on. However, if the PB mode flag is not set, i.e. in the event of the recording mode, the flow of operation proceeds to a step #R- 2 . Step #R- 2 : A check is made to see if there obtains the ID signal setting mode in which the ID signal is superimposed on the video signal and is monitored. The method for setting that mode will be later described in detail with reference to FIG. 20. If the apparatus is not in that mode, the flow branches off to a step #R- 10 and comes back to the step #A- 1 of the flow of FIG. 6A. If the apparatus is in that mode, the flow proceeds to a step #R- 3 . Step #R- 3 : The CPU 40 reads from the register P of the RAM 27 data indicative of a set position in which the set ID signal is to be displayed on the monitor. Then, the data corresponding to some of the ten-key switches 63 to 72 which have been turned on is written in the address of the RAM 27 corresponding to the set position. The CPU 40 then controls the character generator 84 to have the data displayed on the monitor 13 according to the read set position. Step #R- 4 : The flow of operation waits until the ten-key switch turns off. When the switch which has been on comes to turn off, the flow proceeds to a step #R- 5 . Step #R- 5 : In the ID signal, the setting positions for the data other than the data for year, month and day are 11 points from 0 to 10 as shown in FIG. 21( a ). Therefore, if the data of the register P is equal to 11, the flow comes to a step #R- 6 . If not, it comes to a step #R- 7 . Step #R- 6 , the register P is set at 0 and the data setting position is thus initialized. Step #R- 7 : One is added to the value of the register P. The data setting position is shifted to a next position. Step #R- 7 - 1 : The data in the positions stored at the register P blinks. Step #R- 8 : A check is made to see if the ten-key switches 63 - 72 are in their ON state. If so, the flow branches off to the step #R- 3 and the ID data set by the ten-key switches through the flow as described in the foregoing is displayed on the monitor 13 . If not, the flow proceeds to a step #R- 9 . Step #R- 9 : A check is made to see if any switch other than the ten-key switches 63 to 72 is in an ON state. If not, the flow comes to the step #R- 8 . If so, the flow comes to a step #R- 11 . Step #R- 11 : The register P in the ID data setting position is set at 0 to initialize the ID data setting position and the flow comes to a step #R- 9 - 1 . Step #R- 9 - 1 : The ID data display on the monitor stops blinking. The flow comes to a step #R- 10 . Step #R- 10 : The flow comes back to the subroutine (A).
[0257] As mentioned in the foregoing, in case that the PB mode flag is not set and that the apparatus is in the ID data setting mode, i.e. the mode in which the set ID data can be monitored, the CPU 40 controls the character generator 84 , every time some of the ten-key switches 63 to 72 turns on, to have the data corresponding to that switch generated in the position determined by the register P.
[0258] Subroutine (Q):
[0259] The ID switch 73 is arranged as follows: When the switch 73 is turned on in the subroutine (A), a subroutine (Q) which is as shown in FIG. 20 is called. In the subroutine (Q): Step #Q- 1 : a check is made to see if the PB mode flag is set. If so, the flow comes to a step #Q- 2 . If not, it branches off to a step #Q- 7 . Step #Q- 2 : A check is made for an ID display mode, i.e. a mode in which the ID data (or signal) is displayed on the monitor in a state of being superimposed on the video signal. If the apparatus is found to be in the ID display mode, the flow comes to a step #Q- 4 . If not, it proceeds to a step #Q- 3 . Step #Q- 3 : The CPU 40 controls the character generator 84 to bring to a stop the display of the ID data being produced from the generator. The flow then comes to a step #Q- 6 . Step #Q- 4 : The CPU 40 takes in the reproduced ID data from the RAM 27 . The flow proceeds to a step #Q- 5 . Step #Q- 5 : The CPU 40 controls on the basis of the reproduced ID signal the character generator 84 to have the reproduced ID signal data produced from the generator 84 in the form of a character pattern as shown in FIG. 21( a ). The flow of operation then proceeds to a step #Q- 6 . Step #Q- 6 : The flow waits when the switch 73 is on and proceeds to a next step coming back to the subroutine (A) when the switch 73 turns off. Step #Q- 7 : In case that the PB mode flag is not set and there obtains the recording mode, a check is made for the ID setting mode, i.e. the mode in which the ID signal is produced from the character generator 84 in the form of a character pattern superimposed on the video signal. If the apparatus is in that mode, the flow comes to a step #Q- 9 . If not, it proceeds to a step #Q- 8 . A step #Q- 8 : A check is made to see if characters “ID” are produced from the character generator 84 . If so, the flow comes to a step #Q- 10 . If not, it comes to a step #Q- 11 . Step #Q- 9 : The CPU controls the character generator 84 to stop the ID data from being displayed and to have a two character pattern “ID” generated from the character generator 84 as shown in FIG. 21( b ) and to have a mode of displaying the character pattern “ID”. The flow then comes to the step #Q- 6 . In other words, when the ID switch 73 is turned on in the ID setting mode, there is set the character “ID” display mode.
[0260] Step #Q- 10 : The CPU 40 controls the character generator 84 to bring the whole character pattern display to a stop as shown in FIG. 21( c ). The flow then comes to the step #Q- 6 . Step #Q- 11 : The flow comes to this step when the apparatus is not in the ID setting mode nor in the character “ID” display mode. In other words, there obtains a mode of stopping the ID data from being displayed. Therefore, the CPU 40 takes in the set ID data from the RAM 27 . The CPU 40 then controls the character generator 84 to have the set ID data produced from the character generator 84 in the form of a character pattern as shown in FIG. 21( a ). In other words, the ID setting mode is obtained by this step. The flow then comes to the step #Q- 6 .
[0261] As described above, the ID data display mode changes every time the ID switch 73 turns on. Namely, in the case of the reproduction mode, the ID display mode in which the reproduced ID data is displayed on the monitor in a state of being superimposed on the video signal and the ID non-displaying mode in which the reproduced ID data is not displayed are alternately obtained every time the ID switch 73 is operated. More specifically stated, the ID display mode of FIG. 21( a ) and the ID non-displaying mode of FIG. 21( c ) are alternately repeated. In case of the recording mode, the ID data setting mode in which all the ID data to be set are all displayed, the character “ID” display mode in which only the character pattern of “ID” is displayed and another mode in which the ID data is not displayed on the monitor are arranged to obtain repeatedly in rotation every time the ID switch 73 turns on. In other words, the modes as represented by FIGS. 21 ( a ), 21 ( b ) and 21 ( c ) are repeatedly changed from one over to another. The arrangement for displaying the ID data in the recording mode is further described as follows: When the video signal is recorded in the mode which is shown in FIG. 21( a ) or 21 ( b ), the ID data signal which is modulated into a DPSK signal and is recorded in a state of being superimposed on the video signal at the step #N- 5 or #N- 6 as shown in FIG. 12. Further, when the video signal is recorded in the mode of FIG. 21( c ), the ID data is not recorded. However, the data which indicates that the video signal is on the inner side or outer side of frame recording or recorded in the field recording mode is always recorded along with the video signal.
[0262] In short, this specific embodiment is arranged to permit change-over of the ID data display on the monitor 13 by selecting the number of times for which the ID switch is pushed irrespective as to whether the apparatus is in the recording mode or in the reproduction mode.
[0263] In recording the ID signal along with the video signal, this embodiment has, as described in the foregoing, tow different modes of displaying the ID data. One is the ID data setting mode in which a display is made as shown in FIG. 21( a ) and the other the character “ID” display mode in which a display is made as shown in FIG. 21( b ). The reason for this is as follows: It is possible to set a date including the year, month and day or 11 digits as the ID signal data. However, as shown in FIG. 21( a ), it takes a considerably large area on the picture plane of the monitor 13 to completely display the whole ID data. The complete display of the ID data thus might prevent adequate observation of the image display on the monitor. However, this problem can be solved by selecting the other display mode available as shown in FIG. 21( b ).
[0264] In the reproduction mode, with the mode shown in FIG. 21( a ) or 21 ( b ) having been set by the ID switch 73 in the recording mode, the ID signal data recorded along with the video signal is arranged to be displayed in the following manner: When the head is shifted to a new track in the reproduction mode, the ID signal data recorded in the track is reproduced on the monitor 13 . More specifically, after demodulation by the data demodulator 12 of FIG. 1, the reproduced ID data is read out by the CPU 40 . The CPU 40 then drives the character generator 84 to have the ID data displayed on the monitor 13 . In this instance, the ID data read by the CPU 40 is retained at the RAM 27 . The method of displaying this ID data is as described in the foregoing with reference to FIG. 21( a ). In the case of this embodiment, the character data retained at the RAM 27 can be displayed in the following two different modes I) and II):
[0265] I) A display of the set ID data when it is reproduced including only a date consisting of the year, month and day. This is called a first display mode.
[0266] II) A display of the set ID data when it is reproduced including some numerical data in addition to data of a date. This is called a second display mode.
[0267] The first ID data display mode is as shown in FIG. 22( a ) while the second mode is as shown in FIG. 22( b ). As shown, in the first mode, only the date is displayed in the lower righ-hand side corner on the monitor. In the second mode, the date and the numerical data are displayed together at the lower right-hand corner. Since the display is made always in the lower right-hand corner of the picture plane of the monitor, the possibility of hindering the display of the video signal can be minimized. The arrangement to have the display made in the lower right corner may be changed to have it in any other corner of the picture plane.
[0268] To perform the display action, the output signal of the data demodulator 12 of FIG. 1 is read out by the CPU 40 and, after that, a character is generated after confirming that no data other than the data of date is set. The CPU 40 is arranged to have the character generated in different positions for the first and second modes as described in Para. I) and II) above.
[0269] In case where some data other than the data of date is found not to have been recorded by this apparatus, the data is displayed also in the manner as shown in FIG. 22( b ). Such data is distinguishable with a known check code recorded as the ID data.
[0270] Subroutine (S):
[0271] In case that a date is to be set as the ID data, the embodiment operates as follows: When the year setting switch 74 is turned on in the subroutine (A), the flow of operation jumps to a subroutine (S) shown in FIG. 23.
[0272] Step #S- 1 : If the PB mode flag is set, the flow comes to a step #S- 14 to return to the flow of the subroutine (A). If not, it proceeds to a step #S- 2 . Step #S- 2 : A check is made to see if there obtains the mode of having the ID data superimposed on the video signal and produced either to the monitor or the printer. If not, the flow comes to the step #S- 14 to come back to the subroutine (A). If there obtains that mode, it proceeds to a step #S- 3 . Step #S- 3 : The place of the tenth digit in the year setting position on the monitor 13 blinks. This means that a character in the position of a reference numeral (1) in FIG. 24 blinks. In that instance, the CPU 40 controls the character generator 84 to have the character of this position either generated or not generated. This is accomplished by a well known interrupt method. Following this, the flow comes to a step #S- 4 . #S- 4 : The flow waits until the switch 74 is turned off. With the switch 74 turned off, the flow comes to a step #S- 5 . Step #S- 5 : A check is made to see if some of the ten-key switches 63 to 72 is turned on. If so, the flow proceeds to a step #S- 6 . If not, it comes to a step #S- 12 . Step #S- 6 : The CPU 40 writes input data obtained by the ten-key switch into the RAM 27 . The CPU 40 controls the character generator 84 to have a character pattern generated in the year setting position indicated by the reference numeral ( 1 ) in FIG. 24. The flow then proceeds to a step #S- 7 . Step #S- 7 : The unit digit which is in the year setting position is caused to blink. This means that a character in a position ( 2 ) shown in FIG. 24 blinks. This blinking action is performed with the character generator 84 controlled by the CPU 40 . Step #S- 8 : The flow of operation waits until the ten-key switch is turned off. With the ten-key switch turned off, the flow proceeds to a step #S- 9 . Step #S- 9 : A check is made to see if any of the ten-key switches is in its ON state. If so, the flow proceeds to a step #S- 10 . If not, it comes to a step #S- 13 . Step #S- 10 : With the ten-key switch turned on, the CPU 40 writes data received from the ten-key switch into the RAM 27 . The CPU 40 then controls the character generator 84 to have a character pattern generated in the position ( 2 ) of FIG. 24 which is the unit digit in the year setting part. The flow then proceeds to a step #S- 11 . Step #S- 11 : The character in the year setting part is stopped from blinking with the character generator 84 controlled by the CPU 40 . This informs the operator of the end of the year setting action. The flow then comes to a step #S- 14 . Step #S- 12 : If none of the ten-key switches are found in their ON states at the step #S- 5 , a check is made for any switch other than the ten-key switches that is in its ON state. If no switch is found on, the flow branches off to the step #S- 5 to repeat the steps #S- 5 and #S- 12 . If any of other switches is found on, the flow comes to the step #S- 11 . Step #S- 13 : A check is made for the ON state of any switch other than the ten-key switches. If no switch is found on, the flow branches off to the step #S- 9 . If any switch is found on, the flow comes to the step #S- 11 . Thus, the steps #S- 9 and #S- 13 are repeated until some switch other than the ten-key switches comes to turn on. Meanwhile, the character in the year setting part continues to blink to urge the operator to finish his or her year setting action being performed with the ten-key switches. Step #S- 14 : In case that the PB mode flag is set and if the embodiment is in the ID data setting mode, the flow of operation comes back to the subroutine (A) from this step when the blinking of the character is brought to a stop by the step #S- 11 .
[0273] As mentioned in the foregoing, with the year setting switch 74 turned on, the place of the tenth digit in the year setting position first begins to blink to inform the operator of a data setting position. Then, a figure is obtained from the ten-key switch arrangement. By this, the character generator 84 is caused to generate this input data in the form of a character pattern in the blinking position. Meanwhile, the CPU 40 keeps this input data at the RAM 27 . Upon completion of setting the tenth digit, the place of the unit digit in the year setting position begins to blink and then the applicable data is likewise set in this position. The year setting mode comes to an end upon completion of the unit digit setting action. The flow of operation then comes back to the subroutine (A). However, this flow may be changed to come under that condition to a subroutine (T) to enter a month setting mode as follows:
[0274] Subroutine (T):
[0275] Referring to FIG. 25, the details of the month data setting operation are as follows: When the switch 75 is turned on in the flow of the subroutine (A), the subroutine (T) is called and there obtains the month data setting mode.
[0276] Step #T- 1 : If the PB mode flag is set, the flow of operation comes to a step #T- 16 and comes back to the subroutine (A). If not, the flow proceeds to a step #T- 2 . Step #T- 2 : A check is made for the ID setting mode of producing the ID data to the monitor or the printer in the state of being superimposed on the video signal. If the apparatus is not in this mode, the flow comes to the step #T- 16 for coming back to the subroutine (A). If the apparatus is in this mode, the flow proceeds to a step #T- 3 . Step #T- 3 : The place of the tenth digit in a month setting position on the monitor is caused to blink. This means that the character in a position ( 3 ) as shown in FIG. 24 blinks. This blinking action is brought about by the control of the CPU 40 over the character generator 84 alternately allowing and not allowing the generation of the applicable character. The flow then proceeds to a step #T- 4 . Step #T- 4 : The flow waits until the month setting switch 75 is turned off. When the switch 75 is turned off, the flow proceeds to a step #T- 5 .
[0277] Step #T- 5 : A check is made to see if some of the ten-key switches is in an ON state. If so, the flow proceeds to a step #T- 6 . It not, it shifts to a step #T- 13 . Step #T- 6 : A check is made to see if data at “2” or more than “2” has been supplied by means of the ten-key switches. If so, the flow shifts to a step #T- 14 . If not, it proceeds to a step #T- 7 . The flow is arranged to branch out at this step for the purpose of accepting any unit digit only when the initial input figure is “1” or “0” in the case of the month setting mode.
[0278] Step #T- 7 : The CPU 40 writes the input data into the RAM 27 and, at the same time, controls the character generator 84 to have a character pattern generated in a position ( 3 ) of FIG. 24, i.e. in the position blinked at the step #T- 3 . The flow then proceeds to a step #T- 8 . Step #T- 8 : The place of a unit digit in the month setting position is blinked. This means that a character in a position ( 4 ) of FIG. 24 is caused to blink. The flow then proceeds to a step #T- 9 . Step #T- 9 : The flow waits until the ten-key switch turns off. When the ten-key switch turns off, the flow proceeds to a step #T- 10 . Step #T- 10 : A check is made to see if some of the ten-key switches is on. If so, the flow proceeds to a step #T- 11 . If not, it comes to a step #T- 15 . Step #T- 11 : The CPU 40 writes into the RAM 27 the data received from the ten-key switches at the step #T- 5 or #T- 10 . The CPU 40 then controls the character generator 84 to have a character generated in a position ( 4 ) of FIG. 24 which is the place of the unit digit in the month setting position. The flow then proceeds to a step #T- 12 . Further, in case that the flow branches from a step #T- 14 to this step, the data received from the ten-key switch at the step #T- 5 is displayed in the place of the unit digit while “0” is displayed in the place of the tenth digit when the steps #T- 14 and #T- 11 are executed. Step #T- 12 : The data in the month setting position is stopped from blinking to indicate the end of the month setting process. The flow then comes to a step #T- 16 . Step #T- 13 : The flow branches off to this step when none of the ten-key switches are found in their ON states at the step #T- 5 . A check is made to see if any switch other than the ten-key switches is on. If not, the flow of operation comes to the step #T- 12 . In other words, the steps #T- 5 and #T- 13 are repeated until the ten-key switch or some other switch turns on. The flow branches off to the step #T- 6 when the ten-key switch turns on or to the step #T- 12 when some other switch turns on.
[0279] Step #T- 14 : The flow comes to this step when the input data is found to be at least “2” at the step #T- 6 . The CPU 40 writes data of “0” into the RAM 27 and controls the character generator 84 to have a character pattern of “0” generated in the place of the tenth digit in the month setting position. Step #T- 15 : A check is made to see if any switch other than the ten-key switches is on. If not, the flow comes to the step #T- 10 . If so, it comes to the step #T- 12 . Step #T- 16 : The flow comes back to the subroutine (A).
[0280] As mentioned in the foregoing, the place of the tenth digit in the month setting position first blinks when the switch 75 turns on. This indicates the position in which the data coming from the ten-key switch is to be set. If the data is “2” or more than “2”, “0” is automatically set in the place of the tenth digit while the data received is set in the place of the unit digit. In case that the data received does not exceed “1”, the data is of course set in the place of the tenth digit. Then, the blinking position shifts to the place of the unit digit. After that, data received next is of course set in the place of the unit digit. Therefore, in accordance with the arrangement of this embodiment, no value exceeding “2” is set in the place of tenth digit in the month setting process. This simplifies the month setting process.
[0281] At the step #T- 3 , only the place of the tenth digit is caused to blink. This arrangement, however, may be changed to blink both the places of the tenth and unit digits. Further, in the case of this embodiment, the flow is arranged to come back to the subroutine (A) upon completion of the process of setting data in the place of the unit digit. However, this arrangement may be changed to have the flow of operation proceed directly to a subroutine (U) for a day setting process as shown in FIG. 26 without coming back to the subroutine (A).
[0282] Subroutine (U):
[0283] Referring to FIG. 26, the details of the process of setting the data of day are as follows: In the flow of the subroutine (A), when the switch 76 is turned on, a day data setting mode is called. The flow then jumps to the subroutine (U). In the subroutine (U):
[0284] Step #U- 1 : If the PB mode flag is set, the flow jumps to a step #U- 16 to come back to the subroutine (A). If not, it proceeds to a step #U- 2 . Step #U- 2 : A check is made to see if there obtains the ID data setting mode, i.e. the mode in which the ID data is produced at the monitor or the printer in a state of being superimposed on the video signal. If not, the flow comes to the step #U- 16 to come back to the subroutine (A). In the case of this mode, the flow proceeds to a step #U- 3 . Step #U- 3 : The place of a tenth digit in a day setting position on the monitor is blinked. In other words, a character in a position ( 5 ) as shown in FIG. 24 blinks. The blinking action is accomplished by the control of the CPU 40 over the character generator 84 allowing and not allowing it to generate the character. The flow then proceeds to a step #U- 4 . Step #U- 4 : The flow of operation waits until the day setting switch 76 turns off. When the switch 76 turns off, the flow proceeds to a step #U- 5 . Step #U- 5 : A check is made to see if any of the ten-key switches 63 to 72 is in its ON state. If so, the flow proceeds to a step #U- 6 . If not, it comes to a step #U- 13 . Step #U- 6 : A check is made to see if an input data from the ten-key switch is “4” or more than “4”. If so, the flow comes to a step #U- 14 . If not, it proceeds to a step #U- 7 . In other words, in setting the day, the flow is arranged to branch out according to the figure set at this step for the purpose of accepting a figure for the place of the unit digit only when the initially received figure is “3”, “2”, “1” or “0”.
[0285] Step #U- 7 : The CPU 40 writes the input data into the RAM 27 and controls the character generator 84 to have a character pattern generated in the position ( 5 ) of FIG. 24, i.e. in the place blinked at the step #U- 3 . The flow proceeds to a step #U- 8 . Step #U- 8 : The place of the unit digit in the day setting position is blinked. In other words, a character in a position ( 6 ) of FIG. 24 blinks. The flow then proceeds to a step #U- 9 . Step #U- 9 : The flow waits until the ten-key switch is turned off. When the ten-key switch turns off, the flow proceeds to a step #U- 10 . Step #U- 10 : A check is made to see if the ten-key switch is on. If so, the flow proceeds to a step #U- 11 . If not, it comes to a step #U- 15 . Step #U- 11 : The CPU 40 writes data received from the ten-key switch at the step #U- 10 into the RAM 27 and controls the character generator 84 to have a character pattern generated in the position (6) of FIG. 24. The flow then proceeds to a step #U- 12 . Further, in case that the flow has branched off from the step #U- 14 to this step, the input data received from the ten-key switch at the step #U- 5 is displayed in the place of the unit digit while “0” is displayed in the place of the tenth digit.
[0286] Step #U- 12 : The data in the day setting position stops blinking and thus indicates the end of the day setting process. The flow then comes to the step #U- 16 .
[0287] Step #U- 13 : The flow comes to this step from the step #U- 5 when none of the ten-key switches are found not in their ON states at the step #U- 5 . At this step #U- 13 , a check is made to see if any switch other than the ten-key switch is in an ON state. If not, the flow comes to the step #U- 5 . If so, it comes to the step #U- 12 . In other words, the steps #U- 5 and #U- 13 are repeated until either the ten-key switch or some other switch comes to turn on. The flow comes to the step #U- 6 when some of the ten-key switches turns on or comes to the step #U- 12 when some other switch turns on. Step #U- 14 : The flow comes to this step from the step #U- 6 when the input data is found at the step #U- 6 to be “4” or greater than “4”. Here, the CPU 40 writes “0” into the RAM 27 and controls the character generator 84 to have a character pattern of “0” generated in the place of the tenth digit in the day setting position. The flow comes to the step #U- 11 . Step #U- 15 : A check is made to see if any switch other than the ten-key switches is in an ON state. If not, the flow comes to the step #U- 10 . If so, it comes to the step #U- 12 . Step #U- 16 : The flow comes back to the subroutine (A).
[0288] As described above, the place of the tenth digit in the day setting position first blinks when the switch 76 is turned on. This indicates the place in which the data coming from the ten-key switch is to be set. If the input data is “4” or greater than “4”, “0” is automatically set in the place of the tenth digit and then the input data is set in the place of the unit digit. In the event of input data not exceeding “3”, the input data is of course set in the place of the tenth digit and then the blinking position shifts to the place of the unit digit to have next data from the ten-key switch set in the place of the unit digit. The embodiment thus prevents “4” or any value exceeding “4” from being set in the place of the tenth digit in setting the data of day. This arrangement simplifies the day setting process.
[0289] While the step #U- 3 is arranged to have the place of the tenth digit alone blinked, that step may be changed to have both the places of tenth and unit digits blinked. Further, the blinking arrangement of this embodiment may be replaced with some other setting position indicating method. For example, it may be replaced with a method of changing the luminance or color of the setting place.
[0290] Erase Program:
[0291] An erasing sequence is as follows: In erasing, the erasing switch 78 and the erasion standby switch 77 are operated. The apparatus is first set into an erasion standby mode by means of the switch 77 . Then, the other switch 78 is turned on in carrying out erasion. The erasing process includes a mode in which records in a plurality of tracks are continuously erased and another mode in which the record in a single track is alone erased.
[0292] Subroutine (V):
[0293] Referring to FIG. 27 which shows a subroutine (V), the details of the above stated erasing operation are as follows: When the switch 77 is turned on in the flow chart of FIG. 6B, the flow of operation calls the subroutine (V) and comes to a step #V- 1 . At the step #V- 1 , the apparatus is set in a standby state for erasion. Then, “FF” is set at a buffer memory E which is arranged to store the number of the track to be erased. At the seven-segment LED 25 which is arranged to display a track number in two places displays a number assigned to a track to which the head 3 - 1 has access in a blinking manner, repeatedly and alternately being lighted up and extinguished in a cycle of about 2 Hz. This enables the operator to know that the apparatus is in the standby mode for erasion.
[0294] Unlike the method of using a display element specially for displaying the erasion standby mode, the method of this embodiment not only dispenses with the special display element but also more clearly shows the applicable track number as the track number display device is arranged to show the track number in a different manner in this instance. Further, in this specific embodiment, the erasion standby mode is displayed by blinking the displaying state of the seven-segment LED 25 . However, it goes without saying this display element may be replaced with some other display element such as a liquid crystal element. The blinking arrangement also may be replaced with some different arrangement of, for example, changing the color or luminance of the display or changing the shape of the displayed character.
[0295] In cases where some display device for displaying information about something other than the track number, such as a number of vacant tracks is provided instead of the track number display device, the above stated erasion standby mode may be displayed by changing the display state of that display device.
[0296] After the step #V- 1 , the flow of operation proceeds to a step #V- 2 . Step #V- 2 : A check is made to see if the PB (reproduction) mode flag is set. If so, the flow comes to a step #V- 3 - 1 . If not, it proceeds to a step #V- 3 . Step #V- 3 : The subroutine (C) which is provided for setting the reproduction mode as mentioned in the foregoing is called. The apparatus is shifted to the reproduction mode. The flow of operation then proceeds to the step #V- 4 via the step #V- 3 - 1 . Therefore, with the erasion standby switch 77 turned on, there always obtains the reproduction mode and the apparatus is brought into the erasion standby state through the execution of the steps #V- 2 and #V- 3 . Step #V- 3 - 1 : After confirmation of the switch 77 being turned off, the flow proceeds to the step #V- 4 . Step #V- 4 : A check is made to see if the erasion performing switch 78 is in its ON state. If so, the flow proceeds to a step #V- 4 - 1 . If not, it comes to a step #V- 15 . Step #V- 4 - 1 : The branching off destination of the flow is determined at this step by checking with a claw checking switch the casing of the magnetic sheet (not shown) for the presence or absence of a claw initially provided on the casing. This claw is arranged to prevent erroneous erasion. When the claw is broken off, it is impossible to make erasion. Therefore, if the the casing (or jacket) is thus arranged to prevent erroneous erasion, the flow comes to a step #V- 18 . If not, it proceeds to a step #V- 5 . Step #V- 5 : A check is made to see whether the value set at the buffer memory E which is arranged to store an erasing track number is “0” or not. The buffer memory E has been set at “FF” in the step #V- 1 . However, the set value of the buffer memory is changeable at a step #V- 15 as will be described later. At the step #V- 5 , if the value set at the buffer memory E is found to be “0”, the flow comes to the step #V- 18 . If not, the flow proceeds to a step #V- 5 - 1 .
[0297] Step #V- 5 - 1 : A check is made to see if the value set at the buffer memory E is “FF”. If so, the flow proceeds to a step #V- 6 . If not, it comes to a step #V- 5 - 2 . Step #V- 5 - 2 : The field reproduction mode is set by setting the field flag. The flow then comes to the step #V- 6 . Step #V- 6 : The blinking state of the seven segment LED 25 which is arranged to make a track number display is shifted from the cycle of 2 Hz to a quicker cycle of 5 Hz. In the event of continuous track erasion, the seven-segment LED 25 displays a set number of tracks in place of the number of a track being accessed by the head 3 - 1 at the step #V- 17 . Even in that instance, however, the display by the seven-segment LED 25 is automatically changed to the track number display with the step #V- 6 executed. Therefore, this step enables the operator to confirm each of the tracks when it is erased during the continuous track erasing process.
[0298] Step #V- 7 : The CPU 40 controls the erase signal generator 85 to cause it to generate an erasion signal. An erasing action is performed in response to this signal. Further, in carrying out the erasing action, at least one of the heads 3 - 1 and 3 - 2 is connected to the recording amplifier by controlling the switches SW 2 and SW 3 of FIG. 1. In this instance, if the field flag is set, i.e. in the case of the field reproduction mode, an erasing current flows only to the head 3 - 1 to have one track portion of the record erased thereby. However, if the field flag has been cleared to select the frame reproduction mode, erasing currents simultaneously flow to both the heads 3 - 1 and 3 - 2 to have one frame portion of the record, i.e. the record in two adjacent tracks erased. Further, in the specific embodiment, the erasing action is performed in the frame mode only when the flow of operation comes from the step #V- 5 - 1 directly to the step #V- 6 without coming via the step #V- 5 - 2 . In other words, it is only in case that the value of the buffer memory E is found at the step #V- 5 - 1 to be at “FF”, that is, in the event of non-selection of the continuous erasion mode. Step #V- 8 : The flow of operation waits until completion of the erasing action. Upon completion of the erasing action, the flow proceeds to a step #V 8 - 1 . Step #V- 8 - 1 : A check is made to see if the value set at the buffer memory E is equal to “FF”. If so, it indicates a single erasion mode and the flow comes to the step #V- 18 . If not, it indicates the continuous erasion mode and the flow proceeds to a step #V- 9 . Step #V- 9 : One is subtracted from the value set at the buffer memory E. The flow proceed to a step #V- 10 . Step #V- 10 : A check is made to see if the value of the buffer memory E is larger than “0”. In other words, with the continuous track erasion mode selected, the number of tracks to be erased is detected. If this number is larger than “0”, the flow proceeds to #V- 11 . If not, the flow comes to the step #V- 18 on the assumption that the continuous track erasing action has come to an end. Step #V- 11 : A check is made to see if the stop switch 61 is in an ON state. If so, the flow branches off to the step #V- 18 . If not, it proceeds to a step #V- 12 . In other words, in case that the continuous erasion mode is selected and being carried out, the continuous erasing action can be suspended by operating the stop switch 61 .
[0299] Step #V- 12 : A check is made to see if the value N stored at the buffer memory is above 50. In other words, a check is made to see if the track being accessed by the head 3 - 1 is the last track. If so, the flow comes to the step #V- 18 to bring the erasing action to an end. If not, the flow proceeds to a step #V- 13 .
[0300] Step #V- 13 : With this step executed, the track accessing positions of the heads 3 - 1 and 3 - 2 are shifted inward to an extent corresponding to one track respectively. At the same time, the track number memory is set at a value N+1. The flow then proceeds to a step #V- 5 - 2 . Therefore, in the event of the continuous track erasion mode, the steps #V- 5 - 2 to #V- 13 are repeated until either the stop switch 61 is turned on or the record of the innermost track is erased and until the value of the buffer memory E becomes zero, i.e. until the record in the set number of tracks are completely erased.
[0301] The step #V- 15 and ensuing steps relate to the flow of operation for setting the continuous erasion mode to be carried out as described above.
[0302] Step #V- 15 : A check is made to see if any of the ten-key switches 63 to 72 shown in FIG. 1 is in its ON state. If so, the flow proceeds to a step #V- 16 . If not, it comes to a step #V- 15 - 1 . Step #V- 16 : The apparatus is brought into the continuous track erasion mode. More specifically, a number supplied from some of the ten-key switches 63 to 72 becomes the number of tracks to be subjected to a continuous erasing action. At the erasing track number buffer memory E, the value of the switch turned on among the ten-key switches is set in the place of the unit digit. Following that, the flow of operation proceeds to a step #V- 17 . Step #V- 17 : The value of the buffer memory E is displayed at the seven-segment LED 25 in a manner as shown in FIGS. 28 ( a ) to 28 ( c ). At the step #V- 15 , the value of one of the ten key switches which is first turned on is set in the place of the unit digit at the step #V- 16 . Then, at the step #V- 17 , this value is displayed in the place of the unit digit at the LED 25 as shown in FIG. 28( a ). Before the display of FIG. 22( a ) is obtained, the track number is displayed at the display device in a blinking manner. Further, the value F set at the buffer memory E is displayed as “0”. The blinking display of the step #V- 1 is continuously repeated. Therefore, the display “01” which is as shown in FIG. 28( a ) also blinks. The flow then proceeds to a step #V- 17 - 1 . Step #V- 17 - 1 : The flow waits until the ten-key switches turn off. After that, the flow comes to a step #V- 15 - 1 . Step #V- 15 - 1 : A check is made to see if the erasion standby switch 77 is in an ON state. If so, the flow comes to a step #V- 18 . If not, if proceeds to a step #V- 15 - 2 .
[0303] In other words, the erasion standby mode set by turning on the erasion standby switch 77 at the step #V- 1 is automatically cancelled by the step #V- 18 and ensuing steps after the standby switch 77 is again turned on. This arrangement obviates the necessity of an additional switch otherwise required specially for cancellation of this mode.
[0304] Step #V- 15 - 2 : A check is made to see if any switch other than the switch 78 and the ten-key switches is in an ON state. If so, the flow branches off to the step #V- 18 . If not, it branches off to the step #V- 4 . In other words, the erasion standby mode can be automatically cancelled through the step #V- 18 and the steps ensuing it even with a switch other than the ten-key switches turned on. Therefore, the embodiment requires no special switch for cancelling the standby mode. The steps preceding the step #V- 4 are repeated when the results of the checks made at the steps #V- 15 - 1 and #V- 15 - 2 are negative. However, if the LED 25 is already displaying “01” as shown in FIG. 28( a ), the steps subsequent to the step #V- 4 is executed as follows:
[0305] When some of the ten-key switches is turned on at the step #V- 15 , a value supplied from this switch at the next step #V- 16 is set in the place of the unit digit at the buffer memory E. Then, a value which is previously set in that place shifts to the place of the tenth digit at the buffer memory E. A value which has been in the place of the tenth digit then disappears.
[0306] Assuming that the key switch of “5” is turned on among the ten-key switches, the steps #V- 16 and #V- 17 are executed to make a display at the seven-segment LED 25 in a manner as shown in FIG. 28( b ). In this instance, the value set at the buffer memory E is of course 15 . Following this, when “2” is supplied from one of the ten-key switches, the display is made as shown in FIG. 28( c ). In the above stated example of display, the LED 25 is caused to make a display with the key switches of “1”, “5”and “2” operated one after another among the ten-key switches under the condition of the erasion standby mode. The value displayed coincides with a value set at the buffer memory E. More specifically, when a value of “2” or greater than “2” is set by one of the ten-key switches, this setting action is equal to selection of the continuous erasing mode. The set value represents the number of tracks to be subjected to a continuous erasing action. As described in the foregoing, when the value of the buffer memory E is found to be greater than “0” at the step #V- 10 , the flow of operation proceeds to the step #V- 11 . If not, the flow branches off to the step #V- 18 . If the track number N is less than 50, the track number N is increased at the step #V- 13 and the flow of operation branches off from the step #V- 13 to the step #V- 5 - 2 . Then, the step #V- 6 and ensuing steps are executed for the continuous erasing action. In other words, if the stop switch 61 is found to be not in an ON state at the step #V- 11 , the erasing action continues either until the value set at the buffer memory E becomes zero or until it is performed on the 50th track which is the innermost track. After completion of the above stated steps, further steps #V- 18 to #V- 20 are executed in the following manner:
[0307] Step #V- 18 : The seven-segment LED 25 is stopped from blinking. The track number N is displayed on the display device. The flow then proceeds to a step #V- 19 . In short, the erasion standby mode is cancelled at the step #V- 18 . Step #V- 19 : If the switch 77 is in its ON state, the flow waits. If not, it proceeds to a step #V- 20 . Step #V- 20 : The flow comes back to the subroutine (A) which is as shown in FIGS. 6A and 6B.
[0308] In carrying out erasion, this embodiment has different modes as mentioned in the foregoing. In one mode, erasion is performed only once. In another, erasion is continuously performed. The latter include a mode in which continuous erasion is performed after designation of the number of tracks to be subjected to the continuous erasing action. In cases where the erasing track number is not set by the ten-key switches, the flow of operation shifts from the step #V- 5 - 1 directly to the step #V- 6 without coming through the step #V- 5 - 2 as the buffer memory E is in that instance set at “FF”. Therefore, if the field flag is in a cleared state in the erasion standby mode, a two-track portion of the record is erased in a frame mode. If the field flag is set, a one-track portion of the record is erased in the field mode. Thus, in the case of reproduction in the frame mode, a two-track portion of the record being reproduced is erased. In the case of reproduction in the field mode, a one-track portion of the record being reproduced is erased. However, if an erasing track number is set by the ten-key switches, the erasing action is performed always in the field mode, because the flow of operation in that instance proceeds via the step #V- 5 - 2 . In the event that “0” is set by the ten-key switches, however, the erasing action is not performed as the flow of operation at the step #V- 5 branches off to the step #V- 18 . Further, if the value set by the ten-key switches is “1” in the frame reproduction mode, only the record in a track on the outer circumferential side of two tracks forming one frame is erased, because the flow of operation finds the field flag in a set state at the step #V- 5 - 2 in this instance.
[0309] Generally, an additional video signal or the like is newly recorded often in erased tracks in the case of continuous track erasion. In the case of the embodiment described, the head 3 - 1 is located on a last erased track when the continuous track erasion comes to an end. Therefore, in the event of recording new information in the erased tracks, the operator is required to operate the track UP and track DOWN switches 54 and 55 to bring the head 3 - 1 to a track with which the erasing action began. To solve this problem, another flow of operation is arranged as shown in FIG. 29 to automatically cause the head 3 - 1 to have access to a track from which a continuous track erasing action has begun after completion of the continuous track erasing action. This arrangement greatly enhances the operability of the apparatus. The flow shown in FIG. 29 is arranged to be inserted between the steps #V- 18 and #V- 19 of FIG. 27.
[0310] In executing the subroutine (V), the track number N of a track then accessed is stored at a memory N′ at the step #V- 1 . After that, when the flow of operation comes to the step #V- 18 with erasion accomplished through the steps described, the flow of operation shown in FIG. 29 is executed. More specifically, at the step #V- 18 - 1 , the number assigned to a track accessed by the head 3 - 1 is checked for its coincidence with the track number stored in the memory N at the step #V- 1 . If not, steps #V- 18 - 2 and #V- 18 - 3 are executed to cause the head 3 - 1 to have access to a next track on the outer circumferential side of the accessed track. At the same time, the memory N′ is set at N−1 and the seven-segment LED 25 is caused to display the track number N. The flow then comes back to the step #V- 18 - 1 . The steps #V- 18 - 2 and #V- 18 - 3 are thus repeated until the number assigned to the accessed track comes to coincide with the track number stored at the memory N′. When the head 3 - 1 has access to the erasion starting track, the flow of operation comes from the #V- 18 - 1 to a step #V- 19 . Then, the step #V- 19 and steps following it are executed. Therefore, the flow of operation as shown in FIG. 29 causes the head 3 - 1 to be automatically brought to the erasion start track upon completion of the erasing action. This obviates the necessity of a manual search for a track at which an erasing action has started before commencement of a next recording action.
[0311] Further, it is highly advantageous and effective in preventing any erroneous erasing action to enable the operator to confirm erasing images by reproducing their records for a given period of time and to confirm the operability of the stop switch 61 prior to a continuous erasing action. To realize this function, a step of having a delay time of one sec or thereabout inserted in the subroutine (V) of FIG. 27 after execution of the process of “1 track UP, N=N+1” at the step #V- 13 and before execution of the step #V- 7 or preferably immediately after the step #V- 6 . Further, for this purpose, another step may be arranged to be executed during that delay time to make a check to see if the stop switch 61 is in an ON state and, if not, to have the flow proceeds to the step #V- 7 or, if so, to have the flow branch off to the step #V- 18 . The provision of such additional steps enables the operator to confirm the video signal to be erased. Therefore, when any image that is not desired to be erased is reproduced, the continuous reproduction can be suspended by turning the stop switch 61 on. The probability of erroneous erasion thus can be reduced to a minimal rate.
[0312] Further, in the case of continuous erasion, the embodiment is arranged to have track portions of the record erased one by one all in the field mode by executing the step #V- 5 - 2 with the flow shifting from the step #V- 5 - 1 to the step #V- 5 - 2 in the subroutine (V). However, for shortening the length of time required for continuous erasion, erasing currents may be allowed to flow simultaneously to the two heads in the frame mode in such a way as to have the erasing action simultaneously performed on two tracks at least once. An example of this arrangement is as described below:
[0313] A flow of operation shown in FIG. 30( a ) includes the steps to be inserted in between the steps #V- 6 and #V- 7 of FIG. 27. Another flow shown in FIG. 30( b ) includes the steps to be inserted in between the steps #V- 11 and #V- 12 of FIG. 27. The details of these flows of operation:
[0314] After the subroutine (V) of FIG. 27 is executed up to the step #V- 6 , a step #V- 6 - 1 is executed. At this step, a check is made to see if the erasing track buffer memory E is at a value “2” or greater than that thus indicating the continuous track erasion mode. If so, the flow proceeds to a step #V- 6 - 2 . If not, the flow comes to the step #V- 7 . At the step #V- 6 - 2 : The buffer memory E is set at E- 1 and the field flag is cleared. The flow comes to the step #V- 7 . At the step #V- 7 (shown in FIG. 27), an erasion signal is generated. In this instance, if the field flag is set, the erasion signal is supplied to one of the heads 3 - 1 and 3 - 2 which is used for field reproduction. If the field flag is cleared, the erasion signal is simultaneously supplied to both the heads 3 - 1 and 3 - 2 . Upon completion of erasion, the steps #V- 8 to #V- 11 are executed as mentioned in the foregoing. If the continuous erasing action has not been completed, the flow comes from the step #V- 11 to a step #V- 11 - 1 . At the step #V- 11 - 1 , a check is made to see if the field flag is set. If the field flag is set while the continuous track erasion mode is not set, the flow proceeds to the step #V- 12 and the flow proceeds in the same manner as stated in the foregoing. Further, in case that the continuous track erasing mode has been set while the field flag is not set at the step #V- 11 - 1 , the flow comes to a set #V- 11 - 2 and the memory N is set at N+1 as the erasing action has been performed on a two-track portion of the record at the step #V- 7 as mentioned in the foregoing. Then, the heads 3 - 1 and 3 - 2 are shifted inward to an extent corresponding to one track width. Following this, the flow comes to the step #V- 13 . The heads are shifted further inward to the extent of one track width through the steps up to the step #V- 13 .
[0315] With the embodiment arranged as described above, in the case of continuous erasion, the erasing action is performed in the frame mode until the remaining number of continuously erasing tracks becomes one. This arrangement increases the continuous erasing speed. In confirming the erasing record of images prior to erasion in this instance, if the field flag is set after the step #V- 6 , it is necessary to do field reproduction for a given period of time with each of the heads 3 - 1 and 3 - 2 of FIG. 1. Further, in carrying out continuous erasion, selection between a mode in which the erasing images can be confirmed in a reproduced state and another mode in which such confirmation is not allowed may be made possible by omitting the steps #V- 2 and #V- 3 and by effecting switch-over between the PB mode and the recording mode, because: In case that the non-confirming mode is selected in performing a continuous erasing action with the steps shown in FIGS. 30 ( a ) and 30 ( b ) added to the flow of operation shown in FIG. 27, the continuous erasing action can be accomplished within a minimum length of time. This method is highly advantageous particularly in erasing records from all the tracks.
[0316] Subroutine (W):
[0317] [0317]FIG. 31 shows a subroutine (W) which is to be executed when the all track erasion standby switch 79 is operated. The subroutine (W) is as follows:
[0318] Step #W- 1 : The seven-segment LED 25 is caused to blink at 2 Hz a display “AE” (All-Erase) indicating an all track erasion standby mode. Step #W- 2 : A check is made to see if the PB mode flag is set. If not, the flow comes to a step #W- 3 - 2 . If so, if comes to a step #W- 3 - 1 . Step #W- 3 - 1 : The PB mode flag is cleared to inhibit a reproducing operation on the magnetic sheet 1 . Step #W- 3 - 2 : The switch 79 is checked for its OFF state. Upon detection of it, the flow proceeds to a step #W- 4 . Step #W- 4 : A check is made to see if the erasing switch 78 is in its ON state. If so, the flow comes to a step #W- 9 . If not, the flow proceeds to a step #W- 5 . Step #W- 5 : A check is made to see if the all track erasion standby switch 79 is in its ON state. If so, the flow comes to a step #W- 7 . If not, the flow comes to a step #W- 6 . Step #W- 6 : A check is made to see if any switch other than the switch 79 is turned on. If so, the flow comes to a step #W- 7 . If not, the flow comes to the step #W- 4 . Step #W- 7 : The LED 25 is stopped from blinking and is caused to display the track number N assigned to a track to which the head 3 - 1 has access. Step #W- 8 : The flow waits until the switch 79 turns off. After that, the flow comes back to the subroutine (A). Step #W- 9 : In case that the erasing switch 78 is found in its ON state at the step #W- 4 , the flow comes to this step. At this step, a discrimination is made between the presence and absence of an erroneous erasion preventing claw which is not shown. If the claw is found to be present, the flow comes to a step #W- 10 . If not, it comes to the step #W- 7 . Step #W- 10 : A check is made to see if the track number N which is a track number assigned to a track accessed by the head 3 - 1 is “1”. If so, the flow comes to a step #W- 12 . If not, it comes to a step #W- 11 . Step #W- 11 : The heads 3 - 1 and 3 - 2 are shifted toward the outer circumference of the magnetic sheet to an extent corresponding to one track width respectively. One is subtracted from the track number N. The flow then comes back to the step #W- 10 . With the steps #W- 10 and #W- 11 thus repeatedly executed, when the track number becomes “1”, the flow comes to the step #W- 12 . Step #W- 12 : The LED 25 is caused to blink the display of the track number N at 5 Hz. This informs the operator of an extent to which the tracks have been erased during the process of the all track erasing action. Step #W- 13 : The field flag is cleared to obtain the frame mode. Accordingly, both the heads 3 - 1 and 3 - 2 are used for erasion.
[0319] Steps #W- 14 and #W- 15 : These steps are the same as the steps #V- 7 and #V- 8 . Step #W- 16 : Since two tracks are being erased without shifting the heads 3 - 1 and 3 - 2 , these heads are shifted toward the outer circumference of the magnetic sheet to an extent corresponding to two track widths at this step. Further, “2” is added to the track number N. Step #W- 17 : A check is made to see if the track number N is 50 or greater than 50. If so, the flow comes to the step #W- 7 . If not, it branches off to the step #W- 12 . In the latter case, the steps #W- 12 to #W- 17 are repeated until completion of the all track erasing process.
[0320] As described above, in the all track erasing mode which is obtained by turning on the erasing switch 78 after turning on the all track erasion standby switch 79 , the PB mode flag is cleared prior to commencement of the erasing action in such a way as to omit the process of confirming the images to be erased. In addition to that, erasion is arranged to be performed on two tracks at a time by using both the heads 3 - 1 and 3 - 2 . This method enables the all track erasing action to be accomplished in a much shorter period of time than a method of erasing tracks one by one. Further, in erasing all the tracks, the heads are shifted beforehand to one end part (to the outermost peripheral part in the case of this embodiment) and then shifted toward the opposite end gradually erasing all the tracks. This arrangement ensures that all the tracks can be erased without fail no matter where the head 3 - 1 may be located in erasing all the tracks.
[0321] Further, the LED 25 is arranged to display the number assigned to each track to which the head 3 - 1 is having access during the process of erasion. This enables the operator to know the degree of progress of the erasing action.
[0322] While the magnetic sheet 1 is employed as the recording medium in the case of embodiments described, this invention is applicable also to an optical recording medium, a photo-electro-magnetic recording medium and other recording medium. For such different recording media, the recording means may be replaced with suitable means. For example, an optical head may be used in the event of an optical disc. Further, a solid-state memory such as a semiconductor memory, Bloch line memory or the like may be employed.
[0323] As described in the foregoing, this embodiment has different modes of recording the set ID data along with the video signal including: A mode of recording the set ID data while displaying on the monitor the contents thereof as shown in FIG. 21( a ) and another mode of making a display as shown in FIG. 21( b ) indicating that the set ID data is recordable along with the video signal without displaying on the monitor the contents of the ID data. When the mode shown in FIG. 21( a ) is selected, the display range on the monitor of the contents of the ID data becomes broader. In the event that a display of the ID data would come to hinder a monitoring review of the video signal to be recorded, the mode of FIG. 21( b ) is selected in recording the video signal while permitting the ID data to be recorded along with the video signal. This arrangement permits the review on the monitor of the recording video signal without hindrance on and thus enhances the operability of the apparatus.
[0324] Further, in this embodiment, when the video signal is recorded while the character signal is being monitored in a state of being superimposed on the video signal to be recorded, the supply of the character signal is arranged to be temporarily cut off in synchronism with recording of the video signal (the steps #N- 5 and #N- 7 of the subroutine (N) of FIG. 12). This arrangement makes the recording action confirmable by a very simple control process. Therefore, the arrangement not only dispenses with any additional display means arranged specially for indicating the execution of the recording action but also enables the operator to confirm the recording action simply by observing the monitor.
[0325] This embodiment is arranged to permit confirmation of recording through observation of the monitor by temporarily cutting off the supply of the data signal (or the ID data) superimposed on the video signal as mentioned in the foregoing. This arrangement may be changed to temporarily cut off the video signal instead of the DATA signal. In another conceivable modification, some other signal may be temporarily superimposed on the video signal instead of temporarily cutting off the data signal in attaining the same advantageous effect.
[0326] In the case of this embodiment, the data signal is arranged to be displayed in a superimposed state in the lower right corner of the picture plane in either the mode of setting only the data of date or the mode of setting the date data together with other data as shown in FIG. 22( a ) or 22 ( b ). That arrangement effectively prevents the superimposed display of data from hindering the review of the recording video signal by the operator.
[0327] While the data signal or signals relative to the video signal are arranged in this embodiment to be displayed in the lower right corner of the picture plane, the display position is of course not limited to that particular part.
[0328] Further, in this embodiment, the data signals are arranged to include the date data such as year, month and day data and the digits of 11 places for the data relative to the video signal. However, the data relative to the video signal may be replaced by alphabetical letters relative to the video signal. These data may be any other data or characters that can be set by the operator and can be displayed in a superimposed state.
[0329] The embodiment, as described in the foregoing, is a recording and/or reproducing apparatus arranged to record or reproduce the data signal along with the video signal. The embodiment is provided with control means which is arranged such that, in recording, the position in which the data signal is displayed in the state of superimposed on the video signal is changed according to the result of determination as to whether or not at least a part of the data signal is to be set and to be included in the display.
[0330] In accordance with the arrangement of this embodiment, the data signal which is to be recorded along with the video signal is arranged to be omissible from the display of the video signal on the monitor, so that the video signal to be recorded can be protected from being hidden by a display of the data signal superimposed on the video signal display.
|
A recording apparatus for recording a video signal on a recording medium together with data signals relative to the video signal comprises a first signal processing channel in which the data signals are supplied to a monitor in a state of being superimposed on the video signal; and a second signal processing channel in which the data signals are supplied to the monitor without being superimposed on the video signal; and selecting means which is selectively renders said first signal processing channel or said second signal processing channel operative. In case that a display of the recording video signal on the monitor is excessively covered and hidden by that of the data signals, the second signal processing channel is selected and operated to permit adequate visual confirmation on the monitor of the video signal to be recorded.
| 6
|
BACKGROUND OF THE INVENTION
The subject matter of the invention relates to a system or device for the centrifugation of samples comprising a rotor and at least one carrier having several uptakes for samples.
Dosing, mixing, tempering, filtering, closing, opening, washing, numbering, coding, retrieving, arranging and centrifuging are typical procedures when treating samples in laboratories. People endeavor to expedite those procedures by means of a convenient sample organization. Furthermore, they strive for a best possible automatization of the treatment of samples.
To achieve a common handling of the sample receptacles, there are already known chain-like systems using uptaking cylindrical receptacles. The uptaking cylinders are connected to each other by means of axially parallel swivelling joints allowing a chain-like movement around narrow radii, for instance in analyses devices. It's true that the chain simplifies the laboratory organization by facilitating the transportation, numbering, coding and retrieving of laboratory receptacles. However, charging of the receptacles presents a problem and in most cases, makes numerous manual sorting procedures indispensable. As to sample receptacles using a conventional sealing, the centrifugation makes an inclined or horizontal arrangement of the axis of a receptacle on the rotor necessary, which arrangement impairs the mass balance and may result in undesirable intermixtures after taking samples away and putting the chain upright again.
In principle, the sample receptacles may have a horizontal, inclined or vertical arrangement during centrifugation. There also do exist centrifuges with rotors using a swivel arm controlled by centrifugal force, so that the receptacles are vertically aligned as soon as the centrifuge stops, while they show an inclined or nearly horizontal alignment during centrifugation. In biochemical laboratories and in the microbiological field there are preferred rigid rotors where the laboratory receptacles are arranged at a slant angle of 45°. On the one hand, the position of the samples in the centrifuge is of significance since the maximum way of sedimentation--which has an influence on the time of centrifugation and causes the precipitate to separate from the liquid as a result of the difference in density--depends thereon. A horizontal alignment of receptacles entails a maximum way of sedimentation, while a vertical alignment entails a minimum way of sedimentation. On the other hand, it proves to be relevant with respect to the accelerations during the centrifugation procedure, which accelerations, typically, may be equal to 15000 times the acceleration of earth. The cover seal is strained least by the sample when the receptacle is horizontally aligned and is strained most when it is vertically aligned. An inclined alignment of the receptacle might be a good compromise.
Up to now, laboratory centrifuges either had been charged manually or automatically by means of a special laboratory robot. It also became public knowledge to pre-charge the rotor manually or automatically and to connect it to the centrifuge thereafter. A partial charging, however, makes a symmetric mass distribution on the rotor necessary. These procedures are very troublesome and imperfect when choosing the manual way of operation and very time-consuming when preferring the automatization. An automatization of the centrifugation by simultaneously speeding up the procedure would be especially desirable with respect to repeated centrifugations without exchanging receptacles within one procedure. This, above all, is the case in the molecular biological field, for instance, when obtaining DNA from plasmids or bacteriophages. A periodic change between the dosing, mixing, centrifuging and tempering stations is characteristic for such a process.
Taking all this into consideration, the invention is based on the subject to produce a system for centrifugation favoring the treatment of samples in the laboratory field as well as the automatization thereof.
SUMMARY OF THE INVENTION
These and other objects of the invention, which will become apparent hereinafter, are achieved by arranging the uptake elements of the carrier on a circle having its center lying on the rotational axis of the rotor.
Regarding the system according to the invention, the carrier allows to uniformly uptake, transport and treat a plurality of samples. This helps to reduce the number of transmission steps of the sample receptacles as well as the expenditure of time and handling resulting therefrom. So, for example, it is not necessary to change position of individual receptacles when passing over from a mixing station to a centrifuge. On the other hand, it is particularly easy to put the carriers in their bent position on the rotor while containing a plurality of samples. Furthermore, in consideration of the fact that the sample receptacles are arranged on a circle having its center point on the rotational axis of the rotor. The centrifugation itself is influenced positively, especially in regard to the mass balance and an optimum alignment of the samples towards the axis of the centrifuge.
In case a treatment of the samples outside the rotor is desired, the elements and uptakes thereof can be turned into a linear position, i.e. on a straight line. This alignment is to be preferred for other procedures, such as for charging, removing, opening and closing receptacles, adding, diluting and removing as well as transferring samples. The carriers, if necessary, can be automatically handled block by block then. A symmetry of the rotor charge is guaranteed by a uniform arrangement of the same number of receptacles on all carriers of the rotor. The system according to the invention, for the first time, allows an automated run of the centrifugation procedure by, at the same time, including it in an automatic treatment of samples by collecting said samples block by block and optimally aligning them within and/or outside the rotor without changing the carrier of the receptacle.
The alignment of the sample receptacles outside the rotor, preferably, is vertical. Whenever the uptakes for the sample receptacles are arranged parallel to the joint axes of the carrier, the samples are arranged vertically inside the rotor, too. For an inclined arrangement of the samples within and, if necessary, outside the rotor, the uptakes can be inclined towards the swivel axes. In this way, satisfactory centrifugation terms can be realized and intermixing effects are avoided. To avoid unfavourable strains of the covers of the sample receptacles, the uptakes with their charging holes can be closest to the center of the circle when being arranged on a circular path. The sample receptacles, however, can be alignable towards the vertical at a first angle outside the rotor, too, and can be alignable at a second angle outside as well as inside the rotor.
To align the sample receptacles towards the vertical at certain angles, the elements can have first and second alignment faces. Those alignment faces can be contact surfaces supporting said elements. However, there also can be concerned lateral faces where said elements can be secured to.
The chain-like arranged elements of the carrier with all uptakes on a circular path can be turned from a bent position into a position limited by external stops, where all uptakes are arranged on a straight line then. Consequently, the samples in the uptakes are arranged on a circular path when being in the bent position and are arranged on a straight line when being in the linear position. In addition, the carriers can have internal stops preventing the elements from making another swinging movement away from the straight line. "Outer stops" are provided outside with respect to a circle through the uptaking centers in a bent position, while "inner stops" are provided inside with respect to a circle.
Besides, the elements of the carrier can have parallely arranged first and second bearing surfaces extending in the same direction as the uptakes allowing adjacent carriers to connect thereto. Furthermore, to allow a space-saving arrangement and mutual support of various carriers, the elements can be provided with complementarily formed projections and recesses.
The carriers can serve the purpose of uptaking sample receptacles, including centrifuge tubes or glasses. For this purpose, the uptakes, at least certain parts thereof, can be adapted to the external contour of sample receptacles. The uptakes can be shorter than the sample receptacles to be inserted, so that, e.g. for mixing and tempering purposes, said receptacles are influenceable from outside from below and above. If the uptakes are completely surrounding the receptacles to be inserted on the side opposite to the cover, said receptacles are prevented from getting deformed in consequence of high centrifugal forces. Furthermore, the uptakes can be closed below their charging holes for a direct uptaking of samples. The elements will be provided with covers for the receptacles then. To allow an optic measurement and judgement of the receptacles and the contents thereof, the elements, at least partially, can be transparent.
The elements of the carrier can be shaped like blocks, while the holes the blocks are provided with do represent the uptakes. However, to save material, the elements can also be shaped like plates and be provided with uptakes shaped like tubes. The plate-like elements are connected to each other at their lateral edges. Said tubes are arranged at a certain angle towards the plate-like elements.
The joints can be worked as strap hinges either provided additionally or as one piece together with the elements or as additional joining elements using anchorages for the joint uptakes of the elements. Besides, combinations of pegs and peg uptakes can be taken into consideration for adjacent elements.
Preferably, the carriers are provided with means for stabilizing the elements in the bent and/or the linear position which can use elastically mounted elements, lock or magnets being efficient in the final positions.
Furthermore, the carriers can have means for connecting them to the rotor or transportation facilities which, preferably, move into engagement on a special joint level and are provided with positively locking or frictionally engaged means or magnetic means. To allow a stabilization of the position, a radial arm of the rotor can move into engagement between the ends of the carrier each time. Said radial arm can use coupling means in addition to those of the carrier.
Each carrier in a bent position, preferably, covers one segment of the circle only. One rotor is equipped with several carriers then always, which procedure, as a result of a symmetric arrangement of the gap between the carriers, leads to a satisfactory distribution of mass.
The carrier elements, preferably, are made of plastics and/or metal. In general, a resistant and solid material will be chosen.
The rotor can use one contact surface for at least one carrier in a bent position and at least one radial support for that carrier. The radial support can be provided inside and/or outside.
The transfer of said carrier to the rotor or away from the rotor can be made along axial, radial and/or tangential guides. Outside the rotor the carriers can be arranged in a linear position, parallely and/or serially to each other.
Preferably, each carrier passes a moving path where, besides other treatment equipment, a centrifuge can be provided. Irrespective of the design of said moving path, it can use a dosing station, mixing means, tempering means, a cover closing station or cover opening station.
The movement of the carrier along a path can be controlled by an automatic control system, preferably, a program control which can control the carrier transportation as well as the procedures in the treatment stations on the moving path. There can be realized different procedures for different carriers or groups of carriers, too.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the invention result from the following description of the drawings demonstrating preferred embodiments. The drawings show the following:
FIG. 1 is a perspective view of a carrier of a system for centrifugation of sample according to the present invention, with carrier elements being arranged along a straight line and parallel to each other;
FIG. 2 is a top view of the carrier shown in FIG. 1 with the carrier element arranged along a circle;
FIG. 3 is a cross-sectional view of a carrier element with the uptake thereof inclined to a vertical at an angle of 450;
FIG. 4 is a top view of the carrier, an element of which shown in FIG. 3, with the carrier elements in a linear position;
FIG. 5 is a cross sectional view of a carrier element with the uptake thereof inclined towards the joint axis at 45° with first, second and third surfaces.
FIG. 6 is a top view of the carrier element shown in FIG. 5;
FIG. 7 is a side view of two carrier elements of another embodiment of a carrier in an inclined position of the carrier elements;
FIG. 8 is a side view of the carrier elements shown in FIG. 7 in an upright position of the carrier elements;
FIG. 9 is a partial longitudinal view of two carrier elements connected by an articulated joint;
FIG. 10 is a view similar to that of FIG. 9 showing another type of an articulated joint for connecting two carrier elements;
FIG. 11 is a perspective view of an articulated joint shown in FIG. 10;
FIG. 12 is a view showing connection of a carrier with a rotor;
FIG. 13 is a partial top view showing magnetic means for connecting a carrier to a rotor;
FIG. 14 is a cross-sectional view showing mounting on a rotor of a carrier with a sample receptacle received in the uptake of a carrier element;
FIG. 15 is a cross-sectional view showing a different arrangement of a sample receptacle in the uptake of a carrier element;
FIG. 16 is a view showing a carrier inside cover opening means;
FIG. 17 is a view showing a carrier inside cover closing means;
FIG. 18 is a view showing a carrier, with openings provided across the uptake, inside an optic measuring facility;
FIG. 19 is a front view of a one-piece carrier molded of a plastic material;
FIG. 20 is a top view of a carrier shown in FIG. 19;
FIG. 21 is a side view of a carrier element with a sample receptacle molded integrally therewith;
FIG. 22 is a top view of an automatic centrifuge with a tangential rotor charge and separate input and output stations;
FIG. 23 is a schematic top view of automatic analyses means with a closed moving path for the carrier and with a centrifuge arranged in the moving path;
FIG. 24 is a cross-sectional view of a portion of a carrier with peale-like carrier elements with sample receptacles located in the carrier elements;
FIG. 25 is a cross-sectional view along line 25-25 in FIG. 24;
FIG. 26 is a view of an arrangement of two carrier elements on a work desk;
FIG. 27 is a view of an another arrangement of two carrier elements on a work desk than that in FIG. 26;
FIG. 28 is a cross-sectional view of a carrier of FIGS. 26 and 27 supported on a rotor;
FIG. 29 is a perspective view of an embodiment of carrier element according to the invention;
FIG. 30 is a cross-sectional view of a carrier element shown in FIG. 29 supported in a rotor; and
FIG. 31 is a cross-sectional view similar to that of FIG. 30 with another type of a rotor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following descriptions of various examples functionally identical or similar construction elements are provided with identical reference numbers.
A carrier 1 according to FIG. 1 and 2 has several elements 2 which use one uptake 3 each. Said uptakes are supported by first contact surfaces 4 in the linear position according to FIG. 1 as well as in the bent position according to FIG. 2.
Between the elements 2 joints 5 are provided, the axes of which are arranged parallely to uptakes 3 and vertically to said first contact surfaces 4. Besides, each element 2 has outer lateral faces 6 which are arranged parallel to uptakes 3 and vertically to said first contact surfaces 4, too. The outer lateral faces 6 act as stops which meet between the elements when carrier 1 is in a linear position. On the opposite side of joints 5 inner lateral faces 7 are provided which are also arranged parallel to uptakes 3 and vertically to said first contact surface 4 and diverge in each element towards joints 5. The inner lateral faces 7 also act as stops which meet between adjacent elements 2 while carrier 1 is in a bent position.
In said carrier 1, the sample receptacles inserted by upper charging holes 8 of elements 2 are vertically arranged in the linear as well as in the bent position of carrier 1.
A carrier 1 according to FIG. 3 and 4 differs from that carrier according to FIG. 1 and 2 by the fact that uptakes 3 are inclined towards the axes of joints 5 at 45° and, consequently, are inclined towards the first contact surface 4 at 45°, too. Also in this case the slewing capacity of elements 2 is limited by outer lateral faces 6 for the linear position and inner lateral faces 7 for the bent position (not shown). Thus, a sample receptacle 9 inserted by charging hole 8 is inclined towards the vertical at 45° in both final positions of carrier 1. Consequently, the seal provided by means of a receptacle cover 10 is only slightly strained by centrifugal forces. An exact alignment of sample receptacles 9 in carrier 1 is reached by two guides 11 spaced apart from each other and allowing a guiding of cover 10 on both sides.
Elements 2 of a carrier according to FIG. 5 and 6 use first contact surfaces 4 arranged vertically to their uptakes 3. Second contact surfaces 12 supporting element 2 are arranged towards said first contact surfaces 4 at an inclination of 45°. Thus, the sample receptacles inserted into uptakes 3 of elements 2 by means of a charging hole 8 are arranged vertically, while the carrier is supported by said first contact surfaces 4. They are inclined towards the vertical at 45°, while the carrier is supported by said second contact surfaces 12. In the linear position, the carrier, preferably, is supported by said first contact surfaces 4, whereas, in the bent position, it needs to be supported by said second contact surfaces 12.
Limitations of the pivoting angle are provided by means of outer lateral faces 6 on the one side of joints 5 also arranged parallel to each other and by means of inner lateral faces 7 on the other side of said joints being at an angle with each other. The outer lateral faces 6 act as stops for the linear position, while the inner lateral faces 7 act as stop faces for the bent position of the carrier.
To stabilize the position of the carrier in the final positions, each element 2 uses permanent magnets 13 in the outer and inner lateral faces which can have a tight fit in said lateral faces. The permanent magnets 13 are acting together with corresponding magnets of an adjacent element 2 with the effect that magnets in the outer lateral faces 6 are attracted to each other while being in the linear position and magnets in the inner lateral faces 7 are attracted to each other while being in the bent position to keep the carrier in the momentary position.
In the lower portion of elements 2, the inner lateral surfaces 7 adjoin wall sections 14 which are spaced apart from each other and, to stabilize position, can uptake corresponding charging elements of other components of the system.
Joints 5 are worked as strap hinges which are kept in upper and lower grooves 15 of elements 2 and connect to each other all elements of the carrier.
Elements 2 have a third contact surface 16 which is aligned parallel to the uptake 3 as well as the first contact surface 4. Said third contact surface 16 can serve for the horizontal storage of samples in the linearly aligned carrier.
If elements 2 are supported by the first contact surfaces 4, any inserted sample receptacles 9 are aligned vertically. This arrangement is preferred in the linear position of the carrier. In the linear position as well as in the bent position of the carrier, the elements 2 can be supported by the second contact surface 12 which is aligned vertically to the joint axes. The sample receptacles 9 then are inclined towards the vertical at 45°. Finally, in the linear position of the carrier, the elements 2 can be supported by the third contact surfaces 16. In this case, the sample receptacles are aligned horizontally.
Said third contact surface 16, at the same time, is a first bearing surface which goes into effect when adjacent carriers move into one another. As FIG. 7 and 8 show, on the opposite side of uptake 3, a second bearing surface 17 is arranged parallel to the first bearing surface 16. Said second bearing surface 17 is provided with a projection 18 within reach of the second contact surface 12, while the first bearing surface 16 is provided with a complementary recess 19 there. FIG. 8 shows that, in the linear position, adjacent carriers 1 supported by their first contact surfaces 4 can move against each other with their first and second bearing surfaces 16, 17 and, in this way, can move into one another with their projections 18 and recesses 19. Consequently, in spite of the second contact surfaces 12, a space-saving storage of parallel carriers 1 can be realized.
Recess 19 as well as the first contact surface 4 delimit outside steps 20 of each element of carriers 1 at the side of the first bearing surface 16. In the second bearing surfaces 17, however, there are provided inner steps 21 which meet the outer steps 20 of carriers 1 supported by the second contact surfaces 12 and, in this way, cause a mutual support as well as saving of the store room (FIG. 7). Besides, each second bearing surface 17, in its upper portion, has an inclination 22 which, when the carrier is in an inclined position, puts against a wall of recess 19 and provides an additional support.
These carriers 1 also have outer and inner lateral faces 7, 8 which, in a linear and bent alignment, act as stops.
As shown in FIG. 5 to 8, there are provided upper and lower grooves 15 which serve the uptaking of strap hinges for forming a joint. According to FIG. 9, adjacent elements 2 of a carrier can also be linked by means of molded joining elements, a first one of which uses a pin 23 connected with the element by a link and a second one of which is provided with means 24 for uptaking said pin using a feedthrough slot for said link connection.
According to another alternative according to FIG. 10 and 11, a joint 5 can be provided with an additional joining element 25 using a central link 26 and connecting pins 27 at both sides. Said connecting pins 27 are inserted into pin uptakes 24 of two adjacent elements 2 using feedthrough slots for the central link 26.
FIG. 12 shows a carrier I according to FIG. 7 and 8 which, with its second contact surface 12, is supported by a lower marginal flange 28 of a rotor plate 29, while carrier 1, with it second bearing surface 17 and the upper part of its projection 18, is supported against a complementarily formed core 30 of the rotor plate 29.
Said figure also shows said carrier 1 in a adjacent position on a delivery line 31 allowing said carrier 1 to be tilted back in the direction of delivery.
To secure carrier 1 to the rotor 29, however, there, on the second contact surface 12, at least of an outer carrier element 2, there are provided coupling means 32 which can be a permanent magnet, too. Said coupling means 32 can also serve for the coupling of a transportation equipment (chain, band) and are arranged exactly on the same level as joints 5.
According to FIG. 13, said carrier 1, on the inner lateral face 7 of an outer element 2, is additionally provided with a metal plate 33 which acts together with a magnet 34 of a radial link 35 of the rotor 29. The other outer element 2 (not shown) of carrier 1 is provided with a magnet 34 which acts together with a metal surface in a radial link of the rotor 29.
Taking a carrier 1 with elements 2 according to FIG. 5 and 6 as a basis, FIG. 14 and 15 show further details of the system inside and outside the rotor 21. According to FIG. 20, the carrier 1, with its second contact surfaces 12, is supported on the rotor plate 29 in a bent position and is supported radially by the core 30 of the rotor inside, while an inserted sample receptacle 9, with an edge above cover 10, is supported by the upper part of carrier 1 and a bottom portion thereof projects from an opening 38 at the bottom.
Besides, the rotor 29 has a rotor cap 39 which can be moved into an unlocking position--shown while extended--and into a locking position--dashed line--in an axial moving direction V. The rotor cap 39 embraces the carrier 1 while being in the locking position and supports it radially on the third contact surface 16 from outside.
FIG. 15 shows the same carrier 1 supported by its first contact surface 4, while a base 40 acts on the bottom portion of the sample receptacle 9 and lifts it in the lifting direction H, so that its cover 10 removes from the upper portion of said carrier. In this way, said receptacle 9 can be easier accessed. Said sample receptacle, preferably, is aligned vertically then.
The carrier 1 according to FIG. 7 and 8 as well as FIG. 12, 13, is shown, in FIG. 16, inside means 42 for opening the cover. There is provided a base plate 43 using securing strips 44, 45 which take hold of carrier 1, which is supported by its first contact surface 4, which is its projection 18 and its gap 19. The carrier 1, with its guides 11, is pushed under holding-down means 46 which are firmly connected with the base plate 43.
As shown in FIG. 15, inserted sample receptacles 9, with the edge of their cover 10, project from an upper supporting portion of said carrier 1.
Furthermore, the base plate 43 connects to guides 47 using forks 48 movable in direction R. Said forks 48 take hold of one cover 10 each time and open it in upward direction while moving. Said holding-down means 46, meanwhile, are holding each receptacle at a point where the hinge fitting of the cover is provided, which step prevents the fork 48 from pulling said receptacle out of the carrier 1. Those holding-down means 46 can be replaced by a radial load of receptacle 9 to secure the same.
The cover closing means 49 according to FIG. 17 also use a base plate 43 as well as lateral securing strips 44, 45 acting together with projection 18 and uptake 19 of a carrier 1. Compared to means 42, the securing strip 44 of means 49 has got a slightly higher position, so that it is laterally supporting the carrier 1 by the second bearing surface 17.
Considering the fact that the carrier 1 is supported by the base plate 43, the inserted sample receptacles 9 are slightly lifted, while an opened cover 10 projects from the guides 11. A pressure roller 50 can be moved towards the base plate 43 in parallel direction P, so that, when acting on cover 10, puts it together with the main portion of the sample receptacle 9 by swinging movements, closes and locks it.
FIG. 18 shows a carrier which is similar to that according to FIG. 7 and 8 as well as 12, 13, however, is additionally provided with openings 51 across the uptake 3 containing a sample receptacle 9. Also in this case the carrier 1, with its first contact surface 4, is supported by a base plate 43, so that the sample receptacle is slightly pushed out.
The opening 51 serves for the optic control of the contents of the receptacle. For this purpose, a photometric device 52 using a light transmitter 53 and a receiver 54 is aligned with the axis of said opening 51.
FIG. 19 and 20 show another carrier 1 which is molded of plastics as one piece. Its elements 2 have uptakes 3 which are vertically aligned towards a first contact surface. A second contact surface 12 is provided at an angle of 45° therewith. The axes of joints 5 are arranged parallely to the second contact surface 12 and, consequently, are aligned at an angle of 45° with the uptakes 3.
The elements 2 of said carrier have inner and outer lateral faces 36 for limiting the pivoting angle. FIG. 20 shows that, in a linear position, the outer lateral faces 6 are somewhat spaced apart from each other, so that the elements can be arranged at a slight angle with each other.
Joints 5 are formed as strap hinges and, at the side facing the inner lateral faces, have a radius which facilitates a tilt into the bent position, however, counteracts a tilt beyond the linear position. Joint 5 so far takes part in the limitation of the pivoting angle.
According to FIG. 21, a carrier 1 molded of plastics as one piece, can form a receptacle with its uptakes 3 for uptaking samples directly. Uptake 3 is closed in downward direction towards the first contact surface 4 and can be closed by a cover 10 above which is linked by means of a strap hinge. Furthermore, there is provided a second contact surface 12 for a sample arrangement made diagonally to the centrifuge axis. The axes of joints 5 for connecting separate elements of this one-piece carrier 1 cross the intersection line of the first and second contact surfaces 4, 12.
FIG. 22 shows the basic structure of an automatic laboratory centrifuge 74. The rotor 29 is provided inside a central area behind a control panel 77. On the one side of said central area there is arranged an input station 78, while on the other side, an output station 79 is provided. A guide rail 80 runs from the input station 78 to the output station 79 and passes said rotor 29 tangentially.
At the input station there are arranged several rows of carrier 1 which are actuated towards the input arrow E. These are carriers which were described with reference to FIG. 7, 8, 12, 13.
Just before reaching the guide rail 80, each carrier 1 is tilted from the first contact surface 4 to the second contact surface 12 by means of suitable facilities. It then is pushed on guide rail 80 and passed on to rotor 29. According to FIG. 22, said rotor 29 is so constructed that it can take two carriers 1 between two radial links 25. Said rotor 29 has a rotor cap which, to radially lock or unlock carrier 1, is axially movable.
Further facilities not shown here cause the carrier 1 to return from rotor 29 to guide rail 80 after the centrifugation of the samples. Said guide rails takes them to the output station 79, where they are transported in the direction arrow A. While changing from the guide rail 80 to the output station 79 another mechanism causes the carriers 1 to tilt from their tilted position on the second contact surface 12 back to their original position on the first contact surface 4 with vertically arranged receptacles. The change of position is symbolized in FIG. 22 at the outer edge of the output station 79.
FIG. 23 shows an automatic centrifuge 74 integrated into automatic anylyses facilities 82 which the carriers 1 pass through on a closed curved park 83.
The carriers 1 are charged with new sample receptacles 10 by means of charging facilities 84. Subordinate to said charging facilities there are arranged supply means 85 in circulation direction U of carriers 1 for delivering, dosing or diluting samples. The covers of the sample receptacles are closed there, too.
Said supply means are followed by mixing facilities 86 also arranged in circulation direction U and supplying carriers 1 to storing and tempering facilities 87.
After a certain residence time in said storing and tempering facilities 87 the carriers 1 reach the centrifuge 74. After termination of the centrifugation there are passed decanting facilities 88 which are followed by measuring facilities 89. Thereafter, the carriers 1 are passed on to output facilities 90, where the sample receptacles 9 are removed and passed over in a suitable manner.
Carriers according to FIG. 24 and 25 have plate-like elements 2 linked at their lateral edges by means of joints 5 formed as strap hinges. Like the form of construction according to FIG. 19 and 20 said joints 5 allow the elements 2--starting from the linear position of carrier 1--to turn in both directions. The slewing capacity, however, is limited by means of inner and outer lateral faces of carrier 1.
Each element 2 is provided with a tube 91 which is aligned at an acute angle with the plate and, accordingly, with the axes of joints 5. Said tubes 91 surround uptake 3 crossing elements 2.
According to FIG. 24, the uptakes 3 contain, frictionally engaged, sample receptacles 9. Said sample receptacles 9, near their cover portion, are taken between guides 11 of the plate-like base components of elements 2. Besides, the lateral portions of covers 10 are supported by the upper faces of the tubes 91. The elements 2 as well as the sample receptacles 9, with their bottom portions, are supported on a base defining a contact surface. According to the drawn position outside the rotor, the sample receptacles 9 are aligned at a relatively small angle with the vertical. This causes a satisfactory CG position for stability.
To additionally improve the stability and space-saving arrangement, the sample receptacles 9, with another lateral portion of their covers 10, are taken by a gap 19 in the upper portion of an adjacent element 2. The bottom portions of sample receptacles 9 use projections engaging with gaps 19 in the lower portion of an adjacent element 2.
According to FIG. 26 and 27, there can be provided a work desk 92 for positioning the before-explained carriers 1 outside a rotor. Said work desk 92 uses parallel insert grooves 92 for opening connection to lower portions of the plate-like elements 2. Carriers 1 are kept in their grooves 93 frictionally engaged, so that a handling is possible while exerting on sample receptacles 9 an influence of force, e.g. while inserting or removing or opening or closing the covers
According to FIG. 26, the carriers are so aligned that the sample receptacles 9 hardly restrict an access to the upper portion of carrier 1. The alignment of said sample receptacles 9 according to FIG. 27 allows inserting or taking samples in the same direction. In both cases, the sample receptacles 9 are more inclined towards the vertical than FIG. 24 shows, which fact makes an access from aside easier.
A carrier is designed for six sample receptacles 9, so that several carriers are to be arranged on a rotor 29 according to FIG. 28. Said rotor 29 uses a circular groove 94 for opening a connection to the lower portions of the plate-like elements 2. Groove 94 has a higher groove wall radially outside than radially inside for largely supporting the carrier 1 towards any effects by centrifugal forces. In the upper portion of their elements the carriers 1 are supported by a rotor cap 39, while receptacles 9, with their bottom portions, are supporting against said rotor cap 39, too.
Carrier 1 explained before can be molded of plastics as one piece. As a result of the short tubes 91 which cover the sample receptacles 9 partly only, the contents of said receptacles can be easily controlled. The carrier according to FIG. 29 explained in the following allows a control of the receptacle in as a result of its transparent design. Its elements 2 are connected with each other by means of joining elements 25 shown by FIG. 11.
The transparent elements 2 also use a plate-like base component which, in its lateral portion, shows pin slots 24 above and below for opening a connection to elements 25. Each of the plate-like base components is also connected with one tube 91 which, on the front side of elements 2, as shown, is completely closed. Tube 91, thus, is used as an uptake 3 which completely surrounds an inserted sample receptacle 9 on the side opposite to cover 10. In their upper and lower portions said plate-like elements 2, in return, are provided with openings 19 for the cover portion of the adjacent receptacle 9 or the bottom portion of an adjacent tube 91. In this way, a mutual support of adjacent carriers, similar to that shown by FIG. 24, can be realized. The sample receptacles, in that case, are aligned at a first angle towards the vertical.
According to FIG. 30 and 31, the carriers 1, with the transparent elements 2, are inserted into different rotors 29 of centrifuges, while the receptacles 9 are aligned at a second angle towards the vertical which is higher than the first angle. The lower portions of the plate-like elements 2 are inserted into ring grooves 94 of rotors 29 which are vertically aligned.
According to FIG. 30, the ring groove 94, at its inner side, has a higher side wall 95 than outside allowing the carrier to connect from outside. There are provided additional ribs 96 between the plate-like element 2 and tube 91 as well as ribs 97 between tube 91 and rotor cap 39.
According to FIG. 31, the radial outer side wall 95 of the groove is higher allowing the carrier 1 to connect to the groove 94 from inside. As a result of the supporting effect of said outer side wall 95 any additional ribs are not necessary.
The carriers 1 explained before, for instance, accept sample receptacles for 0.5/1.5/2 mililitres.
|
A system for centrifugation of samples includes at least one carrier, which is provided with a plurality of elements connected with each other by joints and having each an uptake for receiving a sample to be centrifuged, and a rotor for supporting the carrier, with the elements being arranged, in a centrifuged position of the elements, along a circle having its center lying on the rotational axis of the rotor.
| 1
|
FIELD OF THE INVENTION
This invention relates to the field of cranes and particularly to a novel type of kingpost crane.
BACKGROUND OF THE INVENTION
Kingpost cranes have long been known in the art. See for instance Purdy, GB Patent No. 10730, AD-1894. Pedestal crane systems, in which a crane upper works is rotatably mounted on a pedestal, have gained widespread acceptance in the marine industry. A form of pedestal crane in which a central kingpost is mounted on a pedestal and the upper works is rotatable about the kingpost and is supported, at least in part, on the kingpost is described in U.S. Pat. No. 4,184,600 issued to Goss and this applicant.
Kingpost cranes of the type described in the '600 patent and subsequent patents such as U. S. Pat. Nos. 5,328,040 and 5,310,067 issued to this applicant and U.S. Pat. No. 4,354,606 to applicant and another have gained widespread acceptance in the offshore oil and gas industry. A primary advantage of such kingpost cranes is the safety inherent in their structure. Such kingpost cranes are highly resistant to overturning moments.
Such kingpost cranes include an upperworks rotatably supported on a kingpost. The structure of such kingpost cranes involves vertical separation of radial bearings. Such separation is normally obtained by providing an upper radial bearing at an upper extension of the kingpost and by providing a lower radial bearing near the level of the pedestal.
Kenz GB Patent No. 2177374A discloses a crane supported on a pivot section, the pivot point disposed below an upper radial bearing. The GB '374A disclosure is for a rope luffed crane, luffing being the adjustment of lateral travel of the block or hook by means of angular adjustment of the boom. The disclosure indicates an advantage of the crane to be an ability to raise the pivot section to allow changing of the upper radial bearing. A disadvantage of the '374 crane is that the '374 crane does not provide means for inspection or replacement of lower radial and thrust bearings without substantial disassembly of the crane. A further disadvantage of the '374A crane is that the lower bearing, like the bearings of many prior art cranes, involves bearing contact of relatively hard metal bearing members with the relatively soft metal of the pivot member. A bearing failure can result in cutting of the pivot member, possibly resulting in overturn of the crane.
It is an object of the present invention to provide a novel kingpost crane having an inverted kingpost.
It is a further object of the present invention to provide an inverted kingpost crane providing upper and lower bearings constructed of relatively soft bearing materials cooperating in bearing relationship with relatively hard kingpost and upperworks structures.
It is a further object of the present invention to provide an inverted kingpost crane providing ready access to upper and lower bearings for inspection and replacement.
SUMMARY OF THE INVENTION
The foregoing and other objects of the present invention are accomplished by an inverted kingpost crane, the crane including an upperworks supporting a crane boom, the upperworks supported on a rotating kingpost, the kingpost extending downwardly into a sleeve, an upper radial bearing structure intermediate an upper section of the kingpost and the sleeve, a lower bearing structure comprising a thrust bearing and a radial bearing disposed intermediate a lower section of the kingpost and the sleeve. The upper bearing and the lower bearing structure are constructed of a relatively soft bearing material, providing a sacrificial wearing surface between the rotating kingpost and the stationary sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a partial cross-sectional view of the inverted kingpost crane of the present invention.
FIG. 2 depicts a plan view of the inverted kingpost crane.
FIG. 3 depicts an isometric view of the sleeve of the kingpost crane of the present invention.
FIG. 4 depicts a cross-sectional view of the sleeve of FIG. 3.
FIG. 5 depicts a bottom view of the sleeve of FIG. 3.
FIG. 6 depicts an isometric view of the kingpost of the present invention.
FIG. 7 depicts the lower bearing block of the inverted kingpost crane.
FIG. 8 depicts the bearing retainer for the lower bearing block.
FIG. 9 depicts an upper bearing shoe.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the inverted kingpost crane 10 of the present invention is depicted in partial cross-section. The crane 10 includes generally an upperworks 12 supported on a kingpost 14, the kingpost 14 supported interior of a vertical sleeve 16. A boom 18 is supported on the upperworks 12, the boom 18 supporting a hook 20.
The kingpost 14 includes an elongated, cylindrical body 72. Kingpost body 72 extends downwardly into cylindrical sleeve 16. The kingpost body 72 and the sleeve 16 are concentrically arranged about vertical axis 30. The kingpost body 72 is rotatable within the sleeve 16, the kingpost 14 supported on a lower bearing structure 22. The lower bearing structure 22 comprises a thrust bearing and a radial bearing. An upper radial bearing structure 24 (not shown in FIG. 1) is provided intermediate the kingpost body 72 and the sleeve 16 near the sleeve upper end 26.
The upperworks 12 includes a turntable 28 supporting parallel, upwardly extending support struts 32. The struts 32 each have an inclined upper edge 34 extending at an acute angle to axis 30. A base end 36 of boom 18 is pivotally attached to the struts 32 at upper pivot connector 40. The pivot connector 40 is attached to the struts 32 at an upper portion of the struts 32 vertically removed from the turntable 28. The boom 18 may be pivoted in a vertical plane about the pivot connector 40.
A hydraulic ram 42 is pivotally connected to the struts 32 at lower pivot connector 44. The hydraulic ram 42 is pivotally connected at its distal end to the boom 18 at connecting ears 46, which connecting ears 46 are fixedly attached to the underside of the boom 18. The boom 18 is angularly adjustable in a vertical plane by the hydraulic ram 42 in cooperation with the pivot connectors 40, 44 and 46.
A hoist 48 is fixedly attached to the boom 18 near the base 36 of the boom 18. Hoist 48 serves to extend and retract a hoist line 50, which hoist line 50 extends to boom sheaves 52 and thence to hook 20. The boom 18, the hydraulic ram 42 and the hoist 48 are of conventional construction. Details of construction of the boom 18, ram 42 and hoist 48 are therefore not depicted. An operator cabin and controls may be provided on the turntable 28 adjacent struts 32. Such cabin and controls have been omitted from the drawings as they are of conventional construction.
Still referring to FIG. 1, sleeve 16 is depicted in partial cross-section. Sleeve 16 is a vertically-oriented, hollow, elongated cylinder having a cylinder wall 54 extending from the underside of the turntable 28 downwardly. The sleeve 16 is attached to a support structure (not shown).
Referring to FIG. 3, an isometric view of sleeve 16 is depicted. A tooth gear 56 is provided at the upper end 26 of sleeve 16. The tooth gear 56 comprises a plurality of teeth 58 extending radially outwardly from a flange 60. The flange 60 extends horizontally from upper end 26.
Referring to FIG. 4, a partial cross-sectional side view of the sleeve 16 is depicted. A horizontal cross-member 62 is provided interior of sleeve 16. The horizontal cross-member 62 is positioned in a lower segment of the sleeve 16 spaced from the lower end 64 of the sleeve 16. The cross-member 62 is fixedly attached, such as by welding, to the cylinder wall 54. An opening 70 is provided in the cylinder wall 54 of the sleeve 16 intermediate the cross-member 62 and the lower end 64 of the sleeve 16.
Referring to FIG. 5, a bottom view of the sleeve 16 is depicted. The cross-member 62 is, in the preferred embodiment, a circular plate welded along its periphery to the cylinder wall 54. A square opening 66 is provided in the center of the cross-member 62. The square opening 66 is centered on axis 30. A plurality of bolt holes 68 are provided in the cross-member 62 near the square opening 66 and space around the periphery of the square opening 66.
Referring to FIG. 6, an isometric view of the kingpost 14 of the present invention is depicted. The kingpost 14 includes an elongated cylinder body 72. The kingpost body 72 and the sleeve 16 are constructed with respective diameters such that the kingpost body 72 fits within the sleeve 16 defining an annular opening 74 (depicted in FIG. 1) between the kingpost body 72 and the sleeve 16.
The turntable 28 is fixedly attached, preferably by welding, to the kingpost body 72 at the kingpost body upper end 74.
A cylindrical kingpost pin 76 extends from the kingpost lower end 82. The kingpost pin 76 has a lesser diameter than the kingpost body 72 and is concentrically aligned with the axis 30. A lower end surface 78 is provided on the kingpost 14, the lower end surface 78 extending from cylindrical body 72 lower end 82 to the exterior of the kingpost pin 76. The kingpost lower end surface 78 is fixedly attached, such as by welding, to the kingpost body 72 and to the kingpost pin 76.
In the preferred embodiment depicted, the kingpost pin 76 is an extension of an elongated cylinder 80 (depicted in FIG. 1). The cylinder 80 extends from the upper end 74 of the kingpost body 72 beyond the lower end 82 of the kingpost body 72. The pin cylinder 80 is fixedly attached, preferably by welding, to the underside of turntable 28 at its upper end (not shown). An opening (not shown) in the turntable 28 at the upper end of pin cylinder 80 allows hydraulic hoses to extend interior of pin cylinder 80 between turntable 28 and pin 76.
Referring to FIG. 5 and FIG. 1, the square opening 66 provided in the cross-member 62 is sufficiently large that the kingpost pin 76 extends through such square opening 66. An annular space 82 is defined by the exterior of the kingpost pin 76 within the square opening 66.
Referring to FIG. 6 and FIG. 9, the upper radial bearing 24 is depicted. The upper radial bearing 24 consists of a plurality of upper radial bearing shoes 88 located near the upper end 74 of kingpost body 72. The bearing shoes 88 are spaced around the circumference of the kingpost body 72 below the upper end 74. The bearing shoes 88 are provided with a curvilinear radially exterior surface 90 and a curvilinear radially interior surface 92. The interior surface 92 is shaped in an arc conforming to an arc defined by a section of the exterior of the kingpost body 72. The exterior surface 90 of each bearing shoe 88 is shaped in an arc conforming to an arc defined by a section of the interior of the cylinder wall 54.
A plurality of bearing housings 94 are provided on the kingpost body 72 to house the bearing shoes 88. The bearing housings 94 comprise a series of generally rectangular boxes 96 extending around the circumference of the kingpost body 72. The boxes 96 so constructed that the bearing shoes 88 fit within the boxes 96 with an exterior segment 89 of the bearing shoes 88 extending radially outward. The exterior surfaces 90 of the bearing shoes 88 extend to a close fit with the interior of cylinder wall 54 of sleeve 16.
Referring now to FIG. 7 and FIG. 1, the lower bearing 22 is depicted. The lower bearing 22 comprises a segmented rectangular block 98 having a cylindrical opening 100 extending vertically through its center. The bearing block 98 comprises two symmetrical segments 98a and 98b. Segments 98a and 98b are symmetrical along a vertical plane extending through the center of the bearing block 98. The bearing block 98 is constructed such that its laterally exterior surfaces fit within the square opening 66 of cross-member 62. The bearing block 98 is further constructed such that its central cylindrical opening 100 extends around the circumference of kingpost pin 76. The bearing block 98 is segmented to allow insertion of each of the segments 98a and 98b in the respective space between the opening of kingpost pin 76 and square opening 66.
The bearing block 98 is constructed with a vertical dimension such that the bearing block 98 is vertically thicker than the cross-member 62.
Referring to FIG. 8, a lower bearing retainer 102 is depicted. The lower bearing retainer 102 is a square plate. The lateral dimensions of the bearing retainer 102 are such that the bearing retainer 102 extends beyond the lateral edges of the square opening 66 in the cross-member 62. The bearing retainer 102 is provided with a plurality of bolt holes 104. The bolt holes 104 are constructed of a size and with dimensions to allow alignment with bolt holes 68 exterior of square opening 66 in cross-member 62.
The bearing retainer 102 is bolted to the underside of cross-member 62, the bearing retainer 102 supporting bearing block 98. Upon installation, the upper surface 118 of bearing block 98 extends above the cross-member 62 with the kingpost lower surface 78 resting on the upper surface 118 of bearing block 98. The edges of the square opening 66 retain bearing block 98 in a fixed lateral position.
Referring to FIG. 2, a motor 106 is provided on the turntable 28 at a lateral extension 29 of turntable 28. In the preferred embodiment depicted, the motor is hydraulically powered. A spindle (not shown) extends downwardly from the motor 106 through an opening 108 (depicted in FIG. 6) in the turntable 28. A pinion gear (not shown) is connected to the spindle. Teeth of the pinion gear operably engage the teeth 58 of tooth gear 56. As the turntable 28 is supported on the kingpost 14, rotation of the pinion gear by motor 106 results in rotation of the turntable 28 and the kingpost 14 in relation to the sleeve 16, the motor 106 and pinion revolving around the circumference of the tooth gear 56.
Referring again to FIG. 1, a hydraulic connector 110 is attached to the lower end of kingpost pin 76. Hydraulic hoses 108 extend from hydraulic connector 110. The hydraulic hoses 108 extend to pumps and reservoirs (not shown) for hydraulic fluid, which pumps and reservoirs are of conventional construction. The hydraulic connector 110 is connected to additional hydraulic hoses (not shown) extending internally of kingpost pin 76 and elongated cylinder 80, the hydraulic hoses extending to hydraulic ram 42 and motor 108. The hydraulic connector allows for connection of hoses interior of the kingpost 14, which hoses rotate with the kingpost 14, to hoses exterior of the kingpost 14, which hoses are relatively stationary. The hydraulic connector 110 is a commercially-available product appropriate for fluid connection of hydraulic hoses such as the present application.
The upper bearing shoes 88 and the lower bearing block 98 are constructed of a solid lubricated or self-lubricating nonmetallic material suitable for bearing interface with a metal. A lubricated nylon material such as a nylon material impregnated with molybdenum disulfide sold by Polymer Corporation of Reading, Pa. under the trademark NYLATRON® has been found to be a suitable material for the bearing shoes 88 and the lower bearing block 98. A ultra high molecular weight polyolefin material may also be used.
Referring to FIG. 4, a plurality of alignment openings 120 are provided in the cylinder wall 54 of the sleeve 16 intermediate the cross-member 62 and the tooth gear 56. Cylindrical bosses 110 are affixed to the cylinder wall 54 at the openings 108, the bosses 110 having threaded openings concentrically arranged with openings 120. Two upper openings 120 and bosses 110 are provided near the upper end 26 of the cylinder wall 54 and two lower openings 120 and bosses 110 are provided near the lower end 64 of sleeve 16. The upper openings 120 are spaced angularly from each other and the lower openings 120 are spaced angularly from each other.
Upon installation of the kingpost 14 within sleeve 16, the kingpost 14 is rotatably supported within sleeve 16. The kingpost 14 is supported on upper surface 118 of bearing block 98. Bearing block is in turn supported on bearing retainer 102. The kingpost 14 is restrained from horizontal displacement at its upper end by bearing shoes 88 and is restrained from horizontal displacement at its lower end by bearing block 98. The bearing block 98 therefore serves as a lower radial bearing and as a thrust bearing.
The upper bearing shoes 88 of the present invention may be readily installed and replaced by raising the kingpost 14 upward until the bearing housings 94 are above the upper end of the sleeve 16. Such raising may be accomplished by placing a suitable jacking device below the kingpost pin 76 and jacking the kingpost 14 upward. The existing bearing shoes 88 may then be removed from the bearing housings 94. Replacement bearing shoes 88 may then be installed. Upon installation of the replacement bearing shoes 88 the kingpost 14 may be lowered such that the bearing shoes 88 are intermediate the kingpost 14 and the sleeve 16. The bearing shoes 88 need not be attached to the kingpost 14 by means other than insertion in the housings 94 as they are retained in place by the cylinder wall 54 of sleeve 16.
The lower bearing block 98 may be readily installed and replaced. Upon insertion of the kingpost 14 into sleeve 16 without the bearing block 98 and lower bearing retainer 102 installed, the kingpost pin 76 extends through square opening 66 and the kingpost lower end 78 rests on cross-member 62. The position of the kingpost 14 within sleeve 16 may be laterally adjusted by means of alignment openings 120 and bosses 110. Specifically, threaded alignment bolts (not shown) may be threaded into bosses 110. An alignment bolt may be threaded through a boss 110 until the bolt engages the kingpost body 72 and horizontally displaces the kingpost 14 in a desired direction. As a plurality of bosses 110 are provided, various bosses 110 and alignment bolts may be concurrently used to center the kingpost 14 within sleeve 16.
Upon centering of the kingpost 14 within sleeve 16, the lower bearing block segments 98a and 98b may be inserted in the square opening 66, within the annular opening 100 around the kingpost pin 76. Lower bearing retainer 102 may then be placed against the underside of bearing block 98 and bolts (not shown) inserted through the bolt holes 104, the bolts extending to corresponding bolt holes 68 in cross-member 62. As the bolts are threaded through bolt holes 68, the bearing block 98 and the kingpost 14 are raised. By threading the bolts until bearing retainer 102 is adjacent the underside of cross-member 62, the kingpost lower end 78 is supported on the upper surface 118 of bearing block 98 above the cross-member 62. The alignment bolts may then be removed.
It will be seen that the upper bearing structure 22 and the lower bearing structure 24 each provide dynamic interface of metal to a relatively soft bearing material such as NYLATRON®. It will be further seen that a failure of the upper bearing 22 or of the lower bearing 22 will not result in overturning of the kingpost crane 10 due to the relatively close fit of the kingpost 14 within the sleeve 16.
The present invention has been described in terms of a preferred embodiment of a cylindrical kingpost 14 and a cylindrical sleeve 16. A non-cylindrical kingpost or a non-cylindrical sleeve may be practiced within the concept of the present invention, with appropriate substructures to allow for a circular upper bearing interface.
While the present invention has been described in terms of a preferred embodiment, it should be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
|
An inverted kingpost crane is disclosed, the crane including an upperworks supporting a crane boom, the upperworks supported on a rotating kingpost, the kingpost supported in a sleeve, an upper radial bearing structure intermediate an upper section of the kingpost and the sleeve, a lower bearing structure comprising a thrust bearing and a radial bearing disposed intermediate a lower section of the kingpost and the sleeve. The upper bearing and the lower bearing structure are constructed of a relatively soft bearing material, the bearing material providing a sacrificial wearing surface between the rotating kingpost and the stationary sleeve.
| 1
|
RELATED APPLICATIONS
This patent application is a Continuation of U.S. patent application Ser. No. 10/987,086, filed on Nov. 15, 2004 entitled “DEBIT PURCHASING OF STORED VALUE CARD FOR USE BY AND/OR DELIVERY TO OTHERS”, which is a continuation of U.S. patent application Ser. No. 10/441,067, filed on May 20, 2003, now U.S. Pat. No. 6,892,187, which is a continuation of U.S. patent application Ser. No. 09/102,044, now U.S. Pat. No. 6,615,189 which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
This invention relates to a system for purchasing or transferring of stored value or debit purchasing cards, which can be pre-arranged to be given as a gift to a designated recipient.
BACKGROUND OF THE INVENTION
On many occasions, consumers, other bank customers, credit card holders, and other persons find it is desirable to arrange for another person, perhaps a relative, to have access to a specified sum of money. For example, a parent might want to arrange for a child to have access to money when the child is taking a trip or going away to college. One may also find it desirable to mail a gift to another person who is geographically distant. In these and other cases, it is often undesirable to give away or send cash. If lost or stolen, cash is practically unrecoverable. Traveler's checks are also undesirable as they must be purchased at a bank and are not acceptable for many types of purchases. Gift certificates are also undesirable because they require the recipient to purchase from the merchant that issued the gift certificate. These and other drawbacks exist to the aforementioned alternatives.
SUMMARY OF THE INVENTION
An object of the invention is to overcome these and other drawbacks in existing purchase schemes.
Another object of the invention is to provide a method for issuing a purchase card comprising: presenting a purchaser with the opportunity to buy the purchase card, determining whether the purchaser has sufficient funds to pay for the purchase card, creating a purchase card account for a recipient designated by the purchaser; and issuing the purchase card.
A further object of the invention is to provide a purchase card where the recipient activates the purchase card.
A further object of the invention is to provide a purchase card where the purchase card account contains a monetary amount determined by the purchaser of the purchase card.
A further object of the invention is to provide a purchase card where money can be added to the balance of an issued purchase card account.
A further object of the invention is to provide a purchase card where the purchase card is activated when the issuer of the purchase card is notified that the recipient has received the purchase card.
A further object of the invention is to provide a purchase card where the issuer of the purchase card notifies the purchaser that the recipient has received the purchase card.
A further object of the invention is to provide a purchase card where the purchaser may designate with which merchants the purchase card may be used.
A further object of the invention is to provide a purchase card where the purchase card is activated for a predetermined period of time.
Another object is to provide a method for issuing a purchase card as a rebate award comprising: issuing a credit card to a cardholder, said credit card being associated with a sponsor. calculating a rebate amount based upon cardholder purchases made with said credit card, issuing a purchase card to a cardholder or to a recipient designated by said cardholder, said purchase card having a purchase value determined by said rebate amount.
A further object of the invention is to provide a purchase card where the recipient of the purchase card activates the card.
A further object of the invention is to provide a purchase card where the recipient activates the purchase card by notifying the issuer that the recipient has received the purchase card.
A further object of the invention is to provide a purchase card where the purchase card is activated for a predetermined period of time.
A further object of the invention is to provide a purchase card where the rebate is calculated based on all purchases made with the credit card.
A further object of the invention is to provide a purchase card where the rebate is calculated based on purchase from the sponsor made with the credit card.
A further object of the invention is to provide a purchase card where the sponsor notifies the issuer of the amount of rebate due a credit card holder, and the issuer creates a purchase card in that amount.
A further object of the invention is to provide a purchase card where the rebate is based on the monetary value of the purchases.
Another object of the present invention is to provide a method for converting a purchase card into a credit card comprising: creating a purchase card account for a recipient designated by the purchaser; issuing the purchase card; receiving a request from the recipient to convert the purchase card into a credit card; determining whether the recipient meets predetermined credit criteria to convert the purchase card into a credit card; creating a credit card account; and converting the purchase card into a credit card.
A further object of the invention is to provide a purchase card where the balance of the purchase card account is transferred to the credit card account.
A further object of the invention is to provide a purchase card where the credit cards is immediately activated upon being converted from a purchase card.
Other objects and advantages exist for the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a flow diagram for a portion of the purchase card system.
FIG. 2 shows a flow diagram for another portion of the purchase card system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the purchase card system is shown in FIG. 1 . In this embodiment the purchase card process begins with an offer to purchase a gift card at step 100 . The offer may be in any suitable form that would notify prospective purchasers 105 of the availability of the purchase card. For example, a written solicitation may be mailed or otherwise distributed to potential purchasers 105 . The offer may also be in the form of oral notification, for example, a telephone call to prospective purchasers 105 . Alternatively, the offer may be published over a computer network, for example, on an Internet Web site. Other forms of offering the sale of a purchase card are also possible. In one embodiment of the invention, offers are made to prospective purchasers who already have a financial relationship with the offeror. Other potential purchasers may also be offered the opportunity to obtain a purchase card.
The offer may be accepted by a purchaser 105 by notifying a customer service center 110 . The acceptance may be in any form acceptable to the customer service center 110 . For example, the purchaser may mail, fax, or otherwise transmit a written acceptance, telephone an acceptance, or electronically transmit, for example, via Web Site, an acceptance by computer or other suitable device. At step 120 , the customer service center 110 receives pertinent information to identify the purchaser 105 and the purchaser's desired spending limit for the purchase card. For example, the customer service center may identify the purchaser 105 by name, address, credit card account number, social security number, other unique identifiers or a combination of identifiers.
At step 130 , the customer service center 120 is checked to verify that the caller or purchaser was included in the solicitations for this program. If the caller or purchaser was not originally solicited, customer service 120 determines whether to extend an offer in step 135 .
If the caller or purchaser was solicited 130 , certain purchaser 105 information may be accessed at 140 . If, for example, the purchaser wishes to pay for the purchase card with a credit card, the purchaser's credit card account information may be accessed. For example, the purchaser's available credit limit may be accessed at 145 to verify that sufficient credit is available to cover the spending amount of the purchase card. If the available credit is insufficient, the purchaser 105 may be so informed at 150 . The purchaser 105 may be given the opportunity to modify the purchase card spending amount, at 155 , in order to ensure that the purchase amount does not exceed the available credit.
The process may terminate at 160 it for example, the purchaser 105 does not wish to modify the purchase amount.
After it has been determined that the purchaser's available credit is sufficient, a transaction may be posted to the purchaser's credit card for the amount of the purchase at 170 . In another embodiment of the present invention, a purchaser may use a check, cash, or other financial methods to obtain a purchase card. Regardless of the purchasing method, the issuer of the purchase card must determine whether the purchaser has sufficient funds to purchase the card.
When the purchase card is paid for by credit or bank account, the purchaser's account balance is updated at 175 to reflect the purchase. The account balance information, as well as information identifying the purchaser 105 and the recipient, may be stored in a retrievable and accessible fashion. For example, the information may be stored in computer database 180 . After the purchaser 105 has paid (or authorized payment) for the purchase card, and it is posted to a credit card account, the acceptance process is complete and the acceptance process terminates at 160 .
An account for the purchase card is created at 190 . This may be performed by a third party processor that establishes and manages purchase card accounts. for example, at 200 . Creation of the purchase card account may comprise various actions, such as, recording the recipients 215 name, address and phone number, imprinting a card with an account number, a recipient name and an expiration date, encoding the card to record the purchase value stored thereon, and other actions, such as, for example, preparing account fulfillment documents (e.g. card carrier activation, etc.).
When the purchase card account is complete, the card is delivered. In one embodiment of the invention, card may be affiliated with a particular network, such a credit network, or debit network. For example, a card may be affiliated with the VISA® network. The delivery may be to the purchaser 105 or to the recipient 215 , as shown at 210 . The place of delivery may be arranged during the initial purchase of the card or other suitable time before delivery.
Information regarding an account is sent to account file 220 , where an account can be monitored. In one embodiment, account file 220 allows monitoring of the current balance of an account, any activity in the account, including debits and credits, transaction updates, and the like. Other information about an account, such as purchase dispute resolutions, the history provided by the customer, and account status, may also be monitored.
Before the purchase card can be used to make purchases, it must be activated as shown in FIG. 2 at 230 . Activation may be accomplished in any suitable manner. For example, the recipient 215 of the card may place a telephone call to an activation center 240 . Activation center 240 may act as a telemarketing vendor by verifying information about the recipient (i.e. name, address, telephone number, etc.) before the purchase card is activated. The activation center 240 may then transmit the data about the recipient to Data Service 200 to activate the purchase card for use. Activation center 240 may also modify information about a recipient, such as, for example, a change of address. Other forms of activation, such as by computer network may also be used.
During activation certain verifications may be made at 250 to ensure that the intended recipient 215 is the person attempting to activate the purchase card. These security checks 250 may entail questions about personal information (e.g., name, address, telephone number, etc.) or may utilize other well known methods of authenticating the recipient 215 . If the person attempting to activate the purchase card does not pass the security check 250 , the purchase card will be denied activation at 255 and the activation process may terminate at 260 . If the person attempting to activate the purchase card passes the security check 250 , they may be prompted at 252 for more information. The information may be used for subsequent security checks, should they be required, or to verify or complete the purchase card account information.
After activation the purchase card is ready for use. In some embodiments of the invention the activation process will end at this point. The recipient 215 may now use the purchase card to make purchases where ever, for example, VISA® cards are accepted. Each time a purchase is made using the card, the amount of the purchase will be debited from the card's available balance. The purchase card will continue to operate as long as a positive balance remains on the card. Some embodiments of the purchase card may have the capacity to have additional purchase value added to them after they have been activated.
If the recipient of a purchase card is someone other than the purchaser, the issuer of the card may notify the purchaser regarding various aspects of the card. For example, in one embodiment of the invention, the issuer could notify the purchaser that the purchase card has been received and activated by the intended recipient. An issuer may also notify a purchaser where the purchase card is being used, or what products are being purchased with the purchase card.
Some embodiments of the purchase card will include an expiration date. After the expiration date has passed the purchase card will be de-activated and cease to operate. In another embodiment of the present invention, a recipient or a purchaser of a purchase card may add to the balance of the purchase card account. This may take place in a manner substantially similar to the original purchasing of the purchase card. For example, a recipient of a purchase card may request that an amount be posted to the recipient's credit card and that the same amount then be credited to the recipient's purchase card account. Other methods of adding to the balance of a purchase card account may also be used.
Another embodiment of the invention allows the recipient 215 to convert the purchase card into a credit card. Conversion may be accomplished in the following manner. The recipient 215 calls the activation center 240 to activate the purchase card and the security check 250 may be performed in the usual manner. After passing the security check, the age of the recipient 215 is determined at 270 . If the recipient 215 is an adult (e.g., over the age of 18) an offer to convert the purchase card into a credit card may be extended at 271 . At step 275 the recipient 215 may decline the offer to convert, in which case the process may terminate at 280 . If the recipient 215 elects to convert the purchase card to a credit card the activation center 240 may capture additional data 285 from recipient 215 , in order to complete a credit card application. At step 290 the credit card application data is forwarded to a credit decisioning office 300 . The credit decisioning office 300 may make inquiries to a credit bureau 305 , for example, obtaining a credit report on the recipient 215 . At 310 the decision is rendered whether to approve the credit card application. If the application for a credit card is declined at 315 , the recipient 215 may be notified at 320 . Notification may be in any suitable form, for example, a letter explaining the declined application may be mailed at 320 to the recipient 215 . Other forms of notification may also be used to notify recipient 215 of the declined application.
Even though the credit card application is declined at 310 , the purchase card is activated for use. At 330 , the account settings allowing a card to be used at merchants are sent to the data service 200 and the card will be activated as a purchase card account. Information pertaining to the purchase card account is stored in a retrievable and accessible manner. For example, the purchase card account information may be stored in a computer 332 .
If the decision at 310 is to accept the application for a credit card, the recipient 215 may be notified at 340 . Again, notification may be in any suitable form, for example, a letter or other suitable notification. Regardless of the decision whether to convert the purchase card into a credit card, the purchase card is activated at the end of the activation call. If the purchase card is not already active, it may be activated at 345 . At 350 the purchase card is converted to a credit card. The credit card will function in a manner usual for such credit instruments. For example, a credit limit may be assigned, periodic account activity statements may be generated and finance charges may be applied to any outstanding balance. In one embodiment, any remaining balance from the purchase card account may be transferred and applied to the credit card account. At 355 an update is sent to a retrievable data storage system, for example, computer 360 . The update 355 sends credit card application decisions into a database.
In another embodiment of the purchase card, a financial institution (e.g., a bank) issues a credit card to a cardholder. The card may be a co-branded card issued in cooperation with a sponsor. In this embodiment, the sponsor offers a rebate to the cardholder based upon the dollar value amount of purchases made with the co-branded credit card. The rebate may apply to all purchases made or just to purchases made from the sponsor. The rebate may be calculated in a manner specified by the terms of the cardholder agreement or other disclosures to the cardholder. In one embodiment of the invention, disclosure about the rebate is provided to the cardholder in a separate form included with the cardholder agreement. For example, the sponsor may offer a flat percentage rebate for purchases made. In one embodiment of the invention, the card issuer calculates the rebate due the cardholder based on the balance paid.
In another embodiment, the sponsor notifies the financial institution of the amount of rebate to be awarded to the cardholder. The financial institution will then issue a purchase card for the amount of the rebate. The purchase card may be used for purchases in the above described manner, for example, everywhere VISA® is accepted, or the purchase card may be used for purchases solely with the sponsor or other designated entities.
Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification and examples should be considered exemplary only. The scope of the invention is only limited by the claims appended hereto.
|
A method of issuing a purchase card is provided. The method includes the steps of presenting a purchaser with the opportunity to buy the purchase card, determining whether the purchaser has sufficient funds to pay for the purchase card, creating a purchase card account for a recipient designated by the purchaser, and issuing the purchase card. The purchase card may also be issued in connection with another credit card, for example as a rebate for purchases on the credit card. The purchase card may also be converted to a credit card.
| 6
|
BACKGROUND OF THE INVENTION
[0001] The invention is concerned with a glazing comprising filaments, for example an automotive glazing comprising heating filaments.
[0002] It is well known that parallel straight heater wires integrated into a glazing and viewed in transmission against a bright light source can produce obtrusive light diffraction patterns, particularly obvious in night time viewing conditions. Such diffraction patterns, also known as ‘starburst’, ‘sparkle’ or ‘star filter’ effect, comprise rays emanating from a point light source.
[0003] US20070187383 (Southwall) discloses that if a driver's eyes are focused into the far distance and heating wires stretched between the top and bottom of a windshield, then a ‘star filter’ pattern will be observed to the sides of any light source, causing distraction. A wire shape is disclosed, formed of a succession of quarter arcs, wherein no portion is linear.
[0004] US20100200286 (Saint Gobain) discloses a conductive grid structure for minimising the optical impact of diffraction patterns. The structure is applied by a deposition and removal process, preferably optical lithography.
[0005] EP2284134, EP2381739 and EP2555584 (L G Chem) disclose many interconnecting conductive lines between nodes aimed at minimizing diffraction and interference of light. Irregular patterns of many interconnecting lines are disclosed which provide uniform heating per unit area. A disadvantage of many interconnecting lines for heating is that not all conductive lines carry equal current. Vision may be unnecessarily blocked by conductive lines which are electrically redundant.
[0006] EP2286992 and EP2278850 (Fujifilm) disclose wires formed into wavy lines and arranged in a mesh. A number of periods of the waves occur between intersections with the aim to reduce deterioration of a displayed image due to interference of diffracted light.
[0007] There remains a need for an alternative glazing comprising filaments for heating, which further minimises a starburst effect.
STATEMENT OF INVENTION
[0008] According to the present invention, a glazing is provided comprising the features set out in claim 1 attached hereto.
[0009] The present invention offers a glazing having reduced starburst effect, i.e. optical effects due to diffraction, by providing filaments formed into sequences of portions of the perimeters of ellipses having particular ellipse aspect ratios.
[0010] This invention is aimed at automotive windscreens, and in particular those installed at an angle, commonly referred to as a rake angle. Rake angle is selected to make a vehicle more aerodynamic or for styling. In the prior art, semi-circles formed from wire in the plane of the glass have the effect of diffracting light into many angles equally from the direction of view of the observer only if the glass is viewed in a perpendicular orientation. According to the present invention, because the typical windscreen is viewed at an angle to its surface, particular ellipse aspect ratios have superior properties.
[0011] It is known that displays comprising two grid structures superposed can suffer from the formation of Moiré patterns. Many ways have been found to bend, kink and align wires to reduce the Moiré problems but they should not be confused with the objectives in this invention.
[0012] Semi-ellipses formed in the plane of the glass can be arranged to appear as semicircles from the direction of view of the driver. Semi-ellipses, like semicircles, have no locations where the wire curvature is zero and have portions of wire that are at every angle from the point of view of the driver. Axial ratio is defined for ellipses as the ratio of the longer and shorter diameters. Axial ratio describes the shape of the ellipse but not its size.
[0013] An X-shaped starburst night time diffraction effect, which occurs in many wire heated windscreens, can be eliminated by forming wires into sequences of semi-ellipses rather than conventional sine wave shapes.
[0014] Although forming wire into semi-ellipses is harder than forming into sine waves, it is easier and more reliable than generating total randomness. If heater wires are not manufactured from a spool of wire, but created by printing, or etching processes then almost arbitrary conductor patterns can be fabricated.
[0015] Computer programs can generate intricate patterns often involving thousands of wires with good optical properties. A semi-ellipse is a good basic element to use in heater patterns from the point of view of good diffraction performance and implementation into algorithms.
[0016] Preferably smaller fragments of ellipses are used, to reduce diffraction when the driver is focused on the wires rather than the road ahead.
[0017] Preferably adjacent heater wires cross and branch. Fragments of ellipses can be used to advantage to implement these crosses and branches.
[0018] More than one type of diffraction pattern is seen by a vehicle driver using a wire heated windscreen. Two types of diffraction pattern are observable by a driver in a vehicle when focussing (A) on the wires and (B) into the far distance. There is an evolution between these patterns if the driver's focus is moved between these extremes. If both types of pattern are reduced, then all distraction effects are reduced, regardless where the driver focuses.
[0019] In the prior art, wires formed as sine waves have the property that at the point they cross the central axis there is no curvature in the wire. As the wire is relatively straight at these locations the straight sections may sparkle particularly brightly if the eye is focused on them, as well as generating a starburst effect when the eye is focused into the far distance. Distraction effects on a driver of a vehicle are at a lower severity than, but essentially similar to, effects occurring if wires are not crimped. Relatively straight sections of wire occur in two directions as the sine wave profile alternates between the two sides of the central axis. As viewed from the direction of the driver, the wire directions are perpendicular to rays in an X-shaped starburst.
[0020] The X-shaped starburst from sine waves is made more obtrusive because four bright ‘arms’ emanate from a central point and because of the contrast between light scattered to one side of each ‘arm’ and no light scattered to the other side. In fog, rain or simply observing objects out of focus, the human brain is accustomed to objects being surrounded by scattered and inaccurately focused light and pays relatively little attention to it. The ‘X’ attracts human attention because the brain's processing of an image is known to involve finding ‘lines’ and ‘edges’ of objects and then comparing these with learned objects.
[0021] ‘Wiggles’, i.e. non-sinusoidal wave-shaped filaments, have a similar disadvantage to sine waves because each individual deviation from the general vertical wire direction is typically an arc with relatively straight sections of wire as the wire curvature changes from one hand to the other. Wires rarely take a direction perpendicular to the general direction of current flow so there can not be a uniform diffraction of light to all angles around a lamp as seen by a vehicle driver, so the result is a starburst effect.
[0022] Perfect semicircular arcs of alternating direction are known in the art, in part because they are aesthetically attractive patterns. Their significance in reducing the starburst effect, over and above sine wave shaping of wires, appears not to have been fully appreciated. Semicircles have been used in heaters, either for aesthetic reasons or ease of drawing on a computer system.
[0023] According to the present invention, semi-ellipses are used so that the wire axis is distributed equally into all directions, (as perceived by the driver), and because the magnitude of the wire curvature (as perceived by the driver) is constant with no part of the wire ‘straighter’ than any other. The curvature of successive semi-ellipses, (seen as semicircles by the driver), alternates in polarity but theoretically is never zero. The effect is based on an understanding, not present in the prior art, that a windscreen is raked and the driver's view is rarely normal to the glass, which modifies the perceived starburst effect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will now be described by means of non-limiting examples with reference to the attached figures:
[0025] FIG. 1 shows a basic arrangement of semi-ellipses according to the invention
[0026] FIG. 2 shows ellipses viewed from a pre-defined viewing position
[0027] FIG. 3 shows portions of the perimeters of ellipses, adapted for a rake angle
[0028] FIG. 4 shows portions of the perimeters of ellipses, not divided on major or minor axis
[0029] FIG. 5 shows ellipses of different sizes used in combination
[0030] FIG. 6 shows ellipses of different sizes and a branch
[0031] FIG. 7 shows ellipses arranged to form crossing points
[0032] FIG. 8 shows ellipses arranged to form a crossing point
[0033] FIG. 9 shows ellipses arranged to form a regular network
[0034] FIG. 10 shows a windshield according to the invention
[0035] FIG. 11 shows a cross-section of the windshield of FIG. 10
DETAILED DESCRIPTION OF THE INVENTION
[0036] FIG. 1 shows an embodiment of the invention. Filaments are shaped into a sequence of portions of the perimeters of ellipses having ellipse axial ratios greater than unity.
[0037] FIG. 2 shows a transparent flat sheet positioned in front of an eye, having circles and ellipses drawn on the sheet. It is possible to choose ellipses with different axial ratios and orientations so that the eye perceives each one of them as a circular shape. Where the eye views along the normal to the sheet, there is a circle which is a special case of an ellipse with axial ratio of unity.
[0038] FIG. 3 shows a series of ellipses on a sheet suitable for installation at a rake angle. No ellipse has an axial ratio of unity. Each ellipse will appear as a circle to the eye. Ellipses have been added so that they touch and are centred at points on three central axes. Three wire shapes are created by using half of the outline of each ellipse. It should be understood that in a practical automotive heater these ellipses are much smaller and more densely packed.
[0039] FIG. 4 shows that the semi-ellipses used have half the perimeter length of the complete ellipse. Only in special cases is the semi-ellipse used that would be formed by dividing the ellipse on its major or minor axis. The angle of the tangent to the ellipses at the touching point on the wire axis typically differs from the angles of both the major and minor axis. It also shows, for use later, that each semi-ellipse can be divided into two parts by selecting points on the semi-ellipses with tangents in the wire axis direction. This is not the only way to divide the semi-ellipses but it is a convenient way.
[0040] The lengths of each portion of semi-ellipse will not be exactly a quarter of the circumference of the ellipse. These parts are described as quarters of the ellipse only because the ellipse circumference has to be divided into four parts.
[0041] FIG. 5 shows a series of ellipses not centred on a common axis and having variable spacing between centre lines.
[0042] FIG. 6 shows the formation of a branch. Filaments comprising branches can be used to provide heating in non-rectangular areas.
[0043] FIG. 7 shows ellipses having crossing points. This embodiment provides an interconnected mesh, which is advantageous because heating may still be provided even if one section of the mesh should break.
[0044] FIG. 8 shows an embodiment of the invention in which ellipses are arranged to allow a filament to extend from one axis to another axis via a single crossing point.
[0045] FIG. 9 shows an embodiment of the invention in which ellipses are arranged in a regular grid. Crossing points between filaments are arranged at regular intervals, in a repeating pattern, which is advantageous for easy manufacturing.
[0046] FIG. 10 shows a plan view of a windshield 10 , comprising first and second transparent substrates 11 , 12 . At least one ply of interlayer material 21 is arranged between the two sheets of transparent substrate 11 , 12 . First and second busbars 41 , 42 are arranged on the ply of interlayer material 21 . Heating filaments 31 are arranged between the first and second busbars 41 , 42 . FIG. 11 shows a cross-section corresponding to FIG. 10 on line A-A.
EXAMPLES OF THE INVENTION
[0047] A heater designer may select an ellipse axial ratio suited to a driver's direct ahead view and then repeat this same ellipse axial ratio all over the screen, in the knowledge it will also be approximately correct for the forward view from a passenger seat. The heater designer may also try to simplify the heater design by computing ellipse shapes needed for a single wire passing from the top to bottom of the screen directly in front of the driver and then repeat the choices of ellipses in every wire between the left and right sides of the vehicle. Though not optimum for the driver's vision, this will be a good compromise for the drivers view, the front seat passenger's view and any rear seat is passenger's view. Also for manufacturing simplicity, the optically optimum axial ratios may not always be used.
[0048] A heater designer may select an ellipse axial ratio suited to when the driver focuses on distant objects. At the other extreme of the diffraction effects, when the driver focuses on the wires, the driver will see many ‘sparkling points’ over the windscreen concentrated around highway and vehicle lighting that is causing starburst effect to the driver's eyes. Human distraction can be high when the brain notices these ‘sparkling points’ because it is well known that it attempts to associate and group isolated points of light into constellations that allow it to classify the points as belonging to a recognisable familiar object. It is also well known that the brain watches very closely to see how points within constellations move relative to each other so that it can identify how that represented object may be moving in space. A perfectly regular pattern of wires has the risk of creating perfectly regular patterns of ‘sparkling points’ extending over large areas of the screen. More randomised forms of wire will tend to randomise the positions of individual ‘sparking points’ and reduce the probability that the brain starts to imagine them representing familiar objects. Randomness implies a total lack of order but for the purposes of this invention it is possible to define which aspects of regular order can be relaxed and limits to the relaxation of order in three ways, as follows.
[0049] 1) In the case of a wire formed into a series of semi-ellipses, it is not necessary for the ellipses to be any particular scale, only specific shapes defined by axial ratios. The complete wire can therefore be formed from a sequence of semi-ellipses of differing scale to create a randomisation of ‘sparkling points’. In practice there are preferred limits to this randomness because machinery will have a minimum bend radius capability and the use of too large an ellipse scale may cause adjacent wires in a heated screen to cross and overlap. Crossings and overlapping can cause undesirable appearances when wires are viewed in daylight.
[0050] 2) A wire has an axis and modulations away from that axis, and semi-ellipses have an undesirable property that the wire always crosses that axis in a perpendicular direction. There are viewing situations where there will be a sequence of sparkles observed in perfect alignment on the wire axis. It has been found that by using a randomised selection of quarters of an ellipse that the diffraction advantages conferred by the semi-ellipses still occurs and there is a reduction in this alignment effect. Practical limitations to randomness are caused by minimum bending radii and the spacing of adjacent heater wires, because it is optically preferable that adjacent wires do not intersect and cross. The largest sizes of quarter-ellipse can be accommodated only when the randomised quarter-ellipses are chosen with an understanding of the shapes and positions of the quarter-ellipses on the adjacent wires.
[0051] 3) If heater wires are not uniformly spaced in all areas of the screen it can be advantageous to adapt the maximum scale of the semi- or quarter-ellipses.
[0052] Further examples of the invention are of greatest utility in glazings using electrically conducting heater lines typically diameter/width of 50 um and below, for example formed by metal etching or metal deposition, printing or plating on a supporting substrate. It can be desirable when using these delicate wires occasionally to break the optical preference against wires touching and crossing to improve the ability and reliability of the wires to generate heat. Wire branching is another possibility that can be useful, particularly when the technique of creating wires allows arbitrary wire branching without significant extra manufacturing processes. It has already been described that semi-ellipse and quarter-ellipse shapes generate less optical distraction than other shapes and so these examples concentrate on the use of these shapes in wire intersections and branches. There is a closely related category where wires cross that differs from wire intersections only by there being no electrical connection at the crossing location.
[0053] Reasons to use branches, intersections and crossings on the wires include:
[0054] 1) The wires may contain manufacturing defects that break their electrical conductivity. Some intersections can be used to divert heating current around damaged wire filaments.
[0055] 2) Many heater areas are roughly rectangular and every wire is connected to both busbars (at opposite sides of the heater assembly), but some areas to be heated are not rectangular and constraining every wire to contact both busbars can result in unacceptably high or low densities of wires. In this scenario wire branching can be used. Branching may be used with wires where cross sectional areas are also carefully chosen for the different branches to optimise the uniformity of heating from the wires.
[0056] 3a) If obstructions to implementing a uniform heating pattern occur in a more central part of the screen, e.g. around a rain sensor or a camera.
[0057] 3b) Design restrictions may force a busbar to be partitioned around some obstruction into two busbars maintained at near equal electrical potentials by the external electrical power supplies. Wires then have to be adjusted in position and perhaps cross sectional area around this obstruction. Branches and intersections can both be useful techniques. The techniques used are likely to vary with the heating power required around the obstacle. If the busbar is divided then careful control of the voltages on the divided parts will be required if wires branch or intersect in such a way that unexpected heating could occur due to current flow in wires between separated lengths of the partitioned busbar.
[0058] 4) A windscreen may be divided into different independent heater regions. These heater regions may overlap. They may also involve wires with axes oriented in different directions. For example a windscreen may have a windscreen wiper rest area heater, comprising horizontally aligned wires, that physically overlaps but is electrically separate from a driver vision area heater, comprising wires oriented between the top and bottom of the screen. In these cases heater wires are highly likely to cross.
[0059] Sections of ellipse perimeter can be used in the following ways:
[0060] 1) Crossovers and interconnections can be formed by selecting sizes of semi-ellipse or quarter-ellipse that cause neighbouring wires to cross with an adjacent filament twice, as shown in FIG. 7 . An aim in selecting the sizes of the semi-ellipses is that the crossover intersections are substantially perpendicular to each other. This is advantageous because two wires in close proximity and almost parallel can look like a defect when wires are viewed in daylight.
[0061] 2) Crossovers and interconnections can be formed by selecting sizes of semi-ellipse or quarter-ellipse that cause neighbouring wires to cross such that a filament extends from one axis to another axis via a single crossing point, as shown in FIG. 8 . An axis is a straight line joining a filament end at a first busbar with a nearest filament end at a second busbar.
[0062] 3) Branches can be created with sections of ellipse perimeter where the branch is in a T-shape, as shown in FIG. 6 . A branch filament substantially perpendicular to a parent filament is advantageous for avoiding close spaced parallel lines, as explained above in relation to FIG. 7 .
|
A glazing comprising a transparent substrate, a plurality of electrically conductive filaments extending over the transparent substrate, wherein the filaments are shaped into a sequence of portions of the perimeters of ellipses, wherein ellipse axial ratios of the ellipses are in the range 1.1 to 4.0 and are selected so that from a pre-defined viewing position and in corresponding pre-defined viewing directions the ellipses in the plane of substrate are viewed as circles. In a preferred embodiment, major axis angles are selected so that from a pre-defined viewing position and in corresponding pre-defined viewing directions the ellipses in the plane of substrate are viewed as circles. In an example of a heated vehicle window, diffraction patterns caused by oncoming headlights interacting with heating filaments of a vehicle window are thereby minimised.
| 7
|
PRIORITY
This application is a continuation-in-part of U.S. patent application Ser. No. 13/683,844 filed on Nov. 21, 2012, entitled KEYSEAT WIPER, which claims the benefit of United States Provisional Patent Application No. 61/562,272 filed on Nov. 21, 2011, entitled KEYSEAT WIPER, the disclosures of which are incorporated herein by reference in their entireties. This application also claims benefit of U.S. Provisional Patent Application No. 61/565,732 filed on Dec. 1, 2011, entitled BALL AND SOCKET ROLLER REAMER, the disclosure of which is also incorporated herein by reference in its entirety.
FIELD
This application relates generally to tools for drill strings and methods of making and using such tools. In particular, this application relates to ball and socket roller reamers and keyseat wipers for use with drill rods that are used in exploratory and production drilling, as well as methods for making and using such ball and socket roller reamers and keyseat wipers.
BACKGROUND
In a conventional process used in drilling, an open-faced drill bit is attached to a drill string, which is a series of connected drill rods and tools that are assembled section by section as the drill string moves deeper into a formation during a drilling operation. During drilling operations, the walls of the borehole sometimes become marred or deformed for a variety of reasons. For example, boreholes may develop doglegs, key seats, and ledges during normal drilling operations that tend to bind and damage drill strings and tools. For example, during drilling operations, the drill string sometimes deviates from directly vertical, making at slightly arced path through the formation being drilled. In such cases, withdrawing a drill string from the borehole can be problematic as the drill string can bind against the curved wall of the bore hole. In particular, the pipe connections of the drill string, being wider at the connections than the pipe lengths, tends to dig into the side wall of the borehole creating what is known as a keyseat.
Attempts to work the drill string loose can case the borehole to deform and even collapse, causing additional problems with the drilling. In extreme circumstances, portions of the drill string may be damaged or destroyed while being withdrawn from the borehole. Reamers and keyseat wipers have been used to maintain the condition of the sidewalls of boreholes and to stabilize the drill string in the borehole during drilling operations. Reamers generally use replaceable blocks and rollers in three or four locations around the reamer tool, as the blocks and rollers tend to become worn during drilling operations. Replacing blocks and rollers in reamer tools can be very difficult and time consuming as the blocks are generally pounded into place in slots in the tool and held from sliding by a bolt or pin. Additionally, traditional roller reamers include a shaft passing through the center of the reamer cutter around which the reamer cutter rotates. The creates the necessity of securing the shaft securely at both ends, necessitating the blocks that are pounded into place.
SUMMARY
Embodiments of roller reamer and keyseat wiper tools for use in drilling processes, as well as methods for making and using such tools, are described herein. Exemplary tools for placement in a drill string may include a body; a plurality of reamer cutters; and a plurality of ball and socket connectors configured to attach the plurality of reamer cutters to the body, wherein the plurality of ball and socket joints are configured to permit rotation of each of the plurality of reamer cutters.
Each of the plurality of reamer cutters may be replaceable by removing at least one of the plurality of ball and socket connectors from the reamer body. Each of the ball and socket connectors may be attached to the reamer body with bolts. Each of the ball and socket connectors may include titanium dioxide and/or titanium carbide coatings where the connectors interface with the reamer cutters.
In some embodiments, tools may include a first tapered section tapering from a first diameter to a second larger diameter; a wiper section having the second larger diameter; a second tapered section tapering from the second larger diameter to the first diameter; and a reduced section in the wiper section, the reduced section having a diameter smaller than the second larger diameter. The wiper section may include reamers cutters.
In other embodiments, the first tapered section and the second tapered section may each include flutes, the flutes of the first tapered section being rotationally offset from the flutes of the second tapered section. In other embodiments, the tool may further include at least one outside reduced section located adjacent to the first diameter of the first tapered section. In some embodiments, exemplary tools can include changing cross-sections and a relief sections that permit cut materials to pass by the tool, reducing the possibility of a drill string with the tool in place from binding in a curved hole when being retrieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description can be better understood in light of Figures, in which:
FIG. 1 illustrates an exemplary, side view of a roller reamer tool;
FIG. 2 illustrates a cross-sectional view of a section of the roller reamer tool of FIG. 1 taken along section line 2 - 2 ;
FIG. 3 illustrates a cross-sectional view of a section of the roller reamer tool of FIG. 1 taken along section line 3 - 3 ;
FIG. 4 illustrates a further detailed cross-sectional view of the roller reamer tool of FIG. 1 , including a detailed look at an exemplary ball and socket joint;
FIG. 5 illustrates a partial cross-sectional view of an exemplary roller reamer tool;
FIG. 6 illustrates a partial cross-sectional view of an exemplary ball and socket joint for an exemplary roller reamer or roller reamer and keyseat wiper tool;
FIG. 7 illustrates a side view of an exemplary roller reamer and keyseat wiper tool;
FIG. 8 a illustrates a cross-sectional view of the roller reamer and keyseat wiper tool of FIG. 7 taken along section line a-a;
FIG. 8 b illustrates a cross-sectional view of the roller reamer and keyseat wiper tool of FIG. 7 taken along section line b-b;
FIG. 8 c illustrates a cross-sectional view of the roller reamer and keyseat wiper tool of FIG. 7 taken along section line c-c;
FIG. 8 d illustrates a cross-sectional view of the roller reamer and keyseat wiper tool of FIG. 7 taken along section line d-d;
FIG. 8 e illustrates a cross-sectional view of the roller reamer and keyseat wiper tool of FIG. 7 taken along section line e-e;
FIG. 8 f illustrates a cross-sectional view of the roller reamer and keyseat wiper tool of FIG. 7 taken along section line f-f.
Together with the following description, the Figures demonstrate and explain the principles of the roller reamer and keyseat wiper tools and methods for using such tools. In the Figures, the thickness and configuration of components may be exaggerated for clarity. The same reference numerals in different Figures represent the same component.
DETAILED DESCRIPTION
The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus and associated methods of using the apparatus can be implemented and used without employing these specific details. Indeed, the apparatus and associated methods can be placed into practice by modifying the illustrated apparatus and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry. For example, while the description below includes examples of rotary drilling, the apparatus and associated methods could be equally applied in other drilling process, such as core drilling, percussive drilling, and exploratory drilling, as well as other drilling procedures and systems. Indeed, the apparatus and associated methods could be used in any type of drilling process where a drill string may alter to a curved or arced borehole. And the term “drill rod” will be taken to include all forms of elongate members used in the drilling, installation and maintenance of bore holes and wells in the ground and will include rods, pipes, tubes and casings which are provided in lengths and are interconnected to be used in a borehole.
The drill string reamer and keyseat wiper tools described in this application can have any configuration consistent with their operation described herein. Reamer and keyseat wiper tools may be designed such that cutters clear passageways for a drill string to be withdrawn from an arced borehole without binding in the borehole. Reamer tools may include a body and cutters connected to the body with connectors.
One exemplary configuration of a reamer tool 100 is illustrated in FIGS. 1-4 . The reamer tool 100 may a roller reamer and be designed such that the reamer cutters 120 clear passageways for a drill string to be withdrawn from an arced borehole without binding in the borehole. Roller reamer tools 100 may include reamer body 110 and reamer cutters 120 connected to reamer body 110 with ball and socket connectors 130 .
The roller reamer tool 100 may be included in a drill string 10 to maintain a desired borehole dimension. The reamer cutters 120 may be able to cut away excess portions of a borehole wall to provide the desired dimension. The reamer cutters 120 may be able to rotate with respect to the reamer body 110 such that when the roller reamer tool 100 is being used, the reamer cutters 120 may press against the borehole walls and rotate as the entire drill string is rotated as part of the drilling process. As such, the cutting inserts 122 may press and grind against the borehole wall while the cutters 120 are able to rotate freely to facilitate the rotating drill string 10 within a borehole.
In some embodiments, the reamer body 110 may include fluted sections 118 to allow cut material from the borehole and cutting fluid to pass by the outside of the roller reamer tool even when engaged with the borehole walls. The reamer body 110 may have an outside diameter slightly smaller than the desired diameter of the borehole, and larger than couplings in the drill string 10 , such that the roller reamer tool 100 fits easily within to borehole while providing borehole dimension maintenance for the drill string 10 . Reamer body 110 may also include center passageway 150 for the passage of drilling fluid 20 down to the cutting head of the drill string 10 . Reamer body 110 may be formed of any suitable material used in the industry and/or coated with any coating used in the industry for durability, hardness, lubrication, etc.
As best shown in FIG. 2 , reamer cutters 120 may be included at spaced intervals around the roller reamer tool 100 . In the illustrated embodiments, three reamer cutters 120 are shown spaced evenly around the roller reamer tool 100 . However, in other embodiments, two, four, or more reamer cutters 120 may be included on the periphery of the roller reamer tool 100 . Reamer cutters 120 are able to rotate about a central axis such that when the drill string 10 rotates in the borehole, the roller reamer tool 100 is able to rotate within the borehole and the reamer cutters 120 engage with the borehole walls with minimal rotational friction.
The rotational axis of each of the reamer cutters 120 may be such that only a small arc of the reamer cutter 120 extends beyond the outer diameter of the reamer body 110 . Reamer cutters 120 may be any style of conventional reamer cutters with cutting flutes, cutting inserts 122 , as shown in the figures, or other configurations. For example, the reamer cutters 120 are shown having a step with two different outer diameters in different sections of the reamer cutters, but reamer cutters may have an unstepped outer diameter (such as the reamer cutter 220 shown in FIG. 5 ), a lenticular shape, or a sloped or conical shape providing different outer diameters and different positions along the reamer cutter.
The cutting inserts 122 may be any shape or size used in the industry and may be formed of any appropriate material. The cutting inserts 122 may be formed of a hard material, such as tungsten carbide or tool steel, to reduce wear as the reamer cutters press against the interior of a borehole. The cutting inserts 122 may further provide additional tool life to the other components of the reamer cutter 100 by taking the brunt of the impact and wear as the reamer cutter tool 100 is used. Similarly, the cutting inserts 122 , the reamer cutters 120 , and other various surfaces of the reamer cutters 120 and reamer body 110 may include an additional abrasive coating, or may be formed from a material for cutting (such as cut-rite) for assisting in cutting the materials away from the borehole wall where appropriate and to improve tool life.
As shown in FIGS. 3 and 4 , the reamer cutters 120 may be attached to the reamer body 110 with ball and socket connectors 130 , which may be easily removed to replace worn or broken parts of the roller reamer 100 . Replacing blocks and rollers in traditional reamer tools can be very difficult and time consuming as the blocks are generally pounded into place in slots in the tool and held from sliding by a bolt or pin. Additionally, traditional roller reamers include a shaft passing through the center of the reamer cutter around which the reamer cutter rotates. This can create the necessity of securing the shaft securely at both ends, requiring the blocks to be pounded into place, which makes them difficult to pound out of place.
The ball and socket connectors 130 of the exemplary embodiments may eliminate the need for a shaft passing through the center of the reamer cutters 120 and facilitate changing worn components. The socket connectors 130 may be held in place in the reamer body 110 with bolts 132 to provide an easy way to remove worn components. Bolts 132 may be standard hardened machine bolts of an appropriate size (for example, #6, #8, etc.) and may be additionally secured with lock pins 133 to keep them from loosening during drilling operations. Because an operator only needs to remove a few bolts to change reamer cutter 120 , repairing roller reamer 110 and replacing reamer cutters 120 is significantly easier than with traditional blocks and reamer cutters with a center shaft.
The socket connectors 130 may include a ball end 136 that interfaces with corresponding sockets 124 of the reamer cutters 120 . As such, the reamer cutters 120 may be solid with pockets (sockets) 124 formed at each end to interface with the ball end 136 of the connectors 130 . In some embodiments, the reamer cutters 120 may by cylindrical with a channel extending through the center that can also accommodate and interface with the ball ends 136 . The mating surfaces of ball end 136 and socket 124 may be coated with titanium dioxide or titanium carbide, or some other hard coating, to reduce wear as reamer cutters 120 rotate. Additionally, in some embodiments, the socket connectors 130 may include fluid channels 134 from the center passageway 150 to allow drilling fluid 20 to lubricate the mating surfaces to extend the tool life.
Turning now to FIG. 5 , other embodiments of a reamer cutter 220 may include sockets 224 and ball ends 236 in socket connectors 230 similar to the sockets 124 and the socket connectors 130 of the embodiments illustrated in FIGS. 1-4 and discussed above. The reamer cutter 220 may generally have a single outer diameter instead of a stepped outer diameter as illustrated with respect to the reamer cutter 120 . Additionally, the bolts 232 securing the socket connectors 230 to the reamer body 110 may be held in place using lock rings 233 instead of pins. The lock rings 233 may be held in a groove within the bolt holes 238 in the socket connectors 230 to prevent the bolts 232 from loosening due to vibrations during drilling operations.
FIG. 6 , illustrates other embodiments of a socket connector 430 , including a removable ball end 450 with ball 456 . Because the ball 456 experiences wear and friction against the pocket of the reamer cutter, the ball 456 will generally become worn long before the rest of the socket connector 430 . The ball end 450 may be removably coupled to the socket connector 430 by a threaded connection 452 to allow worn ball ends 450 to be replaced without having to replace the entire socket connector. The ball end 450 may be secured with a pin 458 to prevent vibrational loosening of the threaded connection 452 when in use. The pin 458 may be prevented from sliding out by the adjacent walls of the reamer body 110 when the socket connector is in place.
Similarly to the embodiments shown in FIG. 5 , the bolts 432 holding the socket connector 430 may be secured using lock rings 433 engaged in grooves 439 of the bolt holes 438 in the socket connector 430 . Thus, in order to replace a worn ball end 450 , the lock rings 433 may be removed, followed by the bolts 432 , which then allows the socket connector 430 to be pulled out of the reamer body along with reamer cutter. Once out of the reamer body, the pin 458 securing the threaded connection 452 between the ball end 450 and the socket connector 430 may be removed and the ball end 450 may then be unscrewed from the socket connector 430 and replaced, potentially saving money over replacing the entire socket connector.
In other embodiments, one end of the reamer cutter may be held with a socket connector that is pinned to the reamer body instead of the bolted down, which may allow the reamer cutter and the socket connector attached to the other end of the reamer cutter to rotate away from the reamer body. The socket connector and reamer cutter may then rotate about the pin holding the pinned socket connector when the bolts holding the second socket connector are removed. In such a configuration, the effort required to change reamer cutters may be even less than with both socket connectors 130 bolted to the reamer body 110 . Similarly, in some embodiments, the ball end may be on the reamer cutter and the socket may be on the socket connector instead of the ball end being on the socket connector and the socket being on the reamer cutter.
Turning now to FIG. 7 , reamer cutters 520 may be incorporated into a keyseat wiper tool 500 . Reamer cutters 520 may include any of the features described above with respect to the reamer cutters and socket connectors discussed above. Keyseat wiper tool 500 may include different cross sectional configurations to cut and create passageways for a drill string to be withdrawn from an arced borehole, thereby removing keyseats which may be formed in the borehole during drilling operations. Some prior art has provided keyseat reamers that encourage the drill string to exit the borehole without binding against the inner walls by cutting the keyseat to the width of the pipe connections. U.S. Pat. No. 4,330,043 includes a detailed description of the problem caused by keyseat formation and proposes a solution. However, the solution of the '043 patent suffers from cut materials collecting in the flutes and binding the tool in the borehole as the excess cut materials have no way of passing by the keyseat wiper or being removed. To solve this problem, relief sections 560 , 570 , may be provided in some embodiments with a narrower cross-sectional thickness to permit material cut by the keyseat wiper tool to aggregate and then fall past the relief sections down the borehole, solving the problems of conventional keyseat wipers.
Additionally, different cutting sections may be provided to facilitate removing keyseats. FIGS. 8 a -8 f illustrate various cross sections which may be provided in the keyseat wiper tool 500 . FIG. 8 a corresponds to cross-section a-a, FIG. 8 b to cross-section b-b, and so forth to FIG. 8 f , which corresponds to cross-section f-f. It should be understood that the different cross sectional views may transition into each other. As can be seen, different ends of the cutting section between sections a-a and f-f may be generally symmetric, but at a different rotational position such that the flutes 590 may not align linearly with each other from section to section. For example, cross-section a-a may be similar to f-f, and cross-section b-b may be similar to cross section e-e, and cross-section c-c may be similar to cross-section d-d, except that the corresponding sections may be rotated. For example, as shown in the figures, the features of cross-section c-c may be rotationally different from the features of cross-section d-d by about 45 degrees. The rotated features allow cut materials to pass to the bottom of the borehole while providing a more consistent overall diameter to reduce potential binding should the cutting flutes attempt to cut too much material. In some embodiments, the different ends of the cutting section between sections a-a and f-f may vary, depending on the desired use, soil type, and drilling configuration. As such, the cutting tapers and profiles of the various sections may be provided as desired for particular conditions.
The transition section 505 between cross-sections a-a and b-b, and the transition section 515 between cross-section f-f and e-e, may be tapered to provide a sloped engagement to reduce the amount of cutting that any given section of the keyseat wiper tool 500 may perform. The taper, along with the rotational offset as described, may help force the drill string into the correct alignment with the borehole in harder substrate materials, reducing the amount of time and energy required to withdraw the drill string from the borehole. Thus, transition portions 525 and 535 with cross-sections c-c and d-d, respectively, have a larger diameter than cross-sections b-b and f-f.
As shown in the Figures, the tapered sections between cross-section a-a and b-b and between cross-sections f-f and e-e may include multiple cutting teeth 580 separated by flutes 585 to remove materials from the sidewall. Similarly, cross-sections c-c and d-d may include flutes 590 to permit cut material to move along the keyseat wiper tool 500 . Because of the rotated features, the flutes 590 of cross-sections c-c and d-d may be deeper since an extended portion of cross-sections c-c or d-d and the reamer cutters 520 would always be in contact with the side wall of the borehole.
The diameter of cross-sections d-d and c-c may be about the same or slightly smaller than as the desired diameter of the borehole. When the diameter of cross sections d-d and c-c are about the same as the diameter of the borehole, the keyseat wiper tool may serve to effectively guide the drill string out of the borehole without unnecessary cutting by the keyseat wiper or reamer cutters 520 . In some embodiments, keyseat wiper tools may be provided without reamer cutters.
Reduced portions 570 may be provided on one or both ends of the tool outside of the tapered section between cross-sections a-a and f-f. The reduced portions 570 may help cut materials to pass by the keyseat wiper tool 500 . Similarly, between cross-sections d-d and c-c, a reduced section 560 may be included to allow cut materials collecting in the flutes 590 of cross sections d-d and c-c to loosen and pass along the tool, thus overcoming the problems of compacted cut materials that tend to bind prior reamers and keyseat wipers.
Similar to the reamer tools described above, the various surfaces of the different features of the illustrated cross-sections may include an abrasive coating, or may be formed from a material for cutting (such as cut-rite) for assisting in cutting the materials away from the keyseat wiper tool 500 .
In addition to any previously indicated modification, numerous other variations and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of this description, and any claims are intended to cover such modifications and arrangements. Thus, while the information has been described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred aspects, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, form, function, manner of operation and use may be made without departing from the principles and concepts set forth herein. Also, as used herein, examples are meant to be illustrative only and should not be construed to be limiting in any manner.
|
Exemplary drill tools for placement in a drill string may include a body; a plurality of reamer cutters; and a plurality of ball and socket connectors configured to attach the plurality of reamer cutters to the body. Each of the plurality of reamer cutters may be replaceable by removing at least one of the plurality of ball and socket connectors from the reamer body. Each of the ball and socket connectors may be attached to the reamer body with bolts. Each of the ball and socket connectors may include titanium dioxide and/or titanium carbide coatings where the connectors interface with the reamer cutters.
| 4
|
CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON COMPACT DISC, OR AS TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)
Not Applicable.
STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR
Not Applicable.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to a household appliance according to the preamble of claim 1 .
(2) Description of Related Art Including Information Disclosed Under 37 C.F.R. 1.97 and 1.98
Dishwashers with drying air circuits are known in the prior art for example from WO 2005/053503 A1. Into said drying air circuits there is incorporated a closed system composed of an ice water vessel and of a storage vessel which is connected to the ice water vessel via a line and which contains zeolite. Here, the drying air is dehumidified by condensation on the outer wall of the ice water vessel and is heated on the outer wall of the storage vessel by means of zeolite.
Household appliances are also known, from DE 10 2010 047 058 A1, which have a drying system for wet articles, having a primary circuit for extracting moisture from drying air and having a secondary circuit for drying wet articles by means of drying air. The circuits contain, on the one hand, a single-phase liquid circuit, composed of at least 2 components, of a liquid refrigerant and fully dissolved solid matter, generally fully dissociating salts, the primary circuit, and on the other hand, a substantially single-phase gas/vapor circuit, the secondary circuit. The operating direction of the primary and secondary circuits, as a function of the selected process temperatures and media states, constitutes in each case one section of a thermodynamic two-substance absorption circuit which is operated in a divided manner. One operating direction realizes the absorption phase of the cycle, the other operating direction describes the desorption or expulsion phase of the cycle. In the absorption phase, the two-component solution is enriched with the component which functions as refrigerant, and in the desorption or expulsion phase, the two-component solution which is present is freed from parts of the refrigerant valve.
The two circuits, the primary and the secondary circuit, comprise a dedicated on-site actuator by means of which the mass conversions in the circuits are maintained and assisted in a common reaction chamber for performing the extraction of moisture by hygroscopic action of the extraction medium. Said reaction chamber constitutes the residence and mass transfer zone of the gas/vapor flow of the secondary circuit and of the single-phase flow of the primary circuit for the thermodynamic drying circuit, and determines, by its absorption efficiency, the efficiency of the drying action. The provision of an adequately large reaction surface for the no longer positively guided single-phase flow in the area of reaction with the gas/vapor flow thus takes up a large structural space and entails cumbersome and expensive structural measures to ensure that, in any orientation of the household appliance, even when not in operation during shipping and transportation, the liquid phase is contained exclusively in the primary circuit.
Furthermore, DE 10 2010 047 058 A1 discloses a household appliance, wherein for improved thermal and/or energy management the primary circuit comprises a hygroscopic extraction medium for the exothermic extraction of the moisture from the drying air, and wherein the heating device in the secondary circuit is designed to heat the drying air by means of the thermal energy released during the exothermic extraction of the moisture.
BRIEF SUMMARY OF THE INVENTION
Disadvantages of the prior art are however the relatively high outlay in terms of construction and energy and thus also the financial expenditure for producing and operating such household appliances.
It is an object of the present invention to propose a household appliance with a drying system which reduces the outlay in terms of construction and/or energy and thus also the financial expenditure for producing and/or for operating such household appliances.
The object is achieved, taking as a starting point a household appliance according to the preamble of claim 1 , by means of the characterizing features of claims 1 and/or 2 and/or 3 . Advantageous embodiments and refinements of the invention are possible by means of the measures specified in the dependent claims.
Accordingly, the dispersal element of the contact chamber has at least one drive for imparting drive and/or movement, such that for the surface area enlargement, the hygroscopic liquid can be dispersed with kinetic drive energy. As an alternative to or in combination with this, according to the invention, the dispersal element is movable in the contact chamber and has at least one drive, such that a surface area enlargement of the hygroscopic liquid is provided by means of the transfer of kinetic drive energy by the movement of the dispersal element. Likewise as an alternative to or in combination with this, according to the invention, the dispersal element of the contact chamber is in the form of a dispersal nozzle and has at least one drive for driving and/or pressurizing the hygroscopic liquid, such that for surface area enlargement, the hygroscopic liquid can be dispersed with kinetic drive energy.
The common concept according to the invention is that of the hygroscopic liquid not flowing down passively or under the force of gravity, as in the prior art, but rather advantageously being actively acted on with kinetic energy such that it is dispersed or atomized/nebulized as advantageously as possible. That is to say, according to the invention, the greatest possible number of droplets, which are as small as possible, is generated so as to generate a particularly large overall contact surface of the hygroscopic liquid. Said relatively large contact surface of the hygroscopic liquid with the drying air to be dried permits particularly effective and also efficient drying. Above all, it is possible according to the invention to realize good drying results in a relatively short time, such that the convenience for the user of the household appliance is very high, and such that the drying can advantageously be integrated effectively into the program cycles of the household appliance.
It has furthermore been found, in initial tests, that the energy efficiency of the invention is particularly high in relation to the prior art.
It is basically possible for a separate drive to be provided for the dispersal element. In one particular refinement of the invention, a drive which is already provided for other purposes or functions within the household appliance is additionally used for driving the dispersal element.
It is particularly advantageous for the fan motor of the secondary circuit to be used as a drive of the dispersal element. With this advantageous double utilization of the fan motor or fan, it is possible for the outlay both in terms of construction and also in terms of control and also the costs for production and operation to be reduced.
It is advantageously provided that the contact chamber is in the form of an interior space of a fan housing of the fan, and/or that the dispersal element is in the form of a fan impeller of the fan. It is achieved in this way that not only the fan motor but also the main parts/components of the fan which is already provided are used for multiple purposes. This additionally reduces the outlay for the realization of the invention.
Furthermore, as a result of the additional or implemented double utilization of the fan wheel and/or of at least a part of the interior space of the fan housing, it is achieved that particularly advantageous swirling and mixing of the hygroscopic liquid with the drying air to be dried are realized. As a result of relatively high rotational speeds of the fan impeller/blade, intense turbulence and high accelerations of the hygroscopic liquid are attained. The hygroscopic liquid is dispersed into a multitude of relatively small droplets and centrifuged through and/or into the drying air. As a result of an impingement of the hygroscopic liquid against walls or components of the fan housing or against advantageous separation elements, it is possible for the hygroscopic liquid to furthermore be atomized/dispersed and for the contact surface to be correspondingly enlarged. Hygroscopic liquid running down on walls or components of the fan housing or on the separation elements also increases the contact surface of the hygroscopic liquid with the drying air, which has a positive effect on the drying action and the efficiency.
The drive is preferably in the form of a pump motor of a pump, in particular of a rotary pump, for pumping the hygroscopic liquid of the primary circuit. Said additional utilization or triple utilization of the drive of the dispersal element additionally reduces the outlay in terms of construction and control and also the financial expenditure.
The drive of the dispersal element is for example formed as a fan motor and furthermore as a pump motor. Accordingly, said common drive has not only the fan wheel but rather also a pump wheel for pumping the hygroscopic liquid. The fan impeller is furthermore in the form of a dispersal element according to the invention. In this way, not only is an advantageous multiple utilization of the relatively expensive (electric) motor realized, but rather a particularly high integration density of the components is also attained. This also leads to a particularly space-saving or compact design, such that the integration of the drying system into a household appliance is possible in a particularly effective manner.
In one advantageous variant of the invention, the pump comprises at least one hollow truncated cone, which widens in the direction of the dispersal element, as pump impeller and/or feed element for feeding the hygroscopic liquid to the dispersal element. Here, the hollow truncated cone forms the rotor or pump impeller of the pump. As a result of the conical form of the rotor which widens in the direction of the dispersal element/fan impeller, it is achieved that the hygroscopic liquid is delivered or moves along the wall under centrifugal force not only outward but rather also in the axial direction and/or upward. Here, the hygroscopic liquid may be transported or delivered axially both on the outer wall and also on the inner wall of the rotor or hollow truncated cone. The pump preferably sucks the hygroscopic liquid out of a reservoir and forces it toward the dispersal element or fan impeller.
For an improved pumping action, it is advantageous for rotor blades or fins or the like to be provided which are arranged at least partially in the radial direction. The rotary drive of the hygroscopic liquid, which is stored in particular in a reservoir, is improved in this way, such that higher centrifugal or pumping forces are realized. The pumping action is hereby improved.
The fan impeller including fan blades is preferably formed as a single-piece structural unit together with the pump impeller including pump impeller blades/fins. This may be produced for example from plastic in a relatively effective and expedient manner for example by means of injection molding.
In one advantageous embodiment, at least one separation unit for separating the hygroscopic liquid from the drying air is arranged downstream of the dispersal element in the flow direction of the drying air. The fan housing preferably at least partially encompasses the separation unit. At least a part of the walls of the fan housing is for example formed as a separation unit or separation element. Separate or further separation elements are provided if appropriate. These may advantageously be adapted for the separation of the hygroscopic liquid from the drying air. A surface area enlargement of the separation unit is for example provided, such that the dispersed or atomized hygroscopic liquid can adhere thereto and is separated from the drying air.
The separation unit advantageously comprises at least one annular or spiral duct. Said duct is preferably integrated in the fan housing and/or forms the pressure side of a rotary and/or radial fan.
If appropriate, a separation device may be provided which is separate from and/or additional to the fan. Said separation device may for example comprise a labyrinth seal or the like. Particularly efficient division or separation of the hygroscopic liquid from the drying air can be realized by means of the separation device. It is hereby achieved that as little hygroscopic liquid as possible or no hygroscopic liquid passes into the region of the articles, such as crockery or laundry, to be dried, which would lead to an escape of the hygroscopic liquid from the household appliance. If an escape of the hygroscopic liquid from the household appliance were to occur, said hygroscopic liquid would have to be correspondingly replenished or compensated again.
A reservoir of the hygroscopic liquid preferably comprises a heating unit for heating the hygroscopic liquid. A concentration or regeneration of the hygroscopic liquid after the absorption of water from the drying air to be dried is thus realized. It would also by all means be possible to provide some other regeneration of the hygroscopic liquid, such as for example by means of a centrifuge and/or a semipermeable membrane for separating off the absorbed water.
The household appliances in question may basically be inter alia dishwashers, tumble dryers or for example also combined washing and drying machines, so-called washer-dryers, or fully automatic washing machines. Consideration may however also be given to other household appliances which can implement such drying processes. In the case of washer-dryers or combined washing and drying machines, the wet articles are generally items of laundry or clothing, and in the case of dishwashers, the wet articles are correspondingly generally plates, pots, pans, cutlery or other crockery. A use in beverage machines is also conceivable.
Drying air within the meaning of the invention is a gas, in particular air, which is utilized for drying the wet articles and which accordingly absorbs moisture during the drying process. The drying air is thus generally relatively dry before the drying process, and relatively moist thereafter.
The extraction medium or the hygroscopic liquid within the context of the invention serves for extracting moisture from the drying air and thus dries the drying air.
The primary circuit is advantageously designed for extracting moisture from drying air. The drying air itself advantageously circulates in a secondary circuit. Preferably wet articles in the household appliance are dried by means of the drying air. In the case of a dishwasher, the wet articles are for example crockery to be cleaned in the dishwasher, which crockery, after the end of the cleaning program, is dried according to the invention in order that the user can remove dry crockery from the household appliance and either immediately use it or store it for example in a cupboard. Here, the drying air is for example conducted or actively blown to the wet articles, absorbs the moisture from said articles there, and can/should subsequently be regenerated to a certain extent such that it can be used again for drying.
For the regeneration of the drying air, the moisture is for example extracted therefrom. Furthermore, the drying air may also (subsequently) be heated again, because heated air can generally absorb more moisture. Said heating step may for example take place before the drying air is blown to the corresponding wet articles by means of the fan. For this purpose, the secondary circuit comprises a heating device for heating the drying air.
In the primary circuit, a hygroscopic extraction medium or the hygroscopic liquid is stored in a reservoir. A substance is hygroscopic if it can absorb moisture from the environment, for example from the air surrounding it. Said extraction of the moisture from the environment may be an exothermic process, that is to say one in which thermal energy is released. In thermodynamics, exothermic processes are processes in which there is a negative (by definition) reaction enthalpy of reaction ΔH=ΔU+W<0, wherein ΔH is the enthalpy of reaction, ΔU is the internal energy stored in the corresponding participating substances and W is the work done during the process. Here, according to the invention, the drying air must come into direct contact with the hygroscopic extraction medium.
A particular advantage of the household appliance according to the invention is that the thermal energy released during the exothermic extraction of the moisture is put to further use, thus permitting greater heat utilization. The heating device for heating the drying air is designed to utilize said released heat.
In order that the drying air can come into direct contact with the extraction medium, it may be advantageous for the primary and secondary circuits to have a common flow section, that is to say to be directly coupled to one another.
Various substances may be taken into consideration as extraction medium. In particular, for exemplary embodiments of the invention, consideration is given to a range of electrolyte solutions, that is to say generally solutions which have hygroscopic properties, with dissociated ions, for example a salt. Among others, an aqueous lithium chloride solution, for example, may be used as extraction medium.
It is however basically also conceivable for other aqueous solutions, in particular aqueous salt solutions, to be used. Another possibility consists for example in using an alcohol solution, in particular a methanol solution. The selection of the extraction medium may for example be dependent on parameters of the household appliance and/or on what demands are to be placed on the corresponding drying process. For example, the selection of the boiling point of the solution, the intensity of the hygroscopicity, the question of whether the extraction medium is admissible for the corresponding application for example from a health aspect, etc., could be of relevance in this regard.
If the extraction medium has come into contact with moist drying air, that is to say if moisture has correspondingly been transferred from the drying agent to the extraction medium, said extraction medium may also advantageously be re-concentrated in order that it can continue to be used for removal of moisture from the drying air. The primary circuit may thus comprise a device for increasing the concentration of the extraction medium or of the hygroscopic liquid.
Said device for increasing the concentration of the extraction medium may for example be in the form of a heater. As a result of the corresponding heating, liquid originating inter alia from the wet articles can then be evaporated from the extraction medium, as a result of which the concentration of the extraction medium can be increased again. It is basically possible for this purpose to use a dedicated heating device within the household appliance.
It is however furthermore possible to utilize the fact that other components in the household appliance already become warm or must be warmed in any case. For example, the device for increasing the concentration of the extraction medium may advantageously be coupled to the heating device of the household appliance. This may have the advantage that otherwise unutilized waste heat is utilized here for the functioning of the household appliance, and thus has a positive effect on efficiency and on heat utilization in particular with regard to the household appliance as a whole.
It is basically also possible to utilize the device for increasing the concentration to dissipate heat from other components, and thus to a certain extent provide cooling for said components. It is thus advantageously possible, if appropriate, to dispense with hitherto conventional heating and/or cooling devices.
It is furthermore conceivable for other devices or methods to also be used in accordance with the invention, in particular for increasing the concentration of the extraction medium, such as for example centrifuges, evaporation with negative pressure, etc.
In the case of intense concentration of the electrolyte solution or of the hygroscopic liquid, it is then possible if appropriate to realize a formation of salt crystals. This may for example be utilized for an advantageous latent heat accumulator, which likewise serves to realize increased heat utilization.
Greater heat utilization and/or improved efficiency can not only contribute to a household appliance and/or a drying process according to the invention and/or embodiments and refinements thereof being made more environmentally friendly and more ecological, but rather can also contribute to a cost reduction during operation of the machine.
If liquid has advantageously been evaporated out of the extraction medium inter alia by means of the heating device, said evaporated liquid can be placed or conducted into an advantageous condensation unit and condensed there. The liquid may then for example be collected or if appropriate conducted directly to the outlet from the household appliance. A decrease in the concentration of the extraction medium can thus be prevented.
Condensation heat is basically released during the condensation process. Said condensation heat, too, may be advantageously utilized within the operation of the household appliance. It is for example possible for corresponding heat exchangers or the like to be provided for this purpose. For example, said heat may be utilized in conjunction with a liquor and/or crockery heating device. In this way, too, it is possible to realize increased heat utilization and improved efficiency of the appliance.
In one advantageous refinement of the invention, the absorption capability of the extraction medium may be increased for example by virtue of its surface area being increased or enlarged, and thus also a larger reaction surface being provided. In the case of a liquid extraction medium, the primary circuit may have provided therein for example a trickling device, a nebulizing unit or the like out of which the extraction medium can trickle, for example in the direction of gravitational force, or nebulized.
It is basically also conceivable, for example, for the extraction medium to be sprayed out of an (atomizer) nozzle, similar to a fountain or the like, by means of the drive according to the invention in order thereby to provide a larger surface area. The nozzle, too, may be designed such that it can be moved by means of the drive according to the invention in order to realize improved dispersal in the contact chamber. The effectiveness of the moisture extraction can thus be increased further.
In order that the drying air in the secondary circuit can circulate in an advantageous manner, in one particular refinement of the invention, a fan or the like may be provided. In this way, the drying process of the wet articles can be accelerated further. In order that the liquid extraction medium in the primary circuit can circulate in an advantageous manner, a pump, for example a rotary pump, may be provided here. Pumps of advantageous size/power are already commercially available and may generally be purchased and installed without excessively high expenditure.
The wet articles in the household appliance are generally accommodated in a working or loading chamber, for example in a working chamber with corresponding crockery baskets in the case of a dishwasher, and generally in a corresponding storage drum in a washing and drying machine. In order that the wet articles can be dried in an advantageous manner, the working chamber may be integrated within the secondary circuit, and advantageously traversed by the flow of drying air.
The drying air which is laden with moisture may subsequently, after drying the wet articles, be sucked out again, for example by means of the fan, owing to the secondary circuit, such that said drying air does not, in a reverse process, wet the crockery again. The moist drying air is thereafter advantageously regenerated as described above and passes for example back into the working chamber, where it can dry the already partially dried articles yet further, etc. The moist drying air may also if appropriate be conveyed out of the household appliance rather than back into the working chamber.
In order that the drying air in the secondary circuit can absorb yet more moisture, it is advantageous for said drying agent to undergo prior heating. It may be particularly advantageous for the corresponding heating device to be arranged in the secondary circuit within the common flow section or in the contact chamber, and/or between the common flow section and the working chamber, such that the drying air comes into contact with the articles to be dried as soon as possible after said drying air is heated.
A household appliance according to the invention having a primary circuit of a liquid, hygroscopic extraction medium for extracting moisture from drying air and having a secondary circuit of drying air for drying wet articles by means of the drying air is preferably characterized in that the material flows of the primary and secondary circuits are driven by a common actuator.
In the household appliances in question, to improve the drying processes, in each case one primary circuit and one secondary circuit are provided which transport in each case one material mass flow in a closed circuit. For said material transport, drives are required which generate pressure differences in order to effect flows of the respective phases in the circuits.
An advantage of the drying process according to the invention and of the household appliance according to the invention is that the material flows are realized in particular by means of only one actively operated component, and the required common reaction chamber is reduced in size through improved and more intensive dispersal of the phase flows, and can thus be realized at lower cost.
Since the primary and secondary circuits must be merged in a reaction chamber in order to perform absorption and desorption/expulsion, it is the object of the reaction chamber to provide a sufficient dispersal surface area for the interaction processes of a liquid flow and of a gaseous flow. In other words, good Nusselt numbers (heat transfer) and Reynolds numbers (flow/turbulence characteristics) must be realized in order to attain high efficiency of said process.
The secondary circuit is a material flow of moist or dry air which originates from the drying or condensation chamber of the household appliance mentioned in the introduction and which is linked to the subject matter according to the invention.
The subject matter according to the invention furthermore encompasses devices which ensure that liquid constituents of the primary circuit do not pass into the drying chamber or condensation chamber of the household appliance both in the use position of the household appliance and in the non-use position during packaging and shipping.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Exemplary embodiments of the invention are illustrated in the drawing and will be explained in more detail below, with further details and advantages being specified. In detail:
FIG. 1 is a schematic illustration of the primary and secondary circuits in a household appliance having a dispersal element, in the form of a rotor, according to the invention,
FIG. 2 is a schematic perspective illustration of a compact structural unit having a drive according to the invention,
FIG. 3 is a schematic side-on illustration of the compact structural unit as per FIG. 2 ,
FIG. 4 is a schematic sectional illustration in the region of a fan impeller in a plan view of the compact structural unit as per FIG. 2 , and
FIG. 5 is a schematic, sectional illustration in the region of the drive axis of the fan impeller in a cross-sectional view of the compact structural unit as per FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
A block circuit diagram of a dishwasher with a drying system is illustrated schematically in FIG. 1 . Said drying system comprises a secondary circuit 2 , wherein drying air flows out of a working chamber 11 via an inlet 22 to a fan impeller 9 and flows out of a fan housing 14 again in the direction of the working chamber 11 via an outlet 23 . Also provided is a primary circuit 1 having a hygroscopic liquid 4 or lithium chloride solution 4 and also having a pump 6 . Said pump, by means of a pump impeller 8 or hollow cone wheel 8 , pumps the liquid 4 out of a vessel 3 or reservoir 3 to a dispersal element 9 .
Furthermore, the pump wheel 8 has radially aligned fins 25 which improve the pumping action. The liquid in the store 17 is hereby more intensely set in rotation, such that the pumping force owing to the centrifugal force is increased. The liquid adheres to the pump wheel 8 and is displaced outward in the radial direction and, owing to the conical or oblique shape of the pump impeller 8 , is correspondingly advantageously transported upward and to the dispersal element.
The dispersal element 9 is in the form of a fan impeller 9 and has an electric motor 12 as a drive. Accordingly, the fan impeller 9 rotates about a drive axis 20 of the motor 12 , such that the fan 10 or blower 10 can firstly circulate or transport the drying air of the secondary circuit 2 . Secondly, the fan impeller 9 , by means of its blades 13 , can advantageously disperse the liquid which is transported or pumped up to the fan impeller 9 by means of the hollow cone wheel 8 . This takes place in that the liquid is very finely dispersed or atomized owing to the centrifugal force acting on the liquid and owing to the turbulence of the drying air within a fan housing 14 . In this way, it is possible to generate a particularly large contact surface of the liquid with the drying air, such that the drying is realized particularly efficiently and relatively quickly.
The liquid adheres to the hollow cone wheel 8 and travels along the pump wheel 8 as far as a web 24 , at which the liquid detaches or is centrifuged radially outward and is already in part dispersed into droplets and additionally atomized or dispersed by the fan impeller 9 . Here, again owing to the turbulent flows in the fan housing, fine dispersal and mixing of the liquid in the drying air are generated, and the drying action is improved.
An annular duct or spiral duct 15 is formed such that the liquid which is centrifuged or accelerated/driven radially outward impinges on walls of the duct 15 and is in part yet more finely dispersed or atomized, the remaining part remaining adhered to and/or flowing down said walls. A liquid film generated here thus also contributes to the drying action as a result of its contact surface with the drying air, and at the same time a separation or division of the liquid from the drying air of the secondary circuit 2 is realized in this way. This is important in order to ensure that as far as possible no liquid escapes from the primary circuit 1 into the secondary circuit 2 .
A separate and/or further separation/division of liquid from the drying air may if appropriate take place downstream of the structural unit 5 and/or downstream of the annular duct 15 in order that the retention or recovery of the liquid for/in the primary circuit 1 is optimized or attained as completely as possible. It is for example possible for a labyrinth seal arrangement or the like to be used here.
As a result of the advantageous separation or division of the liquid from the drying air, a virtually closed liquid circuit is generated, such that no retroactive replenishment, or if appropriate only very infrequent replenishment, of the liquid in the primary circuit 1 is necessary. This improves the operation and reduces the outlay for maintenance and servicing during operation.
Furthermore, a regeneration or concentration of the hygroscopic liquid after the absorption of water from the moist drying air is advantageous. A heater 7 or a heating element/heating bar 16 is preferably provided. The heating bar 16 is arranged in the reservoir 17 of the structural unit 5 . In this way, the thinned liquid 4 can be regenerated or concentrated again for later/subsequent drying.
It is basically possible in a household appliance according to the preamble of claim 1 for the inlet water to be used for cooling the hygroscopic liquid 4 and/or the reservoir 17 . In general, a fluid distributing unit, a so-called diverter, may be provided for the distribution of service water for at least two or preferably three outlets or exits, said fluid distributing unit having a directing element or switch which rotates about an axis of rotation, for example as per document DE 10 2004 040 423. Here, in the washing/sump circuit of the machine, the third outlet may be used for energy management. The two other outlets have hitherto preferably been used for the two spray arms, and the third outlet may inter alia supply water or washing liquid to a consumer and/or to a latent heat accumulator or heat exchanger or the like, or incorporate these into an advantageous energy management system.
Entrances 18 and/or exits 19 of the store 17 are advantageously arranged such that, in the operating position of the structural unit 5 or of the store 17 , the exit 19 is arranged in the liquid 4 or below the liquid level. Said liquid can thus advantageously be pumped out by the pump impeller 8 . The store 17 is filled with liquid via a supply duct 18 during operation. Here, separated liquid can flow back from the contact chamber or fan housing 14 and/or from a further separation unit after the absorption of water/moisture from the drying air, such that the primary circuit 1 is realized. The duct 18 or the opening 20 thereof is arranged or formed such that, in all tilted positions or angular positions of the structural unit 5 , any liquid situated therein flows down/back to the base of the structural unit 5 (that is to say in the direction of the heating bar 16 in the normal operating position), or such that the duct 18 is empty or arranged above the liquid level. The same also applies to the outlet 19 , but with the above-described feature that said outlet is arranged below the level in the operating position (as per FIG. 5 ) in order to be able to discharge liquid. In the advantageous variant of the invention as per FIGS. 2 to 5 , the outlet 19 of the accumulator 17 is formed by the hollow cone wheel 8 or pump wheel 8 or the surface thereof.
Furthermore, the structural unit 5 has advantageous cavities 21 or elevations 21 into which, in the tilted position, in particular in the tilted position 180° offset with respect to the normal operating position (“upside down”), liquid can flow and can be stored such that the inlets 18 and/or outlets 19 are situated or arranged above the liquid level.
In the illustrated exemplary embodiment, the exits/entrances 18 , 19 are designed so as to empty or drain when the structural unit 5 is in an acute-angled inclined position. If the structural unit 5 is inclined further/to a greater extent, at least the openings of the exits/entrances are arranged above the liquid level.
It is generally advantageous if/that the store 17 has a store volume larger than a resting volume of the liquid, that is to say at rest or when the primary circuit 1 is out of operation. During operation, the liquid volume within the store 17 is smaller than the resting volume, because for the drying process, liquid adheres to the pump wheel 8 and is situated in the fan housing 14 or in the contact chamber.
The accumulator 17 is thus larger, by a differential volume, than the resting volume of the liquid 4 , such that said differential volume above the liquid level is filled with gas/air. Said differential volume is of such a size that, in the inclined position, the outlets/inlets 18 , 19 are situated above the level. In this way, for example during transportation of the structural unit 5 or of the household appliance, a situation cannot arise in which liquid 4 is inadvertently lost and must be replaced or replenished. This improves operational reliability and has the effect that for example the structural unit 5 is produced separately and first installed during the assembly of the household appliance according to the invention, without liquid being able to escape. If appropriate, the structural unit 5 must be placed transversely during assembly owing to restricted spatial conditions of the already partially assembled household appliance. Nevertheless, as a result of the abovementioned advantageous measures, no liquid escapes. All of this has the effect that the hygroscopic liquid 4 can be fully installed and if appropriate checked independently of the assembly or the transportation of the rest of the appliance/the appliance as a whole, and it is ensured that said hygroscopic liquid is not at too low a level after assembly and during operation. This improves the operational reliability and in particular also the warranty of the structural unit 5 according to the invention.
In one advantageous embodiment of the subject matter of the invention, a common mixing/reaction chamber or contact chamber of the primary and secondary circuits is realized. Said chamber is composed for example of a housing as a liquid sump, which contains, in terms of a balance volume, the liquid volume of the extraction medium. The fill quantity corresponds at least to the lower balance volume. The vessel is furthermore composed of a fan cover, a fan housing. The fan housing bears, at the exit, a spiral fin. The secondary circuit is however connected to the fan suction side of the housing cover and to the pressure port of the fan housing. The vessel furthermore bears the motor which drives the rotor and the pump hollow cone which is connected to the rotor. The pump hollow cone bears, on the inside, hollow cone guide fins which, via the pump hollow cone inlet and via the pump annular gap, conduct the liquid extraction medium via the rotor blade internal fin to the pump mixing fan impeller. Via the liquid return line, the liquid return line is supplied from the fan housing and the connected fan pressure port to the liquid sump.
At the rotor, therefore, the pumped liquid two-substance mixture is merged and placed in intimate mass-transfer contact with the gas flow passing via the fan suction side, and is transported to the fan pressure port. Transported liquid constituents are recirculated via the spiral housing and possibly via a droplet separator connected downstream of the fan pressure port. The gap dimension between the pump hollow cone and the conical projection of the radial fan housing prevents the escape of the liquid quantity present in the liquid sump in the event that the usage position of the appliance departs from the vertical working position illustrated here. It must be taken into consideration here that the upper balance volume of the sump constitutes a greater volume than the lower balance volume, which corresponds to the nominal fill quantity, of the sump.
It is also conceivable to realize a transportation of liquid in the gap between the hollow cone and conical projection of the fan housing with a simple external fin arrangement on the hollow cone.
For absorption operation, the moist air from the drying chamber is supplied from the household appliance via the fan suction side and is supplied as substantially dry air back to the drying chamber via the fan pressure port.
In the case of desorption/expulsion, the liquid quantity present in the liquid sump is directly or indirectly heated. The moist air generated is connected via the fan pressure port to the condensation chamber of the household appliance and supplied from here again as dry air via the fan suction side.
LIST OF REFERENCE NUMERALS
1 Primary circuit
2 Secondary circuit
3 Vessel
4 Lithium chloride solution (LiCl aq.)
5 Structural unit
6 Pump
7 Heater
8 Hollow cone or pump impeller
9 Fan impeller or dispersal element
10 Fan
11 Working chamber
12 Motor
13 Blade
14 Housing
15 Duct
16 Heating bar
17 Store
18 Entrance
19 Exit
20 Axis
21 Cavity
22 Inlet
23 Outlet
24 Web
25 Rib
|
Provided is a household appliance, in particular dishwasher, tumble drier or the like, having a primary circuit which has a hygroscopic liquid, in particular brine solution, for extracting moisture from drying air, and a secondary circuit for drying wet articles by drying air, wherein a contact chamber is provided which has at least one dispersal element for surface area enlargement of the contact surface of the hygroscopic liquid for the drying air, characterized in that the dispersal element of the contact chamber has at least one drive for imparting drive and/or movement, such that for the surface area enlargement, the hygroscopic liquid can be dispersed with kinetic drive energy.
| 3
|
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application Ser. No. 60/615,943 filed 6 Oct. 2004 which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a liposome drug loading method and composition that provides superior drug retention, enabling enhanced delivery of therapeutic compounds in vivo.
BACKGROUND OF THE INVENTION
[0003] Liposomes are microscopic particles that are made up of one or more lipid bilayers enclosing an internal compartment. Liposomes can be categorized into multilamellar vesicles, multivesicular liposomes, unilamellar vesicles and giant liposomes. Liposomes have been widely used as carriers for a variety of agents such as drugs, cosmetics, diagnostic reagents, and genetic material. Since liposomes consist of non-toxic lipids, they generally have low toxicity and therefore are useful in a variety of pharmaceutical applications. In particular, liposomes are useful for increasing the circulation lifetime of agents that have a short half-life in the bloodstream. Liposome encapsulated drugs often have biodistributions and toxicities which differ greatly from those of free drug. For specific in vivo delivery, the sizes, charges and surface properties of these carriers can be changed by varying the preparation methods and by tailoring the lipid makeup of the carrier. For instance, liposomes may be made to release a drug more quickly by decreasing the acyl chain length of a lipid making up the carrier.
[0004] The most efficient method of encapsulating a high drug payload in liposomes is via active loading. This process is mediated by the creation of pH gradients (ΔpH) or metal ion gradients (ΔM2+) across the liposomal membrane. For example, a ΔpH generated by preparing liposomes in citrate buffer pH 4.0 followed by exchange of external buffer with buffered-saline pH 7.5, can promote the liposomal accumulation of weakly basic drugs. The neutral form of the drug passively diffuses across the lipid bilayer and becomes trapped upon protonation in the low pH environment of the liposome interior. This process can result in >98% drug encapsulation and high drug-to-lipid ratios (e.g. vinorelbine). Drug loading via ΔM2+ follows an analogous process, with drug accumulation being driven by metal ion-complexation (e.g. doxorubicin-Mn2+). Drug loading efficiencies driven by metal ion-complexation are comparable to those described for ΔpH.
[0005] A further active loading procedure uses a combination of an ionophore, such as A23187, and divalent metal ions (M2+). A23187 incorporates into the lipid bilayer and exchanges 1M2+ from the interior liposome buffer for 2H+ from the external buffer, thereby generating and maintaining a ΔpH. A23187 and an internal Mn2+ buffer have been used previously to efficiently encapsulate vincristine, ciprofloxacin, topotecan and irinotecan. The role of Mn2+ in this system is believed to be an ‘inert’ facilitator for the creation of a ΔpH. Indeed, exchanging the internal Mn2+-based buffer with a Cu2+-based buffer does not result in any differences in the kinetics of anticancer drug loading.
[0006] The present invention relates to the use of divalent copper ions (Cu2+) to significantly enhance intra-liposomal drug retention attributes and hence in vivo therapeutic effects. For example, a Cu2+/A23187 liposomal irinotecan formulation described herein demonstrated significantly improved efficacy against murine xenograft models of colorectal cancer when compared to the Mn2+/A23187 equivalent. The Applicant's loading procedure combines high encapsulation efficiencies (>98%), high drug-to-lipid ratios and enhanced drug retention. It is notable that existing inventions describe the use of transmembrane pH gradients, defining the utility of ionophores to generate a transmembrane pH gradients, or alternatively disclose the use of transition metals, such as Mn2+ or Cu2+, in the presence of a neutral environment and in the absence of a transmembrane pH gradient (Fenske et al., U.S. Pat. No. 5,837,282; Tardi et al., US 20030091621). The prior art does not teach methods and compositions that rely on divalent copper ions (Cu2+) in a low pH environment, and it was not anticipated that such compositions would result in improved drug retention attributes.
[0007] Liposomes containing metal ions encapsulated in the interior of the vesicle have previously be used in diagnostic applications. For example, liposomes have been used for delivery of contrast agents with the goal of accumulating a contrast agent at a desired site within the body of a subject. In the latter application, liposomes have mainly been used for delivery of diagnostic radionucleotides and paramagnetic metal ions in gamma and magnetic resonance imaging, respectively. However, liposomally encapsulated metal ions in these applications are not employed for drug retention purposes.
[0008] Camptothecins are a class of anticancer drugs that inhibit the nuclear enzyme, topoisomerase I (topo I). Topo I facilitates DNA replication during the S phase of the cell cycle by inducing transient single strand breaks in the DNA double-helix. The complex formed between DNA and topo I is referred to as the ‘cleavable complex’. Camptothecins induce caspase-mediated cellular apoptosis by stabilising this cleavable complex. Camptothecins, such as irinotecan, possess a lactone ring. This lactone ring is crucial for cytotoxic activity. Liposome formulations of camptothecins are an attractive option based on the potential for these carrier systems to maintain the drug in an environment that favours the active closed ring lactone form. An equilibrium exists between the closed lactone ring form of camptothecins and an inactive open-ring carboxylic acid form ( FIG. 1 ). This equilibrium is influenced by pH. At acidic pH, equilibrium is driven towards the closed lactone ring. At neutral or alkaline pH (e.g. physiological conditions), equilibrium favours the inactive open-ring form.
[0009] The need has arisen for improved liposomal formulations which both enhance retention of encapsulated drugs and also preferably maintain the drugs in their active form for improved delivery and efficacy at a target site.
SUMMARY OF THE INVENTION
[0010] In one embodiment the invention relates to a composition comprising a liposome encapsulating a therapeutic agent, wherein the therapeutic agent is loaded into the liposome in the presence of intra-liposomal copper ions, and wherein the copper ions enhance the retention of the therapeutic agent within the liposome. The liposome may comprise an interior buffer solution containing the therapeutic agent, the solution having a pH less than 6.5 and most preferably approximating pH 3.5. At least some of the copper ions are retained within the interior solution. In a particular embodiment the therapeutic agent may be an anti-cancer drug, such as irinotecan or vinorelbine.
[0011] The invention also relates to a method of enhancing the retention of a therapeutic agent within liposomes comprising the steps of (a) providing within an interior of the liposomes an intra-liposomal solution comprising copper ions; (b) maintaining the pH of the intra-liposomal solution below 6.5; (c) providing a therapeutic agent in the external solution, wherein the therapeutic agent diffuses into the interior and is encapsulated within the liposomes, and wherein the presence of the copper ions enhances the retention of the therapeutic agent therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In drawings which describe embodiments of the invention but which should not be construed as restricting the spirit or scope of the invention in any way.
[0013] FIG. 1 is a chemical scheme showing a dynamic equilibrium, influenced by pH, which exists between the active closed lactone ring form and inactive open-ring carboxy form of irinotecan.
[0014] FIG. 2 is a graph showing irinotecan loading efficiencies (drug/lipid ratios) >90% using liposomes with encapsulated unbuffered solutions of CuS04 or ZnS04.
[0015] FIG. 3 is a graph showing irinotecan loading efficiencies (drug/lipid ratios) >90% using liposomes with encapsulated buffered CuS04 pH 7.5 or unbuffered CuS04+A23187 ionophore (which maintains low pH environment).
[0016] FIG. 4 (A)-(C) are excitation scans showing liposome internal pH following loading of the drug irinotecan. The pH sensitive fluorescent probe, HPTS, suggests that the internal pH of liposomes with encapsulated unbuffered CuS04 increases following active loading of irinotecan.
[0017] FIG. 5 are HPLC plots demonstrating that irinotecan exists predominately as its lactone form irrespective of whether the encapsulated CuS04 solution was unbuffered or buffered to pH 7.5
[0018] FIG. 6 shows the results of TLC analysis demonstrating that irinotecan exists predominately as its lactone form irrespective of whether the encapsulated CuS04 solution was unbuffered or buffered to pH 7.5
[0019] FIG. 7 is a graph showing lipid release of various liposomal formulations in plasma over time.
[0020] FIG. 8 is a graph showing percentage lipid release of various liposomal formulations in plasma over time.
[0021] FIG. 9 is a graph showing relative drug:lipid ratios over time.
[0022] FIG. 10 is a graph showing percentage drug release in plasma over time.
[0023] FIG. 11 is a graph showing percentage in s.c. LSI80 tumor volume following a single dose of free or encapsulated CPT-11.
[0024] FIG. 12 is a graph showing percentage increase in tumor volume following a single 50 mg/kg dose of free or encapsulated CPT-11.
[0025] FIG. 13 is a graph showing percentage increase in tumor volume following a single 100 mg/kg dose of free or encapsulated CPT-11.
[0026] FIG. 14 is a graph showing percentage increase in tumor volume following a single dose of free CPT-11.
[0027] FIG. 15 is a graph showing percentage increase in tumor volume following a single dose of pH 7.5 encapsulated CPT-11.
[0028] FIG. 16 is a graph showing percentage increase in tumor volume following a single dose of pH 3.5 encapsulated CPT-11.
[0029] FIG. 17 is a graph showing percentage increase in tumor volume following a single dose of pH 3.5+ionophore encapsulated CPT-11.
[0030] FIG. 18 is a table summarizing data derived from analysis of a single dose of CPT-11 (free or DSPC/Chol encapsulated (55:45 mol %) used to treat SCID/Rag2M mice with established tumours derived following s.c. injection of LSI80 human adenocarcinoma cells.
[0031] FIG. 19 is graph showing relative irinotecan-to-lipid ratios in the plasma following a single i.v. bolus injection (73.8 μmol/kg; 50 mg/kg) administered to Rag-2M mice. The formulations consisted of the same liposome composition (DSPC/Chol 55:45 mol %) with different internal solutions as indicated in the legend. The formulation prepared by the Cu2+/A23187 drug loading technology demonstrates significantly better plasma drug retention as demonstrated by the higher relative irinotecan-to-lipid ratio after 24 hours.
[0032] FIG. 20 is a graph showing relative vinorelbine-to-lipid ratios in the plasma following a single i.v. bolus injection (18.5 μmol/kg; 20 mg/kg) administered to Rag-2M mice. The formulations consisted of the same liposome composition (DSPC/Chol 55:45 mol %) with different internal solutions as indicated in the legend. The formulation prepared by the Cu2+/A23187 drug loading technology demonstrates significantly better plasma drug retention as demonstrated by the higher relative vinorelbine-to-lipid ratio after 8 hours.
[0033] FIG. 21 is a table summarizing data derived from analysis of a single dose of (73.8 μmol/kg; 50 mg/kg) of unencapsulated irinotecan or liposomal irinotecan (DPSC/Chol 55:45 mol %; irinotecan loading mediated by different technologies) administered to Rag-2M mice. The pharmacokinetic parameters of the different irinotecan treatments were determined and related to their therapeutic effectiveness against established s.c. LSI80 tumours (human colorectal carcinoma xenograft).
DETAILED DESCRIPTION OF THE INVENTION
[0034] Throughout the following description specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the present invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
[0035] The Applicant's invention provides new methods and compositions to improve the effectiveness of liposomal drug delivery. The invention is based on the discovery that the drug retention properties of a liposome employing a divalent metal cation for drug loading purposes is surprisingly dependent on the metal employed. By selecting the optimal metal, namely divalent copper, retention properties can be tailored to achieve a desired release of a selected agent from a liposome.
[0036] As described above, various methods are known in the prior art for actively loading drugs into liposomes. The present invention relies on a pH gradient established across the liposomal membrane for moving a therapeutic agent from an external solution into the interior of the liposomes. The pH gradient may be established and maintained in various manners as will be appreciated by a person skilled in the art. In one embodiment of the invention, an intra-liposomal solution is maintained at a pH below about 6.5. In particular embodiments the intra-liposomal pH is maintained within the range of about 2 and 5, most preferably about pH 3.5. This may be achieved, for example, by providing a buffer in the intra-liposomal solution or by providing an ionophore for facilitating exchange of ions between the interior solution and the external solution. The ionophore may be of any chemical class enabling the exchange of the internal metal ion for two external protons. In one preferred embodiment it consists of A23187. In an alternative embodiment the ionophore may consist of ionomycin, or X-537A.
[0037] Irrespective of how the therapeutic agent is actively loaded into the liposomes (i.e. how the pH gradient is established), the present invention relates to the use of divalent copper ions within the intra-liposomal solution to enhance retention of the encapsulated therapeutic agent. The exact mechanism by which the copper ions function has not yet been elucidated. For example, the copper may bind to the therapeutic agent and/or it may modify the permeability of the liposome membrane. Even in the case where the ionophore facilitates exchange of copper ions in divalent form from the interior of the liposome to the external solution, at least some copper ions remain retained within the liposomes. As described further below, the presence of copper in the intra-liposomal solution may significantly enhance the retention and therapeutic efficacy of the agent in vivo. As will be apparent to a person skilled in the art, the retention of the therapeutic agent is “enhanced” in comparison to similar liposomal formulations which lack copper. As described in detail below, enhanced drug retention may be determined by in vivo tests, such as plasma drug retention ( FIGS. 19 and 20 ).
[0038] The therapeutic agents may be of any class which has improved retention in liposomes when loaded in the presence of intra-liposomal copper. In one preferred embodiment the compound may be any weakly basic compound. In another preferred embodiment the therapeutic compound may be a topoisomerase inhibitor, preferably a camptothecin or an analogue thereof, most preferably irinotecan (CPT-11). In an alternative embodiment, the therapeutic compound may be a compound that binds to tubulin preferably from the class of vinca alkaloids. Vinblastine and vincristine are alkaloids found in the Madagascar periwinkle, Catharanthus roseus (formerly classified as Vinca rosea , which led to these compounds becoming called Vinca alkaloids). They and vindesine and vinorelbine, semisynthetic derivatives of vinblastine, all work by inhibiting mitosis (cell division) in metaphase. The preferred vinca alkaloid for this invention is vinorelbine.
[0039] In another alternative embodiment, this invention provides the use of small molecules (chemical compounds), proteins, antibodies or peptides or any new or known composition of matter or pharmaceutically acceptable salt thereof, to be encapsulated into a liposome in conjunction with a divalent copper ion to achieve superior retention properties.
[0040] The composition of the liposome consists of lipids 1,2-distearoyl-sn-glycero-3-phosophocholine (DSPC)/Cholesterol (55:45 mol %) and the ratios of the lipids may vary according to embodiments visualized by persons skilled in the art of liposome preparation. In an alternative embodiment the liposome may consist of lipids including phosphoglycerides and sphingolipids, representative examples of which include phosphatidylcholine, phosphatidylethanolamine, phosphatidylserine, phosphatidylinositol, phosphatidic acid, palmitoyloleoyl phosphatidylcholine, lysophosphatidylcholine, lysophosphatidylethanolamine, dipalmitoylphosphatidylcholine, dioleoylphosphatidylcholine, distearoylphosphatidylcholine or dilinoleoylphosphatidylcholine. Other compounds lacking in phosphorus, such as sphingolipid and glycosphingolipid families are also contemplated. Additionally, the amphipathic lipids described above may be mixed with other lipids including triacyglycerols and sterols.
[0041] A further modification contemplated within the scope of this invention, is inclusion of a targeting antibody on the surface of the liposome to enable specific localization of the liposome to areas of disease; for example metastatic cancer cells which have spread to other sites in the body.
[0042] Numerous diseases and conditions can be contemplated which would benefit from liposomes which increase drug retention, enabling therapeutic drug interventions with superior ADMET (absorption, distribution, metabolism, excretion and toxicity) properties. Such diseases would be including but not limited to the treatment of cancer.
[0043] Preferably the pharmaceutical liposomal compositions are administered parentally, i.e. intraarticularly, intravenously, subcutaneously, or intramuscularly. In other embodiments, the pharmaceutical preparation may be administered topically.
[0044] In one particular embodiment of the invention, encapsulated irinotecan with copper in the presence of A23187 ionophore exhibited unexpectedly superior retention of the irinotecan within the liposome in vivo and in addition exhibited enhanced potency compared to irinotecan prepared with copper-mediated loading in the absence of A23187 ionophore. In addition, the encapsulated irinotecan exists predominately in the clinically active lactone form.
[0045] The following examples will further illustrate the invention in greater detail although it will be appreciated that the invention is not limited to the specific examples.
Example 1.0
1.1 Materials and Methods
1.1.1 Liposome Formation
[0046] DSPC/Chol (55:45 mol %) large unilamellar vesicles (LUVs) were prepared by the extrusion method. Briefly, lipids were dissolved in chloroform at the required molar ratio, labelled with the non-exchangeable, non-metabolizable lipid marker, 3H-CHE and dried to a thin film under a stream of nitrogen gas. Subsequently, the lipid was placed in a high vacuum for 3 hours to remove any residual solvent. The lipid films were then hydrated at 65° C. by mixing with the appropriate buffer (300 mM CuS04, 300 mM C0S04, 300 mM ZnS04 and 300 mM MnS04). The mixture was subjected to five cycles of freeze-and-thaw (5 minutes each, freezing in liquid nitrogen and thawing at 65° C.). The formed multilamellar vesicles (MLV's) were extruded 10 times through stacked polycarbonate filters of 0.1 μm pore size at 65° C. (Extruder, Northern lipids). The resultant LUVs typically possessed mean vesicular diameters in the range 110 nm±30 nm. The LUVs' external buffer was exchanged with SHE pH 7.5 (300 mM sucrose, 20 mM HEPES, 15 mM EDTA) using sephadex G-50 size exclusion chromatography.
1.1.2 Metal Ion Gradient Formation
[0047] Extruded DSPC/Chol liposomes were prepared in unbuffered sulfate salt solutions of copper, zinc, manganese, or cobalt. The external buffers were exchanged with sucrose/HEPES/EDTA (SHE) buffer pH 7.5 to create a metal ion gradient. The efficiency of irinotecan loading (drug-to-lipid ratio of 0.2 mol:mol) at 50° C. was determined over 60 min. The role of internal liposome pH on the efficiency of drug loading was assessed using internal buffers comprising (CuS04/HEPES/TEA pH 7.5), or unbuffered CuS04+A23187 ionophore. When using A23187, Cu2+ ions from the liposome interior are exchanged for two protons from the external buffer thus maintaining a low internal pH. The membrane-impermeant pH-sensitive fluorescent probe, HPTS was used to investigate any changes in internal pH following copper-mediated irinotecan encapsulation (initial internal pH of 7.5 or 3.5—no ionophore). HPLC and TLC methods were used to assess the carboxy and lactone contents of liposomal irinotecan.
1.1.3 Irinotecan Loading
[0048] Drug was incubated with lipid at 50° C. at a drug:lipid ratio=0.2:1 (mol:mol). Uptake of the drug was determined at various timepoints by sampling aliquots and separating encapsulated drug from unencapsulated drug using 1 ml sephadex G-50 spin columns equilibrated with the appropriate buffer (680 g×3 min). The excluded fractions, containing the liposomes, were analyzed in order to determine drugdipid ratios. Lipid concentrations were measured using liquid scintillation counting. Irinotecan concentrations were determined by measuring absorbance at 370 nm.
1.2 Results
1.2.1 Irinotecan Loading Efficiencies
[0049] Extruded DSPC/Chol liposomes were prepared in unbuffered sulfate salt solutions of copper, zinc, manganese, or cobalt. The external buffers were exchanged with sucrose/HEPES/EDTA (SHE) buffer pH 7.5 to create a metal ion gradient. The efficiency of irinotecan loading (drug-to-lipid ratio of 0.2 mol:mol) at 50° C. was determined over 60 min. The role of internal liposome pH on the efficiency of drug loading was assessed using internal buffers comprising (CuS04/HEPES/TEA pH 7.5), or unbuffered CuS04+A23187 ionophore. When using A23187, Cu2+ ions from the liposome interior are exchanged for two protons from the external buffer thus maintaining a low internal pH. The membrane-impermeant pH-sensitive fluorescent probe, HPTS was used to investigate any changes in internal pH following copper-mediated irinotecan encapsulation (initial internal pH of 7.5 or 3.5—no ionophore). HPLC and TLC methods were used to assess the carboxy and lactone contents of liposomal irinotecan.
[0050] Irinotecan loading efficiencies were >90% using liposomes with encapsulated unbuffered solutions of CuS04 and ZnS04. The inclusion of A23187 ionophore, to maintain a low internal pH, did not influence the copper-mediated loading behaviour. When the internal and external buffers were adjusted to pH 7.5 (internal buffer—CuS04/HEPES/TEA pH 7.5), irinotecan loading was again found to be >90%. HPTS measurements suggest that the internal pH increases following loading via unbuffered CuS04. HPLC and TLC indicate that encapsulated irinotecan exists predominately as the lactone form ( FIG. 5 and FIG. 6 ) regardless of the initial internal pH of the transition metal solution.
[0000] 1.2.2 Active Drug Loading of DSPC/Chol Liposomes with Irinotecan
[0051] Drug was incubated with lipid at 500 C at a drugrlipid ratio=0.2:1 (mol:mol). Uptake of the drug was determined at various timepoints by sampling aliquots and separating encapsulated drug from unencapsulated drug using 1 ml sephadex G-50 spin columns equilibrated with the appropriate buffer (680 g×3 min). The excluded fractions, containing the liposomes, were analyzed in order to determine drug:lipid ratios. Lipid concentrations were measured using liquid scintillation counting. Irinotecan concentrations were determined by measuring absorbance at 370 nm ( FIG. 2 ).
1.2.3 Liposome and Ionophore Preparation
[0052] DSPC/Chol (55:45 mol %) large unilamellar vesicles (LUVs) were prepared as described above. The encapsulated buffers in this instance comprised 300 mM CuS04 (unbuffered), 300 mM CuS04/20 mM HEPES/220 mM TEA pH 7.5, or 300 n1M CuS04+A23187 ionophore. The ionophore is incorporated into the liposomal membrane, immediately prior to irinotecan loading, by incubating at 500 C for 10 min. The presence of A23187 facilitates the outward movement of 1×Cu2+ from the liposome interior in exchange for the inward movement of 2×H+ from the exterior buffer. Resultantly, the interior of the liposome is maintained at low pH.
[0000] 1.2.4 Active Drug Loading of DSPC/Chol Liposomes with Irinotecan:
[0053] Liposomes were loaded with irinotecan as described above. Irinotecan loading efficiencies remained >90% using liposomes with encapsulated buffered CuS04 pH 7.5 or unbuffered CuS04+A23187 ionophore (which maintains low pH environment) as shown in FIG. 3 .
1.2.5 Determination of Liposome Internal pH Following Drug Loading
[0054] DSPC/Chol (55:45 mol %) liposomes were prepared as previously described. The liposomes were formulated with the following internal buffers, both in the presence or absence of the fluorescent dye, HPTS (12.5 mM): 300 mM CuS04 unbuffered, 300 mM CuS04/20 mM HEPES/220 mM TEA pH 7.5, 300 mM citrate pH 3.5 and 20 mM HEPES pH 7.5 Following extrusion the external buffer was exchanged with SHE pH 7.5 using column chromatography as previously described.
[0055] Irinotecan was actively loaded into DSPC/Chol liposomes formulated with the internal buffers 300 mM CuS04 pH 3.5 HPTS and 300 mM CuSO4/20 mM HEPES/TEA pH 7.5 HPTS. Loading conditions were as previously described and the presence of HPTS did not impair the efficiency of irinotecan loading.
[0056] HPTS detection was performed using a LS-50B Luminescence Spectrometer (Perkin-Elmer). Liposome solutions were diluted in HBS pH 7.5 to a final lipid concentration of 0.5 mM in order to eliminate lipid-induced interference. The anionic fluorophore HPTS is water-soluble and membrane-impermeant and therefore, can be trapped in the internal compartment of the liposome. The excitation properties of HPTS are dependent on pH such that under acidic conditions the dye has an excitation maximum at 405 nm whereas, increasing pH results in a diminished fluorescence intensity at 405 nm and an increasing intensity at 450 nm. This is exemplified by the scan shown in FIG. 4A which, represents HPTS fluorescent emission at 510 nm following excitation at 350-490 nm for 2 control DSPC/Chol liposome formulations. When the internal buffer is citrate at pH 3.5, HPTS excitation is at a maximum at 405 nm. In contrast, an internal buffer of HEPES pH 7.5 results in a diminished signal at 405 nm and the emergence of significant excitation at 450 nm. The presence of Cu significantly quenches the HPTS signal to approximately 20% of that seen in comparable conditions in the absence of copper ( FIG. 4B ).
[0057] One aim of this experiment was to elucidate any internal pH changes following loading of irinotecan into DSPC/Chol liposomes. FIG. 4C represents the excitation scan of the same Cu-containing liposomes described in FIG. 4B with the exception that irinotecan has been actively loaded under the conditions previously described. The increased excitation intensities observed for <400 nm is an artefact of irinotecan loading. Irinotecan is a fluorescently active compound with an excitation wavelength of 368 nm and an emission wavelength of 423 nm. The main point of interest from this excitation scan is the emergence of a significant signal centred around 450 nm for the liposome formulation comprising the unbuffered CuS04 (pH ˜3.5). As we observed from the previous scans there is no significant signal at this wavelength for our control liposome formulation at pH 3.5 ( FIG. 4A , FIG. 4B ).
[0058] Accounting for the effects of irinotecan on the excitation scans shown in FIG. 4C , the loading of this drug into Cu-containing liposomes at pH 7.5 resulted in no appreciable change in the scan when compared with the drug-free counterpart ( FIG. 4B ).
1.2.6 Irinotecan Lactone Ring Detection
[0059] Irinotecan was resolved on a CI 8 column (3.9×150 mm) using a mobile phase comprising 78% triethanolamine solution (3% v/v) and 22% acetonitrile. Drug was quantified by fluorescence (lexci=363 nm; lemiss=425 nm). Peak area analysis indicates that for liposomes containing the unbuffered CuS04, 96% of irinotecan exists as the lactone form and 4% as the carboxylate form ( FIG. 5 ). The equivalent values for liposomes possessing an interior buffer of CuS04 pH 7.5 are 83% lactone and 17% carboxylate.
[0060] Irinotecan controls and liposomal samples were solubilized in CHC13:MeOH (1:1 v/v) and spotted on a TLC plate. The lactone and carboxy forms of the drug were separated by exposing the TLC plate initially to a mobile phase of CHC13:MeOH:acetone (9:3:1 v/v/v) followed by a mobile phase of butanohacetic acid:water:acetone (4:2:1:1 v/v/v/v). The drug was visualized under UV light and confirmed that irinotecan existed predominantly in the lactone form ( FIG. 6 ).
1.2.7 In Vivo Liposome Stability Studies
[0061] Analysis of the liposome stability was determined by measuring free lipid and free drug levels in the plasma at specific timepoints ( FIGS. 7-10 ). These results showed that Cu2+ with ionophore A23187 at pH 3.5 provided superior drug retention in the liposomes versus use of Mg2+ or in the absence of the ionophore or at pH 7.5 (see FIG. 9 and FIG. 10 ).
1.2.8 Efficacy Studies
[0062] The effect of encapsulating the drug irinotecan (CPT-11) on tumor volume is shown in FIGS. 11-17 . The effects of encapsulation in the presence of Cu2+ at pH 7.5 versus pH 3.5 versus pH 3.5 with ionophore were compared at two doses of irinotecan (CPT-11). Encapsulation at pH 3.5 or at pH 3.5 with ionophore both provided highly effective therapeutic regimes. A more detailed analysis ( FIG. 18 ) showed that encapsulation in the presence of Cu2+ at pH 3.5 in the presence of ionophore provided the longest growth delay for the tumour, highest log cell kill and superior cell kill at the lowest dose (50 mol/kg). In FIG. 18 , T−C is the difference in days for a treatment tumour to increase in volume by 400% compared to control tumours; % Growth Delay=(T−C)/C×100, where C is the day of experiment when control tumour reaches 400%; Log Cell Kill=(T−C)/(3.32×Td), where Td is the tumour doubling time of control tumours; and % Cell Kill=(1−( 1/10 x ))×100, where x is the Log Cell Kill.
[0063] Taken together, these efficacy results show that the composition consisting of Cu2+ with ionophore and irinotecan provides the most potent composition. This is consistent with the observations that this composition provides the best plasma stability.
[0064] Irinotecan loading efficiencies were >90% using liposomes with CuS04. The inclusion of A23187 ionophore, to maintain a low internal pH, did not influence the copper-mediated loading behaviour, but strongly enhanced drug retention in liposomes when measured in plasma. Furthermore, HPLC and TLC indicate that encapsulated irinotecan exists predominately as the clinically-active lactone form regardless of the initial internal pH of the transition metal solution. This composition provides enhanced drug retention in plasma yielding increased drug exposure in vivo and resulting in enhanced efficacy for lower doses of irinotecan in the mouse xenograft tumor model.
[0065] In summary, irinotecan can be encapsulated into DSPC/Chol liposomes using transition metal Cu2+ and an ionophore in a composition which provides excellent drug retention and superior efficacy in vivo.
Example 2.0
2.1 Plasma Drug Retention
[0066] FIGS. 19 and 20 illustrate drug to lipid ratios in the plasma following in vivo administration to Rag-2M mice. In each case the administered formulations consisted of the same liposome composition with different internal solutions as indicated in the figure legends. In the case of both the drug irinotecan ( FIG. 19 ) and vinorelbine ( FIG. 20 ) the formulation prepared by Cu2+/A23187 drug loading technology demonstrated significantly better plasma drug retention as indicated by the higher relative drug-to-lipid ratios.
2.2 Pharmacokinetic Parameters of Different Irinotecan Treatments
[0067] FIG. 21 is a table similar to FIG. 18 summarizing pharmacokinetic parameters of different irinotecan treatments. The delay in tumour growth was most effective in the case of the formulation prepared by Cu2+/A23187 drug loading technology. In FIG. 21 , irinotecan plasma-area-under-the-curve (AUG) was calculated using WinNonLin pharmacokinetic software (noncompartmental model) following a single i.v. bolus dose administered to Rag-2M mice (n=3/timepoint). The irinotecan plasma mean residence time (MRT) was calculated using WinNonLin pharmacokinetic software (noncompartmental model) following a single i.v. bolus dose administered to Rag-2M mice (n=3/timepoint). The % growth delay was calculated following a single dose of irinotecan treatment administered to Rag-2M mice with established s.c. LSI 80 tumours (human colorectal carcinoma xenograft). % Growth Delay=(T−C)/C×100, where C is the day of experiment when control tumours reach 400% and T−C is the difference in days for a treatment tumour to increase in volume by 400% compared to control tumours. Efficacy values are not stated for liposomal irinotecan (unbuffered 300 mM MnS04+A23187) because no head-to-head studies have been conducted. We have previously published efficacy data relating to this murine model and this liposome formulation (Messerer et al., Clin. Cancer Res. 10:6638-49, 2004).
[0068] As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
|
The present invention relates to the use of copper ions to achieve enhanced retention of a therapeutic agent within a liposome. The invention may be employed to more effectively deliver a liposomally encapsulated therapeutic agent to a target site in vitro and in vivo for anti-cancer or other therapy. The liposome may comprise an interior buffer solution containing the therapeutic agent, the solution having a pH less than 6.5 and most preferably approximating pH 3.5. At least some of the copper ions are retained within the interior solution. In a particular embodiment the therapeutic agent may be a chemotherapeutic drug, such as irinotecan. The invention may also comprise an ionophore to facilitate loading of drug into the liposome. In one particular embodiment the combination of the ionophore A23187 and encapsulated divalent copper (Cu2+) resulted in an irinotecan formulation that exhibited surprisingly improved drug retention attributes.
| 0
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of U.S. patent application Ser. No. 10/334,490 filed Dec. 30, 2002 which in turn claims benefit of U.S. Provisional Patent Application No. 60/392,200, filed Jun. 28, 2002, now U.S. Pat. No. 7,093,180 which is incorporated by reference as if fully set forth herein.
FIELD OF INVENTION
The present invention is related to data communication systems. More particularly, the present invention is directed to an improved Turbo decoder in a data communication system.
BACKGROUND
Turbo codes are used for data communication systems [such as a High Speed Downlink Shared Channel (HS-DSCH) in High Speed Downlink Packet Access (HSDPA) in wireless communication systems] as a forward error connection (FEC) scheme. Decoding of Turbo codes is iterative in nature. That is, each Turbo code block is decoded several times. In general, there is a tradeoff between the Turbo code performance, which improves with the number of decoding iterations, and the decoding delay and computational complexity. Conventionally, the number of decoding iterations is fixed (for example, at 4 or 8 iterations). However, some Turbo code blocks may need only a few decoding iterations to successfully decode the code blocks, (i.e. to converge), before reaching the last decoding iteration and further iterations are not necessary. In such a case, if the Turbo decoder stops the redundant decoding iterations for the good blocks, it reduces the decoding delay and power consumption without degrading performance.
To prevent an endless loop when the stopping rule is never satisfied, the decoder stops after a maximum number of iterations. Several stopping rules for Turbo decoding have been addressed in the prior art. However, prior art stopping rules are focused on the case where decoding iterations converge (e.g., for good Turbo coded blocks).
SUMMARY
The present invention not only implements a stopping rule for good code blocks, but also includes a stopping rule for bad code blocks which fail to be correctly decoded even at the last decoding iteration. This benefits data communication systems such as HSDPA which employ an H-ARQ (hybrid-automatic repeat request) protocol, since the H-ARQ protocol requests bad blocks to be retransmitted. It is particularly applicable with HS-DSCHs with H-ARQ that may require raw block error rates (BLERs) before retransmission on the order of 10 −1 , which leads to frequent occurrences of bad Turbo coded blocks for HS-DSCH. It should be noted that although the present invention will focus on HSDPA as an example, other data communication system using Turbo coding and an H-ARQ technique may also be used in accordance with the teachings of the present invention.
The H-ARQ protocol used for HSDPA sends the transmitter an acknowledgement (ACK/NACK) of each H-ARQ process where generation of the acknowledgement is typically based on the cyclic redundancy check (CRC) check result of the individual H-ARQ process. There is some delay in deriving the CRC result, which may be on the order of 10 msec. The CRC processing delay may cause H-ARQ performance degradation. As an alternative to the H-ARQ acknowledgement generation, the result of the stopping rule testing may be used to determine whether a given H-ARQ process is in error (NACK generation) or error-free (ACK generation).
In addition, HSDPA employs adaptive modulation and coding (AMC) as a link adaptation technique. The modulation and coding format can be changed on a radio frame basis in accordance with variations in the channel conditions, subject to system restrictions. In order to more efficiently implement the Turbo decoder with a stopping rule, the maximum number of Turbo decoding iterations may be dynamically selected depending on a code rate and modulation type for the HS-DSCH.
The present invention provides the advantage of a reduction in the decoding delay and computational complexity at the user equipment (UE) receiver. In addition, reduction in the decoding delay leads to earlier availability of H-ARQ acknowledgements at the Node B, which improves HSDPA performance.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with reference to the drawing figures wherein like numerals represent like elements throughout and wherein:
FIGS. 1 and 2 are flow diagrams useful in describing alternative techniques of the present invention.
FIG. 3 is a modified block diagram showing apparatus utilized to perform the turbo decoding technique of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The stopping rule known as Sign Change Ratio (SCR) is implemented for Turbo decoding in accordance with the present invention. This rule depends upon the sign changes of the extrinsic information provided by the component decoders in the Turbo decoder between the (k−1) th and k th iterations for both good and bad Turbo code blocks. The conventional SCR stopping rule attempts to determine, by checking the sign changes, when the iteration converges and then terminates the iteration process. This SCR stopping rule is applied only to good received code blocks. However, in accordance with the present invention, the SCR stopping rule is applied to bad code blocks as well. This especially benefits HSDPA systems employing a H-ARQ protocol, since the H-ARQ protocol requests bad H-ARQ processes consisting of Turbo code block(s) to be retransmitted. It should be noted that although the present invention will focus on the SCR based stopping rule as an example, other stopping criterion may also be used in accordance with the teachings of the present invention. By way of example, other known stopping criteria include: (a) CRC wherein, after each decoding iteration, CRC bits are checked for errors and the iteration is stopped if there is no CRC error and (b) Cross Entropy wherein after each iteration, the cross entropy between log-likelihood ratios of the component decoders is calculated and the iteration is terminated if the estimated cross entropy is less than a given threshold.
To see the behavior of iterative decoding in the Turbo decoder, Turbo code simulations were performed with a fixed number of iterations k where k is (set to 8). Table 1 shows typical samples of the simulation results in terms of the number of sign changes at each iteration for good Turbo code blocks, and Table 2 shows typical samples of the simulation results in terms of the number of sign changes at each iteration for bad Turbo code blocks. As observed in Table 1, with good code blocks the number of sign changes between (k−1) and k (for k>1) iterations converges before the last (8 th ) iteration. In this case, if the stopping rule is applied, the average number of iterations would be reduced to approximately 4.
TABLE 1
Typical samples of TC simulation results in terms of the
number of sign changes for successful decoded (good) blocks
when 16 QAM, ¾ rate, BLER = 10%
# of sign changes between (k − 1) and k iterations
Stopped
Blocks
K = 2
K = 3
K = 4
K = 5
K = 6
K = 7
K = 8
iteration
1
3
0
0
0
0
0
0
K = 3
2
8
3
0
0
0
0
0
K = 4
3
16
9
0
0
0
0
0
K = 4
4
4
8
7
3
0
0
0
K = 6
5
11
2
0
0
0
0
0
K = 4
6
18
20
11
10
0
0
0
K = 6
7
19
5
0
0
0
0
0
K = 4
8
16
9
0
0
0
0
0
K = 4
9
4
5
3
0
0
0
0
K = 5
10
10
0
0
0
0
0
0
K = 3
In Table 2, it is shown that with bad code blocks the number of sign changes never converges.
TABLE 2
Typical samples of TC simulation results in terms of the
number of sign changes for unsuccessfully decoded (bad) blocks
when 16 QAM, ¾ rate, BLER = 10%
# of sign changes between (k − 1) and k iterations
Stopped
Blocks
K = 2
K = 3
K = 4
K = 5
K = 6
K = 7
K = 8
iteration
1
30
39
29
37
46
49
31
K = 3
2
24
36
39
39
38
35
28
K = 3
3
33
27
24
23
24
14
17
K = 8
4
11
11
12
20
21
37
34
K = 5
5
9
14
9
8
11
9
16
K = 3
6
18
10
7
9
17
14
7
K = 5
7
3
34
39
38
39
23
25
K = 3
8
16
14
34
36
12
22
35
K = 4
In the present invention, it is proposed that the iterative decoding process is terminated if either the iteration converges or the iteration diverges. Otherwise the decoding ceases after a maximum number of iterations.
Referring to FIG. 1 , a flowchart of the method 10 in accordance with the present invention for Turbo decoding is shown. The method 10 commences by receiving a Turbo code block from a demodulator (step 14 ). A counter for decoding iterations is then initialized (i=0) (step 16 ) and then the counter incremented (i=i+1) (step 18 ). The ith decoding iteration is performed (step 20 ) and it is determined whether or not this is the first iteration (step 22 ). If it is the first iteration, the procedure 10 reverts to step 18 . If not, the method 10 makes a determination of whether or not the iteration converges or diverges.
If the SCR is considered as the stopping criterion, then the iteration convergence and divergence can be defined as follows. If the number of the sign changes between the (k−1) th iteration and k th iteration (for k>1) becomes zero, the iteration is determined to be converging. If the number of the sign changes between the (k−1) th iteration and k th iteration (for k>2) is greater than that between the (k−2) th iteration and (k−1) th iteration, the iteration is determined to be diverging. Accordingly, at step 26 , it is determined whether the iteration converges. If so, the iteration process is terminated and the decoded sequence is output (step 36 ). If not, it is determined whether the iteration diverges (step 30 ). If the iteration diverges, the iteration process is terminated and the decoded sequence is output (step 36 ). If the iteration does not diverge, it is determined whether the maximum number of iterations (i=Nmax) has been reached (step 34 ). If so, the iteration process is terminated and the decoded bit sequence is output (step 36 ). If not, the process returns to step 18 whereby the counter is incremented (i=i+1) and steps 20 - 36 are repeated. It should be noted that the maximum number of iterations Nmax may be dynamically selected as a function of the applied code rate and modulation type. For example, the higher the code rate and the higher the order of the modulation type, the less the maximum number of iterations Nmax.
FIG. 2 is a flow chart of an alternative method 70 in accordance with the present invention for Turbo decoding. In this embodiment 70 , the results of the stopping rule are used for H-ARQ acknowledgement generation. The like steps of the method 70 shown in FIG. 2 are numbered the same as the steps of the procedure 10 shown in FIG. 1 and therefore will not be further described with reference to FIG. 2 .
In accordance with this embodiment of the present invention, after a determination of whether or not the iteration converges, an acknowledgement (ACK) or non-acknowledgement (NACK) for H-ARQ is generated. More specifically, referring to step 26 , if it is determined that the iteration converges (step 26 ), an ACK is generated (step 28 ) assuming that an H-ARQ process has a single Turbo code block. When there are multiple Turbo code blocks in an H-ARQ process, the ACK for the H-ARQ process will be generated, if all the iterations with all the code blocks converge. The iteration process is then terminated and the decoded bit sequence is output (step 36 ). If the iteration does not converge as determined at step 26 , it is then determined whether or not the iteration diverges (step 30 ). If so, a NACK is generated (step 32 ) for the H-ARQ process carrying the decoded block, the iteration process is terminated and the decoded bit sequence is output (step 36 ). When there are multiple Turbo code blocks in an H-ARQ process, if any one code block is determined to be dive (generating NACK), then all the iterations with other relevant code blocks may be terminated as well. If the iteration does not diverge, as determined at step 30 , it is determined whether or not the iteration has reached the maximum number of iterations Nmax (step 34 ). If so, the. iteration process is terminated and the decoded sequence is output (step 36 ). If the maximum number of iterations Nmax has not been reached, as determined at step 34 , the counter is incremented (step 18 ) and steps 20 - 36 are repeated. Accordingly, if the iteration process does not converge or diverge, the H-ARQ acknowledgement generation will be based on CRC check results as in the prior art. The use of the Turbo decoding aided H-ARQ acknowledgement generation may reduce H-ARQ processing delay at the receiving station, taking into account the delay in CRC processing (on the order of 10 msec).
In FIG. 3 , a block diagram of the Turbo decoder structure 100 is shown, including the stopping rule decision unit. In general, the Turbo decoder 100 consists of (2) two SISO (soft input soft output) modules, SISO 1 106 and SISO 2 108 . Each SISO provides soft-valued log-likelihood ratios (LLR) for the other SISO through the Turbo internal interleaver/de-interleaver 110 , 112 . After each iteration, a stopping rule decision unit 114 checks whether the decoding iteration converges or diverges, or neither. If the decision turns out to be either “converged” or “diverged”, the iteration is stopped and either “Ack” or “Nack” indication depending on convergence or divergence is generated for H-ARQ processing. Otherwise, the decoder continues the iteration.
More specifically, the Turbo decoder 100 processes soft-valued input data 102 in each Turbo code block in a transmission. The input 102 to the Turbo decoder is passed through a demultiplexer 104 which separates the input into three sequences: systematic bit sequence, parity bit 1 sequence, and parity bit 2 sequence. The systematic bit sequence and parity bit 1 sequence are initially sent to the SISO 1 decoder 106 (soft-input soft-output decoder), along with a priori information data derived from the SISO 2 decoder 108 . The SISO 1 decoder 106 generates log-likelihood ratios (LLRs) (i.e. extrinsic information plus systematic information) of the information bits. The LLRs from the SISO 1 decoder 106 are permuted by a Turbo internal interleaver 110 and passed to the SISO 2 decoder 108 . Along with the interleaved LLRs, the parity bit 2 sequence is fed into the SISO 2 decoder 108 . The extrinsic information output of the SISO 2 decoder are deinterleaved in accordance with the Turbo internal deinterleaver 112 performing an inverse permutation with respect to the Turbo internal interleaver 110 . The permuted extrinsic information is then fed back as the a priori information of the SISO 1 decoder 106 to repeat the process. After each iteration, the stopping rule decision unit 114 determines whether the iteration converged, diverged or neither converged or diverged. If the decision turns out to be either “converged” or “diverged,” the iteration is stopped, the decoded bit sequence is output at 116 , and a corresponding H-ARQ acknowledgement is provided at 114 a for H-ARQ processing. Otherwise the process continues to be iterated.
The present invention provides the advantage of a reduction in the decoding delay and computation complexity at the receiving station. In addition, a decrease of the decoding delay leads to make H-ARQ acknowledgements available earlier at the transmission, which improves H-ARQ performance.
Although the present invention has been described in detail, it is to be understood that the invention is not limited thereto, and that various changes can be made therein without departing from the spirit and scope of the invention, which is defined by the attached claims.
|
A stopping rule for Turbo decoding that is applied for both good and bad code blocks is disclosed. If the iteration either converges or diverges, decoding is terminated. In an alternative embodiment, the result of the stopping rule testing may be used for hybrid automatic repeat-request (HARQ) acknowledgement generation: if the iteration converges, an acknowledgment (ACK) is generated and if the iteration diverges, a negative acknowledgement (NACK) is generated. Optionally, the maximum number of decoding iterations may be dynamically selected based on modulation and coding scheme (MCS) levels.
| 7
|
This application is a divisional of application Ser. No. 10/368,014, filed Feb. 19, 2003 now U.S. Pat. No. 6,773,468, which claims the benefit of Provisional Application No. 60/357,128, filed Feb. 19, 2002, the entire contents of which is hereby incorporated by reference in this application.
FIELD OF THE INVENTION
The present invention relates to energy storage devices, and specifically, to electrochemical capacitors, and to a method for preparing the same. In particular, the invention relates to the production of electrochemical capacitors or batteries based on aqueous electrolyte, and to an improved method of encapsulation thereof.
BACKGROUND OF THE INVENTION
There exists a need, in many different technological areas, for using electrochemical capacitors or batteries having small dimensions as energy storage devices.
In their most usual configuration, electrochemical capacitors, also known in the art as double layer capacitors, comprises a pair of flat electrodes saturated with a suitable electrolyte, wherein said electrodes are separated by a separating medium disposed therebetween. The separating medium, which may be either a porous sheet (known in the art as a separator), or a membrane, prevents the passage of electrical current in the form of electrons between the electrodes, while allowing ionic current to flow therebetween, due to the porous nature of the separator or the gel type matrix of the membrane. Each of the flat electrodes is placed on a surface of a suitable plate, said plate often being referred to in the art as a current collector. The appropriately sealed capacitor is electrically connected to a suitable load by means of external terminals.
The electrical capacity of the above-described system is attributed to the double-layer formed at the interface of the solid electrode and the electrolyte solution following the application of electrical potential on the pair of electrodes.
Electrochemical capacitors are generally divided into two distinct categories, according to the type of electrolyte used for preparing the electrode, which may be either an aqueous or organic electrolyte solution. The former type may generate up to 1.2 volt per cell, whereas the latter type typically provides about 2.5 to 3.0 volts per cell.
The operating voltage of electrochemical capacitors may be increased by assembling a plurality of individual capacitors described above in series, to obtain an arrangement known in the art as a bipolar capacitor. The art has suggested numerous types of electrochemical capacitors, attempting to improve, inter alia, the structural features of the capacitor, the chemical composition of the electrode material placed therein and of the adhesives used for sealing said capacitor, and the processes for fabricating the same.
Attempts to fabricate a single electrochemical capacitor and a bipolar arrangement based thereon have met with two main difficulties. The first difficulty is related to the attachment of the electrode to the current collector plate, or its deposition thereon. The second difficulty relates to the sealing of the circumferential region of the electrochemical capacitor, in order to prevent the seepage of the electrolyte solution from the electrochemical cell.
U.S. Pat. No. 3,536,963 discloses an electrochemical capacitor comprising electrodes which are made by mixing activated carbon particles with an aqueous electrolyte (e.g., sulfuric acid), to obtain a viscous paste, which is subsequently compressed to form the electrodes. Each of the electrodes is placed within an annular gasket which is affixed to a circular current collector plate, following which the separator is interposed between the electrodes.
U.S. Pat. No. 4,604,788 discloses a chemical composition for carbon paste electrodes comprising activated carbon particles, aqueous electrolyte and fumed silica, to provide a pumpable carbon-electrolyte mix. The fabrication of the capacitor involves the filling of an electrode cavity with the pumpable mixture, following which excess water is removed by a procedure described in the patent.
U.S. Pat. No. 6,212,062 discloses an electrochemical capacitor based on a solution of organic electrolyte, and a method for fabricating the same.
It is an object of the present invention to provide an improved, economically superior and industrially applicable method for manufacturing energy storage devices that comprise an aqueous electrolyte, such as electrochemical capacitors or batteries, which method is based on printing techniques.
It is another object of the present invention to provide a printable composition suitable for the preparation of electrodes for use in electrochemical capacitors, which printable composition may be easily and conveniently applied in the production of said capacitors by means of various printing techniques.
It is yet another object of the present invention to provide an electrochemical capacitor featuring novel electrode composition and improved structural characteristics.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a method for preparing energy storage devices that contain electrochemical cells, and specifically, double layer capacitors, comprising the steps of:
a) Providing a printable composition suitable for use as an electrode, comprising an active material, which is preferably in the form of carbon particles in admixture with an aqueous electrolyte;
b) Placing a first template on one face of a current collector, wherein said first template is provided in the form of a sheet consisting of region(s) permeable to said printable composition, and masked region(s), non-permeable to said composition, wherein said masked region(s) of said first template include the margins thereof;
c) Applying said printable composition through said first template onto said face of said current collector, thereby forming well-defined electrode region(s) thereon;
d) Repeating steps b) and c) to produce a second current collector identical to the current collector of step (c);
e) Placing a second template on a face of a separating medium which may be either a porous film or a membrane, wherein said second template is provided in the form of a sheet consisting of masked and non-masked region(s), wherein said second template is essentially complementary to said first template, such that said masked regions on said second template correspond with the permeable regions of the first template;
f) Blocking the pores of said separating medium in those regions thereof which correspond with those regions of the current collector that have no electrodes printed thereon, and subsequently applying through the non-masked regions of said second template one or more adhesive materials onto said face of said separating medium;
g) Attaching the adhesive face of said separating medium to the first current collector, such that the non-masked region(s) on said face of said separating medium coincide with the electrode(s) printed on the face of said first current collectors, with respect to position, geometric form and size;
h) Repeating steps e) and f) with respect to the second face of said separating medium;
i) Placing said second current collector on said second face of said separator, such that the non-masked regions on said second face of said separator coincide with the electrode(s) printed on the face of said second current collector, with respect to position, geometric form and size.
As used herein, the term “printable composition” refers to a mixture exhibiting the necessary physical properties for application in printing techniques, such as screen-printing, stencil-printing and roller-coating. The inventor has surprisingly found that it is possible to improve the flowability properties and the thixotropicity of the composition used to prepare the electrodes according to the invention, thus rendering said composition particularly suitable for screen-printing applications, by mixing the active components (e.g., the carbon material and the aqueous electrolyte) in specific weight ratios and by introducing into the composition a combination of specific additives.
According to a particularly preferred embodiment of the invention, the printable composition used for preparing the electrodes comprises high surface area activated carbon particles and an aqueous electrolyte, wherein the preferred weight ratio between said activated carbon particles and said aqueous electrolyte is in the range of 1:8 to 1:20, and most preferably in the range of 1:10 to 1:18.
Preferably, the printable composition used for preparing the electrodes according to the invention further comprises one or more additives selected from the group consisting of inorganic fillers, which are preferably chosen from among fumed silica, high surface area alumina, bentonites or other clays, glass spheres and ceramics; one or more hydroxy-containing compounds, such as alcohols or polyols, wherein the hydroxy group(s) is (are) attached to C 1 -C 7 alkyl, C 2 -C 7 alkenyl, C 3 -C 7 alkynyl or C 3 -C 7 carbocyclic radical; and a salt. The inventor has surprisingly found that the presence of small amounts of one or more salts in combination with polyols reduces the viscosity of the printable composition. Thus, according to a particularly preferred embodiment, the printable composition comprises hydroxy-containing compound that is a polyol, and most preferably, propylene glycol, together with a small amount of a salt, which is preferably NaCl.
As used hereinabove, the term “separating medium” encompasses both separators and membranes according to their acceptable meanings in the art. Most preferably, the separating medium is provided in the form of a porous film known in the art as a separator.
Preferably, the method according to the invention comprises blocking the pores of said separator in those regions thereof which correspond with those regions of the current collector that have no electrodes printed thereon by applying through the non-masked regions of said second template a suitable sealant onto the face of said separator and rapidly curing said sealant to prevent passage thereof into those regions of the separator which need to be in contact with the electrode. Subsequently, one or more adhesive layers are applied onto the blocked regions of the separator, to allow the attachment of said separator to the current collector.
The fabrication method according to the invention provides a laminated structure, the external layers of which are the current collectors plates having well-defined electrode regions printed on their internal faces, and intermediate layer, which is a continuous separating medium interposed between the internal faces of the current collectors and affixed thereto by means of suitable adhesives, such that the electrodes are confined within said well-defined regions, the seepage of the electrolyte solution from said regions being prevented by virtue of the sealant blocking the pores of the separating medium and the adhesives provided along the perimeter of the electrodes.
The fact that the intermediate separator constitutes a continuous medium along the laminated structure described above is an important feature of the present invention, since, as may be readily appreciated, the electrochemical capacitors may be easily isolated from said laminated structure such that in each individual capacitor, the separator interposed between the electrodes is contiguous with the boundaries of the capacitor, and therefore, each individual capacitor is provided with an effective circumferential enclosure due to the sealant peripherally blocking the pores of the separator, and the adhesive layer(s) deposited on said sealant in the margins of said separator.
The electrochemical capacitor obtained by a preferred embodiment of the preparation method according to the invention is characterized by novel structural features, associated with the sequential blocking of the pores of the separator. Thus, in another aspect, the present invention provides an electrochemical capacitor comprising:
at least a pair of current collector plates that are placed in parallel to each other,
flat electrodes containing aqueous electrolyte printed on opposing faces of said current collectors, such that a peripheral region is defined on each of said faces of said current collectors, which region is not covered by said electrode, and
a separator interposed between said electrodes, the geometric form and size of said separator being identical to the form and size of said current collector plates, said separator having a central region permeable to said electrolyte, surrounded by a peripheral masked region which is non-permeable to said electrolyte, such that the permeable region of said separator coincide with the electrodes printed on the opposing faces of said current collectors, with respect to position, geometric form and size;
wherein the pores in the peripheral region of the separator are impregnated with a suitable sealant, and wherein one or more layers of adhesives are deposited on said sealant.
Preferably, the sealant blocking the pores of the separator in the electrochemical capacitor according to one preferred embodiment of the present invention is made of a printable, rapidly curable material, and is most preferably UV curable epoxy.
The electrochemical capacitor obtained by a preferred embodiment of the preparation method according to the invention is characterized by novel chemical features, associated with the composition of the electrode. Thus, in another aspect, the present invention provides an electrochemical capacitor comprising:
at least a pair of current collector plates that are placed in parallel to each other,
flat electrodes containing aqueous electrolyte printed on opposing faces of said current collectors, such that a peripheral region is defined on each of said faces of said current collectors, which region is not covered by said electrode, and
a separator interposed between said electrodes, the geometric form and size of said separator being identical to the form and size of said current collector plates, said separator having a central region permeable to said electrolyte, surrounded by a peripheral masked region which is non-permeable to said electrolyte, such that the permeable region of said separator coincide with the electrodes printed on the opposing faces of said current collectors, with respect to position, geometric form and size;
and wherein the electrode comprises carbon particles, aqueous electrolyte, inorganic filler selected from the group consisting of fumed silica, high surface area alumina, bentonites, glass spheres and ceramics and one or more hydroxy-containing compound(s), which are preferably alcohols or polyols, wherein the hydroxy group(s) is (are) attached to C 1 -C 7 alkyl, C 2 -C 7 alkenyl, C 3 -C 7 alkynyl or C 3 -C 7 carbocyclic radicals, and optionally an inorganic salt, which is preferably selected from the group of alkali halides. Preferably, the inorganic filler is fumed silica, the hydroxy-containing compound is a polyol, which is preferably propylene glycol, and the salt is NaCl.
In another aspect, the present invention relates to bi-polar electrochemical capacitor comprising, as a basic cell unit, the electrochemical capacitor disclosed above.
All the above and other characteristics and advantages of the present invention will be further understood from the following illustrative and non-limitative description of preferred embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a current collector before and after the deposition of electrodes thereon by the method of the present invention.
FIG. 2 shows a separator before and after the partial masking of well-defined regions thereof by the method of the present invention.
FIGS. 3 a and 3 b provide sectional views of laminated structures obtainable according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The method for preparing an electrochemical capacitor according to the present invention involves the preparation of a printable composition comprising carbon material, an aqueous electrolyte and preferably one or more additives selected from the group consisting of fumed silica and hydroxy-containing compounds which are preferably alcohols or polyols.
Preferably, the printable composition used to prepare the electrodes according to the present invention comprises carbon particles having specific surface area above 800 m 2 ·g −1 , and more preferably above 1200 m 2 ·g −1 . Suitable carbon particles include, but not limited to, activated carbon or activated charcoal and carbon black. Methods for preparing activated carbon suitable for use in the preparation of electrodes for electrochemical capacitors are known in the art (see, for example, U.S. Pat. No. 6,310,762). Commercially available activated carbon for use according to the present invention is, for example, Black Pearl carbon 2000 manufactured by Cabot. The percentage of the carbon material of the total weight of the printable composition is in the range of 4 to 10 (wt %), and more preferably in the range of 5 to 9 (wt %).
The printable composition used to prepare the electrodes according to the present invention comprises an aqueous electrolyte, which may be either acidic or alkaline solution. Preferred electrolytes are strong or weak acids such as sulfuric acid, phosphoric acid and hydrobromic acid, most preferred being an aqueous solution of sulfuric acid. The weight percentage of the aqueous solution of the electrolyte of the total weight of the printable composition is in the range of 80 to 96 (wt %), and more preferably in the range of 85 to 95 (wt %), with the weight ratio between the carbon material and said aqueous electrolytic solution being above 1:8, and more preferably between 1:10 to 1:18.
The printable composition used to prepare the electrodes according to the present invention comprises inorganic filler having thickening and thixotropic properties selected from the group consisting of fumed silica, high surface area alumina, bentonites or other clays, glass spheres and ceramics, most preferred being fumed silica, which is amorphous silicon dioxide having high external surface area. Commercially available fumed silica includes, for example, CAB-O-SIL™ M-5 (CAS No. 112945-52-5). The weight percentage of the inorganic filler of the total weight of the printable composition is in the range of 0.1% to 4%, and more preferably in the range of 0.5% to 2.5%.
The printable composition used to prepare the electrodes according to the present invention preferably comprises a compound containing one or more hydroxy groups, and more specifically, alcohols or polyols, wherein the hydroxy group(s) is (are) attached to C 1 -C 7 alkyl, C 2 -C 7 alkenyl, C 2 -C 7 alkynyl or C 3 -C 7 carbocyclic radicals, or a mixture of such hydroxy-containing compounds. Most preferred are polyols such as 1,2-ethanediol or 1,2-propandiol (i.e, propylene glycol). The percentage of the hydroxy-containing compound(s) of the total weight of the printable composition is in the range of 0.1 to 20 (% wt), and more preferably in the range of 0.3% to 10%.
It has been unexpectedly found that the presence of alkali halide salt in an amount of about 0.2 to 5 (wt %) of the total weight of the printable composition, improves the flowability properties of said composition.
Other additives that can be used in the preparation of the printable composition according to the present invention may be selected from the group consisting of metal oxides (e.g., oxides of platinum, titanium and ruthenium), thickening and thixotropic agents, surface-active agents, wetting agents, emulsifiers (e.g., fish oil), polymers and copolymers such as polyvinylacetate (PVA), polymethyl methacrylate (PMMA), polyethylene glycol (PEG), PAA, Carbomer, gelatin, water based adhesives, quinones or polyquinones. Graphite and carbon in the form of carbon fibers, fullerenes and buckeyballs may also be used in the preparation of the printable composition.
The printable composition according to the invention may be prepared by mixing together the solid constitutes (i.e., the carbon material and the inorganic filler), and subsequently gradually adding the liquids comprising the aqueous electrolyte and the hydroxy-containing compound, (i.e., the alcohol(s) or polyol(s)) to the solid mixture, optionally together with the salt, while continuously vigorously mixing the blend to obtain a uniform composition having paste-like consistency. However, the printable composition may also be prepared by a different order of operations, such as by adding the fumed silica into a mixture of the carbon material, the electrolyte solution and the alcohol(s) or polyol(s).
FIG. 1 schematically illustrates the process of forming well-defined electrode regions on a current collector plate by means of screen-printing technique. It should be noted, however, that other printing techniques, such as stencil printing, may also be applied for depositing the electrodes onto the current collector.
Referring now to FIG. 1 , current collector plate 1 is made of a conductive material that is chemically inert to the aqueous electrolyte contained in the electrode. The current collector may be provided in the form of a metal foil, such as aluminum foil, plated metal or metal coated with a protective oxide. Alternatively, the current collector is a polymeric sheet, such as polyethylene or Polytetrafluoroethane (Teflon), loaded with conductive particles such as carbon black, graphite, metallic or plated metallic particles. In another embodiment, the current collector has a multilayer structure comprising alternating layers of suitable polymers, metal foils and carbon or graphite, or similar combinations. The thickness of the current collector is preferably in the range of 10 μm to 150 μm.
Template 2 is provided in the form of a mesh or stencil suitable for use in printing techniques, wherein said mesh or stencil consists of regions 3 permeable to the printable composition, and masked regions 4 , non-permeable to said composition, wherein each of said permeable regions has a well-defined geometrical form corresponding to the form of the final electrochemical capacitor to be produced. For the purpose of illustration, sixteen separated non-masked, permeable regions having a square shape are shown in the figure, although, of course, a different number of non-masked regions of other shapes, such as rectangular or circular shapes, is also applicable. Typically, in case that the non-masked, permeable regions are in the form of a square, the side thereof has a size in the range of 0.5 to 60 mm, more preferably 5 to 20 mm. An important feature of the template is that its margins 5 are always masked.
The template 2 may be prepared by masking commercially available screen (40 to 250 mesh) according to the desired pattern by methods well known in the art.
Current collector 1 is placed on the vacuum surface of a screen-printing device (not shown), wherein template 2 is used as the screen. The printable composition according to the present invention is screen-printed through template 2 onto one face of the current collector 1 . Numeral 11 shows the resulting current collector, having sixteen well-defined, separated electrode regions 12 thereon. The thickness of the electrode layer is typically about 10 to 120μ. The procedure described above is repeated in respect to a second current collector, to produce a second current collector having electrodes printed thereon.
FIG. 2 illustrates a preferred mode of blocking the pores of the separator in those regions thereof that correspond with those regions of the current collectors that have no electrodes printed thereon. It should be noted, however, that various techniques may be used according to the present invention in order to selectively block the pores of the separator in the desired regions, which techniques include impregnating said pores with a suitable sealant, or with a mixture of sealants, wherein said sealant(s) may optionally be carried in a liquid vehicle. The impregnation may be accomplished by means of screen-printing or spraying the sealant onto said regions.
Alternatively, a polymeric sheet may be placed on the separator, following which said sheet is selectively heated in the desired regions, such that the molten polymer flows into the pores in said regions.
Other techniques for blocking the desired regions of the separator include the application of heat and/or pressure, in order to cause the porous structure to collapse in said regions. Combinations of the above-described techniques are also applicable according to the present invention.
It may be appreciated that according to the present invention, the sealant needs to be rapidly curable, that is, the sealant must be capable of transforming from a flowable form into solid, non-flowable form, within a short period of time, in order to avoid its passage into those regions of the separator which need to be in contact with the electrode. Typically, the sealant needs to be cured within seconds or minutes, depending on the thixotropic properties thereof and the characteristics of the separator (e.g., material, pore size). The curing of the sealant may be accomplished by methods known in the art, such as UV, IR or microwave or heat drying curing, or by polymerizing the sealant monomer by other means.
FIG. 2 shows the selective blocking of the desired regions of the separator by means of screen-printing technique. Separator 6 used according to the present invention is provided in the form of an inert, porous, electronically non-conductive, ion-permeable film, made of material inert to the aqueous electrolyte contained in the electrodes. The separator may be a glass fiber sheet or may be made of polyethylene, polypropylene, polyester, cellulose, Teflon or PVDF, or a composite of a polymer and a suitable filler. Teflon or cellophane-made separators may be used in case of acidic or alkaline electrolyte, respectively. The thickness of the separator is in the range of 5 to 50μ and its porosity typically varies within the range of 30 to 80%.
A second template 7 is provided in the form of a screen or stencil suitable for use in printing techniques. The screen may be made of polyester, nylon, stainless steal or coated stainless. As shown in the figure, the screen consists of a plurality of separated masked regions 8 and a non-masked region 9 , such that said screen is essentially complementary to the first template 2 shown in FIG. 1 . The preparation of template 7 is carried out similarly to that of template 2 . The meshes of the template 7 must permit the penetration of the adhesive materials, which need to be screen printed onto the separator, into the pores of the separator. To this end, a mesh corresponding to about 20 cm 3 per square meter printing volume is generally satisfactory.
Separator 6 is placed on the vacuum surface of a screen-printing device (not shown) wherein template 7 is used as the screen. The pores of separator 6 are blocked by a suitable sealant that is screen-printed onto Separator 6 through template 7 . The resulting, partially blocked separator is indicated by numeral 10 , wherein the non-masked and blocked regions are indicated by numerals 13 and 14 , respectively. The sealant used may be selected from the group consisting of hot melt adhesives, solvent based adhesives, polyurethanes, silicones, cyanoacrylates, PVC adhesives, Acrylic adhesives, UV based adhesives, water based glues, polysulfides rubber or synthetic rubbers, phenolic resins pressure sensitive adhesives, UV cured pressure sensitive adhesives and solvent based pressure sensitive adhesives. Most preferably, epoxy that is based on UV curing is screen-printed onto the separator 6 , and is subsequently immediately cured by means of exposure to UV light.
Having cured the sealant used to block region 14 of separator 10 , one or more adhesive layers are screen-printed onto separator 10 through template 7 . Suitable adhesives may be selected from among the classes specified above.
The adhesive face of separator 10 is subsequently affixed to the first current collector, such that the non-masked regions 13 on said face of said separator coincide with the electrodes 12 printed on the face of said first current collectors, with respect to position, geometric form and size. The current collector and the separator may be pressed or laminated together in vacuum to exclude air voids. The structure obtained is placed on the vacuum table of a screen-printing device, with the separator facing upwardly, and the procedure described above regarding the blocking of the desired regions of the separator, and the subsequent application of adhesive layers onto the blocked regions is repeated with respect to the second face of the separator.
A second current collector is then affixed to the separator, to produce the laminated structure represented in FIG. 3 a . The laminated structure comprises external layers, which are the current collectors plates 11 having sixteen well-defined electrodes printed on their internal faces (not shown), and intermediate layer, which is a continuous separator 10 interposed between the internal faces of the current collectors 11 , said separator being impregnated with a suitable sealant, such that the pores of the separator are essentially blocked in those regions thereof which are not placed between the electrodes. The separator 10 is affixed to the current collectors 11 by means of adhesive layers 15 , 16 (shown in black in the figure).
It is apparent from the figure that the laminated structure according to the invention is sealed along its circumference by means of the sealant blocking the pores of separator 10 , and adhesive layers 15 and 16 deposited on said sealant. The existence of distinct layers of a sealant material blocking the pores of the separator and one or more adhesives deposited thereon, is an important feature of the laminated structure according to the invention, which feature may be detected by using optical means.
Individual electrochemical capacitors may be easily isolated from the laminated structure described in FIG. 3 a , such that each individual capacitor comprises a pair of current collectors having electrodes printed on their internal faces and a separator interposed therebetween, the geometric form and size of said separator being identical to the form and size of said current collector, said separator being contiguous with the boundaries of the capacitor. Each of the isolated capacitors obtained is capable of storing charge and may be used as an electric double-layer capacitor with a dielectric strength corresponding to about 0.7 to 1.0 volts. For many practical utilities, however, it is preferred to assembly together a plurality of laminated structures of FIG. 3 a to produce the bi-polar arrangement illustrated in FIG. 3 b . it should be noted, that each face of internally placed current collector plates 17 is provided with well-defined regions of electrodes (not shown) printed thereon. According to the bi-polar configuration, the electrodes printed on different faces of a given current collector are oppositely charged. The assembly of a plurality of laminated structures of the invention, to obtain the bi-polar configuration shown in FIG. 3 b , may be accomplished by methods known in the art.
The electrochemical capacitor according to the invention, either in its simplest form comprising one pair of current collectors having electrodes printed on their internal faces and a separator interposed therebetween, or in the bi-polar configuration, are isolated from the laminated structures of FIGS. 3 a and 3 b , respectively, and are subsequently packed within a suitable casing and connected to external terminals by methods well known in the art.
The following non-limiting working examples illustrate various aspects of the present invention.
EXAMPLES
Example 1
Preparing a Printable Composition for the Electrodes
Ingredients:
Activated carbon
Sulfuric acid
Fumed silica
6 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 1 gram of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained were added 93 grams of an aqueous solution of H 2 SO 4 (4M). Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 2
Preparing a Printable Composition for the Electrodes
Ingredients:
Activated carbon
Sulfuric acid
Fumed silica
Propylene glycol
35 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 2 grams of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained was added a mixture of 520 grams of an aqueous solution of H 2 SO 4 (3M) and 16 grams of propylene glycol. Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 3
Preparing a Printable Composition for the Electrodes
Ingredients:
Activated carbon
Sulfuric acid
Fumed silica
butanol
35 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 2 grams of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained was added a mixture of 520 grams of an aqueous solution of H 2 SO 4 (2.5M) and 16 grams of butanol. Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 4
Preparing a Printable Composition for the Electrodes
Ingredients:
Activated carbon
Sulfuric acid
Fumed silica
Propylene glycol
Sodium chloride
35 grams of high-surface area activated carbon (Black Pearl Carbon 2000 Manufactured by Cabot Corporation) were mixed with 2 grams of fumed silica (CAB-O-SIL™ grade M-5 of Cabot Corporation). To the powder obtained was added a mixture of 520 grams of aqueous solution of H 2 SO 4 (2M), 13 grams of propylene glycol and 3 grams of sodium chloride. Following an extensive mixing for 24 hours using ball mills, a paste-like composition is formed, suitable for screen-printing applications.
Example 5
Depositing Electrodes on Current Collectors
A current collector plate was placed on the vacuum table of a screen-rinting device provided with a polyester screen of 165 mesh, said screen having the form illustrated in FIG. 1 . The printable composition of example 4 was screen printed onto the one face of the current collector, to form sixteen separated electrodes thereon. The procedure was repeated in respect to a second current collector.
Example 6
Masking the Pores of a Separator and Depositing Adhesives Thereon
A separator was placed on the vacuum table of a screen-printing device provided with a polyester screen of mesh corresponding to 18 cc per m 2 (325 mesh), which screen has the form illustrated in FIG. 2 . UV curable epoxy (Vitralit 1712) was screen-printed onto the separator, which was immediately subjected to UV radiation, in order to rapidly cure the epoxy. The separator was placed again on the vacuum table of the screen-printing device, and a suitable adhesive (Diglyceretherbisphenol CH 2 OCHCH 2 O—C 6 H 4 C (CH 3 ) 2 —C 6 H 4 OCH 2 CHOCH 2 (Epon-828 manufactured by shell or GY-250 manufactured by Henkel), in combination with Polypropyletheramine (Aradur 76 manufactured by Henkel)) was screen-printed thereon using the mesh described above.
Example 7
Preparation of a Laminated Structure
The adhesive face of the separator obtained by Example 6 was affixed to the printed face of one of the current collectors according Example 5, and the procedure of Example 6 was repeated in respect to the open face of said separator, following which the second current collector was affixed thereto.
While specific embodiments of the invention have been described for the purpose of illustration, it will be understood that the invention may be carried out in practice by skilled persons with many modifications, variations and adaptations, without departing from its spirit or exceeding the scope of the claims.
|
The invention relates to a double layer capacitor comprising:
at least a pair of current collector plates that are placed in parallel to each other,
flat electrodes containing aqueous electrolyte printed on opposing faces of said current collectors, such that a peripheral region is defined on each of said faces of said current collectors, which region is not covered by said electrode, and
a separator interposed between said electrodes, the geometric form and size of said separator being identical to the form and size of said current collector plates, said separator having a central region permeable to said electrolyte, surrounded by a peripheral masked region which is non-permeable to said electrolyte, such that the permeable region of said separator coincide with the electrodes printed on the opposing faces of said current collectors, with respect to position, geometric form and size;
wherein the pores in the peripheral region of the separator are impregnated with a suitable sealant, and wherein one or more layers of adhesives are deposited on said sealant in said peripheral region.
Also provided are method involving printing techniques for preparing electrochemical cells based-energy storage devices, and printable composition suitable for the preparation of electrodes for electrochemical cells based-energy storage devices.
| 8
|
FIELD OF THE INVENTION
[0001] This invention relates to medical uses of radiopharmaceuticals. Specifically, the present invention relates to the use of radioisotope complexes to treat osteomyelitis.
BACKGROUND OF THE INVENTION
[0002] Osteomyelitis is infection in the bones. Often, the original site of infection is elsewhere in the body, and spreads to the bone by the blood. The bone may be predisposed to infection due to a recent minor trauma that results in a blood clot or hemostasis. In children, the long bones are usually affected. In adults, the vertebrae, head, and the pelvis are most commonly affected. Bacteria or fungi are the usual organisms, but any microbe may be responsible for the infection. Pus is produced within the bone, which may result in a bone abscess. The abscess then deprives the bone of blood supply. Chronic osteomyelitis results when the causative microbes become resistant to antimicrobial agents. This may occur due to development of cellular mechanisms to circumvent the antimicrobial agents, formation of biofilms which allow quiescent organisms to remain untouched by antimicrobial agents, death of bone tissue as a result of the lost blood supply, and other mechanisms. Chronic infection can persist for years with intermittent exacerbations. Risk factors for chronic infection are recent trauma, diabetes, hemodialysis patients, IV drug abuse, and infection with organisms that are more adept at forming biofilms or developing antimicrobial resistance. Tuberculous osteomyelitis is caused by tubercle bacilli that enter the bloodstream and settle in a bone. The disease progresses slowly and is chronic. Any bone may be infected but those most commonly involved are the vertebrae. Spinal tuberculosis, or “Pott's disease” causes bone destruction and spinal deformities. Other bones that may be affected are the longer bones of the hands or feet. The total incidence of osteomyelitis is 2 out of 10,000 people.
[0003] Symptoms of osteomyelitis primarily include pain in the bone, bone tenderness, local swelling and warmth (facial swelling), fever, nausea, general discomfort, uneasiness, or ill feeling (malaise), and drainage of pus through the skin in chronic infection. Additional symptoms include sweating, excessive chills, back pain, and low-grade swelling of the ankle, feet, or the leg. Osteomyelitis is diagnosed through physical examination showing bone tenderness, swelling and redness, elevated white blood cell count, elevated ESR, blood cultures that identify the causative organism, needle aspiration of vertebral space for culture, bone lesion biopsy and culture, bone scans, and drainage of a skin lesion with a sinus tract (the lesion “tunnels” under the tissues) for culture.
[0004] The outcome of treatment for acute osteomyelitis is usually good, but when treatment of acute osteomyelitis fails the outcome of treatment for chronic osteomyelitis is worse, even with surgery. Chronic infection may result in bone destruction, in stiffening of joints if the infection spreads to the joints, and, in extreme cases occurring before the end of the growth period, in the shortening of a limb if the growth center is destroyed. Resistant chronic osteomyelitis may result in amputation and can threaten life through seeding of the microorganisms to cardiac valves, the lungs, and the brain.
[0005] Treatment for osteomyelitis focuses on eliminating the infection and preventing the development of chronic infection. High-dose intravenous antibiotics are given initially. The type of antibiotics and the route of administration may later be changed depending on culture results. Typical lengths of treatment for acute osteomyelitis vary from 6 weeks to 6 months depending on the organism and the anatomy of the infection site. In chronic infection, surgical removal of dead bone tissue is indicated. The open space left by the removed bone tissue may be filled with bone graft or by packing material to promote the growth of new bone tissue. Antibiotic therapy is continued for at least 3 weeks after surgery. Infection of an orthopedic prosthesis requires surgical removal with debridement of the infected tissue surrounding the area. A new prosthesis may be implanted in the same operation, or delayed until the infection has resolved, depending on its severity. Estimates of the percentage of acute osteomyelitis cases that become chronic osteomyelitis cases vary from about 10% to about 30%. Once the osteomyelitis has become chronic, biofilms or abscesses usually have developed, protecting the microbes from treatment with antibiotic drugs.
[0006] The currently available antibiotic treatments are expensive, inconvenient, frequently ineffective, and subject to many complications. Thus, there is a need for additional therapies for osteomyelitis.
SUMMARY OF THE INVENTION
[0007] In one aspect, the present invention is a method for the treatment of osteomyelitis comprising: providing a subject suffering from osteomyelitis and a pharmaceutical composition comprising a radionuclide; and parenterally (usually intramuscularly or intravenously) administering the composition to the patient under conditions such that the osteomyelitis is reduced.
[0008] In a second aspect, the present invention is a method for the treatment of osteomyelitis comprising: locally administering a composition comprising a radionuclide to a subject suffering from osteomyelitis under conditions such that the osteomyelitis is reduced.
[0009] In a third aspect, the present invention is a method for the treatment of osteomyelitis comprising the steps of applying a tourniquet to a subject suffering from osteomyelitis; and administering a composition comprising a radionuclide to the subject under conditions such that the osteomyelitis is reduced. The present invention provides improved system and methods of for the direct delivery of radiopharmaceuticals to the site of osteomyelitis.
[0010] The present invention provides improved system and methods of for the direct delivery of radiopharmaceuticals to the site of osteomyelitis.
DESCRIPTION OF THE INVENTION
[0011] Before the present compositions and methods are described, it should be noted that the present invention is not limited to the particular methodology and compositions described herein as these may vary. It should also be understood that the terminology used herein is for the purpose of describing particular aspects of the invention, and is not intended to limit its scope, which will be limited only by the appended claims.
[0012] It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a subject” includes a plurality of such subjects, reference to the “radionuclide” is a reference to one or more radionuclides and equivalents thereof known to those skilled in the art, and so forth.
[0013] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods, devices, and materials are now described. All publications mentioned herein are incorporated herein by reference for the purpose of describing and disclosing the compositions and methodologies that are reported in the publications which might be used in connection with the invention. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.
[0014] As used herein, the term “disease” refers to pathologies and deleterious conditions, such as infections, inflammatory responses, cancer, autoimmune, and genetic disorders.
[0015] As used herein the term “microorganism” refers to microscopic organisms and taxonomically related macroscopic organisms within the categories of algae, bacteria, fungi (including lichens), protozoa, viruses, and subviral agents. The term microorganism encompasses both those organisms that are in and of themselves pathogenic to another organism (e.g., animals, including humans, and plants) and those organisms that produce agents that are pathogenic to another organism, while the organism itself is not directly pathogenic or infective to the other organism.
[0016] As used herein the term “pathogen” refers to an organism (including microorganisms) that causes disease in another organism (e.g., animals and plants) by directly infecting the other organism, or by producing agents that cause disease in another organism (e.g., bacteria that produce pathogenic toxins and the like).
[0017] As used herein, the term “osteomyelitis” refers to an infection of the bone. Osteomyelitis infections are generally caused by a pathogenic microorganism (e.g., a bacteria or a fungus). Osteomyelitis includes both acute and chronic (e.g., persistent) bone infections.
[0018] “Systemic infection” as used herein denotes infection throughout a substantial part of an organism including mechanisms of spread other than mere direct cell inoculation but rather including transport from one infected cell to additional cells either nearby or distant.
[0019] As used herein, term “subject suffering from osteomyelitis” refers to a subject that has one or more symptoms of osteomyelitis (e.g., including but not limited to, pain in the bone, bone tenderness, and swelling or warmth) or a positive diagnosis based on one or more diagnostic tests (e.g., including but not limited to, a bone scan, blood culture, or culture of the infectious lesion).
[0020] As used herein, the term “subject suffering from osteomyelitis at a particular site of infection” refers to a “subject suffering from osteomyelitis” wherein the osteomyelitis has been identified as being in a particular bone or region of bone or in several particular bones or regions of bones.
[0021] As used herein, the term “such that said osteomyelitis is reduced” refers to the reduction of infection based on the lack of one or more symptoms of osteomyelitis (e.g., including but not limited to, pain in the bone, bone tenderness, and swelling or warmth) or a negative diagnosis based on one or more diagnostic tests (e.g., including but not limited to, a bone scan, blood culture, or culture of the infectious lesion).
[0022] As used herein, the term “radionuclide” refers to a nuclide that disintegrates with the emission of corpuscular or electromagnetic radiation. As used herein, the term “nuclide” refers to a species of atom characterized by the charge, mass number and quantum state of its nucleus that is stable for a measurable lifetime (e.g., greater than 10-10 seconds). The methods of the present invention are not limited to a particular radionuclide. Any suitable radionuclide may be utilized, including but not limited to, those disclosed herein.
[0023] As used herein, the term “pharmaceutical composition comprising a radionuclide” refers to any pharmaceutically acceptable composition that comprises a radionuclide and any sterile, biocompatible pharmaceutical carrier. Pharmaceutical compounds may also include additional active agents such as, including but not limited to, ligands complexed to the radionuclides.
[0024] The terms “pharmaceutically acceptable” and “pharmacologically acceptable,” as used herein, refer to compositions that do not substantially produce adverse allergic, immunological or other reactions when administered to a host (e.g., an animal such as a human). As used herein, “pharmaceutically acceptable carrier” includes any and all solvents (e.g., including but not limited to, saline, buffered saline, dextrose and water), dispersion media, coatings, wetting agents (e.g., sodium lauryl sulfate), isotonic and absorption delaying agents, disintrigrants (e.g., potato starch or sodium starch glycolate), and the like.
[0025] As used herein, the term “locally administering a composition comprising a radionuclide to subject suffering from osteomyelitis at said site of infection” refers to administering a pharmaceutical composition of the present invention directly to the site of osteomyelitis (e.g., a limb bone).
[0026] As used herein, the term “ligand” refers to any compound capable of physically interacting with a radionuclide of the present invention. In some embodiments, the radionuclide is chelated by electron donor groups of the ligand. However, any interaction that results in stable complexes when administered to a subject using the methods of the present invention is suitable. The term “ligand” is also not intended to be limited by the chemical nature of the compound. In preferred embodiments, a macrocyclic or acyclic aminophosphonic acid is used as a ligand for complexing with a radionuclide of the present invention.
[0027] The term “cyclic compounds” refers to compounds having one (i.e., a monocyclic compounds) or more than one (i.e., polycyclic compounds) ring of atoms. The term is not limited to compounds with rings containing a particular number of atoms. While most cyclic compounds contain rings with five or six atoms, rings with other numbers of atoms (e.g., three, four, or twelve atoms) are also contemplated by the present invention. The identity of the atoms in the rings is not limited, though the atoms are usually predominantly carbon atoms. Generally speaking, the rings of polycyclic compounds are adjacent to one another. However, the term “polycyclic compound” includes those compounds containing multiple rings that are not adjacent to each other.
[0028] The terms “macrocyclic compound” and “macrocycle” refer to a “cyclic compound” with a ring containing more than about eight atoms.
[0029] The term “heterocyclic compounds” refers broadly to cyclic compounds wherein one or more of the rings contains more than one type of atom. In general, carbon represents the predominant atom, while the other atoms include, for example, nitrogen, sulfur, and oxygen. Examples of heterocyclic compounds include benzimidazole, furan, pyrrole, thiophene, and pyridine.
[0030] As used herein, the term “parenteral administration” includes all routes of administering an agent (e.g., a pharmaceutical composition of the present invention) that are not through the gastrointestinal route. Examples of parenteral administration include, but are not limited to, intravenous, intra-arterial, intramuscular, local, subcutaneous, intradermal, and transcutaneous administration.
[0031] The terms “aromatic,” “aromatic compounds,” and the like refer broadly to compounds with rings of atoms having delocalized electrons. The monocyclic compound benzene (C 6 H 6 ) is a common aromatic compound. However, electron delocalization can occur over more than one adjacent ring (e.g., naphthalene [two rings] and anthracene [three rings]). Different classes of aromatic compounds include, but are not limited to, aromatic halides (aryl halides), aromatic heterocyclic compounds, aromatic hydrocarbons (arenes), and aromatic nitro compounds (aryl nitro compounds).
[0032] As used herein the terms “meta substitution” and “meta position” when used in terms of substituted benzenes, refer to benzene derivatives substituted at positions 1 and 3 or 1 and 5 (i.e., each of the 6 carbons of the 6 membered benzene ring is numbered consecutively). As used herein, the terms “para substitution” and “para position” when used in terms of substituted benzenes, refer to benzene derivatives substituted at positions 1 and 4 of the benzene ring.
[0033] As used herein, the terms “aliphatic” and “aliphatic compounds” refer to compounds which comprise carbon atoms in chains, rather than the ring structure of cyclic compounds.
[0034] The term “mixture” refers to a mingling together of two or more substances without the occurrence of a reaction by which they would lose their individual properties. The term “solution” refers to a liquid mixture. The term “aqueous solution” refers to a solution that contains some water. In many instances, water serves as the diluent for solid substances to create a solution containing those substances. In other instances, solid substances are merely carried in the aqueous solution (i.e., they are not dissolved therein and are a “mixture” of an aqueous solution and the non-dissolved solid substances). The term aqueous solution also refers to the combination of one or more other liquid substances with water to form a multi-component solution.
[0035] “Acylate” as used herein, refers to the introduction of an acyl group into a molecule, (i.e., acylation).
[0036] “Biologically active”, as used herein, refers to a molecule having the structural, regulatory, or biochemical functions of a naturally occurring molecule.
[0037] “Cell culture” as used herein, refers to a proliferating mass of cells that may be in either an undifferentiated or differentiated state.
[0038] “Immunologically active” refers to the capability of a natural, recombinant, or synthetic polypeptide, or any oligopeptide thereof, to bind with specific antibodies and induce a specific immune response in appropriate animals or cells.
[0039] “Purified” as used herein when referring to a chemical compound or molecule, indicates that the molecule is present in the substantial absence of other chemical or biological compounds of the same type. The term “purified” as used herein preferably means at least 95% by weight, more preferably at least 99.8% by weight, of molecules of the same type present.
[0040] The term “pure” as used herein preferably has the same numerical limits as “purified” immediately above.
[0041] “Sample” as used herein, is used in its broadest sense. A biological sample may comprise a tissue, a cell, an extract from cells, blood, serum, and other bodily fluids.
[0042] The present invention provides methods for the treatment of osteomyelitis. Osteomyelitis is often diagnosed by a nuclear medicine bone scan using known radiopharmaceutical agents. The radiopharmaceuticals concentrate at the site of bone infection to show the presence of infection. Radiopharmaceuticals have also been used to treat bone cancers, arthritis, and to ablate bone marrow.
[0043] Accordingly, the present invention provides methods for the use of radiopharmaceuticals to treat osteomyelitis. The methods of the present invention find use in the treatment of all forms of osteomyelitis (e.g., acute or chronic infection). The present invention further provides delivery methods that increase the localization of the radioactivity to the bone, thus reducing the systemic radiation dose.
[0044] The methods and compositions described below are exemplary and are not intended to limit the scope of the invention. One skilled in the relevant art recognizes that additional suitable radiopharmaceuticals, ligands, dosages, and treatment formulations may be substituted for those disclosed herein.
[0045] I. Radiopharmaceuticals
[0046] The present invention provides radiopharmaceuticals for the treatment of osteomyelitis. The invention is not limited to a particular radioisotope or ligand. Any suitable radioisotope or ligand that functions to treat osteomyelitis may be utilized, including but not limited to, those disclosed herein. Guidance for selecting and screening agents for use in the methods of the present invention are described below.
[0047] A. Radionuclides
[0048] The radiopharmaceutical compositions of the present invention comprise one or more radionuclides. In preferred embodiments, the half-life of the radionuclides is sufficiently long to allow for localization and delivery of the complex in the bone tissue while still retaining sufficient radioactivity to kill pathogens present in the bone. Generally, it is preferred to use a radionuclide-ligand complex that results in rapid biolocalization of the radionuclide in the bone tissue so as to achieve rapid onset of pathogen irradiation. In preferred embodiments, a radionuclide having sufficient alpha or beta energy is utilized.
[0049] By preferentially delivering the radionuclide to the site of active bone infection, the radiation can be performed with nuclides that emit radiation with relatively short path lengths before absorption (e.g., beta radiation) with good microbe kill and less damage to other tissues. In addition, directly targeting the radionuclide to the site of infections allows the use of a nuclide with a relatively short half life (e.g., one or two days) that delivers its radiation dose quickly. This results in a higher likelihood that more of the pathogen will be killed. This is in direct contrast to the currently available methods of delivering a lower per minute dose of radiation over a longer time period that has the potential to allow more bacteria to repair any radiation damage and survive the treatment.
[0050] For example, in some embodiments, radionuclides utilized in the methods of the present invention exhibit beta energy >0.5 MeV, preferably >1 MeV with an effective half-life of about <5 days, preferably <3 days. Radionuclides useful in the methods and compositions of the present invention include, but are not limited to, Arsenic-77 ( 77 As), Molybdenum-99 ( 99 Mo), Rhodium-105 ( 105 Rh), Lutetium-177 ( 177 Lu), Cadmium-115 (115Cd), Antimony-122 ( 122 Sb), Promethium-149 (149Pr), Osmium-193 ( 193 Os), Gold-198 ( 198 Au), Tin-117m ( 177m Sn), Strontium-89 ( 89 Sr), Thorium-200 ( 200 Th) Indium-115 ( 115 In), Dysprosium-165 (165 Dy), Lanthanum-140 (140La), Ytterbium-175 ( 175 Yb), Scandium-47 ( 47 Sc); preferably Samarium-153 ( 153 Sm), Yttrium-90 ( 90 Y), Gadolinium-159 ( 159 Gd), Rhenium-186 (86 Re), Rhenium-188 (188 Re), and Holmium-166 ( 166 Ho). Especially preferred is 166 Ho, which emits high-energy beta particles and gamma radiation (80 KeV, 6.0%) useful for imaging and exhibits a half-life of 26.8 hr. In other embodiments, alpha emitters such as Actinium-225 ( 225 Ac), Bismuth-212 ( 212 Bi) and Bismuth-213 ( 213 Bi) are utilized.
[0051] The respective radionuclides can be obtained using procedures well known in the art. Typically, the desired radionuclide can be prepared by bombarding an appropriate target, such as a metal, metal oxide, or salt with neutrons. Another method of obtaining radionuclides is by bombarding nuclides with particles in a linear accelerator or cyclotron. Yet another way of obtaining radionuclides is to isolate them from fission product mixtures. The present invention is not limited to a particular method of obtaining radionuclides. Any suitable method that results in the generation of the desired radionuclide may be utilized.
[0052] B. Ligands
[0053] In some embodiments of the present invention, radionuclides are conjugated to pharmaceutically acceptable ligands. In particularly preferred embodiments, aminophosphonic acids, particularly macrocyclic and acyclic aminophosphonic acids, are utilized as ligands. These compounds are prepared by any suitable technique. Known synthetic techniques involve reacting a compound containing at least one reactive amine hydrogen with a carbonyl compound (aldehyde or ketone) and a phosphorous acid or appropriate derivative thereof.
[0054] Methods for carboxyalkylating macrocyclic amines to give amine derivatives containing a carboxylalkyl group are disclosed in U.S. Pat. No. 3,726,912, herein incorporated by reference. Methods to prepare alkylphosphonic acid amines and hydroxyalkylamines are disclosed in U.S. Pat. Nos. 3,398,198, 5,066,478, and 5,300,279, each of which is herein incorporated by reference.
[0055] The amine precursor (1,4,7,1 0-tetraazacyclododecane) employed in making certain of the macrocyclic aminophosphonic acids utilized in some embodiments of the present invention is a commercially available material. The preparation of macrocyclic aminophosphonic ligands can also be found in U.S. Pat. No. 5,059,412, herein incorporated by reference. The preparation of these ligands has also been described in U.S. Pat. Nos. 4,973,333, 4,882,142, 4,853,209, 4,898,724,4,897,254, 5,587,451, 5,714,604, 5,064,633, 5,587,451, 5,066,478, 5,300,279, 5,059,412, and 5,064,633, each of which is herein incorporated by reference. In preferred embodiments, ligands are selected from the group consisting of ethylenediaminetetramethylenephosphonic acid (EDTMP), diethylenetriaminepentamethylenephosphonic acid (DTPMP), hydroxyethylethylenediaminetrimethylenephosphonic acid (HEEDTMP), nitrilo-trimethylenephosphonic acid (NTMP), 1,4,7,1 0-tetraazacyclododecanetetramethylenephosphonic acid (DOTMP), tris(2-aminoethyl)amine hexamethylene-phosphonic acid (TTHMP), methylene diphosphonate, hydroxymethylenediphosphonate, hydroxyethylidene diphosphonate (HEDP), and ethane-1-hydroxy-1,1-diphosphonic acid. In particularly preferred embodiments, ligands are macrocyclic aminophosphonic acid ligands of which 1,4,7,10-tetraazacyclododecanetetramethylenephosphonic acid (DOTMP) is an example.
[0056] In addition to phosphorus based chelates, aminocarboxylic acids such as diethylenetriaminepentaacetic acid can also be used to deliver isotopes to bone tissue. For example, U.S. Pat. No. 6,231,832 teaches the delivery of Sn-117m to bone using such a chelator. Also, U.S. Pat. No. 4,897,254 teaches the uses of hydroxyethylethylenediaminetriacetic acid in combination with Sm-153 to deliver a radiation dose to bone.
[0057] C. Radionuclide-Ligand Complexes
[0058] In preferred embodiments, the methods and compositions of the present invention employ complexes of radionuclides and ligands. The complexes may be generated using any suitable method, including but not limited to, those disclosed herein. In preferred embodiments, the radionuclide complex must be taken up preferentially by bone so that it is possible to deliver radiation to the bone with minimal exposure to other tissues such as lung, liver, bladder or kidneys. In is also preferred that the radionuclide complex be rapidly cleared from the blood, thereby further reducing exposure to non-target tissues.
[0059] The radionuclide and ligand are combined under any conditions that allow the two to form a complex. Generally, mixing in water at a controlled pH (the choice of pH is dependent upon the choice of ligand and radionuclide) is suitable. The complex is formed by chelation of the radionuclide by an electron donor group or groups that results in a stable radionuclide complex (e.g., stable to the disassociation of the radionuclide from the ligand). For example, 166 Ho-DOTMP is formed by adding a 166 Ho salt, such as the chloride or nitrate in aqueous HCI (0.1-1 N), to a sterile, evacuated vial containing at least 3 equivalents of DOTMP in aqueous base (KOH, NaOH and the like). After stirring at a pH of 10.5, the pH is then adjusted to 7-8 by adding phosphate buffer and a stabilizing agent such as ascorbic acid. Complexation of >99% is generally achieved using such a method.
[0060] For the purpose of the present invention, radionuclide compositions described herein and physiologically acceptable salts thereof are considered equivalent. Physiologically acceptable salts refer to the acid addition salts of those bases which will form a salt with at least one acid group of the ligand or ligands employed and which will not cause adverse physiological effects when administered as described herein. Suitable bases include, but are not limited to, for example, the alkali metal and alkaline earth metal hydroxides, carbonates, and bicarbonates such as, for example, sodium hydroxide, potassium hydroxide, calcium hydroxide, potassium carbonate, sodium bicarbonate, magnesium carbonate and the like, amine hydroxides, carbonates, and bicarbonates such as, for example, ammonium hyroxide, ammonium carbonate, and the like, or primary secondary and tertiary amine hydroxides, carbonates, and bicarbonates such as, for example, trimethyl ammonium carbonate and the like. Physiologically acceptable salts can be prepared by treating the macrocyclic aminophosphonic acid with an appropriate base.
[0061] The macrocyclic aminophosphonic acid complexes when formed at approximately a ligand to metal molar ratio of 1:1 to 20:1 give biodistributions that are consistent with those exhibited by known agents that are bone-specific. The optimum ratio depends on the particular ligand utilized. Preferred osteomyelitic treating radionuclide compositions include 166 Ho-DOTMP, 177 Lu-DOTMP, and 153 Sm-EDTMP. Preferably, molar ratios of DOTMP to 166 Ho are above 1, e.g., from 1.5 to 3.5:1. The most preferred ratio is about 3.5:1. Such a ratio provides adequate complexation of the radionuclide while compensating for radiolysis of the ligand. By contrast, other acyclic aminophosphonic acid complexes can result in substantial localization of radioactivity in soft tissue (e.g., liver) if large excess amounts of ligand are not used. Large excesses of ligand are undesirable since uncomplexed ligand may be toxic to the patient or may result in cardiac arrest or hypocalcemic convulsions. In addition, the macrocyclic aminophosphonic acid ligands are useful when large amounts of metal are required (i.e. for metals that have a low specific activity). In this case, the macrocyclic aminophosphonic acid ligands have the ability to deposit more tolerable doses of radioactivity in the bone than is possible when using non-cyclic aminophosphonic acid ligands.
[0062] In the case of other ligands, such as EDTMP, a large excess of ligand is necessary. The most preferred ratio of EDTMP to Sm is 273:1. Aminocarboxylic acid ligands are also preferably present in large excess over radionuclide.
[0063] D. Pharmaceutical Compositions
[0064] In preferred embodiments, radionuclides and radionuclide-ligand complexes are administered as pharmaceutically acceptable compositions. A pharmaceutically acceptable means of protecting the radionuclide complex from radiolytic decay of the chelator is highly preferred. Preferred radioprotectants of the present invention are radio-stable anti-oxidants, compounds that either reduce the number or the activity of oxidizing radicals. Exemplary radio protectants that can be employed in the practice of the present invention are ascorbic acid, gentisic acid, nicotinic acid, ascorbyl palmitate, HOP(:O) H 2 , monothioglycerol, sodium formaldehyde sulfoxylate, Na 2 S 2 O 3 , SO 2 , or a reducing agent combined with BHA, BHT, pyrogallate, tocopherol, and the like. Ascorbic acid is the preferred radioprotectant for use in the practice of the present invention, and can be used at about 35-75 mg/ml of liquid composition. This concentration of ascorbate can provide a solution of 166 Ho-DOTMP that is stable (e.g., therapeutically useful), for at least 72 hours at ambient conditions (e.g., unfrozen).
[0065] The formulations of the present invention are in the solid or preferably liquid form containing the active radionuclide complexed with the ligand. These formulations can be in kit form such that the chelator and radionuclide are mixed at the appropriate time prior to use in a suitable liquid carrier with the radioprotectant. Whether premixed or as a kit, the formulations usually require a pharmaceutically acceptable carrier, such as water.
[0066] The pharmaceutical dosage forms suitable for injection or infusion can include sterile solutions, dispersions, emulsions, or microemulsions, comprising the active ingredients that are adapted for the extemporaneous preparation of sterile injectable or infusible solutions or dispersions, optionally encapsulated in protective matrices such as nanoparticles or microparticles. In all cases, the ultimate dosage form must be sterile, fluid, and stable under the conditions of manufacture and storage. The liquid carrier or vehicle can be a solvent or liquid dispersion medium comprising, for example, water, ethanol, a polyol (for example, glycerol, propylene glycol, liquid polyethylene glycols, and the like), DMSO, and suitable mixtures thereof. In many cases, it will be preferable to include isotonic agents, for example, sugars, buffers or sodium chloride.
[0067] Injectable suspensions as compositions of the present invention require a liquid suspending medium, with or without adjuvants, as a carrier. The suspending medium can be, for example, aqueous polyvinylpyrrolidone, inert oils such as vegetable oils or highly refined mineral oils, or aqueous carboxymethyl cellulose solutions. If necessary to keep the complex in suspension, suitable physiologically acceptable adjuvants can be chosen from among thickeners such as, for example, carboxymethylcellulose, polyvinylpyrrolidone, gelatin, and the alginates. Many surfactants are also useful as suspending agents, for example, lecithin, alkylphenol, polyethylene oxide adducts, naphthalenesulfonates, alkylbenzenesulfonates, and the polyoxyethylenesorbitan esters. Many substances that effect the hydrophobicity, density, and surface tension of the liquid suspension medium can assist in making injectable suspensions in individual cases. For example, silicone antifoams, sorbitol, and sugars are all useful suspending agents.
[0068] II. Treatment of Osteomyelitis
[0069] The present invention provides novel methods of treating osteomyelitis using radiopharmaceutical compositions. In some preferred embodiments, the compositions are delivered directly to the site of infection, thus decreasing the amount of radioactivity required to reduce infection. The present invention is not limited to the dosages and methods of administration described below. One skilled in the art recognizes that other suitable dosages and administration methods may be utilized in the practice of the present invention.
[0070] A. Dosages
[0071] The effective therapeutic amount of radionuclide composition administered to achieve elimination of osteomyelitis will vary according to factors such as the age, weight and health of the patient, the disease state being treated (e.g., chronic or acute infection), the treatment regimen selected (e.g., mode of administration), the amount of oxygen in the system, as well as the nature of the particular radionuclide composition to be administered. For example, less activity will be needed for radionuclides with longer half lives. The energy of the emissions will also be a factor in determining the amount of activity necessary. In some embodiments, a dose of about 10 to 1000 Gy is used. Preferably, a total dose of about 20-60 Gy, most preferably about 30-60 Gy, e.g., 40-50 Gy of radiation is delivered to bone parenterally (e.g., preferably via intramuscular injection or locally).
[0072] The radiation exposure is reported using the Grey scale (Gy). One Gy is equivalent to 100 Rads. A rad is defined as adsorbed energy of 100 ergs per gram. Because the biodistribution of radiopharmaceuticals vary from patient to patient, it is preferred to first administer a small dose and determine the biodistribution of the agent prior to giving the therapeutic dose. Radioactivity measurements of the isotope in blood, urine, bone, and infected areas are used to estimate the dose to the target and non-target areas. This is translated into a therapeutic dose for the individual patient. For example, in some embodiments, a diagnostic dose of about 1110-1850 MBq (about 30mCi to about 50 mCi) of Ho-166-DOTMP is used as a diagnostic dose to determine the therapeutic dose. Alternatively, a different agent, such as Tc-99m-MDP, that has a very similar biodistribution as the therapeutic agent can be given prior to the therapeutic dose. Determination of the doses of radiation delivered by the present complexes can be determined in accord with known methodologies (See e.g., Bardies et al., Physics in Medicine and Biology, 41,1941 (1996); Beddoe et al., Physics in Medicine & Biology, 21, 589 (1976); Bigler et al., Health Physics, 31, 213 (1976); Champlin et al., Semin. Hematol, 24, 55 (1987); Champlin et al., Cancer Treatment Reports, 68, 145 (1984); Eckerman et al., Journal of Nuclear Medicine, 35, 112P (1994); Spiers et al., British Journal of Radiology, 54, 500 (1981)).
[0073] B. Additional Therapeutic Agents
[0074] In some embodiments, radiopharmaceuticals are administered in combination with additional agents (e.g., including but not limited to, antibacterial, anti-parasitic, and antifungal agents, including those disclosed in The Physicians Desk Reference, 50th Edition, 1996).
[0075] Useful antibiotic agents include systemic antibiotics, such as aminoglycosides, cephalosporins (e.g., first, second, and third generation), macrolides (e.g., erythromycins), monobactams, penicillins, quinolones, sulfonamides, and tetracyclines, including those disclosed in The Physicians Desk Reference, 50th Edition, 1996. In addition, antibacterial agents include 2-isocephem and oxacephem derivatives disclosed in U.S. Pat. No. 5,919,925, herein incorporated by reference; pyridone carboxylic acid derivatives disclosed in U.S. Pat. No. 5,910,498, herein incorporated by reference; water miscible esters of mono- and diglycerides disclosed in U.S. Pat. No. 5,908,862, herein incorporated by reference; benzamide derivatives disclosed in U.S. Pat. No. 5,891,890, herein incorporated by reference; 3-ammoniopropenyl cephalosporin compounds disclosed in U.S. Pat. No. 5,872,249; 6-O-substituted ketolides disclosed in U.S. Pat. No. 5,866,549, herein incorporated by reference;
[0076] benzopyran phenol derivatives disclosed in U.S. Pat. No. 5,861,430, herein incorporated by reference; pyridine derivatives disclosed in U.S. Pat. No. 5,859,032, herein incorporated by reference; 2-aminothiazole derivatives disclosed in U.S. Pat. No. 5,856,347, herein incorporated by reference; penem ester derivatives disclosed in U.S. Pat. No. 5,830,889, herein incorporated by reference; lipodepsipeptides disclosed in U.S. Pat. No. 5,830,855, herein incorporated by reference; dibenzimidazole derivatives disclosed in U.S. Pat. No. 5,824,698, herein incorporated by reference; alkylenediamine derivatives disclosed in U.S. Pat. No. 5,814,634, herein incorporated by reference; organic solvent-soluble mucopolysaccharides disclosed in U.S. Pat. No. 5,783,570, herein incorporated by reference; arylhydrazone derivatives disclosed in U.S. Pat. No. 5,760,063, herein incorporated by reference; carbapenem compounds disclosed in U.S. Pat. No. 5,756,725, herein incorporated by reference; N-acylpiperazine derivatives disclosed in U.S. Pat. No. 5,756,505, herein incorporated by reference; peptides disclosed in U.S. Pat. No. 5,714,467, herein incorporated by reference; oxathiazines and their oxides disclosed in U.S. Pat. No. 5,712,275, herein incorporated by reference; 5-amidomethyl alpha beta-saturated and -unsaturated 3-aryl butyolactone compounds disclosed in U.S. Pat. No. 5,708,169, herein incorporated by reference; halogenated benzene derivatives disclosed in U.S. Pat. No. 5,919,438, herein incorporated by reference; sulfur-containing heterocyclic compounds disclosed in U.S. Pat. No. 5,888,526, herein incorporated by reference; and oral antibacterial agents disclosed in U.S. Pat. No. 5,707,610, herein incorporated by reference.
[0077] Antifungal agents include dermatological fungicides, topical fungicides, systemic fungicides, and vaginal fungicides, including those disclosed in The Physicians Desk Reference, 50th Edition, 1996. In addition, antifungal agents include terpenes, sesquiterpenes, diterpenes, and triterpenes disclosed in U.S. Pat. No. 5,917,084, herein incorporated by reference; sulfur-containing heterocyclic compounds disclosed in U.S. Pat. No. 5,888,526, herein incorporated by reference; carbozarnides disclosed in U.S. Pat. No. 5,888,941, herein incorporated by reference; phyllosilicates disclosed in U.S. Pat. No. 5,876,738, herein incorporated by reference; corynrcandin derivatives disclosed in U.S. Pat. No. 5,863,773, herein incorporated by reference; sordaridin derivatives disclosed in U.S. Pat. No. 5,854,280, herein incorporated by reference; cyclohexapeptides disclosed in U.S. Pat. No. 5,854,213, herein incorporated by reference; terpene compounds disclosed in U.S. Pat. No. 5,849,956, herein incorporated by reference; agents derived from aspergillus furnigatus disclosed in U.S. Pat. No. 5,873,726, herein incorporated by reference; inula extracts disclosed in U.S. Pat. No. 5,837,253, herein incorporated by reference; lipodepsipeptides disclosed in U.S. Pat. No. 5,830,855, herein incorporated by reference; polypeptides disclosed in U.S. Pat. No. 5,824,874, herein incorporated by reference; pyrimidone derivatives disclosed in U.S. Pat. No. 5,807,854, herein incorporated by reference; agents from spororniella minimizes disclosed in U.S. Pat. No. 5,801,172, herein incorporated by reference; cyclic peptides disclosed in U.S. Pat. No. 5,786,325, herein incorporated by reference; polypeptides disclosed in U.S. Pat. No. 5,773,696, herein incorporated by reference; triazoles disclosed in U.S. Pat. No. 5,773,443, herein incorporated by reference; fusacandins disclosed in U.S. Pat. No. 5,773,421, herein incorporated by reference; terbenzimidazoles disclosed in U.S. Pat. No. 5,770,617, herein incorporated by reference; and agents obtained from hormones disclosed in U.S. Pat. No. 5,756,472, herein incorporated by reference.
[0078] C. Delivery of Radiopharmaceuticals
[0079] The present invention contemplates the use of radiopharmaceuticals to treat osteomyelitis in animals, including but not limited to, humans. The methods of the present invention are suitable to treat acute or chronic osteomyelitis in any bone. Suitable radiopharmaceuticals, ligands, and dosages include, but are not limited to, those described above. One skilled in the relevant art understands how to determine suitable compositions and dosages for a specific animal and site or extent of infection.
[0080] The direct administration methods of the present invention provide the advantage of delivering an increased concentration of the radionuclide to the affected area and decreasing the exposure of the rest of the body. This is in contrast to systemic intravenous injection of bone agents, which results in radioactivity deposited in the entire skeletal system of the subject. The dose from the bone to the bone marrow is of most concern. This is especially true of radionuclides such as Ho-166 or Y-90 that are high-energy beta emitters. If a portion of the marrow can be spared from radioactivity, then it is probable that the affected area will regenerate without putting the patient at risk. Application to the infected area after isolating the blood flow using an arterial obstruction device, such as a tourniquet, will result in a larger dose to the infected area and reduce the dose to bone marrow. Similarly, application of one or more arterial obstruction devices to isolate portions of the skeletal system from the site of injection of the radionuclide will protect those portions of the bone marrow.
[0081] Accordingly, in preferred embodiments, radiopharmaceuticals are administered locally to the area of the infected bone. Local administration can be performed by techniques known in the art, including but are not limited to, intravenous injection, intra-arterial injection, intramuscular injection, subcutaneous injection, intraosseous injection, and transcutaneous administration. In some embodiments, radiopharmaceuticals are injected intramuscularly near the site of infection.
[0082] In some preferred embodiments, a tourniquet or other arterial obstruction device is placed above the area of injection in order to aid in the localization of the radiopharmaceuticals. In some embodiments, the tourniquet is placed on the limb prior to injection and removed immediately following injection. In preferred embodiments, the tourniquet is left in place for a short period of time following injection (e.g., long enough for the radiopharmaceutical to localize to the site of infection). In preferred embodiments, the tourniquet is left in place for greater than 2 minutes (e.g., preferably 5 minutes and more preferably 10 minutes) and then removed. It is preferred that the tourniquet is left in place no greater than 60 minutes in order to avoid hypoxic damage to the tissues due to restricted blood flow.
[0083] In other embodiments (e.g., where the osteomyelitis is located in an area proximal to the most proximal limb location for a tourniquet, such as in a rib, vertebrae, pelvis, femoral head, humeral head, clavicle, scapula, skull, or mandible), tourniquets are applied to one or more extremities to prevent access of the radiopharmaceutical agent to these areas. For instance, in some embodiments, tourniquets are applied proximally to each leg to protect the bone marrow in the legs from exposure to the radiopharmaceutical. The radiopharmaceutical agent is then given intravenously into a brachial vein to be carried through the blood stream to an osteomyelitis site, for instance in the mandible or the vertebral column. The tourniquet is then removed after an appropriate time (less than 60 minutes but greater than 2 minutes, more preferably greater than 5 minutes, most preferably about 10 minutes) after injection.
[0084] In some embodiments, radiopharmaceuticals are administered with additional antibacterial or fungal agents. Suitable agents include, but are not limited to, those described above.
[0085] In preferred embodiments, administration of a radiopharmaceutical agent result in the reduction of osteomyelitis (e.g., as determined by a bone scan). If the infection is not sufficiently reduced or eliminated, additional doses of radiopharmaceuticals are given. Alternatively, or in combination, increased doses of radiopharmaceuticals are administered until symptoms and diagnostic tests reveal that the infection is eliminated.
EXAMPLES
[0086] The following examples are provided in order to demonstrate and further illustrate certain preferred embodiments and aspects of the present invention and are not to be construed as limiting the scope thereof.
[0087] In the experimental disclosure which follows, the following abbreviations apply: eq (equivalents); M (Molar); μM (micromolar); N (Normal); mol (moles); mmol (millimoles); μmol (micromoles); nmol (nanomoles); g (grams); mg (milligrams); μg (micrograms); ng (nanograms); l or L (liters); ml (milliliters); μl (microliters); cm (centimeters); mm (millimeters); μm (micrometers); nm (nanometers); ° C. (degrees Centigrade); U (units), mU (milliunits); Ci (Curie); min. (minutes); sec. (seconds); and % (percent).
Example 1
[0088] Preparation of 166 Ho-DOTMP
[0089] 165-Ho-nitrate targets are prepared from dissolution of holmium oxide in nitric acid followed by reduction to dryness. A target containing 6 mg of holmium is irradiated in a reactor for approximately 155 hours at a flux of 4.5×10 14 n/cm 2 /s. The specific activity is typically in the range of 1.3-2 Ci/mg.
[0090] The 66Ho-nitrate target is dissolved in 0.3 N HCl. In a typical 9 Ci preparation, 166 Ho-chloride is supplied from the reactor in 10 ml of 0.3 N HCl. DOTMP (60 mg DOTMP and 168 mg NaOH) is dissolved in 4 ml water and added to the 166 Ho chloride. The ligand to metal ratio is 3.5. The reaction mixture is allowed to mix for 10 minutes at a pH of 10.5. This is followed by addition of 4.8 ml of 1.0 M sodium phosphate buffer and ascorbic acid. The final concentration of ascorbic acid is 55 mg/ml. Dilution with water is performed to assure that the final activity concentration does not exceed 322 mCi/ml. The pH of the final product is 7-8.
Example 2
[0091] Treatment of Osteomyelitis in Rats with 166 Ho-DOTMP
[0092] This example describes the successful treatment of osteomyelitis in rats using 166 Ho-DOTMP. Four 150 g male Sprague Dawley rats were anesthetized and prepared for surgery by shaving the left leg. The skin over the left tibia and fibula was opened, a hole was drilled into the bone marrow, and an 18-gauge needle was inserted into the bone marrow. Through the needle, a piece of 0 surgical suture and approximately 0.1 ml of Staphylococcus aureus culture in Trypticase soy broth were introduced into the bone marrow. The needle was removed and the bone defect sealed with cyanoacrylate glue. The skin was closed with 0 surgical suture. The rats were followed with serial radiographs of the left leg. Lytic lesions diagnostic of osteomyelitis developed in the fibula over the next three weeks. The entire bone appeared radiolucent.
[0093] Two rats were followed without treatment. One week later, both of the rats died. Necropsy revealed that the tibia was eroded with only a very thin layer of bone encasing a thick fluid. Culture of the fluid grew Gram positive cocci consistent with the original Staphylococcus aureus infection.
[0094] Two rats were treated with 166 Ho-DOTMP. A tourniquet was placed on the left leg above the knee. An intramuscular injection of 30 Gray (9 milliCurie) of 166 Ho-DOTMP was given after application of the tourniquet. The tourniquet was released after 10 minutes. The rats were followed with continued serial radiographs of the leg. The radiographs showed a return to normal appearance of the tibia and fibula in two weeks.
Examples 3 Through 6
[0095] Biodistribution of radiopharmaceuticals in rats with and without the application of a tourniquet to a limb bone.
[0096] A. Methods
[0097] 1. Preparation of DOTMP and EDTMP
[0098] DOTMP and EDTMP were prepared according to methods described in U.S. Pat. Nos. 4,898,724 and 4,976,950.
[0099] 2. Preparation of Holmium and Samarium radionuclide solutions Ho-166, obtained from the University of Missouri Research Reactor, Columbia Mo., was dissolved in 0.1N HCl to yield a 6×10 −3 M 166 HoCl 3 solution. Sm-153, obtained from the University of Missouri Research Reactor, Columbia, Mo., was dissolved in 0.1 N HCl to yield a 6.6×10 −3 M solution.
[0100] The radioactive 166 HoCl3 solution was then mixed with non-radioactive 165 HoCl3 solutions to prepare solutions that would have only a tracer amount of 166 Ho. For complexation with DOTMP, 0.25 μL of the 6×10 −3 M 166 HoCl 3 solution was mixed with 1 mL of a 6.04×10 −4 M 165 HoCl3 solution. For complexation with EDTMP, 0.25 μL of the 6×10 −3 M 166 HoCl 3 solution was mixed with 1 mL of a 4.84×10 −3 M 165 HoCl 3 solution. These concentrations are chosen to fulfill the requirements of the DOTMP and EDTMP kits used for complexation.
[0101] Similarly, the radioactive 153 SmCl 3 solution was mixed with non-radioactive SmCl 3 solutions to prepare solutions that would have only a tracer amount of 153 Sm. For complexation with DOTMP, 0.25 μL of the 6×10 −3 M 153 SmCl 3 solution was mixed with 1 mL of a 6.06×10 −4 M solution of non-radioactive Sm (CH 3 COO) 3 . For complexation with EDTMP, 0.25 μL of the 6×10 −3 M 153 SmCl 3 solution was mixed with 1 mL of a 4.84×10 −3 M solution of non-radioactive Sm (CH 3 COO) 3 .
[0102] 3. Preparation and Analysis of Complexes
[0103] Preparation of EDTMP complexes and DOTMP complexes was accomplished by the methods described in U.S. Pat. Nos. 4,898,724 and 4,976,950. Following preparation of the complexes, the percentage of complexation was determined. This was accomplished by placing an aliquot of the complexation solution onto a column of swollen Sephadex C-15 cation resin and eluting with a 4:1 physiologic saline:concentrated ammonium hydroxide solution. Percentage complexation can then be determined by comparison of the counts from non-complexed metal left on the column to the total of counts from the non-complexed metal on the column and the complexed metal in the eluted solution.
[0104] 4. Biodistribution Studies
[0105] Rat biodistribution studies were done on Male Sprague-Dawley rats weighing 180-200 g that had been acclimated for approximately one week prior to this study. Four test complexes were used, Ho-DOTMP (Example 3), Ho-EDTMP (Example 4), Sm-DOTMP (Example 5) and Sm-EDTMP (Example 6). The rats were placed in a restraining cage that afforded accessibility to the left hind leg and tail. Prior to injection a tie wrap tourniquet was placed on the left hind femur above the knee to restrict blood flow. The amount of pressure induced by the tourniquet was standardized by using a tie wrap gun and was sufficient to stop arterial flow. Three rats per complex each received a 100.0 μL intravenous injection in a lateral tail vein. The tourniquets were allowed to remain in place for 5, 10 or 20 minutes post injection and were then removed. The rats were then watched for two hours, the usual biodistribution period used to allow excretion of all radioactive complexes not bound to tissue. The rats were then sacrificed for removal of tibias. The number of radioactive counts were then determined and compared to the average of number of counts of three 100.0 uL standards of the same material that was injected. Several additional tissues (femur, injection site, liver, kidney, spleen, muscle, and blood) were collected and counted for rats that had the 20 minutes restricted blood flow to check for expected renal excretion of radioactive complexes.
[0106] B. Results
[0107] Of the tissues checked, only the bone had significant radioactive counts present. This indicates normal clearance of the complexes not bound to bone and stability of the metal complexes.
[0108] Tables 1 and 2 show data as percent dose of administered radioactivity per gram of tissue. This reflects the concentration of the radioactive complex in the bone. Table 1 combines the data on the radioactivity found in the tibias of the rats from Examples 3 to 6 for each of the three times of tourniquet placement. Table 2 combines the data on the radioactivity found in the femurs of the rats from Examples 3 to 6 for the tourniquets applied for 20 minutes. The degree of “protection” of the bone by the tourniquet can be seen by comparison of the radioactivity in the bones on the left side (“protected” by the tourniquet for the time specified) as compared to the corresponding bones on the right side (fully exposed to the systemic, intravenous dose). Table 3 shows this comparison as the percentage of the concentration of radioactive complex in the unprotected bone found in the corresponding protected bone.
[0109] The 20 minute animal data indicates high uptake of the radioactivity in bone with very little activity remaining in any soft tissue. Examination of Table 3 reveals that the tibias behind the tourniquets concentrated less of the radioactive bone-seeking agents than the corresponding tibias regardless of the length of time the tourniquet remained in place or the specific complex used. However, leaving the tourniquets in place for 20 minutes provided much better protection than shorter time periods. Examples 3, 4, and 5 all showed only 20% to 25% of the unprotected radioactivity concentration in the protected tibias while Example 6 (Sm-EDTMP) was less effective at 36%. The tourniquet was placed in the middle of the left femur. Thus the femur was only partially protected from the systemically administered radioactive bone-seeking agents. Table 3 shows that Examples 3 and 5 (Ho-DOTMP and Sm-DOTMP) were still able to keep the concentration of radioactivity in the 20% to 25% range in the femur. Examples 4 and 6 (Ho-EDTMP and Sm-EDTMP) were only able to lower the concentration of radioactivity to 40% to 50% of unprotected concentration in the femur.
TABLE 1 Tibial Percentage Dose per Gram for Examples 3 to 6 5 minute 10 minute 20 minute Ho-DOTMP Right Tibia 7.06 7.52 6.39 Ho-DOTMP Left Tibia 3.19 3.41 1.35 Ho-EDTMP Right Tibia 1.60 6.95 5.33 Ho-EDTMP Left Tibia 1.35 3.49 1.25 Sm-DOTMP Right Tibia 7.91 6.79 8.34 Sm-DOTMP Left Tibia 4.82 3.38 2.06 Sm-EDTMP Right Tibia 6.73 6.17 5.73 Sm-EDTMP Left Tibia 5.33 2.56 2.04
[0110] [0110] TABLE 2 Femoral Percentage Dose per Gram for Examples 3 to 6 20 minute Ho-DOTMP Right Femur 5.59 Ho-DOTMP Left Femur 1.33 Ho-EDTMP Right Femur 4.31 Ho-EDTMP Left Femur 2.33 Sm-DOTMP Right Femur 6.46 Sm-DOTMP Left Femur 1.40 Sm-EDTMP Right Femur 5.44 Sm-EDTMP Left Femur 2.05
[0111] [0111] TABLE 3 Dose per Gram in Left Leg as a Percentage of Dose per Gram in Right Leg for Examples 3 to 6 5 minute 10 minute 20 minute Ho-DOTMP Tibia 45 45 21 Ho-EDTMP Tibia 84 50 23 Sm-DOTMP Tibia 61 50 25 Sm-EDTMP Tibia 79 41 36 Ho-DOTMP Femur 24 Ho-EDTMP Femur 54 Sm-DOTMP Femur 22 Sm-DOTMP Femur 38
[0112] All publications and patents mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the described compositions and methods of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with particular preferred embodiments, it should be understood that the inventions claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art and in fields related thereto are intended to be within the scope of the following claims.
|
This invention relates to medical uses of radiopharmaceuticals. Specifically, the present invention relates to the use of radiopharmaceuticals to treat osteomyelitis. The present invention provides improved system and methods of for the direct delivery of radiopharmaceuticals to the site of osteomyelitis.
| 0
|
FIELD OF THE INVENTION
This invention is in the field of flame-retardants. More particularly, it relates to fire-retardant polyolefin compositions.
BACKGROUND OF THE INVENTION
Brominated organic compounds are commonly used as additives for retarding and slowing the flammability of plastic compounds they are blended with. They may be blended alone or in combination with other brominated or non-brominated flame-retardants in a synergistic manner. Optionally, additional compounds may be added to the blend in order to achieve good flame-retarding results and maintain durability. In general brominated aliphatic compounds are more effective flame-retardants than brominated aromatic compounds since they tend to break down more easily (International Plastics Flammability Handbook, 2 nd edition, Jurgen Troitzsch, p. 45).
GB 2,085,898 discloses a self-extinguishing polyolefin composition containing polypropylene, a brominated arene together with Sb 2 O 3 and a free radical initiator. JP 63/027,543 discloses a flame-retardant polyolefin composition comprising a blend of chlorinated polyethylene and polyethylene, together with an organic brominated compound and Sb 2 O 3 , a free radical initiator and a metal hydroxide. U.S. Pat. No. 4,430,467 discloses a self-extinguishing propylene polymer where the propylene polymer is blended with 5,6-dibromonorbornane and a free radical initiator. This flame-retardant has low bromine content and it is not melt blendable.
Another flame-retardant widely used in polyolefins is Tetrabromobisphenol A bis (2,3-dibromopropyl ether) (International Plastics Flammability Handbook, 2 nd edition, Jurgen Troitzsch, p. 56), but it suffers from heavy blooming and has limited UV stability. By “blooming” it is meant that a separation of the additive from the polymer matrix occurs, which has a negative effect on the surface appearance of the plastic articles. Many of the above mentioned flame-retardants require the additional use of antimony trioxide as a synergist.
Another flame-retardant used in polyolefins is tris(tribromoneopentyl) phosphate, which is also known as tris(3-bromo-2,2(bromomethyl)propyl) phosphate. Some of the advantages of this flame-retardant are: minimal impact upon the properties and the processing of the polymer; easily extrudable with polypropylene; free flowing powder; melt and mix with polypropylene resin to give a uniform product; exceptional heat stability which results in processing stability, storage stability, and performance permanence; it can be used without antimony trioxide, for instance, for the production of fine denier polypropylene fibers (Proceedings of the Flame Retardants '96 Conference, p. 107).
Only a combination of very high loadings of tris(3-bromo-2,2 (bromomethyl) propyl) phosphate with antimony trioxide give rise to a composition that may pass the UL (Underwriters Laboratory) 94 V-0 test. Such a composition is not commercially competitive.
WO 98/17,718 discloses adding a halogenated flame-retardant having at least one halogen atom attached to an aliphatic carbon atom to tris(tribromoneopentyl) phosphate in order to achieve V-0 in the UL 94 test in a polyolefin at a low loading. U.S. Pat. No. 5,393,812 discloses a composition of polyolefin, a phosphate or phosphonate ester of a halogenated organic compound and a light stabilizer of a certain type.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide non-blooming flame-retardant polyolefin formulations having good flame-retardancy, excellent UV and light stability, and excellent thermal stability.
It is yet another object of the present invention to significantly improve the flame-retardancy of tris(tribromoneopentyl) phosphate, which is known to be less efficient than other commercial flame-retardants in similar applications (Proceedings of the Flame Retardants 2000 Conference, p. 82).
It is a further object of the present invention to achieve very short burning time in polypropylene objects.
Still yet another object of the present invention is to provide a polyolefin with a higher standard of flame-retardancy, such as UL 94 V-0, and excellent thermal stability with a low amount of halogenated aliphatic compounds and without the use of halogenated aromatic compounds.
In addition a further object is to provide a flame-retardant polyolefin formulation containing tris(tribromoneopentyl) phosphate and polyolefin that does not include antimony trioxide.
Thus, the flame-retardant polyolefin composition of the present invention comprises:
(a) At least one polyolefin;
(b) tris(tribromoneopentyl) phosphate; and
(c) free radical source
The polyolefin may be a polymer blend comprising at least 20% (w/w) polypropylene. It may either be a homopolymer or a copolymer. The amount of the tris(tribromoneopentyl) phosphate is preferably in the range of about 0.5% to about 20% (w/w) of the entire composition, and the amount of the free radical source is in the range of between about 0.01% to about 4% (w/w) and preferably in the range of between about 0.05% to about 2% (w/w).
The composition may further comprise another fire-retardant compound, which may serve as a synergist. In such a composition, the amount of the organic brominated compound may be reduced, thus leading to a lower amount of bromine in the composition, which makes the composition more economic.
DETAILED DESCRIPTION OF THE INVENTION
The present invention deals with flame-retardant polyolefin compositions, which, due to their unique additives to the polyolefin and the percentage in the composition, retain most of the physical characteristics of a pure polyolefin polymer while attaining strict fire-retardance standards. The flame-retardancy properties of the olefin composition are achieved by selecting an appropriate brominated compound and a free radical source. The brominated compound is tris(tribromoneopentyl) phosphate which is also known as FR-370 (manufactured by Dead Sea Bromine Group). The compound is a very stable brominated aliphatic compound, which does not undergo chemical reactions common to aliphatic brominated compounds. This stem from the fact that there is no hydrogen atom bound to the carbon atom, which is in the β-position in relation to the bromine, thus avoiding the possible elimination of HBr.
The free radical source in accordance with the present invention is an organic compound which is stable at processing temperatures of about from 150° C. to about 250° C., and decomposes above these temperatures (at about from 220° C. to about 350° C.) to give relatively stable free radicals. Examples of free radical initiators are 2,3-dimethyl-2,3-diphenyl-butane and 2,3-dimethyl-2,3-diphenyl-hexane.
The polyolefins useful in this invention (sometimes also referred to as “polyolefin resins”) may be derived from a variety of monomers especially from propylene, ethylene, butene, isobutylene, pentene, hexene, heptene, octene, 2-methyl propene, 2-methyl butene, 4-methylpentene, 4-methyl hexene, 5-methyl hexene, bicyclo (2,2,1)-2-heptene, butadiene, pentadiene, hexadiene, isoprene, 2,3 dimethyl butadiene, 3,1 methyl pentadiene 1,3,4 vinyl cyclo hexene, vinyl cyclohexene, cyclopentadiene, styrene and methyl styrene. The polyolefins include copolymers produced from any of the foregoing monomers and the like, and further include homopolymer blends, copolymer blends, and homopolymer-copolymer blends. The polyolefins may be in a molding grade, fiber grade, film grade or extrusion grade
The preferred polyolefins are polypropylene and polyethylene, including atactic, syndiotactic and isotactic polypropylene, low density polyethylene, high density polyethylene, linear low density polyethylene, block copolymers of ethylene and propylene, and random copolymers of ethylene and propylene. The polyolefins useful in this invention may be produced using a variety of catalytic processes including metallocene-catalyzed processes. The polymers may have a broad range of melt flow indexes (MFI) but will typically have MFI values in the range 0.5 to 30. The invention finds particular applications in polymers, which are fabricated into finished articles by molding processes. Preferred grades are fiber grades, film grades, molding grades, and extrusion molded grades.
The addition of tris(tribromoneopentyl) phosphate together with the free radical initiator results in a polyolefin composition having a high degree of flame-retardancy.
This flame-retardancy can be further enhanced by the use of other flame-retardant compounds which may serve as synergists such as antimony compounds (e.g. antimony-trioxide, -tetraoxide, -pentaoxide, and sodium antimonate), tin compounds (e.g. tin-oxide and -hydroxide, dibutyl tin maleate), molybdenum compounds (e.g. molybdenum oxide, ammonium molybdate), zirconium compounds (e.g. zirconium-oxide and -hydroxide), boron compounds (e.g. zinc-borate, barium-metaborate), zinc compounds such as zinc stannate, silicon compounds such as silicon oil, fluoro compounds such as polytetrafluoroethylene, and hydroxystannate or any mixtures of two or more of them. Such compounds serve as synergists, which reduce the overall, required amount of flame-retardant compounds in the polyolefin composition.
The composition may further comprise other halogenated or non-halogenated flame-retardant compounds such as but not limited to tetrabromobisphenol A bis (2,3-dibromopropyl ether), brominated expoxy resins and related end capped derivatives, brominated polycarbonate resins and their end capped derivatives, brominated diphenyl ethers, brominated diphenyl ethanes, tetrabromobisphenol A, hexabromocyclododecane and their various thermally stabilised grades, BT-93 (flame retardant produced by Albemarle), poly (pentabromobenzyl acrylate), tris (tribromophenyl) cyanurate, chlorinated paraffins, chlorinated polyethylene, dechlorane, magnesium hydroxide, alumina trihydrate, ammonium polyphosphate, and melamine derivatives (melamine cyanurate and/or pyrophosphate).
The composition may further comprise additional additives which are known in the art such as ultraviolet and light stabilizers, UV screeners, UV absorbers, release agents, lubricants, colorants, plasticizers, fillers, blowing agents, heat stabilizers, antioxidants, reinforcement (e.g. fibers), impact modifiers, processing aids, and other additives. The UV screeners may be for example TiO 2 The ultraviolet and light stabilizers may be from the family of hindered amine light stabilizers (HALS), HALS that are alkoxyamine functional hindered amines (NOR-HALS), or UV absorbers such as benzotriazole or benzophenone or a combination of them. Compositions containing tris(bromoneopentyl) phosphate, free radical initiators, and NOR-HALS have especially good UV stability.
The composition may further comprise additional fillers such as talc, calcium carbonate, mica, carbon black, of fiber reinforcement such as glass fibers and carbon fibers. The composition may further contain additives to improve electrical conductivity of the compounds.
Generally, the compositions of the present invention comprise between about 0.5% to about 20% (w/w) of tris(tribromoneopentyl) phosphate and between about 0.01% to about 4% (w/w) free radical initiator together with a polyolefin, preferably between about 0.05% to about 2% (w/w) free radical initiator together with a polyolefin. In cases where a synergistic compound is used, typically an amount from about 0.5% to about 10% (w/w) of a synergist such as antimony trioxide is used. In cases where another fire-retardant is used, typically an amount from about 0.5% to about 60% (w/w) of the fire-retardant is used.
In some instances, it is preferred to use an antimony trioxide-free system. For instance, in fiber applications in order to avoid the clogging of the spinerette during the fiber extrusion.
In many applications such as production of polypropylene fiber and multifilament, it is preferred to add the flame-retardant composition as a masterbatch concentrate in order to obtain a more homogeneous fiber, where the composition is evenly distributed. Thus the use of masterbatch concentrates allows a more stable production of PP fibers.
The masterbatch concentrate contains about 2% to about 90% (w/w) of tris(tribromoneopentyl) phosphate and about 0.03% to about 12% (w/w) of free radical initiator. Preferably, the masterbatch concentrate will contain about 25% to about 80% (w/w) of tris(tribromoneopentyl) phosphate and about 0.1% to about 10% (w/w) of free radical initiator. The masterbatch can also contain about 0.7% to about 30% (w/w) of antimony trioxide.
Due to the very stable and good mechanical properties, the polyolefin compositions of the present invention may be used in many applications. Non-limiting examples of potential use of compositions of the present invention are fibers for a textile structure, carpets, upholstery, injection products such as stadium seats, electrical parts (connectors, disconnectors and sockets), and electrical appliances, extrusion products such as profiles, pipes, sheets for roofing, films and boards for packaging and industry, insulation for cables and electric wires.
Flame-retardancy was measured using the Underwriters Laboratory standard UL 94. In some cases, a UL 94 V-2 standard is achieved, but with a very long burning time, especially in polypropylene block copolymers, which are known to be rather difficult to convert into flame-retarding copolymers (Proceedings of the Flame Retardants 2000 Conference, p. 89). For many applications, it is desirable to have a polypropylene copolymer with a short burning time. Some of the compositions of the present invention achieve this goal.
The resin composition can easily be prepared by pre-mixing prescribed amounts of a thermoplastic resin and compounding additives in a mixing machine, e.g., a Henschel mixer and a tumble mixer. The mixture is then introduced into an extruder, a kneader, a hot roll, a Banbury mixer, etc. in order to melt the resin and evenly distribute the additive throughout the resin.
EXAMPLES 1 TO 4
Samples of the flame-retardant systems according to the invention have been prepared and their compositions are shown in Table 1 as flame-retardant (FR) FR blend 1 and FR blend 2. FR blend 3 and FR blend 4 were prepared for comparison purposes.
TABLE 1
1
2
3
4
FR
FR
FR
FR
Example
blend 1
blend 2
blend 3
blend 4
Composition, weight %
Tris(tribromoneopentyl)
90.91
83.33
—
—
phosphate
(FR-370 - DSBG)
Stabilised grade of HBCD**
—
—
90.91
—
(FR-1206 HT - DSBG)
Tetrabromobisphenol A bis(2,3-
—
—
—
97.8
dibromopropyl ether) (FR-720 -
DSBG)
2,3-Dimethyl-2,3,diphenyl
9.09
16.67
9.09
2.2
butane* (CCDFB-90 - Peroxid-
Chemie)
*free radical initiator;
**Hexabromocyclododecane thermally stabilized sold by DSBG as FR-1206 HT
The two additives of the compositions were weighted on Sartorius semi-analytical scales and mixed manually in a plastic bag but for better quality mixing and/or for larger quantities, the mixing operation can be done in any suitable equipment for the mixing of powder such as Loedige, Henschel, Diosna or Papenmeyer low and high speed mixers.
EXAMPLES 5 to 14
The formulations having the compositions shown in Table 2, some of them containing the flame-retardant systems according to the invention and some others used as a reference were compounded and pelletized in a Berstorff ZE25 co-rotating twin-screw extruder, with L/D=32:1.
The processing conditions to prepare and pelletize the compounds are summarized in Table 3.
The polypropylene (PP) used is characterized by its melt flow index (MFI) that is measured according to the Standard ASTM D1238-82 at 220° C. with a load of 2.16 Kg.
The pellets were dried at 70° C. for two hours in an air-circulating oven prior to injection molding on an Arburg Allrounder machine model 320S/500-150. Injection molding conditions to prepare test bars for property measurement are summarized in Table 4.
TABLE 2
Examples
5
6
7
8
9
10
11
12
13
14
Composition, weight %
PP homopolymer
—
—
—
—
—
83.29
85.75
69.05
87.9
84.4
(MFI: 10 g/10 min)
PP homopolymer
—
—
99.2
97.8
95.6
—
—
—
—
—
(MFI: 3 g/10 min)
PP block copolymer
94.7
93.55
—
—
—
—
—
—
—
—
(MFI: 4 g/10 min)
FR blend 1 (example 1)
2.25
—
0.8
—
—
11
—
—
—
—
FR blend 2 (example 2)
—
—
—
—
—
—
9.6
—
—
10.8
FR blend 3 (example 3)
—
—
—
2.2
4.4
—
—
—
—
—
Tris(tribromoneopentyl) phosphate (FR-
—
3
—
—
—
—
—
20
—
—
370 DSBG)
FR blend 4 (example 4)
—
—
—
—
—
—
—
—
9.1
—
Antimony trioxide
0.8
1.2
—
—
—
5.36
4.3
10.6
3
4.8
Tinuvin 327* (Ciba Geigy)
0.25
0.25
—
—
—
0.25
0.25
0.25
—
—
Irganox 1010** (Ciba Geigy)
—
—
—
—
—
0.1
0.1
0.1
—
—
Titanium dioxide***
2
2
—
—
—
—
—
—
—
—
*Benzotriazole type of UV absorber;
**Hindered phenol type of antioxidant;
***White pigment
TABLE 3
PARAMETER
UNITS
Set values
Actual values
Temperature profile:
Feeding zone temperature (T 1 )
° C.
no heating
100
T 2
° C.
180
187
T 3
° C.
160
161
T 4
° C.
180
183
T 5
° C.
190
190
T 6
° C.
190
193
T 7
° C.
180
186
T 8
° C.
200
200
T 9
° C.
225
216
Temperature of melt
° C.
221
Screw speed
RPM
350
350
Ampere
A
9
10
Feeding rate
kg/hour
12
12
TABLE 4
PARAMETER
UNITS
VALUES
Temperature profile:
T1 (Feeding zone)
° C.
200
T2
° C.
210
T3
° C.
220
T4
° C.
230
T 5 (nozzle)
° C.
230
Mold temperature
° C.
40
Injection pressure
bar
1200
Holding pressure
bar
700
Back pressure
bar
20
Injection time
sec
0.1
Holding time
sec
10
Cooling time
sec
5
Mold closing force
KN
500
Filling volume (portion)
Cm 3
17
Injection speed
Cm 3 /sec
20
EXAMPLES 15 and 16
Flame-retardancy properties of molded samples using compositions of examples 5 and 6 have been compared. Flame-retardancy was measured using the Underwriters Laboratory standard UL 94 on samples with a thickness of 1.6 mm.
In the UL 94 test, a specimen is exposed vertically to a flame for 10 seconds. The specimen is ignited at the bottom and burns up. If the specimen self-extinguishes within 30 seconds, another 10 seconds application is made. Flaming droplets are allowed to fall on cotton located below the sample. If the average burning time is less than 5 seconds and the droplets do not ignite the cotton, the material is classified as 94 V-0. If the average burning time is less than 25 seconds and the droplets do not ignite the cotton, the material is classified as 94 V-1. If the average burning time is less than 25 seconds but the droplets ignite the cotton, the material is classified as 94 V-2.
The results are summarized in Table 5.
TABLE 5
Example
15
16
Composition, weight %
PP block copolymer (MFI: 4 g/10 min)
94.7
93.55
FR blend 1 (example 1)
2.25
—
Tris(tribromoneopentyl) phosphate (FR-370 DSBG)
—
3
Antimony trioxide
0.8
1.2
Tinuvin 327 (Ciba Geigy)
0.25
0.25
Titanium dioxide
2
2
Flame-retardancy
UL 94 (1.6 mm):
Maximum after flame time, sec
5
22
Total after flame time, sec
21
92
Cotton ignition, number
5
5
Class
V-2
V-2
It should be noted that the composition of example 15 prepared according to the invention has significantly shorter burning times than the reference composition 16 while its content of flame-retardants and antimony trioxide is reduced.
EXAMPLE 17-19
Flame-retardancy properties of molded samples using the compositions of examples 7 to 9 have been tested. All these compositions do not contain antimony trioxide. Flame-retardancy was measured using the Underwriters Laboratory standard UL 94 on samples with a thickness of 1.6 mm. The results are summarized in Table 6.
The flame-retardancy of the composition of Example 17 is classified V-2 while it has a very low flame-retardant content of 0.8%. Furthermore, the V-2 standard is achieved despite the fact that this composition does not contain antimony trioxide frequently used as a synergist for brominated flame-retardants
TABLE 6
Example
17
18
19
Composition, weight %
PP homopolymer
99.2
97.8
95.6
(MFI: 3 g/10 min)
FR blend 1 (example 1)
0.8
—
—
FR blend 3 (example 3)
2.2
4.4
Antimony trioxide
—
—
—
Bromine content, w %
0.5
1.3
2.6
Flame-retardancy
UL 94 (1.6 mm):
Maximum after flame time, sec
11
90
10
Total after flame time, sec
71
411
47
Cotton ignition, number
5
5
5
Class
V-2
Fail
V-2
Comparison of the flame-retardancy properties of the compositions of examples 17-19 which do not contain antimony trioxide demonstrates the advantage of using a mixture of tris(tribromoneopentyl) phosphate and a free radical source. The composition of example 17 contains tris(tribromoneopentyl) phosphate, while the compositions of examples 18 and 19 contain FR blend 3, which is a blend between the same free radical initiator and a stabilized grade of hexabromocylcododecane (FR-1206 HT containing mainly aliphatic bromine). Table 5 demonstrates that a mixture of FR-1206 HT and a free radical initiator is much less efficient in fire retardancy than a mixture of tris(tribromoneopentyl) phosphate and a free radical source and about 3 times more bromine is needed to reach the class V-2 according to the UL 94 standard.
EXAMPLES 20-23
Flame-retardancy properties of molded samples using compositions of examples 10, 11 and 12 have been compared. Flame-retardancy was measured using the Underwriters Laboratory standard UL 94 on sample with a thickness of 1.6 mm. The results are summarized in Table 7.
Comparing the various compositions reveals that the composition of examples 20 and 21 prepared according to the invention achieve flame-retardancy standard of V-0 (with 1.6 mm thickness) having very short burning time while a loading of about twice more flame-retardant (examples 22 and 23) is needed for the composition that does not contain the free radical initiator.
TABLE 7
Example
20
21
22
23
Composition, weight %
PP homopolymer (MFI: 10 g/10 min)
83.29
85.75
69.5
69.0
FR blend 1 (example 1)
11
—
—
—
FR blend 2 (example 2)
—
9.6
—
—
Tris(tribromoneopentyl) phosphate (FR-
—
—
17.5
20
370 DSBG)
Antimony trioxide
5.36
4.3
12.6
10.6
Tinuvin 327* (Ciba Geigy)
0.25
0.25
0.25
0.25
Irganox 1010** (Ciba Geigy)
0.1
0.1
0.1
0.1
Flame-retardancy
UL 94 (1.6 mm):
Maximum after flame time, sec
1
1
1
1
Total after flame time, sec
10
10
5
10
Cotton ignition, number
0
0
3
0
Class
V-0
V-0
V-2
V-0
*Benzotriazole type of UV absorber;
**Hindered phenol type of antioxidant
EXAMPLES 24-25
UV stability and appearance after thermal aging have been compared for compositions 13 and 14. Composition 14 is prepared with the FR blend 2 according to the invention while composition 13 has been flame-retarded with FR blend 4, which is based on tetrabromobisphenol A bis(2,3-dibromopropyl ether), a flame-retardant particularly recommended for polypropylene applications. Molded samples prepared with these two compounds are classified V-0 according to the UL 94 standard.
Table 8 shows that the sample of example 25 prepared according to the invention has a much better UV stability measured by the color change after 300 hours of exposure and also does not bloom significantly. On the other hand, the samples produced in the example 24 have significant blooming and have poor UV stability.
TABLE 8
Example
24
25
Composition, weight %
PP homopolymer
87.9
84.4
(MFI: 10 g/10 min)
FR blend 2 (example 2)
—
10.8
FR blend 4 (example 4)
9.1
—
Antimony trioxide
3
4.8
Flame-retardancy
UL 94 (1.6 mm):
Class
V-0
V-0
Blooming properties (2 weeks 80° C.)
+ +*
0*
UV stability (Xenotest - ASTM 300 h):
Initial color DE
6
6
Color after 300 h exposure
17
30
*+ + Represents significant blooming; 0 represents no significant blooming
EXAMPLE 26 and 27
In these examples, thermal stability properties of the FR blend 1 prepared in example 1 have been compared with another flame-retardant containing only aliphatic bromine, a stabilized grade of hexabromocyclododecane (Stabilized HBCD SP-75 produced by Great Lakes Chemical Corporation).
The thermal stability has been measured by isothermogravimetric analysis at 230° C. The results are given in Table 9.
It can be seen that the FR blend 1 (example 1) according to the invention loses less than 10% of its weight after 20 minutes at 230° C. while a stabilized grade of hexabromocyclododecane (SP-75—Great Lakes Chemical Corporation) loses 10% of its weight after only 9 minutes.
TABLE 9
Example
26
27
Flame-retardant
FR blend 1
Stabilized HBCD
(Example 1)
(SP-75 Great Lakes)
Isothermal
thermogravimetric
analysis at 230° C.
Time to lose 10% weight,
More than 20
9
minutes
EXAMPLE 28 and 29
In these examples, masterbatch concentrates have been prepared with the FR blend 1 given in example 1.
Table 10 shows the compositions and the processing conditions to produce typical flame-retardant masterbatch concentrates prepared with the FR blend 1 given in example 1. Example 29 contains antimony trioxide, which acts as a synergist.
TABLE 10
Example
28
29
Composition, w %:
FR blend 1 (example 1)
40
34
Antimony trioxide
—
15.2
PP homopolymer (MFI: 20 g/10 min)
60
50.8
Processing condition:
Compounding extruder
Berstorff ZE25 co-rotating
twin-screw extruder,
with L/D = 32:1
Temperature profile, ° C.
100-160-160-180-190-
190-180-180-200
Speed, Rpm
350
Throughput, Kg/h
15
EXAMPLES 30-33
The formulations having the compositions shown in Table 11 were prepared in the same way as the formulations in Examples 5-14. The test bars obtained were subjected to flammability testing according to the UL 94 standard at 1.6 mm thickness. Accelerated weathering was made by UV radiation by using a QUV tester made by the Q Panel Company using 313 lamps and panel temperature of 55° C. The color change of the test samples was recorded after the exposure time as shown. Test results are summarized in the table.
TABLE 11
COLOR CHANGE IN QUV/P.P WITH FR-370, FR-720
Example
30
31
32
33
Reference Number
-1068
-1068
-1268
-1268
49
49
14
14
7.
1-7.
5.
14.
P.P R-50E HOMOPOLYMER
%
83.2
83.2
87.2
89
CAPILENE
Tris(tribromoneopentyl)
%
9
9
phosphate (FR-370 DSBG)
Tetrabromobisphenol A
%
8.9
7.42
bis(2,3-dibromopropyl ether)
(FR-720-DSBG)
2,3-Dimethyl-2,3,diphenyl
%
1.8
1.8
0.2
0.5
butane (CCDFB-90-
Peroxid-Chemie)
A.O L-0112 M.B *
%
6
6
3.7
3.08
ex KAFRIT
CGL 116 ex Ciba
%
0.3
NOR-HALS type UV stabilizer
UL-94
V-0
V-0
V-0
V-0
COLOR CHANGE QUV
100 hr exposure
DE
10.3
10.2
24.2
23.2
280 hr exposure
DE
9.1
8.5
25.9
25
460 hr exposure
DE
9.5
7.8
32.2
29.9
595 hr exposure
DE
12.6
7.2
35.4
33.1
* Masterbatch containing 80% antimony trioxide
This example is another demonstration of the excellent flame-retardancy which may be obtained from formulations containing brominated FR and free radical initiator.
The UV light stability of the formulation containing FR370 according to the present invention is much better than the comparative formulation with FR720 (lower color change). It can also be seen that after long exposure time, the formulation with both FR 370 and NOR-HALS UV stabilizer has a better UV stability than the formulation without NOR-HALS.
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims.
|
The present invention relates to A flame-retardant polyolefin composition or to a fiber that are comprised of (i) at least one polyolefin; (ii) a tris(tribromoneopentyl) phosphate; and (iii) afree radical source. The composition may further comprise an additional flame-retarding compound, which may be selected from an inorganic or an organic compound. It may further comprise ultra violet protectants. The invention is also related to a textile object comprised of a plurality of said fibers and to injection or extruded molded articles produced from said flame-retardant compositon.
| 2
|
BACKGROUND OF THE INVENTION
This invention relates to a multipath noise reducer, an audio output circuit including a multipath noise reducer, and a frequency-modulation (FM) radio receiver including a multipath noise reducer.
Radio receivers are afflicted by various types of electromagnetic noise. Radio broadcast receivers mounted in automobiles, for example, must contend with ignition noise and mirror noise, which are impulsive in character and are generally referred to as impulse noise. These so-called car radios also experience episodes of multipath noise due to reflection of radio waves from hills, high buildings, and other passing objects. Multipath noise occurs because the car radio antenna receives both a line-of-sight signal, coming directly from the transmitting antenna, and reflected signals, reflected from the passing objects. The reflected signals tend to be out of phase with the line-of-sight signal, causing the line-of-sight signal to be partly attenuated by the reflected signals. The resulting deterioration in quality of the audio output from a car radio is a familiar experience to automobile riders.
Various methods of reducing noise are known. In an FM stereo car radio, one method is to detect the strength of the electric field received at the antenna, and take noise countermeasures when the field is weak. One countermeasure is to reduce the degree of stereo separation, or to switch completely from stereo to monaural operation. This countermeasure will be referred to below as stereo separation control. Another countermeasure is to attenuate or “cut” high-frequency components in the demodulated signal. This countermeasure will be referred to below as high-cut control. Both of these countermeasures improve the signal-to-noise (S/N) ratio during intervals when the electric field received at the antenna is weak.
To reduce impulse noise, car radios may also include an impulse noise reducer that detects the onset of impulse noise and generates a gate signal having a predetermined length sufficient to cover the expected duration of the impulse noise. When the gate signal is active, the signal output by the car radio is held constant, effectively suppressing the noise.
The gate pulse used in this type of impulse noise reducer is too short to mask multipath noise, the duration of which is typically much longer than the duration of impulse noise. The gate pulse could be lengthened to cover multipath noise intervals, but a long gate pulse would noticeably distort the audio output signal. Furthermore, the long gate pulse would be triggered by each short occurrence of impulse noise, resulting in much needless audio distortion during times when no noise was present.
Another problem is that although the effects of multipath noise vary depending on signal reception conditions and the audio signal level, the gate pulse width is conventionally the same for all reception conditions and audio signal levels. Accordingly, regardless of how the gate pulse width is set, it will sometimes be too long, causing needless audio distortion, and will sometimes be too short, so that multipath noise is inadequately reduced.
Further details of these problems will be given in the detailed description of the invention.
SUMMARY OF THE INVENTION
An object of this invention is to reduce multipath noise adequately, with minimal output distortion.
The invented multipath noise reducer includes a signal state determiner determining a state of an input signal, a threshold generator generating a threshold value responsive to the resulting state information, a high-frequency signal extractor detecting high-frequency components of the input signal, a comparator unit comparing the resulting high-frequency signal with the threshold value, thereby generating a multipath noise detection signal, and a correction unit modifying the input signal responsive to the multipath noise detection signal and the state information.
By comparing the high-frequency signal with a threshold value, the invented multipath noise reducer is able detect and remove individual multipath noise spikes, thereby removing bursts of multipath noise without distorting other parts of the input signal.
By determining the threshold value adaptively, on the basis of the state information, and by modifying the input signal adaptively, again on the basis of the state information, the invented multipath noise reducer is able to reduce multipath noise adequately under all signal conditions, without unnecessary distortion.
The multipath noise reducer preferably also includes an input smoothing unit that smoothes the input signal. The smoothed input signal is used when the input signal is modified, enabling the correction unit to reduce distortion in the corrected signal still further.
In this case, the correction unit preferably includes a gate generator that generates a gate signal by expanding pulses in the multipath noise detection signal by an amount depending on the state information, and a replacement unit. The replacement unit latches the smoothed input signal during each expanded pulse in the gate signal, and replaces the input signal with the latched value for the duration of the expanded pulse. The length of the gate pulse is thereby tailored to signal conditions, and replacement of the input signal with possibly distorted values is avoided.
The gate generator preferably expands the gate pulses by increasing amounts as the received field strength of the input signal decreases, so that as the effects of multipath noise worsen, more of the multipath noise is removed.
The gate generator also preferably expands the gate pulses by increasing amounts as the audio signal level decreases, so that as multipath noise becomes more noticeable, more of the multipath noise is removed.
The high-frequency signal extractor preferably includes a high-pass filter and an absolute-value calculation unit, which together generate a high-frequency signal suitable for comparison with a threshold value.
The multipath high-pass filter preferably receives input from the absolute-value calculation unit, an arrangement that tends to shorten the intervals in which multipath noise is detected so that they match the actual multipath noise intervals more closely.
The threshold generator preferably includes a high-frequency smoothing unit that smoothes the high-frequency signal, and an adaptive limiting unit that limits the smoothed high-frequency signal according to the state information. The threshold value can thereby be kept from becoming too large during episodes of multipath noise.
The threshold generator may also include an amplitude limiter that limits variations of the high-frequency signal before the high-frequency signal is smoothed, so that the threshold value can be kept from becoming too large without the need for a long smoothing interval.
The adaptive limiting unit preferably includes a parameter adjustment unit that selects a comparison value and a limit value responsive to the state information, and a limiting unit that reduces the high-frequency signal to the limit value when the high-frequency signal exceeds the comparison value. The threshold value can thereby be lowered during episodes of multipath noise, so as to be sure of detecting all of the multipath noise.
The parameter adjustment unit preferably increases the comparison value as the received field strength of the input signal decreases, to avoid reducing the threshold value when multipath noise is absent.
The invention also provides an audio output circuit including the invented multipath noise reducer.
The invention furthermore provides an FM receiver including both the invented multipath noise reducer and an impulse noise reducer, the impulse noise reducer removing residual impulse noise from the corrected signal output by the multipath noise reducer.
The invention moreover provides a method of reducing multipath noise, essentially as described above. The invented method is useful when the invention is practiced using digital signal-processing circuitry.
BRIEF DESCRIPTION OF THE DRAWINGS
In the attached drawings:
FIG. 1 is a block diagram of an FM stereo radio receiver illustrating a first embodiment of the invention;
FIGS. 2A and 2B illustrate a typical multipath noise waveform;
FIGS. 3A to 3 E are waveform diagrams illustrating the operation of the multipath noise reducer in FIG. 1;
FIGS. 4A to 4 C are waveform diagrams illustrating the operation of the comparator unit and gate generator in the multipath noise reducer;
FIG. 5 is a block diagram illustrating one possible structure of the threshold generator in FIG. 1;
FIGS. 6A to 6 D are waveform diagrams illustrating the operation of the limiting unit in FIG. 5;
FIGS. 7A to 7 D are waveform diagrams illustrating the operation of the parameter adjustment unit in FIG. 5;
FIG. 8 is a block diagram illustrating another possible structure of the threshold generator in FIG. 1;
FIG. 9 is a block diagram illustrating the internal structure of the gate generator in FIG. 1;
FIGS. 10A to 10 D are waveform diagrams illustrating the operation of the gate generator in FIG. 9;
FIG. 11 is a block diagram of an FM stereo radio receiver illustrating a second embodiment of the invention;
FIGS. 12A to 12 E are waveform diagrams illustrating the operation of the multipath noise reducer in FIG. 11; and
FIG. 13 is a block diagram of a conventional FM stereo radio receiver.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention will be described with reference to the attached drawings, following a description of a conventional FM stereo radio receiver with an impulse noise reducer. This description is relevant because the impulse noise reducer is also used in the embodiments of the invention. Like elements in different drawings will be indicated by like reference characters.
Referring to FIG. 13, the conventional FM stereo radio receiver comprises an antenna 1 , a radio-frequency (RF) front-end circuit 2 , an intermediate-frequency amplifier (IF AMP) 3 , an FM detector (DET) 4 , an impulse noise reducer 6 , a stereo demodulator (DEMOD) 7 , a low-frequency amplifier (AMP) 8 , a pair of loudspeakers 9 , 10 , a stereo separation controller (SP CNTRL) 11 , and a high-cut controller (HC CNTRL) 12 .
The RF front end 2 amplifies the radio-frequency signal received from the antenna 1 and down-converts the amplified RF signal to the intermediate frequency. The IF amplifier 3 amplifies the resulting IF signal, and outputs both the amplified IF signal and a signal-meter signal or S-meter signal. The S-meter signal indicates the field strength received at the antenna. The FM detector 4 demodulates the amplified IF signal to generate an FM composite signal. The impulse noise reducer 6 reduces impulse noise in the FM composite signal. The stereo demodulator 7 separates the FM composite signal into a left-channel signal and a right-channel signal. The low-frequency amplifier 8 amplifies these two signals for output to the loudspeakers 9 , 10 . The stereo separation controller 11 performs stereo separation control on the basis of the S-meter signal. The high-cut controller 12 performs high-cut control, also on the basis of the S-meter signal.
The impulse noise reducer 6 comprises a buffer amplifier 6 a, a delay unit 6 b, a gate unit 6 c, a high-pass filter (HPF) 6 d that extracts high-frequency impulse noise from the output of the FM detector 4 , a noise detector (DET) 6 e, a gate pulse generator 6 f that generates a gate pulse of a predetermined duration or width on the time axis when noise is detected, an automatic gain control (AGC) circuit 6 g for the noise level, an output unit 6 h, and a memory unit 6 i that stores the immediately preceding output signal. When noise is not detected, the gate unit 6 c remains closed, and the FM composite signal output from the FM detector 4 propagates through the buffer amplifier 6 a, delay unit 6 b, gate unit 6 c, and output unit 6 h to the stereo demodulator 7 and memory unit 6 i. When noise is detected in the FM composite signal by the noise detector 6 e, a gate pulse of the predetermined width is output from the gate pulse generator 6 f, opening the gate unit 6 c. While the gate unit 6 c remains open, the output signal from the delay unit 6 b is blocked, and the signal stored in the memory unit 6 i just before noise was detected is output instead, so that the noise does not reach the stereo demodulator 7 .
The impulse noise reducer 6 is designed primarily to reduce impulse noise, but when the FM composite signal includes multipath noise, the multipath noise is also detected, and is reduced to some extent.
The waveform in FIG. 2A shows a typical episode of multipath noise in an FM composite signal. The waveform in FIG. 2B shows an enlargement of one multipath noise burst. Multipath noise comprises a series of spikes occurring at intervals equal to the FM composite subcarrier period. The enlarged burst, for example, includes ten such noise spikes, each having a positive component and a negative component.
The gate pulse generated by the gate unit 6 c, if set to reduce ignition noise, for example, has a width equivalent to only the first few spikes in the waveform in FIG. 2 B. Consequently, the impulse noise reducer 6 is inadequate to the task of rejecting multipath noise. If the gate pulse width in the impulse noise reducer 6 were to be increased to cover the longest bursts of multipath noise, however, then much valid information would be lost following shorter bursts of multipath noise, leading to noticeable distortion of the audio output signal. In the worst case, the audio output signal might completely disappear for a noticeable length of time.
Valid information is also lost in the brief intervals between noise spikes in the multipath noise waveform.
As a first embodiment of the invention, FIG. 1 shows an FM stereo radio receiver comprising an antenna 1 , an RF front end 2 , an IF amplifier 3 , an FM detector 4 , a multipath noise reducer 5 , an impulse noise reducer 6 , a stereo demodulator 7 , a low-frequency amplifier 8 , a pair of loudspeakers 9 , 10 , a stereo separation controller 11 , a high-cut controller 12 , and a signal state determiner 13 . The multipath noise reducer 5 comprises a high-pass filter (HPF) 5 a, an absolute-value calculation unit (ABS) 5 b, a comparator unit (COMP) 5 c, a threshold generator 5 d, a delay unit 5 e, a replacement unit 5 f, a gate generator 5 g, and a smoothing unit 5 h.
The high-pass filter 5 a and absolute-value calculation unit 5 b constitute a high-frequency signal extractor 5 ab in which the output of the high-pass filter 5 a becomes the input of the absolute-value calculation unit 5 b. The gate generator 5 g and replacement unit 5 f constitute a correction unit. The multipath noise reducer 5 , impulse noise reducer 6 , stereo demodulator 7 , low-frequency amplifier 8 , stereo separation controller 11 , high-cut controller 12 , and signal state determiner 13 constitute an audio output circuit.
The elements other than the multipath noise reducer 5 and signal state determiner 13 are similar to the corresponding elements in the conventional FM receiver in FIG. 13, so detailed descriptions will be omitted. The gate pulse width in the impulse noise reducer 6 is adjusted for the removal of impulse noise such as, for example, automobile ignition noise.
The signal state determiner 13 and multipath noise reducer 5 may include either analog or digital circuit elements, or a combination of both. The signal state determiner 13 and multipath noise reducer 5 may also be implemented partly or entirely by software running on a computing device such as a digital signal processor.
Next, the overall operation of the first embodiment will be described.
An FM broadcast signal is received by the antenna 1 and processed by the RF front end 2 , IF amplifier 3 , and FM detector 4 as described above. The FM composite signal output by the FM detector 4 will be referred to below simply as a demodulated signal. The demodulated signal passes through the multipath noise reducer 5 , which reduces multipath noise, then through the impulse noise reducer 6 , which reduces impulse noise. After these two types of noise reduction, the demodulated signal is supplied to the stereo demodulator 7 . The stereo demodulator 7 , low-frequency amplifier 8 , stereo separation controller 11 , and high-cut controller 12 operate as in the conventional FM radio receiver. The amplified left-channel and right-channel audio signals are reproduced through the loudspeakers 9 , 10 . In addition, the S-meter signal from the IF amplifier 3 and the audio signals output from the stereo demodulator 7 are supplied to the signal state determiner 13 . The signal state determiner 13 determines the state of the signal as received at the antenna 1 and as output from the stereo demodulator 7 , recognizing both the received field strength and the audio signal level, and provides corresponding state information to the threshold generator 5 d and gate generator 5 g in the multipath noise reducer 5 .
Next, the operation of the multipath noise reducer 5 will be described in more detail with reference to the waveforms in FIGS. 3A to 3 E and 4 A to 4 C.
The waveform in FIG. 3A is the enlarged multipath noise waveform that was shown in FIG. 2 B. The waveform in FIG. 3B is the corresponding output of the high-pass filter 5 a in the multipath noise reducer 5 . The cut-off frequency of the high-pass filter 5 a is set to detect the noise spikes, while flattening out the slower variations between the noise spikes. The signal output by the high-pass filter 5 a accordingly sits substantially at the ground level between noise spikes, and reverses between positive values in the rising parts of each noise spike and negative values in the falling parts of each noise spike.
The absolute-value calculation unit 5 b rectifies the output of the high-pass filter 5 a by replacing negative values with positive values of like magnitude, as shown in FIG. 3 C. Multipath noise can accordingly be detected by comparing the signal output by the absolute-value calculation unit 5 b with a threshold signal, indicated by the dotted line in this waveform (FIG. 3 C). The comparison is performed by the comparator unit 5 c; the threshold signal is generated by the threshold generator 5 d. The comparison results are then modified by the gate generator 5 g to generate a gate signal, shown in the FIG. 3 D.
FIGS. 4A to 4 C illustrate the operation of the comparator unit 5 c and gate generator 5 g. The first waveform (FIG. 4A) illustrates a single noise spike occurring in a multipath noise burst. The next waveform (FIG. 4B) illustrates the output of the comparator unit 5 c, referred to below as the multipath noise detection signal. The noise spike is detected as a single pulse. The gate generator 5 g delays and enlarges this pulse, as indicated in the third waveform (FIG. 4 C). The enlargements are shown with dotted lines because the degree of enlargement varies, depending on the state information received from the signal state determiner 13 . The delay D also depends on this state information, as will be described later.
The threshold generator 5 d generates the threshold signal by smoothing and limiting the output of the absolute-value calculation unit 5 b. Accordingly, the threshold signal is not constant, but tracks variations in the average level of the absolute value of the high-frequency signal output by the high-frequency signal extractor 5 ab. The reason for using this type of threshold signal is that under adverse receiving conditions, as the field strength at the receiving antenna 1 deteriorates, so does the signal-to-noise (S/N) ratio of the demodulated signal, raising the base noise level or ‘noise floor’ and causing the high-frequency signal extractor 5 ab to generate an increasing level of output due to noise other than multipath noise. The threshold value used by the comparator unit 5 c must be high enough so that the comparator unit 5 c does not detect noise that is part of the general noise floor.
The delay unit 5 e delays the demodulated signal for the length of time taken by the high-frequency signal extractor 5 ab, comparator unit 5 c, threshold generator 5 d, and gate generator 5 g to detect multipath noise therein and generate the gate signal. The resulting delayed demodulated signal is supplied to the replacement unit 5 f.
The smoothing unit 5 h smoothes the demodulated signal, and supplies the smoothed signal to the replacement unit 5 f. The smoothing process involves a delay substantially equal to the delay imparted by the delay unit 5 e. A detailed description of the smoothing unit 5 h will be omitted, because a detailed description of a smoothing circuit in the threshold generator 5 d will be given later.
The replacement unit 5 f operates as both a latch and a switch. When the gate signal output by the gate generator 5 g is at the low level, indicating that the delayed demodulated signal is free of multipath noise, the replacement unit 5 f passes the delayed demodulated signal received from the delay unit 5 e to the impulse noise reducer 6 . When the gate signal goes high, the replacement unit 5 f latches the current value of the smoothed demodulated signal received from the smoothing unit 5 h. While the gate signal remains high, the replacement unit outputs the latched value to the impulse noise reducer 6 , in place of the delayed demodulated signal. When the gate signal goes low again, the replacement unit 5 f resumes output of the delayed demodulated signal received from the delay unit 5 e. The signal output by the replacement unit 5 f will be referred to as the corrected output signal.
The corrected output signal is illustrated by the waveform in FIG. 3 E. During each of the gate pulses in the 3 D, the corrected output signal remains constant. For simplicity, the delay introduced by the gate generator 5 g is ignored in this waveform (FIG. 3E) and the preceding waveform (FIG. 3 D).
Each spike in the multipath noise is thereby replaced with a smoothed version of the preceding demodulated signal value. The reason for using a smoothed value, instead of the actual demodulated signal value preceding the spike, is that the part of the demodulated signal waveform immediately preceding each noise spike is somewhat distorted by the noise spike, so use of a value latched from this part of the waveform might lead to audio distortion. By replacing each noise spike with a smoothed value, the multipath noise reducer 5 is able to remove the noise spikes without risking such distortion. Moreover, by replacing only the noise spikes, and not the parts of the waveform between the noise spikes, the multipath noise reducer 5 is able to avoid loss of the audio signal even during relatively long episodes of multipath noise.
Next, more detailed descriptions of several of the components of the multipath noise reducer 5 will be given.
FIG. 5 shows a circuit that can be used as the threshold generator 5 d. The values received from the high-frequency signal extractor 5 ab are denoted x(n), n being a discrete time variable; x(n) will also be referred to as the n-th sample received from the high-frequency signal extractor 5 ab. The letter K denotes a positive constant that operates as a time constant. Roughly speaking, the threshold generator 5 d smoothes out variations lasting less than K samples in the output of the high-frequency signal extractor 5 ab. The letter L is a coefficient or gain by which the smoothed value is multiplied to raise the threshold value above the noise floor. L is set to produce a threshold value intermediate between the noise floor level and the typical noise level when multipath noise is present.
The circuit in FIG. 5 comprises multipliers 5 d 1 , 5 d 4 , 5 d 5 , an adder 5 d 2 , a one-sample delay unit 5 d 3 , a limiting unit 5 d 6 , and a parameter adjustment unit 5 d 7 . Multiplier 5 d 1 multiplies the n-th received sample x(n) by 1/K. Adder 5 d 2 adds the outputs of multipliers 5 d 1 and 5 d 4 to obtain a smoothed signal y(n). Delay unit 5 d 3 delays the smoothed signal y(n) by one sample period and supplies the delayed signal y(n−1) to multiplier 5 d 4 . Multiplier 5 d 4 then multiplies the delayed signal y(n−1) by (K−1)/K. The smoothed signal y(n) is accordingly given by the following equation.
y ( n )=(1/ K )· x ( n )+{( K− 1)/ K )}· y ( n− 1)
Multipliers 5 d 1 , 5 d 4 , adder 5 d 2 , and delay unit 5 d 3 constitute a high-frequency smoothing unit. Multiplier 5 d 5 multiplies the smoothed signal y(n) by L and supplies the result to the limiting unit 5 d 6 . The limiting unit 5 d 6 compares the received signal L·y(n) with two values c 1 , c 2 supplied by the parameter adjustment unit 5 d 7 (c 1 <c 2 ), replaces L·y(n) with a smaller value r 1 if L·yn)exceeds c 1 , replaces L·y(n) with a still smaller value r 2 if L·y(n) exceeds c 2 , and thereby obtains the threshold signal t(n) supplied to the comparator unit 5 c. The values of r 1 and r 2 are also supplied by the parameter adjustment unit 5 d 7 . The threshold signal t(n) can be described by the following equations.
t ( n )= L·y ( n when L·y ( n ) ≦c 1
t ( n )= r 1 when c 1 <L·y ( n ) ≦c 2
t ( n )= r 2 when c 2 <L·y ( n )
The parameter adjustment unit 5 d 7 selects c 1 , c 2 , r 1 , and r 2 on the basis of the state information (STT-INF) obtained from the signal state determiner 13 , indicating whether receiving conditions are good or bad. The limiting unit 5 d 6 and parameter adjustment unit 5 d 7 constitute an adaptive limiting unit 5 d 67 .
FIGS. 6A to 6 D illustrate how the threshold value t(n) varies during periods when multipath noise is present and absent. The first waveform (FIG. 6A) is the signal x(n) received from the high-frequency signal extractor 5 ab during a certain interval, indicated schematically using vertical lines. Multipath noise begins about halfway through this interval. As is commonly the case, there is considerable variation in the height of the multipath noise spikes.
The next waveform (FIG. 6B) is the smoothed waveform L·y(n) output from multiplier 5 d 5 . If this waveform were to be used directly as the threshold value, some of the smaller noise spikes in the multipath noise interval might be missed.
The next waveform (FIG. 6C) shows the smoothed signal L·y(n) again, and the two comparison values (c 1 , c 2 ) supplied by the parameter adjustment unit 5 d 7 . The last waveform (FIG. 6D) shows the threshold signal t(n) output by the limiting unit 5 d 6 . During the multipath noise interval, the threshold value is reduced first to r 1 , then to r 2 , then again to r 1 . While the threshold value is limited to these relatively low values (r 1 , r 2 ), no noise spikes are missed.
The parameter adjustment unit 5 d 7 raises the comparison values (c 1 , c 2 ) and limit values (r 1 , r 2 ) as receiving conditions deteriorate; that is, as the received field strength decreases. When receiving conditions improve, these values (c 1 , c 2 , r 1 , r 2 ) are lowered again. FIGS. 7A to 7 D show this process for two cases, in both of which multipath noise begins halfway through the illustrated interval. The first waveform (FIG. 7A) is the output of the high-frequency signal extractor 5 ab under good reception conditions, with a strong electric field received at the antenna 1 . The second waveform (FIG. 7B) shows the smoothed signal L·y(n) and the two comparison values c 1 , c 2 selected by the parameter adjustment unit 5 d 7 under these conditions. The third waveform (FIG. 7C) shows the output of the high-frequency signal extractor 5 ab under poor reception conditions, with a weak electric field. Under these conditions, the noise floor rises, as illustrated in the left part of the fourth waveform (FIG. 7 D), and the parameter adjustment unit 5 d 7 increases the comparison values to higher values c 1 ′, c 2 ′. Under both strong and weak field conditions, the comparison values are well above the noise floor, but are low enough to limit the threshold value appropriately during multipath noise.
If the circuit in FIG. 5 uses analog components, then the multipliers 5 d 1 , 5 d 4 , 5 d 5 are amplifiers with the indicated gain values, the adder 5 d 2 is a summing amplifier, the delay unit 5 d 3 is an analog delay line, and n is a continuous time variable.
FIG. 8 shows another circuit that can be used as the threshold generator 5 d. This circuit is identical to the circuit in FIG. 5, with the addition of a limiter 5 d 8 on the input side of the first multiplier 5 d 1 . The limiter 5 d 8 compares the received sample value x(n) with the output of multiplier 5 d 4 ; that is, with the delayed smoothed signal y(n−1) multiplied by the quantity (K−1)/K. If x(n) differs greatly from the output of multiplier 5 d 4 , the limiter 5 d 8 limits x(n) so that the signal received by multiplier 5 d 1 does not differ from the output of multiplier 5 d 4 by more than a predetermined amount.
The limiter 5 d 8 operates as a type of amplitude-swing limiter, limiting the range of variation of the threshold signal output by the threshold generator 5 d. Even during intervals of multipath noise, accordingly, the threshold value does not increase too rapidly, enabling an appropriate threshold signal to be obtained without the use of an extremely large value of K. The reduction in the necessary value of K in turn enables the threshold generator 5 d to track changes in the noise floor more accurately.
FIG. 9 shows a circuit that can be used as the gate generator 5 g. The multipath noise detection signal d(n) received from the comparator unit 5 c is delayed by a variable amount in a delay unit 5 g 1 , then held for a variable length of time in an expansion unit 5 g 2 , and finally sent as a gate signal g(n) to the replacement unit 5 f. The state information (STT-INF) provided by the signal state determiner 13 is received by a parameter setting unit 5 g 3 , which controls the delay time applied in the delay unit 5 g 1 and the holding time applied in the expansion unit 5 g 2 .
FIGS. 10A to 10 D illustrates the operation of the gate generating means 5 g in FIG. 9 . The first waveform (FIG. 10A) shows the multipath noise detection signal output from the comparator unit 5 c, illustrating a single pulse corresponding to the detection of a single noise spike.
The next waveform (FIG. 10B) shows the gate signal output from the gate generator 5 g to the replacement unit 5 f when the gate pulse is delayed but not expanded. In this case, the parameter setting unit 5 g 3 designates a delay D in the delay unit 5 g 1 , and a holding time of zero in the expansion unit 5 g 2 . The value of D is predetermined so that the delayed gate pulse is centered on the noise spike received by the replacement unit 5 f from delay unit 5 e.
The next waveform (FIG. 10C) shows the gate signal when the pulse is expanded by one unit of time (e.g., one sampling period) both in front and in back. In this case, the parameter setting unit 5 g 3 shortens the delay time by one time unit (from D to D−1), and designates a holding time of two (1*2) time units for the expansion unit 5 g 2 . The expanded pulse is consequently centered at the same point as the non-expanded pulse in the preceding waveform (FIG. 10 B).
The last waveform (FIG. 10D) shows the gate signal when the pulse is expanded by w units of time both in front and in back, where w is an arbitrary quantity not exceeding D. In this case, the parameter setting unit 5 g 3 designates a delay of D minus w time units (D−w) in the delay unit 5 g 1 , and a holding time of two times w time units (w*2) in the expansion unit 5 g 2 . The expanded pulse is again centered at the same point as the non-expanded pulse.
The gate generator 5 g thus outputs gate pulses that are expanded by varying amounts, depending on the state information received from the signal state determiner 13 , but are always centered on the corresponding noise spikes.
As noted above, the signal state determiner 13 receives both the S-meter signal indicating the received field strength at the antenna 1 , and the audio signals output by the stereo demodulator b 7 . The signal state determiner 13 provides the parameter setting unit 5 g 3 with information indicating both the received field strength and the audio signal level. The parameter setting unit 5 g 3 increases the amount of expansion (w) as the received field strength decreases, because under weak field conditions, the effects of multipath noise become relatively greater, so more of the noise must be removed. The parameter setting unit 5 g 3 also increases the amount of expansion (w) as the audio level decreases, because as the audio output becomes more quiet, the effects of multipath noise become more noticeable. Conversely, when the audio level is high, the effects of multipath noise tend to be masked by the strong audio output, and it is more important to avoid unnecessary blocking of the audio signal than to remove all of the multipath noise.
By replacing noise spikes with a smoothed version of the demodulated signal, and by adapting the operation of the threshold generator 5 d and gate generator 5 g to the reception conditions and the audio signal level, the first embodiment is able to reject multipath noise effectively without causing noticeable audio distortion.
In a variation of the first embodiment, the positions of the impulse noise reducer 6 and stereo demodulator 7 are interchanged. The stereo demodulator 7 now receives the output of the multipath noise reducer 5 . The impulse noise reducer 6 receives the output of the stereo demodulator 7 , and removes impulse noise from the left- and right-channel audio signals.
As a second embodiment of the invention, FIG. 11 shows an FM stereo radio receiver that differs from the first embodiment only in the internal configuration of the high-frequency signal extractor in the multipath noise reducer. The high-frequency signal extractor 50 ab in the multipath noise reducer 50 in the second embodiment has the same high-pass filter 5 a and absolute-value calculation unit 5 b as the multipath noise reducer 5 in the first embodiment, but connects them in the reverse order, the high-pass filter 5 a now following the absolute-value calculation unit 5 b. Accordingly, the output of the FM detector 4 is supplied to the absolute-value calculation unit 5 b, the output of the absolute-value calculation unit 5 b is supplied to the high-pass filter 5 a, and the output of the high-pass filter 5 a is supplied to the comparator unit 5 c and threshold generator 5 d.
Referring once again to FIGS. 3A to 3 E, a typical noise spike in the demodulated signal (FIG. 3A) has a negative component followed by a positive component. It therefore has a falling transition followed by a rising transition, then by another falling transition. In the first embodiment, the high-pass filter 5 a converts the two falling transitions to negative values and the rising transition to positive values, producing a negative component followed by a positive component, then another negative component, as seen in the waveform in FIG. 3 B. The absolute-value calculation unit 5 b then converts the two negative components to positive components, so that all three components are detected above the threshold value, as indicated in the waveform in FIG. 3 C.
Referring to FIGS. 12A to 12 E, in the second embodiment, the absolute-value calculation unit 5 b converts the negative component of each noise spike in the demodulated signal (FIG. 12A) to a positive component, as shown in the waveform in FIG. 12B, so that each noise spike has two positive components. Each noise spike therefore has a rising transition followed by a falling transition, then another rising transition, then another falling transition. The high-pass filter 5 a converts the two rising transitions to positive values, as indicated in the waveform in FIG. 12C, and the two falling transitions to negative values, which have been omitted from this waveform (FIG. 12C) because they automatically fall below the threshold value, which is indicted by the dotted line.
In the second embodiment, accordingly, only the leading edges of the negative and positive components of each noise spike are detected. The gate pulses, shown in FIG. 12D, are narrower than in the first embodiment, which detected both leading and trailing edges. The signal output from the multipath noise reducer 50 , shown in FIG. 12E, therefore includes more of the actual waveform of the demodulated signal than in the first embodiment. The gate pulses in the second embodiment (FIG. 12D) represent the actual widths of the noise spikes more accurately. Thus in eliminating multipath noise, the second embodiment causes even less distortion of the audio output signal than does the first embodiment.
Another advantage of the second embodiment is that the high-pass filter 5 a can have a simpler internal structure than in the first embodiment. To detect multipath noise spikes accurately, the high-pass filter 5 a in the first embodiment requires a sharp cut-off characteristic, to avoid spreading out the noise spikes. The high-pass filter 5 a in the second embodiment does not require such a sharp cut-off characteristic; more spreading of the noise spikes can be tolerated, because only leading edges are detected. Thus the high-pass filter 5 a can be less expensive and more compact in the second embodiment than in the first embodiment.
The variations described in the first embodiment can also be applied in the second embodiment.
Those skilled in the art will recognize that further variations of the embodiments described above are possible within the scope claimed below.
|
A multipath noise reducer detects and removes the individual noise spikes occurring in an interval of multipath noise, thereby reducing the multipath noise with relatively little distortion of the output signal. The threshold signal used to detect multipath noise is varied depending on reception conditions. The gate pulses indicating the presence of multipath noise spikes are preferably expanded by variable amounts, depending on both reception conditions and the signal level. Multipath noise spikes are preferably replaced by a smoothed signal. These provisions further reduce perceived distortion of the audio output signal.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of and claims priority to U.S. patent application Ser. No. 14/216,639, filed Mar. 17, 2014, which in turn claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/801,831 to the inventors, filed Mar. 15, 2013, the entire contents of which are hereby incorporated by reference herein.
BACKGROUND
[0002] 1. Field.
[0003] Example embodiments in general relate to child-resistant closure systems for containers.
[0004] 2. Related Art
[0005] The Consumer Product Safety Commission (“CPSC”) proposed a rule in early 2012 to require child-resistant (“CR”) packaging for any over-the-counter or prescription product containing the equivalent of 0.08 milligrams or more of an imidazoline, a class of drugs that includes tetrahydrozoline, naphazoline, oxymetazoline, and xylometazoline, in a single package. Imidazolines are a family of drugs that are vasoconstrictors indicated for nasal congestion and/or ophthalmic irritation. Products containing imidazolines can cause serious adverse reactions, such as central nervous system (“CNS”) depression, decreased heart rate, and depressed ventilation in children treated with these drugs or who accidentally ingest them. Based on the scientific data, the CPSC has preliminarily found that availability of 0.08 milligrams or more of an imidazoline in a single package, by reason of its packaging, is such that special packaging is required to protect children under 5 years old from serious personal injury or illness due to handling, using, or ingesting such a substance. The CPSC has taken this action under the Poison Prevention Packaging Act of 1970.
[0006] Accordingly, as it is expected that this rule will become law, manufacturers will be required to develop child-resistant closure (CRC) systems for their nasal pump sprayers and eye-dropper dispenser products (such as Visine®), as each of these products contain the equivalent of 0.08 milligrams or more of an imidazoline. In doing so, one goal is to ensure that the newly developed dispensers are robust enough to prevent children five years old and under from being able to inadvertently open the bottle to use or ingest the contents, while still being “senior friendly” to mature adults.
[0007] Moreover, the same child-resistant principals as to be applied to nasal sprayers and eye-dropper (squeeze) bottles so as to comply with impending CR packaging regulations, could also be made applicable to other fields of fluid dispenser/packaging. For example, little or no thought has be given to developing CRC systems for consumer fluid pump dispensers having a viscosity generally higher than that of water or water-based medicinal fluids, such as those dispensers holding lotions, shampoos, baby oils, and paints.
SUMMARY
[0008] An example embodiment is directed to a child-resistant closure system for a pump sprayer. The system includes a protective cap, a dispensing tip configured to receive the cap thereon, a lower end of the dispensing tip including a pair of finger-depressing shoulders in opposite relation to one another, each shoulder extending horizontally outward from the dispensing tip, with a cylindrical portion provided beneath the shoulders to serve as a bottom end of the dispensing tip, the cylindrical portion including a pair of buttons spaced 180° apart on a vertical facing of the cylindrical portion, the buttons adapted to control whether the dispensing tip is in a locked or unlocked condition so as to permit actuation, via the shoulders, of a sprayer pump unit that is partially contained within the dispensing tip, each button including an undercut formed on a back face thereof within the interior of the dispensing tip, and a cylindrical base having its upper end secured to the dispensing tip and its lower end configured to be secured to a dispenser bottle which contains fluid, the dispensing tip and base housing the sprayer pump unit therein which is actuated by depressing the shoulders on the dispensing tip once the dispensing tip is in an unlocked condition, the base top end including a circular thread formed around its circumference on an external surface thereof. In a locked condition of the dispensing tip, the undercuts on the back faces of the buttons engage an underside of the circular thread on the base to prohibit actuation of the sprayer pump unit and to lock the dispensing tip. To achieve an unlocked condition of the dispensing tip to permit actuation of the sprayer pump unit via depressing the shoulders, the buttons are pressed simultaneously to deflect the undercuts outward and away from the circular thread on the base, permitting the dispensing tip to move upward to a home dispensing position under a force applied to the dispensing tip from a spring in the sprayer pump unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Example embodiments will become more fully understood from the detailed description given herein below and the accompanying drawing, wherein like elements are represented by like reference numerals, which are given by way of illustration only and thus are not limitative of the example embodiments herein.
[0010] FIG. 1 is a front view of a child-resistant closure system for a pump sprayer according to an example embodiment.
[0011] FIG. 2 is a front view of a dispensing tip according to the system of FIG. 1 .
[0012] FIG. 3 is a bottom perspective view of the dispensing tip according to the system of FIG. 1 .
[0013] FIG. 4 is a side view of a base according to the system of FIG. 1 .
[0014] FIG. 5 is a sectional view B-B taken from FIG. 4
[0015] FIG. 6 is a bottom perspective view of the base shown in FIG. 4 .
[0016] FIG. 7 is a dispensing bottle usable with the system of FIG. 1 .
[0017] FIG. 8 is a top view of the bottle shown in FIG. 7 .
[0018] FIG. 9 is a portion of a cross-cut of the dispensing tip in the xz-plane to show positions of the base legs and buttons in a locked position.
[0019] FIG. 10 is a portion of a sectional view of the system taken in the xy-plane to show a locked position.
[0020] FIG. 11 is a perspective view of a child-resistant closure system for a pump sprayer according to another example embodiment.
[0021] FIG. 12 is a perspective view of a cap according to the system of FIG. 11 .
[0022] FIG. 13 is a perspective view of a base according to the system of FIG. 11 .
[0023] FIG. 14 is a perspective view of a dispensing tip according to the system of FIG. 11 .
[0024] FIG. 15 is a portion of a sectional view of the system taken in the yz-plane to show a locked position.
[0025] FIG. 16 is a perspective view of a child-resistant closure system for a pump sprayer according to another example embodiment.
[0026] FIG. 17 is a front view of a dispensing tip according to the system of FIG. 16 .
[0027] FIG. 18 is a sectional view C-C taken from FIG. 17 .
[0028] FIG. 19 is a front view of a base according to the system of FIG. 16 .
[0029] FIG. 20 is a front view of the dispensing cap and base of the system in FIG. 16 .
[0030] FIG. 21 is a sectional view A-A taken from FIG. 20 to show a locked position.
[0031] FIG. 22 is a sectional view A-A taken from FIG. 20 to show an unlocked position.
[0032] FIG. 23 is a perspective view of a child-resistant closure system for a pump sprayer according to another example embodiment.
[0033] FIG. 24 is a partial side perspective view of a dispensing tip according to the system of FIG. 23 .
[0034] FIG. 25 is a partial bottom perspective view of the dispenser tip of FIG. 24 .
[0035] FIG. 26 is a front view of a base according to the system of FIG. 23 .
[0036] FIG. 27 is a portion of a sectional view of the system taken in the xz-plane to show a locked position.
[0037] FIG. 28 is sectional view of the cap, dispenser tip and base taken in the xz-plane to show a locked position.
[0038] FIG. 29 is a portion of a sectional view of the system taken in the xz-plane to show an unlocked position.
[0039] FIG. 30 is sectional view of the dispenser tip and base taken in the xz-plane to show an unlocked position.
[0040] FIG. 31 is a front view of a child-resistant closure system for a pump sprayer according to another example embodiment.
[0041] FIG. 32 is a portion of a sectional view of the system taken in the xz-plane to show a locked position.
[0042] FIG. 33 is a sectional view A-A taken from FIG. 31 to show a locked position.
[0043] FIG. 34 is a sectional view A-A taken from FIG. 31 to show an unlocked position.
[0044] FIG. 35 is a perspective view of a child-resistant closure system for a pump assembly according to another example embodiment.
[0045] FIG. 36 is an exploded view of the system of FIG. 35 .
[0046] FIG. 37 is a partial bottom perspective view of the dispenser of FIG. 35 .
[0047] FIG. 38 is a sectional view of the system taken in the xy-plane to show an unlocked position with the cap installed.
DETAILED DESCRIPTION
[0048] FIG. 1 is a front view of a child-resistant closure system for a pump sprayer according to an example embodiment. The child-resistant closure (CRC) system 100 includes a cap 110 , a dispensing tip 120 and a base 130 . Each of the cap 110 , dispensing tip 120 and base 130 may be injection molded or extruded or otherwise formed of a suitable plastic material, as is known. The cap 110 is 3-sided to minimize rolling and avoid losing the cap 110 . The base 130 has interior grooves or threads for coupling it to a threaded member on dispenser bottle 140 which holds the medicinal fluid therein. The base 130 and dispensing tip 120 also partially enclose a sprayer pump unit 150 (not shown) which partly extends into the dispenser bottle 140 interior.
[0049] In an example, the CRC system 100 described here and child-resistant based embodiments to be described hereafter may be applicable, but not limited to: single or multi-dose dispensers such as nasal sprayers, ocular sprayers, dermal sprayers, misters, aerators, airless dispensers, air-use dispensers, spouted and non-spouted pump assemblies, and the like. The containers or dispensers foreseeable have applications in the healthcare, home and garden, beauty and food and beverage industries, thus the embodiments described herein are applicable to dispensers or containers configured for, but not limited to dispensing nasal medicine, sunscreens, food products, paints and protectants, deodorants, insect repellants, sealed breath fresheners, ear medicine, dermal medicine, lotions, fragrances, air fresheners, spray starches, oxygen, insecticides, fungicides, herbicides, rodenticides, spray oils, talcs, and spray food stuffs. Further, the CRC systems can be varied in size and applied as a platform to handle any desired viscosity of fluid.
[0050] FIG. 2 is a front view of a dispensing tip according to the system of FIG. 1 , and FIG. 3 is a bottom perspective view of the dispensing tip according to the system of FIG. 1 . Dispensing tip 120 includes a pair of spaced, dished buttons 122 on a collar 126 that permit locking and unlocking of the dispensing tip 120 for rotation thereof to allow dispensing via a pair of shoulders 121 , which are used to depress the sprayer pump unit 150 within (not shown) under finger pressure, as is known. A button 122 is provided on either side of collar 126 and includes a relief 124 separated by a hinge 125 that acts as a cam when the button 122 is actuated by the user. A ramp 127 is positioned on the back side of each relief 124 ; this interfaces with an upstanding leg 135 that is formed on either side atop of base 130 , as to be shown hereafter. A pair of internal catches 129 within dispensing tip 120 also come into contact with the legs 135 of the base 130 in a locked condition, locking out the dispensing tip 120 .
[0051] FIG. 4 is a side view of the base, FIG. 5 a sectional B-B taken from FIG. 4 of the base, FIG. 6 is a bottom perspective view of the base, FIG. 7 is a dispenser bottle usable with the system of FIG. 1 , and FIG. 8 is a top view of the bottle shown in FIG. 12 . Referring to FIGS. 4-8 , the base 130 includes a pair of upstanding legs 135 in spaced relation on a top surface thereof, and includes a series of grooved internal threads 131 for coupling with a dispenser bottle 140 . There is also a vertical clearing 136 adjacent each leg that is formed into base 130 that permits product dispensing. Additionally, an anti-back off feature has been added to both the dispenser bottle 140 and base 130 . The base 130 is formed with internal threads 131 , and serrated teeth 132 at its bottom skirt. Upon full seating of the base 130 to the bottle 140 , the downward force of application will push the bottom skirt of the base 130 over formed teeth 142 in the bottle 140 , providing a secure method of application where tampering to remove the base 130 would be evident and would eliminate accidental removal.
[0052] FIG. 9 is a portion of a cross-cut of the dispensing tip in the xz-plane to show positions of the base legs and buttons in a locked position, and FIG. 10 is a portion of a sectional view of the system taken in the xy-plane to show a locked position. Referring to FIGS. 9 and 10 , basic operations are described. The cap 110 is retained simply by an undercut on the dispensing tip 120 . All that is required to remove cap 110 is a vertical pull.
[0053] FIG. 10 shows a locked condition with the leg 135 of the base 130 held by catch 129 ; FIG. 9 shows this in another orientation and additionally shows the tab 127 on the dispenser tip engaged with leg 135 . Both horizontal dished buttons 122 on dispensing tip 120 are to be simultaneously depressed in order to release the dispensing mechanism. Depressing the buttons cants the ramps 127 outward via hinges 125 , which releases the upstanding legs 135 on the base 130 , allowing each leg 135 to turn and release from its corresponding catch 129 . The dispensing tip 120 pivots 30° on center axis and aligns with the vertical clearing 136 on the base 130 , which allows for product dispensing.
[0054] Although the embodiment shown in FIGS. 1-10 describes a base 130 having two legs that is twist to unlock, in which the dispenser tip 120 locks out actuation of a sprayer pump unit, the exact same embodiment can be accomplished with a dispenser 120 having two buttons, but actuating a single leg 135 . The functions of locking and unlocking described above with a single leg having the same construction as leg 135 would accomplish the same goal of locking out dispensing, as the leg 135 would extend all the way to catch 129 . The other side would by legless, but the interlock would still require simultaneous two-button interaction for child-resistant purposes.
[0055] FIG. 11 is a perspective view of a child-resistant closure system for a pump sprayer according to another example embodiment, and FIG. 12 is a perspective view of a cap according to the system of FIG. 11 . Referring to FIGS. 11 and 12 , the child-resistant closure (CRC) system 200 includes a cap 210 , a dispensing tip 220 and a base 230 . Each of the cap 210 , dispensing tip 220 and base 230 may be injection molded or extruded or otherwise formed of a suitable plastic material, as is known. The cap 210 is 3-sided to minimize rolling and avoid losing the cap 210 and includes a lower rim 223 .
[0056] The dispensing tip 220 includes two raised ribbed buttons 222 on opposite sides thereof that control whether the dispensing tip 220 is in a locked or unlocked condition so as to permit actuation of the sprayer pump unit 250 (not shown). The base 230 has interior grooves or threads for coupling it to a threaded member on dispenser bottle 240 which holds the medicinal fluid therein. The base 230 and dispensing tip 220 also partially enclose a sprayer pump unit 250 (not shown) which partly extends into the dispenser bottle 240 interior.
[0057] FIG. 13 is a perspective view of a base according to the system of FIG. 11 . The base 230 includes a pair of upstanding legs 235 in spaced relation on a top surface thereof, and includes a series of grooved internal threads (not shown) for coupling with a dispenser bottle 240 . There is also a horizontal groove 237 outside each leg 235 to facilitate dispenser tip 220 rotation around the base 230 when rotating to an unlocked state to permit dispensing. The base 230 and dispenser bottle 240 have serrations similar to that shown in FIGS. 5-8 ; in other words, an anti-back off feature is included. The base 230 is formed with internal threads and serrated teeth at its bottom skirt. Upon full seating of the base 230 to the bottle 240 , the downward force of application pushes the bottom skirt of the base 230 over formed teeth in the bottle 240 , providing a secure method of application where tampering to remove the base 230 would be evident and would eliminate accidental removal.
[0058] FIG. 14 is a perspective view of a dispensing tip according to the system of FIG. 11 . The dispenser tip 220 includes shoulders 221 that is the finger-depressing surface for actuating the internal sprayer pump unit 250 . The center between the shoulders 221 has a circular downward cutout 224 in which the rim 213 of the cap 210 can seat in. The upper ends of the buttons 222 includes catches 225 that clamp onto the rim 213 of the cap 210 seated in the circular cutout 224 to fixedly retain the cap 210 .
[0059] FIG. 15 is a portion of a sectional view of the system taken in the yz-plane to show a locked position. In operation, both raised ribbed buttons 222 on dispensing tip to be depressed in order to release the top cap 210 . Actuation is achieved through depression of the buttons 220 that twist the arms at the midpoint releasing the catches 225 that are slightly elevated from the cap deck of the dispensing tip 220 . The cap 210 can then be removed.
[0060] However, the system 200 is still locked (as shown in FIG. 15 ) and will not dispense. To operate, the dispensing tip 200 needs to be rotated 30° to release the sprayer pump unit 250 . The dispensing tip 220 is locked by the two vertical legs 235 that protrude from top surface of the base 230 . When the dispensing tip 220 is rotated, reliefs (not shown in FIG. 15 ) cut though the dispensing tip 220 to allow the legs 235 to pass through on the dispensing stroke.
[0061] FIG. 16 is a perspective view of a child-resistant closure system for a pump sprayer according to another example embodiment, FIG. 17 is a front view of a dispensing tip according to the system of FIG. 16 , FIG. 18 is a sectional view C-C taken from FIG. 17 , and FIG. 19 is a front view of a base according to the system of FIG. 16 . Referring to FIGS. 16-19 , the child-resistant closure (CRC) system 300 includes a cap 310 , a dispensing tip 320 and a base 330 . Each of the cap 310 , dispensing tip 320 and base 330 may be injection molded or extruded or otherwise formed of a suitable plastic material, as is known. The cap 310 is 3-sided to minimize rolling and avoid losing the cap 310 .
[0062] The dispensing tip 320 includes a pair of finger-depressing shoulders 321 in opposite relation thereto (180 degrees apart), as well as two buttons 322 on opposite sides of a cylindrical portion of the dispenser tip 320 below the shoulders 321 that control whether the dispensing tip 320 is in a locked or unlocked condition so as to permit actuation of the sprayer pump unit 350 (not shown) via the shoulders 321 . An undercut 324 is formed on the back side of each button 322 , the undercuts 324 are configured to interface and engage a single circular thread 337 at the top of a base 330 . The base 330 has interior grooves or threads for coupling it to a threaded member on dispenser bottle 340 which holds the medicinal fluid therein. The base 330 and dispensing tip 320 also partially enclose a sprayer pump unit 350 (not shown) which partly extends into the dispenser bottle 340 interior.
[0063] FIG. 20 is a front view of the dispensing tip and base of the system in FIG. 16 , FIG. 21 is a sectional view A-A taken from FIG. 20 to show a locked position, and FIG. 22 is a sectional view A-A taken from FIG. 20 to show an unlocked position. Referring to FIGS. 20-22 , in the A-A views the cap 310 is shown removed. This is because in this embodiment the cap 310 is not locked; it can be removed from the dispensing tip 320 by simply pulling upward. With the dispensing tip 320 in place, dispensing actuation is locked out. Specifically, the dispensing tip 320 is retained by the two undercuts 324 , each undercut 324 located on the back face of two buttons 322 180° apart on the dispensing tip 320 . The undercuts 324 engage with the underside of continuous, circular thread 337 at the top of the base 330 , as shown in the locked configuration of FIG. 21 . When engaging, the undercuts 324 will initially deflect outwards until they pass the thread 337 , where after they will snap back to vertical and engage the underside of thread 337 of base 330 , as shown.
[0064] To release the dispensing tip 320 , the buttons 332 on the dispensing tip 320 must be pressed simultaneously, causing the undercuts 324 to once again deflect outwards. The dispensing tip 320 will move vertically (by force of the spring in the sprayer pump unit 350 , shown obscured by the dispensing tip 320 ) to the home dispensing position. This is shown in FIG. 22 . With the dispensing tip 320 now released, the sprayer pump unit 350 is now free to dispense a single dose via pressing down using one's fingers on the shoulders 321 , as is known. For each dose, the dispensing tip 320 must be released.
[0065] FIGS. 21 and 22 also show the internal threads 331 and serrations 332 on the inside of the base 330 . As previously shown in FIGS. 5-8 , an anti-back off feature is added to both the bottle 340 and base 330 . Upon full seating of the base 330 to the bottle 340 , the downward force of application will push the bottom skirt of the bottle (containing serrations 332 ) over the formed teeth in the bottle 340 , providing a secure method of application where tampering to remove the base 330 would be evident and would eliminate accidental removal thereof
[0066] FIG. 23 is a perspective view of a child-resistant closure system for a pump sprayer according to another example embodiment, FIG. 24 is a partial side perspective view of a dispensing tip according to the system of FIG. 23 , FIG. 25 is a partial bottom perspective view of the dispenser tip of FIG. 24 , and FIG. 26 is a front view of a base according to the system of FIG. 23 . Referring to FIGS. 23-26 , the child-resistant closure (CRC) system 400 includes a cap 410 , a dispensing tip 420 and a base 430 . Each of the cap 410 , dispensing tip 420 and base 430 may be injection molded or extruded or otherwise formed of a suitable plastic material, as is known. The cap 410 is 3-sided to minimize rolling and avoid losing the cap 410 .
[0067] The dispensing tip 420 includes two levers 422 on opposite sides thereof that control whether the dispensing tip 420 is in a locked or unlocked condition so as to permit actuation of the sprayer pump unit 450 (not shown). A pair of slits or reliefs 424 are formed on either side of each lever 422 to provide flexibility. The dispensing tip 420 includes finger-depressing shoulders 421 which serve to engage the internal pump sprayer unit (not shown). Centrally located between the shoulders 421 is a circular recessed cutout 424 for receiving the rim of the cap 410 so that the cap 410 may be seated therein. As shown in FIGS. 24 and 25 , each lever 422 includes two undercuts, on set on the top end of the lever 422 , another undercut on a back side thereof. There is a top set of undercuts 425 that is designed to engage the rim of the cap 410 to secure the cap 410 into the recessed cutout 424 to lock out operation of the dispenser tip 420 . There is a lower undercut 427 that engages a horizontal single thread rim 437 on the upper end of base 430 which also locks out actuator operation. Accordingly, user action on the levers 422 control the action of the undercuts 425 , 427 .
[0068] The base 430 has interior grooves or threads for coupling it to a threaded member on dispenser bottle 440 which holds the medicinal fluid therein. The base 430 and dispensing tip 420 also partially enclose a sprayer pump unit 450 (not shown) which partly extends into the dispenser bottle 440 interior.
[0069] FIG. 27 is a portion of a sectional view of the system taken in the xz-plane to show a locked position, FIG. 28 is sectional view of the cap, dispenser tip and base taken in the xz-plane to show a locked position, FIG. 29 is a portion of a sectional view of the system taken in the xz-plane to show an unlocked position, and FIG. 30 is sectional view of the dispenser tip and base taken in the xz-plane to show an unlocked position. FIGS. 27-30 should be generally referred to for the following discussion.
[0070] With the cap 410 in place seated in cutout 424 and the dispenser 420 depressed, dispenser actuation is locked out. Specifically, the cap 410 is retained by the top undercuts 425 on the end of levers 422 that act as the release/retention mechanism. The undercuts 425 engage with the topside of the cap 410 to hold it in place. When engaging, the levers 422 will deflect outwards until the undercuts 425 pass the platform of the cap 410 , where they will snap back to vertical and engage.
[0071] The same lever 422 controls the lockout of the dispensing tip 420 . There is a second set of undercuts 427 , each on the back side of its corresponding lever within the interior of dispenser 420 , that provides the platform for the thread retention of horizontal thread rim 437 on base 430 . When engaging, the levers 422 will deflect outwards until the undercuts 427 pass the horizontal thread 437 , where they will snap back to vertical and engage.
[0072] To release the cap 410 /dispensing tip 420 , the levers 422 on the dispensing tip 420 must be pressed simultaneously, causing the levers 422 to once again deflect outwards. The dispensing tip 420 will pop up to dispensing mode (under spring pressure of the internal sprayer pump unit 450 ) and the cap 410 can be drawn up and off of the dispenser tip 420 . With the cap 410 having been removed (as shown in FIG. 30 ), the shoulders 421 can now be depressed to actuate the sprayer pump unit 450 to dispense a single dose. For each subsequent dose, the act of simultaneously depressing the levers 422 must be repeated to release the dispensing tip 420 .
[0073] FIGS. 28 and 30 also show the internal threads 431 and serrations 432 on the inside of the base 430 . As previously shown in FIGS. 5-8 , an anti-back off feature is added to both the bottle 440 and base 430 . Upon full seating of the base 430 to the bottle 440 , the downward force of application will push the bottom skirt of the bottle (containing serrations 432 ) over the formed teeth in the bottle 440 , providing a secure method of application where tampering to remove the base 430 would be evident and would eliminate accidental removal thereof
[0074] FIG. 31 is a front view of a child-resistant closure system for a pump sprayer according to another example embodiment. The child-resistant closure (CRC) system 500 is essentially identical to that described above regarding system 300 in FIGS. 16-22 . However, unlike system 300 , the dispenser tip 520 in system 500 has a double walled construction to increase strength and robustness of the dispenser tip 520 , with an outer dispenser cap 520 and an inner wall 520 ′. As such, the following figures are provided merely to review operation for locked and unlocked conditions of the system.
[0075] FIG. 32 is a portion of a sectional view of the system taken in the xz-plane to show a locked position, FIG. 33 is a sectional view A-A taken from FIG. 31 to show a locked position, and FIG. 34 is a sectional view A-A taken from FIG. 31 to show an unlocked position. Referring to FIGS. 32-34 , in the A-A view of FIG. 34 , the cap 510 is shown removed. This is because in this embodiment the cap 510 is not locked; it can be removed from the dispensing tip 520 by simply pulling upward. With the dispensing tip 520 in place, dispensing actuation is locked out. Specifically, the dispensing tip 520 is retained by the two undercuts 524 on the back face of two buttons 522 180° apart on the base 520 . The undercuts 524 engage with the underside of continuous horizontal thread 537 on the base 530 , as shown in the locked configuration of FIG. 33 . When engaging, the undercuts 524 will initially deflect outwards until they pass the thread 537 , where after they will snap back to vertical and engage the underside of thread 537 of base 550 , as shown.
[0076] To release the dispensing tip 520 , the buttons 522 on the dispensing tip 520 must be pressed simultaneously, causing the undercuts 524 to once again deflect outwards. The dispensing tip 520 will move vertically (by force of a spring in the sprayer pump unit 550 ) to the home dispensing position. This vertical movement is shown in FIG. 34 . With the dispensing tip 520 now released, the sprayer pump unit 550 is now free to dispense a single dose. For each dose, the dispensing tip 520 must be released by simultaneously pressing buttons 522 .
[0077] FIGS. 33 and 34 also show the internal threads 531 and serrations 532 on the inside of the base 530 . As previously shown in FIGS. 5-8 , an anti-back off feature is added to both the bottle 540 and base 530 . Upon full seating of the base 530 to the bottle 540 , the downward force of application will push the bottom skirt of the bottle (containing serrations 532 ) over the formed teeth in the bottle 540 , providing a secure method of application where tampering to remove the base 530 would be evident and would eliminate accidental removal thereof
[0078] FIG. 35 is a perspective view of a child-resistant closure system for a pump assembly according to another example embodiment FIG. 36 is an exploded view of the system of FIG. 35 , and FIG. 37 is a partial bottom perspective view of the dispenser of FIG. 35 . System 600 differs from the previous embodiments in that CR is provided for a spray pump, with a spray head 615 and nozzle 616 . Additionally, the cap 610 serves no part in the child resistance, it can be pulled off at any time.
[0079] System 600 includes cap 610 , having a flat rim 613 to be seated in dispenser 620 , a pump head 615 with nozzle 616 , base 630 , and tank 640 with or without fluid therein. The dispenser 620 includes a button 622 that actuates similar to the button described in system 400 , as it includes a pair of undercuts 627 , each on a back side of a corresponding button 622 for engaging the single thread 637 at the top of base 630 .
[0080] FIG. 38 is a sectional view of the system taken in the xy-plane to show an unlocked position with the cap installed. The cap 610 is not locked in this embodiment and is removed by simply pulling upward. FIG. 38 shows the thread 637 disengaged from the undercuts 627 on the back of buttons 622 ; the dispenser is released and unlocked. However, assuming the dispenser 620 and cap in place, the pump head 615 is locked out. Specifically, the dispenser 620 is retained by the two undercuts 627 on the back face of two buttons 622 on the dispenser 620 that are 60° apart. The undercuts 627 engage with the underside of continuous horizontal thread 637 at the top of the base 630 . When engaging, the undercuts 627 will deflect outwards until the undercuts 627 pass the thread 637 where they will snap back to vertical and engage.
[0081] To release the dispenser, the buttons 612 must be pressed simultaneously, causing the undercuts 627 to once again deflect outwards and the dispenser 620 will move vertically (by force of the spring in the pump head 615 ) to the home dispensing position. With the dispenser 620 released, the pump head 615 is now free to dispense one dose.
[0082] The example embodiments being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as departure from the example embodiments, and all such modifications as would be obvious to one skilled in the art are intended to be included herein.
|
A child-resistant closure system for a container comprises a protective cap, a dispensing tip, and a cylindrical base. The dispensing tip includes a pair of buttons adapted to control whether the dispensing tip is in a locked condition so as to prevent actuation or an unlocked condition so as to permit actuation, via the shoulders, of a sprayer pump unit that is partially contained within the dispensing tip. The cylindrical base has a pair of spaced apart upwardly extending legs. In an locked condition of the dispensing tip, the upwardly extending legs are not aligned with slots defined in a horizontal circumferential portion of the dispensing tip such that downward movement of the dispensing tip in relation to the base is blocked by the upwardly extending legs to prohibit actuation of the sprayer pump unit and to lock the dispensing tip.
| 1
|
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to a cyclized rubber-type negative-working photoresist coating composition which provides high resolution.
II. Description of the Prior Art
ICs are currently being packed at higher densities to form LSIs or VLSIs. With this trend, a photoresist providing a higher resolution is required.
A positive-working photoresist is conventionally used for an integrated circuit which requires a high resolution. However, a positive-working photoresist is inferior in sensitivity, adhesion strength, and mechanical strength to a negative-working photoresist. On the other hand, even though a negative-working photoresist is superior to a positive-working photoresist in these respects, it cannot respond to a requirement of micronization beyond a certain limit. That is, when a rubber-type negative-working photoresist is exposed, is developed with an organic solvent and is thereafter rinsed, the crosslinked photoresist swells to degrade the resolution.
In view of this problem, one proposal suggests changing from a negative-working photoresist of the type most often used currently which mainly consists of xylene to one of the aliphatic hydrocarbon type having 5 to 12 carbon atoms, which swells only slightly. Another proposal is proposed to adopt dry developing which results in no swelling of the photoresist at all. However, these proposals have not yet led to actual satisfactory results.
SUMMARY OF THE INVENTION
It is an object of the present invention not to improve a developing solution or method but to improve the photoresist main base material itself so as to provide a cyclized rubber-type photoresist which swells only slightly and which can improve resolution.
According to the present invention, there is provided a negative-working photoresist coating composition containing a cyclized polyisoprene having a weight-average molecular weight of 10,000 to 100,000 and a molecular weight distribution of not more than 1.9, an organic solvent of the cyclized polyisoprene, and a bisazido compound as a crosslinking agent.
As described above, according to the present invention, a cyclized polyisoprene having a weight-average molecular weight of 10,000 to 100,000 and preferably 27,000 to 49,000, and a molecular weight distribution of 1.9 or less and preferably 1.7 or less, is used.
The weight-average molecular weight is a value measured by gel permeation chromatography (GPC).
A cyclized polyisoprene used in a conventional rubber-type photoresist composition has a far larger weight-average molecular weight than that of the present invention (within the range of one hundred thousand to two hundred and eighty thousand), and has a molecular weight distribution of about 2.0 to 2.7.
The molecular weight distribution is obtained by dividing the weight-average molecular weight (M w ) by the number-average molecular weight (M n ).
As described above, it was found, according to the studies made by the present inventors, that a cyclized polyisoprene having a weight average molecular weight and a molecular weight distribution in certain ranges can significantly improve the resolution of the photoresist. This is considered to be attributable to the following:
As shown in FIG. 1, when a photoresist film 2 formed on a wafer 1 is exposed to ultraviolet light (indicated by arrows) through a photomask 3, cyclized polyisoprene (indicated by the solid lines) is crosslinked by a crosslinking agent to form giant molecules at a crosslinking portion 4. However, the cyclized polyisoprene is not crosslinked at a non-crosslinking portion 5. When this photoresist film 2 is developed, the cyclized polyisoprene at the non-crosslinking portion 5 is dissolved and is removed. However, the cyclized polyisoprene molecule having one terminal end at the crosslinking portion 4 and the other terminal end at the non-crosslinking portion 5 is not dissolved. Then, a part 6 of the molecular chain remains extending into the non-crosslinking portion 5, thus resulting in an irregular pattern. Accordingly, when the pattern width is narrowed, the cyclized polyisoprene molecules extending from both sides are eventually connected to each other and patterning cannot be performed. In contrast to this, a cyclized polyisoprene used in the photoresist of the present invention has a weight average molecular weight which is in the small range of 10,000 to 100,000 and has a significantly short molecular chain when compared with a conventional chain length. Accordingly, extension of molecular chains into the non-crosslinking portion 5 is prevented, an image with sharp edges can be formed, and the resolution is improved.
The effect of the molecular weight distribution on the resolution will now be described. When the weight-average molecular weights of polymers are assumed to be the same, the narrower the molecular weight distribution of the polymer, the greater the difference between the dissolution rates of the exposed and non-exposed portions of the photoresist. This is considered to result in a good contrast (γ value) and sensitivity. From the above, it is seen that a narrower molecular weight distribution results in a better resolution.
The effect of the present invention will now be described with reference to swelling after development, which is the most important factor adversely affecting the resolution of cyclized polyisoprene. The development reaction of a photoresist consisting of a cyclized polyisoprene is a swelling dissolution phenomenon caused by the developer. Swelling of the photoresist is caused by thermal diffusion which is caused by a difference in concentration of the developer in the photoresist. Swelling cannot be stopped until the developer concentration in the photoresist reaches a certain value. In general, the swelling amount (Q) of a polymer can be given by the following equation:
Q=[(0.5-μ)×M.sub.w /(ρ.sub.p V.sub.a)].sup.3/5
where μ is the mutual action coefficient of a solute and a solvent, ρ p is the density of a polymer and V a is the molar volume of the solvent.
When the weight-average molecular weight (M w ) of a cyclized polyisoprene is small, the swelling amount (Q) can be decreased, and the resolution is improved.
A crosslinking agent (sensitizer) to be used in a rubber-type photoresist coating composition of the present invention may be a known bisazido compound crosslinking agent such as 2,6-di-(4'-azidobenzal)-4-methylcyclohexanone or 2,6-di-(4'-azidobenzal)-cyclohexanone. The amount of the crosslinking agent to be used is 2 to 5% by weight based on the amount of the cyclized polyisoprene and can be determined according to the sensitivity, the degradation in performance, etc. of the photoresist.
A stabilizer, a light-absorbing agent and other additives of a conventional rubber-type photoresist coating composition may be added to the rubber-type photoresist coating composition according to the present invention, as needed. The amounts of these additives can be determined in accordance with each application so as to provide optimal performance. A solvent for dissolving solid contents may be another known organic solvent such as an aromatic hydrocarbon-type organic solvent like xylene which is used in a rubber-type photoresist coating composition of this type.
According to a photoresist of the present invention, since a cyclized polyisoprene as the main base material has a low molecular weight and a narrow molecular weight distribution, it has a short molecular chain, causes little swelling, and has a high contrast (γ value). The composition of the present invention can provide a resolution of 1.5 to 2.0 μm as compared to a conventional resolution of 3.0 μm. A coating of the composition of the present invention can be formed sufficiently thick, and the sensitivity is also comparable to that of the conventional photoresist coating composition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representation showing the relationship between the molecular chain length and resolution when a photoresist is developed; and
FIG. 2 is a graph showing characteristics of a negative-working photoresist of the present invention together with those of a conventional photoresist.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described by way of examples.
EXAMPLE 1
A rubber-type photoresist coating composition I was prepared by adding 3% by weight of 2,6-di-(4'-azidobenzal)-4-methylcyclohexanone to a cyclized polyisoprene having a weight-average molecular weight of 49,000 and a molecular weight distribution of 1.7.
As a control, a photoresist coating composition II was also prepared following the same procedures of Example 1 except that the cyclized polyisoprene used had a weight average molecular weight M w of 142,000 and a molecular weight distribution (M w /M n ) of 2.2.
The compositions I and II were respectively spin coated on a wafer to a thickness of 1.0 μm by a spin coater in a test pattern having widths of 1.5, 1.75, 2.0, 2.5, 3.0, 3.5, and 4.0 μm. The composition II provided a minimum resolution of about 3.0 μm, and caused pattern distortion and was unable to provide a linear pattern with a smaller width. In contrast to this, the composition I provided a minimum resolution of 1.5 μm, thus resulting in an improvement of about 1.5 μm in resolution.
As for the coating thickness, the photoresist of Example 1 provided a coating thickness of 1.15 μm with a spin coater of 4,000 rpm despite its low molecular weight. Thus, the photoresist of Example 1 was satisfactory in this respect. When the sensitivity of the photoresist of Example 1 was examined using an integrating exposure meter "Mask aligner PLA 500F" (Canon), a sensitivity curve as shown in FIG. 2 was obtained with a coating thickness of 1.0 μm. Thus, the photoresist of Example 1 was satisfactory in this respect as well. In general, when the weight-average molecular weight of the main base material of the photoresist is decreased, the sensitivity is degraded. However, in the case of a photoresist main base material of the present invention, the narrow molecular weight distribution range apparently prevents such a degradation in sensitivity. The ratio of remaining film after development as defined by the ratio of the film thickness of the photoresist after development to the original coating thickness is as shown in FIG. 2, thus providing a practical photoresist film.
The γ value, which is a well known index of resolution, will be examined. The γ value is defined by the gradient of the linear portion of a curve obtained when exposure energy is plotted along the axis of abscissa and the ratio of remaining film after development is plotted along the axis of ordinate. Thus, the γ value indicates the dependency of the ratio of remaining film on the exposure energy. A higher γ value indicates a higher resolution. FIG. 2 shows a characteristic curve I of the composition I (Example 1) having a coating thickness of 1.0 μm and a characteristic curve II of the composition II (control). It is seen from FIG. 2 that the γ value of the composition II is 1.67 while that of the composition I is 5.25. Accordingly, the photoresist composition of the present invention provides a higher resolution than the conventional composition.
EXAMPLE 2
A rubber-type photoresist coating composition was prepared following the procedures in Example 1 using a cyclized polyisoprene having a weight average molecular weight of 27,000 and a molecular weight distribution of 1.2. The resultant composition was subjected to the same test as in Example 1, and provided a minimum resolution of 1.5 μm, resulting in an improvement in resolution of about 1.5 μm. Good results similar to those in Example 1 were also obtained with the composition of Example 2 regarding the ratio of remaining film and the γ value.
EXAMPLE 3
A rubber-type photoresist coating composition was prepared following the procedures in Example 1 using a cyclized polyisoprene having a weight average molecular weight of 37,000 and a molecular weight distribution of 1.2. The resultant composition was subjected to the same test as in Example 1, and provided a minimum resolution of 1.5 μm, resulting in an improvement in resolution of about 1.5 μm. Good results similar to those in Example 1 were also obtained with the composition of Example 3 regarding the ratio of remaining film and the γ value.
EXAMPLE 4
A rubber-type photoresist coating composition was prepared following the procedures in Example 1 using a cyclized polyisoprene having a weight average molecular weight of 62,000 and a molecular weight distribution of 1.9. The resultant composition was subjected to the same test as in Example 1, and provided a minimum resolution of 2.0 μm, resulting in an improvement in resolution of about 1.0 μm. Good results similar to those in Example 1 were also obtained with the composition of Example 4 regarding the ratio of remaining film and the γ value.
|
There is proposed a negative-working photoresist coating composition of an improved resolution, which comprises a cyclized polyisoprene having a weight-average molecular weight of 10,000 to 100,000 and a molecular weight distribution of not more than 1.9, an organic solvent of the cyclized polyisoprene, and a bisazido compound as a crosslinking agent.
| 2
|
CROSS REFERENCE TO RELATED APPLICATIONS
This case is a continuation-in-part of U.S. patent application Ser. No. 947,963, by Jacob Crane, Eugene Shapiro, Stanley Shapiro and Brian Mravic for HIGH CONDUCTIVITY HIGH TEMPERATURE COPPER ALLOY, filed Oct. 2, 1978, now abandoned, which in turn is a continuation of U.S. patent application Ser. No. 547,367, by Jacob Crane, Eugene Shapiro, Stanley Shapiro and Brian Mravic for HIGH CONDUCTIVITY HIGH TEMPERATURE COPPER ALLOY, filed Feb. 5, 1975, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to high conductivity high temperature copper alloys, and particularly to such alloys which are free from internal copper oxides.
Oxygen free copper must be used in applications where the alloy is to be annealed in a hydrogen containing atmosphere, as the presence of oxygen in either its elemental state or as copper oxide results in the formation of water vapor during the annealing process which causes embrittlement of the alloy.
Two major methods are used to reduce the oxygen level of copper so as to avoid embrittlement. The first method involves casting the alloy in an inert atmosphere and fluxing the molten copper with an inert gas to reduce the oxygen level. This is a complex process and difficult to perform satisfactorily. The other major method of deoxidizing copper consists of adding a reactive material to the melt which will form an oxide in preference to copper oxide. The reactive material is chosen so that its oxide will be stable and will not be reduced by hydrogen during annealing. Unfortunately, most of the reactive materials used have a highly deleterious effect on electrical conductivity if excess reactive material remains in solution in the deoxidized copper alloy. Because of the reactive nature of the materials used, it is difficult to accurately control the amount of reactive material which is actually needed to deoxidize the molten copper without causing a loss of conductivity.
In addition to the above, it is known that oxygen free copper has relatively low mechanical properties and it is highly desirable to improve these properties while simultaneously maintaining a high electrical conductivity. Further, oxygen free copper has a very low softening point and for many applications it would be highly desirable to maximize strength and conductivity and to increase the softening temperature. Finally, care must be taken in the processing of oxygen free copper to avoid the reintroduction of oxygen into the alloy. For example, when welding oxygen free copper, an inert atmosphere must be used so as to protect the molten material in the weld zone from oxidation.
Mischmetal has been used as a deoxidizing material in the production of oxygen free copper, however, when excess mischmetal is present, a low melting point eutectic forms between Cu and CeCu 6 compound which results in an alloy which is unsuitable for high temperature brazing and other similar applications where high temperatures are encountered.
SUMMARY OF THE INVENTION
In accordance with the present invention, copper base alloys possessing high conductivity and temperature stability together with freedom from internal copper oxides are prepared which contain mischmetal or lanthanides in place thereof, phosphorus and magnesium with the balance essentially copper. The mischmetal content of the alloys of the present invention ranges from 0.012 to about 0.5%, the phosphorus content may range from about 0.011 to about 0.5% and magnesium content ranges from about 0.007 to about 0.4%. The phosphorus, mischmetal and magnesium contents of the present invention are interrelated, and a specific ratio of phosphorus to mischmetal and magnesium must be maintained for improved results.
The three alloying additions serve as deoxidizing elements and a strengthened condition results in the alloys which is believed to be related to the formation of magnesium containing precipitates. This strengthening mechanism allows the development of a desirable combination of conductivity and strength properties.
The alloys of the present invention are characterized by being oxidation resistant in high temperature contact with air. Since their preparation in accordance with the present invention employs chemical deoxidizing techniques, the alloys are resistant to internal copper oxide formation and subsequent hydrogen embrittlement during hot processing or other elevated temperature exposure. This is a significant advantage over high purity copper produced by a mechanical type of degassing operation which is susceptible to surface oxidation and internal oxide formation during thermal applications such as welding conducted in oxygen containing atmosphere.
The alloys of the present invention likewise exhibit improved properties in comparison with conventionally produced oxygen free copper and copper which has been deoxidized with mischmetal alone. Increases on the order of 50° C. are observed in softening temperatures and improvements are noted in tensile properties.
Accordingly, it is a principal object of the present invention to provide a copper base alloy in the deoxidized condition which possesses high conductivity, improved strength and thermal stability.
It is a further object of the present invention to provide a copper base alloy as aforesaid which is easily and inexpensively fabricated.
It is a yet further object of the present invention to provide an alloy as aforesaid which is resistant to surface and internal oxidation during high temperature contact with oxygen containing atmosphere.
Further objects and advantages will be apparent after a consideration of the invention proceeds with reference to the description which follows.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention the foregoing objects and advantages are readily obtained.
The alloys of the present invention are copper base alloys containing in excess of 99% copper and intentional alloying additions of mischmetal, phosphorus and magnesium. The term mischmetal describes a material composed largely of lanthanides comprising Elements Nos. 58-71 on the Periodic Table. A typical mischmetal composition is listed below:
______________________________________Cerium 50%Lanthanum 27%Neodymium 16%Praseodymium 5%Other Rare Earth Metals 2%______________________________________
However, as used in this application the term mischmetal is intended to include any material comprised predominately of lanthanide regardless of the relative proportions thereof. For example, cerium alone could be used in place of mischmetal and would provide equally satisfactory results.
The mischmetal content of the alloys of the present invention will range from 0.012 to 0.5% and will preferably range from 0.018 to 0.4%. Phosphorus will be present from 0.011 to 0.5% and will preferably be present in levels from 0.017 to 0.4%. Magnesium is present from 0.007 to 0.4% and preferably from 0.01 to 0.32%.
It has surprisingly been found that the alloying additions of the present invention react to form intermetallic compounds within the alloy thereby conferring desirable mechanical properties upon the alloy. Specifically, the mischmetal and phosphorus are believed to combine to form a series of compounds analogous to the compound CeP at the stoichiometric ratio of 4.52 phosphorus:1 mischmetal:phosphorus upon solidification of the alloy or shortly thereafter. During subsequent thermal treatments, it is believed that the magnesium reacts with phosphorus to form a compound which is believed to be Mg 3 P 2 . The stoichiometric relationship of this compound is 1.17 phosphorus to 1.0 magnesium. To maximize the formation of this compound, it is desirable to provide excess phosphorus over that which would be required to react completely with the mischmetal. Therefore, the preferred relationship between the alloy additions is given by the equation: phosphorus equals mischmetal divided by 4.52 plus magnesium divided by 1.17. Magnesium should be added slightly in excess of that required to completely form Mg 3 P 2 and, preferably, in quantities of less than 0.1% in excess of the phosphorus which remains in solid solution after the mischmetal phosphorus reaction. Preferably, a slight excess of magnesium should be present over that required to completely form Mg 3 P 2 , since magnesium in solid solution has less deleterious effect upon conductivity than does phosphorus in solid solution.
In addition to an excess of magnesium, it is contemplated that an excess of phosphorus may be present in amounts ranging up to about 0.025% without deleteriously affecting the properties of the alloy. Specifically, excess phosphorus will tend to increase strength while maintaining conductivity at an acceptable level.
During the course of the formation of the aforenoted compounds of mischmetal, phosphorus and magnesium, small amounts of compounds containing mixtures of mischmetal and/or phosphorus and/or magnesium may be formed which contain other incidental elements. While these compounds may affect conductivity somewhat, they will not affect the strength of the resulting alloy.
Metallographic and X-ray spectrographic analysis of an alloy processed in accordance with this invention containing nominally 0.12% mischmetal, 0.05% magnesium, 0.05% phosphorus and the balance copper revealed particles possessing a large, coarse string-like structure. These particles are believed to form at a relatively high temperature such as the temperature level adjacent but after solidification of the alloy. X-ray spectrographic analysis revealed that the particles included magnesium, phosphorus and mischmetal in the form of cerium and lanthanum. It is, therefore, believed that the particles comprise a combination or compound involving components of mischmetal, magnesium and phosphorus. It is believed that the precipitate particles form at a point in time during the processing of the alloy prior to the time the alloy is cold worked and aged. It is believed that the formation of a precipitate particle including three elements comprising mischmetal or a lanthanide, along with magnesium and phosphorus in accordance with the present invention provides a structural novelty which is in contrast to the teachings of the prior art.
The preceding discussion has assumed that the compounds formed are based on cerium, however, it will be appreciated that because of the great chemical similarity between the lanthanides, analogous compounds will be formed based on the other lanthanides and these analogous compounds will have very similar characteristics.
The magnesium-phosphorus reaction appears to occur between temperatures of 200° C. and 500° C. and reaction times vary from 15 minutes to 10 hours depending upon temperature and composition. Extremely desirable properties are obtained by subjecting the alloy to repeated cycles of cold working and annealing at temperatures ranging from 200° to 400° C. The intermediate cold working is believed to provide a defect structure which enhances the Mg 3 P 2 reaction.
The alloys of the present invention possess a further significant advantage over conventionally prepared oxygen free copper in that they retain their resistance to oxide formation even when exposed to high temperatures in air, as, for example, in welding applications since the mischmetal, phosphorus and magnesium which remain in the alloy will oxidize in preference to the copper constituent. Accordingly, even after the alloys have been welded in air, they may be annealed in hydrogen without embrittlement.
Because of the reactive nature of the additives of the present invention, it is highly desirable to add the mischmetal in a continuous form immediately before the molten metal enters the mold. This form of addition is particularly practical in a continuous casting operation. Reference is made to U.S. Pat. No. 3,728,827 which deals with this subject and which is assigned to the assignee of the present invention. Because of its reactivity, magnesium may be added in a similar fashion, however, this is not absolutely necessary. Likewise, the phosphorus may be added in bulk form to the molten metal, or in the continuous fashion discussed above. Subsequently, casting of the alloys of the present invention may be performed using conventional techniques and, in general, the methods used may be similar to those used for other high copper alloys.
The alloys of the present invention may be processed to final form using conventional processing techniques. If it is desired to obtain maximum strength with moderate conductivity, the following procedure may be followed; the alloy should be hot rolled at a temperature of more than 500° C. to a desired intermediate gauge. The alloy should then be cold worked at a temperature of less than 200° C. to obtain a reduction in excess of 10%. The alloy may then be heat treated at a temperature from 250° to 400° C. for a time of between 15 minutes and 24 hours. A particularly desirable combination of properties may be obtained by successively repeating the cold working and heat treating steps a plurality of times.
The present invention will be more readily understandable from a consideration of the following illustrative examples.
EXAMPLE I
Alloys of varying compositions were produced by melting copper and making additions of the desired elements which were wrapped in copper foil and submerged in the molten copper. The composition of these alloys is listed in Table I, below.
TABLE I______________________________________ANALYZED ALLOY COMPOSITIONS, WEIGHT PERCENTAlloy Identification Cu P Mg MM* Excess**______________________________________V401 bal. 0.070 0.057 0.12 .007 MgV402 bal. 0.050 0.054 0.12 .027 MgV403 bal. 0.037 0.023 0.11 .006 MgV404 bal. 0.042 0.037 0.13 .033 Mg1699 bal. 0.068 0.031 0.15 .009 P______________________________________ *MM is mischmetal **Based on all the mischmetal first reacting to form CeP then the remaining phosphorus reacting with magnesium to form Mg.sub.3 P.sub.2.
Referring to the table, the values listed in the column labeled "Excess" were calculated on the basis of mischmetal first reacting with phosphorus to form CeP with the remaining magnesium to form Mg 3 P 2 . The quantity given in the column is the excess material remaining after the completion of these reactions. After solidification these alloys were hot rolled at a temperature of 800° C. from a thickness of 1.75" to 0.6". No difficulties were encountered in this hot rolling operation.
EXAMPLE II
The hot rolled alloys of Example I were given a variety of thermal mechanical treatments to investigate aging behavior. The aging behavior was evaluated through measurement of electrical conductivity. In general, electrical conductivity decreases when precipitation occurs, since the formation of precipitate particles remove solute material from solid solution. The thermal mechanical treatments included various combinations of cold rolling and annealing steps as set forth in Table II, below.
TABLE II______________________________________CONDUCTIVITY % IACS OF Cu-MM-P-Mg ALLOYS Alloy IdentificationProcessing V401 V402 V403 V404 1699______________________________________As hot rolled (HR) 68HR + CR* 45% 66 74 81 84HR + 500° C./2 hrs. 93HR + CR 45% + 500° C./2 hrs 93 95 90 93HR + CR 45% + 350° C./1 hr 79 82 85 86HR + CR 45% + 350° C./8 hrs 94 95 93 95______________________________________ *Cold Rolled
Referring to the table, it should be noted that the effect of these treatments is also set forth therein, and precipitation thus appears to occur when the alloys are heat treated at temperatures between 350° and 500° C. It is also evident that any of the alloys in Example I can be heat treated to achieve an electrical conductivity of at least 93%.
EXAMPLE III
The alloys of Example I were given a variety of thermal mechanical heat treatments in an effort to determine what processing would provide optimum conductivity and what processing would provide optimum mechanical properties. Starting at hot rolled gauge of approximately 0.006" the processing sequences were as follows:
(A) cold roll to 0.200", anneal at 350° C. for 4 hours, cold roll to 0.100", anneal at 350° C. for 4 hours, cold roll to 0.020" and to 0.008" to provide total reductions of 90% and 96%, respectively;
(B) cold roll to 0.200", anneal at 350° C. for 8 hours, and cold roll to 0.020" and 0.008" to provide total reductions of 90% and 96%, respectively;
(C) cold roll to 0.200", anneal at 500° C. for 2 hours, cold roll to 0.020" and 0.008" to provide total reductions of 90% and 96%, respectively;
(D) cold roll to 0.036" and 0.010" to provide total reductions of 90% and 97%, respectively.
Table III, presented below, shows the effect of these processing sequences on the alloys of Example I in terms of ultimate tensile strength and electrical conductivity.
TABLE III__________________________________________________________________________ULTIMATE TENSILE STRENGTH, KSI, AND CONDUCTIVITY OFCu-MM-P-Mg ALLOYS GIVEN DIFFERENT PROCESSINGProcess Sequence A: HR + CR* 0.200" + 350° C./4hr + CR 0.100" + 350° C./4hr + CR 0.020" (90% CR) and 0.008" (96% CR)Process Sequence B: HR + CR 0.200" + 350° C./8hr + CR 0.020" (90% CR) and 0.008" (96% CR)Process Sequence C: HR + CR 0.200" + 500° C./2hr + CR 0.020" (90% CR) and 0.008" (96% CR)Process Sequence D: HR + CR 0.036" (90% CR) and 0.010" (97% CR)__________________________________________________________________________ PROCESSING SCHEDULE A B C DAlloy % CR* UTS** % IACS UTS % IACS UTS % IACS UTS % IACS__________________________________________________________________________V401 90 80 88 88 78 74 88 -- --V401 96 84 89 90 78 78 88 -- --V402 90 79 88 84 83 75 89.5 -- --V402 96 83.5 86 89 80.5 77 92 -- --V403 90 73 87 78 82 71 88 -- --V403 96 77.5 87 80 82 76.5 88 -- --V404 90 74 89 79 86 71 89.5 -- --V404 96 79.5 86 79.5 86 75 89 -- --1699 90 73.5 80.5 73.5 691699 97 75 80.5 78.5 69__________________________________________________________________________ *Cold Rolling **Ultimate Tensile Strength
From the data presented above, it can be seen that the alloys of the present invention are susceptible to a wide variety of processing schemes and that different processing techniques will yield different combinations of properties. Processing sequence A provides the best combination of strength and conductivity, while processing sequence B improves strength at the expense of electrical conductivity. Processing sequence C emphasizes electrical conductivity at the expense of tensile strength and processing sequence D demonstrates that some intermediate thermal treatments are necessary if beneficial properties are to be obtained in the present alloys.
EXAMPLE IV
An effort was made to improve upon the results obtained through applying processing sequence A of Example III to the present alloys. This process was designated as processing sequence E and consisted of cold rolling hot rolled plate to 0.200", annealing at 350° C. for 4 hours, cold rolling to 0.100" and annealing at 350° C. for 4 hours, cold rolling to 0.020", and annealing at 250° C. for 1 hour. The material was then cold rolled to 0.008" for a total reduction of 96%. A comparison of the results of this process with the results of process A is given in Table IV, below.
TABLE IV______________________________________ULTIMATE TENSILE STRENGTH, KSI, AND CONDUC-TIVITY, % IACS, FOR Cu-MM-P-MG ALLOYS GIVENLOW TEMPERATURE AGINGProcess HR + CR 0.200" + 350° C./4hr + CR 0.100" +Sequence A: 350° C./4hr + CR 0.008 (96% CR*)Process HR + CR 0.200" + 350° C./4hr + CR 0.100" +Sequence E: 350° C./4hr + CR 0.020" + 250° C./1hr + CR 0.008" (96% CR) Process A Process BAlloy UTS** % IACS UTS % IACS______________________________________V401 84 89 83.5 90V402 83.5 86 82.5 89V403 77.5 87 78.5 89V404 79.5 86 79 89.5______________________________________ *Cold Rolling **Ultimate Tensile Strength
From the data presented above, it can be seen that the additional low temperature heat treatment present in process E improves the electrical conductivity by 1 to 3%, while having little effect on the ultimate tensile strength. For properties where electrical conductivity is important, process E is preferred.
EXAMPLE V
A variety of competitive commercial alloys were evaluated and compared to the alloys of the present invention. All materials received a total reduction of 90%, the alloy of the present invention was treated according to process A set forth in Example III. The results of this comparison are given in Table V, below.
TABLE V______________________________________COMPARISON OF 90% COLD ROLLED STRENGTH ANDCONDUCTIVITY OF Cu-MM-P-Mg ALLOYS WITH THOSEOF COMPETITIVE COMMERCIAL COPPER ALLOYS Ultimate Tensile ConductivityAlloy Strength, ksi % IACS______________________________________CDA 102 OFHC 66 99CDA 129 SilverBearing Cu 65 96Cu-Zr 60 93CDA 194 Cu-Fe-P 78 60V401 Cu-MM-Mg-P 80 88______________________________________
It is evident from this table that the alloy of the present invention possesses significantly higher strengths than any of the competitive alloys having comparable electrical conductivities.
EXAMPLE VI
Additional alloy samples of this invention were prepared and processed in a variant manner. The alloys were cast as in Example I, and the cast structures were solutionized at a temperature of 900° C. After solutionizing, the alloys were cold worked 75% and then aged at temperatures of from 400° to 500° C. Solutionizing and aging were conducted for 2 hours. After aging, the alloys were cold worked 75%. After the final cold working was completed, tensile, elongation and conductivity measurements were taken. The results of these tests together with the composition of the respective samples are set forth in Table VI, below.
TABLE VI______________________________________CONDUCTIVITY - STRENGTH - ELONGATIONOF Cu-MM*-P-Mg ALLOYS Conduc- YieldComposition tivity Strength Elong.(Weight %) (% 0.2% Offset 2 in.Alloy Cu MM* P Mg IACS) (ksi) %______________________________________61 Bal. 0.24 0.06 0.04 88 67 381 Bal. 0.1 0.20 0.24 76 82 3 81** Bal. 0.1 0.20 0.24 89 71 3______________________________________ *MM Mischemetal **Aging treatment conducted at 500° C.; other samples aged at 400° C.
From the above data, it can be seen that the alloys of this invention are capable of a wide variety of formulations and processing to prepare materials possessing properties suitable for diverse applications.
The alloys of the present invention are suitable for high temperature applications such as welding or brazing, as well as electrical applications such as receptacles, connectors and the like.
Throughout the specification, all percentages are expressed as percentage by weight.
This invention may be embodied in other forms or carried out in other ways without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes which come within the meaning and range of equivalency are intended to be embraced therein.
|
A high conductivity high temperature copper alloy containing mischmetal, phosphorus and magnesium with specific ratios among them. The alloy is free from internal copper oxides and may be annealed at elevated temperatures in hydrogen atmospheres without embrittlement. Strengths on the order of 80 KSI and conductivities on the order of 90% IACS are obtainable in cold worked material.
| 2
|
This application is a continuation of application Ser. No. 07/786,001 filed on Oct. 31, 1991, now abandoned, which was a Continuation-in-Part application of Ser. No. 07/527,915, filed on May 24, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the use of bistriazene compounds as chemotherapeutic agents useful in the treatment of various cancers. As such, these compounds find wide utility in both human and veterinary medicine. The invention also relates to the use of these compounds as crosslinking reagents useful in a wide variety of laboratory and chemical applications involving the synthesis and manipulation of polymeric macromolecules.
2. Description of Related Art
A number of chemotherapeutic agents exist which act as alkylating agents capable of forming covalent linkages with a variety of substances, including phosphate groups in DNA. Alkylation of bases in DNA often leads to gene miscoding, serious damage to the DNA molecule, and/or major disruption in nucleic acid function, and results in the inhibition of a wide range of other cellular functions. These agents act by forming lethal crosslinks in nucleic acid molecules, and can often shrink tumors in a matter of days after intravenous administration. Among these compounds are 2-chloroethyl-nitrosoureas such as bis(2-chloroethyl)nitrosourea (BCNU), mitomycin, cyclophosphamide (cytoxan), and ifosphamide. These agents are themselves potentially mutagenic, teratogenic, and carcinogenic, and their anti-neoplastic activity is exerted throughout the cell cycle, i.e., toxicity is cell cycle independent.
Vaughan et al. (1984) Jour. Med. Chem. 27:357-63 have reported the formation of a certain bistriazene as a byproduct in the preparation of other triazenes. This bistriazene is chemically and structurally different from those of the present invention, and was not tested for antitumor activity. Furthermore, this bistriazene differs from those of the present invention in that it would require two-fold metabolic activation to release the same alkylating moiety, and is susceptible to hydrolysis, thereby releasing monotriazenes.
The use of the bistriazene compounds of the instant invention as chemotherapeutic and crosslinking agents has yet to be reported.
SUMMARY OF THE INVENTION
The bistriazene compounds of the present invention are novel alkylating agents which are structurally similar to polyamines such as spermine and spermidine, which interact with DNA. Most currently employed chemotherapeutic alkylating agents interact covalently or noncovalently with the target DNA, after which a crosslinking reaction may occur. The bistriazene compounds of the present invention differ from any known chemotherapeutic agents in that their chemical structure allows them to interact with the DNA molecule while maintaining their chemical integrity. This interaction depends on the formation of multiple hydrogen bonds with the DNA, and in this manner they appear to mimic natural polyamines which normally interact with DNA. In fact, it is possible that due to the structural similarity of the bistriazenes to some of the polyamines, the bistriazenes may occupy the same sites in DNA as the polyamines themselves. Subsequent to this binding, the bistriazenes decompose on the surface of the DNA, releasing the "Linker" in the form of a bisdiazonium ion. This highly reactive substance covalently interacts with the DNA, causing multiple double strand breaks and interstrand crosslinks. As the bisdiazonium ion can be made to vary in its properties by structural modification of the Linker in the bistriazene molecule, the reactivity of the entire molecule can be modulated by appropriate chemical modification. Thus, it appears that bistriazenes may interact with DNA in a polyamine-like fashion, subsequently breaking down to form crosslinking agents which result in the formation of crosslinks lethal to cells. The use of the bistriazene compounds of the present invention as chemotherapeutic drugs therefore confers great specificity of drug interaction with DNA, and because the reactive diazonium ions are formed on the surface of the DNA, delivers a much higher effective dose of the ultimate cytotoxic agent per molecule of administered compound than for simple monodentate drugs. This feature achieves the advantage that the dosage of such bistriazene-based drugs administered will be low in comparison to that of other conventional chemotherapeutic alkylating agents. The combination of specificity and low effective dose portends bistriazene-based anti-cancer drugs with much lower systemic toxicities than those currently in use.
Thus, the bistriazene compounds of the present invention represent an entirely novel class of bidentate, chemotherapeutic alkylating agents with greater specificity and lower toxicity as compared to present treatments.
Accordingly, it is an object of the present invention to provide a bistriazene compound, or a physiologicaly acceptable salt thereof, of the formula: ##STR1## wherein the Linker is selected from the group consisting of ##STR2## where n=1-5, and R 3 is selected from the group consisting of hydrogen and a C 1 -C 5 n-alkyl, ##STR3## where n=1-5, m=1-5, and R 4 and R 5 each=C 1 -C 5 n-alkyl,
--(CH 2 ) n --O--(CH 2 ) n --, where n=1-5,
--(CH 2 ) n --S--(CH 2 ) n --, where n=1-5,
--(CH 2 ) n --Se--(CH 2 ) n --, where n=1-5, ##STR4## where n=1-5, and --(CH 2 ) n --SO 2 --(CH 2 ) n --, where n=1-5;
EG is identical or independently selected from the group consisting of a phenyl group, a substituted phenyl group, an arylalkyl group, a substituted arylalkyl group, a condensed ring arylalkyl group, a heterocyclic group, an amine group, and a polyamine.
The final substituent on the triazene moiety, i.e., R or R', is perhaps the most fungible, and may be added following assembly of the basic triazene moiety by methods described for simple dialkyltriazenes (R. H. Smith, Jr., et al., J. Org. Chem., 1986, 51, 3751; R. H. Smith, Jr., et al., J. Org. Chem., 1988, 53, 1467; D. H. Sieh, et al., J. Am. Chem. Soc., 1980, 102, 3883; R. H. Smith, Jr. and C. J. Michejda, Synthesis, 1983, 476). R or R' may be identical to EG or to one another, or may be independently selected from the groups comprising hydrogen, alkyl groups, substituted alkyl (including, but not limited to, alkylamines, alkyl ethers and thioethers, haloalkyl, silanes, phosphines, alcohols, amines, etc.) of chain length 1-20, preferably 1-6. R or R' may also include aralkyl or substituted aralkyl (with modifications analogous to those for substituted alkyls), polycyclic aralkyl, aryl groups, and heterocyclic groups of 2-40 non-hydrogen atoms, containing 1-6 rings. Additionally, R may be an acid derivative where the original acid includes, but is not limited to, carboxylic, sulfuric, sulfonic, phosphoric, phosphinic, arsenic, and selenic acids.
R may also include, in the examples cited above, compounds where R equals R', or R is linked to R' such that a cyclic bistriazene compound is formed. Cases where R equals R' may be expanded to include multivalent metals including, but not limited to, palladium, platinum, titanium, zirconium, silicon, selenium, magnesium, and copper. Several metal species such as cisplatin and titanocene dichloride are clinically active as antineoplastic agents, and the bistriazene moiety may serve as a bidentate ligand for these classes of compounds in order to generate compounds with multiple modes of cytotoxic action. If R is linked to R', polymeric compounds may result in addition to cyclic bistriazenes. The polymers produced would have unusual physical properties due to the hydrolytic instability of triazenes. It can be envisioned that this can be used to prepare polymers which could be implanted, and which would hydrolytically decompose to produce active cytotoxic agent in a time release manner. Similarly, it may be that the polymer would only provide a slowly dissolving matrix. This matrix may be used for structural applications, or to release an entrapped substance.
Furthermore, it should be noted that, while for simplicity, all modifications mentioned above have been discussed as being symmetrical, this need not be the case, and asymmetrical bistriazene molecules are encompassed among the compounds of the present invention.
Another object of the present invention is to provide a pharmaceutical composition, comprising an anti-cancer effective amount of said bistriazene compound or physiologically acceptable salt thereof, and a pharmaceutically acceptable carrier.
Yet another object of the present invention is to provide a method for treating cancer in a mammal, including humans, which comprises administering to the subject an anti-cancer effective amount of said bistriazene compound or a physiologically acceptable salt thereof.
A further object of the present invention is to provide a method of inhibiting breakage or digestion of DNA or proteins, comprising treating said DNA or proteins with said bistriazene compound or physiologically acceptable salt thereof.
A still further object of the present invention is to provide a method of producing chemical polymers, comprising treating their monomeric constituents with said bistriazene compound or physiologically acceptable salt thereof.
These objects and others are accomplished in accordance with the present invention by administering an anti-cancer effective amount of a pharmaceutical composition containing a bistriazene compound or a physiologically acceptable salt thereof. Representative bistriazene compounds useful in treating cancer include bis(methyltriazeno)-p-xylene, bis(methyltriazeno)-2-butene, bis(methyltriazeno)ethane, and other bistriazene derivatives which are anti-cancer agents, such as the following: ##STR5##
The compounds of the present invention can be used for the treatment of human and animal cancers.
In addition to the use of bistriazene compounds for the therapeutic treatment of neoplastic disease, the use of these compounds as laboratory reagents is also envisioned as another object of the present invention. In the laboratory manipulation of macromolecules such as DNA and proteins, reagents are often employed which interact with the molecule of interest such that the molecule is:
1) Cut in a specific region;
2) Blocked from being enzymatically cut in a specific region;
3) Bound to another molecule with which it is loosely associated;
4) Bound to a matrix such as nitrocellulose or nylon to facilitate handling and probing;
5) Bound to a matrix such as a chromatography support as a ligand for affinity chromatography; or
6) Conjugated to unrelated macromolecules (e.g., toxins to antibodies, antibodies to enzymes, small molecules to oligonucleotide DNA probes, etc.).
Bistriazenes can be adapted for use in these and other laboratory manipulations of macromolecules.
If the bistriazene is modified such that the substituent groups afford a high degree of sequence recognition, then upon alkylation at a labile site, breakage of the DNA or protein backbone may occur (#1 above). Alternatively, alkylation at a stable site may block enzymatic digestion such as restriction enzyme digestion of DNA or protease digestion of proteins (#2 above).
Multifunctional chemical crosslinking agents are presently widely used in applications #3, #5, and #6 cited above. The use of bistriazene compounds in such applications is another object of the present invention.
It is further envisioned that bistriazene compounds will be employed as highly active chemical crosslinking agents useful in immobilizing molecules such as RNA, DNA or proteins on nitrocellulose, nylon, or other similar membranes (application #4, above), thereby facilitating the handling and probing of these biopolymers on such membrane supports.
Yet another object of the present invention is to employ bistriazenes as crosslinking agents in the formation of chemical polymers from their monomeric constituents.
The bistriazene compounds of the present invention may be employed as chemical crosslinking agents in a manner similar to that of other well known crosslinking agents, as would be apparent to one of ordinary skill in the art.
Further scope of the applicability of the present invention will become apparent from detailed description and drawings provided below. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention are given by way of illustration only since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the survival in vitro of several human tumor cell lines exposed to various concentrations of bis(methyltriazeno)-p-xylene.
FIG. 2 shows the survival in vitro of several human tumor cell lines exposed to various concentrations of bis(methyltriazeno)-2-butene.
FIG. 3 shows the survival in vitro of several human tumor cell lines exposed to various concentration of bis (methyltriazeno)ethane.
FIG. 4 shows the survival in vitro of several human tumor cell lines exposed to various concentrations of 5-(3,3-dimethyltriazeno)imidazole-4-carboxamide (DTIC).
In FIGS. 1-4, the abbreviations of the cell lines represent the following:
CXF, Colon Cancer Xenograft; GXF, Gastric; LXF, Lung: A adeno, L large cell, E epidermoid cell, S small cell; MAXF, Mammary Cancer Xenograft; MEXF Melanoma; PXF, Pleuramesothelioma; SXF, Sarcoma; TXF, Testicular; XF, miscellaneous Cancer Xenograft.
FIG. 5 shows the results of the oligonucleotide crosslinking assay.
FIG. 6 shows the results of the supercoiled plasmid DNA assay.
FIG. 7 shows supercoiled plasmid pBR322 treated with various bistriazenes and triazenes indicated in the figure at the concentrations shown. The treated DNA was applied to agarose gels and electrophoresed. Bands were visualized by ethidium bromide staining. The bands of interest are SC=supercoiled plasmid, OC=open circular plasmid, linear=linearized plasmid. An absence of bands in a lane to which DNA had been applied indicates complete destruction of the DNA by the agent at that concentration. Formation of OC requires a single strand break; linearization requires a double strand break.
FIG. 8 shows data for the bistriazenes and triazenes indicated, obtained in a manner similar to that in FIG. 7. The applied concentrations of bis 2-(methyltriazeno)-ethyl!methylamine (3) were orders of magnitude lower than those for the other bistriazenes.
DETAILED DESCRIPTION OF THE INVENTION
As those of ordinary skill in the art will recognize, the basic bistriazene structure contains a number of elements which can be modified to affect the desired use of these compounds. These elements are indicated in the following structure: ##STR6##
The "Linker" moiety is involved in the structural definition of the molecule and in crosslink formation. The Linker can be either an alkyl group, substituted alkyl (including, but not limited to, alkylamines, alkyl ethers and thioethers, haloalkyl, silanes, phosphines, alcohols, amines, etc.), of chain length 1-20, preferably 2-8. The Linker may also include aralkyl or substituted aralkyl (with modifications analogous to those for substituted alkyls), polycyclic aralkyl, heterocyclic aralkyl, and their substituted derivatives wherein the triazine moieties can be separated by 1-30 carbon atoms, preferably 4-12 carbon atoms. With regard to the "End Group" (EG), this moiety is crucial in modulating the reactivity of bistriazenes. The EGs may be identical or independently selected from groups comprising alkyl groups, substituted alkyl (including, but not limited to, alkylamines, alkyl ethers and thioethers, haloalkyl, silanes, phosphines, alcohols, amines, etc.), of chain length 1-20, preferably 1-6. The EG may also include aralkyl or substituted aralkyl (with modifications analogous to those for substituted alkyls), polycyclic aralkyl, aryl groups and heterocyclic groups of 2-40 non-hydrogen atoms, containing 1-6 rings, including nucleic acid bases and a DNA oligomer(s) bonded to the EG of the bistriazene compound through either the 3' or 5' deoxyribose oxygen of the terminal nucleic acid base.
The final substituent on the triazene moiety, i.e., R or R', is perhaps the most fungible, and may be added following assembly of the basic triazene moiety by methods described for simple dialkyltriazenes (R. H. Smith, Jr., et al., J. Org. Chem., 1986, 51, 3751; R. H. Smith, Jr., et al., J. Org. Chem., 1988, 53, 1467; D. H. Sieh, et al., J. Am. Chem. Soc., 1980, 102, 3883; R. H. Smith, Jr. and C. J. Michejda, Synthesis, 1983, 476). R or R' may be identical to EG or to one another, or may be independently selected from the groups comprising hydrogen, alkyl groups, substituted alkyl (including, but not limited to, alkylamines, alkyl ethers and thioethers, haloalkyl, silanes, phosphines, alcohols, amines, etc.) of chain length 1-20, preferably 1-6. R or R' may also include aralkyl or substituted aralkyl (with modifications analogous to those for substituted alkyls), polycyclic aralkyl, aryl groups, and heterocyclic groups of 2-40 non-hydrogen atoms, containing 1-6 rings. Additionally, R may be an acid derivative where the original acid includes, but is not limited to, carboxylic, sulfuric, sulfonic, phosphoric, phosphinic, and arsenic acids.
R may also include, in the examples cited above, compounds where R equals R', or R is linked to R' such that a cyclic bistriazene compound is formed. Cases where R equals R' may be expanded to include multivalent metals including, but not limited to, palladium, platinum, titanium, zirconium, silicon, magnesium, and copper. Several metal species such as cisplatin and titanocene dichloride are clinically active as antineoplastic agents, and the bistriazene moiety may serve as a bidentate ligand for these classes of compounds in order to generate compounds with multiple modes of cytotoxic action. If R is linked to R', polymeric compounds may result in addition to cyclic bistriazenes. The polymers produced would have unusual physical properties due to the hydrolytic instability of triazenes. It can be envisioned that this can be used to prepare polymers which could be implanted, and which would hydrolytically decompose to produce active cytotoxic agent in a time release manner. Similarly, it may be that the polymer would only provide a slowly dissolving matrix. This matrix may be used for structural applications, or to release an entrapped substance.
Furthermore, it should be noted that, while for simplicity, all modifications mentioned above have been discussed as being symmetrical, this need not be the case, and asymmetrical bistriazene molecules are encompassed among the compounds of the present invention.
SYNTHESIS OF BISTRIAZENES
The synthesis of bistriazenes is readily accomplished by the reactions shown below:
______________________________________ ##STR7## ##STR8##R X Yield______________________________________-- Cl 32%CH.sub.2 Br 46%(CH.sub.2).sub.2 Br 58%(CH.sub.2).sub.4 Br 73% ##STR9## Cl 20% ##STR10## Cl 50% ##STR11## Cl 55% ##STR12## OTs 29%______________________________________
In general, bistriazenes are prepared by the reaction of 1,ω-diazidoalkanes with two equivalents of an alkyllithium. The diazidoalkanes are prepared from the corresponding dihaloalkanes and sodium azide in dimethylformamide solution. For example, the simplest bistriazene, 1,2-bis(methyltriazeno)ethane (BMTE), is prepared by the reaction of 1,2-diazidoethane with two equivalents of methyllithium.
In contrast to simple triazenes, bistriazenes are crystalline solids. X-ray crystal structure determination of BMTE reveals that the molecule adopts a conformation in the solid state which maximizes hydrogen bond interactions with its neighbors. In this regard, BMTE is remarkably similar to polyamines such as spermine, spermidine, and their phosphatidyl derivatives, which are known to bind strongly to DNA.
The synthesis and X-ray crystal structure of bistriazenes are described in Blumenstein et al., Tetrahedron Letters, submitted for publication, and Blumenstein et al., Chemical Communications, submitted for publication, respectively. The synthesis of particular bistriazenes is as follows:
EXAMPLE 1
Trans-1,4-bis(methyltriazenomethyl)cyclohexane
A flask is charged with 3.0 g (6.6 mmole) of trans-1,4-di(methyl 4-toluenesulfonate)cyclohexane, 1.08 g (16.6 mmole) of sodium azide, and 50 ml of dimethylformamide (DMF). The mixture is heated at 50° C. with stirring under argon for 2 days. The mixture is then diluted with 150 ml of water and extracted four times with 40 ml of petroleum ether. The combined organic layers are dried over Na 2 SO 4 , filtered, and evaporated to afford a pale yellow oil. The residual oil is dissolved in 100 ml of anhydrous ether and cooled to -20° C. under argon. A 1.5M solution of MeLi in ethyl ether (11 ml, 16.5 mmole) is added to the solution over 0.5 hr. A white precipitate begins to form after a small amount of the MeLi has been added. The cooling bath is removed and the mixture is allowed to stir overnight. Excess MeLi is quenched by the careful addition of 30 ml of half-saturated NH 4 Cl with cooling of the solution. Vigorous gas evolution accompanies the addition of the first several ml of NH 4 Cl, and the addition is carried out as quickly as possible. The aqueous layer is then rapidly separated, washed with 40 ml of water, dried over Na 2 SO 4 , filtered, and evaporated to afford a pale tan solid. The solid is recrystallized from ether/petroleum ether to yield 430 mg (29% yield) of a white solid, mp 72°-3° C. Mass spectra (FAB) Calc (M+H) 227.1984, Found 227.2017±0.0023.
EXAMPLE 2
1,4-Bis(methyltriazenomethyl)benzene
A flask is charged with 2.0 g (11.4 mmole) of 1,4-di(chloromethyl)benzene, 1.86 g (28.6 mmole) of sodium azide, and 50 ml of DMF. The mixture is heated at 50° C. with stirring under argon overnight. The mixture is worked up and treated with 20 ml of a 1.4M solution of MeLi (28 mmole) as described above. After workup, a yellow solid is obtained. Crystallization from ether/petroleum ether affords 1.26 g (50% yield) of a pale yellow solid, mp 90°-2° C. Mass spectra (FAB) Calc (M+H) 221.1514, Found 221.1558±0.0022.
EXAMPLE 3
1,2-Bis(methyltriazenomethyl)benzene
A flask is charged with 7.96 g (45 mmole) of 1,2-di(chloromethyl)benzene, 7.39 g (114 mmole) of sodium azide, and 150 ml of DMF. The mixture is heated at 50° C. with stirring under argon overnight. The mixture is worked up, and in 300 ml of anhydrous ether, is treated with 90 ml of a 1.3M solution of MeLi (117 mmole) as described above. After workup, a yellow-orange oil is obtained. Kugelrohr distillation (110°-120° C., 0.5 mm) affords 5.40 g (55% yield) of a pale yellow oil which darkened and became a semi-solid upon standing. Mass spectra (FAB) Calc (M+H) 221.1514, Found 221.1513±0.0022.
EXAMPLE 4
1,4-Bis(methyltrizeno)butane
A flask is charged with 4.0 g (18.5 mmole) of 1,4-dibromobutane, 3.6 g (55 mmole) of sodium azide, and 50 ml of DMF. The mixture is heated at 50° C. with stirring under argon overnight. The mixture is worked up and treated with 45 ml of a 1.3M solution of MeLi (58 mmole) as described above. After 3 hr the reaction is worked up as described above, and a yellow solid is obtained. Crystallization from ether/petroleum ether affords 1.86 g (58% yield) of a white solid, mp 40°-2° C. Mass spectra (FAB) Calc (M+H) 173.1514, Found 173.1510±0.0017.
EXAMPLE 5
1,2-Bis(methyltriazeno)ethane
A flask is charged with 5.0 g (27 mmole) of 1,2-dibromoethane, 3.8 g (58 mmole) of sodium azide, and 50 ml of DMF. The mixture is heated at 50° C. with stirring under argon overnight. The mixture is worked up as described above, except that the azide solution is not evaporated down totally. When about 30 ml of solution remains the mixture is treated with 45 ml of a 1.3M solution of MeLi (58 mmole) as above. After 3 hr the reaction is worked up as described above, and a yellow solid is obtained. Crystallization from ether/petroleum ether affords 1.23 g (32% yield) of an off-white solid, mp 64°-6° C. Mass spectra (FAB) Calc (M+H) 145.1201, Found 145.1220±0.0015.
EXAMPLE 6
1,6-Bis(methyltriazeno)hexane
A flask is charged with 10.0 g (41 mmole) of 1,6-dibromohexane, 6.66 g (102 mmole) of sodium azide, and 100 ml of DMF. The mixture is heated at 50° C. with stirring under argon overnight. The mixture is worked up and as a solution in 400 ml of anhydrous ether, is treated with 77 ml of a 1.3M solution of MeLi (100 mmole) as described above. After 3 hr the reaction is worked up as described above, and a yellow solid is obtained. Crystallization from ether/petroleum ether affords 5.96 g (73% yield) of a white solid, mp 54°-5° C.
EXAMPLE 7
1,4-Bis(methyltriazeno)-trans-2-butene
A flask is charged with 12.5 g (100 mmole) of 1,4-dichloro-trans-2-butene, 14.3 g (220 mmole) of sodium azide, and 200 ml of DMF. The mixture is stirred under argon overnight, worked up, and as a solution in 400 ml of anhydrous ether, is treated with 130 ml of a 1.4M solution of MeLi (183 mmole) as described above. After 3 hr the reaction is worked up, and a yellow solid is obtained. Crystallization from ether/petroleum ether affords 3.34 g (20% yield) of a pale yellow solid, mp 71°-4° C. Mass spectra (FAB) Calc (M+H) 171.1358, Found 171.1397±0.0017.
EXAMPLE 8
1,6-Bis(methyltriazeno)propane
A flask is charged with 10.0 g (49.5 mmole) of 1,3-dibromopropane, 7.08 g (109 mmole) of sodium azide, and 100 ml of DMF. The mixture is stirred under argon overnight, worked up, and as a solution in 400 ml of anhydrous ether, is treated with 80 ml of a 1.4M solution of MeLi (112 mmole) as described above. After 3 hr the reaction is worked up as described above, and a yellow solid is obtained. Crystallization from ether/petroleum ether affords 3.61 g (46% yield) of a white solid, mp 55°-7° C. Mass spectra (FAB) Calc (M+H) 159.1358, Found 159.1360±0.0016.
EXAMPLE 9
1,2-diazidoethane and 1,4-diazidobutane
The procedures described in Examples 4 and 5, above, were followed.
EXAMPLE 10
1,2-Bis(phenyltriazeno)ethane
A solution of 1.12 g (10 mmoles) of 1,2-diazidoethane in 10 ml. of tetrahydrofuran (THF) was cooled to -45° C. To this was added dropwise with stirring 15 ml. of 2.0M phenylmagnesium chloride in THF, and stirring was continued overnight with the temperature being allowed to rise slowly to ambient. The reaction mixture was diluted with 200 ml. of diethylether and the ether solution was washed first with 30 ml. of 10% ammonium chloride in 10% ammonium hydroxide, followed by water (3×30 ml.), and then dried over anhydrous sodium sulfate. The solvent was distilled off leaving 2.50 g of a pale yellow residue. This was redissolved in 40 ml. of ether and allowed to crystallize slowly, which resulted in 1.20 g of powdery crystals, m.p. 125°-127° C. (dec.). The material migrated as a single spot on TLC and the nmr and the mass spectra were fully consistent with the structure.
EXAMPLE 11
1,4-Bis(phenyltriazeno)butane
A reaction of 1.40 g (10.0 mmoles) of 1,4-diazidobutane with 30 mmoles of phenylmagnesium chloride in 15 ml. of THF was carried out in an identical fashion to the foregoing example of 1,2-bis(phenyltriazeno)ethane. The residue following the evaporation of the ether weighed 2.8 g. This was crystallized from THF/ether mixture and then recrystallized from THF/benzene (2:1) to produce 1.34 g of white crystals, m.p. 116°-118° C. (dec.). This material was poorly soluble in diethylether and only soluble in warm (50° C.) benzene, and freely in THF. The nmr and mass spectra were fully consistent with the structure.
EXAMPLE 12
1,4-Bis(benzyltriazeno)butane
A solution of 1.40 g (10 mmoles) of 1,4-diazidobutane, in 10 ml. of THF and chilled to -45° C., was treated dropwise with 15 ml of 2.0M benzylmagnesium chloride in THF (30 mmoles). The reaction mixture was magnetically stirred overnight at room temperature. The solvent was removed under vacuum and the residue was dissolved in 200 ml. of diethylether and washed with 30 ml. of ammonium buffer (50 g. ammonium chloride, 178 ml. of 10% ammonium hydroxide and 272 ml. of water), followed by 2×30 ml of water. The solution was dried over sodium sulfate and concentrated on a rotary evaporator and dried under high vacuum at room temperature. The crude product was recrystallized from diethylether in the -20° freezer to produce 2.6 g. of white crystals m.p. 71°-74° C. The nmr and mass spectra were fully consistent with the structure.
EXAMPLE 13
1,2-Bis(benzyltriazeno)ethane
A solution of 1.12 g (10 mmoles) of 1,2-diazidoethane in 20 ml. of THF was cooled to -60° C. This solution was treated with 15 ml of 2.0M benzylmagnesium chloride in THF (30 mmoles) dropwise with stirring. The reaction mixture was allowed to come to room temperature slowly, and was then cooled again to -60° C., and 10 ml. of ammonium buffer (see preparation above) was added and the reaction was allowed to come to room temperature. The reaction mixture was mixed with 100 ml. of diethylether and the organic layer was separated, dried over anhydrous sodium sulfate, and the solvent was removed on a rotary evaporator. The pink residual oil was subjected to high vacuum overnight, which produced a pale yellow solid. This material was crystallized from ether/pentane (1:1) to produce 1.71 g of colorless powdery solid m.p. 73°-75° C. Spectroscopy (nmr and mass) were consistent with the structure.
EXAMPLE 14
1,4-Bis(2-pyridyltriazeno)butane
A solution of 3.95 g (25 mmoles) of 2-bromopyridine in 20 ml of dry pentane was added dropwise to 10 ml. of 2.5M butylithium in hexane at -78° C. To the resulting yellow slurry was added dropwise with stirring 1.75 g (12.5 mmoles) of 1,4-diazidobutane in 10 ml. of pentane. Stirring was continued for 2 hr. at -78° and then the reaction mixture was allowed to warm to room temperature. The reaction mixture was treated with 60 ml. of ammonium buffer which caused a precipitate to appear after the reaction was cooled to -78° C. The solid was filtered off. It was poorly soluble in common solvents such as halomethanes, acetone, methanol and water. It was sparingly soluble in dimethylsulfoxide. The yield was 2.3 g., m.p. 133-136. Spectroscopic data were consistent with the structure.
EXAMPLE 15
1,2-Bis(2-pyridyltriazeno)ethane
A solution of butyllithium in hexane (5 ml., 2.5M) was dissolved in 10 ml. of tetrahydrofuran and cooled to -78° C. To this was added dropwise with stirring a solution of 1.98 g (12.5 mmoles) of 2-bromopyridine in 10 ml. of tetrahydrofuran. The dark yellow solution of the pyridine anion was mixed with a solution of 0.70 g (6.2 mmoles) of 1,2-diazidoethane in 10 ml. of tetrahydrofuran at -78° C. After 1 hr. of stirring the dark green solution was treated with 10 ml. of ammonium buffer. The color changed to yellow. The organic solvent was removed in vacuo, and the precipitate was isolated by filtration and washed with copious quantities of diethylether. The powdery material was finally dried under high vacuum. The yield was 770 mg. This material was not soluble in most solvents, except dimethylsulfoxide. It did not have a sharp melting point since decomposition began before it was reached (rapid above 100° C.). The spectra, however, were fully consistent with the structure.
EXAMPLE 16
1,4-Bis(3-pyridyltriazeno)butane
To 12.5 mmoles of butyllithium in hexane (5 ml. of 2.5 M butyllithium diluted with 10 ml. of hexane) and chilled to -90° C. (acetone & liquid nitrogen) was added dropwise 1.978 (12.5 mmoles) of 3-bromopyridine in 10 ml. of hexane. The reaction was further diluted with 20 ml. of hexane to aid stirring at -75° C. for 2 hr. and was then treated with 0.876 g. (6.25 mmoles) of 1,4-diazidobutane. The reaction mixture was allowed to stir at room temperature overnight. It was then chilled to -40° C. and treated with 10 ml. of the ammonium buffer. This produced two layers and a polymer-like precipitate. The mixture was diluted with 100 ml. of hexane and the layers were separated. The organic phase was washed with water (2×20 ml.) and was dried over sodium sulfate. After removal of solvent in vacuo, 0.98 g of oily residue was obtained. This did not contain the desired product. The polymer-like solid, however, was triturated with 30 ml. of diethylether overnight. This resulted in the formation of a pale yellow microcrystalline material, which was filtered and dried under high vacuum. The yield was 0.40 g. of pure bistriazene, which decomposed before melting. The nmr and mass spectra, however, were fully consistent with the structure.
EXAMPLE 17
1,2-Bis(3-pyridyltriazeno)ethane
A solution of 5 ml. of 2.5M butyllithium in hexane, diluted further with 10 ml. of hexane, was chilled to -90° C. This was treated by dropwise addition with 1.97 g (12.5 mmoles) of 3-bromopyridine in 10 ml. of hexane. The yellow slurry was stirred at -60° C. for 1 hr. and then treated by dropwise addition with 0.70 g (6.2 mmoles) of 1,2-diazidoethane. The solution remained yellow, and was stirred at room temperature overnight. The reaction mixture was then treated with ammonium buffer and the solvents were removed in vacuo. The residue was treated with 50 ml. of diethylether and 10 ml. of water overnight. The residual powder was virtually pure product in a yield of 120 mg (pale orange). The product migrated as a single spot on thin layer chromatography and the nmr and mass spectra were fully consistent with the structure.
EXAMPLE 18
Bis 2-(methyltriazeno)ethyl!ether
A flask was charged with 2.08 g (14 mmole) of bis(2-chloroethyl)ether, 2.73 g (42 mmole) of sodium azide, and 150 ml of dimethylformamide. The mixture was heated at 50° C. with stirring under argon for 5 days. The mixture was then diluted with 250 ml of water and extracted four times with 50 ml of pentane. The combined organic layers were dried over sodium sulfate, filtered, and concentrated to afford approximately 25 ml of a solution of the diazide in pentane. The solution was diluted with 100 ml of anhydrous ether and cooled to -20° C. under argon. A 3.0M solution of methyl magnesium bromide in ethyl ether (14 ml, 42 mmole) was added to the solution over 0.5 hr. A white precipitate began to form after a small amount of the reagent had been added. The cooling bath was removed and the mixture was allowed to stir for 2 hr. Excess Grignard reagent was quenched by the careful addition of 50 ml of half-saturated ammonium chloride with cooling of the solution. Vigorous gas evolution accompanied the first several milliliters of ammonium chloride, but the addition was carried out as fast as possible. The aqueous layer was then rapidly separated and washed with 50 ml of pentane. The organic layers were combined, dried over sodium sulfate, filtered and evaporated to afford a pale tan solid. The solid was recrystallized from ether/petroleum ether to yield 1.28 g of a white solid. 1 H NMR(CDCl 3 , 200 MHz): 3.195 (br, 4 H), 3.679 (br, 6 H), 7.32 (br, 2 H).
EXAMPLE 19
Bis 2-(methyltriazeno)ethyl!methyl amine
A flask was charged with 2.0 g (10.4 mmole) of bis(2-chloroethyl)methyl amine hydrochloride, 2.03 g (31.2 mmole) of sodium azide, and 100 ml of dimethylformamide. The mixture was heated at 50° C. with stirring under argon for 5 days. The mixture was then diluted with 150 ml of 2.5% aqueous sodium hydroxide solution and extracted four times with 50 ml of pentane. The combined organic layers were dried over sodium sulfate, filtered, and concentrated to afford approximately 25 ml of a solution of the diazide in pentane. The solution was diluted with 100 ml of anhydrous ether and cooled to -20° C. under argon. A 3.0M solution of methylmagnesium bromide in ethyl ether (10.4 ml, 31.2 mmole) was added to the solution over 0.5 hr. A white precipitate began to form after a small amount of the reagent had been added. The cooling bath was removed and the mixture was allowed to stir for 2 hr. Excess reagent was quenched by the careful addition of 50 ml of 2.5% NaOH with cooling of the solution. Vigorous gas evolution accompanied the first several milliliters of sodium hydroxide but the addition was carried out as fast as possible. The aqueous layer was then rapidly separated and washed with 50 ml of pentane. The organic layers were combined, dried over sodium sulfate, filtered and evaporated to afford a yellow oil. The oil was distilled under vacuum using a kugelrohr apparatus at 0.1 mm Hg with a pot temperature of 80°-120° C. to yield 3.120 g of a clear oil. 1 H NMR (CDCl 3 , 200 MHz): 2.67 (br), 2.652 (br), 2.962 (br), 3.406 (br), 3.708 (br), 7.412 (br), 7.716 (br).
BIOLOGICAL ACTIVITY
The bistriazene compounds of the present invention are useful in the treatment of a wide variety of cancers, as shown from the data below.
Clonogenic Assay. The response of a variety of human tumor cell lines to bistriazenes was determined via the clonogenic assay described in Fiebig et al. (1987) European Journal of Cancer and Clinical Oncology 23: 937-948.
Briefly, the assay system consists of a modified, two-layer soft agar culture system. The bottom layer consists of 1 ml of modified Dulbecco medium supplemented with L-glutamine, containing 10% fetal calf serum and 0.5% agar, in a 35 mm petri-dish. The upper layer contains 2-5×10 5 viable human tumor cells suspended in a 1 ml volume, consisting of 0.3% agar, 30% fetal calf serum, and the medium. The drugs to be tested, contained in 1 ml of medium containing 30% fetal calf serum, are included in the upper layer. Control plates are identical, except for the omission of the drugs. The plates are incubated at 37° C. in a humidified atmosphere containing 7% carbon dioxide for varying periods (7-21 days). The time in culture is determined by the rate of colony formation in the control plates. At the end of the culture period, the number of colonies in the drug treated cultures is compared to the number of colonies in the control plates, after visualization of the live colonies by staining with tetrazolium chloride.
Three different bistriazenes were examined in the assay. In all cases, the End Group (EG) was methyl, while the Linker was varied:
EG--NH--N═N--Linker--N═N--NH--EG
Linker
p-xyleleno, --CH 2 --C 6 H 4 --CH 2 --trans-2-buteno, --CH 2 CH═CHCH 2 --ethano, --CH 2 CH 2 --
Each of these compounds was evaluated against a panel of human tumor cells, the identity of which is indicated in FIGS. 1-4. The tumors included those derived from colon cancer, three types of lung cancer, mammary cancer, ovarian cancer, two types of kidney cancer, a mesothelioma, a gastric cancer, and a sarcoma. These tumors represent some of the most important cancers for which current treatments are inadequate. For comparison, the assays of the various bistriazenes were compared to the response induced in the same tumors by DTIC, a drug employed in clinical practice.
FIG. 1 shows dose-response curves obtained in the in vitro clonogenic cytotoxicity assay against several human tumor cell lines employing bis(methyltriazeno)-p-xylene. At a dose of 100 ug/ml, this compound was highly toxic to all tumor cell lines. At a dose of 10 ug/ml, it exhibited toxicity against approximately half of the cell lines examined. Some activity was also evident at a dose of 1 ug/ml in about half the cell lines.
The data in FIG. 2 disclose the results obtained with 1,4-bis(methyltriazeno)-trans-2-butene. This drug exhibited potent cytotoxic activity against all the tumors tested at 100 ug/ml. This activity persisted at 10 ug/ml, especially for the large cell lung carcinoma LXFL529 and the renal cancer RXF423/17. At a dose of 1 ug/ml, there was still significant activity against the lung cancer. Thus, 1,4-bis(methyltriazeno)-trans-2-butene is a potently active compound, the cytotoxic activity of which is highly specific for certain types of cancers.
FIG. 3 discloses the results obtained with bis(methyltriazeno)ethane in the clonogenic assay. This compound was highly cytotoxic at 100 ug/ml to most of the tumor cell lines. Relatively little or no activity was observed, however, in the mesothelioma, the gastric carcinoma, or the renal cancer RXF 423/17. At 10 ug/ml, only marginal, but significant, activity was seen in the large cell lung cancer and in the mammary cancer.
For comparative purposes, the activity of DTIC (5-(3,3-dimethyltriazeno)imidazole-4-carboxamide) was tested in these cell lines. The results are shown in FIG. 4. DTIC is used clinically against metastatic melanoma, non-Hodgkins lymphoma, and soft-tissue sarcomas. At each point, the dose of DTIC was 3 times larger than that of the bistriazenes. Thus, at 300 ug/ml, DTIC was potently cytotoxic on all cell lines. At 30 ug/ml, it showed activity against the gastric carcinoma GXF251/16 and the ovarian cancer OVXF899/9. At 3 ug/ml, it exhibited marginal activity against the gastric cancer. Thus, all of the bistriazenes tested in this assay were at least as potent as DTIC. The bistriazene 1,4-bis(methyltriazeno)-trans-2-butene is highly potent against several tumors, especially the large cell lung carcinoma.
It may be concluded from these data that bistriazenes, as a class of compounds, are cytotoxic agents which exhibit considerable selectivity toward certain tumors. It is also clear from these data that the nature of the Linker is of paramount importance in modulating the activity and selectivity of cytotoxic action of these compounds. The clonogenic assay system facilitates rapid testing of the anti-tumor activities of newly synthesized bistriazenes containing systematically varied EG's and Linkers, in order to establish the chemical and biological characteristics which will result in additional useful drugs.
CHEMICAL ACTIVITY
Crosslinking of Oligonucleotides: The reaction of bistriazenes can afford interstrand crosslinks if the triazene decomposition produces alkydiazonium ions at each end of the Linker chain.
Bistriazenes react with varying efficiency with different oligonucleotides. Unsaturated bistriazenes such as p-xylyl and trans-butenyl produce stable crosslinked species in oligonucleotides. The amount of crosslinked species varies with the oligonucleotide sequence. The level of crosslinking is comparable to that seen with nitrogen mustard, and exceeds that observed with 1-(2-chloroethyl)-3-cyclohexyl-1-nitrosourea.
The crosslinking of oligonucleotides by bistriazenes was demonstrated in the following assay system:
A solution of 6.2 ng of 32 P-endlabeled oligonucleotide in 0.1M cacodylic acid buffer (0.1M NaCl, pH 7.4) was allowed to react with the desired compound dissolved in 1/10 volume DMSO. Final concentrations of the compounds in the oligonucleotide solution were 0.1 mM NMUST, 1.0 mM CCNU, or 10 mM bistriazene. Reactions were incubated at 37° C. for 42 hours, and analyzed by denaturing polyacrylamide gel electrophoresis (20% gel) followed by autoradiography. the gels were intentionally overexposed to better visualize bands corresponding to interstrand crosslinks. Large amounts of unreacted oligonucleotides were also visualized under these conditions.
As shown in FIG. 5, the results obtained with nitrogen mustard and the p-xylyl bistriazene derivative demonstrate that the oligonucleotides were stably covalently crosslinked by both the nitrogen mustard, a known crosslinking agent, as well as by the p-xylyl bistriazene of the instant invention. As can also be seen from FIG. 5, CCNU, a clinically employed DNA interstrand crosslinking agent, was not as effective at forming crosslinks as the p-xylyl bistriazene derivative.
All compounds examined caused extensive DNA strand breakage, because of which labile adducts were not observable.
Plasmid DNA Strandbreaking. DNA strand breaks may occur via the hydrolysis of labile alkylation sites. A single strand break allows the relaxation of supercoiled DNA to afford a nicked open circular form. Double strand breakage producing linear plasmid DNA occurs upon the hydrolysis of two labile alkylation sites close to one another on opposite DNA strands. These alkylation events may be either an interstrand crosslink, or discrete, but closely located, monoalkylations.
Dialkyltriazenes afford more strand breakage than alkylsulfates and sulfonates. Bistriazenes are approximately 10-200 times more efficacious at producing strand breaks than dialkyltriazenes. Bistriazenes afford significant quantities of linear DNA, whereas simple dialkyltriazenes produce only small amounts of the linear form, and only traces are detectable in the reaction of alkylsulfates with plasmid DNA. Restriction endonuclease treatment of bistriazene-modified DNA suggests that linearization is not highly specific for sequences on the plasmid.
The supercoiled plasmid strand break assay was carried out in a solution of 0.15 ug of pBR322 DNA in 9.5 ul of TE buffer (10 mM) Tris, 0.1, mM EDTA, pH 7.4) prepared at room temperature. A 0.5 ul aliquot of compound in DMSO was added, the solution vortexed lightly, and the samples incubated at 37° for 48 hours. Loading buffer (2 ul, 40% glycerol, and 1% bromphenol blue in TAE buffer) was added to each sample, and a 3 ul aliquot was analyzed by agarose gel electrophoresis (0.9% gel, 1.5 ug ethidium bromide/ml gel), and visualized by fluorescence.
The experimental results shown in FIG. 6 indicate that the bistriazenes examined afford higher levels of DNA modification than do simple dialkyltriazenes such as dimethyltriazene, and that the bistriazenes afford far more linearized DNA, indicated labile alkylation events on opposite strands of the DNA in close proximity to one another. These alkylation events may be a labile interstrand crosslink or discrete alkylation events near one another on opposite strands.
This suggests interaction of the bistriazine with DNA prior to forming active alkylating agent rather than simple hydrolysis to alkyldiazonium ion.
BISTRIAZENES POSSESSING ENHANCED CHEMICAL STABILITY AND THE SAME OR GREATER CYTOTOXIC EFFECTS
The bistriazenes described above are highly chemically reactive. It was therefore deemed desirable to prepare bistriazenes possessing the same or greater cytotoxic effects, but which are more stable chemically. The rationale for the preparation of such bistriazenes is described below.
The bistriazenes described supra have -CH 3 (methyl) as the EG. Since the EGs appeared to have little influence on the reactivity of these molecules toward DNA, it was reasoned that they could be employed to modulate the reactivity of bistriazenes. It was further reasoned that electron attracting groups would increase the chemical stability of the bistriazenes. Accordingly, bistriazenes, where the linker was ethano (CH 2 ) 2 ! or butano (CH 2 ) 4 !, and the EG groups were phenyl (C 6 H 5 ) or benzyl (C 6 H 5 CH 2 ), were prepared. These compounds proved to be much more stable toward decomposition than those where the EG was methyl. It was further reasoned that the stability of bistriazenes could be enhanced even more if the EG could be protonated at physiological pH. The reason for this hypothesis is that if the EG had a positive charge, it would be much more difficult to decompose the bistriazene molecule since this reaction requires the addition of a proton to the triazene moiety. The bistriazenes bis(3-pyridyltriazeno)ethane (1a), bis(3-pyridyltriazeno)butane (1b), and the isomeric bis(2-pyridyltriazeno)ethane (2a) and bis(2-pyridyltriazeno)butane (2b) were prepared by the reaction of the corresponding pyridyl lithium with 1,2-diazidoethane or 1,4-diazidobutane via procedures described above. ##STR13##
The rates of decomposition of the bistriazenes (1) and (2) were measured in buffer at pH 7.4. Bistriazenes 1 had half-lives of approximately 5 hours under those conditions, while bistriazenes 2 were somewhat less stable, having half-lives of about 5 minutes. This is compared to bistriazenes where EG is methyl, which have half-lives on the order of several seconds under these conditions. The nature of the linker had little effect on the decomposition rate.
The enhanced chemical stability of bistriazenes (1) and (2) had little effect on their ability to interact with DNA. This was determined by the reaction of the bistriazenes with the supercoiled plasmid pBR322. For example, the ability of bistriazene (la) to open, linearize, and finally to shear the plasmid (FIG. 7) was essentially identical to that observed for 1,2-bis(methyltriazeno)ethane (FIG. 6). Thus, electron withdrawing groups EG stabilize bistriazenes with respect to proteolytic decomposition in buffer, while leaving unaffected the DNA-damaging activity.
Furthermore, preliminary cytotoxicity data obtained via the clonogenic assay described above revealed that bistriazenes (1a) and (1b) are potently cytotoxic. These data are shown in Table 1, below.
TABLE 1______________________________________Cytotoxicity of bis(3-pyridyltriazeno)ethane(1a) andbis(3-pyridyltriazeno)butane(1b) on Human Tumor Cell Lines Test/Control (%) at Drug Concentration (μg/ml)Drug Cell Line.sup.a 1.0 10.0 100.0______________________________________1a LXFL 529 51 0+++ 0+++ PRCL DU145Y 84 44+ 0+++ RXF 1220 99 74 4+++1b LXFL 529 71 1+++ 1+++ PRCL DU145Y 94 62 4+++ RXF 1220 82 70 8+++DTIC.sup.b LXFL 529 63 35+ 8+++ PRCL DU145X 70 44+ 43+ RXF 1220 54 44+ 24+CYCM.sup.c LXFL 529 115 94 19++ PRCL DU145X 108 90 47+ RXF 1220 67 51 9+++______________________________________ .sup.a LXFL 529 is a large cell lung cancer line, PRCL DU145X is a prostate carcinoma, and RXF 1220 is a renal carcinoma. .sup.b DTIC (5(dimethyltriazeno) imidazole4-carboxamide) is a clinically used drug, and is positive in this panel. .sup.c CYCM, 4hydroperoxycyclophosphamide, is an activated form of the wellknown cytotoxic agent cytoxan.
Thus, electron attracting EGs in the bistriazenes encompassed by the present invention impart desirable enhanced chemical stability without affecting the DNA damaging effect of these drugs.
Specifically, the following types of EGs fulfill this requirement:
(a) Phenyl and substituted phenyl groups:
The substituents can include electron attracting moieties such as one or more nitro (--NO 2 ) groups, one or more halogen atoms (such as fluorine, chlorine, bromine, or iodine), one or more cyano (--CN) groups, one or more trifluoromethyl groups, one or more carboxyl groups or various combinations of these substituents.
(b) Arylalkyl or substituted arylalkyl groups:
These include benzyl (C 6 H 5 CH 2 ) and benzyls substituted as described in (a) above. Also included are condensed ring arylalkyls such as naphthylmethyl.
(c) Heterocyclic ring systems:
These include, but are not limited to, 2-pyridyl, 3-pyridyl and 4-pyridyl, 4-imidazolyl and 4-imidazolyl-5-carboxamide, various EGs derived from pyrimidines (cytosine, thymidine and uracil) and purines (adenine and guanine), and various oligonucleotides derived from combinations of purines and pyrimidines. The oligonucleotides can be held together by normal phosphate links, or by methylphosphonate or phosphorothioate links.
(d) Amine and polvamine-derived EGs:
Since amines can be protonated at physiological pH, and would thus fulfill the same stabilizing role, groups such as 2-aminopropyl, and 2-(N,N-dialkylamino)propyl such as 2-(N,N-dimethylamino)propyl or 2-(N,N-diethylamino)propyl are useful. Also contemplated are groups which have more than one amino group, such as 2-(N- 4-(N'-propylamino)butyl!amino)propyl(--CH 3 CH 2 CH 2 NH--CH 2 CH 2 CH 2 CH 2 NHCH 2 CH 2 CH 2 --). These are analogs to natural polyamines.
As a means of enhancing the reactivity of bistriazenes toward DNA, resulting in drugs that would require administration in lower doses to achieve similar therapeutic results, the present inventors have modified the linker in the bistriazene structure. Specifically, bistriazene (3) was prepared:
CH.sub.3 --N═N----NH--CH.sub.2 CH.sub.2 N(CH.sub.3)--CH.sub.2 CH.sub.2 NH--N═N--CH.sub.3 (3)
This compound is at least 100 times more reactive toward pBR322 than 1,2-bis(methyltriazeno)ethane (cf. FIGS. 6 and 8). At the beginning of this application there is discussed a paper by Vaughan et al. (1984) J. Med. Chem. 27:357-63 which describes a bistriazene in which the linker is the same as in bistriazene (3). The Vaughan et al bistriazene is, however, substantially different from (3) for the following reasons:
1. The saturated nitrogens therein have additional substituents (methyl groups). Such bistriazenes would require a double metabolic demethylation in order to become alkylating agents--a very unlikely scenario. In contrast, the bistriazenes of the present invention require H atoms instead of alkyl groups in that position.
2. The synthetic method is very different, as is the chemistry of the Vaughan et al bistriazene, as compared to the bistriazenes of the present invention.
3. The Vaughan et al. bistriazene would be expected to act like a monotriazene in biological systems, i.e., it would be a simple alkylating agent.
Thus, the bistriazenes of the present invention include those with the following linker modifications:
(a) The linker shown in structure (3), together with various modifications of that scheme, i.e., a central nitrogen flanked by (CH 2 ) n , where n=1-5.
(b) Instead of a methyl on the central nitrogen, the latter can be substituted by hydrogen or other normal alkyl groups from methyl to pentyl.
(c) The linker can also possess more than one nitrogen. Specifically, the following linker, which would closely mimic a polyamine structure, is contemplated: ##STR14## where n=1-5, m=1-5, and R 4 and R 5 =normal alkyl up to pentyl.
(d) Instead of the central atom being N, it can also be oxygen, or sulfur. In those cases, no other substituents on the oxygen atom would be possible, except those forming the linker. In the case of sulfur, however, the atom could be oxidized to the sulfoxide or the sulfone.
PHARMACEUTICAL PREPARATIONS
The bistriazene compounds of the present invention, or physiologically acceptable salts thereof, can be formulated into a pharmaceutical composition comprising an effective anti-cancer amount of the compound and a pharmaceutically acceptable carrier. An effective anti-cancer amount of the pharmaceutical composition will be administered to the subject, human, animal, or mammal, in a manner which inhibits cancer cell growth or replication. The amount of the compound and the specific pharmaceutically acceptable carrier will vary depending upon the host and its condition, the mode of administration, and the type of cancer being treated.
In a particular aspect, the pharmaceutical composition comprises a bistriazene anti-cancer compound or physiologically acceptable salt thereof in effective unit dosage form. As used herein, the term "effective unit dosage" or "effective unit dose" is denoted to mean a predetermined anti-cancer amount sufficient to be effective against the cancer in vivo. Pharmaceutically acceptable carriers are materials useful for the purpose of administering the medicament, which are preferably non-toxic, and may be liquid materials which are otherwise inert and medically acceptable, and are compatible with the active ingredients.
The pharmaceutical compositions of the present invention can also contain an anti-cancer effective amount of at least one conventional alkylating agent, such as chlorambucil, melphalan, uracil, mustard NF, cyclophosphamide, mechlorethamine hydrochloride, carmustine (BCNU), lomustine, dacarbazine (DTIC), thiotepa NF, and busulfan, or combinations thereof. Pharmaceutical compositions of the present invention can also contain, in addition to a bistriazene compound or physiologically acceptable salt thereof, at least one conventional chemotherapeutic agent other than an alkylating agent, as would be apparent to one of ordinary skill in the art of cancer chemotherapy. Also contemplated in the present invention are pharmaceutical compositions containing a bistriazene compound or physiologically acceptable salt thereof, at least one conventional alkylating agent, and at least one conventional chemotherapeutic agent other than an alkylating agent. Pharmaceutical compositions of the present invention can also include those wherein more than one of the bistriazene cmpounds described supra are employed in conjunction with one another, either alone or in combination with at least one conventional alkylating agent and/or at least one conventional chemotherapeutic agent other than an alkylating agent. All pharmaceutical compositions of the present invention can also contain other active ingredients such as antimicrobial agents and other agents such as preservatives, and can be employed in treating cancer in a mammal, including humans.
These pharmaceutical compositions may take the form of a solution, an emulsion, suspension, ointment or cream. They may be administered parenterally, orally or topically, as an aerosol, spray, or drops, said parenteral administration being conducted intraperitoneally, intramuscularly, subcutaneously, intravenously, intraarticularly, intraarterially, or transdermally, depending upon whether the preparation is used to treat internal or external cancers.
The compositions may contain the compound in an amount of from about 0.1% - about 99% by weight of the total composition, preferably about 1 to about 90% by weight of the total composition. For parenteral injection, the bistriazene compound can be dissolved in a pharmaceutically suitable carrier such as purified corn oil, propylene glycol, triolene, or dimethyl sulfoxide, and the dose may be about 0.1 mg to about 1000 mg per kilogram per day. If administered intraperitoneally, the compounds may be dissolved in a suitable vehicle, as above, and the dose may be about 1 mg to about 500 mg per kilogram per day. If injected intramuscularly, the compounds can be dissolved in oil or another compatible vehicle, and the dose can be about 0.1 mg to about 1000 mg per kilogram per day. In any case, injections can be carried out once or several times per day over a five day course depending upon the route of administration and the condition of the patient. After such courses, a recovery period of various length may be necessary. Additional courses may then be required under specific conditions. Total adult doses can range from about 0.1 to about 5000 mg, with dosages in the range of from about 10 to about 1000 mg being preferred. For certain particular applications, oral administration of bistriazenes encapsulated in liposomes or time-release formulations or dispersed in compatible emulsions together with stabilizing and/or dispersing agents may be the method of choice.
For topical application, to treat surface lesions such as basal cell and squamous cell carcinomas or non-metastasized melanomas, as well as certain non-malignant conditions which are characterized by rapid cell proliferation but which may not be amenable to surgical treatment, bistriazenes may be formulated in oil or cream.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
|
The present invention is directed to bistriazene compounds, pharmaceutical compositions containing effective anti-cancer amounts of these compounds, a method for treating cancer comprising administering to affected subjects an anti-cancer effective amount of a bistriazene compound, and the use of bistriazene compounds as crosslinking reagents applicable to the synthesis and manipulation of polymeric macromolecules.
| 2
|
This application is a continuation of application Ser. No. 10/271,053, filed Oct. 15, 2002, now U.S. Pat. No. 6,770,048 B2, issued Aug. 3, 2004, which is a continuation of application Ser. No. 09/952,093, filed Sep. 11, 2001, now U.S. Pat. No. 6,475,176 B2, issued Nov. 5, 2002, which is a continuation of application Ser. No. 08/888,777, filed Jul. 7, 1997, now U.S. Pat. No. 6,287,270 B1, issued Sep. 11, 2001, the contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is in the field of devices for use in surgical procedures. More particularly, the present invention relates to a device having both a venous blood reservoir and a cardiotomy reservoir for use in an extracorporeal circuit.
BACKGROUND OF THE INVENTION
Many surgical operations involve circulating the blood of a patient through an extracorporeal circuit. In particular, many open-heart surgical procedures require that the patient's heart be stopped, and that various biological functions (i.e., blood circulation and oxygenation) be performed mechanically by various devices included in the extracorporeal circuit. In addition to a pump and to the tubing through which the blood will flow, devices including oxygenators, heat exchangers, and blood accumulation reservoirs may be employed. Each of these devices is monitored and managed by persons who may be present in the operating room, or at remote monitoring and control stations.
One type of blood accumulation reservoir used in such procedures is a venous reservoir. The venous reservoir serves as a receptacle for blood, typically blood that has been removed from the patient through a vein, which is subsequently oxygenated and further processed prior to being recirculated back to the patient. Thus, the venous reservoir typically serves to collect blood as it first enters the extracorporeal circuit. The use of the venous reservoir enables the operator to control the blood flow rate, blood pressure, blood volume and related parameters necessary to maintaining the patient during the surgical procedure.
A second type of blood accumulation reservoir used in such procedures is a cardiotomy reservoir. The cardiotomy reservoir is used to contain blood which has been collected from the operating field. Blood collected in the cardiotomy reservoir can be reinfused into the patient after being filtered to remove any clots or other unwanted contaminants.
Since the space in the operating room available to operators is often limited, devices have been proposed which combine the venous reservoir and the cardiotomy reservoir in a single structure. In such devices, inlets for the venous blood and for the blood from the operating field are separated from one another. Blood entering the device is filtered and then collected in a common chamber.
These devices, however, are known to have certain disadvantages. For example, the surface area of such devices which comes into contact with the blood is relatively large. As a result, the blood becomes susceptible to damage or coagulation. Additionally, even under relatively normal operating conditions, retrograde blood flow may be induced, causing the blood to be reverse filtered. This is particularly problematic if only venous blood is being collected, because the retrograde flow causes the blood to be sequestered within the cardiotomy filter, thereby reducing the volume of blood available for oxygenation and recirculation to the patient.
OBJECTS AND SUMMARY OF THE INVENTION
One object of the present invention is to provide a combined device having both a venous blood reservoir and a cardiotomy reservoir. Another object of the invention is to provide a device which allows venous blood and cardiotomy blood to be optionally integrated if surgical conditions or requirements warrant. Still another object of the invention is to provide a combined venous blood reservoir and cardiotomy reservoir which minimize blood contact with large surface areas of the device and which eliminate the risk of reverse filtration.
These and other objects of the invention are achieved by a combined device having a venous blood reservoir and a cardiotomy reservoir. The device is characterized in that it includes a housing having a partition which separates a lower reservoir from an upper reservoir. The lower reservoir is adapted for use as the venous reservoir, and the upper reservoir is adapted for use as the cardiotomy reservoir. The venous reservoir is provided with a blood inlet connector and a blood outlet connector, and the cardiotomy reservoir and is provided with a blood inlet connector and with an air outlet connector. Each of the blood inlet connectors is positioned so that blood entering the device is caused to flow through a defoaming substance and a filter. Additionally, the partition which separates the venous reservoir from the cardiotomy reservoir is provided with at least two ducts which, starting from apertures formed in the partition, project upward into the cardiotomy reservoir and reach different elevations therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of one embodiment of the invention, taken along a longitudinal plane.
FIG. 2 is an enlarged sectional view, taken along the plane II—II of FIG. 1 .
FIG. 3 is the same sectional view of FIG. 2 , but with the device in a different operating mode.
FIG. 4 is a sectional view, taken along the plane IV—IV of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the device of the present invention is depicted in FIGS. 1–4 . Regarding FIGS. 2 and 3 , and for the sake of clarity, a view of the device taken along plane II—II of FIG. 1 is shown. In FIGS. 2 and 3 , the column 16 has been rotated 90° into the page with respect to its position shown in FIG. 1 . With reference to the above Figures, the reference numeral 1 designates a housing of the device and the reference numeral 2 designates a partition which divides the space enclosed by the housing 1 into a venous reservoir 3 , and a cardiotomy reservoir 4 . The housing is preferably formed of a transparent polymer to allow the interior of the device to be viewed by an operator. Numerous transparent, medically useful polymers are known to those having ordinary skill in the art.
The venous reservoir 3 is provided with a venous inlet connector 5 , terminating at 5 a , for the venous blood. Venous blood entering the venous reservoir 3 through the venous inlet connector 5 enters a distribution chamber 22 where it is passed outward, in a substantially uniform manner, into a central region of the venous reservoir through a plurality of slotted apertures 23 formed in the distribution chamber 22 . The central region of the venous reservoir is defined by a generally cylindrical wall 6 of a defoaming material. The defoaming material is surrounded by a filter 6 a through which the blood must also pass as it enters the venous reservoir 3 . Blood exits the venous reservoir 3 through a venous outlet connector 7 .
In one embodiment, the defoaming material comprises a porous polymeric material such as a polyurethane foam. In one preferred embodiment, the defoaming material is a polyurethane foam having a pore size of approximately 5 to 50 pores per inch, more preferably approximately 20 to 30 pores per inch. The defoaming material may optionally be treated with a medically acceptable antifoaming agent such as a silicone antifoaming agent. The filter is a screen, preferably formed of a polyester, having an aperture size in the range of about 20 to 50 microns.
The top of the venous reservoir 3 is defined by a partition 2 which separates the venous reservoir 3 from the cardiotomy reservoir 4 . The cardiotomy reservoir 4 is provided with a cardiotomy inlet connector 8 for receiving blood arriving from the operating field, and an air outlet connector 10 . Blood entering the cardiotomy reservoir 4 through the cardiotomy inlet 8 first encounters a flow distributor 24 , which distributes the blood outwardly in a substantially uniform manner. As with the blood entering the venous reservoir, the blood next encounters a generally cylindrical wall 9 of a defoaming material. The defoaming material is surrounded by a filter 9 a through which the blood must also pass as it enters the cardiotomy reservoir 4 . The defoaming material is as described above, namely, a porous polymeric material such as a polyurethane foam. As before, in one preferred embodiment, the defoaming material is a polyurethane foam having a pore size of approximately 5 to 50 pores per inch, more preferably approximately 20 to 30 pores per inch, and the filter is a screen, preferably formed of a polyester, having an aperture size in the range of about 20 to 50 microns.
The partition 2 which separates the venous and cardiotomy reservoirs is typically a substantially flat plate. When the device is in operation, it is positioned in a manner that maintains the partition in a substantially horizontal orientation. The partition 2 is provided with a plurality of apertures that provide for operation of the device in the manner discussed below.
In one embodiment, shown in FIGS. 1–3 , the partition 2 includes two apertures 11 and 12 , from which extend two ducts 13 and 14 . The ducts preferably extend substantially at right angles to partition 2 and therefore are maintained in a vertical orientation when the device is oriented in its proper operating position. The ducts 13 and 14 extend into the cardiotomy reservoir 4 and reach approximately the same elevation. The upper edge of each duct is typically provided with a plurality of axial notches 15 .
An axially moveable column 16 is positioned preferably in the center of the cardiotomy reservoir 4 and extends upward through the housing 1 . The column 16 includes a first passageway 17 and a second passageway 18 . In the first passageway 17 , a lower end 17 a communicates with the venous reservoir 3 through a central aperture 20 in the partition 2 , and an upper end 17 b communicates with the cardiotomy reservoir 4 . Likewise, in the second passageway 18 , a lower end 18 a communicates with the cardiotomy reservoir 4 and an upper end 18 b communicates with the exterior of the housing.
Column 16 can be caused to move axially by manual action on tab 19 . As such, the column can be moved between a lower stroke limit position, illustrated in FIGS. 1 and 2 , and an upper stroke limit position, shown in FIG. 3 . While in the lower stroke position, the lower end 17 a of the first passageway is sealingly inserted into a central aperture 20 provided preferably at the center of the partition 2 . The seal may optionally be enhanced through the use of an O-ring 25 positioned around the exterior of the lower end 17 a of the first passageway. The seal, when engaged, serves to prevent blood in the cardiotomy reservoir from entering the venous reservoir. When the seal is engaged, the upper end 17 b of the first passageway is caused to be positioned at an elevation which is above that of the upper edges of the ducts 13 and 14 . Alternatively, when the column 16 is moved into its upper stroke position, the lower end 17 a of the first passageway 17 is extracted from the central aperture 20 , thereby disengaging the seal and allowing blood in the cardiotomy reservoir 4 to flow directly into the venous reservoir 3 . It should be noted that regardless of the position of the column 16 , fluid communication through the second passageway 18 is substantially unaffected. A second O-ring 27 may optionally be provided around the exterior of an upper portion of the column 16 . The second O-ring 27 serves to provide a seal between the upper portion of the column and the portion of the housing 1 through which the column passes.
When the column 16 is at the lower stroke limit, i.e., in the position shown in FIGS. 1 and 2 , blood flowing into venous inlet connector 5 enters the venous reservoir 3 . If the amount of blood entering the venous reservoir is greater than the amount exiting through the venous outlet connector 7 , the level of blood inside the venous reservoir 3 is caused to rise. It is possible that the rising level of blood can lead to the complete filling of the venous reservoir. At this point, one advantage of the present invention becomes apparent, since an additional accumulation of blood is allowed because the blood can enter the ducts 13 and 14 , as well as the first passageway 17 . Such excess blood can then rise in the ducts and passageway until it overflows into the cardiotomy reservoir 4 through the ducts 13 and 14 . By integrating the venous reservoir 3 and the cardiotomy reservoir 4 , the device, whenever necessary, allows the accumulation of an amount of venous blood which is far greater than the capacity of the venous reservoir alone.
Integration of the venous and cardiotomy reservoirs also allows air and other gaseous emboli entrained in the venous blood, resulting for example from poor cannulation, to be released from the device by passing through the ducts 13 , 14 and the first passageway 17 and allowing it to collect in the upper portion of the cardiotomy reservoir 4 , from which it may exit or be withdrawn through the air outlet connector 10 .
Likewise, the functionality of the cardiotomy reservoir 4 is also enhanced. Specifically, blood entering the cardiotomy reservoir 4 through the cardiotomy inlet connector 8 gradually rises in that reservoir until it is almost filled. Rather than completely filling the cardiotomy reservoir, however, once the blood reaches a certain level, it is caused to enter the ducts 13 and 14 and flow downward therethrough, accumulating in the venous reservoir 3 . As such, the device is configured to allow excess accumulation of either venous or cardiotomy blood.
Even if excess cardiotomy blood is flowing into the venous reservoir, air and other gaseous emboli present in the venous blood can still be removed from the device. Since the upper end 17 b of the passageway 17 is configured to remain above the upper edges of the ducts 13 and 14 , even if the ducts are communicating blood into the venous reservoir, the passageway 17 remains blood-free and capable of communicating air from the venous reservoir into the cardiotomy reservoir, and ultimately, to the exterior of the housing through the air outlet connector 10 .
When the column 16 is positioned at its upper stroke limit, as shown in FIG. 3 , all of the blood contained in the cardiotomy reservoir 4 will flow into the underlying venous reservoir 3 through the central aperture 20 . As such, in this configuration, the central aperture 20 acts as a drainage port which may be plugged and unplugged by the column 16 .
Finally, it should be noted that a situation can arise in which the operator does not wish to mix blood contained in the cardiotomy reservoir 4 with blood contained in the venous reservoir 3 . This can occur, for example, if undesirable substances are present in the cardiotomy blood. In that situation, the blood contained in the cardiotomy reservoir is effectively isolated from the blood in the venous reservoir and can be completely removed from the device through passageway 18 .
It should be noted that the advantages of the device of the present invention are not intended to be strictly limited to those described above. For example, in the embodiments of the device shown in FIGS. 1–4 , the amount of blood contact with the internal surfaces of the device has been minimized, as has the possibility of reverse filtration of blood contained within the device. Furthermore, due to the relatively non-complex design and operation of the device, the device will respond rapidly to control manipulations by the operator.
Of course, the described invention is amenable to numerous modifications and variations, all of which are intended to be within the scope of the inventive concept. Thus, for example, the number of ducts provided on the partition can be different from the configuration described.
Likewise, the invention is not intended to be limited to the particular materials employed, nor to the shapes or any dimensions employed. Rather, the device may be made according to the specific requirements of a particular application for which its use is intended.
EQUIVALENTS
Various modifications and alterations to this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention. It should be understood that this invention is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the invention intended to be limited only by the claims set forth herein as follows.
|
A combined device having a reservoir for venous blood and a reservoir for cardiotomy blood is disclosed. The device is characterized in that the venous reservoir is separated from the cardiotomy reservoir by a partition which includes a plurality of apertures. The apertures are in fluid communication with a plurality of ducts and passageways which are configured to provide various modes of operation depending upon whether, for the particular surgical conditions, it is desired to mix venous and cardiotomy blood, or to isolate those blood pools from each other.
| 6
|
This application is a continuation of U.S. patent application Ser. No. 11/525,298 entitled “THREE DIMENSIONAL RF SIGNATURES” to Ashwood-Smith et al., filed Sep. 22, 2006.
BACKGROUND
1. Field of the Invention
The present invention relates to Radio Frequency (RF) tags and, more particularly, to three dimensional RF tag signatures.
2. Description of the Related Art
Radio Frequency tags, also known as Radio Frequency Identification (RFID) tags use electromagnetic radiation to temporarily charge a circuit, which may be programmed to wirelessly transmit a data code. If the data transmitted by the circuit is received by an RF tag reader, it is possible to determine that the RF tag is in the proximity of the RF tag reader. By causing different chips to transmit different RF tag codes, the identity of the RF tag may be determined, which will allow a RF tag processing system interfaced with the RF tag reader to uniquely place that RF tag in a particular place at a particular point in time. Thus, by associating the RF tags with individual articles that are to be tracked, it is possible to keep track of many different articles electronically. RF tags may be used in many applications, and the number of applications of RF tags has been increasing dramatically in the last few years. For example, RF tags are used in retail establishments to keep track of merchandise, in manufacturing to keep track of inventory, in corporations for example in building access badges, and in many other fields.
FIG. 1 shows an example RF tag. As shown in FIG. 1 , a standard RF tag 10 includes a coil 12 that will be used to capture electromagnetic radiation to produce a current. As is well known, changing an electromagnetic field relative to a coil will cause an electrical current to flow in the coil. Thus, by modulating an electromagnetic field it is possible to cause a current to be generated in the coil of an RF tag. Where the coil 12 is connected to an electromagnetic circuit 14 , and the electrical current is used to power to circuit 14 . The circuit may be used for many different things, but generally is configured to transmit a tag response including a tag code that may be read by a RF tag reader 20 (see FIG. 2 ). RF tags are well known, and many different types and sizes/shapes of RF tags and circuits have been developed.
As shown in FIG. 2 , in operation a RF tag reader 20 generates a strong electromagnetic field 22 which will cause a current to be generated in any RF tags within a given distance of the RF tag reader. When an RF tag 10 comes into proximity of the RF tag reader 20 , the RF tag will generate the tag response 24 which may be sensed by the reader 20 if the tag is sufficiently close to the reader 20 .
RF tags provide an indication of presence of the tag relative to the reader, but generally do not provide an indication of where the RF tag is located within the reader's field of view. While it is possible to use an RF tag reader that has one or more directional antennas to help determine the relative position of the RF tag, doing so reduces the ability of the RF tag reader to detect the presence of RF tags outside of the directional antenna beam.
Similarly, when an RF tag is associated with an article, for example where RF tags are to be used to track boxes of merchandise or luggage, sensing the presence of an RF tag will enable the reader to determine the rough location of a particular article at that particular point in time. The RF reader is not able however, to determine the state of the article or whether the article has been damaged or altered since the last time the RF tag presence was sensed. Accordingly, while RF tags are very useful for tracking where articles are at particular points in time, it would be advantageous to provide a way in which the RF tags could provide additional information about the articles being tracked.
SUMMARY
Three dimensional RF tag signatures may be obtained from a three dimensional RF tag or multiple two or three dimensional RF tags so that information in addition to presence information may be obtained. In one embodiment, a three dimensional RF tag having two or more power coils disposed in non-coplanar planes, enables the coils to experience different levels of excitation from an electromagnetic field associated with the RF tag reader. This information may be transmitted along with the RF tag response to enable the orientation of the RF tag relative to the RF tag reader to be determined. In another embodiment, multiple RF tags (either standard RF tags or three dimensional RF tags) may be used on a given article and a response signature from the article as a whole may be recorded. The three dimensional response signature thus collected may be compared with previous versions of the response signature to determine if the article has been altered.
BRIEF DESCRIPTION OF THE DRAWINGS
Aspects of the present invention are pointed out with particularity in the appended claims. The present invention is illustrated by way of example in the following drawings in which like references indicate similar elements. The following drawings disclose various embodiments of the present invention for purposes of illustration only and are not intended to limit the scope of the invention. For purposes of clarity, not every component may be labeled in every figure. In the figures:
FIG. 1 is a functional block diagram an RF tag;
FIG. 2 is a functional block diagram of the interaction between an RF tag reader and an RF tag;
FIG. 3 is a functional block diagram of an RF tag having three non-coplanar power coils according to an embodiment of the invention;
FIG. 4 is a diagram showing the electrical interconnection of the power coils an circuit of the RF tag of FIG. 3 in greater detail;
FIG. 5 is a diagram of an article having a plurality of RF tags;
FIG. 6 is a functional block diagram of an RF tag reader obtaining a three dimensional signature from an article such as the article of FIG. 5 ;
FIG. 7 is a flow chart illustrating a process of determining a relative orientation of an RF tag from a signature of a three dimensional RF tag, such as the RF tag of FIGS. 3-4 , according to an embodiment of the invention;
FIG. 8 is a flow chart illustrating a process of comparing a three dimensional RF tag signature from an article having a plurality of RF tags, such as the article shown in FIGS. 5-6 , with a previous signature for the same article according to an embodiment of the invention; and
FIG. 9 is a functional block diagram of a computer system configured to implement an RF tag processing system according to an embodiment of the invention.
DETAILED DESCRIPTION
The following detailed description sets forth numerous specific details to provide a thorough understanding of the invention. However, those skilled in the art will appreciate that the invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, protocols, algorithms, and circuits have not been described in detail so as not to obscure the invention.
FIG. 3 illustrates an example of a RF tag having more than one power coil, in which the power coils are not formed to be co-planar. By using non-co-planar power coils, the several power coils will generate different amounts of power when subjected to a directional electromagnetic field. The chip may transmit a power coil value indicative of the amount of power, current, voltage, or another measurable quantity, that it received from each power coil in connection with generating its tag response. These power coil values may be used by the RF tag reader or RF tag processing system to deduce an orientation of the RF tag relative to the RF tag reader.
In the embodiment shown in FIG. 3 , the three dimensional RF tag 30 includes three power coils 12 X, 12 Y, and 12 Z. The three power coils are connected to the circuit 32 and provide power to the circuit. Although the embodiment shown in FIG. 3 has three power coils, the invention is not limited in this manner as two power coils or a larger number of power coils may be used as well. Additionally, although the embodiment shown in FIG. 3 has the power coils disposed on orthogonal planes, this is merely a preferred embodiment. The invention is not limited to this particular embodiment as other types of three dimensional RF tags having more than one power coil disposed in a non-planar fashion may have the power coils disposed on differently oriented planes.
FIG. 4 provides additional details about how the power received from the several power coils is used by the circuit 32 . As shown in FIG. 4 , the power received from each of the power coils 12 X, 12 Y, and 12 Z is added together to form an input power to the circuit 32 . Additionally, the electrical signals from the power coils 12 X, 12 Y, and 12 Z are each measured by the RF tag. The RF tag may measure the power from the power coils, the amount of current being generated, the voltage, or another electrical characteristic derivable from measuring the output of the power coils.
Once the RF tag has taken measurements of the power coils, it will transmit the tag code 34 along with power coil values to the RF tag reader via an antenna 36 . The power coil values are indications of the electrical characteristics of the several power coils and may be actual readings of the characteristic that is being measured, or one or more values derived from the measured characteristic. The tag code may be a standard tag code, and the rest of the circuit that is configured to actually transmit the data may be the same as a standard RF tag, except that instead of transmitting only a tag code the RF tag will also transmit the power coil values as well.
The amount of current generated in a given coil depends not only on the strength of the electromagnetic field, but also on the orientation of the coil relative to the field. If a RF tag reader is transmitting electromagnetic (EM) radiation, the direction of the radiation over the area occupied by the three dimensional RF tag may be considered to be relatively constant in one direction, given the size of a typical RF tag relative to the distance to the RF tag reader. By placing the power coils in different planes such as the orthogonal planes shown in FIGS. 3 and 4 , the power coils will therefore be oriented at different angles relative to the EM radiation source. Thus, different currents should be produced in each of the power coils of the RF tag. If the tag has a known geometry, such as if the tag is formed to have three power coils on three mutually orthogonal planes as shown in FIGS. 3 and 4 , the orientation of the tag relative to the reader may be determined.
The amount of current generated in a given coil may be expected to be dependent on the strength of the EM field at the RF tag. If a point EM source radiating in all directions is used to generate the EM field, then the strength of the radiation should be expected to drop off on the order of d.sup.3, where d is the distance from the point source to the RF tag. By measuring the magnitude of the electrical response in these power coils, a rough estimate of the distance between the RF tag and the tag reader may be obtained.
The distance and/or orientation information obtainable from an RF tag having multiple non-co-planar power coils may be used in many different applications. For example, in manufacturing, a stationary RF reader may use RF tags to identify when particular parts are approaching a manufacturing station. Knowing the orientation of the RF tag may enable the RF tag reader to determine if the part has been incorrectly placed on the conveyance system, may help the RF tag reader to know where the part is within its field of view, and may help in other ways. For example, knowing the orientation of a tag may enable the system to know if the article associated with the tag is up-side-down.
Similarly, where the location of the RF tag has been fixed and the RF tag reader is mobile, knowing the direction from the reader to the RF tag, and optionally the distance between the reader and the RF tag, may help the RF tag reader stay on a desired side of the fixed RF tags. This may be useful, for example in connection with self-propelled vehicles and in other applications. For example, if the RF tags are embedded in a roadway, the three dimensional signatures may enable an RF tag reader in an automobile to know whether it is traveling on the left side or right side of the RF tags.
The several example applications described herein are not intended to limit application of the invention to one or two fields, but rather have been provided to show some practical utility for the invention. The invention is thus not limited to the use of the inventive three dimensional RF tag signatures in these several applications, since the signatures may be used in many different ways that are too numerous to list herein.
Although an embodiment has been described in which multiple antennas are connected to a given circuit, according to another embodiment of the invention, multiple RF tags 10 associated with an article may be used to generate a three dimensional signature for the article. These RF tags may be conventional tags such as the tag shown in FIG. 1 , may be tags such as the RF tags discussed above in connection with FIGS. 3 and 4 , or may be differently configured RF tags. FIG. 5 shows one example of this where three RF tags 52 are placed at different locations on an article 50 . Since the RF tags will provide a spatial signature for the article that is dependent on their position on the article, changing the position of one or more of the RF tags will cause the three dimensional signature for the article to change. Detecting a change in the RF signature may thus enable a system to determine that the article has been altered between readings. This may be useful, for example, where security is an issue and it is important to detect whether tampering has occurred. Similarly, although an embodiment will be described in which the RF tags have been applied to an article, the invention is not limited in this manner as the RF tags may also be applied to a set of articles that are required to be kept together.
The signature will be unique to the article and depend on the orientation of the RF tags, the placement of the RF tags, and possibly the configuration of the article as well. For example, the RF tags may be distributed to form a spatial signature for the article. The RF tags may also be set to respond at different times so that the set of RF tags is able to form a temporal signature. Similarly, the response of one or more of the RF tags may be encoded, so that the signature is encoded. Thus, the three dimensional signature may include spatial signatures, time signatures, coding signatures, and combinations of these types of signatures.
Once an initial three dimensional RF signature is received for a given article, the signature may be stored for use at a later time. When a new signature is received for the article, the new signature may be compared with the stored signature to determine if the two signatures are sufficiently alike. If the signatures are sufficiently similar, it may be inferred that the RF tags or the relative placement of the RF tags has not been disturbed. If the signatures are sufficiently dissimilar, it is possible that the article has been tampered with, and an appropriate notification may be provided.
The three dimensional signature provided by a set of RF tags disposed within a given volume may be used in many different applications. For example, a signature may be obtained from a box of items. If the signature changes, it may be that the box has been opened. Similarly from a security standpoint, if one or more RF tags are associated with a piece of luggage, detecting a change in the luggage signature may indicate that the luggage has been opened, which may indicate that something has been stolen or added to the piece of luggage. In either instance, further inspection of the luggage may be warranted. The three dimensional signatures may be used in other applications as well and the invention is not limited to these several mentioned applications.
FIG. 6 shows an embodiment of a reader that may be configured to obtain RF signatures from a set of RF tags disposed within a volume. As shown in FIG. 6 , responses 60 from tags 10 may be gathered by an antenna 62 and passed to an RF tag reader 64 . The antenna may be integrated into the RF tag reader 64 and the invention isn't limited by the manner in which the response from the individual RF tags are collected by the RF tag reader 64 .
The response from the RF tags 52 will be input to processing circuitry 66 where the tag codes 68 for the various RF tags will be extracted. In addition, the particular manner in which the RF tags responded may be stored as an RF signature 70 for the article. The tag codes and/or signature may be transmitted to a central area for further processing and/or storage. The invention is not limited by the particular manner in which these values are used once they have been obtained. However, as described above, multiple signatures from the same article 50 may be compared over time to determine if the article has been changed in a way that would change the RF signature of the article.
The RF tags 52 may be standard RF tags 12 described above in connection with FIGS. 1-2 , or may be RF tags 30 that are configured to also provide an indication of the electrical characteristics of at least one of their power coil(s). For example, each RF tag may be configured to transmit not only its tag code, but also an indication of at least one electrical characteristic associated with its power coil. This may be implemented as discussed above in connection with FIGS. 3-4 . The relative power levels of the several RF tags when interrogated from a particular angle and/or distance may provide information as to whether any of the RF tags have been moved relative to the location of the RF tag reader, and thus provide a way for tampering to be detected from an RF tag signature associated with a given set of RF tags.
FIGS. 7 and 8 show two processes that may be used to implement embodiments of the invention. As shown in FIG. 7 , power from antennas in multiple dimensions may be used to power an RF tag ( 100 ). The power level (or other electrical characteristic) from each antenna may then be transmitted along with the RF tag code to a tag reader ( 102 ). The tag reader or an associated RF tag processing system will interpret the power levels from the antennas to determine an orientation of the RF tag relative to the RF tag reader ( 104 ). Alternatively, the tag reader may pass this information back to a central RF tag processing system that may then interpret the power levels of the antennas to determine the orientation of the RF tag relative to the RF tag reader. The particular location where this process happens will depend on how the invention is implemented and the invention is not to be limited in this manner to any particular implementation.
Where the tag reader is mobile, the mobile tag reader may be able to determine its position based on the orientation information obtained from a fixed RF tag ( 106 ). Similarly, where the tag reader is fixed, the location of the RF tag may be determined by analyzing the power levels recorded by the RF tag ( 108 ). The relative location information may then be used in many different ways depending on the particular application being implemented.
In the process shown in FIG. 8 , when an article containing multiple RF tags enters an EM field associated with a tag reader ( 110 ), the RF tags in the article are powered by the EM field and emit a tag code, optionally in conjunction with information about the electrical characteristics of their one or more power coils ( 112 ). The combination of tag codes, the order in which the RF tags respond, the encrypted/unencrypted nature of the tag codes, and the other characteristics associated with the transmissions from the RF tags on the article are used to form a signature for the article as a whole ( 114 ). The RF tag codes may then be compared with expected RF tag codes to identify the article and to determine whether all of the expected RF tags have responded ( 116 ). The signature may also be checked against a previous signature for the article to determine if the signature has changed significantly ( 118 ). The signatures for the article may be used in many different ways as well, depending on the particular application being implemented.
FIG. 9 shows a functional block diagram of a RF tag processing system embodied as a computer system 120 that may be used to enable three dimensional RF signatures to be used to understand information about articles associated with the RF tag(s). In the embodiment shown in FIG. 9 , the computer system 120 includes one or more input/output ports 122 to enable RF tag information to be received from one or more RF tag readers. The input/output ports may be standard network ports configured to enable the RF tag readers and the RF tag processing system to be interconnected by a communication network. Alternatively the input/output ports may be serial ports or other types of ports, for example where the RF tag reader(s) are directly connected to the computer system. Although the embodiment shows the computer system as separate from the RF tag readers, alternatively the processing functions described in connection with FIG. 9 may be performed by processing circuitry integrated with one or more of the RF tag readers. Thus, part of the functionality described as being attributable to the RF tag processing system may be distributed and instantiated in the RF tag reader or another component associated with the RF tag processing system. Similarly, some of the processing may be implemented on the RF tags themselves, particularly in connection with the three dimensional RF tags, and the invention is not limited to an embodiment in which all of the processing is done in the precise manner described herein.
The computer system includes a processor 124 containing control logic 126 configured to enable the processor to perform the functions associated with the RF tag processing system described herein. Specifically, the control logic may be connected to a memory 128 containing software and/or data that will enable the computer system to process RF tag responses, individually and collectively, to enable three dimensional information to be extracted from the RF tag responses.
In the embodiment shown in FIG. 9 , the memory 128 includes RF tag software 130 enabling the RF processing system to maintain a correlation between RF tags and the articles with which they are associated. Many commercial systems have been developed to track articles using RF tags, and the RF tag software 128 in FIG. 9 may be configured to implement article tracking features in a manner similar to one or more of these commonly available systems. For example, the RF tag software may access a database of RF tags 132 and associated articles so that the system may provide information associated with particular articles to an operator of the RF processing system. Similarly, the RF tag software may have access to a database of RF tag readers 134 to determine the physical location of the readers that are providing RF tag information to the RF tag processing system.
The RF tag processing system shown in FIG. 9 also includes multiple power coil RF tag direction determination software 136 . The software 136 may be a software module that is incorporated into the RF tag software 130 or may be a stand-alone software program. The software 136 may be configured to perform the process shown in FIG. 7 and described in greater detail in connection with FIGS. 3-4 . In connection with this, the software 136 may access the RF tags database 132 to obtain characteristic and/or calibration information for particular tags, and may also access the RF tag reader information database 134 to obtain information about particular RF tag readers so that it can determine how the power coil information should be interpreted for a particular RF tag and with reference to the particular RF tag reader that registered the RF tag response.
The RF tag processing system may also include multiple RF tag article signature software 138 which, like the software 136 , may be incorporated into the RF tag software 130 or may be a stand-alone software program. The software 138 may be configured to perform the process shown in FIG. 8 and described in greater detail in connection with FIGS. 5-6 . In connection with this, the software 138 may be configured to receive RF tag signature information associated with an article, or to create a RF tag signature from multiple RF tags associated with a given article, and optionally then to compare the RF tag signature with a previous RF tag signature for the article. RF tag signatures from combinations of RF tags associated with a given article may be stored in an article signatures database 140 to enable different signatures for the same article to be compared at different points in time to detect tampering with the article.
The control logic 126 may implement one or more processes in addition to those shown here, or as an alternative to those shown here, to enable the computer system to implement an RF tag processing system that can generate and/or use three dimensional RF tag signatures. Many other standard components of the computer system have not been illustrated to avoid obfuscation of the more relevant aspects. As is well known in the art, a complete computer system will include many additional components that have not been shown here.
The functions described above may be implemented as a set of software program instructions that are stored in a computer readable memory and executed on one or more processors. However, it will be apparent to a skilled artisan that all logic described herein can be embodied using discrete components, integrated circuitry such as an Application Specific Integrated Circuit (ASIC), programmable logic used in conjunction with a programmable logic device such as a Field Programmable Gate Array (FPGA) or microprocessor, a state machine, or any other device including any combination thereof. Programmable logic can be fixed temporarily or permanently in a tangible medium such as a read-only memory chip, a computer memory, a disk, or other storage medium. Programmable logic can also be fixed in a computer data signal embodied in a carrier wave, allowing the programmable logic to be transmitted over an interface such as a computer bus or communication network. All such embodiments are intended to fall within the scope of the present invention.
It should be understood that various changes and modifications of the embodiments shown in the drawings and described in the specification may be made within the spirit and scope of the present invention. Accordingly, it is intended that all matter contained in the above description and shown in the accompanying drawings be interpreted in an illustrative and not in a limiting sense. The invention is limited only as defined in the following claims and the equivalents thereto.
|
Method and systems to detect tampering in a physical article are described herein. A method includes receiving, at a first point in time, at least two response signals from at least one RF tag in a set of RF tags associated with the physical article; forming a first response signature for the physical article based on the received response signals; receiving a second response signal from at least one other RF tag in the set of RF tags associated with the physical article at a second point in time; assessing a relative spacing between the RF tags associated with the physical article has changed from the first point in time to the second point in time; and determining tampering of the physical article as a result of the spacing assessment.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to communications. Particularly, the present invention relates to frequency discrimination in a communications environment.
[0003] 2. Description of the Related Art
[0004] CDMA communications systems typically use directional antennas located in the center of a cell and broadcasting into sectors of the cell. The antennas are coupled to base stations that transmit control the cells. The cells are typically located in major metropolitan areas, along highways, and along train tracks to allow consumers to communicate both at home and while traveling.
[0005] Even though both a mobile and a base station are transmitting on a frequency that is known to each, there are factors such as multipath errors and Doppler shift in the frequency that introduce errors in the frequency that is received. For example, if a mobile is approaching a base station, the Doppler effect increases the signal's frequency as observed by the base station. If the mobile is moving away from the base station, the base station observes a signal having a frequency that is less than the frequency transmitted by the mobile. The amount of frequency shift is a function of the speed of the mobile.
[0006] Another source of frequency error is the fact that the two local oscillators (one at the base station and one at the mobile that are used for generating the “clock” signal) can never be operating at exactly the same frequency. Typically, the mobile uses a less expensive local oscillator that can introduce a frequency error of up to 10 KHz when the carrier frequency is around 2 GHz.
[0007] During communication, the base station transmits a pilot channel that is received by the mobile. The pilot channel, comprised of pilot symbols, contains no information. The mobile utilizes the pilot symbols to generate time, frequency, phase, and signal strength references.
[0008] In some systems, the mobile also transmits a pilot signal. The mobile's pilot signal is then similarly used by the receiving base station to generate time, frequency, phase, and signal strength references relative to the mobile.
[0009] In order for a base station to communicate with a mobile on a certain frequency, both need to use a frequency discriminator in a frequency-tracking loop.
[0010] [0010]FIG. 1 illustrates a typical prior art frequency-tracking loop (FTL) 100 . This figure shows a signal, Δf, entering a summer 101 . Δf represents the frequency error present in an incoming signal of successive pilot symbols. The summer 101 subtracts from Δf an initial estimate Δ{circumflex over (f)}.
[0011] Frequency discriminator 105 is known and operates on the frequency error associated with successive pilot symbols. The value of each pilot symbol is herein represented by variable y k . The period of each symbol y k is denoted by T S .
[0012] An incoming sequence of pilot symbols are accumulated after input signal rotation to result in a residual frequency error, out of summer 101 , equal to Δf res . A pilot symbol y k having residual frequency error Δf res k may be denoted as:
y
k
=Ae
j2πT
s
Δf
res
k
+n
k
[0013] where n k is the additive noise corrupting the k th symbol and A is a complex amplitude that is a function of, among other things, the current channel attenuation. It is assumed that fading is slow enough so that successive symbols have roughly the same complex amplitude.
[0014] A time constant (τ) is herein defined as the time it takes FTL 100 to converge to 1/e of an initial frequency error. A pull-in range conventionally defines a maximum initial frequency error for which FTL 100 is able to converge. A design goal is to minimize time constant τ, all the while maximizing the pull-in range, to maintain the standard deviation of the frequency error under steady-state conditions to within desirable levels.
[0015] A loop filter L(z) 110 , series coupled to the output of frequency discriminator 105 , is used to adjust the time constant τ, pull-in range, and standard deviation of the frequency error.
[0016] A known type of frequency discriminator 105 is a cross product discriminator, the operation of which may be expressed as Δf res cp =imag(y k y k-1 *), with * denoting complex conjugation. From the above equation for y k and Δf res cp we get
Δ f res cp =|A| 2 sin(2π T s Δf res )+ n,
[0017] with n being a noise component. Thus as Δf res approaches 1/2T s , the value of sin(2πT s Δf res ) becomes smaller, resulting in the following condition:
[0018] First, the pull-in range of the FTL 100 is smaller than a theoretical pull-in range due to the effects of noise. Second, when the initial frequency error Δf is greater than ½ the theoretical pull-in range, FTL 100 takes a long time to converge to 1/e of an initial frequency error Δf.
SUMMARY OF THE INVENTION
[0019] The invention encompasses a process and apparatus for improved frequency discrimination. In particular, the invention provides a frequency tracking loop (FTL) providing a large effective pull-in range and fast convergence characteristics when an initial frequency error greater than ½ a theoretical pull-in range is detected.
[0020] In an embodiment, a cross product is first determined on an input to the FTL. This cross product is of form imag(y k y k-1 *), where y k is one sample or symbol of the received signal and y k-1 is a preceding symbol. A dot product, expressed as real(y k y k-1 *), is then also determined.
[0021] When the cross product is greater than a predetermined threshold, the cross product is decremented by the product of the dot product multiplied by a predetermined constant value. In a specific implementation, a predetermined threshold of value zero and a predetermined constant value in the range of 0 to 5 are selected.
[0022] Conversely, when the cross product is less than the selected predetermined threshold, the cross product is incremented by the product of the dot product multiplied by the predetermined constant value. The calculation of and incrementing and decrementing of the cross product is generated by a frequency discriminator. The output of the frequency discriminator is used to derive a residual frequency error for an incoming signal comprised of successive pilot symbols. Successive symbols signals are fed into the frequency discriminator and the previously derived residual frequency error used to adjust the output of the frequency discriminator that then provides a new output to the FTL.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a general block diagram of a known frequency-tracking loop (FTL).
[0024] [0024]FIG. 2 shows a more detailed block diagram of the frequency discriminator in FIG. 1, constructed in accordance with the present invention.
[0025] [0025]FIG. 3 shows a block diagram of a mobile station incorporating a FTL including the frequency discriminator of the present invention.
[0026] [0026]FIG. 4 shows a block diagram of a base station incorporating a FTL including the frequency discriminator of the present invention.
[0027] [0027]FIG. 5 shows a plot of the response of the frequency discriminator of the present invention compared to a known frequency discriminator.
[0028] [0028]FIG. 6 shows a plot of the residual frequency and a first initial frequency error as a function of time, assuming a first pilot strength, derived using the frequency discriminator of the present invention.
[0029] [0029]FIG. 7 shows another plot of the residual frequency error as a function of time, assuming a second pilot strength and the first initial frequency error, derived using the frequency discriminator of the present invention.
[0030] [0030]FIG. 8 shows a plot of the residual frequency error as a function of time, assuming a second initial frequency error, and the first pilot strength.
[0031] [0031]FIG. 9 shows a plot of the residual frequency error as a function of time, assuming a second/third initial frequency error, and the second pilot strength.
[0032] [0032]FIG. 10 shows a block diagram of a frequency discriminator for use with signals having low signal-to-noise ratios.
DETAILED DESCRIPTION
[0033] A frequency discriminator characterized by the following description provides a large effective pull-in range and fast convergence in comparison to known cross-product discriminators.
[0034] In accordance with an embodiment, the frequency includes both a simple cross product discriminator and a dot product discriminator. As used above, the cross product discriminator, denoted as cp, is expressed as:
cp=imag ( y k y k-1 *)
[0035] where y k is the k th pilot symbol in a renewed signal and y* k-1 is the complex conjugate of the k th −1 pilot symbol.
[0036] A dot product discriminator, denoted as dp, by convention is expressed as:
dp=real ( y k y k-1 *)
[0037] From the above, a frequency discriminator in accordance with an embodiment, to be derived in further detail below shall be expressed as:
Δ{circumflex over (ƒ)} new res = cp when (dp < θ) if (cp > 0), then Δ{circumflex over (ƒ)} new res = Δ{circumflex over (ƒ)} new res −α · dp else Δ{circumflex over (ƒ)} new res = Δ{circumflex over (ƒ)} new res +α · dp end end
[0038] where α and θ are constants whose values are design parameters based on a desired system.
[0039] In a first embodiment, α is in the range of 0 to 5. For α=0 the frequency discriminator collapses to a simple cross product discriminator. This can be seen by substituting 0 for α in the above expression for Δ{circumflex over (f)} res new .
[0040] In another embodiment, a is chosen to be a power of 2. This is derived in a frequency discriminator hardware-specific implementation where multiplication with α, where α is a power 2, becomes a simple left shift operation.
[0041] In one embodiment, θ is in the range of a real number that is less than 0. However, other ranges for θ can be used as well.
[0042] It should be further appreciated that the frequency discriminator operation described herein maybe implemented by a digital signal processor (DSP). Also, the dot product measurement may be calculated in parallel with the cross product measurements using hardware. The “if” statements can be implemented as multiplexers which use the sign bits of the cp and the dp calculation as output selectors.
[0043] A hardware block diagram of one embodiment of the frequency discriminator is illustrated in FIG. 2. Those skilled in the art will recognize that alternate embodiments may encompass different hardware variations to arrive at the same desired result.
[0044] The frequency discriminator of FIG. 2 includes a cross product block 201 and a dot product block 202 . Both blocks 201 and 202 receive as inputs, sequential pilot symbols y k and y k-1 .
[0045] In the illustrative embodiment, the output cross product generated by cross product block 201 is a real value (as opposed to a complex value). The real value is expressed as cp=real(y k )real(y k-1 )+imag(y k )imag(y k-1 ).
[0046] The output dot product block ( 202 ) also generates a real value. This value is expressed as dp=imag(y k )real(y k-1 )−real(y k )imag(y k-1 ).
[0047] Output cross product (cp) is fed to the new (0) input of the first multiplexer 235 , as shown. In the present example, when α=0, a simple cross product is output by the frequency discriminator 105 .
[0048] Output dot product (dp) is fed to the zero (0) input of a first multiplier 215 where it gets multiplied by α. The output of the first multiplier 215 is input to a second multiplexer 225 . The output of the first multiplier 215 is also input to a second multiplier 220 where the sign of the αdp signal gets inverted by multiplying the input with − 1 . The output of second multiplier 220 is also input to the second multiplexer 225 . A select input of second multiplexer 225 is received from decision block 205 .
[0049] When the output from decision block 205 is true, (i.e., cp<0), a logic high is generated and the non-inverted αdp signal is output from multiplexer 225 . When not true, i.e. cp>0, the inverted αdp signal is output by multiplexer 225 .
[0050] The second multiplexer 225 output is coupled to summer 230 and either αdp or (−αdp) is added to output. The output from summer 230 is input to one (1) input of first multiplexer 235 .
[0051] Referring to the bottom of FIG. 2, the output of decision block 210 outputs a logic high when the condition dp<θ holds true. A logic high signal as a select input to the first multiplexer 235 , will cause the first multiplexer 235 . This is to select the output of summer 230 . When the dot product is 0, the condition is false and the cross product is selected as the output to first multiplexer 235 , and decision block 210 selects the 0 input of the first multiplexer 235 .
[0052] It should be understood that the above-described signal selection process may be implemented in various programming languages. In one embodiment, the process can be implemented in the “C” programming language, and is expressed by:
if(dp<θ) if(cp>0) cp−=alpha*dp; else cp+=alpha*dp; end end.
[0053] The exemplary frequency discriminator can be used in any situation that requires a low-complexity frequency estimator, such as in the frequency-tracking loop of FIG. 1. In one embodiment, the frequency discriminator is used in a FTL in a mobile communication device such as a mobile telephone. In a mobile telephone, the frequency discriminator is used on the downlink direction of the communication, i.e. the base station to mobile link.
[0054] Because the signal-to-noise ratio (SNR) of a downlink pilot is relatively high, a frequency discriminator as described above is particularly desirable.
[0055] The above frequency discriminator can also be used on the uplink direction, i.e., the mobile-to-base station link. In the uplink, the SNR of a pilot is very low. For example, a pilot SNR (E c /I O ) might be as low as −38 dB. Frequency discriminators described above may be used in a low SNR uplink.
[0056] However, compensating for the low SNR to adjust lower SNR, it might be desirable to increase the accumulation length of the pilot symbols (i.e., increase Ts). Alternatively, low-pass filtering the cross product and the dot product will also work. Using such an embodiment changes the above equations. Factoring in a low SNR, a frequency discriminator for use in an uplink for example may be expressed as follows:
cp 0 = imag(y k y * k−1 ) dp 0 = real(y k y * k−1 ) cp = (1 − β)cp + βcp 0 dp = (1 − β)dp + βdp 0 Δ{circumflex over (ƒ)} new res = cp if (dp < θ) if(cp > 0) Δ{circumflex over (ƒ)} new res = Δ{circumflex over (ƒ)} new res −α · dp else Δ{circumflex over (ƒ)} new res = Δ{circumflex over (ƒ)} new res +α · dp end end
[0057] where β is constant between 0 and 1 and the cp and dp terms are outputs of one-tap IIR filters. For very low pilot SNRs, a β closer to 0 is best. For β=1, the above expression yields the same discriminator result as the high SNR frequency discriminator expression described earlier.
[0058] [0058]FIG. 10 illustrates a frequency discriminator in an embdodiment of the present invention as might be found on the uplink of a communication system. This block diagram is not discussed in detail since it is substantially similar to the frequency discriminator of the downlink as illustrated in FIG. 2. However, the frequency discriminator for the uplink incorporates a one-tap IIR filter 1001 at the output of the cross product generator and a second one-tap IIR filter 1005 at the output of the dot product generator. Filters 1001 and 1005 are responsible for low-pass filtering the cross products and dot products, respectively.
[0059] A block diagram of a mobile station incorporating the frequency discriminator of the present invention is illustrated in FIG. 3. The mobile station includes of a transmitter 302 and receiver 301 coupled to an antenna 303 . Transmitter 302 modulates the aural signals from the microphone 305 for transmission. Depending on the type of communication device, transmitter 302 or like device may digitize the aural signal from a microphone 305 prior to modulation. Antenna 303 then radiates the signal to the intended destination.
[0060] Receiver 301 incorporates an FTL 301 ′ constructed as described herein. Receiver 301 is responsible for receiving and demodulating signals received over antenna 303 . FTL 301 ′ is used within receiver 301 to lock the receiver on to a desired received frequency. In some communication devices, the receiver may be responsible for converting received digital signals into their analog equivalent for transmission by a speaker 306 .
[0061] The communication device is controlled by a controller 304 such as a microprocessor or other controlling device. The controller is coupled to and controls the transmitter 302 and receiver 301 functions.
[0062] A display 307 and keypad 308 are coupled to the controller 304 for displaying information entered by a user on the keypad 308 . For example, the user may enter a telephone number using the keypad 308 that is displayed on the display 307 and subsequently transmitted to a base station using the transmitter 302 .
[0063] In one embodiment, the communication device is a cellular radiotelephone incorporating the frequency discriminator of the present invention. Alternate embodiments include personal digital assistants with communication capabilities and computers with communication capabilities such that they are required to lock on to a desired frequency using an FTL.
[0064] A block diagram of a base station incorporating the frequency discriminator as described herein is illustrated in FIG. 4. The base station is comprised of a transmitter 401 that receives a signal from the network to which the base station is coupled. The transmitter 401 modulates the signal and transmits the signal, at the proper power level, over the antenna 405 .
[0065] A received signal is received by the antenna 405 and distributed to the receiver 403 having a frequency discriminator 403 . Receiver 403 tracks the frequency of the received signal using FTL 403 and demodulates any appropriate signals. The demodulated signals are sent over the network that is coupled to the base station to the appropriate destination.
[0066] In one embodiment, the base station illustrated in FIG. 4 operates in a cellular environment. Alternate embodiment base stations can be any base station that allows a mobile, wireless communication device to communicate with a fixed infrastructure.
[0067] [0067]FIG. 5 illustrates a plot of the frequency response of a frequency discriminator in accordance with an embodiment operation under various values of a. More specifically a plot of Δ{circumflex over (f)} res new is shown using T s = 256 /3.84×10 6 sec. and assuming no noise. The curve corresponding to α=0 represents a regular cross-product discriminator. It can be seen from FIG. 5 that when α=2, the discriminator output closely approximates f(2πT s Δf res )=2πT s Δf res and can be assured from this that we have a very efficiently performing frequency-tracking loop. For each of the curves of FIG. 5, θ is assumed to be of value zero (0).
[0068] The output of the illustrative embodiment frequency discriminator is large for values of Δf res larger than half a pull-in range. The small value cross discriminator results of conventional solutions are ignored. The present frequency discriminator provides a larger effective pull-in range while also converging very fast when an initial frequency error is large.
[0069] FIGS. 6 - 9 illustrate results from simulations using a frequency discriminator as described herein. In each simulation, the pilot symbol accumulation length is assumed to be N=256 chips. This results in a T s = 256 /3.84×10 6 seconds, which is equivalent to a theoretical pull-in range of ±7.5 kHz.
[0070] [0070]FIG. 6 illustrates a plot of residual frequency error, f, as a function of time generated by each of two different frequency discriminators, one a conventional cross product frequency discriminator and the other a frequency discriminator as described herein. An initial frequency error of 7.4 kHz and pilot SNR of E C /I O =−26 dB is assumed.
[0071] It can be seen that, with the assumed initial frequency error, a conventional cross product discriminator will cause the FTL output to diverge. On the other hand, an FTL using a frequency discriminator of a present embodiment converges relatively quickly.
[0072] [0072]FIG. 7 illustrates what happens when the pilot strength is increased to E C /I O =−20 dB. While both present invention and prior art FTLs eventually converge, the presently disclosed frequency discriminator converges substantially faster than a cross product discriminator.
[0073] The plots of FIGS. 8 and 9 are similar to FIGS. 6 and 7 respectively. FIG. 8 better illustrates residual frequency error as a function of time with a pilot SNR of E C /I O =−26 dB. FIG. 9 illustrates frequency error with a pilot SNR of E C /I O =−20 dB. In both FIGS. 8 and 9, the initial frequency error is changed to 7.0 kHz. From these plots, it can be quickly seen how present embodiment frequency discriminator yields converges results that are substantially faster than conventional cross product discriminators.
[0074] The frequency discriminator of the present invention is not limited to any various embodiments of the specific air interface. One implementation utilizes an embodiment in a wideband code division multiple access (WCDMA) system. One skilled in the art would readily recognize that the invention has utilized any number of varying air interfaces such as general CDMA system, cdma2000, FDMA, and TDMA.
[0075] In summary, the frequency discriminator of the presently described embodiment is a relatively low complexity frequency estimator that can be used in any system requiring frequency estimation. By using dot product calculations, either in isolation or in combination with dot product measurements, results in an improved solution requiring only comparisons, additions, and simple multiplications at best.
[0076] It should be noted that in all the embodiments described above, method steps can be interchanged without departing from the scope of the invention.
[0077] Those of skill in the art will understand that information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.
[0078] Those of skill will further appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
[0079] The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
[0080] The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal.
[0081] In the alternative, the processor and the storage medium may reside as discrete components in a user terminal. The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded with widest scope consistent with the principles and novel features disclosed herein.
|
A cross product is determined for a received signal. A dot product is also determined for the received signal. If the cross product is greater than a predetermined threshold, the cross product is decremented by the product of the dot product multiplied by a constant value. If the cross product is greater than or equal to the predetermined threshold, the cross product is incremented by the product of the dot product multiplied by the constant value. The incrementing or decrementing is continued until the frequency error approaches a minimum value.
| 7
|
BACKGROUND OF THE INVENTION
Various systems have been developed for dispensing measured quantities of liquids by many different means. The most precise types use a positive displacement pump, usually with a controlled stroke piston, to fill and empty a container of the required volume with each stroke. The piston can be driven by mechanical means, such as a crank drive or similar reciprocating device, or by compressed air or the like. With mechanical drives the apparatus is bulky, complex and requires considerable maintenance. In apparatus operated by high pressure means, it is difficult to control leakage and avoid contamination of the liquid by propellant gas. Some systems dispense several liquids selectively through a common outlet, in order to reduce the bulk of the apparatus and permit the use of common drive means. Contamination is again a problem and breakdown of one component may require shut down and servicing of the entire system.
SUMMARY OF THE INVENTION
The apparatus described herein is so simple and compact that a separate system may be used for each beverage to be dispensed. The system uses a positive displacement piston pump driven by low pressure gas, such as Freon, from an easily replaceable pressurized can. A push button, or similar means, initiates an operating cycle to draw liquid from a reservoir into a pump chamber and then dispense the liquid through a suitable outlet. The volume delivered is controlled by an adjustment in the stroke of the piston, which is driven and returned by the low pressure gas. Once a cycle is started the push button is inoperative until the cycle is completed.
All valves for the propellant gas and for the liquid are contained in the compact pump body and are readily accessible for servicing. The operations are automatically counted and the system shuts off if the liquid level is too low to ensure a full volume delivery, the liquid path being kept full at shut off so that there is no break in correct volume of each delivery when the reservoir is replenished.
The primary object of this invention, therefore, is to provide a new and improved beverage dispensing system.
Another object of this invention is to provide a beverage dispensing system by which a precise quantity of a beverage is delivered by low pressure gas actuated means.
Another object of this invention is to provide a beverage dispensing system wherein the pump and all associated valves are contained in a single compact unit, with the propulsion gas and beverage sections separated.
A further object of this invention is to provide a beverage dispensing system having means for preventing delivery of a short measure.
Other objects and advantages will be apparent in the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates the complete system in diagrammatic form.
FIG. 2 is an enlarged view, partially cut away, of the replaceable pressurized gas source and adapter.
FIG. 3 is an enlarged view, partially cut away, of the liquid reservoir and level sensing valve.
FIG. 4 is an enlarged top plan view of the pump unit of FIG. 1.
FIG. 5 is an enlarged sectional view taken on line 5--5 of FIG. 4.
FIG. 6 is an enlarged end view of the pump unit, as taken from the right hand end in FIG. 1.
FIG. 7 is a sectional view taken on line 7--7 of FIG. 6.
FIG. 8 is a sectional view taken on line 8--8 of FIG. 6.
FIG. 9 is a sectional view similar to FIG. 7, but with the pump partially through a delivery stroke.
FIG. 10 is a sectional view taken on line 10--10 of FIG. 6.
FIG. 11 is a similar sectional view but with the pump in operation, as in FIG. 9.
FIG. 12 is an end view of the pump unit, partially cut away, as taken from the right hand end of FIG. 4.
FIG. 13 is a longitudinal sectional view of the cut off valve of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The system as illustrated in FIG. 1 includes a beverage reservoir 10 having a supply outlet 12, from which a supply hose 14 leads to the inlet 16 of a pump unit 18. The pump unit has an outlet 20 with a delivery hose 22 leading to a nozzle 24, from which the beverage is dispensed. The beverage may be supplied directly from a bottle 26 inverted in the reservoir 10.
Pump unit 18 is actuated by low pressure gas from a source such as a pressurized cartridge 28, removably held in an adapter 30. The pressure line 32 from the adapter leads to the pump unit 18 through a shut off valve 34, which is controlled by a low liquid level sensing means, hereinafter described in detail, through a bleed line 36 from the supply outlet 12. A pressure indicator 38 of any suitable type is installed in the pressure line 32 to indicate low pressure in cartridge 28, so that it may be replaced when necessary. An actuating switch 40 is connected to the pump unit 18 to start a delivery cycle and a counter 42 keeps count of the cycles.
Adapter 30, illustrated in FIG. 2, is a block member having a threaded bore 44 to receive the threaded neck 46 of cartridze 28. A port 48 opens from bore 44 into a transverse channel 49, the pressure line 32 being secured in one end of the channel. At the other end of channel 49 is a pressure relief valve 50 with a brust diaphragm 52, or similar means, to prevent damage to the system from excess pressure. A puncture pin 54, seated in the adapter, extends through port 48 to open the valve of the cartridge 28 as it is inserted, the arrangement being well known.
Reservoir 10 is a cylindrical container, the upper end of which will hold most standard sized beverage bottles in inverted position. The lower end of the reservoir, illustrated in FIG. 3, contains a float 56 which floats on the liquid 57, and has a valve plug 58 extending below the float. The closed lower end 60 of reservoir 10 has a sump opening 62, from which a channel 64 leads to outlet 12. When the liquid falls below a predetermined level, valve plug 58 enters opening 62 and shuts off the liquid supply. However, a small bleed port 66 extends from the interior of the reservoir into channel 64 to allow a slow leak of liquid, the purpose of which is hereinafter described. Outlet 12 has a Tee connection 68, to which supply hose 14 is connected. Also connected to channel 64 through Tee connection 68 is the bleed line 36, which provides for operation of shut off valve 34.
The shut off valve 34, illustrated in section in FIG. 13, contains an axially slidable valve spool 70, on one end of which is a piston 72 sliding in a cylinder 74. Bleed line 36 is connected to a vacuum port 75 communicating with cylinder 74. Valve spool 70 slides in a sleeve 76 which has an inlet port 78 and an axially spaced vent port 80 on one side, and an outlet port 82 on the other side. Pressure line 32 is connected across the shut off valve between inlet and outlet ports 78 and 82. The valve structure is conventional and may vary from the arrangement shown.
On the end of the valve spool opposite piston 72 is a reset button 84, which projects from the end of the valve. In the ON position, shown in full line, the reset button 84 is retracted, piston 72 is at the outer end of cylinder 74, and inlet port 78 is connected across the spool to outlet port 82. When a vacuum is applied through bleed line 36, the vacuum pulls piston 72 to the left, sliding the valve spool 70 and closing inlet port 78, while at the same time connecting outlet port 82 to the vent port 80. Pressure to the pump unit 18 is thus shut off and reset button 84 is extended, as in the broken line position, to indicate an OFF condition of the valve.
The shut off action is caused by low liquid level in reservoir 10, when valve plug 58 closes socket 62 while the pump is drawing liquid. The shut off of liquid causes the pump to empty channel 64 and draw a partial vacuum in bleed line 36, which actuates the shut off valve 34 and stops the pump. The cavitation is only momentary, because liquid leaks slowly through the bleed port 66 to refill channel 64. Thus the supply hose 14 remains filled with liquid while the pump is off, so that successive delivery cycles always supply a full measure of liquid. The system is reactivated by replenishing the liquid supply in reservoir 10 and depressing reset button 84 to open the shut off valve. For convenience, valve spool 70 has an annular bead 86 which rides over an O-ring 88 inset in sleeve 76, to provide a snap action for the reset button 84. The button may be distinctively colored or illuminated in a suitable manner to indicate low liquid level.
Pump unit 18 comprises a cylindrical body in the form of a cylinder 90 of glass, plastic, or the like, held between end blocks 92 and 94. The cylinder is seated agains O-rings 96 in the end blocks and the assembly is secured by bolts 98 between the blocks. End block 92 contains the inlet 16 and outlet 20, through which the liquid passes. As illustrated in FIG. 12, inlet 16 includes a socket 100 leading to an inlet port 102 which opens into cylinder 90. Socket 100 has a shoulder 104 on which an inlet valve element 106 is held by a retaining sleeve 108. Outlet 20 has a similar socket 110 with an outlet port 112 opening from cylinder 90. Socket 110 has a shoulder 114 on which an outlet valve element 116 is held by a retaining sleeve 118. The valve elements are illustrated as being rubber duckbill types, but could be any suitable types which open and close under low pressure.
End block 94 has an integral barrel 120 extending coaxially into cylinder 90. Slidably mounted in cylinder 90 is a hollow piston 122 which telescopes over barrel 120 and has a closed end 124 and an open end 125. An O-ring 126 seals the piston to the cylinder. On the end of barrel 120 remote from the end block is an end ring 128, having an external O-ring 130 which seals against the inside of piston 122. Secured in the open end 125 of the piston is a sealing ring 132, with an internal O-ring 134 which seals against barrel 120. The piston is circumferentially spaced from barrel 120 and the space between end ring 138 and axially spaced sealing ring 132 forms an annular cushion chamber 136. Piston 122 also has an axial boss 138 which fits loosely into an axial bore 139 in barrel 120. Threaded into boss 138 through closed end 124 is a stop screw 140, which strikes the end block 92 when the piston is extended, and is adjustable to control the stroke of the piston. End block 92 has an access bore 142 for adjustment of the stop screw 140, the access bore being sealed by a closure plug 144.
Inset in end block 94 is a valve body 146 coaxial and communicating with bore 139. The valve body has an external flange 148 which seats against the outer face of end block 94 and is secured by retaining screws 150. Axially slidable in valve body 146 is a spool 152 having a pair of axially spaced channels 154 and 156. The end of the spool 152 adjacent bore 139 has an enlarged head 158 and a central bore 160 extends through the spool. In the end of central bore 160 adjacent the outer end of the valve body is a metering orifice 162, preferably in a replaceable element to allow adjustment of bleed rate. Valve body 146 has a pair of axially spaced inlet ports 164 and 166 and a vent port 168 opening to the channels in the valve spool. Vents 170 and 172 also connect vent port 168 to the exterior of end block 94, clear of the piston.
Valve body 146 has internal bypass grooves 174 which bypass head 158 from bore 139 to the vent port 168, when spool 152 is in the starting position toward the outer end of the valve body. Also in the valve body are bypass grooves 176 which bypass the other end of the spool 152 from channel 154 to the outer end, when the spool is in the operating position toward bore 139. To provide a snap action of spool 152 in its two positions, the valve body 146 has an internal rib 175 adjacent bore 139, and head 158 has an external O-ring 177 which rides over the rib.
Barrel 120 has a longitudinal duct 178 opening to the cushion chamber 136 adjacent end ring 128, the duct being connected by a further duct 180 to one side face, the coupling face 182 of end block 94. The coupling face is where the various connections are made for the gas actuating system through a manifold 184, which is secured against the face.
Inset in the end block 94 are two control valves 186 and 188 spaced on opposite sides of the axis and adjacent coupling face 182. Control valve 186 has a cylindrical body 190 with a slidable spool 192, the spool having a plunger 194 which extends into cylinder 90 and is biased to the extended position by a spring 196. Control valve 188 is identical in construction and the parts are similarly numbered.
Duct 180 connects to one side of control valve 186 and continues to meet duct 178. A duct 198 leads from coupling face 182 to the other side of control valve 186, and a similar duct 200 leads to the same side of the control valve and on to inlet port 166. However, as shown in FIG. 8, duct 200 is closed by a plug 202 at coupling face 182, so that only an internal connection is made between valve 186 and inlet port 166. A central duct 204 extends from the coupling face to inlet port 164 and a duct 206 extends to one side of control valve 188. Two other ducts 208 and 210 extend from the coupling face to the other side of control valve 188. Through the manifold 184, connections are made to apply supply pressure from line 32 to ducts 180 and 210. Duct 198 is coupled to duct 204 through actuating switch 40, duct 206 is connected to counter 42 and duct 208 is vented to atmosphere, as indicated in FIG. 5. Typical connections in the manifold are indicated in FIGS. 6 and 8, but may be arranged in any suitable manner for convenience.
OPERATION
In the starting position, piston 122 is retracted, as in FIGS. 7 and 10, the open end of the piston engaging plungers 194 and holding the spools 192 of control valves 186 and 188 retracted. Spool 152 is also retracted to the outer end of its valve body. With sufficient liquid in the reservoir to allow shut off valve 34 to remain open, supply pressure is applied through line 32 and ducts 180 and 178 into cushion chamber 136, holding the piston retracted. The control valve 186 is coupling the supply pressure from duct 180 to the actuating switch 40 through duct 198. Control valve 188 is closing off duct 210, so that the supply pressure there has no effect.
When actuating switch is pressed, starting pressure is applied through duct 204 to inlet port 164 and behind the spool 152, as indicated by the broken line arrow in FIG. 9. Due to the restriction of orifice 162, the initial pressure snaps the spool over rib 175 to the extended position, as in FIG. 9. The pressurized gas passes through orifice 162 at a controlled rate, through central bore 160 and bore 139 to drive the piston toward end block 92. Since the surface area of the closed end 124 is considerably more than the area of sealing ring 132, the pressure overcomes the standing pressure in cushion chamber 136. As the piston moves away from end block 94, the plungers 194 are free to move and springs 196 extend the spools 192 to operating position, as in FIG. 11. In control valve 186 this transfers the coupling of duct 180 from duct 198 to duct 200, which isolates the actuation switch 40 and prevents improper overlapping control action. Pressure through duct 200 is applied to inlet port 166 and passes through bypass grooves 176, as indicated by the full line arrow in FIG. 9, to sustain the driving force on the piston. The rate of delivery is controlled by the size of orifice 162, which can also be changed to compensate for the length of an extended liquid supply line in an installation which necessitates separation of the beverage supply from the pump.
In control valve 188, duct 210 is coupled to duct 206 and the counter 42 is actuated to record the cycle.
Piston 122 expells the liquid in the cylinder through outlet 20 and nozzle 24. When the piston reaches the end of its stroke, limited by stop screw 140, back pressure builds up inside the piston. Since the area of enlarged head 158 is greater than that of the small end of the spool 152, the back pressure snaps the spool back over rib 175 to the retracted position of FIG. 7. This opens bypass grooves 174 and allows the pressure to escape through vent port 168 and vents 170 and 172. Pressure is still being applied to cushion chamber 136 through duct 178 and this pressure, against sealing ring 132, retracts the piston. A fresh charge of liquid is drawn into the cylinder through inlet 16 as the piston retracts.
At the retraction end of the stroke, piston 122 engages plungers 194 and retracts spools 192, returning all valves to the starting position. In this last action, control valve 188 couples duct 206 to duct 208 and vents the pressure from counter 42 to complete the cycle.
Once the actuating switch is operated, the cycle is automatic and continues to completion, unless the shut-off valve stops the sequence as described above. In the pump unit, the pressurized gas and liquid circuits are isolated by multiple seals and there is no contamination problem. The propellant gas venting through vent 172 is at ambient pressure and will not break the seal of O-ring 126. The entire action is powered by the low pressure gas source, no other services or power connections being required. It has been found that Freon is a particularly suitable propellant and pressurized containers are readily available. The ease of replenishing both the liquid supply and the propellant makes the system practical for installation in many different places. All components are easily dismantled for cleaning and servicing, which is simplified by the small number of parts in the structure. The system can be packaged in a very compact unit to suit a specific installation and is completely self-contained, so that several systems can be used together for selection of multiple beverages. Malfunction of any one system does not affect the operation of the whole installation. The system is particularly suitable for use in aircraft, due to the light weight, compactness, ease of service and independence from aircraft power sources.
|
A beverage dispensing system which will deliver a precise, pre-set quantity of a selected beverage at each actuation. The system is operated by low pressure gas from a quickly replaceable source, and utilizes a controlled stroke piston pump which is driven and returned by the pressurized gas. All the valves for automatic operation of the punp are contained in the compact pump housing, but the gas and liquid sections are completely isolated to avoid contamination. The pump and valve unit contains a minimum of parts, all of which are readily accessible for cleaning and servicing. An automatic count of operations is maintained and the system shuts off when the liquid level is too low for a full serving.
| 1
|
[0001] This application claims the benefit of U.S. Provisional Application No. 60/557,852, filed Mar. 30, 2004, and to co-pending U.S. patent application Ser. No. 11/055,794 from which this application claims priority as a divisional application.
TECHNICAL FIELD
[0002] This invention relates generally to cotton harvesting machines including a cotton receiver for receiving and holding harvested cotton, and more particularly, to an expandable accumulator for a cotton receiver, which can be deployed to increase the capacity of a precompacting area of the receiver, and which can be folded or stored when not in use.
BACKGROUND ART
[0003] Commonly, cotton harvesting machines can unload harvested cotton into a container such as a trailer known as a boll buggy in the field, while remaining in the rows for harvesting the cotton plants. Essentially, a boll buggy is a container open on the top that is pulled by a tractor or other vehicle up to the cotton harvesting machine while in the field. The harvesting machine can be stopped and the boll buggy pulled alongside the cotton receiver, and the cotton in the receiver unloaded into the boll buggy. The cotton harvesting machine can then resume harvesting and the boll buggy is typically transported to a standard module builder located in an accessible location such as the end of the rows, and unloaded. As a result, the harvesting machine does not have to come out of the rows to unload when full. Newer cotton harvesting machines which compact and form or package the cotton into a unitary body or module as the cotton is conveyed into a cotton receiver on the machine, are typically required to unload the cotton module or compacted body of cotton at the end of the rows, or a location where the module or compacted body of cotton can be picked up by a module truck or the like for transport to the gin for processing. The end of the rows provides a suitable location, as the terrain is typically relatively level. It is undesirable to unload a module or compacted body of cotton in the field, as the field contains stalks and the ground is uneven as a result of being formed into raised beds for the plants.
[0004] A typical modern cotton harvesting machine with an on-board module building and/or packaging capability can produce a compacted module or body of cotton that can weigh between about 8,000 and about 11,000 pounds, depending upon crop conditions. Conventional cotton harvesting machines typically can hold a maximum of about 10,500 pounds. This large capacity allows both machines to make one or more passes in the field depending on row length and yield (pounds of cotton per acre). Conventional cotton harvesting machines can unload at any time, either in the field into a boll buggy, or at the end of the rows by driving up to a module maker and unloading the cotton into it. In contrast, for maximum efficiency, a cotton harvesting machine which can package or compact cotton into a unitary module or body, is desirably unloaded when the module or body is completely formed. Partial modules or bodies should only be unloaded when finishing up a field, and these should still be unloaded at the end of the rows in what is known as the turn row where the cotton harvesting machine turns around to enter new rows for harvesting the cotton therefrom Therefore, because of widely varying row lengths and yield conditions, there is a need for cotton harvesting machines to have the capability to hold cotton above the compactor apparatus to allow the operator to continue to harvest cotton until the end of a swath of rows or other suitable location for unloading, is reached.
[0005] Therefore, what is sought is apparatus and a method which overcomes the problems and provides the capability set forth above.
SUMMARY OF THE INVENTION
[0006] What is disclosed is a cotton accumulator for the cotton receiver of a harvesting machine, capable of receiving and holding harvested cotton at a location separate from that in which the cotton is compacted or otherwise formed into a unitary body or module, and then, after a compacted body or module of cotton is unloaded, will allow the collected cotton to fall or be conveyed into the lower compacting region for formation by compactor apparatus into the next compacted body or module.
[0007] The accumulator will preferably have a capability to be movable between a deployed position providing the sought after cotton holding capacity, and a stored position when not in use and for transport. The accumulator is preferably located in association with the upper region of the cotton receiver, in a precompacting area above the compactor apparatus, such that the compactor apparatus can serve to hold the cotton in the accumulator as compacted cotton in the receiver already is compacted or formed into a unitary body or module can be completed and unloaded. The accumulator can be moved between its deployed and stored positions using any suitable apparatus, such as one or more drivers, such as a fluid cylinder, winch, or mechanical actuator. The accumulator can also be moved between its positions by movement of the compactor apparatus, which can be of conventional, well known construction. The accumulator can be deployed manually, by operator action, or automatically, as desired or required.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a side view of a cotton harvesting machine including a cotton accumulator in a deployed position according to the invention;
[0009] FIG. 2 is a simplified side view of a cotton receiver of the machine of FIG. 1 , showing the accumulator in its deployed position above a cotton receiver of the machine and the flow of cotton therein;
[0010] FIG. 3 is another simplified side view of the cotton receiver, showing the accumulator in its stored position;
[0011] FIG. 4 is another simplified side view of the receiver with the accumulator in its stored position, showing airborne conveyance of cotton into the interior of the receiver;
[0012] FIG. 5 is a fragmentary side view of the receiver, showing the accumulator in its stored position, and a representative mechanism for moving the accumulator between its stored position and deployed position; and
[0013] FIG. 6 is another fragmentary side view of the receiver showing the accumulator moved to its deployed position by the mechanism of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring now to the drawings, in FIG. 1 a cotton harvesting machine 10 is shown, including a cotton accumulator 12 constructed and operable according to the teachings of the present invention on a cotton receiver 14 of the machine. Harvesting machine 10 includes a plurality of harvesting units 16 arranged in an array across a forward end 18 of machine 10 for harvesting cotton from plants as machine 10 is moved in the forward direction along rows of the plants (not shown). The harvested cotton is conveyed by air flows through an array of ducts 20 extending upwardly and rearwardly from units 16 to a precompacting area 22 of cotton receiver 14 , as denoted by arrows A, in the well known conventional manner.
[0015] Referring also to FIGS. 2, 3 and 4 , cotton receiver 14 is shown. Cotton receiver 14 is a structure of rectangular shape, including an interior compacting chamber 24 defined by a floor 26 , forward and rearward end walls 28 and 30 , and opposing side walls including a side wall 32 shown. End walls 28 and 30 , and the side walls including side wall 32 , extend upwardly from floor 26 to precompacting area 22 which defines a generally upwardly facing opening, which is occupied and enclosed by cotton accumulator 12 . Cotton accumulator 12 , end walls 28 and 30 , and the side walls are preferably constructed of an air permeable material, such as a mesh or perforated sheeting having holes or openings therein adequate for dissipation of air flow therethrough, but which will retain the cotton conveyed into compacting chamber 24 as denoted by arrows A.
[0016] Compactor apparatus 34 is shown in the upper region of interior compacting chamber 24 . Compactor apparatus 34 includes side-to-side extending cross bars 36 adjacent end walls 28 and 30 which extend through vertical slots 38 through the side walls, including side wall 32 , and are supported by a support structure 40 , including a pair of fluid cylinders 42 located beside the side walls, for moving compactor apparatus 34 upwardly and downwardly within chamber 24 , as denoted by arrow B in each of the figures. A substantially complete compacted body of cotton or module 44 is shown in each of FIGS. 2, 3 and 4 for illustration of usage of accumulator 12 . Essentially, in operation, as cotton denoted by arrows A is conveyed into interior chamber 24 , compactor apparatus 34 will be operated to move in the upward and downward direction denoted by arrow B, against the collected cotton to compact the cotton against floor 26 to gradually build a compacted body or module as represented by module 44 . As explained above, a completed compacted cotton module such as module 44 can have a weight of between about 8,000 and 11,000 pounds, and will be relatively large, having dimensions corresponding to those of compacting chamber 24 . It is an important objective of the use of compacting apparatus such as apparatus 34 and the making of compacted bodies and modules of cotton, such as module 44 , to reduce manpower and handling, and facilitate transport of the cotton from the field to the gin for processing. Currently, compacted bodies of cotton, such as module 44 , are preferably unloaded from machines, such as harvesting machines 10 , on a level surface, such as the ground at the end of the rows of a cotton field, to facilitate picking up and loading the cotton onto trucks used for transporting it. Cotton fields usually include rows of raised beds separated by spaces or channels for carrying irrigation water, and after picking typically include stubble and/or intact plants, which make an undesirable surface onto which to unload a compacted body or module of cotton, as it would greatly inhibit pickup and loading onto a transport truck. As a result, it is desirable to limit unloading to times when machine 10 has completed a swath of rows of cotton, at the turn row where the machine is turned around to proceed along a new swath of rows through the field. However, it has been often found that the interior compacting chamber such as chamber 24 of machine 10 will be filled, and/or a compacted body or module such as module 44 completed, before the end of the rows is reached. This is a problem as without extra cotton carrying capacity, the harvesting operation must be interrupted, the machine moved to a suitable unloading location, unloaded, and returned to the harvesting operation, or the completed module unloaded at an undesirable location in the field.
[0017] Cotton accumulator 12 overcomes the problems and shortcomings set forth above by providing added cotton receiving capacity to precompacting area 22 of cotton receiver 14 . In FIGS. 1 and 2 , cotton accumulator 12 is shown in a deployed position with a rearward end 46 thereof extended upwardly, denoted by arrow C in FIG. 2 , for increasing the interior volume of precompacting area 22 above compactor apparatus 34 for receiving cotton conveyed therein as denoted by arrows A, the cotton being held above module 44 by the compactor apparatus 34 . As a result, the harvesting operation can continue and the harvesting machine moved to a convenient and suitable unloading location such as the end of the rows being harvested, without interruption of the harvesting process. Then, after the body of cotton or module, such as module 44 is unloaded, the cotton collected in accumulator 12 above compactor apparatus 34 can be allowed to fall into, or be moved or conveyed into, the lower portion of chamber 24 for compaction into a compacted body or module in the above-described manner. Here, it should be noted that compactor apparatus such as apparatus 34 will typically include one or more rotatable augers capable of conveying cotton on top of apparatus 34 into the compacting chamber located therebelow, as is well known in the art. Such augers can be actuated to convey the cotton from accumulator 12 into the lower region of the chamber.
[0018] The embodiment of cotton accumulator 12 can have a variety of interior capacities, as required or desired for a particular application. The capacity of accumulator 12 shown is illustrated by dotted crosshatching and is shown having a triangular or wedge sectional shape, but could likewise have other shapes including a more rectangular shape, or a more curved or rounded shape. Accumulator 12 is shown in FIGS. 3 and moved downwardly to a stored position contained at least substantially within precompacting area 22 of receiver 14 when its use is not required. As shown in FIG. 4 , in this position, cotton can be conveyed into receiver 14 in the conventional manner as denoted by arrows A for compaction by compactor apparatus 34 . The illustrated embodiment of accumulator 12 has an upper wall 48 which is generally flat and covers the forward-to-rearward and side-to-side extent of accumulator 12 . Accumulator 12 includes a pair of side walls extending downwardly from upper wall 48 , as illustrated by side wall 50 , the side walls having a wedge shape which tapers divergently in the rearward direction. A rearward end wall 52 extends between upper wall 48 and the side walls including side wall 50 for enclosing the rearward end of accumulator 12 . Side walls 50 and end wall 52 can be of suitable construction, for holding cotton, including of a suitable mesh material or sheet material including holes therethrough for the passage of air but not the cotton, or of an alternative material including a solid sheet metal, or the like. Accumulator 12 has a forward end 54 which in this embodiment is pivotally connected to a forward end of receiver 14 in a suitable manner, for instance, by one or more hinges 56 to allow movement of accumulator 12 between its deployed and stored positions. Suitable seals can be provided as required between the lower periphery of accumulator 12 and walls 28 , 30 and 32 .
[0019] Accumulator 12 can be manually moved between its deployed and stored positions, or automatically moved using a suitable actuator or mechanism such as one or more fluid cylinders, a winch, or the like. FIGS. 5 and 6 illustrate one exemplary embodiment of a mechanism 58 for moving accumulator 12 between its stored position ( FIG. 5 ) and its deployed position ( FIG. 6 ). Mechanism 58 includes an arm 60 mounted by pivot 62 to the side of receiver 14 . Arm 60 includes a first end portion 64 pivotally connected to a rod 66 of a fluid cylinder 68 , and an opposite end portion 70 including a roller which contacts a downwardly facing surface of a plate 72 mounted along the side edge of accumulator 12 . Fluid cylinder 68 is pivotally connected to the side of cotton receiver 14 and when extended will pivot arm 60 about pivot 62 to pivotally move accumulator 12 about hinge 56 to the deployed position as shown in FIG. 6 . Similarly, when fluid cylinder 68 is retracted, arm 60 will be pivoted in the opposite direction to move accumulator 12 to its stored position as shown in FIG. 5 . Here, it should be noted that mechanism 58 is but one of any number of mechanisms that could be utilized for moving accumulator 12 between its deployed and stored positions, and therefore is in no way to be considered as limiting.
[0020] It will be understood that changes in the details, materials, steps, and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown.
|
A cotton receiver for a cotton harvesting machine and a method of operation of the same. The receiver includes a cotton compacting chamber, A precompacting area above the chamber, and an accumulator deployable upwardly from the precompacting area to increase the cotton holding capacity thereof. Compactor apparatus is located in the compacting chamber and is configured for holding cotton thereabove separate from cotton therebelow. The compactor apparatus is moavable downwardly against cotton therebelow for compacting it into a unitary body or module, including while holding cotton thereabove, and is controllably operable for conveying cotton held thereabove downwardly therethrough, subsequent to unloading a completed compacted body of cotton.
| 0
|
TECHNICAL FIELD
This invention relates to a faucet mixer valve for liquids incorporating a ball valve element and more particularly to a ball valve mechanism that has pivotable motion about a fixed longitudinal axis of the valve body and shaped ports to provide a desirable flow pattern based on the position of the ball valve.
BACKGROUND OF THE DISCLOSURE
Single handle faucets, commonly referred to as mixer valves, that control the flow of both hot and cold water have seen vast consumer acceptance. The faucets are commonly constructed such that a handle or knob is movable in two distinct direction to adjust the mix of hot and cold water and to adjust the volume rate or flow.
Two basic types of single handle mixer valves that have seen wide commercial acceptance are plate valves and ball valves. A ball valve faucet is renowned for reliable and durable one piece valve construction that is easily assembled. The handle is rigidly fastened to the ball valve element with no intermediate moving parts to provide for a durable and reliable construction. A plate valve faucet on the other hand offers a drive mechanism that allows motion of the handle in two predefined directions that has found worldwide commercial acceptance. This internationally accepted handle motion allows for an orbiting motion of the handle about a fixed axis of the valve body and a rocking, i.e. pivoting motion about a axis that moves with respect to the valve housing as the handle orbits about the fixed axis. The moving axis is perpendicular to the fixed axis of the valve housing.
A characteristic of this type of handle motion allows for the faucet to be turned off and the mix ratio of hot and cold water to be remembered by the location of the handle so that when the faucet is turned back on, one has the option of obtaining the same mix of hot and cold water flow through the faucet. This type of motion has made plate valve faucet commercially successful even in view of the more complicated linkage necessary between the handle and plate valve element.
Recently, ball valves have been devised that allow the handle to operate in the same fashion as the above described plate type mixer valves. The system is disclosed in U.S. Pat. No. 4,449,551 issued to Lorch on May 22, 1984. Another system is disclosed in PCT application PCT/US91/07816 filed on Oct. 22, 1991 by Dr. Alfons Knapp and is incorporated herein by reference. These systems combine the advantage of an ergonomic desirable handle motion with the high reliability of a ball valve faucet design.
Besides reliability of the faucet, a mixing valve must possess other characteristics to be commercially acceptable. The maximum flow rate must be sufficiently great and the noise level of operation must be sufficiently low. Another characteristic is that the faucet must operate in an ergonomic friendly or intuitive way. The ergonomic friendly characteristic has several identifiable qualities. Firstly, the flow rate and temperature mix must be predictable based on continuous motion of the handle. No abrupt or sudden changes in either flow rate or temperature mix is acceptable based on small amounts of motion of the handle. It is desirable that when the temperature mix is adjusted, the flow rate remain approximately constant. On the other hand, when the flow rate is adjusted, substantial, sudden and unpredictable temperature change is not acceptable. A dead zone at the cold end of the handle motion should exist where no mixing of hot water occurs for a limited angular motion of the handle from the full cold position.
It is desirable that a comfort zone exist whereby in a mixed position, an area of greater movement of the handle is needed to produce a predetermined temperature change as compared to handle movement in the hot or cold region. The comfort zone allows the faucet to be more finely adjusted when the temperature is within a certain range. As such, the graph profile of the handle motion plotted against temperature of discharged water resembles an s-curve. However, the comfort zone must not be overly flat, otherwise insufficient change of temperature occurs and an operator then overcompensates with excessive handle motion thereby leaving the comfort zone and receive surprising temperature changes in the discharged water. The handle motion for volume at a predetermined comfort temperature also desirably produces no temperature change.
The above desirable qualities must all be achieved by choosing the proper size ball valve element, defining the drive motion of the handle to adjust volume and temperature of the ball valve element, and prescribing the range of angular and rotational motion for the two defined drive motions of the handle. The correct locations and configurations of the inlet ports of the valve housing and the inlet openings of the ball valve element also provide the above desirable qualities.
The selection of the size of the ball is relatively constrained by the balancing desires of reducing the size of the faucet body and providing for adequate water flow through the valve element. The prescribed drive motion for the handle by commercial desirability is angular motion about a vertical axis substantially for temperature change and rocking motion about a horizontal axis substantially for flow rate adjustment. The range of motion for angular temperature change is limited by ergonomics to a maximum of one hundred and eighty (180) degrees and desirably in the range of ninety (90) degrees. Therefore, the qualities of a desirable faucet with no sudden temperature changes or volume changes and a desirable comfort zone with predictable flow rate and temperature changes in the operation of the mixing valve are most expeditiously achieved and adjusted by the proper selection of the size, location and configurations of the inlet ports in both the housing and inlet openings in the ball valve.
What is needed is ball valve for a faucet mixing valve that has the commercially desirable drive motion that is easy to install and provides for longevity of the existing sealing elements.
What is also needed is a single handle mixing valve for a faucet that incorporates a ball valve with shaped inlet openings that provide for intuitively predictable flow rates and temperature of the discharged water therethrough.
SUMMARY OF THE DISCLOSURE
In accordance with one aspect of the invention, a faucet mixer valve has a ball valve pivotably mounted in a valve receiving cavity of a housing body. The body has a plurality of ports in fluid communication with the cavity. The ball valve has a plurality of openings in an outer at least partially spherical valve surface with the openings cooperating with the ports to control liquid flow in both flow rate and temperature mix through the ports. The valve body has a control opening therethrough with a longitudinal axis of the valve body passing through the control opening. The ball valve has a first projection in the form of a control stem connected thereto and extending through the control opening. An operating handle is affixed to the control stem. The ball valve has a second projection extending therefrom and has its axis substantially perpendicular to a longitudinal axis of said stem. The second projection has a lateral outer end connected to a circular collar bearing that extends about said ball valve. The collar bearing has a lower surface slidably abutting an annular support surface in the housing body about the ball valve.
Preferably, the annular support surface is a separate ring seat member mounted in the valve cavity and has at least one flange to define in part a cold limit and a hot limit to provide a stop of rotatable motion of the ball valve about the longitudinal axis of the mixing valve body beyond the hot and cold limits. The collar bearing has at least one radially outward cam having at least one side edge for engagement against the flange at the cold limit and hot limit of the ball valve. The ring seat member has a downwardly extending flange fitted within a recess in the body such that the ring member is rotatably fixed with respect to the body about the longitudinal axis of the body.
A flat bearing member is preferably positioned such that a lower surface thereof slidably abuts an upper surface of the collar bearing and an upper surface of the flat bearing member abuts a sealing member lower periphery about the ball valve. The flat bearing member is constructed to be relatively stationary as the collar bearing and the ball valve are rotated about the longitudinal axis of the housing body.
The second projection is rigidly affixed to the collar bearing and pivotably connected to the ball valve. The second projection is formed by a distal end of a pin that passes through the ball valve. The pin has opposite distal ends that extend outwardly from the ball valve surface and each is affixed to the collar bearing member.
Desirably, the plurality of openings of the ball valve are shaped and positioned on the ball valve with respect to the ports in valve body such that when the ball valve is in a position to provide for a mix of hot and cold water through the mixing valve, the ball valve provides a temperature shift toward a predefined comfort temperature when the ball valve is adjusted from a throttled position in proximity to an off position toward a full flow position.
Preferably, the ball valve has two openings for allowing entry of cold water from the cold water port and two openings for allowing entry of hot water from a hot water port. One of the openings through the ball valve has a concave edge section to modulate flow therethrough. Desirably, one of the openings with the concave edge allows entry of cold water therethrough and one of the openings with a concave edge allows entry of hot water therethrough.
The openings with the respective concave edge have a peripheral shape defined by at least five radial arcs having a respective radial center. At least four of the radial centers are located within the periphery of said respective opening and one radial center is located outside of the periphery of the opening at the side of the concave edge section. Preferably, the remaining openings have convex peripheries defined by at least five radial arcs having a respective radial center, and at least two of the radial arcs of each opening are joined at a point sharing a common tangent line. Preferably, each of the radial arcs are joined to another radial arc at a point sharing a common tangent line or alternately to a straight edge section at a point having a tangent line coinciding with the straight edge.
In one embodiment, the openings include a full cold water opening constructed and positioned for allowing only cold water entry when the hot water port is closed off, a mixed cold water opening positioned and constructed for allowing cold water entry simultaneously with hot water entry from said hot water port, a full hot water opening constructed and positioned for allowing only hot water entry when the cold water port is closed off, and a mixed hot water opening positioned and constructed for allowing hot water entry simultaneously with cold water entry from the cold water port. The full cold water opening has a respective concave edge, and the mixed hot water opening has a respective concave edge. In addition, a mixed cold water opening has a straight edge section opposing an edge of said cold water port when said ball valve is in an off-mix position, and a mixed hot water opening has a straight edge section opposing an edge of the hot water port when the ball valve is in the off-mix position.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference now is made to the accompanying drawings in which:
FIG. 1 is a side elevational and segmented view of a mixing valve according to one embodiment of the invention;
FIG. 2 is an exploded perspective view of the mixing valve shown in FIG. 1;
FIG. 3 is cross-sectional view of the mixing valve lower housing member taken along line 3--3 shown in FIG. 1;
FIG. 4 is a plan view of the mixing valve lower housing member;
FIG. 5 is a plan segmented view of the mixing valve with the cap and seal elements removed illustrating the ball valve in the full cold position;
FIG. 6 is view similar to FIG. 5 illustrating the ball valve rotated to the full hot position;
FIG. 7 is a side elevational view of the ball valve rocked to a full on position;
FIG. 8 is a side elevational view of the ball valve rocked to an off position;
FIG. 9 is a bottom plan view of the spherical section of the ball valve with the collar removed;
FIG. 10 is an enlarged view of the cold mix opening through the ball valve;
FIG. 11 is an enlarged view of the full cold opening through the ball valve;
FIG. 12 is an enlarged view of the hot mix opening through the ball valve;
FIG. 13 is an enlarged view of the full hot opening through the ball valve;
FIG. 14 is perspective view through the cold port of the housing at the ball valve in the off full cold position;
FIG. 15 is a view similar to FIG. 14 wherein the ball valve is in the off-full mix position;
FIG. 16 is a view similar to FIG. 14 wherein the ball valve is in the off-full hot position;
FIG. 17 is a view similar to FIG. 14 wherein the ball valve is in the full on-full cold position;
FIG. 18 is a view similar to FIG. 14 wherein the ball valve is in the full on-full mix position;
FIG. 19 is a view similar to FIG. 14 wherein the ball valve is in the full on-full hot position;
FIG. 20 is a perspective view of through the hot port of the valve housing of the ball valve in the off-full cold position;
FIG. 21 is a view similar to FIG. 20 wherein the ball valve is in the off-full mix position;
FIG. 22 is a view similar to FIG. 20 wherein the ball valve is in the off-full hot position;
FIG. 23 is a view similar to FIG. 20 wherein the ball valve is in the full on-full cold position;
FIG. 24 is a view similar to FIG. 20 wherein the ball valve is in the full on-full mix position;
FIG. 25 is a view similar to FIG. 20 wherein the ball valve is in the full on-full hot position;
FIG. 26 is a plan view of the template member;
FIG. 27 is a graph illustrating the flow rate profile at various temperatures;
FIG. 28 is a graph illustrating the temperature profile at various flow rates;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a mixing valve 10 for a faucet generally indicated as 12 includes a valve body 14 and a ball valve 16 operably mounted therein. The ball 16 is seated in a cavity 17 of the body 14 defined between a lower base member 18 and upper body member, i.e. cap member 20. The base member 18 has two inlet ports 22 and 24 therethrough that are in communication with the cavity 17. Each port 22 may have conventional spring biased elastomeric gaskets 23 mounted at its downstream end with the holes therethrough having a diameter of approximately 6.5 mm. The ports 22 and 24 have there downstream ends positioned at approximately 40° up from the bottom of cavity 17. Furthermore, the ports as shown in FIG. 4 are circumferentially positioned approximately 15° from the fore and aft plane as measured from the vertical axis 76.
As shown more clearly in FIG. 3, the base member 18 also has two discharge ports 26 and 28 therethrough. Two supply pipes 30 and 32 are operably connected to the respective inlet ports 22 and 24. The two discharge ports 26 and 28 lead from the cavity 17 and are in communication with a traverse outlet duct 34. A tubular shell 36 is sealingly and slidably mounted about the body 14 and forms an annular chamber 38 in fluid communication with the traverse duct 34. A spout 40 is affixed to the shell and in fluid communication with the annular chamber 38 through aperture 41 in shell 36.
As shown in FIGS. 1 and 2, the ball valve 16 has a spherical surface section 42 and a control stem 44 extending generally upwardly therefrom. The stem 44 is aligned normal to the surface 42 such that its axis 45 intersects the center 122 of the spherical section 42. The spherical section may have a diameter of approximately 25 mm. A collar 46 fits about the equator 120 of the spherical section 42. The equator 120 lies in a plane normal to the axis 45 of stem 44. The collar 46 is interposed between two seating rings 48 and 50. A sealing gasket 52 of elastomeric material fits on top of seating ring 50. The sealing gasket is retained in place by a template guide 54. The template guide 54 is retained in place within the inner periphery of the cap member 20 by a threaded annulus 56. The template guide 54 is rotationally affixed by its key 55 fitting into slot 57 at the top edge of housing member 18. A spring loaded corrugated disc 58 is interposed between the guide 54 and annulus 56 for downwardly biasing the guide 54 and sealing gasket 52 against the spherical section 42 of ball valve 16. The cap member 20 is threadably engaged to the bottom base member 18. A cosmetic shell 60 is positioned over the cap member 20.
The seating ring 50, sealing gasket 52, template guide 54, spring ring 58, cap 20, annulus 56 and shell 60 all have respective apertures 62, 64, 66, 68, 70, 72, and 74 therethrough to allow control stem 44 of the ball valve 16 to extend out of body 14 of the faucet. The longitudinal axis 76 of the faucet extends through the apertures 62-74.
The stem 44 is affixed to a handle 78 that has an operating lever 80 and concealing cap section 82. By manual manipulation of the handle 78, either or both of the inlet ports 22 and 24 may be brought into fluid communication with the discharge passages 26 and 28 via through inlet openings 90, 92, 94, 96 and discharge opening 98 in the ball valve 16 for flow out the faucet spout 40.
As shown more clearly in FIGS. 5, 6, 7, 8, and 9, the ball spherical surface section 42 has a pin member 84 passing through the center of the ball valve spherical section 42. The pin 84 has its longitudinal axis 86 substantially perpendicular to the longitudinal axis 76. The pin 84 has two cylindrical distal ends 88 that extend externally of spherical section 42 at an equator of the spherical section 42. The ends 88 are affixed within two holes 87 at opposing circumferential ends of collar 46. The ends 88 extend through opposing holes 89 in spherical section 42 for pivotable motion with respect thereto about longitudinal axis 86.
This pivotable motion allows the stem 44 to be manipulated back and forth in a rocking motion to pivot the spherical section about the axis 86 of pin 84 with respect to the collar as shown in FIGS. 7 and 8. FIG. 8 represents the off position of the ball valve with the stem 44 tilted forward at approximately 25° from the vertical axis 76. FIG. 7 represents the full on position of the ball valve with the stem 44 tilted rearwardly approximately 10° from the vertical axis 76.
The ball valve may also rotate about vertical axis 76 from a cold position as illustrated in FIG. 5 to a hot position as illustrated in FIG. 6. The rotation about axis 76 may be limited to a desired amount for example 90° or 180°. One way to limit the rotation is to provide the collar 46 with radially extending cams 100 that may be abuttable against an edge 102 of an upright flange 104 upwardly extending from seating ring 48. Ring 48 as clearly shown in FIG. 2 has two flanges 104 positioned 180° apart. The ring 48 is affixed in place within cavity 17 by a downwardly extending tongue 106 that is pressed into a receiving hole 108 within cavity 17.
The collar 46 is circumferentially moved as the ball valve is rotated about vertical axis 76. Elastomeric seal 52 is stationary. In order to prevent frictional wear of the lower edge of the elastomeric seal 52 by collar 46, the smooth metal seating ring 50 is interposed between the collar 46 and seal 52. The collar 46 slides against the ring 50 when the ball is rotated about axis 76.
Alternately, or in addition to the seating ring 48, the rotation of the ball about axis 76 may also be limited by radially extending edges 110, 111, 112, and 113 at the periphery of aperture 66 in guide template 54 as shown in FIGS. 2 and 26. The stem 44 when it abuts the edges 110--113 is prevented from further movement beyond the respective edges. Edges 110 and 111 define the cold limit and edges 112 and 113 define the hot limit. The edges 110--113 allow the ball to rotate about vertical axis 76 for approximately 90°. The aperture 66 also has circumferential edges 114 and 115 that control the extent of rocking motion about axis 86 of pin 84 from the off position to the full on position respectively as illustrated in FIGS. 7 and 8.
The collar 46, ring 48, and guide template 54 determine the prescribed motion of the control stem 44 and handle 78 and the extent of motion of the stem 44 and handle 78 between the full off, full on full cold and full hot positions. The control stem 44 is free to be in any position within aperture 66 of guide template 54 to control of water flow from the inlet ports 22 and 24 to the discharge ports 36 and 38.
The flow profile from off to full-on and from hot to cold at various flow rates is determined by the proper selection of the size, location and configurations of the inlet ports 22 and 24 at the cavity 17 and inlet openings 90, 92, 94, and 96 in the ball valve. The openings 90, 92, 94, 96, and 98 lie generally along a circle 118 that forms an angle of approximately 80° with the stem axis 45. The plane of the circle 118 is generally parallel to axis 86 of pin 84.
In more specific terms, the locations of the openings can be defined in angular terms. The discharge opening 98 may be bisected by a reference plane. Openings 90 and 92 form angles at approximately 50° and 106° clockwise from the bisected discharge opening 98 reference plane as shown in FIG. 9. Openings 94 and 96 form angles at approximately 66° and 107° counterclockwise to the bisected discharge opening 98.
The vertical position can be defined with reference to a plane that contains the equator 120 of the spherical section and the center 122 of spherical section 42. The discharge opening 98 forms an angle with the reference plane at center 122 of approximately 38°. Openings 90 and 92 forms an angle of 60°. Opening 94 forms an angle of approximately 39°. Opening 96 forms an angle of approximately 40°. All angles are referenced with respect to a designated center of the respective opening which is further described later.
While the discharge opening 98 has a generally circular opening for the discharge of water from the interior of the ball valve 16, each of the inlet openings 90, 92, 94, and 96 have asymmetrical and more complex shapes. Referring now to FIG. 10, the cold mix inlet opening 92 has a peripheral edge generally indicated as 125 several contoured sections 126-134. The peripheral edge 125 forms a simple convex shape. Section 126 is defined as a 1.42 mm radial arc centered at radial center 135. Section 127 is a 3.30 mm radial arc centered at radial center 136. The junction point 137 between section 126 and 127 is the point sharing a common tangent. Section 127 is joined to a straight edge section 128. The junction point 138 between the sections 127 and 128 is where the tangent line of the arc section 127 coincides with the straight edge section 128. The arc section 129 is a 1.02 mm arc centered about radial center 139 that is similarly connected to straight section 128 at point 140. The arc section 129 is connected to a 9.12 arc section 130 centered about radial center 141 at their common tangent point 142. Arc section 130 is similarly connected to a 1.60 mm arc section 131 centered about radial center 143 at its common tangent point 144. Arc section 131 is joined to a straight edge section 132 where its tangent coincides with straight edge section at point 145. Straight edge section 132 is similarly connected to a 1.35 mm radial arc section 133 about radial center 149 at point 146. Arc sections 133 and 126 are similarly connected to straight edge section 134 at points 147 and 148.
The radial centers are conveniently located by using a vertical plane 150 containing axis 45 of control stem 44 as a first coordinate and an axis 152 perpendicular thereto that contains the designated center 154 of opening 92 as a second coordinate. All coordinates are measured in millimeters. Radial centers 135, 136, 139, 141, 143, and 149 are located at (0.99, 0.91), (-0.86, 1.27), (1.24,-1.47), (6.81, -0.51), (-0.71, -0.41) and (0.94, 1.07).
Opening 90 for the full cold water flow as illustrated in FIG. 11 has a peripheral edge generally indicated as 155. The peripheral edge 155 is composed of sections 156-162. Section 156 is a 0.71 mm radial arc that is centered about radial center 163. Arc 156 is joined to a 7.44 mm radial arc 157 centered about radial center 164 at common tangent point 165. Similarly, arc 157 is joined to a 2.46 mm radial arc 158 centered about radial center 166 at common tangent point 167. Arc 158 is joined to a 2.87 mm radial arc 159 centered about radial center 168 at common tangent point 169. Arc 159 is joined to a 3.51 mm radial arc 160 about radial center 170 at common tangent point 171. Arc 160 is joined to a 2.79 mm radial arc 161 about center 172 at common tangent point 173. The sections 156-161 are convex sections as references from the exterior of the opening 92. The section 162 is a 2.77 concave arc centered about radial center 174. The section 162 is joined to section 161 and 156 about respective common tangent points 175 and 176.
The coordinates of the radial centers 163, 164, 166, 168, 170, 172 and 174 are (-0.86, 2.74), (-2.90, -3.66), (0.13, 0.33), (-0.08, -0.08), (-0.36, 0.53), (0.08, 0.71), (-4.34, 2.67) with reference to vertical center plane 180 as a first coordinate and perpendicular axis 182 through designated center 178 as the second coordinate. The coordinates are in millimeters.
The opening 94 is has a simple convex periphery 185 composed of radial arc sections 186, 187, 189, 190, 191, and 192 having radii of 2.92 mm from center 194, 1.80 mm from center 195, 1.17 mm from center 196, 1.55 mm from center 197, and 4.52 mm from center 198 respectively. The arcs 186 and 187 are joined at common tangent point 200. The arcs 189-192 are joined at respective common tangent points 201, 202, and 203. The arcs 186 and 192 are joined to straight edge section 193 at points 204 and 205 where the arc tangent coincides with the edge section 193. Similarly arcs 187 and 189 are joined to straight edge section 188 at points 206 and 207 where the arcs' tangents coincide with the straight edge section 188.
The coordinates of the radial centers 194, 195, 196, 197,198, and 199, are (-0.28, -0.25), (-0.36, -1.40), (-1.52, 1.63), (-1.22, 1.37), (-0.66, -1.55), and (-0.10, 0.71) with reference to vertical center plane 210 as a first coordinate and perpendicular axis 212 through designated center 214 as the second coordinate. The coordinates are in millimeters.
The inlet opening 96 illustrated in FIG. 12 has a periphery generally indicated as 215. The periphery 215 has radially convex sections 216-220 having radii of 1.37 mm from center 223, 8.05 mm from center 224, 1.52 mm from center 225, 2.84 mm from center 226, and 0.94 mm from center 227. The concave section 221 has a radius of 2.34 mm from center 228. Section 216-221 are joined at common tangent points 230-235. Sections 216 and 221 are joined to straight edge section 222 at points 236 and 237 respectively where the tangents coincide with the straight edge 222.
The coordinates of the radial centers 223, 224, 225, 226, 227, and 228 are (1.40, 0.76,), (-3.53, 5.28), (-0.97, -0.74), (0.28, 0.28), (-1.45, 0.74), and (-0.89, 3.73) with reference to vertical center plane 240 as a first coordinate and perpendicular axis 242 through designated center 244 as the second coordinate. The coordinates are in millimeters.
Reference is now made to FIG. 14-19 which illustrates the ball valve in various positions from the perspective of the cold water inlet port 22 at cavity 17. The ball valve 16 can be orbited about vertical axis 76 while in the off position such that the ball can be in the cold-off position illustrated in FIG. 14, in the mix-off position illustrated in FIG. 15 and in the hot-off position illustrated in FIG. 16. The stem 44 may also be rocked about pin 84 from the position illustrated in FIG. 14 to the cold-on position illustrated in FIG. 17, from the position illustrated in FIG. 15 to the full mix position illustrated in FIG. 18, and from the position illustrated in FIG. 16 to the hot-on position shown in FIG. 19.
Similarly, FIGS. 20 through 25 illustrate the ball valve in various positions from the perspective of the hot water inlet port 24 at cavity 17. The ball valve 16 can be orbited about vertical axis 76 while in the off position such that the ball can be in the cold-off position illustrated in FIG. 20, in the mix-off position illustrated in FIG. 21 and in the hot-off position illustrated in FIG. 22. The stem 44 may also be rocked about pin 84 from the position illustrated in FIG. 20 to the cold-on position illustrated in FIG. 23, from the position shown in FIG. 21 to the on-mix position shown in FIG. 24 and from the position shown in FIG. 22 to the hot-on position shown in FIG. 25.
Referring back to FIG. 14 and 17, the periphery 155 of full cold opening 90 has its concave section 162 act as a leading edge over port 22 from the off to cold on position. As shown in FIG. 14, when in the cold-off position, the ball valve 16 has concave edge 62 opposing and spaced from the inlet edge 250 of port 22. When in the cold-on position, only opening 90 is aligned with any of the inlet port 22 and 24 as illustrated in FIGS. 17 and 23.
Referring to FIGS. 15, 21, 18 and 24, when the ball valve is in the full mix positions, only cold mix opening 92 and hot mix opening 96 are aligned with respective cold and hot inlet ports 22 and 24. As shown in FIG. 23 and 24, when in the cold-on position, the ball valve 16 has concave edge 221 opposing and spaced from the inlet edge 252 of hot inlet port 24. When rotated from the cold-on position shown in FIG. 23 to the mix-on position shown in FIG. 24, the ball valve 16 has the concave edge 221 of opening 96 act as a leading edge over leading edge 252 of hot inlet port 24. When in the hot-on position, only opening 94 is aligned with any of the inlet ports 22 and 24 as illustrated in FIGS. 19 and 25.
The above described structure for a mixing valve renders a faucet that provides relatively constant flow rates as the handle 78 is rotated about axis 76 from the full hot position indicated at 0° where the stem 44 abuts either edge 112 or 113 of guide 54 as shown in FIG. 26 to a full cold position indicated at 90° where stem 44 abuts either edge 110 or edge 111 of guide 54. The curve 260 represents the profile at full flow with the handle 78 lifted up until the stem 44 abuts edge 115. Curve 262 represents the profile at 3/4 capacity, i.e. 3/4 open flow. Curve 264 represents the profile at 1/2 capacity, i.e. 1/2 open flow. Curve 264 represents the profile at 1/4 flow capacity, i.e. 1/4 open flow.
Furthermore, the construction as described renders a faucet that has predictable temperature changes. Referring now to the graph illustrated in FIG. 28, profile curves 270, 272, 274, and 276 represent the percentage mix of the discharge water exiting discharge port 26 and 28 from the hot inlet port 24 and cold inlet port 22 at full flow, 3/4 open flow, 1/2 open flow and 1/4 open flow respectively. The percentage from each inlet port 22 and 24 may be translated into a temperature of the discharged water. As shown in the graph, the temperature of the discharged water is calculated basing the temperature of hot water at 65° C. and the cold water at 15° C. At the 55° rotated position, changes in flow rate are completely independent of temperature change. The 55° rotated position represents the comfort temperature of approximately 37° C. Between the 0° to 55° rotated positions where the temperature of the discharged water is hotter, movement of the handle from a partial flow position to full flow is accompanied by a slight decrease in temperature toward the designated 37° C. comfort temperature. Similarly, between the 55° and 90° rotated positions where the temperature of the water is colder, movement of the handle from a partial flow position to full flow is accompanied by a slight increase in temperature toward the designated 37° C. comfort temperature.
It should be understood that the same advantages can be accomplished with larger and smaller balls. The ports and openings may be similarly upscaled or downscaled.
Other variations and modifications are possible without departing from the scope and spirit of the present invention as defined by the appended claims.
|
A mixing valve for a faucet has a ball valve (16) mounted for pivotable motion about a longitudinal axis (76) and a second perpendicular axis (86) that is fixed with respect to the pin (84) that extends through the spherical section (42) of the ball valve. Distal ends of the pin are connected to a collar (46) that is fitted about the spherical section (42). The collar has cam stops that abut an edge (102) of the upturned flange (104) of the seating ring (48). The spherical section (42) has inlet openings (90,94) that are configured with convex and concave sections to produce a desired flow pattern.
| 8
|
The present invention relates to thermoplastic molding compositions which are based on an intimate admixture of a copolymer of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride and a grafted, copolymerized or blended impact modifier, with or without a polyphenylene ether resin and optionally a liquid polybutadiene present. The compositions of this invention provide molded articles having good overall mechanical properties, e.g., impact strength, tensile strength, tensile elongation, and the like.
BACKGROUND OF THE INVENTION
Vinyl aromatic resins, e.g., polystyrene, have been found to be useful in thermoplastic molding compositions. Vinyl aromatic resins have poor heat distortion and impact resistance, however, and attempts have been made to upgrade these properties. One approach has been to modify the vinyl aromatic resins by copolymerizing these materials with α,β-unsaturated cyclic anhydrides, to form copolymers such as poly(styrene-maleic anhydride). Although improvements in heat resistance and solvent resistance are provided, the resulting copolymers are somewhat brittle, and they do not have good resistance to impact.
Various attempts have been made to improve the impact resistance of copolymers of vinyl aromatic resins and α,β-unsaturated cyclic anhydrides. For instance, these copolymers have been blended with nitrile rubbers. Blends of nitrile rubber and styrene-maleic anhydride copolymers are disclosed in U.S. Pat. Nos. 2,914,505 and 3,641,212. With some of these compositions, however, the components are not compatible, and the compositions are difficult to prepare.
The following commonly assigned copending applications disclose proposals to solve the problems stated above. Lee and Abolins, Ser. No. 477,435, filed June 7, 1974, who employ block copolymers or graft copolymers in combination with the vinyl aromatic/unsaturated cyclic anhydride copolymers; Lee, Ser. No. 671,569, filed Mar. 29, 1976, who discloses block copolymers with rubber-modified vinyl aromatic/unsaturated cyclic anhydride copolymers; Abolins and Lee, Ser. No. 671,341, who disclose polyphenylene ether resins with vinyl aromatic/unsaturated cyclic anhydride copolymers; and Haaf and Lee, Ser. No. 693,895, filed June 8, 1976, who disclose radial teleblock copolymers in combination with vinyl aromatic/unsaturated cyclic anhydride copolymers, optionally rubber modified. The applications are incorporated herein by reference.
It has now been surprisingly discovered that copolymers of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride can be combined with an all acrylic emulsion graft copolymer to form compositions which can be molded to articles having excellent mechanical properties, including good impact strength, tensile yield and elongation, especially when combined with a polyphenylene ether resin. It has further been discovered that such an all acrylic emulsion graft copolymer can be used to enhance the important properties of rubber modified vinyl aromatic/unsaturated cyclic anhydride copolymers), with and without the addition of a polyphenylene ether resin.
It has been further discovered that the toughness of both unmodified and rubber-modified vinyl aromatic/unsaturated cyclic anhydride copolymers can be remarkably enhanced by combination with a vinyl aromatic, acrylonitrile-diene graft copolymer. The results are surprising in view of earlier work with an acrylic-vinyl aromatic-diene rubber graft copolymer.
Still a further discovery has been made in which compositions comprising a vinyl aromatic/unsaturated cyclic anhydride copolymer, a polyphenylene ether resin, and a graft copolymer resin, a rubber modified vinyl aromatic resin, or a segmented copolyester resin are vastly improved in ductile impact properties by adding a small amount normally liquid diene oligomer.
A further broad discovery resides in finding that lower than expected levels of polyphenylene ether resin can be employed in combination with vinyl aromatic/unsaturated cyclic anhydride copolymers, than would have been expected from work with vinyl aromatic homopolymers and graft copolymers, thus permitting retention of heat distortion temperatures at higher predetermined levels.
SUMMARY OF THE INVENTION
The present invention provides, in its broadest aspects, a thermoplastic composition which comprises an intimate admixture of:
(a) a copolymer of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride, and
(b) an impact modifier comprising (i) a graft copolymer comprising a vinyl aromatic compound, and a diene, alone, or in combination with an acrylonitrile; or (ii) a graft copolymer consisting essentially of acrylic ester units.
In a preferred feature, such compositions will also include a polyphenylene ether resin.
In another aspect, this invention provides a thermoplastic molding composition comprising an intimate admixture of
(a) a diene rubber modified copolymer of styrene and maleic anhydride;
(b) an impact modifier comprising
(i) a graft copolymer comprising a vinyl aromatic compound, and a diene alone or in combination with an acrylonitrile;
(ii) a graft copolymer comprising an acrylic ester, alone, or in combination with a vinyl aromatic compound, alone, or in further combination with a diene;
(iii) a rubber modified vinyl aromatic compound comprising from 20 to 45 percent by weight of a diene rubber; or
(iv) a segmented polyester having a multiplicity of recurring intralinear etherester and/or ester units;
(c) a polyphenylene ether resin; and
(d) an effective ductile impact strength improving amount of low molecular weight normally liquid polybutadiene oligomer.
In still another aspect, the present invention provides a process for the preparation of a thermoplastic composition which comprises intimately admixing
(a) a copolymer of a vinyl aromatic compound and an α,β-unsaturated anhydride, and
(b) a polyphenylene ether resin, (a) being added in an amount which is at least sufficient to improve the processability of the combination of (a) and (b) without decreasing the heat distortion temperature of (a) and (b) substantially in comparison with a composition of (b) with a polymerized vinyl aromatic compound essentially free of any copolymerized α,β-unsaturated anhydride, at the same vinyl aromatic compound control.
DETAILED DESCRIPTION OF THE INVENTION
The copolymers of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride (i) are well known in the art and are described in the literature. In general, they are prepared by conventional bulk solution or emulsion techniques using free-radial initiation. For example, styrene-maleic anhydride copolymers can be obtained by simply reacting the two monomers, i.e., styrene and maleic anhydride, at 50° C. in the presence of benzoyl peroxide. The rate of polymerization may be better controlled if a solvent such as acetone, toluene or xylene is used.
The vinyl aromatic compound of component (a) can be derived from compounds of the formula: ##STR1## wherein R 1 and R 2 are selected from the group consisting of (lower) alkyl or alkenyl groups of from 1 to 6 carbon atoms and hydrogen; R 3 and R 4 are selected from the group consisting of chloro, bromo, hydrogen and (lower) alkyl of from 1 to 6 carbon carbon atoms; R 5 and R 6 are selected from the group consisting of hydrogen and (lower) alkyl and alkenyl groups of from 1 to 6 carbon atoms or R 5 and R 6 may be concatenated together with hydrocarbyl groups to form a naphthyl group. These compounds are free of any substituent that has a tertiary carbon atom. Styrene is the preferred vinyl aromatic compound.
The α,β-unsaturated cyclic anhydride of component (i) can be represented by the formula: ##STR2## wherein the dotted lines represent a single or a double carbon to carbon bond, R 7 and R 8 taken together represents ##STR3## R 9 is selected from the group consisting of hydrogen, vinyl, alkyl, alkenyl, alkylcarboxylic or alkenyl-carboxylic of from 1 to 12 carbon atoms, n is 1 or 2, depending on the position of the carbon-carbon double bond, and m is an integer of from 0 to about 10. Examples include maleic anhydride, citraconic anhydride, itaconic anhydride, aconitic anhydride, and the like.
The preparation of these copolymers is described in U.S. Pat. Nos. 2,971,939; 3,336,267 and 2,769,804, the disclosures of which are incorporated herein by reference.
The copolymers which comprise component (a) include rubber-modified copolymers thereof. The rubber employed in preparing the rubber-modified copolymers of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride can be a polybutadiene rubber, butyl rubber, styrene-butadiene rubber, acrylonitrile rubber, ethylene-propylene copolymers, natural rubber, EPDM rubbers and the like.
The preparation of rubber-modified copolymers of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride is described in Netherlands 72,12714, which is incorporated herein by reference.
Component (a) can comprise from 40 to 1 parts by weight of the α,βunsaturated cyclic anhydride, from 60 to 99 parts by weight of a vinyl aromatic compound and from 0 to 25 parts by weight of rubber. The preferred polymers will contain about 25-5 parts by weight of the α,β-unsaturated cyclic anhydride, 75-95 parts by weight of the vinyl aromatic compound, and 10 parts by weight of rubber.
A preferred unmodified vinyl aromatic α,β-unsaturated cyclic anhydride copolymer useful in the composition of this invention is Dylark 232, commercially available from Arco Polymers. Dylark 232 is a styrene-maleic anhydride copolymer containing about 11% maleic anhydride, the balance being styrene. A preferred rubber-modified vinyl aromatic α,β-unsaturated cyclic anhydride copolymer is Dylark 240, which is also available from Arco Polymers. Dylark 240 is a high impact styrene-maleic anhydride copolymer containing 9-10% rubber and 9% maleic anhydride, the balance being styrene.
The graft copolymers (b) (i) and (ii) are available commercially or can be prepared by following the teachings of the prior art. As an illustration, the graft polymerization product of an acrylic monomer, a vinyl aromatic monomer and/or acrylonitrile monomer and a diene rubber preferably comprises a backbone polymer of the units of butadiene or butadiene and styrene, wherein the butadiene units are present in quantities of at least 40% by weight of the backbone polymer, (a) an acrylic monomer, a vinyl aromatic monomer or an acrylonitrile monomer graft polymerized to (1), said monomer units being selected from the group consisting of lower alkyl methacrylates, alicyclic methacrylates and alkyl acrylates, vinyl or substituted-vinyl aromatics or substituted aromatics, e.g., benzene or naphthalene rings, and/or acrylonitrile or substituted acrylonitriles, monomer graft polymerized to (1); sequentially or simultaneously with the polymerization of (1).
The graft polymerization product of an acrylic monomer alone or with, e.g., styrene monomer and/or with, e.g., acrylonitrile and the rubbery diene polymer or copolymer may be prepared by known techniques, typically by emulsion polymerization. They may be formed from a styrene-butadiene copolymer latex or a butyl acrylate polymer latex and a monomeric material such as methyl methacrylate alone or with another compound, e.g., styrene alone, and/or with an acrylonitrile or substituted acrylonitrile. For example, in the preparation of a representative material, 85-65 parts by weight of monomeric methyl methacrylate or monomeric methyl methacrylate to the extent of at least 55% and preferably as much as 75% by weight in admixture with another monomer which copolymerizes therewith, such as ethyl acrylate, acrylonitrile, vinylidene chloride, styrene, and similar unsaturated compounds containing a single vinylidene group, is added to 15-35 parts by weight of solids in a styrene-butadiene copolymer latex. The copolymer solids in the latex comprise about 10-50% by weight of styrene and about 90-50% by weight of butadiene and the molecular weight thereof is within the range of about 25,000 to 1,500,000. The copolymer latex of solids in water contains a dispersing agent such as sodium oleate or the like to maintain the copolymer in emulsion. Interpolymerization of the monomer or monomeric mixture with the copolymer solids emulsified in water is brought about in the presence of a free-radical generating catalyst and a polymerization regulator which serves as a chain transfer agent, at a temperature of the order of 15° C. to 80° C. Coagulation of the interpolymerized product is then effected with a calcium chloride solution, for instance, whereupon it is filtered, washed and dried. Other graft copolymers and differing from the above only in the ratio of monomeric material solely or preponderantly of methyl methacrylate to the butadiene-styrene copolymer latex in the presence of which it is polymerized extends from 85-25 parts by weight of the former to 15-75 parts by weight of the latter. These materials may extend in physical properties from relatively rigid compositions to rubber compositions. Also, U.S. Pat. No. 3,792,123, which is incorporated by reference, contain additional information as to the preparation of these materials. Other preferred commercially available materials are a styrene-butadiene graft copolymer designated Blendex 525 by Marbon Chemical Co.
In certain compositions herein, a three component graft copolymer comprising an acrylate, a styrene and a diene rubber backbone will be exemplified. This can be made following the foregoing teachings, and is also available from Rohm and Haas as the product designated Acryloid KM-611.
It is also possible to use the so-called "all acrylic impact modifiers" of the type designated Acryloid KM-323B by Rohm and Haas.
Other acrylic modifiers are those comprised of acrylic ester units and vinyl aromatic units, such as the butyl acrylatestyrene graft copolymers made by the procedures described, e.g., by Ito, et al, in Chemical Abstracts, Vol. 84, entry 84:5874 g., 1976.
In other compositions herein, a segmented copolyester will be exemplified. These are made following the general teachings of U.S. Pat. Nos. 3,023,182; 3,651,014; 3,763,109 and 3,766,146, each of which is incorporated herein by reference.
A preferred segmented thermoplastic copolyester is one that hardens rapidly from the molten state consisting essentially of a multiplicity of recurring long chain ester units and short chain ester units joined head-to-tail through ester linkages, said long chain ester units being represented by the formula: ##STR4## and said short chain units being represented by the formula: ##STR5## where G 2 is a divalent radical remaining after the removal of terminal hydroxyl groups from a poly(alkylene oxide) glycol having a melting point of less than about 60° C., a molecular weight of about 400-4000 and a carbon to oxygen ratio of about 2.5-4.3; R is a divalent radical remaining after removal of carboxyl groups from a dicarboxylic acid having a molecular weight less than about 300 and D 3 is a divalent radical remaining after removal of hydroxyl groups from a diol having a molecular weight less than about 250; provided,
(a) said short chain ester units amount to about 48-65% by weight of said copolyester,
(b) at least about 80% of the R groups in A and B are 1,4-phenylene radicals and at least about 80% of the D 3 groups in B are 1,4-butylene radicals, and
(c) the sum of the percentages of R groups which are not 1,4-phenylene radicals and of D 3 groups which are not 1,4-butylene radicals does not exceed about 20; also an additional type of copolyester is that as described hereinabove except that:
(a) said short chain ester units amount to about 66-95% by weight of said copolyester.
(b) at least about 70% of the R groups in Formulas A and B are 1,4-phenylene radicals and at least about 70% of the D groups in Formula B are 1,4-butylene radicals, and
(c) the sum of the percentages of R groups in Formulas A and B which are not 1,4-butylene radicals does not exceed about 30.
The preferred materials are commercially available as Hytrel 4055 and Hytrel 5555 from E. I. duPont de Nemours and Company.
In certain compositions herein, a rubber modified vinyl aromatic compound comprising from 20 to 45 percent by weight of a diene rubber will be exemplified. Those can be made by intimately admixing, e.g., polystyrene and a polybutadiene rubber, and are also available commercially in a preferred embodiment from Union Carbide, product designated TDG-2100.
In certain compositions herein, a normally liquid polybutadiene oligomer will be exemplified. These can be made by conventional means, e.g., by alkali metal or organometallic catalyzed synthesis, to produce a low molecular weight polymer, e.g., of from 500 to 3000 or more, molecular weight, which is normally liquid as described, e.g., in U.S. Pat. No. 3,678,121, incorporated herein. Only a small amount of the butadiene oligomer is needed to improve Gardner (ductile) impact strength, e.g., 0.5 to 5% by weight, based on components (a), (b), (c) and (d). A preferred polybutadiene oligomer has a molecular weight of 2000 and a viscosity, at 50° C., of about 290 poise.
As noted above, the compositions of this invention can also include a polyphenylene ether resin. The polyphenylene ether resins are preferably of the formula: ##STR6## wherein the oxygen ether atom of one unit is connected to the benzene nucleus of the next adjoining unit, n is a positive integer and is at least 50 and each Q is a monovalent substituent selected from the group consisting of hydrogen, halogen, hydrocarbon radicals free of a tertiary alpha-carbon atom, halohydrocarbon radicals having at least two carbon atoms between the halogen atom and the phenyl nucleus, hydrocarbonoxy radicals and halohydrocarbonoxy radicals having at least two carbon atoms between the halogen atom and the phenyl nucleus.
Examples of polyphenylene ethers corresponding to the above formula can be found in Hay, U.S. Pat. Nos. 3,306,874 and 3,306,875 and in Stamatoff, U.S. Pat. Nos. 3,257,357 and 3,257,358, which are incorporated herein by reference.
For purposes of the present invention, an especially preferred family of polyphenylene ethers includes those having alkyl substitution in the two positions ortho to the oxygen ether atom, i.e., those of the above formula wherein each Q is alkyl, most preferably having from 1 to 4 carbon atoms. Illustrative members of this class are: poly(2,6-dimethyl-1,4-phenylene)ether; poly(2,6-diethyl-1,4-phenylene)ether; poly(2-methyl-6-ethyl-1,4-phenylene)ether; poly(2-methyl-6-propyl-1,4-phenylene)ether; poly(2,6-dipropyl-1,4-phenylene)ether; poly(2-ethyl-6-propyl-1,4-phenylene)ether; and the like. The most preferred polyphenylene ether resin is poly(2,6-dimethyl-1,4-phenylene)ether, preferably having an intrinsic viscosity of about 0.5 deciliters per gram as measured in chloroform at 25° C.
The components of the compositions of this invention are combinable in a wide range of proportions. The compositions can comprise, for instance, from about 5 to about 95, preferably from about 40 to about 90 parts by weight of (a) the copolymer of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride, and from about 95 to about 5, preferably from about 60 to about 10, parts by weight of (b) the impact modifier.
When a polyphenylene ether resin is also used, the compositions will preferably include from about 5 to about 95, preferably from about 40 to about 90 parts by weight of the copolymers of a vinyl aromatic compound and an α,β-unsaturated cyclic anhydride, from about 95 to about 5, preferably from about 60 to about 10 parts by weight of the impact modifier (b), and preferably from about 1 to about 75 parts by weight of a polyphenylene ether resin.
The compositions of the invention can also include other ingredients, such as flame retardants, extenders, processing aids, pigments, stabilizers and the like, for their conventionally employed purposes. Reinforcing fillers, in amounts sufficient to impart reinforcement, can be used, such as aluminum, iron or nickel, and the like, and non-metals, such as carbon filaments, silicates, such as acicular calcium silicate, and platey magnesium or aluminum silicates, asbestos, titanium dioxide, potassium titanate and titanate whiskers, glass flakes and fibers.
The preferred reinforcing fillers are of glass. In general, best properties will be obtained if glass filaments are employed in amounts of from about 10 to about 40% by weight, based on the combined weight of glass and resin. However, higher amounts can be used.
The compositions of the invention may be prepared by blending the components in a Henschel mixer and compounding the mixture on a twin-screw 28 mm Werner-Pfleiderer extruder. Thereafter, the extrudate is chopped into pellets and molded on a Newbury injection molding machine.
The present invention is further illustrated in the following examples, which are not to be construed as limiting. All parts are by weight.
EXAMPLES 1-4
Blends of styrene-maleic anhydride copolymers, acrylic unit containing impact modifying polymer and poly(2,6-dimethyl-1,4-phenylene)ether resin are prepared by blending the components in a Henschel mixer and thereafter compounding the mixture on a twin-screw 28 mm Werner-Pfleiderer extruder. Thereafter the extrudate is chopped into pellets and molded on a Newbury injection molding machine. The formulations and test results are set forth in Table 1.
TABLE 1______________________________________Compositions Comprising Styrene/MaleicAnhydride Copolymer andAcrylic Graft CopolymerExample 1 1A* 2 3 4 4A*______________________________________Composition(parts by weight)Styrene-Maleic anhydridecopolymer.sup.a 70 100 60 -- -- --Styrene-Maleic anhydrideCopolymer (rubbermodified).sup.b -- -- -- 80 70 100Acrylic ester impactmodifier.sup.c 30 -- 30 20 20 --poly(2,6-dimethyl-1,4-phenylene ether.sup.d -- -- 10 -- 10 --PropertiesTensile yield, psi 7500 9300 7600 6700 7200 7800Tensile strength, psi 7500 9300 7600 5000 5800 6400Elongation, % 8 9 11 28 50 31Izod impact, ft.-lbs./in.notch 0.5 0.4 0.6 2.1 3.2 1.8Gardner impact, in-lbs. <10 <10 42 20 50 <10Heat distortion temp-erature at266 psi, °F. 212 210 224 210 222 212______________________________________ *Control .sup.a Dylark 232, Arco Chemicals .sup.b Dylark 240, Arco Chemicals .sup.c Acryloid KM 323B Rohm & Haas .sup.d PPO, General Electric Company
Especially noteworthy is the ability of the impact modifier to upgrade the impact properties of the unmodified styrene/maleic anhydride copolymer when used in conjunction with the polyphenylene ether. The impact properties of the rubber modified styrene/maleic anhydride copolymer is efficiently upgraded with the impact modifier in the presence and absence of polyphenylene ether.
EXAMPLES 5-6
The procedure of Examples 1-4 are repeated, substituting a graft copolymer of styrene and polybutadiene rubber. A graft copolymer comprising styrene-methyl methacrylate and polybutadiene rubber is included for comparison purposes. The formulations used and property data obtained are summarized in Table 2.
TABLE 2______________________________________Compositions Comprising Styrene/MaleicAnhydride Copolymer and Styrene-PolybutadieneGraft Copolymers Example 5A* 5 6 6A* 6B*______________________________________Composition (parts by weight)Styrene-maleic anhydride 100 70 60 70 60copolymer.sup.aStyrene-polybutadienegraft polymer.sup.b -- 30 30 -- --Styrene-methyl methacrylatepolybutadiene graft polymer.sup.c -- -- -- 30 30Poly(2,6-dimethyl-1,4-pheny-lene ether.sup.d -- -- 10 -- 10PropertiesTensile yield, psi 9300 5900 6300 7900 7900Tensile strength, psi 9300 5600 5800 5600 5900Elongation, % 9 21 18 20 23Izod impact, ft.-lbs/in. notch 0.43 1.4 3.2 0.69 0.67Gardner impact, in.-lbs. <10 33 32 <10 <10Heat distortion temp. at266 psi, °F. 218 205 219 212 225______________________________________ *Controls .sup.a Dylark 232, Arco Chemicals .sup.b Blendex 525, Marbon Chemicals .sup.c Acryloid KM611, Rohm & Haas .sup. d PPO, General Electric Company
The improvement in toughness of crystal grades of styrene-maleic anhydride is especially marked with the graft copolymer of styrene-polybutadiene.
EXAMPLES 7-8
The general procedure of Examples 1-4 is used to formulate, mold and test compositions which include a normally liquid polybutadiene oligomer as a ductile impact (Gardner) modifier. The formulations and properties are set forth in Table 3.
TABLE 3______________________________________Composition Comprising Styrene-MaleicAnhydride Copolymer, Segmented Copolyester or Acrylic-Styrene Diene Rubber Graft, Polyphenylene Ether andPolybutadiene OligomerExample 7 7A* 8 8A*______________________________________Composition (parts by weight)Styrene-maleic anhydridecopolymer (rubber modified).sup.a 70 70 70 70Segmented Copolyester of Poly(1,4-butylene-propyleneglycol) terephthlate.sup.b 20 20 -- --Styrene-methyl methacrylatepolybutadiene graft.sup.c -- -- 20 20Poly(2,6-dimethyl-1,4-phenyleneether).sup.d 10 10 10 10Liquid polybutadiene Oligomer.sup.e 1 -- 1 --PropertiesTensile yield, psi 7100 7500 7200 7600Tensile strength, psi 5800 7400 5600 5900Elongation, % 25 9 39 38Gardner impact, in.-lbs. 65 7 135 83______________________________________ *Control .sup.a Dylark 240, Arco Chemicals .sup.b Hytrel 5555, Dupont Co. .sup.c Acryloid KM611, Rohm & Haas .sup.d PPO, General Electric Co. .sup.e Molecular weight 2000, viscosity at 50° C., 290 poise
EXAMPLES 9-10
The general procedure of Examples 1-4 is used to formulate, mold and test compositions which include a normally liquid polybutadiene oligomer as a ductile impact (Gardner) modifier. The formulations and properties are set forth in Table 4:
TABLE 4______________________________________Compositions Comprising Styrene/MaleicAnhydride Copolymer, Rubber Modified Polystyrene or Styrene-Butadiene Graft Copolymer, PolyphenyleneEther and Polybutadiene OligomerExample 9 9A* 10 10A*______________________________________Composition (parts by weight)Styrene-maleic anhydride copolymer(rubber modified).sup.a 60 60 70 70Rubber modified Polystyrene.sup.b 30 30 -- --Styrene-polybutadienegraft copolymer.sup.c -- -- 20 20Poly(2,6-dimethyl-1,4-phenyleneether resin.sup.d 10 10 10 10Liquid polybutadiene Oligomer.sup.e 1 -- 1 --PropertiesTensile yield, psi 5900 5800 6500 6700Tensile strength, psi 5300 5300 5600 5800Elongation, % 50 48 36 39Gardner impact, in.-lbs. 49 19 85 20______________________________________ *Control .sup.a Dylark 240, Arco Chemicals .sup.b TGD2500 25% rubber, Union Carbide .sup.c Blendex 525, Marbon Chemicals .sup.d PPO, General Electric Co. .sup.e Molecular weight 2000, viscosity at 50° C., 290 poise.
In Examples 7-10, the addition of only 1% of liquid polybutadiene oligomer improves the Gardner impact strength at least one and one-half times.
EXAMPLE 11
A styrene-maleic anhydride copolymer containing 15 mole % of maleic anhydride is blended 50:50 with poly(2,6-dimethyl-1,4-phenylene ether). After molding and testing it is found that the heat distortion temperature is 40° F. higher than that of a corresponding composition comprising 50:50 of polystyrene and poly(2,6-dimethyl-1,4-phenylene ether. A similar composition in which the anhydride function has been pre-reacted with aniline has only a slightly lower heat distortion temperature, but higher than the polystyrene comparison composition.
Obviously, many variations will suggest themselves to those skilled in the art, in view of the above detailed disclosure. All such variations are within the full intended scope of the appended claims.
|
Thermoplastic molding compositions are disclosed which comprise an intimate admixture of (a) a copolymer of a vinyl aromatic compound and an α, β-unsaturated cyclic anhydride, including rubber-modified copolymers thereof, and (b) impact modifiers comprising graft copolymers, copolyesters, and rubber-modified homopolymers. Optionally, the compositions can also include a polyphenylene ether resin and further, optionally, a normally liquid polybutadiene oligomer. Mixing (a) with a polyphenylene ether leads to a compatible composition, markedly improved in heat deflection temperature.
| 2
|
TECHNICAL FIELD
[0001] The present invention relates in general to intra-board, chip-to-chip and to inter-board communications, at high bit rates and high data throughputs, using electro-optical interfacing and optical data communications.
BACKGROUND
[0002] Increasing bandwidth requirements is becoming hard to meet because of electrical signal attenuation and crosstalk through radiated electromagnetic energy while equalization, coding, and shielding techniques developed to preserve the quality of metal connections may require considerable power and complexity while showing poor scalability.
[0003] Optical communications is considered an alternative to copper links as well as for intra-board chip-to-chip communications and high performance data processing (re: “Silicon Photonics for Next Generation System Integration Platform”, Yasuhiko Arakawa, Takahiro Nakamura, Yutaka Urino and Tomoyuki Fujita, IEEE Communications Magazine, March 2013).
[0004] EP 2639978-A1 discloses a method and a system of data communications for an electro-optical board for data processing and communications based on the use of a silicon photonic interposer between a support PCB and a plurality of electronic chips mounted onto the optical interposer. This is with ordinary techniques using a hybrid integration of photonics and electronics by face-to-face bonding (flip-chip assembly). An array of optical I/O fibers is connected to waveguides defined in the silicon interposer. Through silicon vias (TSV) created in the photonic interposer provide the electrical path to/from the PCB substrate and the optoelectronic devices inside the silicon photonics die. The optical transmission is inside the silicon photonics die. Although somewhat of a higher parasitic phenomena may generally need to be accounted for at photonic and electronic device interfaces (e.g., Cu pillars and Pi pads), a great technological relief of separating photonics and electronics processes is achieved through such a hybrid integration approach.
[0005] The article “A Multi-wavelength 3D-compatible Silicon Photonics platform on 300 mm SOI wafers for 25 Gb/s Applications”, F. Boeuf et al., IEDM13, pages 353-356, reports developments of hybrid integration of silicon photonics. In particular, a 3D assembly of a photonic IC bottom die (PIC) is based on an SOI substrate with an optimized buried oxide (BOX) thickness for insertion loss minimization of grating couplers used to couple light in and out of optical I/O fibers, and companion electronics top die or dies (EIC). This may avoid the technological complications of full monolithic integration (interactions at processing level) and attendant limitation of access by system designers to state-of-the-art CMOS and BiCMOS technologies.
[0006] However, even such a hybrid architecture may fall short of efficiently resolving important technical problems in many situations because of several drawbacks and limitations. In particular, the number of usable electronic dies (ICs) may be limited by the maximum area of a single silicon photonic chip that depends on the overall dimensions of a CMOS mask (commonly about 800 mm 2 ). Large size, thin silicon photonic interposers with dense populations of through silicon vias defined therethrough are delicate to handle and assemble onto a PCB. Heat dissipation requirements of the electronic dies (ICs) limit proximity to optics and are often too high to host the electronic dies close to a laser diode array chip. Optoelectronic components integrated in silicon photonic dies may suffer from high sensitivity to large temperature variations, and thermal management may impose complex control circuitry and expensive packaging arrangements. The presence of large ICs bonded onto the silicon photonic interposer may limit optical interconnectivity underneath them.
SUMMARY
[0007] The drawbacks of known architectures of electro-optical multi-chip interconnection systems are overcome or significantly alleviated by arranging the dissipative electronic chips (ICs) side-by-side alongside or around a photonic waveguide fabric silicon die, onto which are mounted integrated transceiver circuit dies.
[0008] The transceiver circuit of each electronic die may be electrically coupled to a respective one of the dissipative signal processing and control IC chips. The coupling may be through a multi-chip module primary substrate of electrical interconnection for the IC chips with the respective transceiver circuit dies mounted on the photonic waveguide fabric silicon die, interposed between the photonic waveguide fabric silicon die as well as some or all the dissipative electronic chips (ICs), and the underlying printed circuit board (PCB). Some or all of the dedicated transceiver circuits may alternatively be grouped in a reduced number of electronic dies or even in a single die to be mounted over the photonic silicon die.
[0009] Thus, a number of electronic chips of the board may be interconnected with each other through different physical substrates, namely through the PCB and through at least a multi-chip module primary substrate of electrical interconnection, according to a design hierarchy based on the type of signals, bit-rate, density of electrical lanes and distance. The multi-chip module of primary substrate of electrical interconnection may be silicon, for example, a structured silicon wafer, or many other dielectric matrix materials of relatively lower cost, such as different types of thermo setting resins, glasses, ceramics and others. Typically, these dielectric materials are used to fabricate multi-layer substrates with many purposely defined metal layers, with up to sixteen levels.
[0010] The photonic waveguide fabric silicon die mounted over the multi-chip module substrate of electrical interconnection may support a number of optical links dedicated to very high speed data transmission (e.g., above 10 Gbps). Generally, the optical links may be point-to-point between electro-optical I/Os, forming a mesh network in the photonic silicon die. However, other networking topologies may alternatively be implemented, according to design requisites or choices (e.g., optical tree, optical ring, optical star or other common topologies). The photonic waveguide fabric silicon die may have defined therein waveguides and other passive and active optical and electro-optical devices, such as modulators, photo-detectors, optical splitters/combiners, optical taps and grating couplers. These devices are for performing optical modulation, photo-detection, optical signal distribution, optical power delivery and optical monitoring, optical I/O interfaces for high-speed data transfer and optical input means for a continuous wave (CW) laser light from an external source. The external source may be, for example, via an optical fiber and grating coupler, or via an edge-coupling or any other equivalent optical coupling.
[0011] The waveguides integrated in the photonic waveguide fabric silicon die may also realize, through optical I/O fibers coupled to the die, optical links for implementing inter-board communications among integrated circuit chips (ICs) present on different printed circuit boards (PCB) of the electronic system.
[0012] The electrical transceiver dies, atop the photonic waveguide fabric silicon die, may normally integrate, through standard BiCMOS and CMOS fabrication processes, analog and digital control circuits, modulator driver circuits, trans-impedance and limiting amplifiers (TIAs and LAs). These electronic circuits for optical/electrical interfacing may be coupled respectively with the optical modulators and photo-detectors integrated in the photonic waveguide fabric silicon die. The coupling is preferably through copper pillars of a three-dimensional (3D) assembly (i.e., according to a technique of hybrid integration by flip-chip bonding of the electronic integrated circuit (EIC) dies, upside down, onto the independently fabricated photonic integrated circuit die (PIC)), or alternatively, according to common bumps bonding techniques, through metal vias, surface pads and thermally re-flown micro solder bumps.
[0013] Fundamentally, the electrical transceiver dies atop the photonic waveguide fabric silicon die may interconnect with the electronic chips (ICs) through the multi-chip module primary substrate of electrical interconnection that hosts them. The substrate may be interposed between the photonic waveguide fabric silicon die and the underlying PCB, along fast electrical signal lanes of minimized length. The interposed module of primary substrate of electrical interconnection for a number of ICs may support intermediate data rate links on electrical tracks up to about 10 Gbps.
[0014] The interposed, multi-chip module primary substrate advantageously promotes an effective thermal separation of the optical communication links defined in the photonic waveguide fabric silicon die from signal processing and control electronic ICs, often of considerable size and highly dissipative, hosted on the module. Heat removal implementations and the overall heat management sub-system are greatly simplified, overcoming the criticalness and limitations of prior art architectures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The novel features, aspects and advantages of this invention, as well as details of illustrated exemplary embodiments thereof will be more fully understood from the ensuing description in connection with the drawings.
[0016] FIG. 1 is a general circuit diagram of an embodiment of an electro-optical multi-substrate, multi-chip interconnection system for intra-board, chip-to-chip, communications with an optical waveguide fabric layout without crossings.
[0017] FIG. 2 shows the general layout scheme of a transceiver circuit module of integration in a multi-module electrical transceivers die, correlated to optical modulation and photo detection structures realized in the photonic waveguide fabric silicon die underneath.
[0018] FIG. 3 shows an exemplary scheme of an interconnection, for intra-board, chip-to-chip communications, among four ICs through a multi-chip module primary substrate of electrical interconnection, interposed between the photonic waveguide fabric silicon die and the supporting printed circuit board.
[0019] FIG. 4 is a schematic cross-sectional view of the general architecture of the electro-optical multi-substrate, multi-chip interconnection system of FIG. 3 , with signal paths of interconnection of three hierarchically distinct levels, through the PCB, the multi-chip module primary substrate and the photonic waveguide fabric die of optical interconnection, respectively.
[0020] FIG. 5 illustrates a possible signal path, largely through the photonic waveguide fabric die, of high frequency signals to and from two distinct IC chips, hosted over the multi-chip module primary substrate of electrical interconnection.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0021] With reference to FIG. 1 , according to a first exemplary embodiment of the interconnection system of this disclosure, the interconnection structure uses a photonic waveguide fabric die 1 of optical interconnections that is generally coupled to at least one or to a plurality of integrated transceiver circuit dies 5 , four for the example shown, mounted on top of the photonic waveguide fabric die 1 . The mounting is generally in a peripheral position close to the edges of the die 1 .
[0022] The silicon photonic fabric die 1 may comprise an SOT substrate similar to the one described in the cited article “A Multi-wavelength 3D-compatible Silicon Photonics platform on 300 mm SOI wafers for 25 Gb/s Applications”, F. Boeuf et al., IEDM13, pages 353-356. The contents of this article are incorporated by express reference herein.
[0023] Optical modulation devices 4 may be Mach-Zender interferometers (MZI), ring resonators (RR) or Electro-Absorption (EA) modulators, and photonic detection devices 6 . These devices are generally photo detector diodes, and are realized in the photonic waveguide fabric die 1 under the footprints of the integrated transceiver circuit dies 5 to electrically couple with drivers and amplification circuits of a corresponding integrated transceiver circuit die 5 , upon mounting it atop the photonic waveguide fabric die 1 .
[0024] A number of single mode or multimode silicon trench waveguides (MMWs) 8 and 9 are also defined in the silicon photonic fabric die 1 . The waveguides are for distributing a continuous wave (CW) laser light to the modulation devices 6 and for carrying the modulated optical signals, output by the modulators 4 of intra-board, chip-to-chip communications among CMOS and/or BiCMOS integrated circuit system chips hosted on a multi-chip module of primary substrate 14 .
[0025] According to the embodiment shown, the waveguides 8 that distribute a continuous wave (CW) laser light from an on-board or remote source, injected through an input fiber and a grating coupler (or edge coupling) 3 to the optical modulating devices (MZI) 4 , as well as the waveguides 9 carrying modulated optical signals, do not cross. Alternatively, the layout of the waveguides may cross according to common practice physical geometries of silicon photonic waveguide fabrics.
[0026] The network of waveguides 9 carrying modulated optical signals defined in the silicon photonic fabric die 1 may also form dedicated optical links with optical I/O fibers that may be optically coupled to the photonic waveguide fabric silicon die 1 . This is for implementing inter-board communications among integrated circuit chips (ICn) that may be present on different printed circuit boards (PCB) of the electronic system.
[0027] As schematically depicted in FIG. 2 , each transceiver circuit die 5 may generally include several identical integrated circuit modules M. Each module defines pairs of a driver circuit 10 and a trans-impedance amplifier circuit 11 , respectively, for a modulation device 4 and a photo detector diode 6 present in the photonic waveguide fabric die 1 , to which they electrically couple, upon mounting the transceiver die 5 onto the photonic waveguide fabric die 1 . Signal input lines 12 and output lines 13 of the pairs of the integrated circuit modules M of the transceiver circuit dies 5 are metal strip lines defined over the surface photonic waveguide fabric die 1 that extends as far as the nearby edge of the die. This provides pads adapted for wire bonding.
[0028] As schematically depicted in FIG. 3 , generally dissipative CMOS and/or BiCMOS integrated circuit system chips IC 1 , 102 , . . . , ICn are arranged onto the surface of a multi-chip module 14 of primary substrate, side-by-side (i.e., juxtaposed) along the sides of the silicon photonic fabric die 1 . That is, the chips are at a relatively small separation distance, and the high frequency signal I/O bottom metal pads are arranged in a peripheral row, extending along the side of the IC chip facing toward the nearby silicon photonic die 1 . This is for shortening the electrical connection paths toward the metal strip lines 12 and 13 of the transceiver circuit dies 5 , as better illustrated in cross-sectional views of the multi-substrate architecture.
[0029] FIG. 4 is a schematic cross section of the general architecture of the electro-optical multi-substrate, multi-chip interconnection system of FIG. 3 .
[0030] Electrical coupling between the integrated transceiver circuit dies 5 and the modulation devices 4 and photo detector diodes 6 , integrated in the photonic waveguide fabric die 1 , may be implemented with any of the commonly used techniques. The shown embodiment uses the copper pillar technique which forms copper pillars 18 by filling with copper contact vias through a resist layer atop the transceiver circuit die 5 . This is followed by flip-chip bonding with a conductive adhesive of the ends of the copper pillars 18 onto correspondingly aligned metal pads of electrical connection to the modulation devices 4 and the photo detector diodes 6 on the surface of the photonic waveguide fabric die 1 . A void filling thermosetting gel 19 ensures a stable mechanical bond.
[0031] Relatively short bond wire bridges 15 connect the metal strip lines 12 and 13 of I/O metal pads of the transceiver circuit dies 5 to respective metal strip lines 16 defined on the surface of the primary substrate 14 . The metal strip lines 16 connect, through micro solder balls 17 , with respective high frequency signal I/O bottom metal pads of the IC chips hosted on the module 14 .
[0032] The arrows at the two ends of the dotted line traced across the schematic sectional view of FIG. 5 indicate a possible signal path including a photonic interconnection for high frequency signals of two distinct IC chips.
[0033] The interconnection system of this disclosure provides for an efficient implementation of three hierarchically distinct levels of interconnections, respectively through the PCB, through the multi-chip module primary substrate 14 and through the photonic die 1 of optical interconnection.
[0034] The primary substrate of electrical interconnections 14 may be any appropriate material. Silicon (i.e., a purposely structured wafer) or other dielectric matrix materials, such as thermosetting resin (e.g., epoxy resins), glasses, ceramics and others may be used for making a suitably structured primary substrate of electrical interconnections 14 . Typically, the dielectric matrix materials are used to fabricate substrates having several levels of purposely defined metal layers (as many as up to about 16 levels). The defined metal lanes of intermediate levels may be electrically connected through metal vias in the dielectric matrix material. In a test embodiment, a commercially available FR408 board was successfully used.
[0035] The module primary substrate 14 for a plurality of ICs has defined therein one or more intermediate level patterned metal layers besides top and bottom ones, and is electrically coupled to the supporting printed circuit board (PCB) through arrays of bumps 20 of thermally re-flown solder, according to common board mounting techniques.
[0036] Electrical paths between the hosted IC chips and the printed circuit in the PCB are realized through metal vias 21 across the full thickness of the primary substrate 14 or through metal vias 22 and defined portions 23 of an intermediate level metal, and metal vias 24 connecting to pad portions of the top level metal of the primary substrate 14 .
|
An intra-board chip-to-chip optical communications system has a high bit rate and high data throughput based on the use of a silicon photonic interposer. The system includes a multi-substrate electro-optical structure for communications with CMOS and/or BiCMOS IC chips of a PCB. The structure includes a multi-chip module primary substrate mounted over the supporting PCB. The multi-chip module primary substrate implements high frequency electrical interconnections between transceiver circuit chips, mounted on the silicon photonic interposer, and the IC chips.
| 8
|
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to Chinese Patent Application No. ______ (EastIP Ref. No. 05NI2753-1365-SMY), filed Jun. 20, 2005, entitled “System and Method of Electrostatic Discharge Protection for Signals at Various Voltages,” by Inventors Zhiliang Chen, Shifeng Zhao, Lieyi Fang, Zhen Zhu, and Jun Ye, commonly assigned, incorporated by reference herein for all purposes.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] The present invention is directed to integrated circuits. More particularly, the invention provides a system and method for electrostatic discharge protection. Merely by way of example, the invention has been applied to signals at various voltages. But it would be recognized that the invention has a much broader range of applicability.
[0005] For signals at various voltages, excessive electrostatic discharges (ESD) can cause failure of an integrated circuit. Therefore a robust on-chip ESD protection circuit is often required to protect the internal semiconductor circuitry. For example, the ESD protection circuit includes a triggering mechanism. When a pin voltage falls outside certain operating conditions, the triggering element enables the ESD protection circuit to conduct most of the ESD current. On the other hand, under normal operation conditions, the triggering mechanism should often ensure the ESD protection circuit remains in an off state.
[0006] FIG. 1 is a simplified conventional system for ESD protection. A system 100 includes an NMOS transistor 110 , a capacitor 120 , and a resistor 130 . The NMOS transistor 110 is a large transistor and coupled to both pads 140 and 150 . The capacitor 120 is connected to the pad 140 , and the resistor 130 is connected to the pad 150 . As shown in FIG. 1 , the pad 140 provides a signal to an internal circuit, which is protected by the system 100 . The pad 150 is biased to a ground voltage level of V ss . The capacitor 120 and the resistor 130 can provide a triggering mechanism. For example, the gate of the transistor 110 is grounded through the resistor 130 during normal operation. The NMOS transistor usually remains in an off state. During an ESD event, the voltage level at the pad 140 changes quickly with time. Therefore, the gate of the transistor 110 is AC-coupled through the capacitor 120 up to above the threshold voltage of the NMOS transistor 110 . The NMOS transistor 110 is thus turned on to conduct the ESD current. The system 100 has certain weaknesses in high-voltage applications. For example, the NMOS transistor 110 can be turned on by high voltage transient signal at the pad 140 even during normal operation. The system 100 may thus interfere with the normal operation of the internal circuit.
[0007] Hence it is highly desirable to improve techniques for ESD protection.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention is directed to integrated circuits. More particularly, the invention provides a system and method for electrostatic discharge protection. Merely by way of example, the invention has been applied to signals at various voltages. But it would be recognized that the invention has a much broader range of applicability.
[0009] According to one embodiment of the present invention, a system for protecting an integrated circuit is provided. The system includes a first transistor coupled to a first voltage and a second voltage, a second transistor coupled to the gate of the first transistor and the first voltage, a third transistor coupled to the gate of the second transistor and the first voltage, and a capacitor coupled to the gate of the second transistor and the second voltage. The first voltage is provided to the integrated circuit, the gate of the third transistor is configured to receive a first control signal, the gate of the second transistor is configured to receive a second control signal, and the second control signal is capable of turning off the second transistor a time period after the third transistor is turned off.
[0010] According to another embodiment, a method for protecting an integrated circuit includes providing a system for protecting the integrated circuit. The system includes a first transistor coupled to a voltage, a second transistor, a third transistor, and a capacitor. Additionally, the method includes turning on the first transistor, receiving a first control signal by the third transistor, turning off the third transistor in response to the first control signal, and receiving a second control signal by the second transistor a time period after the third transistor being turned off. Moreover, the method includes turning off the second transistor in response to the second control signal, and turning off the first transistor in response to the second transistor being turned off. The voltage is provided to the integrated circuit, and the first transistor is in an on state within the time period.
[0011] According to yet another embodiment of the present invention, a system for protecting an integrated circuit includes a first transistor coupled to a first voltage and a second voltage, and a second transistor including an emitter, a base, and a collector. Additionally, the system includes a resistor coupled to the base, and a first diode including an anode and a cathode and coupled to the second voltage and the resistor. The first voltage is provided to the integrated circuit, the anode is connected to the second voltage, and the cathode is connected to the resistor.
[0012] According to yet another embodiment of the present invention, a system for protecting an integrated circuit includes a first transistor coupled to a first voltage and a second voltage, and a second transistor including an emitter, a base, and a collector. Additionally, the system includes a first diode including an anode and a cathode and coupled to the base and the resistor, and a resistor coupled to the second voltage. The first voltage is provided to the integrated circuit, the cathode is connected to the base and the anode is connected to the resistor.
[0013] According to yet another embodiment of the present invention, a method for protecting an integrated circuit includes providing a system for protecting the integrated circuit. The system includes a first transistor, a second transistor, a diode, and a resistor. Additionally, the method includes receiving a voltage by the first transistor and the second transistor, causing a breakdown of the diode, turning on the second transistor in response to the breakdown of the diode, and turning on the first transistor in response to the second transistor being turned on. The voltage is provided to the integrated circuit. For example, the integrated circuit is protected from any damage due to excessive electrostatic discharges.
[0014] According to yet another embodiment of the present invention, a system for protecting an integrated circuit includes a first transistor coupled to a first voltage and a second voltage, a second transistor coupled to the gate of the first transistor and the first voltage, a third transistor coupled to the gate of the second transistor and the first voltage, and a first capacitor coupled to the gate of the second transistor and the second voltage. Additionally, the system includes a fourth transistor coupled to a third voltage and the second voltage, a fifth transistor including an emitter, a base, and a collector, and a first diode coupled directly or indirectly to the second voltage and the fifth transistor. Moreover, the system includes a second diode coupled to the base and the first voltage, and a clamping device coupled to the gate of the fourth transistor and the second voltage. The first voltage is provided to the integrated circuit, the third voltage is provided to the integrated circuit. The gate of the third transistor is configured to receive a first control signal, and the gate of the second transistor is configured to receive a second control signal.
[0015] According to yet another embodiment of the present invention, a method for protecting an integrated circuit includes providing a system for protecting the integrated circuit. The system includes a first transistor coupled to a first voltage, a second transistor, a third transistor, a capacitor, a fourth transistor, a fifth transistor, a first diode, and a second diode. Additionally, the method includes turning on the first transistor, receiving a first control signal by the third transistor, and turning off the third transistor in response to the first control signal. Moreover, the method includes receiving a second control signal by the second transistor a time period after the third transistor being turned off, turning off the second transistor in response to the second control signal, and turning off the first transistor in response to the second transistor being turned off. Moreover, the method includes receiving the second voltage by the fourth transistor and the fifth transistor, causing a breakdown of the first diode, turning on the fifth transistor in response to the breakdown of the first diode, and turning on the fourth transistor in response to the fifth transistor being turned on. Also, the method includes turning on the second diode if the second voltage is larger than the first voltage by a first predetermined value. The first voltage is provided to the integrated circuit, and the second voltage is provided to the integrated circuit.
[0016] According to yet another embodiment of the present invention, a system for protecting an integrated circuit includes a transistor coupled to a first voltage and a second voltage, a Zener diode including an anode and a cathode and coupled to the gate of the second transistor and the first voltage, and a resistor coupled to the gate of the second transistor and the second voltage. The first voltage is provided to the integrated circuit, the anode is connected to the gate, and the cathode is connected to the first voltage.
[0017] Many benefits are achieved by way of the present invention over conventional techniques. For example, some embodiments of the present invention provide effective triggering schemes, which can improve ESD protections. Certain embodiments of the present invention provide different triggering schemes based on pin voltage ratings and applications. Some embodiments of the present invention provide an ESD protection system that does not cause any noticeable difference during normal operation.
[0018] Various additional objects, features and advantages of the present invention can be more fully appreciated with reference to the detailed description and the accompanying drawings that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a simplified conventional system for ESD protection;
[0020] FIG. 2 is a simplified system for electrostatic discharge protection according to an embodiment of the present invention;
[0021] FIG. 3 is a simplified system for electrostatic discharge protection according to another embodiment of the present invention;
[0022] FIG. 4 is a simplified system for electrostatic discharge protection according to yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention is directed to integrated circuits. More particularly, the invention provides a system and method for electrostatic discharge protection. Merely by way of example, the invention has been applied to signals at various voltages. But it would be recognized that the invention has a much broader range of applicability.
[0024] As shown in FIG. 1 , the system 100 is often not suitable for high voltage applications. For example, the normal voltage at the pad 140 can be up to 40 volts or higher. Hence the rate of voltage change can be large under normal conditions, and can turn on the NMOS transistor 110 to interfere with the internal circuit.
[0025] FIG. 2 is a simplified system for electrostatic discharge protection according to an embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. A system 200 includes a transistor 210 , a resistor 220 , transistors 230 and 240 , and a capacitor 250 . Although the above has been shown using a selected group of components for the system 200 , there can be many alternatives, modifications, and variations. For example, some of the components may be expanded and/or combined. Other components may be inserted to those noted above. Depending upon the embodiment, the arrangement of components may be interchanged with others replaced. Further details of these components are found throughout the present specification and more particularly below.
[0026] The transistor 210 is an NMOS transistor and coupled to both pads 260 and 262 . For example, the NMOS transistor is a high-voltage transistor. As shown in FIG. 2 , the pad 260 provides a signal to another system, which is protected by the system 200 . For example, the protected system includes an integrated circuit. In another example, the pad 260 is biased to a high voltage level of V dd , which serves as a power supply to the protected system. In one embodiment, a high voltage level of V dd is equal to or lower than 40 volts under normal operation of the protected system. Additionally, the pad 262 is biased to a voltage level of V ss . For example, the voltage level of V ss is equal to 0 volt under normal operation of the protected system. The resistor 220 and the capacitor 250 both are connected to the pad 262 .
[0027] According to one embodiment of the present invention, the transistors 230 and 240 each are a PMOS transistor, whose source is coupled to the pad 260 . For example, the PMOS transistor is a high-voltage transistor. In another embodiment, the protected system provides a control signal 270 to the gate of the transistor 240 , and a control signal 272 to the gate of the transistor 230 . For example, the control signal 270 is at a logic high level after the protected system starts powering up, and at a logic low level before the protected system starts powering up. In another example, the control signal 270 is a power-on-reset (POR) signal. Additionally, the control signal 272 is set to a logic high level after a delay period from the time when the control signal 270 changes from the logic low level to the logic high level. For example, the delay period is about several microseconds. In another example, the delay period is shorter than 10 μs. In yet another example, the protected system includes an inverter 274 , which outputs the control signal 272 .
[0028] According to another embodiment, the transistor 210 serves as a protection device for conducting the ESD current. The resistor 220 , the transistors 230 and 240 , and the capacitor 250 can provide for a triggering mechanism. For example, during normal operation of the protected system, the control signals 270 and 272 each are at a logic high level. The control signal 270 turns off the transistor 240 , and the control signal 272 turns off the transistor 230 . The gate of the transistor 210 is thus grounded through the resistor 220 , and the transistor 210 is turned off. The system 200 is in an off state during normal operation of the protected system.
[0029] In another example, the voltage level at the pad 260 increases to a threshold voltage at which the control signal 270 changes from a logic low level to a logic high level. Before the threshold voltage is reached, the gate of the transistor 240 is biased to the logic low level, and the transistor 240 is turned on. In response, the gate of the transistor 230 is pulled high through the transistor 240 . The transistor 230 is turned off, and the gate of the transistor 210 is grounded through the resistor 220 . The transistor 210 is turned off. When the voltage level at the pad 260 reaches the threshold voltage, the control signal 270 changes from a logic low level to a logic high level. The transistor 240 is turned off.
[0030] As discussed above, the control signal 272 is set to a logic high level after a delay period from the time when the control signal 270 changes from the logic low level to the logic high level. Within the delay period, the gate of the transistor 230 is DC floating. For example, the system 200 includes a parasitic capacitor 280 , which includes parasitic capacitors between the gate of the transistor 230 and the pad 260 . In another example, the voltage level at the pad 260 keeps rising during an ESD event. The source voltage of the transistor 230 also increases but the gate voltage of the transistor 230 increases slowly due to a small ratio of the parasitic capacitor 280 to the capacitor 250 . For example, in response to excessive electrostatic discharges, the gate voltage of the transistor 230 is substantially AC grounded. Accordingly, the transistor 230 is turned on in response to excessive electrostatic discharges. When the transistor 230 is turned on, the transistor 210 is also turned on. The transistor 210 serves as a protection device for conducting the ESD current.
[0031] After the delay period, the control signal 272 is set to a logic high level. The control signal 270 turns off the transistor 240 , and the control signal 272 turns off the transistor 230 . The gate of the transistor 210 is thus grounded through the resistor 220 , and the transistor 210 is turned off. The system 200 is in an off state during normal operation of the protected system.
[0032] As discussed above and further emphasized here, FIG. 2 is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. For example, the pad 260 is biased to a voltage other than the power supply V dd . In another example, the delay period is adjusted to cover the duration of an ESD event. For some embodiments, the duration of an ESD event is about a couple of hundred nanoseconds, so the delay period of several microseconds is sufficient.
[0033] FIG. 3 is a simplified system for electrostatic discharge protection according to another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. A system 300 includes a transistor 310 , a resistor 320 , a transistor 330 , a resistor 340 , and a diode 350 . Although the above has been shown using a selected group of components for the system 300 , there can be many alternatives, modifications, and variations. For example, some of the components may be expanded and/or combined. Other components may be inserted to those noted above. Depending upon the embodiment, the arrangement of components may be interchanged with others replaced. Further details of these components are found throughout the present specification and more particularly below.
[0034] In one embodiment, the transistor 310 is a NMOS transistor. For example, the NMOS transistor is a low voltage transistor. Additionally, the transistor 330 is a bipolar transistor. For example, the bipolar transistor is a PNP transistor. In another exampe, the transistor 330 includes a base region inside an N well, and an emitter region and a collector region formed by P + diffusion regions in the N well. Moreover, the diode 350 is Zener diode. As shown in FIG. 3 , the gate of the transistor 310 is connected to the resistor 320 and the collector of the transistor 330 . The base of the transistor 330 is connected to the diode 350 through the resistor 340 . The emitter of the transistor 330 is connected to a pad 360 , which is also coupled to the drain of the transistor 310 . For example, the pad 360 provides a signal to another system, which is protected by the system 300 . In one embodiment, the protected system includes an integrated circuit. In another example, the voltage at the pad 360 ranges from 0 volt to 5 volts under normal operation of the protected system. Additionally, the source of the transistor 310 and the resistor 320 both are connected to a pad 362 , and the pad 362 is biased to a ground voltage level of V ss .
[0035] During normal operation, the Zener diode 350 does not breakdown. The gate of the transistor 310 is hence grounded through the resistor 320 , and the transistor 310 is turned off. Therefore, the system 300 is in an off state under normal operation of the protected system. During an ESD event, the voltage level for the pad 360 increases up to or above the sum of the Zener breakdown voltage and the voltage drop between the base and the emitter of the transistor 330 . In response, the Zener diode breaks down. The diode current biases the base of the transistor 330 and turns on the transistor 330 . Accordingly, the collector current of the transistor 330 raises the gate voltage of the transistor 310 through the resistor 320 . The transistor 310 is turned on for conducting the ESD current.
[0036] For example, the Zener diode 350 has a breakdown voltage ranging from 5.5 volts to 6 volts, and the normal voltage level for the pad 360 ranges from 0 to 5 volts. In one embodiment, the breakdown voltage of the Zener diode 350 is equal to about 5.8 volts. During an ESD event, the voltage level for the pad 360 increases up to or above the sum of 5.8 volts and 0.7 volts, which is equal to about 6.5 volts. In response, the Zener diode 350 breaks down. In another example, the resistor 340 is used to limit the current flowing through the Zener diode 350 . Without the resistor 340 , a high current may cause the failure of the Zener diode 350 . In one embodiment, the resistor 340 is placed between the based of the transistor 330 and the cathode of the Zener diode 350 as shown in FIG. 3 . In another embodiment, the resistor 340 is placed between the anode of the Zener diode 350 and the pad 362 .
[0037] As discussed above and further emphasized here, FIG. 3 is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. For example, additional Zener diodes are added in series with the Zener diode 350 . With additional Zener diodes, the triggering voltage for ESD protection is adjusted. In one embodiment, the Zener diode has a breakdown voltage of about 5.8 volts, and the normal voltage level for the pad 360 is higher than 5 volts. With the additional Zener diodes, the ESD protection is turned off during normal operation.
[0038] FIG. 4 is a simplified system for electrostatic discharge protection according to yet another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. A system 400 includes the transistor 210 , the resistor 220 , the transistors 230 and 240 , the capacitor 250 , the transistor 310 , the resistor 320 , the transistor 330 , the resistor 340 , the diode 350 , a diode 410 , and a claming device 420 . Although the above has been shown using a selected group of components for the system 400 , there can be many alternatives, modifications, and variations. For example, some of the components may be expanded and/or combined. Other components may be inserted to those noted above. Depending upon the embodiment, the arrangement of components may be interchanged with others replaced. Further details of these components are found throughout the present specification and more particularly below.
[0039] As shown in FIG. 4 , the transistor 210 is coupled to both pads 430 and 432 . The pad 430 provides a signal to another system, which is protected by the system 400 . For example, the protected system includes an integrated circuit. In another example, the pad 430 is biased to a high voltage level of V dd , which serves as a power supply to the protected system. In another example, the pad 432 is biased to a voltage level of V ss . Additionally, the resistor 220 and the capacitor 250 both are connected to the pad 432 , and the transistors 230 and 240 are coupled to the pad 430 . Moreover, the protected system provides a control signal 270 to the gate of the transistor 240 , and a control signal 272 to the gate of the transistor 230 . For example, the protected system includes the inverter 274 , which outputs the control signal 272 .
[0040] The gate of the transistor 310 is connected to the resistor 320 and the collector of the transistor 330 . The base of the transistor 330 is connected to the diode 350 through the resistor 340 . The emitter of the transistor 330 is connected to a pad 434 , which is also coupled to the drain of the transistor 310 . Additionally, the source of the transistor 310 and the resistor 320 both are connected to the pad 432 . Moreover, the diode 410 is coupled between the base of the diode 330 and the pad 430 . For example, the diode 410 is a high voltage diode. In another example, the diode 410 includes an N well and a P well. The clamping device 420 is coupled between the gate of the transistor 310 and the pad 432 . For example, the clamping device 420 includes PN junction diodes, NMOS diodes, and/or Zener diodes in series.
[0041] The pads 430 and 434 each provide a signal to the system protected by the system 400 . For example, the pad 430 is biased to a high voltage level of V dd , which serves as a power supply to the protected system. In another example, the pad 434 is biased to a voltage ranging from 0 volt to 5 volts under normal operation of the protected system. In yet another example, the pad 432 is biased to a voltage level of V ss . In one embodiment, the voltage level of V ss is equal to 0 volt under normal operation of the protected system.
[0042] As shown in FIG. 4 , the diode 410 is used to ensure that the voltage at the pad 434 does not exceed the voltage at the pad 430 by a predetermined amount. For example, if a positive ESD strike occurs between the pads 434 and 430 , the ESD current can be conducted through the emitter-base junction of the transistor 330 and the diode 410 . Additionally, there are two parasitic diodes 440 and 442 , which are body diodes for the transistors 310 and 210 respectively. The diode 440 is used to ensure that the voltage at the pad 432 does not exceed the voltage at the pad 434 by a predetermined amount, and the diode 442 is used to ensure that the voltage at the pad 432 does not exceed the voltage at the pad 430 by a predetermined amount. For example, the parasitic diode 440 or 442 can conduct the ESD current if a negative ESD strike occurs between the pad 434 or 430 and the pad 432 respectively.
[0043] Additionally, the clamping device 420 is used to limit the gate voltage of the transistor 310 to a predetermined value. For example, the predetermined value is higher than the threshold voltage of the NMOS transistor 310 . In another example, the clamping device 420 can protect the transistor 310 from being damaged during an ESD event.
[0044] As discussed above and further emphasized here, FIG. 4 is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. For example, the pads 430 and 434 each provide a signal to the protected system. In one embodiment, the pad 430 is biased to a voltage other than the high voltage level of V dd , and/or the pad 432 is biased to a voltage other than one between 0 volt and 5 volts. In yet another embodiment, the pad 432 is biased to a voltage other than the ground voltage level of V ss .
[0045] According to another embodiment of the present invention, the capacitor 120 is replaced by a Zener diode in FIG. 1 . The anode of the Zener diode is coupled to the gate of the transistor 110 , and the cathode of the Zener diode is coupled to the pad 140 . In yet another embodiment, additional Zener diodes are added in series with the Zener diode. Using additional Zener diodes, the triggering voltage for ESD protection is adjusted. In yet another embodiment, the protected system includes an integrated circuit.
[0046] The present invention has various advantages. Some embodiments of the present invention provide effective triggering schemes, which can improve ESD protections. Certain embodiments of the present invention provide different triggering schemes based on pin voltage ratings and applications. Some embodiments of the present invention provide an ESD protection system that does not cause any noticeable difference during normal operation.
[0047] Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims.
|
System and method for protecting an integrated circuit. The system includes a first transistor coupled to a first voltage and a second voltage, a second transistor coupled to the gate of the first transistor and the first voltage, a third transistor coupled to the gate of the second transistor and the first voltage, and a capacitor coupled to the gate of the second transistor and the second voltage. The first voltage is provided to the integrated circuit, the gate of the third transistor is configured to receive a first control signal, the gate of the second transistor is configured to receive a second control signal, and the second control signal is capable of turning off the second transistor a time period after the third transistor is turned off.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
This case claims priority from U.S. Provisional Patent Application No. 60/633,943, filed Dec. 07, 2004, and is related to the companion case, U.S. Provisional Application No. 60/633,889, filed Dec. 07, 2004, entitled “Snap Fit Sealing Gasket with Precisely Located Internal Retainer Ring For Square Pipe Grooves,” by the same inventors, which was filed concurrently.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to sealing gaskets used for pipe joints in which a male spigot pipe section is installed within a mating female socket pipe section and, more specifically, to an improved gasket and installation method for installing a locked-in gasket within a preformed gasket groove in a section of pipe used to form a pipe joint. 2. Description of the Prior Art
Pipes formed from thermoplastic materials including polyethylene, polypropylene and polyvinyl chloride are used in a variety of industries. In forming a joint between sections of pipe, the spigot or male pipe end is inserted within the female or socket pipe end. An annular, elastomeric ring or gasket is typically seated within a groove formed in the socket end of the thermoplastic pipe. As the spigot is inserted within the socket, the gasket provides the major seal capacity for the joint. It is critical, during the installation process, that the gasket not be able to twist or flip since a displaced or dislocated gasket will adversely affect the ultimate sealing capacity of the joint.
One early attempt to ensure the integrity of pipe joints used under demanding conditions was to provide local reinforcement of the groove portion of the female socket end by means of a heavier wall thickness in this region of the pipe. In some cases, reinforcing sleeves were also utilized. Each of these solutions was less than ideal, in some cases failing to provide the needed joint integrity and often contributing to the complexity and expense of the manufacturing operation.
In several of the prior art commercial systems using pipes with preformed grooves, the sealing gaskets were provided in two parts. The main gasket body was formed of an elastomeric material and typically featured an internal groove or recess. A hardened band, formed of rigid plastic or metal, was installed within the groove. While such retaining bands helped to resist axial forces acting on the gasket during assembly of the joint, the band could become displaced or twisted during the insertion operation.
In the early 1970's, a new technology was developed by Rieber & Son of Bergen, Norway, referred to in the industry as the “Rieber Joint.” The Rieber system employed a unique pipe belling operation which seated the sealing gasket during belling. In the Rieber process, an elastomeric gasket was installed within an internal groove in the socket end of the female pipe as the female or belling end was simultaneously being formed by forcing the belling end over a forming mandrel. Rather than utilizing a preformed groove, the Rieber process provided a prestressed and anchored elastomeric gasket during the belling operation. Because the pipe groove was, in a sense, formed around the gasket, the gasket was securely retained in position and did not tend to twist or flip or otherwise allow impurities to enter the sealing zones of the joint, thus increasing the reliability of the joint and decreasing the risk of leaks or possible failure due to abrasion. The Rieber process is described in the following issued United States patents, among others: U.S. Pat. Nos. 4,120,521; 4,061,459; 4,030,872; 3,965,715; 3,929,958; 3,887,992; 3,884,612; and 3,776,682.
Despite the advances offered by the Rieber process, the belling operation was somewhat complicated and costly. Also, certain situations exist in which it would be desirable to install a gasket within a preformed groove in the selected pipe end, rather than utilizing an integrally installed gasket in which the groove in the pipe is formed around the gasket.
The present invention has, as one object, to provide an improved pipe gasket for use in pipe joints which offers the advantage of a Rieber type locked-in seal while allowing the gasket to be installed in a preformed groove.
Another object of the invention is to provide an improved gasket which is securely retained within a preformed pipe groove without the necessity of a separate retaining band.
Another object of the invention is to provide a design formula for precisely locating an internal retaining ring within the elastomeric body of a sealing gasket which is thereafter inserted in a preformed pipe groove.
Another object of the invention is to provide a method for installing a gasket having a known external diameter and having an internal retainer ring within the mouth opening of a bell end of a pipe section where the external diameter of the gasket exceeds the nominal internal diameter of the mouth opening and where the location of the retainer ring is predetermined to facilitate the insertion process.
SUMMARY OF THE INVENTION
A method is shown for installing a sealing gasket within a preformed gasket-receiving groove provided within the bell end of a pipe section. The bell end has a mouth opening which is engageable with a spigot end of a mating pipe section to form a pipe joint. The pipe section having the bell end is first oriented along a longitudinal work axis. A sealing gasket is then inserted within the mouth opening of the bell end. The sealing gasket is oriented at an oblique angle with respect to the longitudinal work axis, whereby a leading edge of the sealing gasket moves past the annular groove provided in the bell end. A retracting force is then exerted on the sealing gasket by pulling the leading edge thereof backwards in the direction of the mouth opening of the bell end until the gasket snaps into a locked-in position within the annular groove.
An improved sealing gasket design is also shown having a body formed of a flexible elastomeric material and having a relatively rigid ring which is located at an embedded location which circumscribes the gasket body at one circumferential location. Preferably, the relatively rigid ring is made of a metal such as steel or a rigid plastic or composite and is generally round in cross-section. The relatively rigid ring tends to resist axial forces tending to displace the gasket from the annular groove when in position within the groove. The embedded location of the ring is precisely determined to allow the gasket to be obliquely inserted within the bell end of the pipe and subsequently snap-fitted into position while securely retaining the gasket in position, whereby the gasket is securely retained in a locked-in position within the preformed groove in the pipe belled end.
Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified side cross sectional view of the preformed gasket receiving groove formed in the bell pipe end of the pipe joint of the invention.
FIG. 2 is a view of the basic joint dimensions of the pipe joint which uses the sealing gasket of the invention. 1 .
FIG. 3 a side cross-sectional view of a sealing gasket of the invention showing the relative dimensions of the gasket and retainer ring.
FIG. 4 is a simplified, schematic view of the installation procedure used to install a sealing gasket of the invention within a mating pipe groove in the bell pipe end of the pipe joint.
FIG. 5 is a side cross sectional view similar to FIG. 4 illustrating the manufacturing constraints which are taken into account in determining the retainer ring placement.
FIG. 6 is a two dimensional model of a pipe groove showing a sealing gasket of the invention installed therein and characterizing the degree of difficulty in installing a sealing gasket having a steel retainer ring into a typical sewer pipe.
FIG. 7 is a side cross-sectional view of a typical sealing gasket of the type under consideration located in a preformed groove of a bell pipe end and illustrating the placement of the retainer ring therein as well as the groove geometry.
DETAILED DESCRIPTION OF THE INVENTION
The improved sealing gasket of the invention is installed within a gasket receiving groove which is preformed within the bell end 19 of a section of thermoplastic pipe. The pipe section can be formed of any of a variety of commercially available thermoplastic materials, such as the polyolefin family including polyethylene and polypropylene as well as polyvinyl chloride and similar materials. Thermoplastic pipes of this general type are used in a variety of industrial settings including water, sewage and chemical industries. The bell end 19 of the thermoplastic pipe section has a mouth opening which is engageable with a spigot end of a mating pipe section to form a pipe joint. By “preformed” is meant that the gasket receiving groove was formed at the pipe manufacturing facility with the intention that a sealing gasket then be installed in the groove at the factory, or that a gasket be later installed in the field. The use of the term “reformed” is intended to distinguish Rieber style pipe which the sealing gasket is simultaneously sealed during the pipe belling operation.
A sealing gasket of the general type under consideration is shown in cross section as 13 in FIG. 7 . Preferably, the gasket 13 is an annular, ring-shaped member formed of a flexible elastomeric material, such as a suitable rubber. As will be apparent from FIG. 7 , the gasket 13 has an external diameter “d 1 ” which is greater than the internal diameter “d 2 ” of the mouth opening of the bell end of the pipe (it being understood that the diameters referred to herein as “d 1 ” and “d 2 ” are actually “half-diameters” as viewed in the quarter sectional view of FIG. 7 ). The elastomeric material used to form the body 23 will vary in composition depending upon the end application but may include natural and synthetic rubbers including, for example, SBR, EPDM, NBR, nitrile rubber, etc. In the embodiment of the gasket shown in FIG. 7 , the gasket includes an inner sealing surface 25 which, in this case, is provided with a series of ribs or serrations 27 . The gasket includes a leading face 29 which joins a convex nose region 31 which continues on to form a primary sealing surface 33 . In this case, the primary sealing surface 33 is an evenly sloping, outer face of the body 23 which forms a lip region 35 thereof. The lip region is separated from a trailing face 37 of the gasket body by means of convex regions 39 , 41 which allows the lip region 35 to “flap” inwardly as the mating male, spigot end of a mating pipe section encounters the primary sealing surface 33 of the gasket and pushes the lip region 35 in the direction of the surface 41 . The lip region 35 is actually shown compressed slightly inwardly in FIG. 7 . The gasket 13 in FIG. 7 is intended to merely represent the type of sealing gasket toward which the principles of the present invention can be applied.
The gasket body 23 also has a relatively rigid ring 43 embedded therein having a midpoint 44 . The relatively rigid ring 43 can be made of a variety of relatively rigid materials such as metals, rigid plastics and composites, but is preferably made of steel. The relatively rigid ring is generally round in cross-section, as shown in FIG. 1 , and circumscribes the annular body 23 of the gasket 13 at one embedded, circumferential location.
The positioning of the relatively rigid ring within the gasket body is critical to the method of the invention. Previously, the ring location was determined primarily by trial and error and was influenced by such factors as manufacturing constraints. In the particular embodiment of the gasket shown in FIG. 7 , the axis 45 passes through the approximate mid-point 47 of the gasket body 13 . The relatively rigid ring 43 is located in front of the vertical axis 45 as viewed along the longitudinal axis of the pipe 46 in a location adjacent the convex nose region 31 . The relatively rigid ring 43 also has a cross-sectional diameter (“d 3 ” in FIG. 7 ) and an internal diameter which defines a locus of points (e.g., point 51 ) which is equal to or greater than the internal diameter (“d 2 ” in FIG. 7 ) of the bell end of the pipe which joins the annular groove 15 .
In other words, if a point 51 on the inner surface of the ring 43 is one point in the locus of points, an imaginary line 53 drawn tangent to the point 51 is approximately at the internal diameter “d 2 ” of the pipe or is located further inward in the direction of the bottom surface 55 of the groove 15 .
The relatively rigid ring 43 of the annular gasket tends to resist axial forces tending to displace the gasket from the annular groove 15 when in position within the groove. To position the ring 43 at a location within the gasket body 23 so that it resides partly or wholly within the groove 15 at first seems unexpected, since the ring diameter then exceeds the normal pipe diameter “d 2 ”. As will be explained in detail, the sealing gasket of the invention has the retainer ring 43 precisely located to both insure that the gasket will not flip or twist or be dislocated, while at the same time achieving the greatest ease of installation. The method of the invention also provides a convenient mechanism for installing the gasket within the preformed pipe groove, even with a relatively rigid ring whose ultimate internal diameter equals or exceeds the internal diameter of the remainder of the pipe.
The present invention contains the results of an analytical study of the geometrical conditions for a feasible installation of a sealing gasket with a retainer steel ring into a typical socket for plastic pressure pipe, with the type of “triangular” groove frequently encountered in industry. By “triangular” is meant a radiussed groove such as that shown in FIG. 1 , which groove is to be distinguished from the “square” groove used in some applications. The inventive method generates a series of ratios initially developed in 3D but presented herein in 2D which characterize the degree of difficulty and possible permanent damage during the assembly of male and female pipes to form a pipe joint. These ratios, in combination with manufacturing constraints, can be used to define the best location for the retainer ring 43 . This methodology can be extended to other groove shapes and seal designs in a straightforward manner.
Modeling Considerations: The assembly is modeled as a study of 3D geometric paths superimposed on a 2D drawing. The analysis which follows is based on the assumption that the retainer ring will slide along a path that is defined by the rubber thickness around it. The path is drawn by generating an offset from the bell profile using this thickness. Since the ring is fairly flexible, it is reasonable to neglect the compression in the rubber. Once the ratios are defined, this path is no longer required, so it is excluded from the drawings.
Basic Geometric Data: The geometrical data was taken from an existing sealing gasket profile.
Mechanical Properties: Mechanical Properties are not considered. It is assumed that the ring and the rubber are flexible enough to bend and twist as necessary to be installed, but incompressible enough to retain their basic thickness.
Joint Dimensions: FIGS. 2 and 3 illustrate the basic joint dimensions. The parameters presented allow a designer to consider the values that are most likely and critical. The most critical values are maximum spigot dimensions (OD) and minimum socket dimensions (all the other dimensions shown). Relevant dimensions are listed in the Table 1 below.
TABLE 1
Joint Dimensions
Symbol
Name
Comments
OD
Spigot Diameter
Use maximum for critical condition.
D s
Socket Diameter
Use minimum for critical condition.
L d
Diagonal Length
Distance from the bottom of the groove to
the edge of the groove on the opposite
side, along a line that passes through the
centers of the corresponding fillets. In the
current example it is obtained by
geometric construction. It might also be
calculated from other basic dimensions.
D g
Groove Diameter
Use minimum for critical condition.
R 1
Lip side fillet radius
This dimension is required for the
construction of the L d dimension.
R 2
Bottom fillet radius
This dimension is required for the
construction of the L d dimension.
α
Lip side angle
Typically 30°
Seal Dimensions: Only three dimensions are required for the purpose of analysis of the ring location. These are shown in FIG. 3 of the drawings and are described in Table 2 which follows. The angle α is usually very close to the corresponding angle in the joint. It can be safely assumed that it is the same.
TABLE 2
Seal Dimensions
Symbol
Name
Comments
D a
Alignment ramp diameter
Used to apply manufacturing
constraints to the ring diameter D r .
E g
Distance to groove wall
Together with D r defines the ring
location.
D r
Ring diameter
Together with E g defines the ring
location.
Installation Procedure: In order to install the seal, the ring is deformed into an oval shape that can be approximated as an ellipse. FIG. 4 of the drawings illustrates the stages in a typical sealing ring installation. First a pipe section 19 is provided having a bell end opening. The pipe section having the bell end opening is oriented along a longitudinal work axis which is usually conveniently a horizontal axis, although other axes are conceivable. The sealing gasket 19 , typically formed of rubber, is provided having a relatively rigid internal retainer ring 43 which circumscribes the gasket interior at one circumferential location. The sealing gasket is temporarily transformed from a generally cylindrical shape to a generally elliptical shape to allow the gasket to be inserted within the bell end of the pipe.
The left most view in FIG. 4 shows the gasket 19 being inserted within the mouth opening of the bell pipe end, the annular gasket being oriented at an oblique angle with respect to the horizontal work axis. As shown from left to right in FIG. 4 , this allows a trailing edge of the gasket to engage the annular groove, and a leading edge of the annular gasket to be moved past the annular groove provided in the bell end. A retracting force is then exerted on the annular gasket by pulling the leading edge thereof backwards in the direction of the mouth opening of the bell end until the gasket again assumes a generally cylindrical shape and snaps into a locked-in position within the annular groove.
The above procedure allows the sealing gasket to travel inside the socket although its diameter is greater than the socket ID. The perimeter of this ellipse can be calculated from its maximum and minimum diameters at critical stages of the assembly. These diameters can be estimated from the joint dimensions. The viability of installing the ring can be established by comparing these parameters to the original ring perimeter, which is fixed. This comparison is equivalent to comparing the corresponding diameters.
Installation ratios: Depending on how much the oval is bent or distorted, three different types of installation conditions have been defined, with their corresponding diameter ratios. These conditions are defined in Table 3 which follows. When each ratio becomes less than 1, the corresponding kind of installation is feasible. As the ratios become larger, the installation becomes increasingly difficult.
TABLE 3
Definition of installation types and their ratios
Type of
installation
Comments
Ratio
Easy
The oval remains flat at all times.Minimum seal distortion. Littleforce is required for the assembly.
R
ie
=
2
D
R
D
S
+
L
D
-
4
E
G
Forced
Forced installation. The ovalshould remain flat, but it can stillbe slightly bent outwards from itsbasic plane, because installationforce is not evenly applied.
R
if
=
2
D
R
D
R
+
L
D
-
2
E
G
Bent
Difficult installation, the oval hasto bend outward from its originalplane (it is no longer flat). Thiscan produce permanentdeformation and severe distortionin the ring.
R
ib
=
2
D
R
L
D
+
D
G
-
4
E
G
Additionally, in order to assess the ability of the ring to remain in position, a retention ratio is defined, which is simply D r /D s . The greater this ratio, the more difficult it is to remove the ring after installation.
Manufacturing Constraints: The thickness of rubber around the steel ring is handled as a manufacturing constraint. As shown in the following figure, two constraint parameters establish the minimum rubber thickness on the groove side (T g ) and on the spigot side (T s ). The Table 4 which follows defines the constraints on the ring location, considering that the location is defined at its center. D w being the ring wire diameter. While these equations may change depending upon the joint shape, they can be easily modified accordingly or replaced by an equivalent graphical procedure.
TABLE 4
Manufacturing constraints on ring location
Constraint
Equation
Rubber thickness on groove side
E
g
≥
T
g
+
D
w
2
Rubber thickness on spigot side
D r ≧ D a + 2T s + D w
Mapping of Installation Ratios: The regions defined by the installation ratios can be mapped on a 2D sketch, so that the difficulty of installation can be visualized, together with the manufacturing constraints.
A reference line where each type of assembly becomes feasible can be found by setting each of the installation ratios to 1. In all cases, this line runs at an angle α/2 with respect to the vertical (see FIG. 5 ). Furthermore, the diameter at which these lines intersect the groove wall can be found by setting the distance E g to 0. This generates the equations listed in Table 5 which follows.
TABLE 5
Reference Diameters for Mapping of Installation Ratios
Settings
Comments
Ratio
R ie = 1E g = 0
Defines the diameter at which the line whereeasy installation becomes feasible intersectsthe groove wall.
D
roe
=
D
s
+
L
d
2
R if = 1
Defines the diameter at which the line where
D rof = L d
E g = 0
forced installation becomes feasible intersects
the groove wall.
R ib = 1E g = 0
Defines the diameter at which the line wherebent installation becomes feasible intersectsthe groove wall.
D
rob
=
L
d
+
D
g
2
The line where R ib becomes 1 can be used to close the region defined by manufacturing constraints. Locating the ring anywhere beyond this line would make installation impossible, at least given the seal shape and installation method under consideration.
This defines the three installation regions (easy, forced and bent), as shown on FIG. 6 which follows. Notice that these regions may lie outside of the region defined by manufacturing constraints. Darker areas define the region that is swept by the ring, including its thickness.
According to this mapping, in the example illustrated it is not possible to find a ring location for easy installation, due to manufacturing constraints. The best possible ring location would be as far as possible to the left inside the triangle defined by manufacturing constraints. In this case the installation would be forced. The other locations defined by manufacturing constraints fall in the region where the assembly would require bending the ring out of its original plane. Mathematically, this can be expressed by the formula:
R
ib
=
2
D
R
L
D
+
D
G
-
4
E
G
where R ib is less than 1; and
where D R =retainer ring diameter;
L D =distance from the bottom of the annular groove to the edge of the groove on the opposite side where the groove is formed by fillets and the distance is drawn along a line that passes through the approximate centers of the corresponding fillets; D G =diameter of the annular groove; E G =distance to the groove wall.
An invention has been provided with several advantages. A procedure has been devised to calculate and evaluate the location of internal retaining rings in rubber seals, according to the degree of difficulty of their installation. This procedure can be expressed in a graphical format, so that the ring location and its difficulty of installation can be easily visualized and chosen. The preferred ring location can also be calculated from a design formula. The methodology was applied to the case of joints with triangular grooves. It can be applied to other joint configuration by applying minor changes and consideration.
While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
|
A pipe sealing gasket is shown which is designed to be received within a groove provided within the belled, socket end of a plastic pipe. The sealing gasket has a body formed of resilient material and has a retainer ring embedded therein which circumscribes the gasket body. The groove in the plastic pipe is preformed during the manufacture of the plastic pipe and the gasket is installed thereafter. The gasket nominal diameter exceeds the internal diameter of the belled pipe end. The retainer ring is placed within the body of the sealing gasket at a precisely determined location which most effectively retains the ring in position while withstanding the forces of the assembly of the pipe joint.
| 8
|
FIELD
The present invention relates generally to vehicle occupant restraints, in particular to a mounting system for a seat-mounted emergency locking retractor.
BACKGROUND
Vehicle occupant restraints, including seat belt devices, are important and well-known components of vehicle safety systems. If a vehicle experiences a severe impact a properly belted-in occupant is generally held in place by the seat belt's webbing, thereby avoiding many serious, if not fatal, physical collisions with the vehicle interior and/or being ejected from the vehicle. Since their introduction seat belts have saved countless lives and reduced the severity of injury in countless more.
Current seat-mounted occupant restraint systems often locate the seat belt emergency locking retractor on the frame of the seat cushion and route the seat belt webbing upwardly along a rear portion of the seat back. However, locating the retractor in this manner may expose it to contact with rear seat passengers or objects stored behind the seat, increasing the potential for damage to the retractor either during normal use or in the event of a collision. Furthermore, the orientation of the retractor is often critical to its proper operation. Accordingly, it must be securely anchored such that its orientation is maintained both during normal use and in the event of a collision. There is a need for a way to protect the seat belt retractor from damage due to contact with passengers or objects behind the seat. There is a further need to maintain the orientation of the retractor to better ensure its proper operation.
SUMMARY
An embodiment of the present invention is a seat belt emergency locking retractor mounting system. The system comprises a bracket and a plate that cooperate with seat cushion frame components of a vehicle seat to form an enclosed mounting environment for the retractor. The bracket and plate form three sidewalls of the enclosure, with a side member of the cushion frame forming a fourth sidewall. The retractor is mounted within the enclosure and is attached to the bracket. The components of an aspect of the disclosed invention are located generally below the reclining apparatus of the seat's seatback in order to allow for adjustment of the seatback. An embodiment of the present invention ensures that the orientation of the retractor is maintained under various operating conditions and that the retractor is securely anchored in all directions. An embodiment of the present invention additionally protects the retractor from contact with passengers and objects located behind the seat.
One aspect of the present invention is a seat belt retractor mounting system for a vehicle seat. The system includes a bracket having a first sidewall and a second sidewall. A generally planar plate is located generally parallel to and spaced apart from the first sidewall of the bracket. The plate is coupled to the second sidewall. In addition, at least one of the bracket and plate are secured to, and cooperate with, a seat cushion frame of the seat to surround and protect an emergency locking retractor mounted to the first sidewall.
Another aspect of the present invention is a method for mounting a seat belt retractor to a vehicle seat. The method comprises the steps of providing a bracket having a first sidewall and a second sidewall, and coupling a generally planar plate to the bracket such that the plate is generally parallel to and spaced apart from the first sidewall of the bracket. Additional steps include securing at least one of the bracket and plate to a seat cushion frame of the seat, and mounting an emergency locking retractor mounted to the first sidewall such that the retractor is generally surrounded by the bracket, plate and frame.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the inventive embodiments will become apparent to those skilled in the art to which the embodiments relate from reading the specification and claims with reference to the accompanying drawings, in which:
FIG. 1 shows the general arrangement of a seat belt retractor mounting system installed into a left-hand vehicle seat frame according to an embodiment of the present invention;
FIG. 2 provides details of the components of the seat belt retractor mounting system of FIG. 1 ;
FIG. 3 depicts a bracket component of the seat belt retractor mounting system of FIG. 1 ;
FIG. 4A is a rear elevational view of a plate component of the seat belt retractor mounting system of FIG. 1 ;
FIG. 4B is a side elevational view of the plate of FIG. 4A ;
FIG. 5 is a rear view of the seat belt retractor mounting system of FIG. 1 ;
FIG. 6 shows details of a portion of a seat cushion frame according to an embodiment of the present invention;
FIG. 7 is a front view of the seat belt retractor mounting system of FIG. 1 ;
FIG. 8 is a side view of the seat belt retractor mounting system of FIG. 1 ; and
FIG. 9 shows an emergency locking retractor being mounted to a bracket of a retractor mounting system installed into a right-hand vehicle seat frame according to an embodiment of the present invention.
DETAILED DESCRIPTION
The general arrangement of a seat belt retractor mounting system 10 is shown in FIGS. 1 and 2 according to an embodiment of the present invention. Retractor mounting system 10 generally comprises a bracket 16 and a plate 18 . Retractor mounting system 10 is attached to a side member of a seat cushion frame 12 of a vehicle seat 14 , as discussed in greater detail below.
With reference to FIGS. 2 and 3 , bracket 16 includes a first sidewall 20 and a second sidewall 22 . Second sidewall 22 may further include a mounting flange 24 . Bracket 16 may be formed as a unitary piece from any suitable material compatible with other components of seat belt retractor mounting system 10 and the expected environment including, without limitation, metals such as steel, plastic, and composites, and may be fabricated using any conventional processes such as, without limitation, molding, stamping, casting and machining. Bracket 16 may also be finished by such processes as painting, plating and coating, or left unfinished.
With reference to FIGS. 4A , 4 B and 5 , plate 18 is generally rectangularly-shaped and planar. Plate 18 may include one or more mounting holes 26 , 28 for attaching the plate to mounting system 10 in a manner detailed further below. Plate 18 may further include one or more channels 30 along its longitudinal axis.
Plate 18 may be formed as a unitary piece from any suitable material compatible with other components of seat belt retractor mounting system 10 and the expected environment including, without limitation, metals such as steel, plastic, and composites, and may be fabricated using any conventional processes such as, without limitation, molding, stamping, casting and machining. Plate 18 may also be finished by such processes as painting, plating and coating, or left unfinished.
With reference now to FIGS. 1 through 9 in combination, seat belt retractor mounting system is assembled by locating bracket 16 and plate 18 at a side member 32 of seat cushion frame 12 such that the side member is positioned between the bracket and plate ( FIGS. 2 and 5 ). Plate 18 is oriented such that channels 30 engage corresponding support braces 34 of frame 12 ( FIGS. 4B and 5 ). Mounting openings 26 , 36 and 38 ( FIGS. 3 , 4 A, 6 ) in plate 18 , bracket 16 and frame side member 32 respectively are aligned, then fastened together with one or more fasteners 40 such as rivets, bolts, nuts and screws, at least a portion of the fastener extending through the aligned openings ( FIGS. 2 and 5 ). Bracket 16 may also be attached directly to plate 18 with one or more fasteners 42 such as rivets, bolts, nuts and screws, at least a portion of the fastener extending through opening 28 in the plate and a corresponding opening 44 in mounting flange 24 of the bracket ( FIGS. 2 and 5 ). Bracket 16 may be further secured to frame 12 by one or more weldments 46 between the bracket and a cross member 48 of the frame ( FIG. 2 ).
With reference to FIGS. 7 and 9 , a seat belt emergency locking retractor 50 is installed into seat 14 by locating the retractor within the sidewalls formed by bracket 16 , plate 18 and frame side member 32 such that a tab 52 of the retractor engages a notch 54 of the bracket. A mounting opening 56 of retractor 50 is aligned with a corresponding opening 58 of bracket 16 and is attached with one or more fasteners 60 such as rivets, bolts, nuts and screws, at least a portion of the fastener extending through the aligned openings. Tab 52 , notch 54 , openings 56 , 58 and fastener 60 cooperate to secure emergency locking retractor 50 at a predetermined orientation to ensure its proper operation, i.e., allowing a seat belt web 62 housed by the retractor to move slidably in and out of the retractor during normal conditions without binding, yet resist movement of the web in the event of a sudden deceleration of the vehicle. Once retractor 50 is oriented and secured seat belt web 62 may be routed through seat 14 as shown generally in FIG. 1 for use by an occupant of the seat.
In operation, retractor 44 is maintained in a predetermined orientation for proper operation of the emergency locking mechanism of the retractor in the event of a sudden deceleration, while allowing web 62 to move slidably in and out of the retractor during normal operation. The rigid, boxlike construction of the sidewalls formed by bracket 16 , plate 18 and frame side member 32 protect retractor 50 from contact with passengers and objects located behind the seat. Retractor mounting system 10 is rigidly secured to cross member 48 , support braces 34 and frame side member 32 , is accordingly securely anchored in all directions, and resists undesirable changes in the position or orientation of retractor 50 in the event of a vehicle collision. Furthermore, as can be seen in FIG. 1 , the components of retractor mounting system 10 are located generally below a seat reclining apparatus 64 in order to allow normal seat adjustability and operation, such as changing the angular position of a seatback 66 of seat 14 without adversely affecting the orientation of retractor 50 . Retractor mounting system 10 also acts as a barrier between retractor 50 and other components of seat 14 , thereby preventing heat generated by the retractor from directly contacting the other components.
It should be noted that the sizes and shapes of the components of retractor mounting system 10 are not critical and may be varied to accommodate the needs of a particular seat frame 12 and emergency locking retractor 50 . For example, cutouts and openings may be installed in the bracket and/or plate to accommodate the various components of seat 14 . Likewise, stiffening elements such as ribs 68 ( FIGS. 3 and 4A ) may be incorporated into bracket 16 and/or plate 18 for added structural strength.
In some embodiments of the present invention seat cushion frame 12 may optionally include a reinforcing brace 70 coupled to the frame, as shown in FIG. 9 . Brace 70 is coupled between cross member 48 and one or more frame support braces 34 , and acts to resist deformation or movement of the cross member and the support brace, thereby further aiding to resist undesirable changes in the position or orientation of retractor 50 in the event of a vehicle collision. Brace 70 may be coupled to cross member 48 and support brace 34 in any conventional manner using fasteners and/or weldments similar to fasteners 40 and weldments 46 , previously detailed above.
Brace 70 may be formed as a unitary piece from any suitable material compatible with other components of seat belt retractor mounting system 10 and the expected environment including, without limitation, metals such as steel, plastic, and composites, and may be fabricated using any conventional processes such as, without limitation, molding, stamping, casting and machining. Brace 70 may also be finished by such processes as painting, plating and coating, or left unfinished.
It should be noted that the figures variously depict embodiments of the present invention installed into seat frames 12 configured for installation into left and right sides of the vehicle interior. The disclosed embodiments of the present invention are generally located at the outboard edge of the seat frame. However, it is understood that the present invention may be likewise located at other positions along seat frame 12 , such as at an inboard edge, if dictated by the configuration of a particular safety restraint system.
While this invention has been shown and described with respect to a detailed embodiment thereof, it will be understood by those skilled in the art that changes in form and detail thereof may be made without departing from the scope of the claims of the invention. For example, the various features of the components of retractor mounting system 10 , seat 14 and retractor 44 may be keyed, indexed or rendered in separate mirror-image components for use in one of left- and right-hand seats in a vehicle. Alternatively, such left- and right-hand features may be incorporated into reconfigurable components having features compatible with installation of mounting system 10 into both left- and right-hand seats.
|
A seat belt retractor mounting system for a vehicle seat includes a bracket having a first sidewall and a second sidewall. A generally planar plate is located generally parallel to and spaced apart from the first sidewall of the bracket. The plate is coupled to the second sidewall. In addition, at least one of the bracket and plate are secured to, and cooperate with, a seat cushion frame of the seat to surround and protect an emergency locking retractor mounted to the first sidewall. A method employs the system.
| 1
|
FIELD OF INVENTION
[0001] This invention relates to apparatus and method for protecting the Advanced Access Content System (AACS) in software video players.
DESCRIPTION OF RELATED ART
[0002] The Advanced Access Content System (AACS) is a standard for content distribution and digital rights management that is intended to restrict access to and copying of High Density (HD) and Blue-ray Disk (BD) media. It was developed by AACS Licensing Administrator, LLC (AACS LA), a consortium that includes Disney, Intel, Microsoft, Matsushita (Panasonic), Warner Brothers, IBM, Toshiba, and Sony.
[0003] FIG. 1 presents a simplified view of encryption and decryption processes for pre-recorded video content provided by AACS. An owner of content that is to be protected provides the content in the form of one or more Titles to a licensed replicator. The licensed replicator selects a secret, random Title Key (Kt) for encrypting each Title. The licensed replicator also assigns a random Volume ID to the protected Title or a set of protected Titles to safeguard against “bit-by-bit copying” of protected content. The Volume ID is stored on a prerecorded medium in a manner that cannot be duplicated by consumer recorders.
[0004] For each protected Title or a set of protected Titles to be included together on the pre-recorded medium, the AACS LA provides to the licensed replicator a Media Key Block (MKB), a Sequence Key Block, and a secret Media Key (Km). The MKB will enable all compliant devices, each using their set of secret Device Keys and Sequence Keys, to calculate the same or variants of the Media Key. If a set of Device Keys is compromised in a way that threatens the integrity of the system, an updated MKB can be released that will cause a device with the compromised set of Device Keys to calculate a different Media Key than the remaining compliant devices. In this way, the compromised Device Keys are “revoked” by the new MKB.
[0005] For each protected Title, the licensed replicator calculates a cryptographic hash of the Media Key and the Volume ID, and uses the result to encrypt the Title's Title Key. The encrypted Title Key and the MKB are stored on the pre-recorded medium.
[0006] The AACS LA provides a set of 253 secret Device Keys to the licensed manufacturer for inclusion into each compliant device or application produced. Device Key sets may either be unique per licensed product, or used commonly by multiple products.
[0007] The licensed product reads the MKB from the pre-recorded medium, and uses its Device Keys to process the MKB and thereby calculate the Media Key. If the given set of Device Keys has not been revoked, then the calculated Media Key will be the same Media Key that was used by the licensed replicator as described above.
[0008] For each protected Title the licensed product then calculates a cryptographic hash of the calculated Media Key and the Volume ID, and uses the result to decrypt the Title's encrypted Title Key. The result is then used to decrypt the Title.
[0009] Playback of AACS content is only performed using the Title Keys and Volume ID which are read from the media. Except otherwise provided by the AACS specifications, the values used to enable playback of AACS content (e.g. Title Keys and Volume ID) shall be discarded upon removal of the instance of media from which they were retrieved. Any derived or intermediate cryptographic values shall also be discarded.
[0010] FIG. 2 illustrates a conventional BD software video player 200 for AACS content. Software video player 200 is typically executed by a processor in a computer or in an appliance from codes and data loaded into volatile memory. Software video player 200 includes a player engine 201 with an AACS engine 202 and AACS keys 203 acquired from AACS LA. AACS keys 203 include a Host Certificate, a set of Device Keys, and a set of Sequence Keys. Using AACS keys 203 , AACS engine 202 decrypts data from an encrypted data source 204 . Depending on the user input, a BDMV (Blu-ray Disk Movie) engine 206 in player engine 201 instructs AACS engine 202 to access the appropriate files on encrypted data source 204 , receives the file from AACS engine 302 , and forwards the appropriate data to codec engine 208 in player engine 201 . Specifically, BDMV engine 206 splits the file that contains both audio and video data (and other data stream such as subtitles) and sends the appropriate data to a video codec and an audio codec (and other modules) in codec engine 208 . BDMV engine 206 also controls the synchronization between the video and audio from the video and the audio codecs. Codec engine 208 decodes the data and presents the content for display. Software video player 200 may include an application layer 207 that generates the user interface for controlling player engine 201 . Application layer 207 receives user controls and notifies BDMV engine 206 to respond to the user controls, such as playing a title. Application layer 207 also receives message from BDMV engine 206 to display to the user.
[0011] Hackers have found various AACS keys by using debuggers to inspect the memory space of running HD-DVD and BD software video players. Thus, what are needed are method and apparatus for safeguarding the AACS content in HD-DVD and BD software video players.
SUMMARY
[0012] In embodiments of the invention, methods are provided to protect AACS Device Keys in a software video player and to encrypt data transfers between modules of the player.
[0013] In one embodiment, AACS Device Keys and their renewal information are packed into a file and then encrypted. When the software video player starts, the encrypted file is read into memory and decrypted. If the Device Keys have expired, the software video player will prompt the user to renew the Device Keys. Otherwise the software video player uses the Device Keys to calculate AACS Title Keys for decoding encrypted content. Afterwards, the software video player clears the memory of keys by filling it with random numbers.
[0014] In one embodiment, to prevent static analysis, the Title Keys are encrypted with a random number and they are decrypted only when they are used. Afterwards use the Title Keys are encrypted immediately with a new random number. In addition, junk codes are inserted into essential places of the binary machine code of the software video player. Furthermore, the binary machine code self-decrypts dynamically only at runtime.
[0015] In one embodiment, to prevent dynamic debugging, a monitoring mechanism in the system service is provided to detect debugging tools and determine whether or not the software video player is under conditions that indicate the player is being debugged.
[0016] In one embodiment, authentication is used between certain modules of the player and encryption is used in data transfer between certain modules of the player.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates a simplified view of the AACS system.
[0018] FIG. 2 illustrates a conventional software video player implemented with AACS.
[0019] FIG. 3 illustrates a software video player implemented with additional safeguards for the AACS system in one embodiment of the invention.
[0020] FIG. 4 illustrates an encrypted pack file format of AACS key data in one embodiment of the invention.
[0021] FIG. 5 is a flowchart of a method for an AACS key manager in the software video player of FIG. 3 in one embodiment of the invention.
[0022] FIG. 6 illustrates the use of junk code in the source code in one embodiment of the invention.
[0023] FIG. 7 illustrates authentication and encrypted data transfer between modules in one embodiment of the invention.
[0024] FIG. 8 illustrates authentication between modules in one embodiment of the invention.
[0025] FIG. 9 is a flowchart of a data encryption process between modules in one embodiment of the invention.
[0026] FIG. 10 is a flowchart of a debugging monitoring process in one embodiment of the invention.
[0027] Use of the same reference numbers in different figures indicates similar or identical elements.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Conventional software video player 200 of FIG. 2 has certain disadvantages against hacking. First, AACS keys 203 are normally encoded into individual binary files for carrying out renewal. These binary files can be detected and analyzed to determine AACS keys 203 . Second, AACS keys 203 are not encrypted so they can be obtained by comparative analysis through memory dump. Even if they were encrypted, a hacker can use a debugging tool to find AACS keys 203 and use other tools to decrypt them. Third, when the modules of software video player 200 are implemented as filters with Microsoft DirectShow software development kit (SDK), data transfers between the modules are not protected.
[0029] In embodiments of the invention, software video player is provided with (1) encryption of the AACS keys, (2) countermeasures against static analysis, (3) countermeasures against debugging tools, (4) authentication between modules of the player, and (5) encryption of data transfer between modules of the player.
[0030] FIG. 3 illustrates a software video player 300 in one embodiment of the invention. To overcome the shortcomings of the conventional video player, software video player 300 includes the five features described above to strengthen the protection provided by the AACS.
[0031] Software video player 300 is typically executed by a processor in a computer or in an appliance from codes and data loaded in volatile memory. Software video player 300 includes a player engine 301 with an AACS engine 302 . AACS engine 302 has hacking countermeasures so it does not directly access AACS keys. Instead, AACS engine 302 requests the AACS keys from an AACS key manager 304 only when the AACS keys are needed. In response, AACS key manager 304 decrypts an AACS key file 306 and provides the AACS keys to AACS engine 302 .
[0032] FIG. 4 illustrates the format of AACS key file 306 . AACS key file 306 includes AACS key data 402 , a pack file header 404 , and an encryption header 406 . AACS key data 402 includes a Host Certificate, a set of Device Keys, and a set of Sequence Keys provided by AACS LA. Pack file header 404 includes the version of the pack file tool, the names of the source files, the creation date of the pack file, and the expiration date of AACS keys provided by AACS LA. Encryption header 406 includes information about the pack file itself, such as file size, the data offset, and so on.
[0033] The contents of AACS key file 306 is packed and then encrypted by a Pack Tool using a random key 307 ( FIG. 3 ). The pack tool can use an encryption algorithm, such as AES. AACS key manager 304 manages random key 307 for AACS key file 306 , uses random key 307 to decrypt AACS key file 306 , retrieves AACS key data 402 from decrypted AACS key file 306 , and provides AACS key data 402 to AACS engine 302 . More importantly, AACS key manager 304 prevents hackers from finding AACS key data 402 through a memory dump. Using a memory dump, a hacker takes several static images of memory of an algorithm under different states and then finds the sensitive information by comparing the static images. To prevent such a memory dump, AACS key manager 304 uses several methods including (1) encrypting random key 307 in the memory with a temporary random key that changes frequently, (2) separating the encrypted random key 307 into several segment stored in noncontiguous memory, (3) creating the necessary AACS keys only when they are used, and (4) clearing the memory by filling the memory with random data after using the AACS keys.
[0034] FIG. 5 is a flowchart of a method 500 performed by AACS key manager 304 in one embodiment of the invention.
[0035] In step 504 , AACS key manager 304 encrypts or masks random key 307 with a temporary random key to prevent random key 307 from appearing directly in the memory during long playbacks. In one embodiment, AACS key manager 304 encrypts random key 307 by XORing it with the temporary random key. AACS key manager 304 creates a new temporary random key each time software video player 300 is started. Step 504 is followed by step 506 .
[0036] In step 506 , AACS key manager 304 divides the encrypted random key 307 into multiple segments and stores them in noncontiguous memory regions. For example, AACS key manager 304 allocates different buffers through the operating system to store the segments. This again prevents random key 307 from appearing directly in the memory. Step 506 is followed by step 508 .
[0037] In step 508 , AACS key manager 304 determines if AACS engine 302 is requesting AACS key data 402 . If so, then step 508 is followed by step 510 . Otherwise step 508 loops until AACS engine 302 requests AACS key data 402 .
[0038] In step 510 , AACS key manager 304 assembles the segments of the key 307 and decrypts encrypted random key 307 with the temporary random key.
[0039] In step 512 , AACS key manager 304 decrypts AACS key file 306 with random key 307 . Step 512 is followed by step 514 . In one embodiment, AACS key manager 304 reads the pack file header 404 to make sure the AACS keys have not expired. If the AACS keys have expired, AACS key manager 304 will prompt for the newest AACS keys. The newest AACS keys may be downloaded through the Internet or read from a disc.
[0040] In step 514 , AACS key manager 304 retrieves AACS key data 402 from the decrypted AACS key file 306 . Step 514 is followed by step 516 .
[0041] In step 516 , AACS key manager 304 provides AACS key data 402 to AACS engine 302 . In response, AACS engine 302 uses the Host Certificate to authenticate the optical drive, and the Device Keys and the Sequence Keys to calculate Title Key(s). As only the Title Key(s) are used for decrypting the media when the player is running, AACS key data 402 and random key 307 can be deleted after the Title Key(s) are determined. Step 516 is followed by step 518 .
[0042] In step 518 , AACS key manager 304 clears AACS key data 402 from the memory by filling their memory locations with random numbers. Step 518 is followed by step 520 .
[0043] In step 520 , AACS key manager 304 clears random key 307 from the memory by filling its memory location with random numbers.
[0044] Referring back to FIG. 3 , AACS engine 302 also includes junk code as a countermeasure against static analysis. Specifically the junk code is inserted into the source code of AACS engine 302 and then compiled into binary machine code. The strategic placement of the junk code in critical character strings and function transfers in the compiled binary machine code, such as those for the AES, makes them more difficult to decipher. FIG. 6 illustrates assembly code 603 disassembled by a disassembler program (e.g., W32Dasm) from the binary machine code compiled from source code 601 . FIG. 6 also illustrates an assembly code 604 disassembled from the binary machine code compiled from code 601 after junk code 602 is inserted. As FIG. 6 shows, the disassembled code is changed by the junk code and is very difficult to decipher.
[0045] AACS engine 302 further uses self-extraction as a countermeasure against static analysis. The binary code of AACS engine 302 is compressed and encrypted into a file by a development tool before release, and the file self-extracts dynamically at runtime. The binary code of AACS engine 302 can be encrypted by XORing the code with a predefined random number.
[0046] Referring back to FIG. 3 , a BDMV engine 308 in player engine 301 instructs AACS engine 302 to access the appropriate data on encrypted data source 204 , receives the data from AACS engine 302 , and forwards the data to a codec engine 312 in player engine 201 . In one embodiment of the invention, the modules of software video player 300 are implemented as filters with Microsoft DirectShow SDK. In one embodiment, AACS engine 302 and BDMV engine 308 are implemented in a single filter.
[0047] Conventionally filters do not authenticate each other before data transfer and data transfer between filters are not protected. This provides opportunities for a hacker to exploit the filters if the hacker forges an empty filter that accepts decrypted data and dumps the data to a file. Therefore, software video player 300 is provided with authentication between certain modules and data encryption in the data transfer between certain modules in one embodiment of the invention. As illustrated in FIGS. 3 and 7 , authentication is provided between BDMV engine 308 and application layer 310 , and between BDMV engine 308 and codec engine 312 . Furthermore, data encryption is provided to data transfer between BDMV engine 308 and codec engine 312 .
[0048] FIG. 8 illustrates an authentication process 800 between a module that initiates the authentication (hereafter “initiator”) and a module that is the target of the authentication (hereafter “target”) in one embodiment of the invention. For example, BDMV engine 308 can be the initiator and one of application layer 310 and codec engine 312 can be the target. Authentication is performed each time the modules connect.
[0049] In step 802 , the initiator sets an authentication flag for the target to FALSE, which indicates that the target has not been authenticated. Step 802 is followed by step 804 .
[0050] In step 804 , the initiator generates a random number (e.g., a 16 byte). Step 804 is followed by step 806 .
[0051] In step 806 , the initiator sends the random number to the target. Step 806 is followed by step 808 .
[0052] In step 808 , the target encrypts the random number with its copy of a predefined key. Both the initiator and the target have the predefined key in their source codes. Step 808 is followed by step 810 .
[0053] In step 810 , the target sends the encrypted random number to the initiator. Step 810 is followed by step 812 .
[0054] In step 812 , the initiator verifies the encrypted random number by decrypting it with its copy of the predefined key. If the decrypted result matches the random number the initiator sent to the target, then the target is authenticated. Step 812 is followed by step 814 .
[0055] In step 814 , the initiator sets the authentication flag to TRUE if the decrypted result matches the random number sent to the target. Otherwise the initiator leaves the authentication flag as FALSE.
[0056] FIG. 9 is a flowchart of a method 900 for BDMV engine 308 to forward data to codec engine 312 in an encrypted data transfer in one embodiment of the invention.
[0057] In step 902 , BDMV engine 308 determines if the authentication flag for codec engine 306 is TRUE. If so, codec engine 312 has been previously authenticated in process 800 ( FIG. 8 ) and step 902 is followed by step 904 . Otherwise step 902 is followed by step 916 , which ends method 900 .
[0058] In step 904 , BDMV engine 308 creates a random number (e.g., 16 byte) as a key. Step 904 is followed by step 906 .
[0059] In step 906 , BDMV engine 308 determines if a certain amount of time has passed since the key was created so it is time for generate a new key. If so, then step 906 is followed by step 908 . Otherwise step 906 is followed by step 910 .
[0060] In step 908 , BDMV engine 308 generates a new random number as a key. Step 908 is followed by step 910 .
[0061] In step 910 , BDMV engine 308 sends the key to codec engine 312 by a function call. Step 910 is followed by step 912 .
[0062] In step 912 , BDMV engine 308 encrypts a stream of data with the key. In one embodiment, BDMV engine encrypts the data by XORing them with the key. Step 912 is followed by step 914 .
[0063] In step 914 , BDMV engine 308 sends the encrypted data to codec engine 312 . In response, codec engine 312 uses the key received in step 910 to decrypt the data and otherwise process the data for display. Step 914 is followed by step 916 , which ends method 900 .
[0064] Referring back to FIG. 3 , software video player 300 includes a monitor process 314 in one embodiment of the invention. Monitor process 314 is a system service that starts running when the operating system is booted. If monitor process 314 detects whether software video player 300 is running a fixed time period after the software video player is started. If so, monitor process 314 starts an anti-debugging process.
[0065] FIG. 10 is a flowchart of a method 1000 for monitor process 314 in one embodiment of the invention.
[0066] In step 1002 , monitor process 314 determines if software video player 300 is running after the software video player was started. If so, then step 1002 is followed by step 1004 . Otherwise step 1002 is followed by step 1008 .
[0067] In step 1004 , monitor process 314 determines if a debugging tool is running. This function is represented by reference numeral 316 ( FIG. 3 ) in monitor process 314 . Monitor process 314 has means to detect common debugging tools that are specific to each tool. If monitor process 314 detects a debugging tool, then step 1004 is followed by step 1010 . Otherwise step 1004 is followed by step 1006 .
[0068] In one embodiment for the Win32 system, a check server is provided to prevent debugging. In the Win32 system, there is a thread information block (TIB) for each running thread. The check server checks TIB for flags that identify running threads of debugging tools in protection ring 3 (applications), such as Microsoft Visual Studio and OllyDbg. The check server also detects some debugging tools that run in protection ring 0 (kernel) by their driver names, file names, and sever names. For example, the check server attempts to create the same object handles with the same driver, file, and server names as the debugging tools. If the creation fails, then the debugging tools are present. When there is debugging tool attacking software video player 200 , the check server closes the player to prevent it from been hacked.
[0069] In addition to the check server, a start server is provided to protect the check server from being attacked. The start server double checks the check server and the player are running without being debugged. Specifically, the start server determines whether or not the check server exists. Since the check server is a program of the Windows operating system, the start server looks for the processes of the check server using the Windows API. If the start server cannot find the processes of the check server, it restarts the check server again to protect the player.
[0070] In step 1006 , monitor process 314 determines if software video player 300 is under conditions that indicate software video player 300 is being debugged. This function is represented by reference numeral 318 ( FIG. 3 ) in monitor process 314 . On Microsoft Windows platforms, an application is generally a child process of Windows Explorer. Thus, monitor process 314 determines if the parent process of software video player 300 is Windows Explorer. If not, then monitor process 314 assumes software video player 300 is being debugged and step 1006 is followed by step 1010 . Otherwise step 1006 is followed by step 1008 .
[0071] In step 1008 , monitor process 314 waits for a timeout and then returns to step 1002 to again loop through method 1000 .
[0072] In step 1010 , monitor process 314 applies debugging countermeasures. This function is represented by reference numeral 320 ( FIG. 3 ) in monitor process 314 . Debugging countermeasures include forcibly terminating software video player 300 and writing random data into process memory of player 300 .
[0073] To thwart any attempt to disable monitor process 314 , application layer 310 and BDMV engine 308 both periodically detect monitor process 314 after software video player 300 is started. If either application layer 310 or BDMV engine 308 cannot detect monitor process 314 , it can forcibly terminate player 300 as a precaution against debugging.
[0074] Various other adaptations and combinations of features of the embodiments disclosed are within the scope of the invention. Numerous embodiments are encompassed by the following claims.
|
A method for protecting a software video player having Advanced Access Content System (AACS) includes reading segments of an encrypted first key from noncontiguous regions of memory, assembling the segments to form the encrypted first key, decrypting the encrypted first key with a second key to form a first key, extracting AACS key data from a pack file, decrypting the AACS key data to retrieve AACS Device Keys, generating an AACS Title Key using the AACS Device Key, clearing the AACS Device Keys and the first key from memory after the AACS Title Key is generated, decrying encrypted AACS content with the AACS Title Key to form AACS content, and displaying the AACS content.
| 7
|
[0001] Systems that process large volumes of data, such as search engine websites, are typically constrained by response times for their clients. As such, it is useful to organize these large volumes to facilitate accesses that meet these constraints.
[0002] In some systems, the large volumes of data may be categorized according to a degree to which the data is recent or current. For example, data within the past hour/day/week/month/year may be considered current. In some estimates, current data may constitute up to 80% of the total data. Because the great majority of requests for data may be for current data, these systems may prioritize access to current data over older data. Prioritizing access may facilitate meeting the response time constraints.
[0003] In many systems, a database may be used to organize data in this way. For example, current data may be stored in fact tables, while older data may be stored in archive tables. In such a database, specific processes may be used to move data between fact and archive tables. However, some systems may include data covering years. As such, moving data in tables with such large volumes may be computationally expensive, impinging upon the response time constraints.
SUMMARY
[0004] The following presents a simplified summary of the innovation in order to provide a basic understanding of some aspects described herein. This summary is not an extensive overview of the claimed subject matter. It is intended to neither identify key or critical elements of the claimed subject matter nor delineate the scope of the subject innovation. Its sole purpose is to present some concepts of the claimed subject matter in a simplified form as a prelude to the more detailed description that is presented later.
[0005] The subject innovation relates to a method and a system for moving large volumes of data between fact and archive tables. A request to move the data may be received. A database may determine that the fact and the archive tables belong to the same file group. The data may be moved by transferring a partition containing the data from the fact/archive table to the other.
[0006] In one exemplary embodiment, a sliding window current data may be kept within the fact tables. All data that falls out of the sliding window may be moved from fact to archive tables.
[0007] The method operates by storing the data within file groups on a storage area network. The file groups may include fact and archive tables. Each of the file groups may include data that is stored on numerous logical unit numbers.
[0008] An exemplary system moves large volumes of data between fact and archive tables.
[0009] Another exemplary embodiment of the subject innovation provides a non-transitory computer-readable medium that includes code to direct the operation of a processing unit. The code may direct the processing unit to move large volumes of data between fact and archive tables by transferring a partition containing the data from the fact/archive table to the other.
[0010] The following description and the annexed drawings set forth in detail certain illustrative aspects of the claimed subject matter. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation may be employed and the claimed subject matter is intended to include all such aspects and their equivalents. Other advantages and novel features of the claimed subject matter will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of an enterprise storage system wherein aspects of the claimed subject matter can be employed;
[0012] FIG. 2 is a block diagram of a storage area network wherein aspects of the claimed subject matter can be employed;
[0013] FIG. 3 is a process flow diagram of a method for moving large volumes of data in accordance with the claimed subject matter;
[0014] FIG. 4 is a block diagram of an exemplary networking environment wherein aspects of the claimed subject matter can be employed; and
[0015] FIG. 5 is a block diagram of an exemplary operating environment that can be employed in accordance with the claimed subject matter.
DETAILED DESCRIPTION
[0016] The claimed subject matter is described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject innovation. It may be evident, however, that the claimed subject matter may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the subject innovation.
[0017] As utilized herein, terms “component,” “system,” “data store,” “engine,” “manipulator” and the like are intended to refer to a computer-related entity, either hardware, software (e.g., in execution), and/or firmware. For example, a component can be a process running on a processor, a processor, an object, an executable, a program, a function, a library, a subroutine, and/or a computer or a combination of software and hardware. By way of illustration, both an application running on a server and the server can be a component. One or more components can reside within a process and a component can be localized on one computer and/or distributed between two or more computers.
[0018] Furthermore, the claimed subject matter may be implemented as a method, apparatus, or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a computer to implement the disclosed subject matter. The term “article of manufacture” as used herein is intended to encompass a computer program accessible from any non-transitory computer-readable device, or media. Non-transitory computer-readable storage media can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, and magnetic strips, among others), optical disks (e.g., compact disk (CD), and digital versatile disk (DVD), among others), smart cards, and flash memory devices (e.g., card, stick, and key drive, among others). Of course, those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope or spirit of the claimed subject matter. Moreover, the word “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs.
[0019] The subject innovation relates to a method and a system for moving large volumes of data from fact to archive tables. The fact and archive tables may contain searchable data for a large volume system, such as a search engine site.
[0020] FIG. 1 is a block diagram of an enterprise storage system 100 , wherein aspects of the claimed subject matter can be employed. However, the techniques are not limited to this configuration for the enterprise storage system 100 , as any number of configurations can be used. For example, a large enterprise storage system 100 may often have many more servers 120 and SANs 130 than shown in this illustration.
[0021] In the enterprise storage system 100 , servers 120 may provide data, such as Web pages, to one or more client computers 102 over a network 110 . The network 110 may be a local area network (LAN), wide area network (WAN), a storage area network (SAN), or other network, such as the Internet.
[0022] The servers 120 may access the data for the clients 102 from storage area networks (SANs) 130 . The SANs 120 may represent architectures that connect remote computer storage devices, such that the remote computer storage devices appear as locally attached to the servers 120 .
[0023] The SANs 130 may store large volumes of data in databases. Current data may be stored in fact tables. Older data may be stored in archive tables. In one embodiment of the invention, a sliding window may be used to move data from between fact and archive tables. In other words, the system 100 may keep one year's worth of data in the fact tables: e.g., a one year window of daily data. Every day, the window slides another day, such that the last day drops out of the window, i.e., the data moves from the fact table to the archive table.
[0024] Typically, moving even a row of a very large table is computationally expensive. However, in an embodiment of the invention, large numbers of rows may be moved between fact and archive tables relatively cheaply. In comparison to the long amount of time that some systems may take to move a row of data in a very large table, embodiments of the invention may move a terabyte of data in
[0025] In such an embodiment, the fact tables and the archive tables may contain the same structure. In other words, the columns, indices, and partition definitions may be the same for a fact table and a corresponding archive table.
[0026] The partitions may define subsets of the fact/archive table data. As the data on a partition ages out of the sliding window, the partition may be re-assigned from the fact table to the archive table. The reverse may also be true. As such, large volumes of data may be moved between a fact table and an archive table by re-assigning the partition from one table to the other.
[0027] As understood by one skilled in the art, database tables and their partitions are stored in files on the SAN 130 . FIG. 2 is a block diagram of the SAN 130 wherein aspects of the claimed subject matter can be employed. The SAN 130 may be a collection of numerous storage devices, e.g., logical units (LUNs) 240 , e.g., L 1 -L 4 . The database table files may be stored on the LUNs 240 , and arranged within file groups 222 , e.g., FG 1 -FG 11 .
[0028] As shown, each file group 222 may include files that are stored on multiple LUNs 240 . Generally speaking, as data ages, the SAN 130 may move older files, e.g., archive table files, to facilitate performance. Even though file is moved to different hardware, the archive table file may remain within the file group 222 . As such, the files within the file group, e.g., FG 1 may be stored on both L 1 and L 2 . Additionally, the files for archive and fact tables may be distributed across each file group 222 .
[0029] The file groups 222 may be organizations of data stored on the SAN 130 . As understood by one skilled in the art, the file groups 222 may vary according to implementations, and may be topical, chronological, etc.
[0030] FIG. 3 is a process flow diagram of a method for moving large volumes of data. The method 300 starts at block 302 , where a request to move a large volume of data may be received. The request may be a structured query language (SQL) statement as received by a database optimizer, or as a query plan executed by a database execution engine. The request may specify a source table and a destination table for the data to be moved, e.g., fact and archive tables. The request may also specify a partition containing the data to be moved.
[0031] At block 304 , it may be determined that the fact table and the archive table belong to the same file group 222 . Because the fact table and the archive table belong to the same file group 222 , at block 306 , the specified partition may be transferred from the fact table to the archive table.
[0032] In order to provide additional context for implementing various aspects of the claimed subject matter, FIGS. 4-5 and the following discussion are intended to provide a brief, general description of a suitable computing environment in which the various aspects of the subject innovation may be implemented. For example, a content filter, as described in the previous figure, can be implemented in such suitable computing environment. While the claimed subject matter has been described above in the general context of computer-executable instructions of a computer program that runs on a local computer and/or remote computer, those skilled in the art will recognize that the subject innovation also may be implemented in combination with other program modules. Generally, program modules include routines, programs, components, data structures, etc., that perform particular tasks and/or implement particular abstract data types.
[0033] Moreover, those skilled in the art will appreciate that the subject innovation may be practiced with other computer system configurations, including single-processor or multi-processor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based and/or programmable consumer electronics, and the like, each of which may operatively communicate with one or more associated devices. The illustrated aspects of the claimed subject matter may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. However, some, if not all, aspects of the subject innovation may be practiced on stand-alone computers. In a distributed computing environment, program modules may be located in local and/or remote memory storage devices.
[0034] FIG. 4 is a schematic block diagram of a sample-computing system 400 with which the claimed subject matter can interact. The system 400 includes one or more client(s) 410 . The client(s) 410 can be hardware and/or software (e.g., threads, processes, computing devices). The system 400 also includes one or more server(s) 420 . The server(s) 420 can be hardware and/or software (e.g., threads, processes, computing devices). The servers 420 can house threads to perform search operations by employing the subject innovation, for example.
[0035] One possible communication between a client 410 and a server 420 can be in the form of a data packet adapted to be transmitted between two or more computer processes. The system 400 includes a communication framework 440 that can be employed to facilitate communications between the client(s) 410 and the server(s) 420 . The client(s) 410 are operably connected to one or more client data store(s) 450 that can be employed to store information local to the client(s) 410 . The client data store(s) 450 do not have to be in the client(s) 410 , but may be located remotely, such as in a cloud server. Similarly, the server(s) 420 are operably connected to one or more server data store(s) 430 that can be employed to store information local to the servers 420 .
[0036] As an example, the client(s) 410 may be computers providing access to social search engine sites over a communication framework 440 , such as the Internet. The server(s) 420 may be search engine sites accessed by the client.
[0037] With reference to FIG. 5 , an exemplary environment 500 for implementing various aspects of the claimed subject matter includes a computer 512 . The computer 512 includes a processing unit 514 , a system memory 516 , and a system bus 518 . The system bus 518 couples system components including, but not limited to, the system memory 516 to the processing unit 514 . The processing unit 514 can be any of various available processors. Dual microprocessors and other multiprocessor architectures also can be employed as the processing unit 514 .
[0038] The system bus 518 can be any of several types of bus structure(s) including the memory bus or memory controller, a peripheral bus or external bus, and/or a local bus using any variety of available bus architectures known to those of ordinary skill in the art.
[0039] The system memory 516 is non-transitory computer-readable media that includes volatile memory 520 and nonvolatile memory 522 . The basic input/output system (BIOS), containing the basic routines to transfer information between elements within the computer 512 , such as during start-up, is stored in nonvolatile memory 522 . By way of illustration, and not limitation, nonvolatile memory 522 can include read only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory.
[0040] Volatile memory 520 includes random access memory (RAM), which acts as external cache memory. By way of illustration and not limitation, RAM is available in many forms such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), enhanced SDRAM (ESDRAM), SynchLink™ DRAM (SLDRAM), Rambus® direct RAM (RDRAM), direct Rambus® dynamic RAM (DRDRAM), and Rambus® dynamic RAM (RDRAM).
[0041] The computer 512 also includes other non-transitory computer-readable media, such as removable/non-removable, volatile/non-volatile computer storage media. FIG. 5 shows, for example a disk storage 524 . Disk storage 524 includes, but is not limited to, devices like a magnetic disk drive, floppy disk drive, tape drive, Jaz drive, Zip drive, LS-100 drive, flash memory card, or memory stick.
[0042] In addition, disk storage 524 can include storage media separately or in combination with other storage media including, but not limited to, an optical disk drive such as a compact disk ROM device (CD-ROM), CD recordable drive (CD-R Drive), CD rewritable drive (CD-RW Drive) or a digital versatile disk ROM drive (DVD-ROM). To facilitate connection of the disk storage devices 524 to the system bus 518 , a removable or non-removable interface is typically used such as interface 526 .
[0043] It is to be appreciated that FIG. 5 describes software that acts as an intermediary between users and the basic computer resources described in the suitable operating environment 500 . Such software includes an operating system 528 . Operating system 528 , which can be stored on disk storage 524 , acts to control and allocate resources of the computer system 512 .
[0044] System applications 530 take advantage of the management of resources by operating system 528 through program modules 532 and program data 534 stored either in system memory 516 or on disk storage 524 . It is to be appreciated that the claimed subject matter can be implemented with various operating systems or combinations of operating systems.
[0045] A user enters commands or information into the computer 512 through input device(s) 536 . Input devices 536 include, but are not limited to, a pointing device (such as a mouse, trackball, stylus, or the like), a keyboard, a microphone, a joystick, a satellite dish, a scanner, a TV tuner card, a digital camera, a digital video camera, a web camera, and/or the like. The input devices 536 connect to the processing unit 514 through the system bus 518 via interface port(s) 538 . Interface port(s) 538 include, for example, a serial port, a parallel port, a game port, and a universal serial bus (USB).
[0046] Output device(s) 540 use some of the same type of ports as input device(s) 536 . Thus, for example, a USB port may be used to provide input to the computer 512 , and to output information from computer 512 to an output device 540 .
[0047] Output adapter 542 is provided to illustrate that there are some output devices 540 like monitors, speakers, and printers, among other output devices 540 , which are accessible via adapters. The output adapters 542 include, by way of illustration and not limitation, video and sound cards that provide a means of connection between the output device 540 and the system bus 518 . It can be noted that other devices and/or systems of devices provide both input and output capabilities such as remote computer(s) 544 .
[0048] The computer 512 can be a server hosting a search engine site in a networked environment using logical connections to one or more remote computers, such as remote computer(s) 544 . The remote computer(s) 544 may be client systems configured with web browsers, PC applications, mobile phone applications, and the like, to allow users to access the social networking site, as discussed herein. The remote computer(s) 544 can be a personal computer, a server, a router, a network PC, a workstation, a microprocessor based appliance, a mobile phone, a peer device or other common network node and the like, and typically includes many or all of the elements described relative to the computer 512 . For purposes of brevity, only a memory storage device 546 is illustrated with remote computer(s) 544 . Remote computer(s) 544 is logically connected to the computer 512 through a network interface 548 and then physically connected via a communication connection 550 .
[0049] Network interface 548 encompasses wire and/or wireless communication networks such as local-area networks (LAN) and wide-area networks (WAN). LAN technologies include Fiber Distributed Data Interface (FDDI), Copper Distributed Data Interface (CDDI), Ethernet, Token Ring and the like. WAN technologies include, but are not limited to, point-to-point links, circuit switching networks like Integrated Services Digital Networks (ISDN) and variations thereon, packet switching networks, and Digital Subscriber Lines (DSL).
[0050] Communication connection(s) 550 refers to the hardware/software employed to connect the network interface 548 to the bus 518 . While communication connection 550 is shown for illustrative clarity inside computer 512 , it can also be external to the computer 512 . The hardware/software for connection to the network interface 548 may include, for exemplary purposes only, internal and external technologies such as, mobile phone switches, modems including regular telephone grade modems, cable modems and DSL modems, ISDN adapters, and Ethernet cards.
[0051] An exemplary embodiment of the computer 512 may comprise a server hosting a search engine site. An exemplary processing unit 514 for the server may be a computing cluster comprising Intel® Xeon CPUs. The disk storage 524 may comprise an enterprise data storage system, for example, holding thousands of user pages. Exemplary embodiments of the subject innovation may move large volumes of data between fact and archive tables in a database. The subject innovation may move large volumes of data without impinging on the response-time constraints of the search engine site.
[0052] What has been described above includes examples of the subject innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the subject innovation are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims.
[0053] In particular and in regard to the various functions performed by the above described components, devices, circuits, systems and the like, the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., a functional equivalent), even though not structurally equivalent to the disclosed structure, which performs the function in the herein illustrated exemplary aspects of the claimed subject matter. In this regard, it will also be recognized that the innovation includes a system as well as a computer-readable storage media having computer-executable instructions for performing the acts and/or events of the various methods of the claimed subject matter.
[0054] There are multiple ways of implementing the subject innovation, e.g., an appropriate API, tool kit, driver code, operating system, control, standalone or downloadable software object, etc., which enables applications and services to use the techniques described herein. The claimed subject matter contemplates the use from the standpoint of an API (or other software object), as well as from a software or hardware object that operates according to the techniques set forth herein. Thus, various implementations of the subject innovation described herein may have aspects that are wholly in hardware, partly in hardware and partly in software, as well as in software.
[0055] The aforementioned systems have been described with respect to interaction between several components. It can be appreciated that such systems and components can include those components or specified sub-components, some of the specified components or sub-components, and/or additional components, and according to various permutations and combinations of the foregoing. Sub-components can also be implemented as components communicatively coupled to other components rather than included within parent components (hierarchical). Additionally, it can be noted that one or more components may be combined into a single component providing aggregate functionality or divided into several separate sub-components, and any one or more middle layers, such as a management layer, may be provided to communicatively couple to such sub-components in order to provide integrated functionality. Any components described herein may also interact with one or more other components not specifically described herein but generally known by those of skill in the art.
[0056] In addition, while a particular feature of the subject innovation may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes,” “including,” “has,” “contains,” variants thereof, and other similar words are used in either the detailed description or the claims, these terms are intended to be inclusive in a manner similar to the term “comprising” as an open transition word without precluding any additional or other elements.
|
The claimed subject matter provides a system and/or a method for moving large volumes of data. An exemplary method comprises receiving a request to transfer a plurality of rows from a first table to a second table. The first table may be determined to be associated with a same file group as the second table. The plurality of rows may be moved from the first table to the second table by transferring a partition for the first table to the second table.
| 6
|
BACKGROUND OF THE INVENTION
The present invention relates to a method for servicing and maintaining heat supply equipment provided with a boiler or the like.
The heat supply equipment is provided with such equipment units as a water treatment unit, a fuel supply unit, and a wastewater treatment unit in addition to the boiler. A cogeneration system, which is one of the heat supply equipment, is provided with such units as an engine, a dynamo, and an exhaust heat recovery boiler. Usually, these units are serviced and maintained by different contractors. Accordingly, when an abnormality occurs in one of the units, a person in charge of managing the heat supply equipment needs to confirm which contractor is responsible for the unit, before making contact for requesting repair works. It takes labor as well as time to confirm the contractor, which elongates the halt period of the unit, resulting in considerable loss in production factories or the like.
The water treatment unit requires proper supply of consumables such as water treatment chemicals to be added to feedwater or salts to be used for a regeneration purpose in water softeners. However, if the person in charge of managing the heat supply equipment neglects supply management, the water treatment unit runs short of the chemicals and the salts, and as a result suffers from inability to function properly, thereby hindering operation of the heat supply equipment. Similarly, in the case of fuel supply of the fuel supply unit, negligence of fuel supply management causes shortage of fuel, which disables operation of the heat supply equipment. In operation of the heat supply equipment, therefore, supply management of the consumables and the fuel is quite important.
SUMMARY OF THE INVENTION
It is an object of the present invention to implement secure and prompt servicing and maintenance in heat supply equipment provided with a plurality of maintenance object units, as well as to decrease a burden on a person in charge of managing the heat supply equipment.
In order to achieve the above object, in a first aspect of the present invention, there is provided a method for servicing and maintaining heat supply equipment based on a servicing and maintenance contract to perform specified servicing and maintenance of a maintenance object unit in heat supply equipment, which includes making a supervisory center for mediating request information from the heat supply equipment communicatable with the heat supply equipment via communication means, while making the supervisory center communicatable with service suppliers who perform the servicing and maintenance works via the communication means, the method comprising the steps of: receiving request information automatically transmitted from the heat supply equipment in the supervisory center; determining necessary servicing and maintenance works based on the request information received; selecting service suppliers who can perform the servicing and maintenance works; transmitting necessary information from the supervisory center to the service suppliers; and instructing the service suppliers to take measures based on the transmitted information.
In a second aspect of the invention, there are provided a plurality of the maintenance object units, and the service suppliers are set for each of the maintenance object units.
Next, embodiments of the present invention are described. Maintenance object units in the heat supply equipment in the present invention include a boiler, a water treatment unit, a fuel supply unit, and a wastewater treatment unit. The boiler includes diverse types of boilers such as steam boilers, hot-water boilers, and heating medium boilers. The maintenance object units also include a unit to supply heat and cold, such as cooling and heating machines. In the case where the heat supply equipment is a cogeneration system, the maintenance object units include an engine, a dynamo, and an exhaust heat recovery boiler.
In implementing servicing and maintenance of the heat supply equipment, first a servicing and maintenance contract is made between an owner of the heat supply equipment or a user thereof (hereinafter referred to as a “contractant”) and a maintenance personnel. The servicing and maintenance contract defines that specified servicing and maintenance shall be given to each of the maintenance object units. For fulfilling the contents of the servicing and maintenance contract, the maintenance personnel installs a supervisory center which mediates request information from the heat supply equipment.
The supervisory center and the heat supply equipment can communicate with each other via a communication means. More particularly, a computer of the supervisory center and a computer of the heat supply equipment are linked so as to enable communication thereamong via the communication means. The computer of the heat supply equipment herein refers to either an individual computer of each maintenance object unit or a computer unifying the maintenance object units. The supervisory center can be installed in a remote place away from the heat supply equipment for a specified distance, or installed inside the heat supply equipment or in the vicinity thereof.
In addition, the supervisory center and a service supplier who performs the servicing and maintenance can communicate via a communication means. More particularly, a computer of the supervisory center and a computer of the service supplier are linked so as to enable communication thereamong via the communication means. The service supplier is set to each of the maintenance object units. The service supplier can be either a servicing department of a company to which the supervisory center belongs or can be another company.
Communication is implemented with use of a public telephone line or a dedicated line, which can be wired or wireless.
In the above constitution, once request information is automatically transmitted from the heat supply equipment, the supervisory center receives the request information. Based on the received request information, the supervisory center determines necessary servicing and maintenance works, and selects a service supplier who can perform the servicing and maintenance works. Then, the supervisory center transmits necessary information to the service supplier, and instructs the service supplier to take measures based on the transmitted information.
Determining the servicing and maintenance works and selecting the service supplier can be implemented automatically by the computer of the supervisory center or by a staff member of the supervisory center. In the case of automatic implementation, the computer of the supervisory center can transfer received request information as it is to the service supplier, or can transmit information for instructing to take measures based on the received request information to the service supplier. When the information is transmitted to the service supplier, detailed information necessary for performing servicing and maintenance works is transmitted together.
The request information includes abnormalities recovery request information transmitted when an abnormality occurs in any of the maintenance object units. In addition to the abnormalities recovery request information, the water treatment unit, for example, transmits information for requesting supply of water treatment consumables such as water treatment chemicals to be added to feedwater or salts to be used for a regeneration purpose in water softeners. Upon reception of the information, the supervisory center transfers the information to the service supplier that is, in this case, a water treatment company. The water treatment company dispatches or delivers the water treatment consumables. In the case of receiving information for requesting fuel supply to the fuel supply unit as the request information, the information is transferred to the service supplier that is in this case, a fuel supply company. The fuel supply company incorporates the fuel supply to the fuel supply unit into a tanker delivery schedule. This ensures supply management of water treatment consumables, fuel, and the like, which prevents operation halt of the heat supply equipment, and decreases a burden on a person in charge of managing the heat supply equipment.
Further, according to the above-stated constitution, in the case where a different service supplier is set to each of the maintenance object units like the case of the cogeneration system, the supervisory center can determine the contents of request information from each of the maintenance object units, and can transfer request information to each of the service suppliers. This saves labor of a person in charge of managing the heat supply equipment to confirm a service supplier in charge, and eliminates delay of report, thereby enabling prompt response to request information.
In the case where the service supplier is a company different from the company to which the supervisory center belongs, the supervisory center concludes a information mediation contract with the service supplier, to charge and collect fees on information transmittance to the service supplier. This means that the supervisory center does a business of information mediation.
According to the above constitution, as described above, in the heat supply equipment provided with a plurality of the maintenance object units, secure and prompt servicing and management, as well as considerable decrease in a burden on a person in charge of managing the heat supply equipment are implemented.
In the case where a different service supplier is set to each of the maintenance object units, it is in general necessary to establish a system to receive request information per maintenance object unit. According to the above constitution, however, installing the supervisory center which collectively conducts information mediation makes it possible to simplify the system and to eliminate necessity for the service supplier to own his own system. It can be said, therefore, that the above-stated constitution brings about large advantages to the service supplier too.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a schematic constitution of a system in the present invention;
FIG. 2 is a schematic view showing a servicing and maintenance method according to a first embodiment of the present invention;
FIG. 3 is a schematic view showing a servicing and maintenance method according to a second embodiment of the present invention; and
FIG. 4 is a schematic view showing a servicing and maintenance method according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinbelow, embodiments of the present invention will be described in details with reference to drawings. In implementing a servicing and maintenance method for a heat supply equipment in the present invention, first a servicing and maintenance contract is made for a consideration between an owner of the heat supply equipment or a user thereof (hereinafter referred to as a “contractant”) and a maintenance personnel. The servicing and maintenance contract defines that specified servicing and maintenance shall be given to each of the maintenance object units. More particularly, abnormalities recovery in occurrence of abnormalities and supply of consumables for maintaining functions are included in the contract. For fulfilling the contents of the servicing and maintenance contract, the maintenance personnel installs a supervisory center described later. Different from the maintenance Personnel, there is set a service supplier who actually performs the servicing and maintenance works. An information mediation contract is concluded between the maintenance personnel and the service supplier.
Next, a schematic constitution of a system for implementing the invention will be described with reference to (FIG. 1 . As shown in FIG. 1, heat supply equipment 1 , 1 , . . . is each equipped with maintenance object units including boilers 2 , 2 , . . . water softeners 3 , 3 , . . . and fuel tanks 4 , 4 , . . . Each of the water softeners 3 is connected to each of the boilers 2 through feedwater lines 5 , 5 , . . . Each of the fuel tanks 4 is connected to each of the boilers 2 through fuel lines 6 , 6 , . . . and provided with Liquid level sensors 7 , 7 , . . . for detecting a residual quantity of fuel.
In every management area, there is installed a supervisory center 8 for receiving request information from each of the heat supply equipment 1 . A first computer 9 is installed in the supervisory center 8 . The first computer 9 is connected to each of the boilers 2 , each of the water softeners 3 , and each of the fuel tanks 4 via a communication means 10 in a communicatable manner. For each of the maintenance object units, there is set a service supplier who performs the servicing and maintenance works based on request information transferred from the supervisory center 8 . In an embodiment shown in the drawing, there are set three service suppliers consisting of a first service supplier A, a second service supplier B, and a third service supplier C. For each of these service suppliers A, B and C, there are provided second computers 11 , 11 and 11 . Each of these second computers 11 is connected to the first computer 9 via the communication means 10 in a communicatable manner.
More particularly, computers (not shown) of each of the boilers 2 , each of the water softeners 3 , and each of the fuel tanks 4 are each connected to first modems 13 , 13 , . . . via first signal lines 12 , 12 , . . . , while the first computer 9 is also connected to a second modem 15 via a second signal line 14 . Further, each of the first modems 13 are connected to the second modem 15 via a public telephone line 16 . Similarly, each of the second computers 11 is connected to third modems 18 , 18 and 18 via third signal lines 17 , 17 and 17 , and each of the third modems 18 is connected to the second modem 15 via the public telephone line 16 . In this embodiment, therefore, the communication means 10 is composed of each of the first modems 13 , the second modem 15 , each of the third modems 18 , and the public telephone line 16 .
Next, description will be given of the particular contents of the servicing and maintenance method in the above-stated constitution with reference to FIGS. 2 to 4 .
First, description will be given of a servicing and maintenance method in the above constitution according to a first embodiment with reference to FIG. 2 . It is noted that given description will be about the case of receiving request information from one of the heat supply equipment 1 .
In the first embodiment, the heat supply equipment 1 transmits, as request information, abnormalities recovery request information. When any abnormalities occur in the heat supply equipment 1 , information to request recovery from the abnormalities is automatically transmitted to the supervisory center 8 , and the supervisory center 8 receives the transmitted abnormalities recovery request information. For example, if a feedwater pump (not shown) of the boiler 2 is in the state of decreased performance, information thereof is transmitted as the abnormalities recovery request information.
Based on the abnormalities recovery request information, the supervisory center 8 determines necessary servicing and maintenance works, and selects the service suppliers A, B and C who can perform the servicing and maintenance works. The selection is automatically conducted by the first computer 9 in the supervisory center 8 . For example, in the case of an abnormality in the boiler 2 , the first service supplier A is selected. In the case of an abnormality in the water softener 3 , the second service supplier B is selected. In the case of an abnormality in the fuel tank 4 , the third service supplier C is selected.
To each of the selected service suppliers A, B and C, the abnormalities recovery request information is transmitted from the supervisory center 8 . At this point, depending on embodiments, detailed information on the abnormalities recovery request information can be transmitted together. More particularly, upon reception of the abnormalities recovery request information, the supervisory center 8 confirms the contents thereof, and at the same time, requests related detailed information to the heat supply equipment 1 and receives thereof, and then transmits the detailed information to each of the service. suppliers A, B and C. This enables each of the service suppliers A, B and C to perform secure and effective recovery from abnormalities.
Further, upon reception of the transferred abnormalities recovery request information, each of the service suppliers A, B and C analyzes the abnormalities recovery request information and/or the detailed information, and based on the analysis result, dispatches a maintenance man or instructs recovery to a person in charge of managing the heat supply equipment 1 . More particularly, the transmitted abnormalities recovery request information and/or the detailed information are displayed on a monitor screen of the second computer 11 in each of the service suppliers A, B and C. Each of the service suppliers A, B and C analyzes the displayed information and takes measure based on the analysis result.
Therefore, it is possible to accurately recognize the current operational state of the heat supply equipment 1 , and therefore adequate instruction can be immediately given. In the case where the maintenance man needs to go to a site, he/she can identify the cause of an abnormality and prepare components and the like necessary for repair works in advance, which enables him/her to do repair works immediately after reaching the site.
As stated above, according to the first embodiment, when an abnormality occurs in each of the maintenance object units of the heat supply equipment 1 , it is possible to save labor of confirming a proper service supplier in charge among the service suppliers A, B and C, as well as to transmit abnormalities recovery request information without delay. This enables secure and prompt implementation of servicing and maintenance works as well as considerable decrease in a burden on a person in charge of managing the heat supply equipment 1 .
Next, description will be given of a servicing and maintenance method in the above constitution according to a second embodiment with reference to FIG. 3 . It is noted that given description will be about the case of receiving request information from one of the heat supply equipment 1 .
In the second embodiment, there is transmitted, as request information, salts supply request information, that is information for requesting supply of salts used for a regeneration purpose in the water softener 3 of the heat supply equipment 1 . More particularly, in the water softener 3 , consumed quantity of the salts is integrated whenever regeneration is conducted. When the integrated value reaches a set value, the salts supply request information is automatically transmitted. The transmitted salts supply request information is received by the supervisory center 8 .
Based on the salts supply request information, the supervisory center 8 conducts selection of a service supplier who can implement supply of salts, and selects a fourth service supplier D that is a salts supply company. Like the first embodiment, the selection is automatically conducted by the first computer 9 in the supervisory center 8 .
The salts supply request information is transferred from the supervisory center 8 to the fourth service supplier D, and the fourth service supplier D dispatches salts to the heat supply equipment 1 . Depending on embodiments, it can be arranged such that the fourth service supplier D delivers salts to the heat supply equipment 1 and also conducts operation of adding the salts to a salts tank (not shown) of the water softener 3 .
As stated above, according to the second embodiment, labor of salts supply management in the water softener 3 is considerably decreased. In addition, secure salts supply management prevents regeneration failure due to shortage of salts, and enables reliable maintenance of a function of the water softener 3 , that is, softening raw water. Further, leakage of hardness components is prevented, which prevents scaling on the boiler 2 , resulting in high efficiency kept in the boiler 2 and breakage of a boiler body being prevented.
Description will now be given of a servicing and maintenance method in the above constitution according to a third embodiment with reference to FIG. 4 . It is noted that given description will be about the case of receiving request information from one of the heat supply equipment 1 .
In the third embodiment, there is transmitted, as request information, fuel supply request information, that is information for requesting supply of fuel to the fuel tank 4 of the heat supply equipment 1 . More particularly, in the fuel tank 4 , a residual quantity of fuel is detected by the liquid level sensor 7 . When the residual quantity reaches a set value, the fuel supply request information is automatically transmitted. The transmitted fuel supply request information is received by the supervisory center 8 .
Based on the fuel supply request information, the supervisory center 8 conducts selection of a service supplier who can implement supply of fuel, and selects a fifth service supplier E that is a fuel supply company. Like each of the aforementioned embodiments, the selection is automatically conducted by the first computer 9 in the supervisory center 8 .
The fuel supply request information is transferred from the supervisory center 8 to the fifth service supplier E, and the fifth service supplier E estimates supply time based on the residual quantity of fuel and average daily quantity consumed in the boiler 2 , incorporates fuel supply into a tanker delivery schedule, and carries out delivery of fuel according to the delivery schedule. Depending on embodiments, it can be arranged such that the supervisory center 8 estimates the supply time and imparts instruction thereof to the fifth service supplier E.
As stated above, according to the third embodiment, labor of fuel supply management in the fuel tank 4 is considerably decreased. In addition, secure fuel supply management promises prevention of operational halt of the boiler 2 due to shortage of fuel, and implements stable supply of steam.
It is noted that the supervisory center 8 mediates information as a business. Accordingly, the maintenance personnel concludes the information mediation contract with each of the service suppliers A, B, . . . , and charges and collects fees on information transmittance to each of the service suppliers A, B, . . . In the servicing and maintenance contract, a specified amount of a contract fee is defined, and it is speculated that when each of the service suppliers A, B, . . . performs dispatch of a maintenance man, supply of salts, supply of fuel, and the like, the contractant pays fees to each of the service suppliers A, B, . . .
According to the present invention, in a heat supply equipment provided with a plurality of maintenance object units, secure and prompt servicing and maintenance is implemented, and a burden on a person in charge of the heat supply equipment can be considerably decreased.
|
In heat supply equipment provided with a plurality of maintenance object units, secure and prompt servicing and maintenance is implemented and a burden on a person in charge of managing the heat supply equipment is decreased. In a method for servicing and maintaining heat supply equipment based on a servicing and maintenance contract to perform specified servicing and maintenance of a maintenance object unit in heat supply equipment, which includes making a supervisory center for mediating request information from the heat supply equipment communicatable with the heat supply equipment via communication means, while making the supervisory center communicatable with service suppliers who perform the servicing and maintenance via the communication means, the method includes the steps of: receiving request information automatically transmitted from the heat supply equipment in the supervisory center; determining necessary servicing and maintenance works based on the request information received; selecting service suppliers who can perform the servicing and maintenance works; transmitting necessary information from the supervisory center to the service suppliers; and instructing the service suppliers to take measures based on the transmitted information.
| 5
|
FIELD OF THE INVENTION
The invention relates generally to the field of semiconductor processing; and more particularly, to the field of nitride film deposition on semiconductor substrates.
BACKGROUND OF THE INVENTION
Recently, a process for the low pressure chemical vapor deposition (LPCVD) of silicon nitride films from ammonia and bis-tertiary-butyl amino silane (BTBAS), having the formula (t-C 4 H 9 NH) 2 SiH 2 , has been proposed in U.S. Pat. No. 5,874,368 to Laxman. In addition to improved film properties, a significantly lower deposition temperature can be used as compared to a conventional process using ammonia and dichlorosilane (DCS), subjecting the semiconductor substrates to a significantly lower thermal budget. The process is operated in a conventional vertical furnace wherein a plurality of wafers, accommodated in a wafer boat in a horizontal position and in a vertically spaced relationship, are processed in a quartz process tube.
However, this BTBAS process has a large disadvantage. After a few deposition runs, or a limited cumulative film thickness of about 300 nm on the quartz process tube and the quartz wafer boat, the particle levels in the process tube start to increase to unacceptably high levels. In order to reduce the particle levels, the quartzware needs to be cleaned, and cleaned relatively frequently. Due to the high frequency of cleaning, this manufacturing process is only economical when the cleaning can be performed in-situ, by feeding a cleaning gas into the process tube, without a need to dismount the process tube for each cleaning. One frequently used cleaning gas is NF 3 . Unfortunately, after cleaning with NF 3 , the deposition rate of the BTBAS process appears to be significantly lower than before the cleaning, perhaps due to undesirable roughening of the exposed quartz surfaces. This effect can be counteracted by performing a pre-coating run using BTBAS without product wafers in the process tube. However, the pre-coating run contributes to the allowable cumulative deposition before a new in-situ cleaning becomes necessary. Thus, using BTBAS is counter-productive since it reduces the number of production runs that can be performed between cleanings.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, a method is provided to reduce the loss in deposition rate following the cleaning of a reaction chamber comprising the steps of: cleaning the reaction chamber; precoating the reaction chamber with silicon nitride using an inorganic silicon reactant and a nitrogen source; and depositing silicon nitride on a workpiece using an organic silicon reactant.
In accordance with another aspect of the invention, a method is provided for treating quartz materials to maintain a relatively constant deposition rate on wafers. The method includes administrating a dichlorosilane-based (DCS-based) silicon nitride pre-coat to quartz materials. A wafer is loaded into a reaction chamber having the pre-coated quartz materials. A film is then deposited onto the wafer using an organic silicon precursor.
In accordance with another aspect of the invention, a method is provided for the operation of a reaction chamber for the deposition of silicon nitride films on semiconductor substrates comprising the steps of: a) carrying out a number of silicon nitride deposition runs on semiconductor wafers in the reaction chamber, using a nitrogen source and bis-tertiary-butyl amino silane (BTBAS) as precursors; b) after building up a cumulative BTBAS-based nitride thickness on parts of the reaction chamber, performing an in-situ clean of the reaction chamber by feeding a cleaning gas into the reaction chamber; c) depositing a nitride pre-coating on the cleaned reaction chamber using a nitrogen source and dichlorosilane (DCS) as precursors; and d) re-starting the cycle of steps a), b), c), and d) in sequence.
An advantage of the preferred embodiments is to provide a method for the operation of a reaction chamber for the deposition of nitride films using BTBAS and ammonia as precursors, that allows for the performance of an economically feasible number of production runs between cleaning cycles. Another advantage is that the pre-coating method is effective for increasing and maintaining the deposition rate of low temperature depositions, following a cleaning of the reaction chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the deposition rates for a number of bis-tertiary-butyl amino silane (BTBAS) nitride deposition runs following an in-situ clean.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In one embodiment, a method is provided for deposition of silicon nitride films workpieces or substrates in a plurality of runs using an organic silicon source, and particularly bis-tertiary-butyl amino silane (BTBAS). This embodiment will be described in further detail with reference to FIG. 1 . FIG. 1 shows the deposition rate for a series of consecutive BTBAS-based nitride deposition runs. Prior to each series, an in-situ cleaning was performed on the quartz process tube and the quartz wafer boat that accommodates the wafers in a vertically spaced relationship. Quartz rings were disposed directly below each wafer to improve the uniformity of the BTBAS-based deposition over each wafer. At the start of the experiments shown in FIG. 1 , the quartzware was new and unused. A first series of four depositions of a thickness of 60 nm to 80 nm each was carried out. During this series the process conditions, in particular the temperatures of five heating zones in a vertical batch processing furnace, were adjusted to improve the uniformity of the deposition process over the wafers along the height of the wafer boat. These first results are not shown in FIG. 1 .
Following the initial BTBAS-based depositions on wafers, an in-situ cleaning was performed using NF 3 as the cleaning gas. The wafer boat and quartz rings were cleaned simultaneously with the process tube. The NF 3 cleaning was thermally activated and performed in a temperature range between 500° C. and 600° C., using a mixture of NF 3 and N 2 . The in-situ cleaning time was in the range of 20 to 30 min. Alternatively, plasma activation of the NF 3 or any other form of non-thermal activation known in the art can be applied. The organic-based nitride deposition is preferably conducted below about 650° C. The BTBAS deposition process was carried out at a temperature of about 600° C., using BTBAS and a supplemental nitrogen source, specifically NH 3 , as reactants. Note that BTBAS is an organic source for both silicon and nitrogen, such that it is possible to omit the supplemental nitrogen source. The deposited film thickness per run was in the range of 60 nm to 80 nm. This deposition tends to coat not only the wafers but also internal quartz parts, such as the furnace vessel and the boat, as well as quartz or ceramic support rings in the boat slots in some arrangements.
As shown in FIG. 1 , in the series of runs performed after the first etch, the deposition rate for the first run was relatively low and increased in the subsequent runs until a saturation level of about 0.775 nm/min was achieved. This decreased deposition rate and slow recovery became more pronounced following each subsequent etch step between runs. Indeed, in the event of prolonged periods of cleaning, the effect became very pronounced. The effect of such a prolonged period of cleaning is demonstrated by the deposition rate of the BTBAS-derived films following the fourth etch, in FIG. 1 . Heavy over-etching resulted from prolonged exposure of the quartz material to the NF 3 etching gas. As a result, the series of deposition runs after etch 4 demonstrated a strongly reduced deposition rate which only slowly recovered during successive applications of the BTBAS-based silicon nitride film. The deposition series after etch 5 and 6 showed similar behavior, although the data is not presented in FIG. 1 . Such a variable deposition rate is not acceptable in a production environment, which emphasizes speed, consistency, and reliability. Additionally, the decrease in deposition rates translates into a longer production time for each workpiece, also adding cost and time to the process.
Without being limited by theory, the most likely explanation for this behavior is that there is an increase in surface roughness of the quartz material, which roughness occurs due to the NF 3 in the in-situ cleaning, or etching, process. This increase in roughness translates into an increase in possible deposition surface area. Thus, since the surface area has increased, but the other characteristics of the device remain unchanged, the deposition rate on the substrates or workpieces accordingly decreases, as more precursor is consumed by deposition on the higher surface area quartz parts.
Without being limited by theory, the inventors hypothesize that the reason each of the progressive runs result in higher deposition rates is that the roughness is reduced by depositing a film over the rough area. The valleys and pits in the surface are gradually filled with increasing film thickness. While it is desirable to reduce over-etching to a minimum, one cannot completely avoid over-etching. This is primarily because the previously deposited nitride film needs to be completely removed to ensure the performance of the process over a number of cycles of in-situ cleans and series of deposition runs between the cleanings.
In one preferred embodiment, a new nitride film is deposited over the freshly etched reaction chamber, including anything that was cleaned in the reaction chamber. Thus, the deposition rate is not reduced as much following a cleaning of the reaction chamber. Preferably, the roughness due to etching is reduced by applying a film over any etched parts, but the film does not contribute to the particle levels in the chamber. The pre-coating film is preferably deposited by chemical vapor deposition using an inorganic silicon source. In a more preferred embodiment, the pre-coating film uses both an inorganic silicon source and an inorganic nitrogen source. Preferably the pre-coating process is conducted at approximately 700° C. or greater. In the illustrated embodiment, the film pre-coat is produced from dichlorosilane (DCS) and ammonia while the film deposited onto the workpiece(s) is produced from BTBAS and ammonia.
An example of the result of using the method of one preferred embodiment of the current invention is demonstrated in FIG. 1 . While the deposition rate of the BTBAS-based nitride following each cleaning had been approximately 0.55 nm/min for the first run following the fourth etching, the deposition rate of BTBAS-based nitride following the seventh etching and a DCS-based nitride pre-coating, resulted in an initial deposition rate of approximately 0.75 nm/min. In this embodiment, after the seventh in-situ etch a silicon nitride pre-coating was deposited on the quartzware, in this case the process tube, boat, and support rings, using ammonia and DCS as precursors. The process conditions for the precoating process were as follows: temperature 750° C. to 780° C., DCS flow=80 sccm, NH 3 flow=280 sccm, pressure=235 mTorr. A film of about 300 nm thickness was deposited in 150 min. One of skill in the art will appreciate how these variables can differ according to the particular reaction chamber designs.
FIG. 1 demonstrates several surprising results of the preferred embodiment. First, the deposition rate following the seventh etch cycle and the DCS pre-coating treatment is superior to the deposition rate following even the first etch cycle without the DCS pre-coat. This demonstrates the incredible effectiveness of this embodiment.
Second, the consistency of the deposition rates between each of the successive runs demonstrates that this method allows one to obtain deposition rates with a very high level of reproducibility. This is particularly surprising since only a single treatment with DCS resulted in such a stable system. A comparison of the reproducibility of the deposition rates between pre-coating using DCS and “pre-coating” the chamber and internal parts using BTBAS demonstrates the ability of the DCS-based pre-coat films to produce a much more stable system. FIG. 1 shows that in the deposition series after etch 4 , using BTBAS as the precursor for both the pre-coating and for the deposition onto the substrates; the deposition rate appears to still be rising, perhaps even after the seventh run, which would equate to approximately 490 nm of cumulative film thickness. Thus, a BTBAS-based “precoating” is unable to achieve a steady deposition rate even after 490 nm of film thickness, a thickness of BTBAS-based nitride that already requires a new round of chamber cleaning due to excessive particle generation. However, the DCS-based nitride pre-coating process resulted in a relatively constant deposition rate of BTBAS-based nitride following a single, although thicker, pre-coating. Notably, this was achieved after a DCS-based nitride precoating of only 300 mm, rather than the 490 nm of the BTBAS-based pre-coat.
An additional surprising result is that the DCS-based nitride film thickness seems to have no significant influence on the allowable thickness of BTBAS-based nitride film, as far as cleaning of the chamber is concerned. That is, the extra thickness created by the DCS-based pre-coating is not an important factor in determining when degradation of the particle performance will occur and when an additional cleaning will be required. Thus, the extra thickness provided by the DCS-based film helps to smooth the roughness from the etching, without reducing the amount of BTBAS-based film one can add during deposition runs. This is in agreement with the much larger tolerable film thickness of DCS-based nitride, 30 μm or more, which can be deposited in a reaction chamber before cleaning is needed. Without being limited by theory, the inventors believe that the reason a greater thickness of DCS-based nitride is permissible over BTBAS-based nitride is that DCS is an inorganic compound. That is, it is the carbon and hydrogen in the BTBAS reactant that makes the BTBAS-based films susceptible to stress and flaking, and thus require cleaning of the reaction chamber frequently.
As one of skill in the art will recognize, in light of the present disclosure, the DCS-based nitride pre-coating thickness that achieves stable BTBAS process performance depends on the condition of the reaction chamber, any quartzware that is part of the process, the number of etches already performed, the degree of over-etching, and many other factors. In a preferred embodiment, the thickness of the pre-coating is estimated to be 50 nm or more. More preferably, the thickness of the pre-coating is in the range of 100 nm to 500 mm.
“Reaction chamber,” as used herein, generally refers to the exposed surface of an environment where the deposition from vapor phase reactants onto a workpiece is to occur. This includes any surface that is exposed to at least one of the following: the precoating reactants, the product or deposition run reactants, or the cleaning gases. Thus, “reaction chamber,” according to one preferred embodiment, encompasses not only the shell of the chamber itself, but also any quartzware or any other objects, that may also be exposed to the pre-coating reactants, product reactants, or cleaning gases. A “processing chamber” or other area where a deposition is to occur is defined similarly. “Reaction chamber” does not include the workpiece itself. In one preferred embodiment, a reaction chamber comprises a quartz process tube. In a more preferred embodiment, the reaction chamber also comprises a wafer boat. In a more preferred embodiment, the reaction chamber comprises a quartz process tube, a wafer boat, and a quartz ring or other support structure.
As one of skill in the art will recognize, the reaction chamber and other pieces of equipment which may benefit from cleaning and thus pre-coating with the film of the preferred embodiments, can be made from many different materials, including, but not limited to the following: ceramic materials, such as alumina, anodized coatings, and silicon nitride; metals, such as, aluminum, and stainless steel; quartz; and other dielectric materials. The reaction chamber of the preferred embodiments was made of quartz material. In an alternative embodiment, the reaction chamber is made from silicon carbide. In another embodiment the reaction chamber is made from silicon impregnated silicon carbide, graphite, or other ceramic materials.
The pre-coating step comprises a deposition, using the pre-coating reactant, onto the reaction chamber. Pre-coating is performed when there is no workpiece in he reaction chamber. In light of the present disclosure, one of skill in the art could predict and test alternatives for the pre-coating reactant. As will be appreciated by one of skill in the art, there may be other compounds that produce films with the same properties as the DCS-based nitride; namely, a high level of build up of the pre-coating film should be permissible before cleaning is required. In one preferred embodiment, compounds that exhibit a permissible film thickness that is similar to DCS-based nitrides, determined as a function of particle performance, could be used instead of DCS. Preferably, an inorganic substance is used to coat the reaction chamber and other materials that have been cleaned. In a more preferred embodiment, the inorganic substance can be an inorganic silane, such as SiH 4 , Si 2 H 6 , and Si 3 H 8 . In an even more preferred embodiment, the silane is a chlorosilane, such as, SiH 3 Cl, SiHCl 3 , SiH 2 Cl 2 , and SiCl 4 .
The “product reactants” are the reactants used during deposition onto a workpiece or substrate. In a preferred embodiment, the workpiece is a wafer. In light of the present disclosure, one of skill in the art will recognize that the identity of the product reactant may be different from BTBAS. Preferably, the product reactant is an organic reactant. More preferably, the organic reactant is a source of silicon. Preferably, the product reactant is an organic source of both silicon and nitrogen. In the illustrated embodiment, the product reactant comprises BTBAS.
In light of the present disclosure, one of skill in the art will recognize that ammonia need not be the only chemical used in both or either of the deposition steps. Preferably, however, only inorganic reactants are used in the pre-coating step. Alternative nitrogen sources can be selected from the group consisting of: (H 3 Si) 3 N (trisilylamine), ammonia, atomic nitrogen, hydrazine (H 2 N 2 ), and hydrazoic acid (HN 3 ). In another embodiment, nitric oxide is used as a source of nitrogen. In the illustrated embodiment, ammonia is used in both of the deposition steps.
Although a thermally activated NF 3 in-situ cleaning process was used in the present experiments, other in-situ cleaning, or etching, processes employing different process conditions, and/or different cleaning gases such as ClF 3 , SF 6 , C 2 F 6 , CF 4 and/or employing plasma activation of the cleaning gas might be used.
The present embodiment has been demonstrated for a process tube, wafer boat, and rings. As one of skill in the art will appreciate, the invention is not limited to these particular structures for its beneficial or inventive aspects.
Accordingly, it will be appreciated by those skilled in the art that various omissions, addition and modifications can be made to the processes described above without departing from the scope of the invention. All such modifications and changes are intended to fall within the scope of the invention, as defined by the appended claims.
|
A method is provided for obtaining stable and elevated deposition rates in a reaction chamber, following the cleaning of the chamber. The method involves cleaning of the chamber, pre-coating the interior surfaces of the reaction chamber with an inorganic composition, and then, using the pre-coated chamber to deposit an organic layer onto a workpiece.
| 2
|
FIELD OF THE INVENTION
[0001] The invention relates generally to a surface treatment for a casting surface, to make the casting surface more suitable for wire bonding and other processes.
BACKGROUND OF THE INVENTION
[0002] Circuit assemblies have different components that are assembled using different manufacturing processes. One of the components often used in a circuit assembly is a metal casting, which is typically in the form of a heat sink. The heat sink is connected to other components, such as a printed circuit board (PCB). The connection between the heat sink and the PCB is typically accomplished using a wire bonding process, where the surface requirements are always high in regard to cleanliness, composition, roughness, and finish.
[0003] Wire bonding is the method by which a length of small diameter soft metal wire is attached to a compatible metallic surface without the use of solder, flux, and in some cases, with use of heat above 150 degrees Celsius. Soft metals includes Gold (Au), Copper (Cu), Silver (Ag), Aluminum (Al), and alloys such as Palladium-Silver (PdAg) and others.
[0004] Some current processes used for wire bonding on the PCB require a specific intermetallic interface between the aluminum bond and nickel phosphorus plating for solder and bonding. These processes also have various failure modes which limit the applications which the wire bonding process may be used for.
[0005] Immersion gold is a robust surface for bonding. However, contamination or imperfections in the gold may result in a non-stick condition. The failures may be the result of supplier manufacturing, shipment, or production environment, or other factors.
[0006] One type of process for polishing the surface is a diamond milling process. However, this process is expensive, and increases manufacturing costs significantly when used.
[0007] Accordingly, there exists a need for a process which provides a surface that is sufficient for wire bonding, minimizes or eliminates failures, and is cost effective.
SUMMARY OF THE INVENTION
[0008] The present invention is a surface treatment process used to improve wire bonding between a PCB and a heat sink in a transmission control module, where the surface of the heatsink has been etched using a laser, thereby cleaning the surface before bonding. In one embodiment, the laser has a 1064 nm wavelength, but it is within the scope of the invention that other wavelengths may be used. This process minimizes the various failure modes that may occur at the bonding interface.
[0009] In another embodiment, the process of the present invention may be used for as-cast base plates. As mentioned above, any contamination or surface faults between an aluminum bond and an aluminum base plate reduces the robustness of the connection. By using the laser process of the present invention, a bond is made with high strength, removing the need for post processing the casting progression, such as diamond milling or surface treatments. The laser process of the present invention involves two steps, the first step is a laser etch ablation process where material is removed, and the second step is a second laser etch to clean and smooth the surface.
[0010] In one embodiment, the present invention involves bonding to a nickel phosphorous (NiP) and Au surface that has been exposed to a laser etch. In another embodiment, there is bonding to an as-cast surface (which has no post-casting surface treatment or finish) using laser ablation. The process of the present invention also involves no-clean flux from Au plated PCB bond pads.
[0011] It is an object of this invention to provide a consistent surface finish due to the placement process, which allows for a very robust wire bonding connection.
[0012] It is another object of this invention to remove contamination to provide a more robust surface for wire bonding post-cleaning.
[0013] It is also an object of this invention to eliminate the need for post-casting surface treatment, providing a cost savings.
[0014] In one embodiment, the present invention is a casting assembly having a bonding interface surface. In one embodiment, the casting assembly includes a base layer and an oxidation layer formed during the casting process. In other embodiments, the casting assembly may include a mold release layer. A contamination layer may form if the outer surface of the casting assembly is exposed to various debris and contaminants after being removed from the mold. There is also an intermediate finish surface, and a bonding interface surface. A material removal process is applied to the outer surface of the casting assembly to remove the contamination layer, the mold release layer, the oxidation layer, and a portion of the base layer to form the intermediate finish surface. Once the intermediate finish surface is formed, a material polish process is applied to the intermediate surface finish to form the bonding interface.
[0015] In one embodiment, the mold release layer is a mold release material for facilitating the removal of the casting assembly from a mold.
[0016] The base layer may be made from one of several materials, such as, but not limited to, aluminum, silver, gold, and copper.
[0017] In an embodiment, the present invention is a method of removing material from a surface, which includes the steps of providing a base layer, providing at least one layer attached to the base layer, providing an intermediate finish surface, and providing a bonding interface surface. The intermediate finish surface is formed by removing the at least one layer and a portion of the base layer during a material removal process. The bonding interface surface is formed by a polishing process applied to the intermediate finish surface.
[0018] In one embodiment, there is a base layer and an oxidation layer formed during the casting process. In other embodiments, the at least one layer may include a mold release layer. A contamination layer may form if the outer surface of the casting assembly is exposed to various debris and contaminants after being removed from the mold.
[0019] The oxidation layer, mold release layer, and the contamination layer are removed during the material removal process. The material removal process involves laser etching the at least one layer to create the intermediate finish surface, but is it within the scope of the invention that other types of processes may be used.
[0020] The polishing process includes the steps of applying a second laser etching to the intermediate finish surface, to form the bonding interface surface. The first laser etching process is different from the second laser etching process to form the bonding interface surface.
[0021] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0023] FIG. 1 is a sectional view of a portion of a metal casting having undergone a surface finish process, according to embodiments of the present invention; and
[0024] FIG. 2 is a perspective view of a first area of a metal casting having undergone a surface finish process, according to embodiments of the present invention;
[0025] FIG. 3 is a perspective view of a second area of a metal casting having undergone a surface finish process, according to embodiments of the present invention;
[0026] FIG. 4 is an enlarged view of a first area of a metal casting having undergone a surface finish process, according to embodiments of the present invention;
[0027] FIG. 5 is a greatly enlarged topographical view of a first area of a metal casting having undergone a surface finish process, according to embodiments of the present invention;
[0028] FIG. 6A is a greatly enlarged view of first area of a metal casting having undergone a surface finish process, that includes a measurement line extending through both a bonding interface surface and a non-lasered area, according to embodiments of the present invention;
[0029] FIG. 6B is a first graph representing depth measurements of the measurement line in FIG. 6A ;
[0030] FIG. 7A is a greatly enlarged view of first area of a metal casting having undergone a surface finish process, that includes a measurement line extending through part of a bonding interface surface in a first direction, according to embodiments of the present invention;
[0031] FIG. 7B is a graph representing roughness measurements of the measurement line in FIG. 7A ;
[0032] FIG. 8A is a greatly enlarged view of first area of a metal casting having undergone a surface finish process, that includes a measurement line extending through part of a bonding interface surface in a second direction, according to embodiments of the present invention;
[0033] FIG. 8B is a graph representing roughness measurements of the measurement line in FIG. 8A ;
[0034] FIG. 9A is a greatly enlarged view of first area of a metal casting having undergone a surface finish process, that includes a measurement line extending through part of an outer surface of a casting assembly in a first direction, outside of a bonding interface surface, according to embodiments of the present invention;
[0035] FIG. 9B is a graph representing roughness measurements of the measurement line in FIG. 9A ;
[0036] FIG. 10A is a greatly enlarged view of first area of a metal casting having undergone a surface finish process, that includes a measurement line extending through part of an outer surface of a casting assembly in a second direction, outside of a bonding interface surface, according to embodiments of the present invention; and
[0037] FIG. 10B is a graph representing roughness measurements of the measurement line in FIG. 10A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0039] A sectional view of a portion of a metal casting assembly is shown in FIG. 1 generally at 10 . The assembly 10 includes a base layer 12 having an outer surface, shown generally at 12 A. When the casting assembly 10 is formed, the process typically involves a mold, where the material used to form the casting assembly 10 is injected into the mold. When the casting assembly 10 is removed from the mold, there is typically an oxidation layer 14 formed on the base layer 12 , a mold release layer 16 attached to the oxidation layer 14 , and some form of contamination material, which forms a contamination layer 18 on the mold release layer 16 .
[0040] The oxidation layer 14 forms as part of the base layer 12 due to heat exposure during the casting process. The mold release layer 16 is made from a mold release material which is used to facilitate the removal of the casting assembly 10 from the mold. The contamination layer 18 is made of debris and other substances that may be located inside the mold during the casting process, or substances that could be anything contacting the casting assembly 10 after the molding process. Any one or a combination of the oxidation layer 14 , the mold release layer 16 , or the contamination layer 18 may be exposed on the outer surface 12 A, depending upon how the casting assembly 10 is made, and the environment the assembly 10 is exposed to after the casting process. In one embodiment, the oxidation layer 14 is formed such that the oxidation layer 14 is part of the outer surface 12 A, and the mold release layer 16 and contamination layer 18 are disposed on the surface 12 A, on top of the oxidation layer 14 .
[0041] The first step of the process according to the present invention is a material removal process, where a laser etch is applied to the outer surface 12 A of the casting assembly 10 such that the contamination layer 18 , the mold release layer 16 , the oxidation layer 18 , and a portion of the base layer 12 are all removed, leaving a rough finish on the outside surface 12 A of the base layer 12 . This rough finish is an intermediate finish surface, shown generally at 20 . This material removal process functions to ablate and remove material. The laser may be any type of laser suitable for removing material from the casting assembly 10 . In one embodiment, during the material removal process, the laser has operating parameters of 38-42 Amps, 3000-10,000 Hertz, a speed range of 50-200 mm/sec, and passes over the surface 10-100 times to create the intermediate finish surface 20 . In yet another embodiment, during the material removal process, the laser has operating parameters of 40 Amps, 3600 Hertz, a speed of 120 mm/sec, and passes over the surface 54 times to create the intermediate finish surface 20 . The laser used during the material removal process has a wavelength of 1064 nm, but it is within the scope of the invention that other wavelengths may be used.
[0042] The second step in the process according to the present invention is a polishing process. The polishing process is applied to the intermediate finish surface 20 , transforming the intermediate finish surface 20 into a bonding interface surface, shown generally at 22 . The polishing process may also be applied using a laser, and in one embodiment, during the polishing process, the laser may have operating parameters of 30-38 Amps, 20,000-40,000 Hertz, a speed of 100-400 mm/sec, and passes over the surface 5-20 times to create the bonding interface surface 22 . In another embodiment, during the polishing process, the laser is operated at 36 Amps, 36,000 Hertz at a speed of 300 mm/sec, and passes over the surface 7 times to create the bonding interface surface 22 .
[0043] Once the bonding interface surface 22 is formed, the bonding interface surface 22 may be used for a wire bonding process, bonding the base layer 12 to a PCB board. In one embodiment, the bonding interface surface 22 has surface characteristics that are a result from undergoing both the material removal process and the polishing process. There is a total amount of material removed from the assembly 10 after undergoing both the material removal process and the polishing process, which places the bonding interface surface 22 at a “depth” relative to the original outer surface 12 A. In one embodiment, the depth 56 of the bonding interface surface 22 is about 3.7-37.0 microns, and the bonding interface surface 22 has a roughness Rz of less than 10 microns, but it is within the scope of the invention that other targets for the depth 56 and roughness may be used, depending on the materials used for the casing assembly 10 .
[0044] Referring to FIGS. 4-10B , various photos and graphs are shown depicting an example of a portion of a casting assembly 10 , with a portion of the outer surface 12 A having the bonding interface surface 22 placed under a digital microscope. There are areas of the outer surface 12 A that have not undergone the material removal process, shown generally at 12 B, along with the bonding interface surface 22 shown in FIGS. 4-10B .
[0045] Referring to FIG. 6A , there is a photo 30 of an area of a casting assembly 10 which has the bonding interface surface 22 . The photo 30 includes a measurement line 32 , which is the distance measured taken along the surface 12 A of the casting assembly 10 and bonding interface surface 22 shown in FIG. 6A . In FIG. 6B , there is a first graph 34 depicting a surface measurement of the casting assembly 10 , including the bonding interface surface 22 (i.e., lasered area), and the areas of the casting assembly 10 that have not been exposed to either the material removal process, or the polishing process (i.e., non-lasered area). In FIGS. 6A and 6B , the measurement line 32 is about 5.0 mm, as can be seen by the lower scale in FIG. 6B , but it is within the scope of the invention that other lengths may be used.
[0046] The first graph 34 from FIG. 6B has three sections, a first section, shown generally at 36 , a second section, shown generally at 38 , and a third section, shown generally at 40 . The first and third sections 36 , 40 represent areas of the outer surface 12 A in FIG. 6A that have not been exposed to either the material removal process, or the polishing process, and the second section 38 represents the area of the outer surface 12 A in FIG. 6A that has undergone both the material removal process and the polishing process. Also included in FIG. 6B is a first reference line 42 , the first reference line 42 is the average height of the non-lasered areas (sections 36 , 40 ) taken along the measurement line 32 in FIG. 6A .
[0047] The second section 38 has a width 44 of just over 2.0 mm, but it is within the scope of the invention that the width 44 may vary, depending upon the location of the measurement line 32 and the size of the bonding interface surface 22 . As is shown in FIG. 6B , there is a maximum height 46 , which is the distance from the reference line 42 to the lowest point in the second section 38 . The second section 38 also has a mean height, which is the difference in the average height of the lasered surface (section 38 ) and the average height of the non-lasered surface (sections 36 , 40 ), which is shown in FIG. 6B as about 9.06 μm.
[0048] Referring now to FIG. 7A , there is the same photo 30 shown in FIG. 6A , however, the measurement line 32 is at a different location and direction, and therefore represents a different surface measurement of the bonding interface surface 22 . The measurement line 32 in FIG. 7A is about 2.0 mm, and there is a second graph 48 in FIG. 7B showing the surface measurement of the measurement line 32 in FIG. 7A . In FIGS. 7A and 7B , the surface measurement taken along the measurement line 32 has a roughness measurement Rz of about 9.18 μm.
[0049] Referring to FIG. 8A , there is again the same photo 30 shown in FIG. 6A , with the measurement line 32 at yet another location and direction, therefore representing a different surface measurement of the bonding interface surface 22 . Again, the measurement line in FIG. 8A is about 2.0 mm, and there is a third graph 50 in FIG. 8B showing the surface measurement line 32 in FIG. 8A . In FIGS. 8A and 8B , the surface measurement taken along the surface measurement line 32 has a roughness measurement Rz of about 9.15 μm. The measurements taken along the measurement lines 32 in both FIG. 7A and FIG. 8A produce similar measured results.
[0050] Referring now to FIG. 9A , again the same photo 30 is shown that is shown in FIGS. 6A, 7A, and 8A . However, in FIG. 9A , the measurement line 32 is taken at a location on the outer surface 12 A that is outside of the bonding interface surface 22 . Once again, the measurement line 32 is about 2.0 mm, and there is a fourth graph 52 in FIG. 9B showing the surface measurement represented by the measurement line 32 in FIG. 9A . It can be seen in FIGS. 9A and 9B that the surface measurement taken along the surface measurement line 32 has a roughness measurement Rz of about 16.35 μm.
[0051] Referring to FIGS. 10A and 10B , again the same photo 30 is shown that is shown in FIGS. 6A, 7A, 8A, and 9A . However, in FIG. 10A , the measurement line 32 is again located outside the bonding interface surface 22 , but in a different location and direction compared to the measurement line 32 in FIG. 9A . Once again, the measurement line 32 is about 2.0 mm, and there is a fifth graph 54 in FIG. 10B showing the surface measurement represented by the measurement line 32 in FIG. 10A . It can be seen in FIGS. 10A and 10B that the surface measurement taken along the surface measurement line 32 has a roughness measurement Rz of about 14.73 μm.
[0052] Furthermore, the roughness measurements (Rz) are about 9.18 μm and 9.15 μm in FIGS. 7A and 8A , respectively, and the roughness measurements are about 16.35 μm and 14.73 μm in FIGS. 9A and 10A , which is significantly larger than the roughness measurements in FIGS. 7A and 8A .
[0053] Examples of the completed wire bond are shown in FIGS. 2 and 3 . The base layer 12 is shown having the outer surface 12 A exposed, and the bonding interface surface 22 , which is formed with both the material removal process and the polishing process. A wire 24 is shown bonded to a bond pad 26 of a PCB board 28 , and the wire 24 is also bonded to the bonding interface surface 22 formed as part of the base layer 12 .
[0054] In one embodiment, the wire used for the wire bonding process is 203.2 μm in diameter, but it is within the scope of the invention that wires of other diameters may be used, such as, but not limited to, 125.0 μm to 508.0 μm, depending upon the type of material used for the process. In this embodiment, the material used for the wire bonding is aluminum, but it is within the scope of the invention that other materials may be used, such as, but not limited to, gold, silver, copper, and nickel. The target roughness value Rz for the bonding interface surface 22 is less than 10 μm, regardless of material or depth 56 . When aluminum is used, the bonding interface surface 22 has a target depth 56 of 3.7 to 37.0 μm.
[0055] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
|
A method of removing material from a surface, which includes the steps of providing a base layer, at least one layer attached to the base layer, an intermediate finish surface, and a bonding interface surface. The intermediate finish surface is formed by removing the at least one layer and a portion of the base layer during a material removal process. The bonding interface surface is formed by a polishing process applied to the intermediate finish surface. There is an oxidation layer which is part of the base layer, as well as a mold release layer and a contamination layer, both of which are part of the at least one layer. The material removal process involves laser etching the at least one layer to create the intermediate finish surface, and the polishing process includes applying a second laser etching to the intermediate finish surface, forming the bonding interface surface.
| 7
|
This application is a continuation of application Ser. No. 07/776,102, filed Oct. 15, 1991, now abandoned.
TECHNICAL FIELD OF THE INVENTION
This invention relates in general to electronic power devices, and more particularly to a lateral double-diffused insulated gate field effect transistor and a process for its fabrication.
BACKGROUND OF THE INVENTION
Lateral double-diffused insulated gate field effect transistors (sometimes known as LDMOS transistors) are the power devices of choice for integration into very large scale integrated circuit (VLSI) logic processes. The on-resistance per unit area (r ds (on)) is the figure of merit for a high voltage power device. Reduced surface field (RESURF) power transistors were introduced by J. A. Appels and H. M. J. Vaes in "High Voltage Thin Layer Devices (Resurf Devices)", IDEM Tech. Dig. 1979, pp. 238-241. RESURF LDMOS device will have, given a (P) type semiconductor substrate, an N-type drift region that surrounds an (N+) drain. Relatively thick LOCOS oxide is grown on a portion of the drift region. A relatively deep (P) type implant is used to make the body of the insulated gate field-effect transistor (IGFET), which spaces the drift region from a source region. A (P+) back gate connection is formed within the (P) body implant region. A conductive gate is formed over and insulated from the IGFET body to extend from the source region over the body to the lateral margin of the LOCOS thicker oxide.
The drift region has a donor dopant concentration N D1 , which is designed to fully deplete with the JFET action from the (P-) substrate gate at the rated voltage. However, the JFET gate dopant concentration is optimized for use of the substrate for other VLSI devices, and is suboptimal for a high voltage power device. A need therefore exists to develop an LDMOS transistor having a low r ds (on) that is yet compatible with VLSI logic processes.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a transistor having a large breakdown voltage and adaptable to carry a large amount of current is formed at a face of a semiconductor layer having a first conductivity type. This transistor includes a JFET gate region of the first conductivity type formed in the semiconductor layer, where the dopant concentration of the JFET gate region is substantially higher than that of the background dopant concentration of the semiconductor layer. A drift region of a second conductivity type is formed to be laterally within the JFET gate region. A thick insulator region is formed at the face on at least a portion of the drift region. An insulated-gate field effect transistor (IGFET) body of the first conductivity type is formed adjacent the JFET gate region. A source region of the second conductivity type is formed to be laterally within the body and spaced from the drift region. A drain region is formed to be of the second conductivity type and to adjoin the drift region and be spaced from the body. A back gate connection region is formed at the face to be of the first conductivity type and to adjoin the body. A conductive gate extends over the face at least between the source region and the thick insulator region, with a thin gate insulator spacing the gate from the body. Preferably, the conductive gate further extends over a portion of the thick insulator region.
According to a further aspect of the invention, the JFET gate region and the drift region are formed using the same hard mask with successive implants. In a subsequent diffusion drive-in, the dopant of the first conductivity type, which has a much higher diffusion constant than the dopant of the second conductivity type, diffuses further into the semiconductor layer, creating a JFET gate region which laterally and downwardly surrounds the drift region. A masking step can also be saved in the formation of the IGFET body and the source region. The same mask can be used to implant both of these regions; with a subsequent diffusion drive-in, dopant atoms of the first conductivity type diffuse outwardly at a faster rate than the dopant atoms of the second conductivity type, which are selected to have a lower diffusion constant. In this way, the body laterally surrounds the source region, and preferably overlaps the dopant limits of the JFET gate region. A back gate connection is preferably subsequently implanted into the body so as to be in ohmic contact with the JFET gate region.
An important technical advantage of the invention in its provision of the JFET gate region with dopant concentration that is enhanced over that of the semiconductor layer. Due to the more highly doped JFET gate region, the drift region doping can also be increased while still meeting the RESURF conditions. This will lower the drift region resistance, leading to a lower r ds (on) for the device. A further technical advantage of the invention is its compatibility with a VLSI logic process in which other, lower-power devices are made simultaneously in the same chip. Only one additional mask is needed to fabricate this device in addition to the others normally encountered in a VLSI logic process.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects of the invention and their advantages will be discerned by referring to the following detailed description in conjunction with the drawings, in which like parts are identified with like characters and in which:
FIGS. 1-5 are highly magnified schematic sectional views of a mirror pair of LDMOS transistors according to the invention, showing successive stages in their fabrication; and
FIG. 6 is a perspective view of a portion of one such LDMOS transistor.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, a (P-) semiconductor substrate is indicated generally at 10. Layer 10 may be an epitaxial layer having a resistance in the range of 25 to 33 ohm-cm. A sacrificial layer 12 of oxide is grown on a face 14 of the semiconductor layer 10. Layer 12 may be approximately 400 Angstroms thick. A layer 16 of photoresist is deposited on the oxide 12 and is developed to define a first implantation area indicated generally at 18. The developed photoresist layer 16 is used as a mask for two implants of different conductivity types. First, a (P) type dopant such as boron is implanted into area 18 at an implantation energy of approximately 100 KeV. The dose may be in the range of 5×10 12 atoms/cm 2 to 2×10 13 atoms/cm 2 . This creates a (P) region 20.
Using the same mask, a second implant is performed, this time using an (N) type dopant having a substantially lower diffusivity than the (P) type dopant employed. In the preferred embodiment, arsenic is used with an implantation energy of approximately 80 KeV and a dose in the range of 5×10 12 to 2×10 13 atoms/cm 2 . This creates an (N) type region 22 that is shallower than the (P) region 20. The region 20 will have a dopant concentration which is substantially higher than the background dopant concentration of the (P-) semiconductor layer 10.
Referring next to FIG. 2, the photoresist layer 16 is stripped and the implants 20 and 22 are driven in to produce a (P) JFET gate region 24 and an (N) drift region 26. The diffusion drive-in may take place, for example, at 1200° C. for approximately 700 minutes. The higher diffusivity of the (P) type dopant causes the dopant to diffuse outwardly at a faster rate than the arsenic atoms used to create the drift region 26. This in turn results in the JFET gate region 24 laterally and downwardly enclosing the (N) drift region 26.
Referring next to FIG. 3, the results of a second set of implantations are shown. A second layer of photoresist (not shown) is deposited and developed to leave open second implantation areas (not shown). A second set of implants is then performed, each using the second developed photoresist mask. A first of these implants is with a high diffusivity, (P) dopant such as boron. The dose should fall within the range of 1.5×10 13 atoms/cm 2 to 1.5×10 14 atoms/cm 2 , and is preferably about 5×10 13 atoms/cm 2 . The implantation energy may be approximately 100 KeV. Second, a relatively low-diffusivity (N) type dopant such as arsenic is implanted. The dose for this species can range from 3×10 13 through 2×10 14 and is preferably about 1×10 14 atoms/cm 2 . A preferred implantation energy is 120 KeV.
Next, a drive-in step is performed, such as one at approximately 1100° C. for 500 minutes. This will produce insulated gate field effect transistor (IGFET) bodys 30 and 32 as respectively surrounding source regions 34 and 36. The IGFET bodys 30 and 32 intentionally overlap the JFET gate region 24. The top of the IGFET region 30 will serve as the channel region of a field effect transistor to be fabricated between source region 34 and the drift region 26, while the top of the IGFET body 32 likewise serves as the channel region for a field effect transistor to be formed between the drift region 26 and source region 36.
After these diffusion drive-ins, a pad oxide layer (not shown) is grown on the surface 14 of the semiconductor layer 10 and a nitride layer is subsequently deposited to together form a hard mask 40. Mask 40 is patterned and etched to leave windows 41 for the subsequent LOCOS thick oxide growth process step to be described immediately below.
Turning to FIG. 4, LOCOS oxide islands 42 and 44 are grown under an oxygen atmosphere to a preferred thickness of about 7600 Angstroms. Each of the LOCOS oxide islands 42 and 44 has "bird's beak" lateral margins 46 which are near the lateral margins 48 of the drift region 26. Next, a gate oxide layer 50 is grown on the surface 14 of the semiconductor layer to a total thickness of approximately 500 Angstroms under an oxygen/steam atmosphere. After this, approximately 4500 Angstroms of polycrystalline silicon (poly) is deposited on the surface of the semiconductor wafer, heavily doped with a dopant such as POCl 3 at a dose of approximately 10 21 atoms/cm 2 , patterned and etched to form conductive poly gates 52 and 54. Poly gate 52 extends from a point near the lateral margin of the source region 34, over the IGFET body 30, across a near area of the drift region 26, and preferably up onto a portion of the LOCOS oxide region 42. Poly gate 54 is disposed similarly in mirror image.
The remaining important steps in the fabrication process are illustrated in FIG. 5. An (N+) source/drain implant is performed as partially self-aligned to lateral edges 56 and 58, respectively, of the poly gates 52 and 54. A developed photoresist layer 59 (see FIG. 4) is used to define the opposing lateral margins of the implant. This first (N+) source/drain implant is performed, for example, with phosphorus, at an energy of approximately 80 KeV and a dose of approximately 4×10 14 cm -2 . This implant enhances the dopant concentration in source regions 34 and 36, and creates the drain region 60, which is self-aligned to LOCOS islands 42 and 44. This first source/drain implant is immediately followed with a second source/drain implant with, for example, arsenic at an implantation energy of approximately 120 KeV and a dose of 5×10 15 atoms cm 2 . This will create particularly heavily doped (N+) regions 62 and 64, and will enhance the dopant concentration of the drain 60. Regions 62 and 34 form a graded-junction source region, as do regions 36 and 64 correspondingly.
Next, a (P) implant area is defined using photoresist, and an implant of a (P) type dopant, as for example boron, is performed to create (P+) back gate connection regions 70 and 72. The back gate connection regions may be formed, for example, with boron at an implantation energy of about 25 KeV and a dose of about 2 ×10 15 atoms/cm 2 . These back gate connection regions 70 and 72 are implanted within the respective IGFET bodys 30 and 32, and preferably are adjacent to their respective source regions 62 and 64. This is to make efficacious a common metal contact (not shown) to both the source region 62 and the back gate connection 70, on the one hand, and to the source region 64 and the back gate connection 72 on the other.
Further steps are necessary to complete the device. These include the deposition of approximately 4000 Angstroms of undoped oxide and approximately 7000 Angstroms of borophosphosilicate glass (BPSG) (not shown). A contact photoresist layer (not shown) is then deposited and developed. Appropriate contacts are etched to expose at least portions of back gate connection regions 70 and 72, source regions 62 and 64, and drain region 60. The exposed contact areas are silicided by depositing platinum, which will create a thin layer 74 of platinum silicide. Excess platinum is then removed. This is followed by the deposition of a relatively refractory metal such as a titanium-tungsten alloy. The first level of metallization is completed using aluminum, to complete contacts 78, 80 and 82.
FIG. 6 is a highly magnified, schematic perspective view of the left one-half of the pair of devices shown in FIG. 5. The completed lateral double-diffused "metal/oxide/semiconductor" (LDMOS) power transistor indicated generally at 90 may take any of several forms. The indicated structures may be elongated indefinitely in parallel to direction 92 to create a series of elongate stripes, as current-carrying characteristics require. In a preferred embodiment, the peak dopant concentration of the JFET gate region is in the range of 3 to 5×10 15 acceptors per cubic centimeter, and the peak dopant concentration of the drift region is in the range of 3 to 5×10 16 donors per cubic centimeter. The source/drain breakdown voltage is about 90 volts. Also, as is partially shown in conjunction with FIGS. 1-5, the transistor 90 may be replicated about planes 94 and 96, and repeated in this manner as many times as is desired. With multiple sources and drains, drain region 60 would alternate with source region 34. Only one such alternation is shown in conjunction with FIGS. 1-5, which shows a common drain region 60 provided for the source regions 34 and 36. The basic structure of transistor 90 may also have curved components (not shown) such that an essentially circular structure may be fabricated; curved components (not shown) can also close off and join together appropriate ones of the "stripes" at either end of an elongated structure.
Silicon has a breakdown voltage characteristic of approximately 30 volts per micron. For a structure designed to have a breakdown voltage (BV) of approximately 90 volts, the length, in a direction perpendicular to direction 92, of the drift region 26 from a lateral margin 98 of the LOCOS oxide 42 to the lateral margin 100 of the drain 60 should be approximately 3.5 microns. This distance may be reduced for devices needing lower breakdown voltages. The distance between points 98 and 100 directly affect the on-resistance, r ds (on). It is desirable to increase the dopant of drift region 26 to lower the on-resistance as much as possible. On the other hand, the breakdown voltage of the part will depend in part on the relationship of the dopant concentration N d of the drift region 26 and the dopant concentration of N a of the JFET gate region 24. As the concentration N a in gate region 24 is increased, the dopant concentration N d in drift region 26 may also be increased while meeting the RESURF conditions. This allows more flexible design, and an optimization of r ds (on) and the breakdown voltage (BV).
For a relatively light arsenic dose of region 26, the breakdown voltage is caused by potential crowding near the (N+) drain 60. In this mode, breakdown voltage increases with the arsenic implant dose. With higher arsenic implant doses, a bulk breakdown is observed. This is the preferred mode of operation since the device 90 will then exhibit the highest possible breakdown voltage and the bulk breakdown gives the device 90 more rugged characteristics. However, further increases in the arsenic implant dose result in lower breakdown voltage due to the high electric fields under the gate electrode 52. After a point, this lowering in breakdown voltage outweighs the incremental improvement in r ds (on).
LDMOS devices 90 suitable for automotive applications were fabricated in a one micron CMOS process. The smallest call scale pitch (between planes 94 and 96) was 10.7 microns. The measured r ds (on) of 1.38 milliohms-cm 2 at a V gs of 15 volts With a breakdown voltage of 80 volts represents the best performance reported to date for a lateral device in this voltage range.
In summary, an improved performance LDMOS power transistor has been shown and described. The addition of an enhanced-dopant concentration JFET gate region allows the dopant concentration of the drift region to be increased, thereby reducing r ds (on), important in the characterization of the performance of the device. Nonetheless, this device may be fabricated such that it is compatible with the VLSI logic process at a minimal extra cost and only one additional mask.
While preferred embodiments have been described and illustrated in conjunction with the above detailed description and the appended drawings, the invention is not limited thereto, but only by the scope and spirit of the appended claims.
|
A transistor has a JFET gate region of a first conductivity type formed at the face of a semiconductor layer to laterally and downwardly surround a drift region of a second conductivity type. A thick insulator region is formed on a portion of the drift region at the face. A IGFET body of the first conductivity type is formed at the face to be adjacent the JFET gate region. This body spaces a source region of the second conductivity type from the drift region. A drain region is formed at the face to be of the second conductivity type and to adjoin the drift region, and to be spaced from the IGFET body. A conductive gate extends over the face between the source region and the thick insulator region, with a thin gate insulator spacing the gate from the IGFET body. The enhanced doping concentration of the JFET gate region with respect to the semiconductor layer allows the dopant concentration of the drift region to likewise be increased, thereby allowing RESURF conditions to be met at the rated voltage and with a lower r ds (on).
| 7
|
BACKGROUND OF THE INVENTION
A toy vehicle is provided with a specially constructed support member on the upper body shell of the toy vehicle to receive and removably support a weighted member such as a coin of monetary value of a predetermined weight. The toy vehicle, when propelled forward, provides an impression of high speed acceleration with its front wheel assembly lifting off the support surface as a result of the location and weight of the weighted member.
In general, children find it very amusing to play with a toy vehicle which is propelled by a springwound motor as the power source, and which has various different modes of travel. The inventor has, therefore, provided a toy vehicle assembly, disclosed in U.S. Pat. No. 4,329,810 issued May, 18, 1982, having a support member provided closer to the rear of the toy vehicle to hold a weighted member such as a monetary coin, and mounting the weighted member thereon allows the toy vehicle not only to run normally, but also run with its front wheel assembly lifting off the support surface.
The toy vehicle assembly disclosed in U.S. Pat. No. 4,329,810, however, has a limitation in its modes of travel, and accordingly additional improvements are still possible.
Therefore the appearance of a toy vehicle having more running variations has been awaited.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention to provide a toy vehicle assembly which allows children to amuse themselves by playing therewith in various ways, by supporting the mount for the weighted member such as a coin of monetary value by an arm member the position of which is adjustable so that it is possible to modify the mode of travel of the toy vehicle with its front wheel assembly lifted off the support surface by variously regulating the position of the mount.
Generally speaking, according to the invention, a toy vehicle assembly is provided comprising: a weighted member; a housing member having a configuration which simulates a vehicle, including an upper body shell and a lower frame member; a front wheel assembly attached to the housing member; a rear wheel assembly including an axle and a pair of wheels attached to the housing member; and a support member supporting the weighted member attached to the rear wheel assembly side of the housing member, wherein the support member includes an arm member with a weighted member holder holding the weighted member provided at one end of the arm member, the other end of the arm member being attached to the upper body shell of the housing member, the arm member being rotatable about a plurality of axes in directions different from each other.
According to another feature of a preferred embodiment, the arm member includes a base and a support rod, the base being rotatably attached to the upper body shell of the housing member as well as being connected to one end of the support rod by a pin joint.
Moreover, in the preferred embodiment, the weighted member holder includes a weighted member holding plate attached to the other end of the support rod, and a first bracket and a pair of retaining projections provided on one surface of the holding plate, whereby the weighted member is supported on that surface of the holding plate by the holding plate, the first bracket and the pair of retaining projections.
A pair of second brackets are provided on the other surface of the holding plate, whereby a second weighted member can be supported on the other surface of the holding plate by the pair of second brackets.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention is set forth in the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily understood by reference to the following detailed description when considered in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of a toy vehicle assembly running with its front wheels lifted off the support surface;
FIG. 2 is a side elevation of the toy vehicle assembly;
FIG. 3 is a side elevation of the toy vehicle assembly with its upper body shell shown in FIG. 2 removed;
FIG. 4 is an exploded perspective view of an example of a motor assembly;
FIG. 5 is a perspective view of the toy vehicle assembly rotating about its rear axle while lying on its side;
FIG. 6a is a perspective view showing the arrangement of one surface of the weighted member holder;
FIG. 6b is a perspective view showing the arrangement of the other surface of the weighted member holder;
FIG. 7 is a sectional side elevation of the weighted member holder;
FIG. 8 is a sectional side elevation of an essential part of an arm member;
FIG. 9 is a sectional side elevation of an essential part of another example of the arm member;
FIGS. 10 and 11 are a perspective view and a sectional side elevation, respectively, of other examples of the weighted member holder; and
FIG. 12 is a side view of a toy airplane assembly to which the invention is applied.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is provided to enable any person skilled in the toy industry to make and use the present invention and sets forth the best modes contemplated by the inventor for carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a novel toy vehicle assembly.
Referring now to the figures wherein like reference characters designate identical or corresponding parts throughout the several views and, more particularly, to FIGS. 1, 2 and 3. The toy vehicle assembly in accordance with a preferred embodiment of the invention shown in these figures comprises a vehicle housing 1 constituted by an upper body shell 2 and a lower frame member 3, a motor assembly 4 mounted on the vehicle housing 1, a front axle 5 and a rear axle 6 attached to the lower frame member 3 and the motor assembly 4 respectively, front wheels 7 and rear wheels 8 attached to the front axle 5 and the rear axle 6 respectively, and a weighted member holder 9 mounted by an arm member 91 closer to the rear part of the upper body shell 2.
The upper body shell 2 and the lower frame member 3 is a combination constituting the vehicle housing 1 and each are molded of plastic and integrally screwed to each other by means of a screw (not shown).
The upper body shell 2 of the embodiment is designed to simulate a truck having a jet engine mounted on its rear part. This configuration of the upper body shell 2 is, however, not exclusive and it is possible to simulate the configurations of various automobiles.
The lower frame member 3 has a retaining tab 31 provided toward the rear of its upper surface and a retaining hook 32 provided toward the front thereof. In addition, bearing hooks 33 for rotatably supporting the front axle 5 are provided in the vicinity of the retaining hook 32.
A guide member or portion 13 forms a slanting surface at the rear end of the lower frame member 3. The guide member 13 is configured to contact and slide along a support surface 100 when the front wheels 7 are lifted off the support surface 100. The guide member 13 is positioned so as to support the toy vehicle when it is rotated about the rear axle 6. Accordingly, the toy vehicle, when propelled forward, provides an impression of high speed acceleration with its front wheel assembly lifted off the support surface 100 as a result of the weight of the weighted member.
The motor assembly 4 has a retaining plate 4a formed on its rear side which engages with the retaining tab 31, and a step 4b formed on its front side which retains the retaining hook 32. The motor assembly 4 is firmly mounted on a substantially central part of the lower frame member 3 by the engagement and retaining effected by these parts.
The motor assembly 4 is a self-contained motor assembly formed by incorporating in a motor housing 41 a pull-back type of spring 42 and a gear train 43 transmitting the power from the spring 42 to the rear axle 6. Referring now to FIG. 4 showing an example of the motor assembly 4, the motor housing 41 comprises side shells 411, 412 and an intermediate plate 413 clamped therebetween and made of a plastic resin. The motor housing 41 accomodates the spring 42 and the gear train 43. The gear train 43 has a winding system, i.e., a system for storing energy in the spring 42, and a driving system, i.e., a system for driving an output shaft, thereby allowing power to be reciprocally transmitted between the spring 42 and the rear axle 6. The gear train 43 is formed so that it is lightweight by employing a plastic resin having a modulus of elasticity of, for example, 0.3.
The winding system of the gear train 43, i.e., the system for storing energy in the spring 42, comprises a pinion 431 secured to the rear axle 6 attached to the housing 41, a first spur gear 432 constantly engaging the pinion 431, a winding pinion 433 engaging the spur gear 432, and a small gear wheel 434 secured to a spring shaft 421 and engaging the pinion 433. The winding pinion 433 is movably borne so that it engages the spur gear 432 only during the winding-up of the spring.
The driving system, i.e., the system for driving an output shaft, comprises a large gear wheel 435 secured to the spring shaft 421, a driving pinion 436 engaging the large gear wheel 435, a second spur gear 437 formed integrally with the pinion 436 and engaging a pinion 438 formed integrally with the first spur gear 432. The driving pinion 436 is movably born so as to engage the large gear wheel 435 only during the driving of the toy car. It must be noted that the above first spur gear 432 and the pinion 431 function as gears in the driving system.
The speed ratio of the rear axle 6 to the spring shaft 421 of the above gear train 43 is 1.18 for the winding system and 25.45 for the driving system. Therefore, a 1.18 revolution of the rear axle 6, i.e., the rear wheels 8, winds the spring 42 one revolution, while unwinding the spring 42 one revolution rotates the rear axle 6, i.e., the rear wheels 8, 25.45 revolutions. Accordingly, a sufficiently large energy can be stored by a short pull-back distance, i.e., retreat distance, and a high-speed long-distance running is made possible by releasing the energy little by little.
The ratio l/L of the length l of the motor assembly 4 to the length L of the lower frame member 3 is set to be larger than 0.5. Accordingly, since the motor assembly 4, which has the largest weight of the constituent elements of the toy vehicle assembly, is positioned in the substantially central part of the vehicle housing 1, it is possible to stabilize the running of the toy vehicle as well as allow it to change course easily when it collides with an obstacle or the like.
The front axle 5 has the front wheels 7 attached to the right and left ends thereof, and is supported by the bearing hooks 33 of the lower frame member 3 as well as a projection 21 extending from the front bumper of the upper body shell 2 so that it is prevented from coming off the lower frame member 3 easily. The rear axle 6 with the rear wheels 8 attached to the right and left ends thereof, has its central portion directly incorporated into the motor assembly 4 as the output shaft thereof as described above. In addition, since the rear axle 6 is made longer than the front axle 5, the distance between the attached rear wheels 8 is larger than that between the attached front wheels 5. Moreover, the diameter and width of each of the rear wheels 8 are made larger than those of each of the front wheels 7. Therefore it is possible to improve the stability of the toy vehicle, as well as prevent it from rolling laterally, when running by those arrangements. In the embodiment, the diameter of each of the front wheels 7 is 17 mm, the width thereof is 8 mm, the diameter of each of the rear wheels 8 is 20 mm, the width thereof is 10 mm, the length of the front axle 5 is 30 mm, that of the rear axle 6 is 36 mm, the distance between the pair of attached front wheels 7, i.e., the distance between the side surfaces of the front wheels 7 is 38 mm, and the distance between the pair of attached rear wheels 8, i.e., the distance between the side surfaces of the rear wheels 8, is 46 mm.
Moreover, as described above, the diameter of each of the rear wheels 8 is made larger than that of each of the front wheels 7 in order to set the relationship between the height of the front axle 5 and that of the rear axle 6 from a flat support surface 100 so that a plane K including the front axle 5 and the rear axle 6 will intersect the flat support surface 100 in front of the front axle 5 at an angle θ as shown in FIG. 3. In addition, a body line B is made to have a larger angle than the angle θ with respect to the flat support surface 100. In consequence, the vehicle housing 1 as a whole is inclined forward. Accordingly, it is possible to improve the stability of the toy vehicle when running as well as allow it to easily effect a course change to a different direction when it collides with an obstacle or the like. In the embodiment, the angle θ is 4 degrees.
Further, it is also possible to enjoy playing with the toy car in the position shown in FIG. 5 by making the distance between the attached rear wheels 8 larger than that between the attached front wheels 7 and also by making the diameter and width of each of the rear wheels 8 larger than those of each of the front wheels 7 as described above. More specifically, when the rear wheels 8 are driven with the toy vehicle lying on its side, the vehicle housing 1 rotates about its rear wheels 8 projecting from the vehicle housing 1, thereby making the toy vehicle rotate. If this rotation takes place after the toy vehicle has accidentally rolled over during running, the rotation succeeds the normal running of the toy vehicle, or the running thereof with its front wheels 7 lifted off the support surface 100, and provides a more amusing impression.
The weighted member holder 9 is mounted on the upper body shell 2 by the arm member 91 closer to the rear part of the vehicle housing 1 as shown in FIGS. 5 thru 8. More specifically, the arm member 91 has a base 91a and a support rod 91b which are connected together so that the arm member 91 can pivot through substantially 180 degrees about a pin joint 92 at the junction between the base 91a and the support rod 91b. In addition, the shaft portion of the base 91a is pivotally fitted in a keyhole-like aperture 22 formed in the upper surface of the upper body shell 2 of the vehicle housing 1 so that it can rotate through 360 degrees as well as be removable.
A weighted member holding plate 94 is integrally provided at the end of the support rod 91b of the arm member 91. The arm member 91 and the weighted member holding plate 94 are molded of a plastic resin in a similar way to that of the vehicle housing 1. The weighted member holding plate 94 is formed as a rectangular shape and has side plates 95 provided on both sides thereof. Moreover, both surfaces of the weighted member holding plate 94 are designed so as to be able to receive and support the weighted member 10 such as a coin of monetary value, e.g., a penny or nickel.
More specifically, one surface of the weighted member holding plate 94 has a bracket 97 having a circular base 97a and an L-shaped cross sectional configuration, provided pointing upward in a substantially central part thereof, together with a pair of small retaining projections 98 provided toward both sides of the upper part thereof. On the other hand, the other surface of the weighted member holding plate 94 has a pair of brackets 99 each having a circular base 99a and an L-shaped cross sectional configuration, provided, inclined at about 45 degrees inward, at positions slightly above the lateral center line of the weighted member holding plate 94 and at the same time symmetrical about the longitudinal center line thereof. Moreover, small projections 97b, 99b are formed on the inner surfaces of the brackets 97 and 99 with L-shaped cross sectional configurations, respectively, on the surfaces of the weighted member holding plate 94.
Accordingly, the weighted member holder 9 can be turned to any desired direction by the rotation of the arm member 91, and its height and angle of inclination can also be changed at will by the pin joint 92 between the base 91a and the support rod 91b. Thereby, it becomes possible to move the position of the center of gravity of the vehicle housing 1 at will by the regulation of the stationary position of the weighted member 10 with respect to the vehicle housing 1. Accordingly, it is possible to optionally modify the running conditions of the toy vehicle with its front wheels 7 lifted off the support surface 100. Moreover, it is possible to enjoy playing with a toy vehicle with various different appearances by changing the external shape thereof. Further, the weighted member holder 9 firmly clamps the weighted member 10 on one surface of the weighted member holding plate 94 by means of the bracket 97 having an L-shaped cross sectional configuration and the two retaining projections 98, and also at the other surface the weighted member holder 9 firmly clamps lower portions of a similar weighted member 10 by two brackets 99 each having an L-shaped cross sectional configuration. Furthermore, since the bases 97a, 99a of these brackets 97, 99 are formed so as to be circular, when a circular coin is used as the weighted member 10, it is received stably so that a reliable clamping can be effected. In addition, since the small projections 97b, 99b are provided on the inner surfaces of the brackets 97, 99, respectively, when the weighted member 10 such as a coin or the like is clamped by the brackets 97, 99, the projections 97b, 99b engage the peripheral edges of the coin or the like, thereby allowing the weighted member 10 to be more firmly clamped.
It must be noted that, in another example of the arm member, a base 191a and a support rod 191b can be connected together by a swivel joint as shown in FIG. 9.
Moreover, besides the example of the weighted member holding plate 94 in the above embodiment, such modifications as those shown in FIGS. 10 and 11 are possible. The example shown in FIG. 10 is such that a weighted member holding plate 194 is formed so as to be longitudinally extended, and has a plurality of brackets 197 (199) each having an L-shaped cross sectional configuration, longitudinally provided on one or both surfaces thereof, thereby making it possible to mount a plurality of weighted members 10. On the other hand, the example shown in FIG. 11 has brackets 297, 299 each having an L-shaped cross sectional configuration formed on one or both surfaces of a weighted member holding plate 294 so that there is a large clamping distance between each bracket and the corresponding surface, so that a plurality of weighted members 10 such as coins or the like can be mounted simultaneously. If the weighted member holding plate is constructed so as to be able to mount a plurality of weighted members 10 removably as in these examples, it becomes possible to regulate the number of weighted members 10 mounted. Accordingly, the running conditions of the toy vehicle can be varied at will by the movement of the center of gravity of the vehicle housing 1.
Various further modifications are possible. For example, the weighted member holding plate could be circular or triangular. Moreover, besides the pivotal connection between the base 91a and the support rod 91b of the arm member 91, the support rod 91b and the weighted member holding plate 94, for example, can be pivotably connected together by a pin joint, a swivel joint or the like. In such a case, the stationary position of the weighted member holder 9 can be further regulated properly. Moreover, since the arm member 91 is removably fitted in the keyhole-like aperture 22 of the vehicle housing 1, if a plurality of weighted member holders 9 different in configuration from each other are prepared, it becomes possible to interchange them, so that a single toy vehicle can provide various enjoyable modifications.
The toy vehicle having the above construction is used in play as follows. When the vehicle is to run normally, the vehicle housing 1 of the toy vehicle is pulled backward to store a sufficient quantity of energy for driving the motor assembly 4, and then the vehicle is released so as to run. In this case, the arm member 91 has been rotated as well as pivoted in order to position the weighted member holder 9 properly, thereby allowing the vehicle to run normally with various different running appearances. When the toy vehicle is to be propelled with its front wheels 7 lifted off the support surface, the required number of weighted members 10 are mounted on the weighted member holding plate 94, and the arm member 91 is rotated as well as pivoted in order to position the weighted member holding plate 94 properly, i.e., the weighted members 10, and then the vehicle housing 1 is pulled backward and released to run. In this case, the toy vehicle runs according to the number of the weighted members 10 and the positions thereof. In both the normal running of the vehicle, and the running thereof with its front wheels lifted off the support surface, owing to the fact that the diameter and width of each of the rear wheels 8 are larger than those of each of the front wheels 7, and that the distance between the attached rear wheels 8 is larger than that between the attached front wheels 7, and moreover that the motor assembly 4 is mounted on a substantially central part of the vehicle housing 1, the running of the vehicle is very stable, and yet the vehicle can easily change its course to a different direction if it collides with an obstacle while running.
On the other hand, when playing with the toy vehicle by making it rotate, the vehicle housing 1 is pulled back to store driving energy in the motor assembly 4. Under this state, the vehicle housing 1 is rolled over and then released. Thereupon, the vehicle is allowed to rotate about the rear axle the rotation of the rear wheels 8 projecting from the vehicle housing 1, and it turns round and round. It is also possible to make the toy vehicle run normally, or run with its front wheels lifted off the support surface, and then rotate it about its rear axle after it rolls over, by making the vehicle run on a steep slope to roll it over deliberately.
As has been described, according to the invention, it is possible to enjoy the running of the toy vehicle with its front wheels lifted off the support surface, in addition to the normal running, by mounting a weighted member thereon, since a pivotable arm member is provided closer to the rear part of the upper body shell of the vehicle and a weighted member holding plate is provided on the arm member. Moreover, it is also possible to move the center of gravity of the vehicle as appropriate by varying the stationary position of the weighted member holding plate, i.e., the weighted member, by pivoting the arm member, thereby making it possible to enjoy a variety of modes of travel. Further, because the stationary position of the weighted member holder is varied by pivoting the arm member, the appearance of the toy vehicle is modified, so that it is possible to enjoy changing the appearance of the vehicle. Furthermore, since a coin can be employed as the weighted member, it is unnecessary to prepare a special weighted member. In addition, since coins are flat, it is possible to simplify the construction of the weighted member holding plate as well as ensure the reliable mounting of a coin thereon.
In the above embodiment, the upper body shell of the housing member has a configuration which simulates a car. However, it will be readily understood that the upper body shell could have a configuration which simulates an airplane as shown in FIG. 12, or it could have any other desired configuration. Since in this case the constructions of the parts other than the upper body shell can be the same as those in the above embodiment, any detailed description thereof will be unnecessary herein.
It will thus be seen that the objects set forth above, among those other objects made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween.
|
A toy vehicle assembly that can be self-propelled by a spring motor and is designed to permit the front wheels to be lifted off of the traveling surface by the addition of a weighted member. The weighted member is positioned on a pivotable bracket which is adjustable relative to the main frame of the vehicle to thereby permit a modification in the mode of travel of the vehicle.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to a process for the production of activated carbon fibers.
Activated carbon fibers are generally produced from polyacrylonitrile fibers, cellulose fibers, cured novolak resin fibers and carbonaceous pitch fibers. Because of their high adsorption power and of easiness to be formed into desired shapes such as cloth, sheet or felt like forms, activated carbon fibers are utilized in a wide variety of applications.
One problem associated with known activated carbon fibers relates to their expensiveness which is attributed to low yield of the carbon fibers in known processes for the production thereof. For example, when activated carbon fibers having a BET specific surface area of 2,500 m 2 /g or more are intended to be produced using the above precursor fibers by conventional processes, the yield is as low as about 15%.
BRIEF SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a process by which activated carbon fibers can be produced from cured novolak resin fibers with a high yield.
Another object of the present invention is to provide a process of the above-mentioned type which can produce activated carbon fibers having a large specific surface area of, for example, 2,500 m 2 /g or more.
The present inventors have found that slow rate of an activation gas in diffusion into precursor fibers accounts for the low yield of the activated carbon fibers in the conventional processes. That is, in the conventional processes, an activation gas such as steam or carbon dioxide is used for the activation of precursor fibers. The activation is effected as a result of solid-gas reactions between the precursor fibers and the activation gas which proceed through mass transfer to outer surfaces of the fibers, mass transfer to inside surfaces of the fibers and reaction within the fibers. In the conventional process, the step of the mass transfer into the fibers is a rate determining step. Since this step proceeds slowly, the activation occurs mainly on the outer surfaces of the fibers rather than in the interior thereof. As a consequence, the diameter of the fibers gradually decreases as the reaction proceeds and the yield of the activated carbon fibers becomes low. On the basis of the above findings, the present inventors have made an extensive study for developing a new process which can yield activated carbon fibers with an improved yield and have found that when novolak resin fibers impregnated with a polymer formed in situ by polymerization of a polymerizable monomer are calcined and activated, activated carbons having a large surface area can be obtained with a high yield.
In accordance with the present invention there is provided a process for the production of activated carbon fibers, comprising the steps of:
(a) providing cured novolak resin fibers;
(b) impregnating said novolak resin fibers with a polymerizable vinyl monomer;
(c) polymerizing said vinyl monomer; and
(d) carbonizing and activating said novolak resin fibers containing the polymerized vinyl monomer.
The reason for why the above process of the present invention can produce activated carbon fibers having a large surface area with a high yield is considered as follows. When a vinyl monomer incorporated into novolak resin fibers is polymerized, the resin fibers are swelled or inflated. Since the yield of residual carbon is lower than that of the resin fiber matrix, there are formed a multiplicity of pores when the polymer-containing resin fibers are carbonized. Therefore, the activation gas can be rapidly diffused within the precursor fibers so that the activation can proceed more easily as compared with that in the conventional process.
Other objects, features and advantages of the present invention will become apparent from the detailed description of the invention to follow.
DETAILED DESCRIPTION OF THE INVENTION
The cured novolak resin fibers to be used in the process of the present invention may be obtained by any conventional method such as a method including the steps of melt spinning a novolak resin into fibers and curing the spun fibers. The novolak resin may be, for example, a resin obtained by polycondensation reaction of a phenol or its derivative with an aldehyde in an acidic condition. Examples of the phenol derivatives include alkylphenols, alkoxyphenols, halogenated phenols, resorcinol and other polyphenols. Examples of the aldehydes include formaldehyde, paraformaldehyde, furfuraldehyde, chloral and acetoaldehyde. The cured novolak resin fibers may be in any form such as fibers, woven or nonwoven fabrics, threads or felt.
As the polymerizable vinyl monomer with which the above novolak fibers are impregnated, there may be used any vinyl monomer which can be polymerized upon being energized by, for example, heat, light, electron beam or radioactive ray in the presence or absence of a polymerization catalyst. Such a vinyl monomer may be, for example, an acrylate such as methyl acrylate or ethyl acrylate; a methacrylate such as methyl methacrylate, propyl methacrylate; acrylamide; methacrylamide; acrylonitrile; methacrylonitrile; an aromatic vinyl monomer such as styrene or ethylstyrene, a vinyl ester such as vinyl acetate, a vinyl halide such as vinyl chloride; a vinylidene halide such as vinylidene chloride; or maleic anhydride.
The impregnation of the cured novolak resin fibers with the polymerizable vinyl monomer is preferably performed by immersing the fibers in a solution or dispersion containing the polymerizable vinyl monomer. The monomer solution or dispersion may contain an effective amount of a polymerization catalyst such as ammonium seric nitrate or ammonium persulfate.
The amount of the polymerizable monomer incorporated into the novolak resin fibers is generally 10-250% by weight, preferably 30-150% by weight based on the novolak resin fibers.
The cured novolak resin fibers impregnated with the vinyl monomer is subjected to polymerization conditions in a manner known per se such as by exposure to heat, light (inclusive of visible and UV rays), X-ray, electron beam or radioactive ray. After the completion of the polymerization, the fibers are preferably washed with a suitable solvent to remove unreacted monomer to obtain polymer-containing fibers having a polymer content of generally 2-120% by weight, preferably 4-80% by weight based on the weight of the novolak resin fibers.
The polymer-containing fibers are then carbonized and activated in any known manner to obtain activated carbon fibers. The activation can be conducted simultaneously with or following the carbonization.
The carbonization, when conducted prior to the activation, may be performed by heating the polymer-containing novolak fibers at a temperature of 600°-2000 ° C. in the atmosphere of an inert gas such as a nitrogen gas or an argon gas. The activation may be performed by heating the carbonized fibers in the atmosphere of an oxidizing gas such as steam, carbon dioxide or air at a temperature of 600°-1300 ° C. When the carbonization and activation are to be simultaneously performed, the polymer-containing fibers are heated at 600°-2000 ° C. in the atmosphere of steam, carbon dioxide or air.
The following examples will further illustrate the present invention. In the examples, "parts" and "%" are by weight except otherwise specifically noted.
EXAMPLE 1
Cured novolak resin fibers (Kynol KF-0270M, manufactured by Gunei Kagaku Kogyo K. K.) were dried in vacuo and about 5 g of the dried fibers were immersed in a solution composed of 50 parts of methyl methacrylate and 50 parts of methanol. The fibers were taken out of the solution and softly squeezed for removal of excess solution. The weight of the fibers thus impregnated with the methacrylate solution was increased to about 12 g. The impregnated fibers were then exposed to an electron beam of 20 Mrad at 35 ° C. for 5 minutes to cause the methacrylate to polymerize. After completion of the polymerization, the fibers were extracted with acetone for 5 hours using a Soxhlet extractor for the removal of unreacted methacrylate to obtain about 7 g of polymethyl methacrylate-containing novolak resin fibers. Microscopic observation revealed that these fibers had about 1.1 times as great diameter as the non-treated fibers. The polymer-containing fibers were then carbonized and activated using a mixed gas consisting of steam and nitrogen and obtained by continuously passing a nitrogen gas through a warm water maintained at 80 ° C. Thus, the fibers were charged in a quartz tube having an inside diameter of 70 mm and the tube placed in an electric oven. The fibers were heated at a heating rate of 5 ° C. per minute. When the temperature of 300 ° C. was reached, the introduction of the mixed gas into the tube was commenced and the heating was continued at the same heating rate until a temperature of 900 ° C. was reached. The fibers were heated at that temperature for 40 minutes in the mixed gas stream. The heating was then stopped and a nitrogen gas was passed through the fibers for cooling same, thereby obtaining activated carbon fibers with a yield of 34% based on the weight of the polymer-containing fibers prior to the carbonization and activation treatment. The activated carbon fibers had a specific surface area of 2740 m 2 /g. The surface area is BET surface area measured by a nitrogen sorption method using a flow-type automatic surface area measuring device MICROMERITICS FLOWSORB 2300 TYPE II (manufactured by MICROMERITICS INC.).
EXAMPLE 2
5 Parts of methyl methacrylate, 0.2 part of ammonium seric nitrate, 0.1 part of polyoxyethylene-sorbitan monolaurate (NISSAN NONION LT-221, manufactured by Nihon Yushi K. K.) and 94.7 parts of water were mixed to obtain an emulsion. Cured novolak resin fibers (Kynol KR-0204, manufactured by Gunei Kagaku Kogyo K. K.) were immersed in the emulsion with a weight ratio of the fibers to the emulsion of 1:100 and treated therewith at 50 ° C. for 4 hours, so that the methacrylate was polymerized. After completion of the polymerization, the fibers were extracted with acetone for 15 hours using a Soxhlet extractor for the removal of unreacted methacrylate to obtain polymethyl methacrylate-containing novolak resin fibers. Microscopic observation revealed that these fibers had about 1.05 times as great diameter as the non-treated fibers. The polymer-containing fibers were then carbonized and activated in the same manner as that in Example 1 to obtain activated carbon fibers with a yield of 32% based on the weight of the polymer-containing fibers prior to the carbonization and activation treatment. The activated carbon fibers had a BET surface area of 2630 m 2 /g.
COMPARATIVE EXAMPLE 1
Cured novolak resin fibers (Kynol KF-0270M, manufactured by Gunei Kagaku Kogyo K. K.) were charged as such into a quartz tube with an inside diameter of 70 mm and carbonized and activated in the same manner as that in Example 1 except that the time period through which the fibers were maintained at 900 ° C. was increased from 40 minutes to 90 minutes. The yield of the activated carbon fibers was 9% based on the weight of the novolak fibers prior to the carbonization and activation treatment. The activated carbon fibers had a BET surface area of 2670 m 2 /g.
COMPARATIVE EXAMPLE 2
Cured novolak resin fibers (Kynol KF-0270M, manufactured by Gunei Kagaku Kogyo K. K.) were charged as such into a quartz tube with an inside diameter of 70 mm and carbonized and activated in the same manner as that in Example 1 except that the time period through which the fibers were maintained at 900 ° C. was decreased from 40 minutes to 10 minutes. The yield of the activated carbon fibers was 37% based on the weight of the novolak fibers prior to the carbonization and activation treatment. The activated carbon fibers had a BET surface area of 1080 m 2 /g.
It is evident from the above results that the process according to the present invention can produce activated carbon fibers having a large surface area with a high yield.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all the changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
Carbon fibers with a large specific surface area are obtained by a process which comprises the steps of:
(a) providing cured novolak resin fibers;
(b) impregnating the novolak resin fibers with a polymerizable vinyl monomer;
(c) polymerizing the vinyl monomer; and
(d) carbonizing the novolak resin fibers containing the polymerized vinyl monomer.
| 3
|
BACKGROUND OF THE INVENTION
In the manufacture of wet laid facial tissue, bathroom tissue, or paper towels it is necessary to crepe the dried fibrous web in order to impart to the web the desired feel characteristics, such as softness and bulk. The creping process involves adhering the web to a rotating creping cylinder, such as a Yankee dryer, and thereafter dislodging the adhered web with a doctor blade. The impact of the web against the doctor blade causes the web to buckle and ruptures some of the fiber-to-fiber bonds within the web. The severity of this creping action is dependent upon a number of factors, including the degree of adhesion between the web and the surface of the creping cylinder. Greater adhesion causes increased softness, although there generally is some loss of strength. In order to increase adhesion, a creping adhesive is generally sprayed onto the surface of the creping cylinder to augment any naturally occurring adhesion which the web may have due to its water content when applied to the creping cylinder. Water content will vary widely depending on the extent to which the web has been previously dried.
A wide variety of creping adhesives are known in the art, such as polyvinyl alcohol, ethylene/vinyl acetate copolymer, animal glue, and polyvinyl acetate, among others. However, a constant effort is being made by tissue manufacturers to fine new and better creping adhesives.
SUMMARY OF THE INVENTION
It has now been discovered that a creping adhesive comprising an aqueous admixture of polyvinyl alcohol and an water-soluble, thermosetting, cationic polyamide resin provides increased adhesion of the cellulosic web to the creping cylinder when compared to either component alone and accordingly yields a softer product. It can be used for tissue and paper towel production. The polyvinyl alcohol component can be of any water-soluble molecular weight sufficient to form an adhesive film. Generally, a weight average molecular weight of from about 90,000 to about 140,000 is preferred. Polyvinyl alcohol in solid form is commercially available under several trademarks such as GELVATOL® (Monsanto) VINOL® (Air Products) and POVAL® (KURARAY). Suitable commercially available grades have a viscosity of from about 21 to about 50 centipoise for a 4% aqueous solution at 20° C. These grades have a degree of hydrolysis of from about 80 to about 90 percent. Those skilled in the art will appreciate that lowering the degree of hydrolysis and the molecular weight will improve water solubility but will reduce adhesion. Therefore the properties of the polyvinyl alcohol will have to be optimized for the specific application.
The thermosetting cationic polyamide resin component comprises a water-soluble polymeric reaction product of an epihalohydrin, preferably epichlorohydrin, and a water-soluble polyamide having secondary amine groups derived from a polyalkylene polyamine and a saturated aliphatic dibasic carboxylic acid containing from about 3 to 10 carbon atoms. The water-soluble polyamide contains recurring groups of the formula
--NH(C.sub.n H.sub.2n HN).sub.x --CORCO--
wherein n and x are each 2 or more and R is the divalent hydrocarbon radical of the dibasic carboxylic acid. Resins of this type are commercially available under the trademarks KYMENE® (Hercules, Inc.) and CASCAMID® (Borden). An essential characteristic of these resins is that they are phase compatible with the polyvinyl alcohol, i.e., they do not phase-separate in the presence of aqueous polyvinyl alcohol.
The preparation of the cationic polyamide resin component useful for purposes of this invention is more fully described in U.S. Pat. No. 2,926,116 issued to Gerald I. Keim on Feb. 23, 1960, and U.S. Pat. No. 3,058,873 issued to Gerald I. Keim et al. on Oct. 16, 1962, both of which are herein incorporated by reference. Although both of these patents teach only the use of epichlorohydrin as the coreactant with the polyamide, any epihalohydrin is believed to be useful for purposes of this invention since all epihalohydrins should yield a cationic active form of the polyamide resin at the proper pH when reacted with the secondary amine groups of the polyamide.
Therefore, in one aspect the invention resides in an aqueous admixture, useful as a creping adhesive, comprising polyvinyl alcohol and a water-soluble, thermosetting, cationic, polyamide resin, which is the polymeric reaction product of an epihalohydrin and a water-soluble polyamide as herein above described. Preferably, the aqueous admixture contains from about 0.1 to about 4 weight percent solids, most preferably about 0.3 weight percent solids, of which about 30 to about 90 weight percent, perferably from about 70 to about 95 weight percent, and most preferably about 80 weight percent, is polyvinyl alcohol and from about 10 to about 70 weight percent, preferably from about 5 to about 30 weight percent, most preferably about 20 weight percent, is the cationic polyamide resin.
In a further aspect, the invention resides in a method for creping cellulosic webs, such as webs useful for facial tissue, bathroom tissue, or paper towels, comprising: (a) applying to the surface of a creping cylinder an aqueous admixture of polyvinyl alcohol and a water-soluble, thermosetting, cationic, polyamide resin which is the reaction product of an epihalohydrin and a water-soluble polyamide as herein above described; (b) adhering a cellulosic web to the surface of the creping cylinder covered by the abovesaid admixture; and (c) dislodging the adhered web from the creping cylinder with a doctor blade. Those skilled in the art of creping adhesives will appreciate that the reason for such a large percentage of water in the admixture is in part the need to only deposit a very thin layer of adhesive on the creping cylinder, which is most easily accomplished with a spray boom.
While not being limited by any particular theory of operation, it is believed that the use of this particular admixture as a creping adhesive is particularly effective for at least two reasons. The first reason is that polyvinyl alcohol is a rewettable adhesive, whereas the thermosetting cationic polyamide resin is substantially less rewettable. Rewettability is an important characteristic of creping adhesives since only very small amounts of adhesive are added per revolution of the creping cylinder. If any portion of the previously added layer of adhesive is permitted to irreversibly solidify during use, it would thereafter be ineffective as an adhesive. On the other hand, if the newly added adhesive wets the existing adhesive layer, all of the adhesive on the cylinder becomes available to adhere to the web. Since the cationic polyamide component is thermosetting, if used by itself it will eventually cross-link and irreversibly harden and therefore lose its effect as an adhesive. However, by diluting this component with polyvinyl alcohol, wettability is greatly improved and the effective life of the adhesive layer on the creping cylinder is extended.
The second reason believed responsible for the success of the adhesive composition of this invention is that the cationic nature of the cationic polyamide resin component makes it a very specific adhesive for cellulose fibers, whereas the polyvinyl alcohol component is not specific. Therefore combining the two components yields a creping adhesive composition which in a sense combines the attributes of both components to yield a synergistic adhesive effect, i.e. wettability and specificity for cellulose fibers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1: Adhesion Data
In order to illustrate the synergistic adhesive effect of the compositions of this invention, adhesion data for creping adhesives containing varying amounts of polyvinyl alcohol and the cationic polyamide resin is shown in TABLES I and II. The polyvinyl alcohol component was GELVATOL® 2060. The cationic polyamide component was KYMENE® 557.
The data in TABLE I was obtained using a laboratory peel strength test procedure. Test samples were prepared by applying an aqueous solution of the test mixture, at 10% solids, to a 2"×5" stainless steel panel, spreading the material with a #26 wire-wound rod, and allowing it to air dry. The panel was placed onto a laboratory hot plate and warmed to a surface temperature of 200° F. A wet cotton cloth (2"×8"), containing approximately 3 times its weight of water, was applied to the hot panel and rolled down with a 2 kilogram cylinder. The panel was left on the hot plate for 2 additional minutes while the cloth and the moistened adhesive dry. The cloth/panel laminate was transferred to an INSTRUMENTORS® Slip/Peel Tester with the heated platen set at 210° F. The cloth was peeled from the panel (180° peel, 6"/minute) and the average peel force was recorded in grams per 2 in. width.
The data in TABLE II was obtained using a more direct method in which the force necessary to continuously remove a web from the surface of a Yankee dryer was actually measured during production on a slow speed (30 ft./min.) pilot scale facility. Specifically, a 15 inch wide cellulosic tissue web having a basis weight of about 15 pounds per 2880 ft. 2 was continuously formed in a conventional manner by wet laying a slurry of papermaking fibers onto a continuously moving foraminous fabric. The web was dewatered and transferred to a Yankee dryer by pressing the web onto the surface of the Yankee with a pressure roll. Creping adhesive was continuously sprayed onto the Yankee at a point prior to the point at which the web contacts the surface of the dryer at an add-on rate of about 5 pounds of solids/ton of dry fibers. The web leaving the Yankee was removed from a point on the cylinder just prior to the position of the doctor blade so that creping was avoided. The dried web was wound onto a reel which was mounted on a freely pivotable frame such that the frame was displaced further from vertical (toward the Yankee) as greater force was required to remove the web from the Yankee. This tendency of the frame to be displaced from the vertical position toward the Yankee was counterbalanced by a variable weight and pulley arrangement whereby weights could be added until the amount of weight added equaled the force necessary to pull the web from the surface of the drying cylinder, thereby bringing the frame back to the vertical position. This weight represented the adhesion force (grams) between the web and the surface of the Yankee.
TABLE I__________________________________________________________________________(Laboratory Peel Strength Test)Adhesion (grams/2 inch) 180 670 750 970 1110 1475 1535 1200__________________________________________________________________________Polyvinyl alcohol 0 30 40 60 70 80 90 100(dry weight percent)Kymene 557 100 70 60 40 30 20 10 0(dry weight percent)__________________________________________________________________________
TABLE II______________________________________(Continuous In-Line Adhesion Measurement)Adhesion(grams/ 15 inch) 750 900 910 910 955 1045 750______________________________________Polyvinyl alcohol 0 30 50 60 70 80 100(dry weightpercent)Kymene 557 100 70 50 40 30 20 0(dry weightpercent)______________________________________
Comparison of the data from Tables I and II shows different absolute values for adhesion, but both methods yield consistent results in that in every instance the level of adhesion is higher for the combination of Kymene and polyvinyl alcohol than would be predicted based on the values of 100% Kymene and 100% polyvinyl alcohol and the percentages of each in the compositions, assuming a linear relationship. Also, both sets of data show a peak adhesion in the range of about 70 to about 95 percent polyvinyl alcohol, in which range the adhesion is greater than either of the individual components. Although graphically not shown, this synergistic effect can be more clearly illustrated by making a plot of adhesion versus composition.
EXAMPLE 2: Production of Facial Tissue
In order to further illustrate the use of the creping adhesives of this invention, facial tissue was prepared by wet-laying a web of papermaking fibers having a dry basis weight of 7.5 lbs./2880 ft. 2 . The web was dewatered and pressed onto a Yankee dryer with a pressure roll. Adhesive was sprayed onto the surface of the Yankee at the 6:00 o'clock position at an add-on rate of 5 lbs./ton of dry fiber. The composition of the creping adhesive was about 0.3 weight percent solids, excluding a small amount (about 0.03%) of a release agent (mineral oil). The solids consisted essentially of about 80 weight percent polyvinyl alcohol and 20 weight percent KYMENE® (cationic polyamide resin). The dried web was dislodged from the Yankee (creped) with a doctor blade and wound onto a reel spool for converting. The resulting web had a softness rating of 8.5 as determined by a trained sensor panel.
By comparison, a web prepared under similar conditions, but using a creping adhesive consisting essentially of solely KYMEME (without polyvinyl alcohol) and an add-on rate of 2 lbs./ton of dry fiber, had a sensory panel softness rating of 7.8. Higher add-on levels using only KYMENE were not possible without developing an unstable adhesive coating on the Yankee, which caused operational difficulties.
Therefore the use of a creping adhesive consisting essentially of polyvinyl alcohol and a cationic polyamide resin resulted in an improved product with more reliable processing. It will be appreciated that the foregoing examples, shown only for purposes of illustration, are not to be construed as limiting the scope of this invention.
|
A creping adhesive comprising an aqueous admixture of polyvinyl alcohol and a water-soluble, thermosetting, cationic polyamide resin provides increased adhesion in the manufacture of creped wadding.
| 3
|
BACKGROUND OF THE INVENTION
[0001] The invention relates to a rolled product, in particular a rolled product made of a metallic material for use as a reflector material in lighting engineering, comprising a first surface and a second surface, in which the surfaces of the two sides exhibit a dispersive reflection behaviour for light. The invention also relates to a method for producing the rolled product, a device for carrying out the production method for the rolled product and the use thereof.
[0002] Metal sheets, such as in particular rolled aluminium sheets, are used in technology for the most varied tasks. Thus, for example, rolled aluminium sheets have been used successfully for a long time as reflectors for lamp housings, in particular for lamp housings of fluorescent lamps (for example neon strip lamps with or without shielding louvres). In order to achieve an adequate gloss level for this application, it is generally still necessary to subsequently polish the rolled metal sheet, which can be achieved, for example, by a mechanical method (for example by glossing) or else by an electrolytic or chemical method (by a treatment in caustic baths), or else as a combination thereof.
[0003] The demands which are to be made of lamp housings of fluorescent lamps are in accordance with the old DIN 5035, UGR DIN 12464 or the newly revised standard DIN 5035, Part 7. These standards aim to prevent people who are in the room lit with the corresponding lamp from being dazzled. This is important, in particular for monitor workstations. In the standard, for example, a light radiation behaviour, which is directed as far as possible downward, is required with different luminances being permissible as a function of the angle of the reflected beam. The standard is currently being revised. According to the old DIN 5035 standard, a luminance of a maximum of 200 cd/m 2 is permissible, for example, at a 50° angle (starting from the vertical). According to the new DIN 5035, Part 7, this value will probably be raised to 1,000 cd/m 2 if the monitors used meet certain minimum requirements.
[0004] The production of the above-described reflector plates—in particular aluminium sheets—by means of a plurality of graduated rolling processes, is known per se.
[0005] In the previously conventional metal sheets, the production of the metal sheet always took place under the premise that only one of the two sides of the metal sheet has to have a defined reflection behaviour for incident light.
[0006] The rolled crude metal sheets, due to manufacturing, have different surface qualities on their upper and lower side. In order to be able to use the crude metal sheets as a reflector plate, polishing methods are required. These polishing methods have only been used on one of the two surfaces of the rolled product up to now. This was based on the assumption that good reflection behaviour on only one surface of the metal sheet is completely sufficient for its use as a reflector plate and therefore costs can be saved.
[0007] However, it has been proven that it is advantageous for many reflector arrangements if the two surfaces of the reflector plate have substantially the same light dispersion behaviour. For certain reflector arrangements, the arrangement can be produced substantially more simply with a metal sheet of this type, as in a number of manufacturing steps, a separation process that would otherwise be necessary and a subsequent connecting process can be replaced by simple punching and bending of the proposed metal sheet. This corresponds to so-called follow-on composite manufacturing. A different reflection behaviour of the front and rear side of the aluminium sheet is also undesirable from the point of view of lighting engineering for use as glare protection plates, as this either spoils the appearance or the glare protection plate has to be implemented in two layers, for example as a V-plate.
[0008] A further problem in known aluminium sheets consists in that the surface of the rolled metal sheet provided for the reflection also generally has an anisotropic light dispersion behaviour. In other words, a light beam shining on the metal sheet surface is conically expanded in the reflection, with, however, the cone in cross-section not having a circle as the base, but a form which differs therefrom, such as generally an ellipse as the base. This reflection behaviour leads to largely random illumination conditions and is therefore undesired.
[0009] Highly diffuse light dispersal is also undesired, as, in this case, a too small directing effect and therefore too little influencing of the illumination conditions results and also the recommendations of DIN 5035, Part 7, would not be met. In particular, regulated light dispersion behaviour can then generally not be achieved. A highly glossy surface is indeed optimally suited per se to achieve the lighting engineering specifications, but the illumination behaviour thus occurring is felt to be unaesthetic by many people and is therefore undesired.
[0010] The object of the invention is therefore to propose a rolled product which is suitable in respect of its properties to a special degree for use as a reflector material in lighting engineering, as well as a production method which is particularly suitable for the production of a rolled product of this type. Moreover, a suitable device is to be provided for carrying out the production method as well as an advantageous use of the proposed rolled product.
SUMMARY OF THE INVENTION
[0011] In the scope of the invention, a rolled product with a first surface and a second surface, in which the surfaces of the two sides exhibit a dispersive reflection behaviour for light, is proposed, in which the reflection behaviour of the two surfaces is substantially the same. Differing from the previously prevailing paradigms, that, to avoid unnecessary costs, only one surface is processed in such a way that it receives the required reflection behaviour, it is therefore proposed, that the two surfaces of the metal sheet exhibit the desired reflection behaviour, and this should preferably be a regulated light-dispersive behaviour. Although this can lead to an increase in costs in the production process for the rolled product and therefore for the rolled product itself, these disadvantages can be balanced for a large number of applications by improved reflection behaviour and a simpler construction of the lamps, mirror optics and other light-directing components produced therefrom, such as louvered light fittings.
[0012] Thus, for example, glare protection plates of louvered lamps with the proposed rolled product could simply consist of one piece of the proposed metal sheet, without the optics of the lamps or the light emitted thereby exhibiting undesired inhomogeneities. The rolled product can also be advantageously used for certain reflector arrangements, as in the case of a fissure line of the reflector, separation of the metal sheet, a rotation by 180° and a subsequent connection of the two parts is no longer necessary. Instead, substantially the same result can be achieved when using the proposed metal sheet, by means of composite manufacturing by simple punching and bending. In this follow-up composite manufacturing, the mirror optics are produced by punching and bending a single piece of, for example, aluminium sheet, so expensive joining of a plurality of parts, in which, moreover, care always has to be taken that the surfaces do not become scratched during the assembly processes, becomes unnecessary. The previously necessary marking of the preferred direction in the case of direction-dependent surfaces can also be dispensed with.
[0013] It is advantageous if the surfaces exhibit an at least partially diffusely dispersive reflection behaviour. Owing to the diffuse light dispersion, relatively uniform illumination behaviour can be improved in different directions. The surfaces preferably exhibit a diffusely dispersive reflection behaviour which is as regulated as possible. Wishes with respect to an aesthetic appearance of the mirror optics can therefore be fulfilled.
[0014] It is advantageous when the surfaces exhibit substantially isotropic reflection behaviour. A uniform illumination and improved glare protection can also be promoted thereby. It is called isotropic reflection behaviour when the light beam emitted from the reflector surface is rotationally symmetrical to the main beam direction (in other words to the angle of incidence). In a reflection with a certain diffuse beam expansion a light cone with a circle as a base would thus be produced, for example, from an incident laser beam, with a plurality of concentric circular lines in each case standing for lines of the same luminous intensity.
[0015] It has been shown to be adequate if the gloss levels of the surfaces measured in different directions differ by less than 15%, preferably by less than 12%, particularly preferably by less than 9%, preferably by less than 6%. On the one hand, a substantially optimum radiation can be achieved thereby, on the other hand, the production costs are kept within limits, so the cost of producing the rolled product is not excessively increased. Values are to be regarded as gloss levels here, which can be measured, for example, with a reflectometer according to Dr. Lange, to DIN 67530 with a measuring angle of 60°. The measuring apparatus was calibrated with a metal mirror and set at 91%.
[0016] It is also proven to be favourable if the gloss levels of the surfaces are higher than 45%, preferably higher than 50%, particularly preferably higher than 60%, preferably higher than 70%.
[0017] It is also advantageous if the gloss levels of the first and second surface of the rolled product differ by less than 15%, preferably by less than 12%, particularly preferably by less than 9%, preferably by less than 6%.
[0018] It is also to be preferred if the total reflection is greater than 80%, preferably greater than 84%, particularly preferably greater than 86%. This is the total reflection to DIN 5036, Part 3 for visible light. In the case of visible light this may be the standard light type A (artificial light) or the standard light type D65 (daylight).
[0019] The values can be produced particularly advantageously if the surfaces have a polished surface layer, an anodised surface layer or a combination of these.
[0020] To protect the surfaces, at least one transparent scratch protection layer, at least one transparent corrosion protection layer or a combination of layers of this type can be arranged on the surfaces.
[0021] Obviously, a combination of said surface layers with one another is also possible.
[0022] It has also proven to be particularly advantageous if the rolled product consists of aluminium or alloys thereof or contains aluminium and alloys thereof, wherein the aluminium base metal contains a purity of at least 99% by weight, in particular at least 99.5% by weight, preferably at least 99.8% by weight, particularly preferably at least 99.85% by weight, preferably at least 99.9% by weight, particularly preferably at least 99.95% by weight.
[0023] Reference is also made to the fact that in all the intervals mentioned above, all the intermediate values are to be regarded as also disclosed.
[0024] It is advantageous when the rolled product is initially rolled and then polished, in such a way that the desired reflection behaviour results. In this case, the crude product produced by rolling can be processed therefrom by means of any gloss methods known per se, such as mechanical polishing methods, electrolytic or chemical polishing methods etc. or by a combination thereof.
[0025] However, it is possible, for the surfaces to be formed initially with different reflection behaviours, and then for at least one surface to be polished in such a way that the surfaces receive substantially the same reflection behaviour. In this method, already available manufacturing routes can be used, in particular. The different surface composition is then compensated by a polishing process of the rougher or matter surface, so the two surfaces as a result have substantially the same reflection behaviour. Obviously, it is also possible for the two surfaces to be polished, one surface then having to be polished more highly, of course, the other surface less highly.
[0026] It is advantageous when the rolling process has a plurality of rolling steps, such as preferably at least one cleaning step for cleaning surfaces. When the rolling process takes place in a plurality of steps, the respective deformation of the rolled product is less, so the surface faults are also reduced. One or more cleaning steps for cleaning the surfaces can be provided for the individual rolling steps, intermediately, or else finally.
[0027] A highly alkaline bath is preferably used for cleaning the surfaces. A bath of this type has already proven advantageous in the treatment of conventional metal sheets.
[0028] In the case of a device that is particularly suitable for carrying out the described production method, rollers are provided, the rollers processing the rolled product having blasted surfaces, in particular surfaces blasted with round or angular grit. Corundums or carbides have proven successful as grit of this type. The blasting should take place in such a way that a homogeneous and isotropic rolling surface is produced.
[0029] A further surface finishing may consist in the rollers processing the rolled product having surfaces which have been prepared by so-called “laser beam finishing”, “electron beam finishing” or “electron discharge texturing”. A combination of these methods, also with the above-described blasting of the surfaces, is obviously possible.
[0030] It is also sensible for at least one speed synchronisation device to be provided which brings about a substantially similar speed of roller surfaces and the surfaces of the rolled product to be processed. There are thus substantially no relative movements between the roller surfaces and the surfaces of the rolled product to be processed. In particular, longitudinal grooves can thus be avoided which could be problematical with respect to an isotropic reflection behaviour of the corresponding surfaces.
[0031] It is advantageous if the described rolled product is used for the reflector of a lamp, for the glare protection of a lamp, or for both. This is particularly advantageous, in particular for lamps for fluorescent tubes, such as, for example, in the case of so-called neon strip lamps or louvered lamps. Obviously, a use for so-called plug louvres, push-through louvres, projection reflector plates and for other reflectors, in which the active side is used on either side in terms of light engineering, is also conceivable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Further advantages, features and details of the invention emerge from the following description of a preferred embodiment and with the aid of the drawings, in which:
[0033] FIG. 1 shows the schematic structure of the measuring process;
[0034] FIG. 2 shows projection images of various surfaces;
[0035] FIG. 3 shows lines of the same brightness for the projection images shown in FIG. 2 .
DETAILED DESCRIPTION
[0036] The rolling method for producing the metal sheets from a blank takes place in a manner which is known per se. For example, a blank of a given thickness is rolled in one or more passages or passes between a pair of rollers or a plurality of pairs of rollers to the desired thickness. The material web can then be moved back and forth in the process between two-rollers, or be moved on in a continuous direction and rolled by a plurality of pairs of rollers. A combination of the two possibilities is also conceivable.
[0037] In the following example, a texturing of the surface of the rolled product then takes place by means of a correspondingly formed pair of rollers. A corresponding texturing on the two surfaces of the material web can then be achieved by a texturing of the pair of rollers, in order to achieve predetermined optical properties of the surfaces.
[0038] Following the rolling process, a further surface finishing can be carried out. In this case, surface processing methods, material deposition methods or material application methods that are known per se, can be used.
[0039] For example, polishing may be carried out by electrolytic or chemical polishing. Moreover, an electrolytic or chemical treatment may not only take place for finishing the surface of the rolled product. A chemical surface treatment, for example, by means of a highly alkaline bath is also conceivable in the course of the production method, in order to clean the surfaces prior to the next rolling step.
[0040] A surface treatment by anodising is also conceivable. This may take place, for example, by means of acid electrolytes from the range of sulphuric acid, phosphoric acid, citric acid, tartaric acid, or chromic acid electrolytes, as well as a combination of these. This may take place both by means of direct current methods or by means of alternating current methods.
[0041] Surface removal by means of vapour or gas deposition from a vacuum is also possible. In the process one or more layers of metals, metalloids or their oxides, nitrides or fluorides or mixtures thereof may be provided.
[0042] Thermal evaporation, electron beam evaporation, sputtering, (in particular magnetron sputtering) with and without ion support may be provided as evaporation methods, in particular. Apart from these or other physical vapour deposition methods (physical vapour deposition, PVD), chemical gas phase depositions (chemical vapour deposition, CVD) can obviously be used with and without ion support.
[0043] A transparent scratch protection layer or corrosion protection layer may also be provided. A layer of this type may also be provided, in particular, on a surface which has already been provided with a metal layer by vapour deposition.
[0044] The surface finishing steps described are carried out in such a way here that substantially similar surfaces of the rolled product subsequently result. If the surfaces of the crude metal sheet thus have an initially different surface quality, different surface finishing steps are accordingly applied to the two surfaces, or the finishing steps used are carried out with a different intensity.
[0045] FIG. 2 shows projection images 29 of different surfaces. FIG. 2 c shows a particularly suitable surface, the two surface sides of the rolled product substantially exhibiting the same reflection behaviour in the present case.
[0046] FIG. 1 schematically shows the measuring arrangement for producing the projection images 29 shown in FIG. 2 . A laser beam 22 generated by a laser 21 falls on a first side 15 of the material web 14 . Only one section of the material web 14 is shown in the present case for reasons of clarity.
[0047] The incident laser beam 22 is partially diffusely dispersed from the first side 15 of the material web 14 . An expanded reflection beam 24 forms around a preferred direction 25 (this is determined according to the conventional reflection law). This generates a projection image 29 in a measuring region 27 of the monitor 26 . The projection image 29 is recorded by a camera 31 , the angle distortion in the present embodiment, which occurred owing to the recording of the projection image 29 at an angle, was corrected by an electronic computer (not shown here).
[0048] In a partial reflection, the projection image has a bright central point 33 , the position of which coincides with the impact point of the preferred direction 25 of the reflection beam 24 on the monitor 26 . Around this central point 33 , the luminous intensity decreases radially outwardly.
[0049] FIG. 2 shows projection images 29 of different surfaces. In this case, the surface shown in FIG. 2 c corresponds very substantially to the ideal of an isotropic expansion in a limited angle space of, for example, 2°. The luminous intensity has dropped to a relatively large degree after the first circle of the graticule and has substantially dropped completely after the second circle of the graticule. A circle of the graticule corresponds to an angle range of 20 . It can also clearly be seen in FIG. 2 c that the light dispersion is substantially isotropic, and consequently the projection image 29 is radially symmetrical to the centre of the central point 33 .
[0050] The surface in FIG. 2 b is too glossy in comparison. In other words, the beam expansion of the reflection beam 24 is too small. The luminous intensity has already dropped substantially completely after an angle range of about 0.50. Moreover, the light distribution is too anisotropic, i.e. the light drop in the x- and y-direction of the coordinate system takes place at different rates.
[0051] In FIG. 2 e and 2 d , the light expansion is relatively marked in each case; moreover, these surfaces have an isotropy. This reflection behaviour lies within a still just usable limit range.
[0052] FIG. 2 e finally shows a very diffusely dispersive surface which moreover exhibits too high an isotropy. The associated surface, similarly to the surface associated with FIG. 2 b , can no longer be used for the provided purpose.
[0053] FIG. 3 finally shows a further manner of application for the projection diagrams of FIG. 2 . The drawn-in lines are lines with the same brightness. The respective numbering below corresponds to that of FIG. 2 . A surface is therefore desirable which exhibits the diagram of FIG. 3 c in the case of a measurement, so the lines with the same brightness lie substantially in a circular manner around the central point 33 and lie at a defined spacing from one another—the spacing of the lines being a measure for the angle expansion of the reflection beam 24 .
[0054] The surfaces should preferably be the same on the two sides of the rolled product and, in the ideal case, have the reflection behaviour according to FIG. 2 c or 3 c.
[0055] Slight deviations between the two sides are tolerable, however. Thus, for example, a rolled product with a first side which has a dispersion behaviour according to FIG. 2 c or FIG. 3 c and the second side of which has a dispersion behaviour according to FIG. 2 b or 2 d or FIG. 3 b or 3 d can still be used advantageously to form a lamp reflector.
[0056] The rolled products preferably consist of a metal, such as, in particular, aluminium. In the use of aluminium, the mass fraction of the aluminium in base metal should fulfil certain minimum requirements, such as for example have a weight fraction of more than 99% by weight, 99.5% by weight, 99.8% by weight, 99.85% by weight, 99.9% by weight or 99.95% by weight.
|
A rolled product, especially a rolled product consisting of a metallic material, such as an aluminium sheet, for using in lighting engineering as a reflector surface, the surfaces on both sides of the rolled product displaying essentially the same reflective properties. One such rolled product is especially suitable as a material for constructing a reflector or for the anti-glare shade of a louvered light fitting. The rolled product is produced by first rolling the product and then providing the two optionally differently reflecting surfaces with similar reflective properties by a polishing process following the rolling.
| 2
|
FIELD OF THE INVENTION
This invention relates to processes for preparing crystalline moricizine in ethanol hydrochloride from moricizine using hydrochloric acid, wherein the crystalline moricizine hydrochloride so obtained is substantially free of occluded water.
BACKGROUND OF THE INVENTION
Pharmaceutical compositions comprising moricizine hydrochloride (10-(3-morpholinopropionyl)-phenothiazine-2-carbamic acid ethyl ester hydrochloride; Formula I) as an active ingredient are known to possess utility in the treatment of heart arrhythmia. For example, U.S. Pat. Nos. 3,740,395 and 3,864,487, in the names of Gritsenko, et al., indicate that moricizine hydrochloride is superior to other antiarrhythmic drugs such as quinidine and novocainamide in that it exhibits a broader spectrum of therapeutic action and is devoid of toxic side effects.
Ethmozine® brand of moricizine hydrochloride is marketed by The Dupont Merck Pharmaceutical Company, Wilmington, DE for the treatment of heart arrhythmia.
The structure of moricizine hydrochloride is shown below: ##STR1##
Typically, moricizine hydrochloride has been synthesized by processes in which moricizine free base (10-(3-morpholinopropionyl)-phenothiazine-2-carbamic acid ethyl ester) is contacted with hydrogen chloride gas in anhydrous organic solvents such as toluene or diethyl ether. Such processes, however, are inherently hazardous due to their employment of gaseous hydrogen chloride and, further, are difficult to control.
Accordingly, there exists a need in the art for synthetic routes to moricizine hydrochloride that do not employ gaseous hydrogen chloride.
SUMMARY OF THE INVENTION
The present invention provides synthetic processes wherein hydrochloric acid, that is , an aqueous solution of hydrogen chloride, is used instead of gaseous hydrogen chloride to convert moricizine free base to moricizine hydrochloride under carefully controlled reaction conditions. Moricizine free base is referred to herein as moricizine. The processes of the present invention comprise contacting a first solution of moricizine and a water-miscible organic solvent with hydrochloric acid to produce a second solution comprising moricizine hydrochloride, and then isolating the moricizine hydrochloride from the second solution. It has been discovered in accordance with the invention that substantially non-hydrated moricizine hydrochloride, substantially free of occluded water, can be isolated from the second solution by optimizing at least one of four identified reaction conditions: (1) the mole ratio of solvent to moricizine used; (2) the mole ratio of acid to moricizine used; (3) the amount of water introduced by the acid; or (4) the rate at which the moricizine hydrochloride is allowed to crystallize from the second solution. In preferred embodiments, all four reaction conditions are optimized as follows: the first solution comprises at least about 30 equivalents ethanol per equivalent moricizine; the hydrochloric acid comprises about 36.5 weight percent hydrogen chloride and at least about 1 equivalent hydrogen chloride per equivalent moricizine; and the isolating step comprises crystallizing moricizine hydrochloride from the second solution at a relatively slow rate to produce crystalline moricizine hydrochloride which is substantially non-hydrated, that is, substantially free of occluded water.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered in accordance with the present invention that the reaction of moricizine and hydrochloric acid produces, depending on the reaction conditions, substantially non-hydrated crystalline moricizine hydrochloride and/or hydrated forms of crystalline moricizine hydrochloride. These hydrated forms of crystalline moricizine hydrochloride, containing occluded water within the crystalline lattice structure, are referred to as moricizine hydrochloride hemi-hydrate. While moricizine hydrochloride hemi-hydrate is believed to possess the same utility as non-hydrated moricizine hydrochloride, the hemi-hydrate requires additional processing steps to remove the occluded water impurity. Non-hydrated crystalline moricizine hydrochloride is substantially free of occluded water. The present invention provides reaction conditions for the preparation of moricizine hydrochloride which minimize or eliminate the formation of the undesired moricizine hydrochloride hemi-hydrate.
The moricizine used in the methods of the present invention can be prepared by any of the many procedures known in the art. A representative synthetic procedure is provided by Makharadze et al. (1988) Khim. Farm. Zh.22: 732. It is preferred, though not necessary, that the moricizine employed be substantially pure.
The moricizine is dissolved in water-miscible organic solvent. Water-miscible solvents according to the present invention are those which exhibit at least partial solubility in water. Representative water-miscible solvents include but are not limited to methanol, ethanol, and n-propanol; absolute ethanol is preferred. The amount of water-miscible solvent employed should be effective to fully dissolve the moricizine in solution at temperatures between from about 20-50° C. In preferred embodiments, moricizine is dissolved in greater than 30 equivalents, and more preferably, greater than 35 equivalents, of absolute ethanol. It may be necessary to use stirring and/or heat to fully dissolve the moricizine.
The solution of moricizine in water-miscible solvent is then contacted with greater than about 1.0 equivalents of hydrogen chloride in the form of hydrochloric acid. In preferred embodiments, about 1.1-1.5 equivalents of hydrogen chloride are added to the moricizine solution, more preferably about 1.2 equivalents. During the addition, the reaction mixture should be maintained at a temperature from about 20° C. to about 50° C. The aqueous acid preferably comprises from about 35 to about 40 weight percent hydrogen chloride, more preferably 36.5 weight percent. In general, the reaction mixture should have a pH of about 1.35-3.0, preferably 1.5-3.0.
After the addition of aqueous acid is complete, the reaction mixture is allowed to cool, typically with stirring. The reaction mixture is then visually monitored for the precipitation of crystalline moricizine hydrochloride. The reaction mixture should be allowed to cool as slowly as possible to effect a correspondingly slow crystallization of moricizine hydrochloride from solution. Preferably, the reaction mixture is allowed to cool under ambient conditions (i.e., about 25° C.) from the temperature maintained during acid addition . The reaction mixture should not be contacted with ice water baths or any other media having a temperature less than about room temperature (i.e., about 25° C.) until crystalline precipitate is observed.
If crystallization is not observed after the reaction mixture has reached room temperature, seeding can be performed by any of the methods known in the art. Preferably, the reaction mixture is seeded with crystalline moricizine hydrochloride.
The amount of water-miscible solvent earlier used to dissolve the moricizine should be selected such that the moricizine hydrochloride can be precipitated from the reaction mixture in the temperature range from slightly greater than room temperature down to about 0° C.
After a precipitate has been observed, the reaction mixture is refrigerated by, for example, immersion in an ice bath to increase the rate of subsequent precipitation. Once precipitation ceases, the resulting crystalline moricizine hydrochloride is separated from its mother liquor and dried by any of the techniques known in the art. To enhance the overall yield of moricizine hydrochloride, the mother liquor can be concentrated and further portions of moricizine hydrochloride recovered therefrom by slowly cooling the concentrate.
Additional objects, advantages, and novel features of this invention will become apparent to those skilled in the art upon examination of the following examples thereof, which are not intended to be limiting.
EXAMPLE 1
To a 250 mL flask equipped with thermometer, condenser, and nitrogen inlet were added 25 grams (0.0585 moles) moricizine and 120 mL (2.048 moles, 35 equivalents) absolute ethanol. The mixture was stirred and heated at 65-80° C. for about 15 minutes, after which time the moricizine was fully dissolved. The heat was turned off and the mixture was allowed to cool with stirring under ambient conditions. When the temperature reached about 35° C., 7.0 grams hydrochloric acid (36.5% HCl, 0.07 moles HCl, 1.2 equivalents HCl) were added. After a precipitate became visible, the mixture was cooled with an ice water bath to about 0° C, maintained at that temperature for about one hour, and then filtered. The solids were dried in a vacuum oven overnight at 50-55° C. to provide 21.98 grams (81% yield) of substantially non-hydrated moricizine hydrochloride. Substantially non-hydrated moricizine hydrochloride was obtained as a white powder having a melt range of 214-217° C., and one strong, sharp peak at about 215° C. on differential scanning calorimetry.
EXAMPLE 2
The procedure of Example 1 was repeated, except that 22 equivalents absolute ethanol were used. The resulting moricizine hydrochloride, containing hydrated moricizine hydrochloride, was a white powder having a melt range of 206-208° C. Differential scanning calorimetry revealed one strong, sharp peak at about 210° C.
EXAMPLE 3
The procedure of Example 1 was repeated, except that the reaction mixture was not allowed to cool at ambient temperature while stirring but was immersed in an ice water bath. The resulting moricizine hydrochloride, containing hydrated moricizine hydrochloride, was a white powder. Differential scanning calorimetry revealed two small, broad peaks at about 88° C. and 210° C.
EXAMPLE 4
The procedure of Example 1 was repeated, except that 0.8 equivalents hydrogen chloride were used. The resulting moricizine hydrochloride, containing hydrated moricizine hydrochloride, was a white powder having a melt range of 200-215° C. Differential scanning calorimetry revealed a medium peak at about 200° C. having a small shoulder at about 217° C.
EXAMPLE 5
The procedure of Example 1 was repeated, except that 26% hydrochloric acid was used. The resulting moricizine hydrochloride, containing hydrated moricizine hydrochloride, was a white powder having a melt range of 200-204° C. Differential scanning calorimetry revealed a medium, broad peak at about 200° C.
Those skilled in the art will appreciate that numerous changes and modifications can be made to the preferred embodiments of the invention and that such changes and modifications can be made without departing from the spirit of the invention. It is therefore intended that the appended claims cover all such equivalent variations as fall within the true spirit and scope of the invention.
|
Processes are provided for preparing crystalline moricizine hydrochloride from moricizine using hydrochloric acid, wherein the crystalline moricizine hydrochloride so obtained is substantially free of occluded water.
| 2
|
This invention relates to the field of plumbing accessories and is particularly concerned with a drain flushing device for allowing a user to unclog a drain in either of two modes. The user is given the option to either use the device as a liquid column guide or as a pump.
BACKGROUND OF THE INVENTION
Water drains are usually clogged by a blockage of foreign matter in the trap area of the drain system. If this blockage is broken up into smaller pieces or forced through the trap, the system will again function properly. Various methods can be used to break up the blockage into smaller particles or to force it through the trap. Examples of such methods include chemical reactions with the foreign matter and force exerted on the foreign matter. One of the methods of applying force to the foreign matter is the usage of water that is usually contained in the drainage system above the clogged area. Since the water is incompressible, any pressure applied above its surface will be directly transmitted to the foreign matter. A conventional method of applying pressure to the surface of the water is the use of a force cup plunger. The force cup plunger has a resilient plunger ring fixed to a substantially elongated handle. In operation, the plunger is positioned on the opening of the clogged drain. The user then pushes down and pulls up the plunger thereby alternatively exerting a downward pressure and a siphon on the water inside the clogged drain. Water being incompressible, the pressure and siphoning effect are transmitted to the clogging matter inside the drain, thus forcing the clogging matter inside the drain and releasing the latter. Because of the relatively small size of conventional plunger rings, the force cup plunger only displaces a small volume of water, thus exerting a limited pressure on the clogging matter. Another type of device conventionally used is the so-called piston-type pump. Piston-type pumps have been inherently complex and require complex piston seals. In operation, the piston-type pump is positioned on the opening of the clogged drain. The pump either uses water that is usually contained in the drainage system above the clogged area or, through an adapter, is hydraulically linked to a source of water under pressure, such as the conventional household water line. The piston inside the pump is reciprocated up and down along the cylindrical body, exerting a pressure and a siphoning effect on water present in the pump, thus releasing the clogging matter inside the clogged drain.
A search amongst prior art has revealed a number of patents disclosing devices either of the piston-type pump or of a type using an adapter for hydraulically linking a source of water under pressure, such as the conventional household water line, to an outlet nozzle which is positioned inside the drain to be unclogged. Examples of such patents are Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger, U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi, U.S. Pat. No. 4,096,597 granted on Jun. 27, 1978 to Duse and U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo.
Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger discloses a pump for unclogging pipes. The pump comprises a cylinder, a plunger rod with an integral handle at one end and the other end threaded to receive nuts retaining a set of leather disc forming a piston for reciprocating within the cylinder. The bottom end of the cylinder is adapted to receive a flexible pipe such as a hose hydraulically linked to a domestic water line. The use of a water supply such as the domestic water line is essential to the operation of the pump, the water being the main source of pressure on the clogging matter. The handle linked to the piston is then reciprocated up and down in order to increase the pressure exerted on the clogging matter. This invention is adapted to function with running water and does not suitably function in the absence of an independent source of water.
U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi is concerned with a drain-flushing device comprising a cylinder closed at its upper end with a piston shaft support, a piston shaft passing there through with its top end connected to a handle and the bottom end connected to a piston. In operation, the user siphons up water which is inside the clogged drain by pulling up the handle and then applies a downward push on the handle, exerting a pressure on the water inside the cylinder and on the clogging matter. In the absence or insufficiency of water into the drain, the invention will not function properly.
U.S. Pat. No. 4,096,597 granted on Jun. 27, 1978 to Duse provides a drain opening device comprising telescoping cylinders sealed by a flexible plastic membrane. The bottom end of the bottom cylinder is covered with a pressure activated valve. The telescoped cylinders can be filled with water through the pressure activated valve. To unclog a drain, the top cylinder is pushed downwardly, thereby telescopingly overriding the bottom cylinder. The water inside the cylinder is thus forced through the pressure activated valve in the form of a high speed water jet. The invention has to be inverted and filled with water, which can prove unergonomical. Furthermore, the device is limited to a predetermined volume of liquid which can prove to be insufficient if the clogging matter is located at a distance from the device.
U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo provides a sanitary pump comprising a cylinder, an elastic disc attached to the bottom of the cylinder, a piston, a piston rod, a cap covering the top of the cylinder and a handle connected to the upper end of the piston rod. In operation, the invention is placed and held on the opening of the clogged drain, the handle is pulled up and pushed down several times, thereby siphoning up and pushing down drain water thus exerting pressure on the clogging matter. Situations sometimes occur when not enough water is present in the clogged drain, or is present but not accessible, to fill the cylinder of this invention. The operation of the latter is thus complicated.
The present invention proposes a device adapted to circumvent the above-mentioned disadvantages.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved drain flushing device.
Accordingly, the present invention allows the user to unclog a drain using a minimum amount of manipulations and relatively problem-free. Contrary to Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger, the present invention necessitates no running water, thus it is not exposed to the problem caused by the absence of the latter. Contrary to U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi and to U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo, the proper operation of the present invention does not depend upon the presence of accessible water inside the clogged drain. The presence of apertures on the top of the cylinder eliminates the problem of possible insufficiency or absence of water inside the clogged drain, and the problem of unavailability of running water. Water can be poured inside a cylinder, part of the invention, through a set of apertures situated adjacent the top end of the cylinder. Contrary to U.S. Pat. No. 4,096,597 granted on Jun. 27, 1978 to Duse, it is not necessary to invert the invention and to use unergonomical manipulations in order to fill it with water. Furthermore, the presence of apertures at the top of the cylinder eliminates the necessity to handle the bottom part of the cylinder, which is often soiled because of its contact with the clogged and often dirty drain.
The present invention operates in either of two ways, as a water column exerting pressure on the clogging matter inside the clogged drain, or as pump.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further understood from the following description with reference to the drawings in which:
FIG. 1, in a perspective view, illustrates a drain flushing device in accordance with a first embodiment of the present invention positioned inside a sink about to be unclogged;
FIG. 2, in a longitudinal cross-sectional view taken along arrows 2--2 of FIG. 1, illustrates the internal mechanism of a drain flushing device in accordance with a first embodiment of the present invention;
FIG. 3, in a longitudinal cross-sectional view, illustrates a drain flushing device in accordance with a first embodiment of the present invention in which water is being poured in order to form a water column; and
FIG. 4, in a longitudinal cross-sectional view, illustrates a drain flushing device in accordance with a first embodiment of the present invention with its piston being pushed in a downward motion.
FIG. 5, in a longitudinal cross-sectional view, illustrates a drain flushing device in accordance with an embodiment of the present invention with its piston being pulled upwardly.
DETAILED DESCRIPTION
Referring to FIG. 1, there is illustrated in a perspective view, a drain flushing device 10 in accordance with a first embodiment of the present invention. The drain flushing device 10 has a substantially cylindrical body 12 and a piston element 14 adapted to reciprocate inside the cylinder 12. The cylinder 12 has a lower discharge aperture 16 and an upper aperture 18 with an upper peripheral rim 24. A substantially funnel-shaped liquid guide 20 extends integrally from the cylindrical body 12 adjacent its upper aperture 18. The funnel shaped liquid guide 20 has a peripheral wall 22 which merges into the cylindrical body 12 at a peripheral junction position indicated by the reference letter P located underneath the upper peripheral rim 24 of the aperture 18. The guide 20 and the upper portion of the cylinder 12 thus define a substantially annular cavity 26 positioned peripherally around the upper portion of the cylinder 12 into which a liquid can be poured. The cylindrical body 12 is provided with a set of peripheral apertures 28 extending there through. The apertures 28 are located intermediate the upper rim 24 and the peripheral junction position P and are thus adapted to allow the liquid poured into the annular cavity 26 to flow into the cylinder 12.
The piston element 14 comprises a piston disk 30 having integrally and downwardly extending peripheral sealing flanges 32 adapted to slidably abut against the inner wall of the cylinder 12. The disk 30 is fixed to an elongated piston rod 34 by a bolt 35 extending through the disk 30 and threadaly inserted into a corresponding longitudinal threaded recess 36 provided in the lower end of the piston rod 34. A rigid spacing disk 38 is provided between the bolt 35 and the disk 30. A cover cap 40 is fittingly positioned on top of the cylinder 12. The cap 40 has a central aperture 42 extending there through. The piston rod 34 is adapted to slidably extend through the aperture 42 of the cap 40. A handle 44 is rigidly fixed to the top end of the piston rod 34 for allowing manual operation of the piston element 14.
Cushioning disks 46 and 48 made of relatively resilient material, are respectively positioned on the rod 34 adjacent the disk 30 and the handle 44 for limiting the course of the piston element 14 and preventing the disk 30 and the handle 44 from knocking on the cap 40. The disks 46 and 48 thus absorb the impact created by the reciprocation of the piston rod 34. A ring adapter 50 fittingly positioned on the lower end 16 of the cylinder 12 is provided with a recess 52. The recess 52 is adapted to slidably receive and fittingly lock a set of angled elbows configured to various sizes, shapes and configurations allowing insertion in correspondingly shaped drain apertures.
In use, the drain flushing device 10 is adapted to be used in two modes. According to one mode, as shown in FIG. 3, the user pulls up the handle 44 until the piston element 14 is positioned above the set of apertures 28, then positions the lower open end 16 of the cylinder 12 on the opening of a clogged drain 54. The user then pours water from a container, such as container 56, into the substantially funnel-shaped liquid guide 20. The water then freely flows through the set of apertures 28 substantially filling the cylinder 12 thus forming a column of water that exerts pressure on a clogging matter 58 in the drain 54, for releasing the clogging matter 58 in the drain 54. A column is thus formed using gravity, contrary to Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger, U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi, and U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo wherein the forming of a column of water needs the use of pressure.
According to an alternative mode, as illustrated in FIG. 4, once the water has been poured into the substantially funnel-shaped liquid guide 20 and substantially fills the cylinder 12, the user holds the cylinder 12 with one hand and pushes down and pulls up the handle 44 with the other hand, thus reciprocating the piston element 14 inside the cylinder 12 and thereby alternately siphoning and exerting a downward pressure on the clogging matter 58 inside the drain 54 until the clogging matter 58 is released. With the present invention, it is also possible to siphon water that is inside the clogged drain 54, if readily accessible, instead of pouring water inside the substantially funnel-shaped liquid guide 20.
|
A drain flushing device for allowing a user to unclog a drain in either of two modes. The user is given the option to either use the device as a liquid column guide or as a pump.
| 4
|
BACKGROUND OF THE INVENTION
The present invention pertains to slat-type conveyors for movement of a load More particularly, the present invention pertains to a liquid-tight reciprocating floor construction for load movement.
Conveyors having interleaved slats in general are disclosed in U.S. Pat. Nos. 3,534,875; 4,143,760; and 4,856,645 all issued to Hallstrom; and U.S. Pat. No. 4,611,708 issued to Foster. U.S. Pat. Nos. 3,534,875 discloses a slat conveyor having three groups of slats, two of which move simultaneously in a load-conveying direction, while at the same time, the third group moves in the opposite direction. In U.S. Pat. Nos. 4,143,760 and 4,611,708, three groups of slats all move simultaneously in a first load conveying direction and then each individual group moves sequentially in the opposite direction. U.S. Pat. No. 4,856,645 teaches a slat conveyor having a group of non-moving "dead" slats spaced between two groups of slats that move simultaneously in a load conveying first direction and sequentially in an opposite direction. All of the above slat conveyors suffer from leakage of liquid containing loads through the spacings between the individual slats and through the supporting floor. This leakage is extremely undesirable when toxic waste such as pesticides, paints, and other chemicals, or garbage is being conveyed. As will be readily apparent below, the liquid-tight reciprocating floor construction of the present invention can be employed with any of the slat reciprocation sequences of the above patents.
U.S. Pat. No. 4,157,761 discloses a discharge mechanism for discharging particulate loads that includes first and second stoker rods each having a plurality of cross bars A fixed floor angle is located between each of the cross bars. The first and second stoker rods reciprocate lengthwise, rapidly, and, at the same time but out of phase. Again, the above patent does not disclose a liquid-tight floor construction, and thus suffers from liquid leakage.
U.S. Pat. Nos. 4,492,303; 4,679,686; 4,749,075; and 4,785,929 all issued to Foster disclose various components for reciprocating floor conveyors including hold-down members, bearing systems, and drive/guide systems However, none of the above references teach a reciprocating floor construction that is liquid-tight.
A need thus exists for a reciprocating floor construction comprised of a plurality of slats slidable on a plurality of stationary liquid-tight bases. The unitary construction of the bases prevents liquid that leaks through the points of contact of each slat and each base from reaching the floor supporting the bases.
The need also exists for the above liquid-tight reciprocating floor construction in which a plurality of bearings cause reciprocation of each slat on each base without compromising the integrity of the base. A need also exists for the above type of liquid-tight reciprocating floor construction in which the base can be fixedly attached to a floor member without causing liquid leakage by compromising the unitary construction of the base.
SUMMARY OF THE INVENTION
The present invention is a liquid-tight reciprocating floor construction for movement of a load, and includes a plurality of slats slidable on a plurality of stationary liquid-tight bases, with each base supporting an individual slat. The unitary construction of the bases prevents liquid that leaks through the points of contact of each slat and each base from reaching the floor supporting the bases.
The bases are interconnected, preferably by either mating flanges or a tongue-in-groove configuration on each base. Seals adjacent the mating flanges or the tongue-in-groove configuration prevent liquid from leaking through these points of attachment to the supporting floor.
In the preferred embodiment of the present invention, the mating flanges or tongue-in-groove configurations are located on the side of each base, and the seals are located between the mating flanges or tongue-in-groove configuration.
In an alternate embodiment of the present invention, the side of each base has a top portion, and the seal is located in a channel formed in each top portion.
In another alternate embodiment of the present invention the side of each base has an outer beveled edge that forms a channel when fitted against the outer beveled edge of another base The seal is located in the channel so formed.
In the preferred embodiment of the present invention, each base is fastened to a flanged floor cross-member by a bolt through the flange of the floor cross-member. The head of the bolt holds a lip on the exterior part of the side of the base against the flange of the floor cross-member. A nut on the bolt braces the bolt against the flange The above configuration allows attachment of the base to the floor cross-member without causing liquid leakage by compromising the unitary construction of the base.
In the preferred embodiment of the present invention, each slat reciprocates relative to each base on three groups of bearings. A side bearing is located between each side of the slat and each side of the base. The slat and base sides are shaped to receive these bearings Additionally, a central bearing is located between longitudinal bearing support guides on the interior of the top of the slat. This central bearing is also supported by a central rib longitudinally bisecting the base.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will be more fully appreciated when considered in light of the following specification and drawings in which:
FIG. 1 is a perspective view of a fragmentary portion of a typical embodiment of the liquid-tight reciprocating floor construction of the present invention;
FIG. 2 is an end view of a first embodiment of the present invention of FIG. 1;
FIG. 3 is an end view of a fragmentary portion of a second embodiment of the present invention;
FIG. 4 is a side view of the fragmentary portion of the second embodiment of the present invention;
FIG. 5 is an end view of a third embodiment of the present invention; and
FIG. 6 is an end view of a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a liquid-tight reciprocating floor construction for movement of loads by sequential slat movement with respect to liquid-tight base portions. Slat reciprocation is accomplished by motor, gearing, and linkage means known in the art, and any one of numerous slat movement sequences also known in the art can be employed. Specific reference is made to the patents described above for examples of slat drive means and slat reciprocation sequences.
Referring to FIGS. 1 and 2, liquid-tight reciprocating floor construction 2 includes slat 4 slidably mounted on base 6. Side bearings 8 and central bearing 10, all preferably being substantially U-shaped, allow sliding reciprocation of slat 4 relative to base 6. Central bearing 10 is braced between central bearing guides 12 on the interior portion of the top of slat 4 and central rib 14 which longitudinally bisects base 6. Each side bearing 8 is held between a side 16 of slat 4 and a side 18 of base 6. Side 18 of base 6 has a sloped face 20 which facilitates attachment of side bearing 8. Side bearing 8 includes a lip 22 that engages side 18 of base 4 below sloped face 20. Side 16 of slat 4 includes a longitudinal groove 24 adapted to mesh with foot 26 located at the end of side bearing 8. Thus, side bearing 8 secures slat 4 to base 6 while allowing slat 4 to reciprocate relative to base 6.
The orientation of slat 4 on base 6 defines a chamber 28. Liquid from a liquid-containing load which collects on the top surface of slat 4 may leak into chamber 28 through the points of contact of sides 16 of slat 4 and side bearings 8. It is important to note, however, that, due to the unitary construction of base 6, any liquid located in chamber 28 cannot pass through base 6 and contact floor member 30. Thus, liquid-tight reciprocating floor construction 2 prevents liquid in chamber 28 or on slat 4 from exiting liquid-tight reciprocating floor construction 2 and contaminating the external environment. It should be noted that the term "unitary" employed to define the construction of base 6 means that base 6 lacks any openings or orifices which communicate with floor member 30.
Base 6 can be fixedly attached to other bases 6' and 6" by a tongue-in-groove attachment construction. In this manner, numerous bases 6 are employed to support numerous slats 4. In this tongue-in-groove construction, the side 18 of base 6 that is adjacent base 6' has a groove 32 therein. Base 6' has a tongue 34 in its side that is oriented to mate with groove 32. On side 18 of base 6 that is adjacent base 6" , is another tongue 34 Another groove 32 is located on the side of base 6" at an orientation to mate with the tongue 34 on side 18 of base 6. In this manner, base 6 can be attached to base 6' and base 6".
In order to ensure that liquid in chamber 28 does not exit base 6 at the points of contact of base 6 with base 6' and base 6", seal 36 is employed Seal 36 is preferably comprised of an elastomeric or a semi-elastomeric polymer composition known in the art. Seal 36 is preferably located between each tongue 34 and groove 32 of the tongue-in-groove constructions connecting base 6 with base 6' and base 6". However, seal 36 can also be located in a channel 38 located in the top of side 18 of base 6. Alternatively, channel 38, containing seal 36, can be located in the top of the side of base 6' and/or base 6". In yet another embodiment of the present invention, two channels 38 containing two seals 36 can be formed by beveling the outer edges of each side 18 of base 6 and the outer edges of the sides of base 6' and 6". In this manner, two V-shaped channels 38 having seals 36 therein are formed.
For bases located adjacent a side wall 40 such as base 6", seals or welds 42 are employed to prevent liquid leakage onto floor member 30. In the present embodiment of the invention as shown in FIGS. 1 and 2, slat 4, base 6 and floor member 30 are all preferably comprised of aluminum or alloys thereof. Thus base 6 is preferably attached to floor member 30 (which is preferably an I-beam) by welding. Prior to welding, channel locks are employed to compress seal 36 when it is located between groove 32 and tongue 34 in order to ensure a liquid-tight attachment of base 6 with base 6' and with base 6".
Referring now to FIGS. 3 and 4, an alternate embodiment of the present invention is shown in which slat 4 and base 6 are preferably comprised of aluminum or its alloys, and floor member 30 (which is preferably an I-beam) is preferably comprised of steel or the like. Due to the difficulties associated with welding aluminum and steel, this embodiment of the present invention contemplates mechanical attachment of base 6 to floor member 30. It is to be noted that reference numerals in FIGS. 3 and 4 which are the same as reference numerals in FIGS. 1 and 2 identify components common to the two embodiments.
In this second embodiment, instead of a tongue-in-groove construction for the attachment of base 6 with additional bases, complementary shaped flanges on adjacent bases are employed. Specifically, side 18 of base 6 includes flange 44 which is preferably substantially L-shaped having an arm 46 oriented substantially downwardly. Base 6" has a complementary flange 48 having an arm 50 oriented substantially upwardly such that flange 44 and flange 48 mate. Note that each of the L-shaped flanges 44 and 48 thus have a seat 52 in which the arm of the complementary flange resides. Seal 36 can be located in one or both of these seats 52 in order to ensure a liquid-tight connection.
Lips 54 on base 6 and base 6" are located adjacent the points of contact of base 6' and 6" with rib or flange 56 of the preferably I-beam shaped floor member 30. Bolt 58 is adapted to pass through rib 56 and brace lips 54 against rib 56 of floor member 30. Retainer 60 passes over bolt 58 and braces the underside of rib 56. Nut 62 is threadedly secured to bolt 58 and, when tightened, urges retainer 60 against flange 56 and tightens the contact between the head of bolt 58 and lips 54 such that base 6 and base 6" are securely attached to rib 56 of floor member 30 and flange 44 and flange 48 compress seal 36 to ensure a liquid-tight connection. It is to be noted that the above attachment of base 6 and base 6" to rib 56 of floor member 30 is accomplished without compromising the integrity of the unitary construction of base 6 (and base ") in chamber 28 thus reducing the likelihood of liquid leakage. Additionally, the opening in rib 56 of floor member 30 and the space between lips 54 through which bolt 58 passes are partitioned by flange 44, flange 48, and seal 36 from any liquid that may have leaked into chamber 28 of base 6. Thus, leakage cannot occur between lips 54 and the opening through rib 56 of floor member 30 in which bolt 58 resides.
Referring now to FIGS. 5 and 6, third and fourth embodiments of the present invention are shown, respectively. The third embodiment of FIG. 5 employs the tongue-in-groove construction (tongue 34 and groove 32) of the first embodiment of FIGS. 1 and 2 for connecting base 6 with additional bases. The fourth embodiment of FIG. 6 employs the interconnecting flange construction (flange 44 and flange 48) of the second embodiment of FIGS. 3 and 4 for connecting base 6 with additional bases. It is to be noted that the reference numerals in FIGS. 5 and 6 which are the same as reference numerals in FIGS. 1 through 4 identify common elements.
Both FIG. 5 and FIG. 6 disclose embodiments which allow modular construction of a slat 4 and a base 6 by the manufacturer to form a discrete pre-assembled unit prior to acquisition by the ultimate user. Thus, the user can more conveniently assemble liquid-tight floor construction 2 merely by connecting the desired number of these pre-assembled modular units comprised of slat 4 and base 6. Connection by the user is preferably either by the tongue-in-groove construction shown in FIG. 5 and described above in conjunction with FIGS. 1 and 2, or by the interconnecting flange construction shown in FIG. 6 and described above in conjunction with FIGS. 3 and 4.
In contrast, the first embodiment of FIGS. 1 and 2 and the second embodiment of FIGS. 3 and 4 are not comprised of modular units of a slat 2 and a base 4 pre-assemblable by the manufacturer. In the first two embodiments, the ultimate user has to first interconnect all of the bases 6, 6', 6", etc., then position all of the required side bearings 8 and central bearings 10, and finally attach all of the slats 4. The above assembly requires the implementation of jigs by the user, and forces the user to undertake additional assembly steps.
The modular unit configuration of liquid-tight floor construction 2 of FIGS. 5 and 6 is mainly due to the use of two separate planar side bearings 64a and 64b in place of the single u-shaped side bearing 8 shown in FIGS. 1 through 4. These side bearings 64a and 64b are preferably comprised of a high density plastic composition known in the art, as is side bearing 8 of FIGS. 1 through 4.
Unlike side bearing 8 of FIGS. 1 through 4, which snaps onto side 18 of base 6 and guides the reciprocation of slat 4 relative to base 6 by meshing of foot 26 of side bearing 8 in longitudinal groove 24 of slat 4, side bearings 64a and 64b of FIGS. 5 and 6 do not guide reciprocation of slat 4 on base 6. Instead, rib 66 on side 16 of slat 4 holds side 18 of base 6 and bearing 64a (or 64b) in channel 68 on side 16 of slat 4 to guide reciprocation of slat 4 relative to base 6.
To assemble each modular unit comprised of a base 6 and a slat 4, the side bearings 64a, for example, are placed on side 16 of base 6 and central bearing 10 is placed on central rib 14. Next, slat 4 is slidably mounted over side bearings 64a and central bearing 10 on base 6 such that side 18 of base 6 is held in channel 68 on side 16 of slat 4 by rib 66. The above modular unit can then be supplied to the ultimate uses in the above pre-assembled configuration. To assemble a liquid-tight floor construction 2 of a desired size, the user then connects the required number of the above pre-assembled modular units by either the above described tongue-in-groove construction or the interconnecting flange construction.
While particular embodiments of the present invention have been described in some detail hereinabove, changes and modifications may be made in the illustrated embodiments without departing from the spirit of the invention.
|
A liquid-tight reciprocating floor construction includes a plurality of slats slidable on a plurality of stationary bases, with each base supporting an individual slat. Each of the bases is unitary in construction such that liquid leaking through the points of contact between the slat and the base cannont reach the floor supporting the bases. The bases are interconnected by mating flanges, and seals adjacent the mating flanges prevent liquid from leaking through the flanges to the supporting floor.
| 1
|
FIELD OF INVENTION
This application is a continuation-in-part of U.S. patent application Ser. No. 09/386,883 filed Aug. 31, 1999 and relates to a low viscosity filler composed of boron nitride agglomerated particles of spherical geometry, a process for forming a low viscosity filler of boron nitride agglomerated particles of spherical geometry and to a low viscosity boron nitride filled composition composed of a polymer selected from the group consisting of a polyester, epoxy or polyamide loaded with a low viscosity filler composition of BN particles in a concentration of between 30-50 wt. % BN with the composition having a viscosity below about 300 cp and preferably below about 250 cp.
BACKGROUND OF THE INVENTION
Boron nitride (BN) is a chemically inert non-oxide ceramic material which has a multiplicity of uses based upon its electrical insulating property, corrosion resistance, high thermal conductivity and lubricity. A preferred use is as a filler material additive to a polymeric compound for use in semiconductor manufacture as an encapsulating material or to form a low viscosity thermosetting adhesive or in formulating a cosmetic material. As presently manufactured boron nitride is formed by a high temperature reaction between inorganic raw materials into a white powder composition of BN particles having an hexagonal structure similar to graphite in a platelet morphology. The platelet morphology is for many applications undesirable and of limited utility. A conventional powder composition of BN particles has the physical attributes of flour in terms of its inability to flow. Accordingly, when added as a filler to a polymer a blended material is formed having poor rheological properties and at loaded concentrations above 30 wt. % BN the blended material is so viscous that it is difficult to dispense from a mechanical dispenser such as a syringe. The physical characteristics of the filled polymer are enhanced at loading concentrations above 30 wt. % BN. Accordingly, a powder composition of BN particles with an improved rheology for use as a filler at high loading concentrations would be desirable.
The surface morphology and shape of conventional platelet BN particles are modified in accordance with the present invention to form boron nitride agglomerated particles bound by an organic binder such that when filled into a polymeric compound at loading levels between 30 to 50 wt. % BN the viscosity of the filled composition remains below 300 cp and preferably below a viscosity of 250 cp.
SUMMARY OF THE INVENTION
In accordance with the present invention, a low viscosity composition of spherically shaped agglomerated particles of boron nitride can be formed by spray drying an aqueous slurry composed of boron nitride particles of random irregular shape in combination with an organic binder and a base adapted to maintain the pH of the slurry above about 7.3 and optimally above a pH of 7.5, at a sustained elevated temperature into a dry powder composition of spherically shaped BN agglomerated particles with the concentration of the organic binder in the slurry adjusted to at least above about 1.8 wt. % of the slurry to form a residue of organic binder and/or a decomposition layer from said organic binder on said particles for modifying the surface viscosity of the composition without degrading the physical properties attributable to boron nitrate such as high thermal conductivity.
Each BN particle in the composition of the present invention represents a composite agglomerate of non-spherical BN particles bound together by an organic binder in a generally spherical geometry. The diameter of each spherically shaped BN particle formed by the spray drying method of the present invention may vary in size over a relatively wide size distribution of sizes but may be controlled so that the majority of particles and up to about 98% of the BN particles have a minimum diameter above one micron and preferably a minimum diameter above about 5 microns. The size distribution of the BN particles may extend to a maximum diameter of about 275 microns. Although the size distribution is relatively wide the BN particles have an average size which falls into a much narrower size range between about 10 microns and 150 microns in diameter and can be adjusted to form an even narrower size range by adjustment of the physical parameters of the spray drying operation and/or the initial size of the non-spherical particles of BN in the slurry. Accordingly, the size of the spherical BN agglomerated particles formed in the spray drying process of the present invention can be controllably varied over of a preferred range of from as low as 1 micron in diameter to a preferred maximum diameter of about 75 microns so as to accommodate a variety of end uses.
The spherical shape of the BN particles formed in accordance with the present invention and the weight concentration of organic binder in the slurry controls the degree to which the particles flow and, in turn, the viscosity of the polymeric compound into which the particles are loaded. The ability to “flow” is an essential characteristic of the spray dried BN material when used as a low viscosity filler. The degree to which a material can “flow” is readily measurable as is well known to those skilled in the art. In contrast, a powder composition of conventional non-spherical BN is unable to flow and inhibits the flow characteristic of the filled polymer. The standard used in the present invention to establish the existence or non-existence of a flowable material is the ASTM B213-77 hall flow standard as is well known to those skilled in the art. In the present invention, it is essential to be able to load the BN spray dried particles into a polymeric compound at loading levels of above at least 30 wt. % BN and preferably between about 35 to 50 wt. % BN without increasing the viscosity of the blend above about 250cp. The BN particles can be loaded into any polymer selected from the group consisting of a polyester, a polymide or an epoxy.
A low viscosity BN filled composition is formed in accordance with the method of the present invention comprising the steps of: forming an aqueous slurry composed of irregular non-spherically shaped BN particles, water, an organic binder and a base for maintaining the pH of the slurry at a pH above 7.3, adjusting the concentration of organic binder to a minimum level above about 1.8 wt. % of the slurry and preferably above about 2 wt. %; spray drying the aqueous slurry into a powder consisting of agglomerated BN particles of generally spherical shape and adding the powder as a filler into a polymeric compound at a loading level of between 30 to 50 wt. % BN.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following description of the preferred embodiment when read in conjunction with the accompanying drawings:
FIG. 1 is a block diagram of a conventional spray drying apparatus for producing the agglomerated spherically shaped BN particles in accordance with the present invention;
FIG. 2 is a photomicrograph of the spherically shaped BN particles formed by the spray drying operation of the present invention at a magnification of 50×;
FIG. 3 is a typical graph of the particle size distribution of the collected BN particles from the spray drying operation of the present invention; and
FIG. 4 is a graph showing the relationship of viscosity at a given loading of spray dried BN filler particles in an organic binder relative to the weight percent of binder in the slurry forming the spray dried BN particles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic block diagram of the spray drying apparatus used in the method of the present invention to form a powder composition of BN composite particles each of generally spherical shape. The spray drying apparatus 10 may consist of conventional equipment including an atomizer 2 and a source of air or an inert gas 3 , such as nitrogen, which forms an atomized spray of particles from an aqueous feed slurry 6 of water, a polymeric binder in the liquid phase and a base selected to maintain the pH of the slurry above a pH of 7.3 and preferably above a pH of 7.5. The atomized particle spray is preheated to a temperature in a range of 250° C.-360° C. preferably by preheating the nitrogen or air before injection at a desired feed rate into a spray drying chamber 1 with the outlet temperature between 110° C.-250° C. The BN particles in the feed slurry 6 preferably have a hexagonal crystalline structure although they may have a turbostratic structure. A dispersant, cross-linking agent and defoamer may also be included in the aqueous feed slurry 6 but are not essential. A polymerization initiator such as ammonium, sodium or potassium persulfate or other peroxide compound or other known polymerization initiator can be included to complete polymerization of the binder.
The particles formed in the spray drying chamber 1 are dried at an elevated temperature to a moisture level typically below 1% and collected. A cyclone 8 may be incorporated to remove superfine size particles before collection. The collected particles are solid particles having the same structure as the initial BN particles in the slurry 1 and will vary in diameter over a distribution range as shown in FIG. 3 from a minimum diameter size of one about micron up to about 275 microns with a mean particle size which varies based upon the size of the non-spherical BN particles, the concentration of binder, and the selected spray drying parameters of operation such as slurry ratio, feed rate, gas pressure etc. The mean particle size for the distribution of particles in FIG. 3 is about 55 microns but can be controllably adjusted.
In accordance with the present invention the powder BN product collected from the spray drying operation possesses particles which are essentially all of generally spherical geometry as evident from the photmicrograph of FIGS. 2 and 3. Each of the collected particles is a solid agglomerated particle formed of irregular non-spherical BN particles bound together by the organic binder in a spherical geometry. The high concentration of the organic binder in the slurry forms a coating over each of the recovered particles which at a concentration of over about 1.8 wt. % of the slurry varies the surface characteristic of the spray dried BN particles such that when added as a filler to a polymer selected from a polyester, epoxy or polyimide even under high loading levels at concentrations of between 30-50 wt. % BN, the flow characteristic of the filled polymer is not inhibited. In fact the viscosity of the filled polymer can be tailored to below about 250 cp. provided the concentration of organic binder is above about 2 wt. % of the slurry and optimally at about 2.5 wt. %. At a viscosity below about 250 cp. the filler polymer is easily dispensed through any conventional mechanical dispenser.
The organic binder is needed to bond the BN particles during spray drying and to modify its viscosity characteristic. The latter requirement limits the choice of organic binder to a water soluble acrylic or acetate which at high concentration has been found to function as a viscosity modifier. A preferably acrylic binder is formed from monoethylenically unsaturated acid free monomers comprising C 1 -C 4 alkyl esters of acrylic or methacrylic acids such as methly acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and isobutyl methacrylate; hydroxylalkyl esters of acrylic methacrylic acids such as hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxyethyl methacrylate and hydroxypropyl methacrylate; acrylamides and alkyl-substituted acrylamides including acrylamide, methacrylamide, N-tertiarybutylacrylamide, N-methacrylamide and N,N-dimethacrylamide, dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate; acrylonitrile and methacrylonitrile. The monoethylenically unsaturated acid free monomer may include the acrylic monomer styrene so as to form a copolymer or may be formed solely from styrene. Preferred examples of acid free monomers include butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, acrylamide, methacrylamide, N-tertiarybutylacrylamide and styrene as a copolymerization agent. Acid containing monomers are less desirable but may equally be used. Such acid containing monomers may be selected from any carboxylic acid monomer preferably acrylic acid and methacrylic acid.
Although any acetate may be used for the organic binder a metal acetate is preferred over a non-metal acetate. The preferred metal acetates include nickel acetate, aluminum acetate, titanium acetate and any transition metal oxide acetate such as zinc acetate. Ammonium acetate is less desirable but is an acceptable non-metal acetate. The elevated drying temperatures used in the spray drying operation may cause the acetate to partially or entirely decompose to an hydroxide film on the surface of the BN agglomerated particles. The concentration of binder and any hydroxide decomposition layer formed on the agglomerated BN particles following spray drying should remain essentially at the same molar ratio as the corresponding weight ratio of binder to boron nitride in the slurry. Accordingly, for a concentration of at least 1.8 wt. % of binder in the slurry, the molar ratio of binder to boron nitride should be in a range of 0.00170-0.008 particularly for metal acetate binders.
The base can be selected from any suitable alkaline which will enable the pH of the slurry to be controllably maintained above a pH of 7 and preferably above 7.3. A preferred base is an hydroxide such as ammonium hydroxide or an alkali metal hydroxide such as sodium hydroxide or potassium hydroxide or a methyl or ethyl ammonium hydroxide.
The following are examples of four ceramic slurries spray dried in accordance with the present invention to substantiate the production of spherical BN particles from a feed slurry of non-spherical irregular shaped BN particles. The four slurries consisted of conventional non-spherical BN powder in water with feed solids ranging from 32% to 49%. The pH of each slurry sample varied between 7.75 and 8.5. The pH was controlled by the addition of an ammonium hydroxide buffer at a concentration of less than 0.5wt %. The binder selected for each example was “Efka” 4550 in a concentration of between about 1 to 5wt %. “Efka” is a registered trademark of the Lubrizol Corporation and is a polyacrylate. A resin dispersant Efka 1501 which is a polyester fatty acid from Lubrizol at a concentration of about 0.25-2.00% was also added. Alternate binders which were found to be just as effective include “DURAMAX” 1022, “DURAMAX” 1020 and “DURAMAX” 3007. “DURAMAX” is a registered trademark of the Rohm and Haas Company in Philadelphia Pa. “DURAMAX” 1020 and “DURAMAX” 1022 are styrene/acrylic copolymers formed from acrylic monomers. It was not necessary to add any resin dispersant. However, a buffer such as ammonium hydroxide used to adjust the pH of the non-spherical BN particle aqueous slurry to above 7.3 was essential.
The following four tables contain all of the process conditions of the spray drying operation:
TABLE I
BN SLURRY FEED PROPERTIES
Feed Number
1
2
3
4
Feed Material
Boron nitride (BN) slurry in Water
Percent EFKA binder
0.25-4.0
Run Number
1
2
3
4
Solids, %*
32.7- 49.0
Temperature, ° C.
19
23
19
19
Density, g/cm 3
1.292
1.195
1.194
0.963
pH
7.75
8.44
8.38
7.77
Viscosity, Avg. CP
104
706
806
3006
TABLE 2
BN TEST DATA PROPERTIES
PRODUCT:
Run no.
1
2
Sample location
Chamber
Chamber
Cyclone
Sample time
10:40
11:10
12:15
Sample weight, g
195.8
210.3
199.5
Total weight, kg
0.59
7.17
9.48
Total residual moisture, % 2
0.30
0.50
0.35
Bulk density, g/cc
0.551
0.562
0.521
Tapped density, g/cc
0.621
0.631
0.611
Particle size, microns,
10% less than
27.02
30.09
11.00
50% less than (median size)
94.07
112.13
23.31
90% less than
189.84
180.28
87.87
Chamber-to-cyclone ratio (kg/kg)
0.82
TABLE 3
BN TEST DATE PROPERTIES
PRODUCT: 2B
Run no.
Sample location
Chamber
Cyclone
Sample weight, g
132.6
74.9
Total weight, kg
5.26
5.33
Total residual moisture, %
0.45
0.79
Bulk density, g/cc
Particle size, microns
10% less than
23.49
15.09
50% less than (median size)
55.03
25.42
90% less than
142.60
43.90
Chamber-to-cyclone ration (Kg/Kg)
2.15
0.99
TABLE 4
BN TEST DATA PROPERTIES
Run no.
3
4
Sample location
Chamber
Cyclone
Chamber
Cyclone
Sample weight, g
141.6
85.2
110.5
NA
Total weight, kg
3.04
6.24
1.13
1.50
Total residual moisture, %
0.59
0.43
0.41
0.39
Bulk density, g/cc
0.331
0-.221
0.305
0.273
Tapped density, g/cc
0.09
0.287
0.382
0.342
Particle size, microns
10% less than
10.83
8.46
7.22
6.91
50% less than (median size)
25.85
14.59
14.69
12.87
90% less than
102.38
21.66
25.89
20.37
Chamber-to-cyclone ration
0.49
0.75
(kg/kg)
The following is another example for forming spray dried boron nitride particles in accordance with the present invention. In this example aluminum acetate is used as the organic binder and bismaliamide is used as the polymer.
A boron nitride powder PT 120 (Lot 5151) was used to demonstrate the effect of surface modification on the viscosity of the BN filled resin. A conventional thermosetting resin, bismaliamide (BMI), from Quantum Chemical was used as the polymer into which non-spherical BN particles were loaded. PT120 is a conventional boron nitride powder with a platelet morphology. The physical and chemical characteristics are shown in the following Tables 5A-5C.
The PT120 filled resin was spray dried using a laboratory scale spray dryer, Mobile Minor Hi Tec, made by Niro Atomizer.
A slurry was prepared by mixing boron nitrate in de-ionized water using a high intensity mixer. Aluminum acetate-dibasic was added to the slurry and the slurry was mixed. After stabilizing the slurry, spray dying was initiated. The slurry composition for three separate runs is described in Table 5A.
TABLE 5A
Run No.
5D7
SD8
SD9
Water (gm)
3000
3500
3000
Boron Nitride (gm)
1050
1225
1050
Aluminum Acetate-
52
91.88
26.25
Dibasic (gm)
BN/Water (wt. %)
35
35
35
Al. Acet./BN (wt. %)
5
7.5
2.5
After the slurry was prepared, it was kept agitated by the mixer. The slurry was then pumped into the feed section of the spray dryer by using a peristalic pump. The spray dryer was operated with its fan on, inlet temperature in the range of 250° C.-270° C. The outlet temperature was in the range of 110° C. to 150° C. Air flow was set in the range of 17 to 22 on the gauge. Boron nitride feed rate (powder basis) was 1016, 1050 and 841 gm/hr for SD7, SD8 and SD9 respectively. Powders were collected from chamber and cyclone and then tested for their rheological properties.
Rheological Testing
Powders were mixed with the BMI resin alone at 37.4 wt. % loading level to form a baseline. About 30 gm. of resin was used in each case. After careful mixing in a cup, it was placed in a vacuum chamber for removal of trapped air. After evacuating for a few hours, it was carefully mixed and then placed into evacuation chamber again. Once air bubbles stopped rising to the surface, the cup was removed. The resultant paste was gently stirred and placed in a water-cooled bath for equilibrating to 25° C. After it reached a constant temperature of 25° C., viscosity was measured by Brookfield rheometer DVII using spindle no. 96. Viscosity was measured at various speeds but the measurements taken at 5 rpm ware used for comparison. Measurements were taken after at least 5 minutes from the start of the rotation to obtain steady state value.
The results of viscosity tests and analytical data are given in Table 5B and 5C for powders collected from chamber and cyclone respectively.
TABLE 5B
PT120-
SD7-
SD8-
SD9-
Baseline
Chamber
Chamber
Chamber
% Oxygen
0.371
5.17
5.71
% Carbon
0.021
0.58
0.84
Surface Area
2.97
4.5
7.91
8.68
MicroTrac Size
D-10 (Microns)
6.15
D-50 (Microns)
12.32
D-90 (Microns)
21.71
Shape
Plate
Spheroidal
Spheroidal
Spheroidal
Agglomerage
70-150
70-150
70-150
Size
(microns)
Viscosity @
400,000
141,000
74,000
242,000
5 RPM (cps)
Comments
No
Increased
Increased
Increased
aluminum
surface
surface
surface
acetate - no
area due to
area due to
area due to
spherical-
coating
coating
coating
ization
TABLE 5C
PT120-
SD7-
SD8-
SD9-
Baseline
Chamber
Chamber
Chamber
Agglomerage Size
10-50
10-50
10-50
(microns)
Viscosity @ 5 RPM
400,000
258,000
216,000
402,000
(cps)
|
A low viscosity filler boron nitride agglomerate particles having a generally spherical shape bound together by an organic binder and to a process for producing a BN powder composition of spherically shaped boron nitride agglomerated particles having a treated surface layer which controls its viscosity.
| 2
|
BACKGROUND AND SUMMARY OF THE INVENTION
Light emitting diodes (LEDs) are becoming increasingly widely used in automobile design because of their longer lives and lower cost compared to the incandescent bulbs they replace. Present day automotive designers are specifying LEDs not only for indicator lamps and alphanumeric digits but also for high power illumination lamps such as center high mounted stop lights. LED stop lights require very high brightness, but often only over a very limited viewing angle. FIG. 1 shows the current U.S. federal standard for LED center high mounted stop light brightness in candela as a function of viewing angle.
In order to be cost competitive with incandescent bulbs, an LED stop light must contain only a minimum number of individual LED lamps. The number of individual lamps can only be minimized if each lamp extracts substantially all of the light flux from the LED chip and concentrates the light within the useful viewing angle. Light flux outside of the viewing angle is wasted and might have been available to increase brightness within the viewing angle. Commercially available indicator lamps, which are designed according to the principles of imaging optics and standard manufacturing techniques, fail to concentrate sufficient light flux within the narrow required viewing angle. The imaging optics design constraint that the emitting surface is imaged onto the viewing plane makes design of a cost effective LED illumination lamp using imaging optics very difficult.
An alternative design approach known as non-imaging optics has been used successfully in the design of high efficiency solar collectors An additional degree of design freedom is available in non-imaging optics since there is no requirement that the emitting surface be imaged onto the viewing plane. An informative discussion of non-imaging optics may be found in the textbook "The Optics Of Nonimaging Concentrators" by W. T. Welford and R. Winston Specific examples of the use of non-imaging optics in solar collectors may be found in the U.S. patents (e.g., U.S. Pat. Nos. 3,923,381 and 3,957,031) issued to Dr. Roland Winston.
In accordance with the illustrated preferred embodiments of the present invention, the inventors have used the concepts of non-imaging optics to provide a high efficiency LED illumination lamp that is well adapted for use in an external automobile light such as a stop light. The lamp, which produces a very bright output over a preselected limited viewing angle, consists of two primary stages plus an optional lens stage. The first stage is a flux extractor which supports the LED and concentrates the three dimensional light flux into a desired angle, such as ±45°, relative to the optical axis. The second stage is a light pipe which continues the concentration to a final desired viewing angle. By using this second stage, instead of continuing the flux extractor's compound parabolic shape, the inventors have greatly simplified manufacturing and improved the cost and reliability of the lamp. One of a number of lenses may be used to increase the apparent illuminated area of the lamp or to allow a decrease in the physical height of the lamp.
In an alternative preferred embodiment of the present invention, a diffusant may be used to scatter the LED light. A bulk diffusant may be located within the structure of the lamp itself or a diffusing layer may be positioned over the lamp. The diffusant operates to increase the apparent size of the illuminated area, to decrease the brightness of the lamp and to increase the flux divergence to an approximately Lambertian distribution at the diffusant surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the U.S. federal specification for the brightness of an LED automobile center high mounted stop light as a function of viewing angle.
FIG. 2 shows a prior art LED lamp designed according to the principles of imaging optics
FIG. 3 shows various design parameters that are important to the design of an LED illumination lamp.
FIG. 4 shows an LED illumination lamp that is constructed in accordance with a preferred embodiment of the present invention.
FIG. 5 is an exploded view of the LED illumination lamp shown in FIG. 4.
FIG. 6 is a detail view of the flux extractor shown in FIG. 4.
FIGS. 7A-B show a number of lenses that may be used in the lamp shown in FIG. 4.
FIGS. 8A-C show the use of diffusant with the lamp shown in FIG. 4.
FIG. 9 shows a center high mounted stop light constructed as an array of the lamps shown in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the current U.S. federal specification for the brightness, in candela, of an LED automobile center high mounted stop light as a function of horizontal and vertical viewing angle. The required brightness is at a maximum within 5° of the optical axis and decreases as the angle increases. Light flux beyond 10° above the optical axis, 5° below the optical axis, or 10° to either side of the optical axis is not required and is, therefore, wasted.
FIG. 2 shows a schematic cross section of a prior art LED indicator lamp, such as the Hewlett-Packard Company model HLMP-3570 ultrabright LED lamp, that is constructed according to the principles of imaging optics. Since this device is not optimized for extracting and concentrating a maximum amount of light flux, a significant portion of the total LED chip light flux either exits the lamp at high angles from the optical axis or is reflected back into the LED chip and absorbed
FIG. 3 shows a number of the design parameters that are important in the construction of an LED illumination lamp. Modern LED chips may be fabricated from GaAs, GaAsP, AlGaAs or other compounds and may use either absorbing or transparent substrates. Many of these chips are capable of emitting a Lambertian distribution of light flux from most, if not all, of the chip surfaces. To minimize input electrical power (P in ) and to optimize efficiency, the lamp should extract and concentrate substantially all of the light flux rather than just that portion emitted by the LED top surface. In order to meet brightness and angular viewing requirements, such as those shown in FIG. 1, light flux of a certain brightness (B) is concentrated within a specified viewing angle (theta v ). In many applications the lamp must provide an illuminated surface having a given area (A) and a specified uniformity of brightness. In addition, it is often necessary to limit the overall height (h) of the lamp because of physical mounting constraints. In a typical illumination application there is no requirement that the LED chip surface be imaged onto the viewing plane.
As shown in FIG. 3, an optimal LED illumination lamp would concentrate all of the light flux from the LED chip to create a maximum brightness, B, within the desired viewing angle, theta v , and zero brightness elsewhere. The sine-brightness equation,
(A.sub.c B.sub.c)(sin .sup.2 theta.sub.c)≧(A.sub.v B.sub.v)(sin.sup.2 theta.sub.v),
relates the area (A c ), brightness (B c ) and viewing angle (theta c ) at the LED chip to the area (A v ), brightness (B v ) and viewing angle (theta v ) at the lamp viewing plane.
FIG. 4 shows an LED illumination lamp 1 that is constructed in accordance with a preferred embodiment of the present invention using the principles of non-imaging optics. The lamp is effective to conserve brightness (B c =B v ) and to maximize intensity by cutting off the flux at a desired angle (theta v ). An LED chip 3 sits within a flux extractor cup 5 which is fabricated within a lead frame 7. A bond wire 9 connects the anode of the LED chip 3 to an anode lead 11. The cathode of the LED chip 3 is electrically connected to a cathode lead 13 by conductive epoxy adhesion to the interior surface of the cup 5. Leads 11 and 13 are electrically isolated from each other. The lead frame 7 is fabricated in a conventional manner from a sheet of nickel plated copper. A stripe of silver may be deposited on the sheet in order to allow formation of the cup 5 as is more fully described with reference to FIG. 6. The lead frame 7, after formation of the cup 5, has a thickness of approximately 0.035 inch. The leads 11, 13 may be bent and cut to a given length as desired.
FIG. 5 shows an exploded view of the lamp 1 shown in FIG. 4. A light pipe 21 is formed by the conical wall 23 of a second stage 27. The bottom opening of the light pipe 21 is slightly larger than the top of the cup 5 to minimize blocking any light exiting the cup 5 caused by misalignment during assembly. The oversize should be kept as small as possible to avoid uniformity problems in the light flux from the lamp 1. The lead frame 7 is attached to the stage 27 by connection of lugs 31, 33 into holes 35, 37 to ensure that the light pipe 21 and the cup 5 are aligned along the optical axis 25. An adhesive may be used to secure lead frame 7 to stage 27 and to minimize light leakage at the interface. A cutout 39 in the wall 23 allows connection of the bond wire 9 from the LED chip 3 to the lead 11.
The second stage 27 may be fabricated from a metallizable plastic such as XHTA-150 which is a commercially available thermoplastic copolymer manufactured by Rohm & Haas Co. The wall 23 is coated with a highly reflective metal such as aluminum or silver and is polished to a bright finish to provide a specularly reflecting surface. The light pipe 21 is 0.813 inches high and the contour of the wall 23 approximates a straight line and is defined by the following table which gives radius (in inches) versus depth (in inches) from the top of the light pipe 21. Alternatively, the wall 23 may have a parabolic contour.
______________________________________ Depth Radius______________________________________ 0 .2944 .1976 .2319 .3456 .1857 .4349 .1584 .4987 .1391 .5488 .1239 .5905 .1114 .6263 .1005 .6575 .0907 .6849 .0818 .7090 .0736 .7301 .0659 .7484 .0589 .7639 .0524 .7771 .0465 .7886 .0413 .7986 .0370 .8067 .0336 .8127 .0311 .8169 .0296 .8186 .0290______________________________________
A lamp 1 may be constructed as shown in FIG. 4 without the addition of the lens 41 shown in FIGS. 4 and 5 and the light pipe 21 may be air filled for ease of manufacturing and improved thermal performance although the epoxy provides a better optical match to the LED chip 3. One disadvantage of such a lens-less design is that the total height, h, of the lamp 1 is kept relatively large. Addition of the lens 41 to the lamp 1 allowed the total height to be decreased from three inches to 0.813 inch with substantially no change in brightness, B v , and area, A v , and at a constant viewing angle, theta v , of ±7.5°.
FIG. 5 shows the immersion lens 41 which may be used with the lamp 1 to decrease total height. Lens 41 is fabricated from an epoxy having an index of refraction of n=1.53 and is available commercially from Essex Polytech Company as "PT" epoxy. The lens 41 has a radius of curvature of 0.4 inch and extends above the top of the second stage 27 a distance of 0.12 inch.
The entire lamp 1 may easily be constructed with reference to FIGS. 4 and 5 by performing the following steps:
1. Attach LED chip 3 inside cup 5 and attach bond wire 9 from the chip 3 to lead 11.
2. Attach lead frame 7 to the second stage 27 with the optical axes aligned.
3. Inject epoxy into the light pipe 21 and the cup 5 and cure.
4. Inject epoxy into a mold cup having the desired shape for lens 41.
5. Attach the mold cup to the top of the second stage 27 ensuring that the optical axes of the lens 41 and the light pipe 21 are aligned
6. Cure the epoxy in the mold cup so that the lens 41 is attached to the epoxy within the light pipe 21 without a reflective interface.
7. Remove the mold cup and finish the surface of lens 41, if desired.
A lamp 1 was constructed as described above using a 16 mil square by 10 mil high absorbing substrate AlGaAs red LED chip 3. The total height of the lamp 1 was approximately one inch and the total diameter was 0.60 inch. Light flux generated by the LED chip 3 was three-dimensional (4 pi sterradian) and the viewing angle relative to the optical axis at the plane of connection of the cup 5 to the second stage 27 was ±60°. The viewing angle, theta v , at the viewing plane at the surface of the lens 41 was ±7.5° and the illuminated area, A v , was 0.28 square inches. The electrical input power, P in , to the LED chip 3 was 40 milliwatts and the brightness, B v , of the lamp 1 was 2.4×10 4 candela/meter 2 (for an intensity of 4.3 candela.
FIG. 6 shows a detailed cross-sectional view of the cup 5 shown in FIGS. 4 and 5. The cup 5 is formed within the lead frame 7 as described above and may be silver coated to provide a specularly reflecting inner surface 49. Light emitted by the LED chip 3 exits the cup 5 within a cup viewing angle theta 1 about the optical axis 25. The cup 5 includes four separate sections 61, 63, 65, 67 which are axially symmetric about the optical axis 25. Formation of these four sections is described only with respect to the left half of the cup 5 shown in FIG. 6. Formation of an actual three-dimensional cup 5 could be accomplished by rotation of this planar representation about the optical axis 25. The LED chip 3 is attached to a flat bottom section 61 of the cup 5 using an electrically conductive silver epoxy. The flat bottom section 61 is normal to the optical axis 25 and is slightly larger than the actual dimensions of the LED chip 3 to allow for dimensional tolerances and slight manufacturing misalignment within an envelope 53. In order to avoid discontinuities, the projection of the envelope 53 onto the bottom of the cup 5 is circular even though the actual projection of the LED chip 3 is square. The envelope is cylindrical with a height of the LED chip 3 plus the tolerances and a diameter equal to the width of the LED chip 3 times 1.414 plus the tolerances.
A circular section 63 extends from a point 71 at the edge of flat bottom section 61 to a point 73. This point 73 is determined as the projection of the cup viewing angle through the nearest top edge point 55 of the envelope 53. Between points 71 and 73, the surface of cup 5 forms a segment of a circle having a constant radius and a center at the nearest top edge point 55 of the envelope 53. Since the envelope 53 projection is circular, the section 63 is axially symmetric about the optical axis 25.
A lower parabolic section 65, which is axially symmetric about the optical axis 25, extends from the point 73 to a point 75. The point 75 is located on the inner surface 49 of the cup 5 at the same distance above the flat bottom section 61 as the top surface 59 of the envelope 53. The lower parabolic section 65 is formed as a parabola having its vertex at point 73, its axis projecting through point 73 and near edge point 55, and a focus at the near edge point 55 of the envelope 53.
An upper parabolic section 67, which is also axially symmetric about the optical axis 25, extends from the point 75 to a point 77. The point 77 is determined as the projection of the cup viewing angle through the far edge point 57 onto the inner surface 49 of the cup 5. Thus, the cup viewing angle could be decreased by extending the height of the upper parabolic section 67. The upper parabolic section 67 is formed as a parabola having an axis extending through the far edge point 57 and parallel to the axis of the lower parabolic section 65. The focus of the upper parabolic section 67 is located at the far edge point 57.
FIGS. 7A-B show two alternative lenses that could be used above the lamp 1 shown in FIG. 4. FIG. 7A shows top and side views of a prism lens 91 that may be used to increase the viewing angle in a single direction, i.e., along a single axis. Prism lens 91 is fabricated from a sheet of optically transmissive material such as 0.200 inch thick acrylic. Triangular grooves 93 at an angle of 5° are cut into the material on, e.g., 100 mil centers, to form the faces 95, 97 of the prism lens 91. Use of the prism lens 91 increases the viewing angle in the direction normal to the direction of the grooves and, at a distance of 25 feet, the human eye is unable to resolve the dark spots produced by the prism lens 91. The actual angular increase was ±2.5°.
FIG. 7B shows top and side views of a fly's eye lens 101 that may be used to increase the viewing angle in two axes. Fly's eye lens 101 is fabricated from a sheet of optically transmissive material such as acrylic and half round domes 103 are formed on the surface of the material. Differential angular increases could be obtained by making the domes 103 elliptical or some other non-circular shape.
FIGS. 8A-C show three types of diffusant that may be used with the lamp 1 shown in FIG. 4. Use of a diffusant causes statistical light scattering and creates a Lambertian light distribution since each diffusant particle acts as a light scattering center and approximates a Lambertian source. Thus, use of a diffusant allows an increase in viewing angle without an increase in brightness variation which may occur with the use of a prism or fly's eye lens.
FIG. 8A shows a bulk diffusant incorporated within the epoxy used to form the light pipe 21 and lens 41 shown in FIG. 4. The bulk diffusant may be made by adding titanium dioxide to the epoxy. Of course, each particle absorbs light and the light loss increases as the amount of diffusant increases. Light loss may approach 50% at an acceptable viewing angle. FIG. 8B shows a diffusant sheet 113 located above the lamp 1. The sheet 113 may be made as a sheet of the same epoxy/titanium dioxide mixture used in FIG. 7A and also creates a Lambertian light distribution at its surface. Since the sheet 113 may be made thin, the amount of light loss may be minimized. FIG. 8C shows a diffusant layer 115 that is fabricated on the surface of the lens 41 and causes only a minimum of light loss. Layer 115 may easily be fabricated by sandblasting lens 41 or by other techniques of roughening or by applying a matte finish to lens 41.
FIG. 9 shows a portion of a 2×10 array of lamps fabricated on, e.g., a printed circuit board to meet the specification shown in FIG. 1. The viewing angle at each lamp 1 was ±7.5° and the 5° prism lens 91 was used to increase the angle in one axis to ±10°.
|
The principles of non-imaging optics, rather than imaging optics, are used to provide a high power LED illumination lamp that has a specified limited viewing angle. A compound parabolic flux extractor extracts and concentrates light emitted by an LED chip and a light pipe continues the concentration into the specified viewing angle. A lens or a diffusant may be used to modify the light output of the lamp. A light constructed as an array of the lamps is suitable for use as an automobile external light such as a center high mounted stop light.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to papermaker's fabrics for supporting and conveying a paper web through the papermaking process. More particularly, the present invention relates to a papermaker's fabric formed from a plurality of tessellated elements.
2. Description of the Prior Art
In the papermaking process, a papermaker's fabric is used in the form of an endless belt-like structure which is supported by and advanced through the equipment by various machine rolls. This process and the various sections of the papermaking equipment, formation, press and dryer, will be known to those skilled in the art.
Recent developments in the field of papermaker's fabrics have lead to widespread use of synthetic materials in the fabrics. Previously, most fabrics were made through the use of a weaving process, using either the endless or flat technique. More recently, spiral fabrics have come into use. Spiral fabrics are not woven in the traditional sense but are produced by forming a plurality of spiral coils on a mandrel and then interconnecting the spiral coils through the use of joining wires or pintles. In spiral fabrics, the spiral coils may be generally equated with machine direction yarns and the pintles may be generally equated with cross machine direction yarns.
Although all of the prior art fabrics have found applications and have generally performed satisfactorily, it has been determined that each technique has its drawbacks. With respect to endless fabrics, it is essential to know the final finished width and length of the fabric before the weaving process starts. Accordingly, each fabric is custom made to a particular application. With respect to flat woven fabrics, it is possible to produce continuous lengths of fabric which may be cut to size, however, it is generally required that the width of the fabric be determined at the time of weaving. With respect to spiral mesh fabrics, they provide tremendous flexibility as to assembly of fabrics in different lengths and widths but are less adaptable to desired changes in drainage, permeability and surface characteristics.
Prior art fabrics have almost always been limited to materials which are available in fiber form or to materials which could be formed into fibers. The fabric designer almost always had to make compromises when designing the fabric because of the limited materials available. For example, when designing for either stretch resistance or wear resistance, the designer frequently had to compromise the fineness of the fabric. Although these compromises were acceptable in many applications, the required compromises frequently resulted in either less than ideal fabrics or less than ideal product.
Although all of the prior art fabrics have performed satisfactorily in given applications, the art still desires a means for quickly and economically producing fabrics of various lengths, widths and surface characteristics. In all papermaking fabrics, the parameters of air permeability, drainage, moisture retention and fabric stability are of concern to the fabric producer and user.
In view of the above, it is the intent of the present invention to produce papermakers fabrics inexpensively and efficiently without any reduction in fabric reliability or adaptability. It is a further intent of the present invention to eliminate design compromises, improve uniformity of the fabric and to eliminate the reliance on a limited range of materials.
In order to achieve such a fabric, one assembles a plurality of elements to achieve the necessary length and width of the fabric. It is contemplated that elements will be provided in standard sizes. However, as will be recognized by those skilled in the art, the required length of fabric will vary according to papermaking equipment. Accordingly, it is contemplated that the elements will be provided in standard sizes which will constitute the majority of the fabric and will be provided in certain other standard complementary sizes in order to form the final closure and the end or selvage of the fabric width.
Consider, for example, the need to finally close a fabric into an endless structure. In order to provide the final closure, the elements may be provided with a width which is the same as the remaining element but with a shorter dimension between the leading and trailing edges. These complementary elements may be provided in a variety of lengths less than the standard elements. Likewise, the end or selvage elements may be provided with the standard length between leading and trailing edges but with a somewhat reduced width. Once again, these elements may be provided in various widths. After final assembly of the tessellation, the width and/or selvage ends may be further trimmed by known techniques which are common with respect to cutting synthetic materials. In this matter, a reasonably precise fabric with uniform selvages may be inexpensively and efficiently assembled.
SUMMARY OF THE INVENTION
It is the purpose of the present invention to provide a papermaker's fabric which is comprised of a plurality of tessellated elements which have been interconnected to produce a tessellation of a desired length and width. Likewise, the fabrics of the present invention are designed to produce the desired air and/or moisture permeability and/or drainage characteristics while providing increased control over the characteristics of the paper carrying surface of the fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred element according to the invention for producing tessellated fabrics.
FIG. 2 is a plan view of the element depicted in FIG. 1.
FIG. 3 is a plan view of a preferred alternative embodiment of the element of FIG. 1.
FIG. 4 is a plan view of a preferred alternative embodiment of the element of FIG. 1.
FIG. 5 is a fragmentary section showing a male or projection member of the element depicted in FIG. 4.
FIG. 6 is a section of a tessellated fabric utilizing the element depicted in FIG. 1 and illustrating apertures therein.
FIG. 7 is an illustration of several various apertures suitable for utilization in the fabric of FIG. 6.
FIG. 8 is an illustrative figure which illustrates a guide means usable with a fabric according to the present invention.
FIG. 9A is an alternative element for use in producing tessellated fabrics.
FIG. 9B is an alternative construction of the element shown in 9A for producing tessellated fabrics.
FIG. 10 is an alternative element for use in producing tessellated fabrics.
FIG. 11 is a fragmentary instant section of the joint depicted in FIG. 10.
FIG. 12 illustrates an alternative embodiment of the element depicted in FIG. 10.
FIG. 13 illustrates another alternative element which utilizes a pintle in construction of the fabric.
FIG. 14 is a second alternative embodiment of an element which utilizes a pintle in construction of the fabric.
FIG. 15 is an instant section taken from the right hand side of FIG. 14.
FIG. 16 is an alternative embodiment of the element depicted in FIG. 14.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a preferred element 2 in accordance with the instant invention. The element 2 may be of any moldable or extrudable synthetic material, however, the material will generally be selected to have favorable characteristics with respect to the harsh environment of the papermaking process. The fabrics according to the instant invention will be a tessellation of elements, similar to 2, which are arranged to a desired width and length. Each element has a body portion 10 which is generally equal sided. That is, the elements are capable of side to side match-ups in the manner of a mosaic. Along two sides of the body 10 there is an integral male member or projection 12 and on each of the remaining two sides a female member or recess 14 is provided which complements the male member or projection 12. In the preferred embodiment the projections 12 and recesses 14 are provided on adjacent sides, however, they could as easily be provided on opposite sides of the body 10. Since the body 10 is preferably square, the projections and recesses could be on opposite sides of the body 10 and the elements could be rotated for interconnection.
Still with reference to FIG.1, it can be seen that the paper contact surface or upper plane 16 of the male member projection 12 is trapezoidal in shape. The base or lower plane 18 of projection 12 is likewise trapezoidally shaped, however, it has a larger area than upper plane 16. Accordingly, side walls 20 of the projection 12 will project inwardly from the plane defined by facing wall 22 of the projection 12 and inwardly toward upper plane 16. In order to complement projection 12, the recess 14 has a similar trapezoidal configuration. The base of recess 14 encloses a trapezoidal area 30 which is greater than the trapezoidal area 32 which is enclosed by the upper plane or paper contact surface of the recess 14.
In the preferred embodiment, it is expected that the upper plane 26 of the element 2 would define the paper carrying surface and the lower plane 28 would define the machine contacting surface. Configured thusly, normal machine forces will tend to continually exert an outward pressure which will serve to lock the projection 12 within the recess 14 and preserve the integrity of the fabric. Likewise, the trapezoidal shape will tend to prevent dislocation of the fabric as a result of running forces developed in the plane of the fabric.
With reference to FIG. 2, a plan view of element 2, the technique for terminating a fabric at the right and left portions thereof will be described. For purposes of explanation, assume that the fabric is assembled with the projection 12 extending along the left hand edge thereof. In this case, the fabric may be assembled in two ways. In the first method, the fabric is assembled to slightly greater than the desired width and then the element is trimmed along the line LL of FIG. 2. This will produce the left hand edge. Similarly, the fabric may be trimmed along the line RR of FIG. 2 to produce the right hand edge. Those skilled in the art will recognize that such trimming may be accomplished by known techniques, such as hot knife techniques or ultrasound techniques. Alternatively, the edge may be accomplished by providing respective elements 2 which have been truncated along the respective lines LL and RR prior to assembly.
Generally, the entire fabric may be assembled in the lengthwise or machine direction dimension employing equal sided elements 2 as depicted in FIG. 1. This is possible due to the normal adjustments which exist on papermaking equipment. However, in those instances where such adjustment is not available, the fabric may be terminated using an element 2 as depicted in FIG. 3. The element 2 of FIG. 3 will have a body portion 10 like that of element 2 in FIG. 1; however, the body portion 10 will be foreshortened in the lengthwise direction but equal to element 2 of FIG. 1 in the widthwise or cross machine direction. In the event that the fabric is constructed of elements which have the projections and recesses on opposite sides of the element, it will be necessary to provide two styles of the foreshortened elements depicted in FIG. 3.
With reference to FIG. 4, there is shown an element 2' which generally corresponds to the element 2 of FIG. 1. Element 2' differs from element 2 in that the male and female member are of a different geometric configuration than that depicted in FIG. 1. In FIG. 4, the projections 12' are truncated conically shaped projections wherein the base 18' has a larger area than the upper plane 16'. This may be seen clearly with reference to FIG. 5. Recess 14' is complimentary to projection 12' as described previously for recess 14.
It will be recognized by those skilled in the art that the male members and female members 12 and 14 respectively may be of a variety of geometric configurations. Likewise, it will be recognized that the complementary geometric configurations do not necessarily have to interlock in the direction of the paper carrying surface. However, it is preferred to maintain simple geometric configurations and to incorporate the locking feature. This preference is based upon both the ease of molding less complex configurations which incorporate the interlocking feature and the desirability of assuring fabric integrity.
With reference to FIG. 6, there is depicted a section of fabric 40 which is a tessellation of elements 2. It can be seen that a tessellation is an assembly of elements which have interlocking geometric shapes which maintain the elements relative to each other, much in the manner of a puzzle. In FIG. 6, the elements 2 are shown as having a plurality of apertures 42. As will be understood by those skilled in the art, the apertures 42 will define the air permeability and/or drainage characteristics of the fabric 40. Apertures 42 may be provided in the element 2 at the time it is produced, such as by molding. However, it is presently preferred to produce the elements 2 in the manner depicted in FIG. 1 and to provide the apertures 42 in a later processing step. For example, the tessellation is assembled to its desired size and then subjected to a heat setting and aperturing process which fixes the respective elements 2 one to the other and produces the apertures 42. In addition to producing apertures in the fabric, it is also possible to produce surface characteristics on the fabric 40 such as through the use of a heated calender roll or embossing roll.
With reference to FIG. 7, there are depicted several of the variations of the apertures which may be produced in fabric 40. Aperture 42 of FIG. 7 corresponds to aperture 42 of FIG. 6 and is a straight through bore. Aperture 44 is an angular bore which may be desirable for directing water flow or for producing gradients in the drainage and moisture characteristics of the fabric. Likewise, aperture 46 may be utilized to produce more rapid drainage characteristics or to enhance gradients within the fabric structure. It will be obvious that other aperture geometry may be utilized according to design applications.
From the foregone, it can be seen that the present invention provides the fabric designer with flexibility which has been unknown heretofore in the art. Since the elements may be molded or constructed from other than filament materials, the designer is no longer limited to those materials which may be produced in yarn like structures. Accordingly, the fabric designer may select any material which can be worked into the required shape. While it is contemplated that the elements will be molded, it is also recognized that the elements may be laminated, extruded or stamped from sheet material through the use of suitable dies. Thus, the fabric designer may take advantage of the characteristics of several materials within a single fabric. In addition to the materials advantages, the designer is also provided with a means for modifying fabric characteristics to meet the different environments which exist across the width of the paper machine. This permits the fabric designer to more fully accommodate the characteristics and environment of the papermaking equipment.
With respect to the structural integrity of the tessellation, it is believed that the assembly will provide sufficient strength to permit handling and installation of the fabric. However, it is suggested that a mild, water soluble adhesive be used during final assembly. The water soluble adhesive will assist in bonding of the fabric but will be readily removed upon installation and operation.
With respect to guiding of the fabric on the papermaking equipment as it circumvents the end rollers, it is believed that the locking nature of the projections and recesses is sufficient to assure fabric integrity. However, provisions may be made to control any potential dislocation of the elements. With reference to FIG. 8 there is shown one method of guidance. The fabric 40 is mounted between carrier rolls 50 as is known to those skilled in the art. The fabric 40 will operate in the same manner as prior art fabrics. However, in realization that the elements may have a potential to separate as they negotiate the circumference of the rolls 50, the papermaking equipment is provided with wrap-around shields 52 and 54. The location and arc size of the shields 52 and 54 will be determined by the particular equipment on which the fabric is to be utilized. As a general matter, each shield will be mounted so as to locate the entry at the point where the fabric begins to conform to the circumference of the roll 50. The ends 56 and 58 are positioned from the roll by a distance greater than the caliper of the fabric but less than the element size. Thus, it can be seen that the elements will not become dislodged since they will be retained by the shield. The distance of the shields from the rollers 50 is continually decreased until it reaches the respective ends 60 and 62. At the respective ends 60 and 62, the shield is positioned from the roller by a minimum distance which is at least equal to the caliper of the fabric.
As can be seen from the above, the fabric 40 will enter the respective shield and be continually monitored so as to assure that the fabric exits the other end as a fabric. Although the shields may be in constant contact with the fabric, it is believed that this is not necessary and will lead to undue wear of the fabric. Since most fabrics are heat set prior to use it is believed that the elements will maintain the complementary fit and it is therefore desirable to reduce the amount of contact, other than that necessary for fabric performance, which takes place between th fabric and shields.
With reference to FIG. 9A, there is shown an alternative embodiment of the invention. In this embodiment, each of the tessellation elements 70 will be made to have a longitudinal length which corresponds to the cross machine direction width of the fabric. The latitudinal length of the element will preferably extend in the machine direction and may be of any length which is consistent with machine design. Each of the elements 70 has alternating tapered projections 72 and recesses 74 formed along the longitudinal edges thereof. Each of the longitudinal edges is preferably configured so as to complement the opposite longitudinal edge on a second element 70. Thus, a plurality of the elements 70 will be provided and the adjacent longitudinal edges interconnected to form the fabric. Although there is no minimum distance between tapered projections 72 and recesses 74, it will be understood that a sufficient distance should be maintained to permit flexing of the element 70 when the elements are tessellated.
With reference to FIG. 9B, there is shown an alternative element 80 which is generally similar to element 70. However, in the embodiment of FIG. 9B, the element 80 has all of the male members or projections 82 aligned along one longitudinal edge thereof and all of the female members or recesses 84 aligned the opposite longitudinal edge thereof. In the embodiment of FIG. 9B, the projections 82 and recesses 84 may be placed very close to each other. Since there is no need to rotate the element 80 in order to tessellate the longitudinal edges, when preserving the tapered geometric configuration, the strip will accommodate minimum distances between adjacent members.
With reference to FIG. 10, there is shown an alternative embodiment of the present invention. In this embodiment, each of the elements 100 is modified to incorporate a snap-fit geometry. Additionally, the elements of the tessellation will be made to have a longitudinal length which generally corresponds to the cross machine direction of the fabric. The latitudinal length of the element will preferably extend in the machine direction and may be of any length which is consistent with machine design. Each of the elements 100 will have a projection 112 formed along one longitudinal edge thereof and a recess 114 formed along the opposite longitudinal edge thereof. The projection 112 will have an arcuate leading edge 120 and will be spaced from the body 110 by a slot 122. The interior portion 124 of the projection 112 is likewise arcuate in shape and terminates behind the trailing edge 126 of projection 112. Thus, projection 112 is formed in the shape of a reversed "J". With reference to the recess 114, it can be seen that it is formed with a complementary structure. The downwardly depending portion 130 is spaced from the body 110 by a slot 113. Slot 113 is dimensioned to accept a projection 112 without causing disruption of the alignment between the various body portions of the respective elements. A second slot 134 is defined between the lower plane of the body portion 110 and the node 136. The slot 134 is dimensioned to accommodate the trailing edge 126 of projection 112. With reference to FIG. 10, it can be seen that the portion 130 is similarly formed as a reverse image "J" and will complement projection 112. It will also be recognized that the terms "projection" and "recess" are used solely for the purpose of description and that the opposite term may equally apply to either lateral edge of the element 100. Interconnection of the projection 112 and recess 114 may be made either by a snap fit, by rotating the edges one to the other or by placing the elements end to end and sliding them in opposite directions to cause interconnection.
With reference to FIG. 11, there is shown an exploded sectional detail of the joint 140 which has been exaggerated for purposes of illustration. It is to be understood that one surface of the element 110 should be designated as the paper carrying surface. To this end, the edges 142 and 144 of the respective elements have been shown as essentially square in order to produce an advantageous paper carrying surface and the edges 146 and 148 have been shown as rounded to assist in running of the fabric about the rollers. It will be understood that this relationship can be reversed such that the projection 112 would run in the upper surface and the recess 114 would run in the lower surface.
With reference to FIG. 12, there is shown another alternative embodiment of the present invention. The embodiment depicted in FIG. 12 utilizes an auxiliary pintle or joining wire to further retain the respective elements 200. The use of pintles is well known to those skilled in the art. The element 200 of FIG. 12 is similar to that of FIG. 10 and differs only as to the auxiliary means of interconnecting the elements.
FIG. 12 has been fragmented to show the pintle connection means in projection 232. The projection 230 is similar to projection 130 of FIG. 10 except that the leading edge 231 has been made concave to accept a pintle.
Element 200 has a plurality of projections 212 which are spaced along a longitudinal edge thereof and separated by recesses 214. Each of the projections 212 is separated from the body portion 210 so as to define a channel 218 for receiving a pintle and a projection 230. The trailing edge 226 of projection 212 is separated from body portion 210 by a slot 220. The slot 220 is dimensioned to accept projection 230 which cooperates with trailing edge 226 to confine the pintle inserted in the channel 218. On the opposite longitudinal edge of the element 200 there is a provided a series of recesses and projections which complement the recesses and projections 212 and 214 respectively. Recess 234 is dimensioned to receive the projection 212 and the projection 232 is dimensioned to be received within the recess 214. In this manner the longitudinal edges of the fabric are placed adjacent to each other and form a carrying surface. The projection 232 includes a pintle channel 236 which is dimensioned in accordance with the pintle dimensions of receiving channel 218. In this manner, elements may be assembled with their respective longitudinal edges in abutment and the pintle inserted through the pintle channel formed by 218 and 236. If desired, the projections 232 and 212 may be identical projections, however, it is believed that the closing of the projection 232 assists in producing a more favorable machine contact surface on the lower plane of the element.
With respect to FIG. 13, there is shown another alternative embodiment of the invention. Each of the elements 300 will have a body portion 310 which is similar to that described previously with respect to the embodiments of FIG. 10 and FIG. 12. However, in the embodiment of FIG. 13, each of the projections 312 is formed so as to be somewhat recessed behind the longitudinal edge 316. Thus, the projection 312 will resemble a "C" shape which has been rotated to rest on its back. On the opposite longitudinal edge of the element 300, the recess 314 is formed by disposing the hook shape element 320 slightly to the rear of the longitudinal edge 318. In assembling the fabric, the hook 320 is disposed within the body of the projection 312 and the leading edge of the projection is received within the recess 314. In this construction, a channel is defined for receiving an auxiliary pintle 330. As can be seen from FIG. 13, the final construction provides a fabric in which the lateral edges are adjacent to each other as described before in previous embodiments.
With reference to FIG. 14, there is shown another alternative embodiment. The embodiment of FIG. 14 is in most respects similar to that described with respect to FIG. 13. However, in the embodiment of FIG. 14, the gauge of the fabric has been increased by disposing the projections 412 and the recesses 414 in a lower plane. Although any of the prior constructions could be made in an equal gauge, the present construction is intended to provide additional machine runners 440 and to provide channelling for drainage and moisture removal. In all other respects, the configuration of FIG. 13 is similar to that of the previously described embodiments.
With reference to FIG. 15, the runners 440 will be further described. It can be seen that the runners 440 are spaced along the longitudinal edge of the element 400. The plurality of runners 440 produce a plurality of cavities 442 which are disposed beneath the body portion 410. In this manner, water or moisture drawn through the apertures in the element body may be quickly removed.
As can be seen with reference to FIG. 14, the configuration of the trailing edge of the runner 440 will not interfere with assembly or use of the fabric but will provide a constant running and transition surface.
With reference to FIG. 16, there is shown an element 500 which is in all respects, save for the runner 440, the same as that previously described for element 400 of FIG. 14. Although the element of FIG. 16 is presently not preferred for those applications in which the element will run with its longitudinal length in the cross machine direction, element 500 of FIG. 16 may find application where the lower plane of the element will not create fabric bounces as a result of contact with the rollers. In addition, element 500 may find application in those constructions where the element runs with its longitudinal length in the machine direction. In these applications, it is contemplated that the fabric ends would be joined by a mechanical mean or a subsequent heat treating and/or a remolding process.
One additional feature of the invention which will be recognized by those skilled in the art is the advantage of fabric repair by replacement of elements in a tessellation. Thus, a fabric need not be discarded if damaged. Good relatively unworn elements may also be reused in other fabrics or as repair elements.
|
A tessellated papermakers fabric and elements for making the fabric are disclosed. The elements are formed so as to have male or projection members which interlock with female or recess members. In alternative embodiments, interlocking elements which further utilize pintles for reinforcement of the connection are disclosed. The elements may be molded, extruded, dye stamped or laminated. The desired permeability is provided by forming apertures in the elements and can provide for air and moisture permeability characteristics which vary throughout the fabric. In addition, tessellated fabrics according to the instant invention may be subsequently processed to produce surface or embossing characteristics.
| 8
|
This application claims priority to Dutch Application No. 1029190 filed on Jun. 6, 2005 in Dutch Patent Office, the entire contents of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The invention relates to an inkjet printhead comprising two substantially closed ink chambers separated by a wall, each of the chambers comprising an electro-mechanical converter, where actuation of the converter corresponding to the first chamber of said printhead will lead to a volume change in the second chamber due to cross-talk. The invention also relates to an inkjet printer comprising this printhead.
A printhead of this kind is known from U.S. Pat. No. 6,161,925. This printhead comprises a row of elongated ink chambers, also referred to as ink ducts, which by application of a machining technique have been fitted inside a so-called duct plate (element 12, see FIG. 1 of the corresponding patent). The chambers are covered by a compliant foil at the top, making them substantially closed. Furthermore, each chamber comprises an inlet opening for feeding ink into the chamber and an outlet opening (nozzle) from where individual ink drops may be ejected from each of the chambers. To this end, each of the chambers is operationally connected to a piezo-electric type electro-mechanical converter. By actuating a converter, it will expand or shrink. This movement is signaled to the chamber corresponding to this converter through the compliant foil, said chamber thus experiencing a sudden volume change. As a result, pressure waves are generated inside the chamber, under the influence of which a drop of ink may be ejected from the chamber.
In the known printhead, the converters are grouped into individual blocks, where each block comprises a carrier element on which two converters have been fitted to generate pressure waves in their corresponding chambers, as well as a support element resting on the foil at the level of the wall between the two chambers. The blocks have been fitted to a rear plate having high rigidity in a direction parallel to the chambers, and low rigidity in a direction perpendicular to the chambers. This construction is designed to prevent cross-talk. Cross-talk is the phenomenon caused by actuation of the converter corresponding to a certain chamber, producing a volume change in an adjacent chamber. This (undesired) volume change may lead to pressure waves which may adversely affect the drop ejection process in this adjacent chamber. However, in this known printhead, cross-talk is still a common occurrence. Within one block, for example, there may be a moderate power closure so that deformation of the one converter will almost certainly lead to deformation of the other converter and therefore also to a volume change in the adjacent duct. Another possible or additional cause of volume change in the adjacent chamber is that due to actuation of the converter and the associated pressure waves, the duct plate is locally stretched into a direction parallel to the direction in which the piezo-electric elements extend. This causes cross-talk between two ducts corresponding to separate blocks to also occur in the case of the known printhead.
SUMMARY OF THE INVENTION
The object of the invention is to obviate the problems described above. To this end, a printhead according to the preamble of this description has been invented, characterised in that the wall is deformable in such a way that it deforms by said actuation and as such generates a second volume change in the same chamber simultaneously with the first one, this second change being, in essence, the same size but the opposite of the first change.
This invention is based on the recognition that it will often not be possible to prevent actuation of a converter to produce a volume change in an adjacent chamber. This is because it is difficult to both achieve a full power closure between adjacent converters and prevent stretching of the chambers. The invention now comprises a deformable wall between the chambers, the above-mentioned volume change, in essence, being fully compensated due to said deformation. In the event of an increase in pressure in the first chamber, for example, the volume in the adjacent chamber may suddenly increase due to local stretching of the chambers. This volume change may be fully compensated by bending the wall towards this adjacent chamber. This bending is induced by the sudden pressure increase in the first chamber and may be tuned by the correct choice of assembly and placing of the wall. If, for example, strong deformation is desired, a very thin wall of rigid material (e.g., titanium) may be chosen, said wall being positioned pliably between the chambers. If the effects which lead to a volume change compensate each other, there will thus be a change in the shape of the adjacent chamber, but not a change in volume (which is, in point of fact, an important cause of undesired cross-talk). It should be noted that there is no net volume change in the present invention, i.e., the compensatory effect of the deformation of the wall is such that there is no volume change to potentially lead to undesirable cross-talk. Undesirable cross-talk occurs when print artefacts are produced which are visible to the naked eye. Completely contrary to the theory of known solutions, which usually try and prevent a change in shape of the walls of an adjacent chamber, the present invention shows that this change in shape may, in essence, be used to prevent a volume change of this chamber and as such, is a more important cause of undesired cross-talk.
In one embodiment, in the event of actuation of the converter which corresponds to the first chamber, the radial diameters of the second chamber, in essence, remain constant. In this embodiment, the wall is formed and placed in the printhead in such a way that it may not only prevent a net volume change of the adjacent chamber due to a compensatory deformation, but may also allow the radial diameters of the chamber (perpendicular to the length axis) to be, in essence, constant as a result of the deformation. In this respect, it is not the shape of the diameter that is referred to but the diameter as surface dimension. Practice has shown that generation of pressure waves in the adjacent chamber may thus be virtually eliminated altogether so that a further improvement occurs in preventing undesirable cross-talk. Also in this embodiment, the shape of the adjacent chamber may vary greatly by actuation of the converter corresponding to the first chamber, but as the radial diameters do not change, no ink replacement will, in essence, occur in axial direction. It will thus be possible to prevent the occurrence of pressure waves which can noticeably affect the drop ejection process.
In one embodiment, the wall has an E modulus (Young's modulus) smaller than 60 GPa. In this embodiment, the wall between the chambers is made from a relatively easily deformable material. This means that the wall can be made relatively thick without restrictions in deformability arising. The advantage of this is that it will be relatively simple to produce the element in which the chambers are formed, separated by walls. In another embodiment, the wall is, in essence, made from carbon. This material combines the special advantages of low rigidity, typically 14 Gpa, and good machinability, so that it is relatively simple to form the elements in which the chambers and walls are joined. In yet another embodiment, the wall is fitted to a carrier plate which is, in essence, made from the same type of carbon. In this embodiment, the chambers and walls may easily be made by milling the chambers from a carbon element, which automatically produces a carbon wall between the chambers. When selecting a certain type of carbon, the wall thickness and height requirements may be determined based on experiments or a model that may be applied in accordance with the present invention.
In one embodiment, the invention also relates to an inkjet printer comprising a printhead as described above. Such a printhead may be applied without producing undesirable print artefacts in a printed image.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be further explained with reference to the following drawings and examples, wherein:
FIG. 1 shows an inkjet printer;
FIG. 2 is a perspective view of the duct plate with assembly; and
FIG. 3 shows a cross-section of the assembly with measurements and a description of the deformations (effect, bending and stretching).
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a diagram showing an inkjet printer. According to this embodiment, the printer comprises a roller 1 used to support a receiving medium 2 , such as a sheet of paper or a transparency, and move it along the carriage 3 . The carriage includes a carrier 5 to which four printheads 4 a, 4 b, 4 c and 4 d have been fitted. Each printhead contains its own color, in this case cyan (C), magenta (M), yellow (Y) and black (K) respectively. The printheads are heated using heating elements 9 , which have been fitted to the rear of each printhead 4 and to the carrier 5 . The temperature of the printheads is maintained at the correct level by the application of a central control unit 10 (controller).
The roller 1 may rotate around its own axis as indicated by arrow A. In this manner, the receiving medium may be moved in the sub-scanning direction (often referred to as the X direction) relative to the carrier 5 , and therefore also relative to the printheads 4 . The carriage 3 may be moved in reciprocation using suitable drive mechanisms (not shown) in a direction indicated by double arrow B, parallel to roller 1 . To this end, the carrier 5 is moved across the guide rods 6 and 7 . This direction is generally referred to as the main scanning direction or Y direction. In this manner, the receiving medium may be fully scanned by the printheads 4 .
According to the embodiment as shown in FIG. 1 , each printhead 4 comprises a number of internal ink chambers (not shown), each with its own exit opening (nozzle) 8 . The nozzles in this embodiment form one row per printhead perpendicular to the axis of roller 1 (i.e., the row extends in the sub-scanning direction). In a practical embodiment of an inkjet printer, the number of ink chambers per printhead will be many times greater and the nozzles will be arranged over two or more rows. Each ink chamber includes a piezo-electric converter (not shown) that may generate a pressure wave in the ink chamber so that an ink drop is ejected from the nozzle of the associated chamber in the direction of the receiving medium. The converters may be actuated image-wise via an associated electrical drive circuit (not shown) by application of the central control unit 10 . In this manner, an image made up of ink drops may be formed on receiving medium 2 .
If a receiving medium is printed using such a printer where ink drops are ejected from ink chambers, the receiving medium, or some of it, is imaginarily split into fixed locations that form a regular field of pixel rows and pixel columns. According to one embodiment, the pixel rows are perpendicular to the pixel columns. The individual locations thus produced may each be provided with one or more ink drops. The number of locations per unit of length in directions parallel to the pixel rows and pixel columns is referred to as the resolution of the printed image, for example indicated as 400×600 d.p.i. (“dots per inch”). By actuating a row of printhead nozzles of the inkjet printer, image-wise, when it is moved relative to the receiving medium as the carrier 5 moves, an image, or some of it, made up of ink drops is formed on the receiving medium, or at least formed in a strip as wide as the length of the nozzle row.
FIG. 2 is a diagram showing an inkjet printhead 4 in which the present invention may be applied. This printhead comprises a carrier 21 having a surface 21 a on which two piezo-electric converters 24 a and 24 b have been fitted. These converters may be actuated by imposing electrical pulses via electrodes 25 a and 25 b respectively. The carrier furthermore comprises support elements 21 b which are involved in carrying the compliant foil 26 onto which the ink chamber structure is fitted. This foil is fitted to the tops 29 a and 29 b of the piezo-electric converters. In this schematic embodiment, only two ink chambers 27 a and 27 b have been shown for the ink chamber structure, separated by the deformable wall 22 . The ink chambers open into nozzles 8 a and 8 b . The chambers are closed by plate 23 , said plate comprising an inlet opening 23 a which may be used for feeding ink into the chambers.
FIG. 3 is a diagram showing a different embodiment of an inkjet printhead in which the present invention has been embodied. The diagram shows a cross-section of the inkjet printhead 40 . In this embodiment, the printhead comprises a carrier 31 on which the converters 34 a and 34 b have been placed, as well as the support elements 31 b . The carrier has a thickness y of 1 mm and has been made from Thomit 600, a ceramic aluminum and oxide containing material originating from Ceramtec from Marktredwitz (Germany). Elements 31 and 34 are multi-layer piezo-electric (generally applied PZT material) elements with a height x of 650 μm and a thickness m of 85 μm. Onto this has been fitted the compliant foil 36 , which in this embodiment is a 10 μm thick Upilex polyamide foil (E modulus 9 Gpa). The ink chambers 37 a and 37 b are shown having a width l of 200 μm and a height z of 140 μm. These chambers are milled into a 2 mm thick carbon plate 33 producing inner walls 32 having a thickness k of 140 μm. As these walls are made from carbon, they may deform in a direction parallel to direction D as indicated. The chosen thickness k, together with the wall configuration as a component of plate 33 mean that they will deform relatively easily if the pressure inside a chamber changes.
If, for example, piezo-electric converter 34 a is actuated, then the adjacent chamber 37 b will be subject to a volume change by pressure waves generated as a result of this chamber being stretched in direction C as indicated (in which the piezo-electric elements extend). However, actuation also increases the pressure inside chamber 37 a, causing the wall 32 to deform towards chamber 37 b . The selected configuration is such that it induces a volume change in chamber 37 b, which is (virtually) fully compensated by the above-mentioned volume change of chamber 37 b as a result of the chamber being stretched. As such, chamber 37 b will not be subject to a net volume change due to actuation of converter 34 a . Practice has also shown that, in this embodiment, the radial diameters in chamber 37 b do not change when converter 34 a is actuated. This, in essence, prevents the occurrence of pressure waves in chamber 37 b, so that cross-talk can be forced back even further.
In one embodiment, where a more rigid material is selected for the wall, this will need to be made thinner and/or configured differently so that it retains adequate deformability. The construction of the wall will also depend on whether full power closure will exist or not between the piezo-electric converters via carrier element 31 . If there is no full power closure, then actuation of the converter which corresponds to a certain chamber will induce a volume change in an adjacent chamber that increases as the power closure deteriorates. To compensate for this volume change, the wall will therefore need to deform to a greater extent upon actuation.
|
A inkjet printhead containing two substantially closed ink chambers separated by a wall, each of the chambers having associated therewith an electro-mechanical converter, where actuation of the converter corresponding to a first chamber of said printhead will lead to a volume change in a second chamber due to cross-talk, whereby the wall is deformable in such a way that it deforms by actuation and as such simultaneously generates a second volume change in the same chamber, either volume change being, in essence, the same size but opposite to the other.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of U.S. patent application No. 970,968, now abandoned which was a continuation of U.S. patent application Ser. No. 835,970, also now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a wear-resistant alloy.
In overhead camshaft internal combustion engines a valve rocker arm such as 1 shown in FIG. 1 is often incorporated for transmitting the rotational movement of a camshaft to an intake or exhaust valve so as to reciprocate it. The valve rocker arm has a pad face 2 at its one end portion which contacts the cam lead face of the camshaft and is driven thereby. Therefore it is desired that the pad face should have high wear resistance and tenacity.
Because of this, there have been proposed various special materials for use as the pad face, or various surface treatments to be applied to the surface of the pad face, such as chromium plating, chilling of cast iron, nitriding, etc. However, these conventional treatments have not yet provided satisfactory results. Chromium plating is liable to exfoliate in use, while chilling of cast iron and nitriding are not satisfactory with regard to wear resistance.
In recent years, it has become known to spray wear resistant alloy such as stellite and self-fluxing alloy by the spray-fuse process onto the pad face, or to make the pad face portion out of a low cast iron including small amounts of Cr, Mo, etc.. However, these conventional materials appear to be unable to match up to ever-increasing requirements for the pad faces of valve rocker arms.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a material for making the pad face of a valve rocker arm which itself has high wear resistance and yet causes lesser wear of a co-operating member and further has good workability, low melting point, and good self-fluxing characteristic.
According to the present invention, the aforementioned object is accomplished by a wear-resistant alloy consisting essentially of about 30%-60% Ni, 6%-10% Si, 0.5%-3% B, 0.5%-2% C, 2%-8% carbide and boride forming element selected from Cr, Mo, and W, and 30%-60% Fe.
The abovementioned composition was found to be good for the following reasons:
If Ni content is less than 30%, workability and grindability of the alloy is seriously reduced, while, on the other hand, if Ni content exceeds 60%, wear resistance of the alloy deteriorates. Therefore, the Ni content is desired to be in the range 30%-60%.
As Si content increases, the amount of silicides formed with Ni and Fe increases, whereby hardness and wear resistance of the alloy increase. On the other hand, however, the alloy becomes brittle, i.e. its impact value decreases.
If Si content is less than 6%, generation of the Ni-Fe silicides is insufficient, so that the micro-Vicker's hardness becomes as low as 400, thereby resulting in poor wear resistance. If Si content exceeds 10%, although the alloy becomes harder, it becomes too brittle, and becomes more liable to suffer cracking in grinding as well as in use, thereby causing damage such as pitting, scuffing, etc.. Therefore Si content is desired to be 6%-10%.
B is incorporated in the alloy as solid solution and also generates borides with Fe, Ni, and Cr, or similar elements such as Mo and W. The borides thus generated and B incorporated in the alloy as solid solution increase strength of the alloy. Further, B, when it exists with Si in the alloy, lowers melting temperature of the alloy and gives the alloy self-fluxing characteristic. If the amount of B is too small, generation of borides is insufficient, so that the alloy is given no effective increase of hardness and no effective self-fluxing characteristic. On the other hand, if the amount of B is too large, impact value of the alloy lowers too much, with simultaneous deterioration of grindability and generation of scuffing. In view of these and in accordance with the results of experiment explained later, B content should be in the range 0.5%-3%.
C generates carbides together with Cr, Mo, and W, and thereby increases hardness of the alloy. However, if its content is less than 0.5%, no effective increase of hardness is available. On the other hand, if C content is higher than 2%, the alloy becomes so hard as to cause scuffing of a member co-operating with the rocker arm. Therefore, C content should be in the range 0.5%-2%.
Cr, Mo and W generate carbides and borides by being combined with C and B, respectively. If the amount of these elements is less than 2%, no effective increase of hardness is available, while if it increase beyond 8%, moldability by welding of the alloy becomes poor. Therefore, the amount of these carbide and boride forming elements should be in the range 2%-8%.
Finally, it is also important that the amount of Fe should be in the range 30%-60%. Fe is indispensable for generating Ni-Fe silicides, while it is one of the base materials of the alloy, and is less expensive than the other base material, i.e. Ni. Table 1 shows a result of experiments performed in order to confirm the effect of Fe content in the alloy of the present invention. These results were obtained by varying the Fe content from 10%-70% in an alloy which contained 8.5% Si, 1.0% C, 5.0% Cr, and the balance Ni. If Fe increases beyond 60%, silicides generated in the alloy becomes richer in Fe-silicide, whereby the alloy becomes harder but undesirably more brittle, and causes heavy wearing of itself as well as the co-operating member. On the other hand, if Fe decreases below 30%, although the impact value of the alloy increases, its wear resistance unduly decreases. Therefore, in view of its own characteristics, and in view of balancing the desirable amount of Ni, the Fe content should be approximately 30 %-60%.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings and photographs, which are given by way of illustration only and thus are not limitative of the present invention, and wherein:
FIG. 1 is a side view of a valve rocker arm having a typical structure;
FIG. 2 is a graph showing comparison of a conventional material for a valve rocker arm and the alloy of the present invention with regard to wear resistance; and
FIGS. 3a, 3b, and 3c are microphotographs of several alloys which give the basic to the present invention, for explaining proportions of Si in the alloy of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
First some wear resistant alloys which were disclosed in the parent application Ser. No. 970,968, now abandoned, and give the basis to the present invention will be described, in order to establish the background to the present invention, and to explain the reasons for the percentages claimed for elements other than B.
Alloys were prepared by changing the Si content in the range of 3.0%-14.0%, in an alloy which also contained 44.1% Ni, 1.0% C, 5.1% Cr, and balance Fe. The alloys were examined by a microscope. As a result, it was found that the alloys were composed of silicides of Ni and Fe, chromium carbide, and Fe-Ni-Si base. In more detail, if Si content is increased, more silicides (having micro-Vicker's hardness of 800-900) are formed, whereby wear resistance is improved, while the alloy becomes brittle. On the contrary, if Si content is decreased, formation of silicides is reduced, whereby wear resistance deteriorates in spite of the existence of carbides.
The microphotographs of FIGS. 3a, 3b, and 3c show the structures of the above alloys including 4%, 6%, and 8% of Si, respectively. The magnification of these photographs is 400. In accordance with EPMA, it was found that portions (a) were phases of solid solution of Fe-Ni-Si-Cr having a relatively low micro-Vicker's hardness such as 380-460, that portions (b) were carbides having hardness of 1100-1500, and that portions (c) were silicides of nickel and iron having hardness of 800-900. When the alloy's Si content is 4% (photograph FIG. 3a) its silicide content is relatively low, as 15%-25% (surface ratio) and its hardness is also low, such as lower than 500. When its Si content increases to 6% (photograph 3b) and to 8% (photograph 3c) its silicide content increases to 25%-45% and 30%-65% respectively, and its hardness also increases to above 550 and above 600, respectively.
Table 2 shows a result of experiments with regard to the relation of silicide content and wear resistance to Si percentage. From these results, it is noted that increase of Si content increases formation of silicide, improves wear resistance, but causes brittleness, while decrease of Si content decreases the formation of silicides, improves impact resistance, but worsens scuff and wear resistance.
From the test results, it is noted that wear of the alloy slightly increases when its Si content is reduced down to 6% and abruptly increases when its Si content is reduced to below 4%. If Si content is above 6%, the value of Si content has no substantial effect on wear. However, when Si content increases beyond 10%, silicide content increases above 85%, and further when Si content becomes 14%, the alloy is almost completely composed of silicides, thereby causing difficulty with regard to grindability. Wear resistance is largely influenced by silicides, and it is desirable that silicide content should be above 15%, particularly between 25%-75%.
The effect of Si content in such an alloy was tested with regard to the relation between impact value and hardness. Table 3 shows the results of the test. From these results, it is clear that impact value becomes higher when Si content lowers. When Si content increases, hardness also increases while impact value lowers, thereby making cracks more liable to occur.
EXAMPLE 2
In order to make clear the effect of variation of the amount of carbide in the alloys of Example 1, three kinds of alloys were prepared to have compositions: 44.1% Ni--8% Si--balance Fe, 44.1% Ni--8% Si--5.1% Cr--1.0% C--balance Fe, and 44.1% Ni--8% Si--5.1% Cr--2.0% C--balance Fe. Hardness of these alloys was tested and found to be in the range 56-58 by Rockwell C scale. The hardness thus obtained showed the tendency of increasing slightly when C content increased. However, it was noted that C content did not contribute very much to the hardness. On the other hand, if C conent increases beyond 2%, the amount of polygonal carbide increased, thereby enhancing the tendency of causing scuffing of co-operating members.
EXAMPLE 3
These above-described alloys can be used for casting, weld-padding, sintering, weld-spraying, etc.. In any event, it is desirable that the melting point of the alloy should be low, in view of workability and energy economy. According to the present invention, it was found that the melting point of such wear resistance alloys as described above was lowered by adding B thereto. In fact, by adding 1.5% of B to the alloy of 44.1% Ni--8.0% Si--5.1% Cr--1.0% C--40.3% Fe described in Example 2, the melting point lowered by about 100°-120° C. When B was added to the aforementioned alloy in amounts of 1.0%, 3.0%, and 5.0%, respectively, it was found that, when more than 3% of B was added, more borides were formed than silicides, and accordingly scuff resistance lowered. Furthermore, it was found that B is effective for lowering melting point only when it does not exceed 4%, while if it exceeds 4%, the melting point rather rises.
EXAMPLE 4
In order to see the effect of B on the hardness, moldability, and grindability of the alloy, we prepared alloys by changing B content from zero to 4% while maintaining the condition of 44.1% Ni--7% Si--1.0% C--5.1% Cr--balance Fe, and tested them. Table 4 shows the results of the test. If B content is lower than 0.3%, self-fluxing characteristic becomes poor, thereby deteriorating moldability of the alloy. If B content is higher than 4%, borides content becomes undesirably high, thereby causing cracks and deteriorating grindability. In view of these facts, it is desirable that B content should be in the range 0.5%--3%.
EXAMPLE 5
Atomizing powder having grains of smaller than 100 mesh of 1.5% C--8.2% Si--1.0% B--5.1% Cr--44.5% Ni--balance Fe was sprayed by means of a thermospray process employing hydrogen--oxygen gases onto the pad face of a rocker arm to the thickness of 1.0-1.2 mm, said pad face having been beforehand treated by the processes of degreasing--rinsing--drying--shotblasting. The sprayed layer was kept in a vacuum furnace having the conditions of 1020° C.-1030° C. and 0.01 mm Hg for 20-30 minutes and thereafter was cooled down in air. The pad face thus formed showed a good appearance and sectional structure free from any hanging portion, exfoliated portion, or other undesirable features.
The grain size of the powder and the spray and fusing conditions have an effect on the condition of the surface and the sectional structure of the coated layer. In more detail, when the grain size is large, the sprayed layer becomes perforated and shows poor pitting resistance. On the other hand, if the grain size is too small, the yield rate of the material in the powder making process is too small, thus increasing the cost of making the powder. Further, the time required for spraying becomes longer, and exfoliation is more liable to occur. Judging from the results of the test, grain size of 100 mesh to 20 microns is desirable. However, in order substantially to reduce perforations in the coated layer, it is more desirable to employ grain size of 200 mesh-20 microns.
The temperature condition for fusing was also examined. Temperatures lower than 950° C. are liable to cause unfused portions, while temperatures higher than 1040° C. are liable to cause hanging down of the surface. In view of this, temperatures between 960° C.-1040° C. are desirable.
With regard to the atmosphere for fusing, in view of the face that the alloy includes a large content of Fe and that perforations exist in the coated layer, an inactive atmosphere, a reducing atmosphere, or vacuum is desirable.
EXAMPLE 6
Rocker arms were prepared to have the pad faces formed by hard chromiun plating (A), by padding of chilled cast iron FC 30 (B), by padding of a nickel base self-fluxing alloy (D), and by padding of the wear resistant alloy of the present invention (C), and were assembled in the cam mechanism of an overhead cam engine rebuilt to be driven by an electric motor for the purpose of testing wear resistance of these pad faces. The wear resistant alloy of the present invention had the composition of 44.5% Ni--8.2% Si--1,0% B--1.5% C--5.1% Cr--balance Fe. The testing conditions were as follows: Engine rotational speed: 600 rpm, contact surface pressure: 70 kg/mm 2 ; material of co-operating member (i.e., camshaft): chilled cast iron; lubricating oil: Castle SAE 10W-30; temperature of lubricating oil: 80° C.; test duration: 1000 hours. The results of the test are shown in FIG. 2, wherein bars A, B, C, and D show wear of the pad faces of the aforementioned kinds A, B, C, and D, respectively. As apparent from this figure, although the alloy of the present invention is slightly inferior to the conventional nickel base self-fluxing alloy and chromium plating with regard to its own wear, it is superior to these conventional materials with regard to the wear of the co-operating member, so that the wear of the co-operating member is reduced to about one third. When compared with the chilled FC30 cast iron, the alloy of the present invention is superior to this with regard to both its own wear and that of the co-operating material. From the foregoing, it will be appreciated that the wear resistant alloy of the present invention has very improved characteristics with regard to its own wear as well as with regard to the wear of the co-operating member.
Although the invention has been shown and described with reference to some preferred embodiments thereof, it should be understood that various changes and modifications can be made therein by one skilled in the art, without departing from the scope of the invention, which it is therefore desired should be defined solely by the appended claim.
TABLE 1______________________________________ Wear (rubbing test) Impact Area of Wear ofFe % Hardness value wear of rubbing(by (Vick- (kg . m/ itself memberwt.) er's) cm.sup.2) (mm.sup.2) (mg) Remarks______________________________________10 450-500 0.35 14.30 0.95 heavy wear of itself20 470-500 0.35 10.10 0.45 considerable wear of itself30 500-520 0.30 8.82 0.20 good wear resistance50 580-630 0.28 8.86 0.20 good wear resistance60 660-680 0.23 9.10 0.25 good wear resistance70 680-700 0.15 12.50 1.25 heavy wear of itself and rubbing mem- ber poor work- ability poor grind- ability______________________________________Test conditions:Rotational speed: 3400 rpmRubbing member: 30.sup.φ × 5mm chilled cast ironLoad: 35 kgTime: 5 hoursOil: Spindle oil (at 70°)
TABLE 2______________________________________ Wear (rubbing test) Silicide Wear ofSi % content % Area of rubbing(by (surface scar memberweight) ratio) (mm.sup.2) (mg) Remarks______________________________________14 almost 8.95 0.2 poor grindability 10012 65-90 8.83 0.18 relatively poor grindability10 55-85 8.80 0.2 good grindability8 30-65 8.85 0.2 good grindability6 25-45 8.92 0.2 good grindability4 15-25 11.00 0.9 slight scruffing3 below 15 15.32 2.7 scruffing and wear of rubbing member______________________________________Test conditions:Rotational speed: 3400 rpmRubbing member: 30.sup.φ × 5mm chilled cast ironLoad: 35 kgTime: 5 hoursOil: Spindle oil (at 70° C.)
TABLE 3______________________________________ Impact valueSi % Hardness (Vicker's) kg-cm/cm.sup.2______________________________________>12 >700 0.1-0.2512 >700 0.1-0.2510 -700 0.2-0.258 600- 0.27-0.326 550- 0.37-0.484 400- 0.46-0.60<4 <400 0.60-______________________________________
TABLE 4______________________________________ HardnessB % (Vicker's) Moldability Grindability______________________________________0 -500 poor good0.3 -510 poor good0.5 520-560 good good1.0 540-600 good good2.0 580-630 good good3.0 600-650 good good4.0 650- good poor______________________________________
|
A wear resistant alloy having the composition of 30%-60% Ni, 6%-10% Si, 0.5%-3% B, 0.5%-2% C, 2%-8% carbide and boride forming element selected from Cr, Mo, and W, and 30%-60% Fe, wherein Si and B form silicides and borides, respectively, of Ni and Fe of the desirable density to provide a good balance between hardness, strength, fusibility, grindability, brittleness, etc. of the material, and to maintain its melting point as low as possible and to allow for good self-fluxing characteristic and moldability.
| 2
|
This is a continuation of co-pending application Ser. No. 257,108, filed Oct. 13, 1988, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an electric motor drive for a spindle of a spinning machine. More particularly, the present invention relates to an electric motor drive for a spindle rotatably supported in a bearing housing on the spindle bank of the spinning machine wherein a rotor is fixedly mounted on the spindle for driving by a stator mounted on the spindle bank.
The assignee of the present application is also the assignee of U.S. Pat. Nos. 4,904,892 and 4,905,534, each of which is directed to an invention which relates to the invention of the present application.
In a conventional electric motor drive having a stator and a rotor, the efficiency of the motor is increased if the radial spacing between the rotor and the stator is decreased. Additionally, the efficiency of the motor is increased if the radial spacing between the rotor and the stator is maintained at a uniform value.
SUMMARY OF THE INVENTION
The present invention provides an electric motor drive for driving the spindle of a spinning machine having a stator to which the axial, shear and tilting movements of the spindle can be transferred to the stator so that the space between the two can be efficiently minimal and the stator can absorb such movements so as to serve as a dampening element to minimize vibration of the spindle.
According to the present invention, the stator is mounted on an interconnecting member, which in turn is mounted on a sleeve that is mounted on the spindle bank, with a resilient member between the sleeve and interconnecting member and received in a recess in one or in recesses in both of the sleeve and interconnecting member. Preferably, up to one half of the extent of the resilient member is received in the recess or recesses, and the resilient member is adhered to the sleeve and the interconnecting member. With this construction differential spring rigidity characteristics of the resilient member which result from the various tension, compression and shear forces exerted upon it are, in the axial and radial directions, controlled toward a uniform value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-section of an electric motor drive of one preferred embodiment of the present invention;
FIG. 2 is a vertical cross-section of the resilient element and the cooperating electric motor mounting structure of one modification of the preferred embodiment of the present invention; and
FIG. 3 is a schematic representation of a coordinate system defining the degrees of movement of a spindle of a spinning machine driven by an electric motor with the mounting of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a preferred embodiment of the mounting of the present invention is illustrated on a spinning station 10 of a spinning machine and, in FIG. 2, one modification of the preferred embodiment shown in FIG. 1 is illustrated. At the spinning station 10, a spindle 13 is rotatably supported on a bearing housing 12 which is fixedly mounted on a spindle bank 11 of the spinning machine. The spindle 13 includes an inner axial portion 23 rotatably supported by means of a foot bearing 29, shown in FIG. 2, on the bearing housing 12 and an outer axial portion 24 coaxial with and fixedly mounted to the inner axial portion 23 and having a bell-like sleeve for surrounding the upper axial portion of the bearing housing 12.
A rotor 14 is coaxial with and fixedly mounted to the outer axial portion 24 of the spindle 13, and is rotated by a stator 15 in which the rotor is centrally disposed. The stator 15 includes a magnetic core 16 of generally square configuration, which can be a stack of individual magnetically active plates, and a plurality of coils 30. The four corner regions of the magnetic core 16 have a plurality of brackets 17 mounted thereto for securing the individual plates of the magnetic core 16 in stacked relation. The brackets 17 retain the individual plates in stacked relation with and are mounted to an interconnecting member 18 which is fixedly mounted by means of a collar to the bearing housing 12. Each bracket 17 includes an inwardly facing arcuate shoulder 31 on its lower axial end for cooperating with a compatibly configured cylindrical surface of the interconnecting member 18 to center the magnetic core 16 with respect to the interconnecting member 18. Each bracket 17 is secured to the interconnecting member 18 by a bolt 25 extending through a bore in the interconnecting member and into a threaded bore in the lower axial end of the bracket.
A pair of protective coverings 26 are respectively mounted between the interconnecting member 18 and the magnetic core 16 and above the magnetic core 16. The upper one of the pair of protective coverings 26 extends axially from the top of the magnetic core 16 to a protective cap 27 mounted to the upper axial end of the brackets 17 by a plurality of rivets 28 inserted therethrough into corresponding bores in the brackets.
A resilient element 19 is disposed between the interconnecting member 18 and a sleeve 20 inserted through a bore in the spindle bank 11. The inner diameter of the sleeve 20 is greater than the inner diameter of the bearing housing 12 which is coaxially received therein and the sleeve 20 is fixedly secured to the spindle bank 11 by a nut 22 threaded along the lower axial end of the sleeve.
As best seen in FIG. 2, the interconnecting member 18 includes a recess 21 along its bottom surface such as, for example, an annular recess, for receiving the resilient element 19 therein at least to a portion of its axial extent. The radial extent of the recess 21 is compatibly dimensioned with the radial extent of the resilient element 19 such that the element is snugly received therein. In one modification of the mounting, up to one half of the extent of the resilient element 19 is received within the recess 21. In another modification of the mounting, the resilient element 19 is adhered to the interconnecting member 18 and the sleeve 20.
The axial, tilting and shear movements of the spindle 13 are transferred via the interconnecting member 18 to the resilient element 19. As illustrated in FIG. 3, the axial movement of the spindle is along the Z axis, the tilting movement of the spindle is along the X axis and the shear movement of the spindle is along the X and Y axes. The tipping movement of the spindle is indicated by the vectors theta and beta. Due to the engagement of the resilient element 19 in the recess 21, the different spring rigidity characteristics of the resilient element 19 due to the tension, compression and shear forces generated by the movement of the spindle 13, are controlled to substantially uniform values.
In another embodiment of the apparatus of the present invention, the resilient element 19 is received in, and engaged by, a recess in the top surface of the sleeve 20, which can be a substitute for or in addition to the recess 21 in the interconnecting member 18. In one modification of this embodiment, up to one half of the resilient element 19 is received in the recess of the sleeve 20.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiment, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
|
An electric motor drive for rotatably driving a spindle of a spinning machines has a resilient member positioned between an interconnecting member and a sleeve mounted to the spindle bank of the spinning machine. The resilient member is partially received in a recess in the interconnecting member, the sleeve or both to facilitate the distribution of forces exerted on the resilient member.
| 3
|
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application, Ser. No. 09/350,722, filed Jul. 9, 1999.
FIELD OF THE INVENTION
The present invention relates to an automatic shut-off device for a valve for compressed or liquefied gases comprising a valve body designed to be mounted on a gas cylinder and provided with an internal passage that allows the cylinder to be filled with pressurized gas.
BACKGROUND OF THE INVENTION
Although not restricted thereto, the invention is more specifically aimed at a valve of the type described in Kerger, U.S. Pat. No. 5,282,496, the entire disclosure of which is hereby incorporated by reference in its entirety. This patent relates to a valve for refillable cylinders and which comprises a level-regulating valve to prevent it from being possible for the cylinder to be filled beyond a certain limit, for example 80% of its maximum capacity, so as to avoid potential risks of an accident.
However, there are still risks of an accident either if the cylinders are refilled by non-specialists and do not have level-regulating valves as proposed in the aforementioned patent, or if they are refilled with an inappropriate gas or if the user manages to neutralize the level-regulating valve, or even for other reasons.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a simple and effective automatic shut-off device for a valve like the one described in the preamble and which prevents a gas cylinder from being filled by a non-specialist or unauthorized individual who does not possess special equipment.
In order to achieve this object, the invention provides an automatic shut-off device as described in the preamble which is characterized in that the internal passage has a widened cross section containing a ball sensitive to a magnetic field and of a diameter greater than the diameter of the passage and which acts as a non-return valve element by blocking the passage in the direction of filling, and in that said valve element can be neutralized by shifting the ball sideways under the effect of a magnetic field generated by a magnet placed on the outside of the valve.
In consequence, any attempt at filling the cylinder is bound to fail given that the ball, under the effect of its own weight and the pressure of the filling gas, is pressed against its seat which is formed by the upper edge of the passage and closes the passage toward the inside of the cylinder. Only somebody who knows how to open the passage and is in possession of an appropriate magnet will be able to carry out filling once he has moved the ball off its seat using this magnet.
Any attempt at filling the cylinder with the cylinder lying on its side is also bound to fail. Admittedly, by lying the cylinder down the passage can be opened because the ball, under the effect of its own weight, moves off its seat, but the pressure of the filling gas returns the ball onto its seat and automatically closes the passage.
According to one preferred embodiment, there is a tube made of synthetic material inside the axial passage. The upper edge of this tube serves to form the seat for the ball.
It is also possible to envisage a niche in the region of the ball in the exterior wall of the valve body and which is intended to accommodate a magnet of complementary shape. It is therefore necessary not only to have a magnet available to open the device but, in addition, this magnet has to have a special shape adapted to suit that of the niche.
The valve may also comprise means for preventing the ball from obstructing the upper passage above the widened cross section. These means may consist of a polygonal cross section of this passage or of a spring provided between this passage and the ball.
BRIEF DESCRIPTION OF THE DRAWINGS
Other specific features of the invention will emerge from the description of an advantageous embodiment, presented below by way of an illustration, with reference to the appended drawings in which:
FIG. 1 depicts a partial section view through the body of a valve provided with a first embodiment of an automatic shut-off device according to the present invention in the shut off position;
FIG. 2 is a view similar to that of FIG. 1 but during the neutralization phase;
FIG. 3 depicts a partial section view through the body of a valve provided with a second embodiment of an automatic shut-off device according to the present invention, in the shut off position;
FIG. 4 depicts a view similar to that of FIG. 3, but during the neutralization phase;
FIG. 5 shows a view similar to that of FIG. 3, while gas is being withdrawn from the gas cylinder;
FIG. 6 is a cross section on the section plane VI—VI of FIG. 5, and
FIG. 7 is a partial section view of a third embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The reference 10 denotes part of a valve designed to be mounted on a refillable gas cylinder. The reference to a gas cylinder is not restrictive and extends to cover all kinds of reservoir. This may be a valve as described in Kerger, U.S. Pat. No. 5,282,496 or any other device allowing the cylinder to be refilled, with or without a level-regulating valve, operating as a two-way valve or a one-way valve. Reference can be hade to Kerger, U.S. Pat. No. 5,282,496 for an exemplary application of the invention.
The body 10 has an axial passage 12 communicating with the inside of the cylinder, not depicted. At a certain point, this passage ends in a widened portion 14 containing a spherical metallic ball 16 , preferably made of special steel. This ball normally rests on its seat which is formed by the upper edge of the passage 12 and therefore prevents filling gas from entering the cylinder.
FIG. 2 shows the neutralizing of the device using a powerful magnet 18 which is brought up close to the body 10 of the valve in the region of the ball 16 and whose field is powerful enough to move the ball 16 off its seat and open the passage to the filling gas. The magnet 18 may be a simple permanent magnet.
In order to further complicate the task of anybody wishing to discover how to neutralize the shut-off system and who may avail himself of a magnet in order to be able to fill the cylinder, it is possible to provide a niche in the wall of the body 10 into which niche the magnet has to be introduced. This niche could extend as far as close to the widened portion 14 , and would also then have the further advantage of bringing the magnet even closer to the ball 16 .
FIGS. 3 and 4 show one such embodiment with a cut-out or niche 22 in the wall 10 in the region of the widened portion 14 . The niche 22 may be cylindrical or frustoconical as shown in the figures. In vertical section, in the figures, the niche 22 may have a round or polygonal cross section, for example a triangular cross section. In order to be able to move the ball 16 away from its seat and uncover the passage 12 , it is therefore necessary to have use of a magnet 24 (FIG. 4) which has a shape that complements that of the niche 22 .
In order to further complicate the task of people who are not authorized to fill the gas cylinder, it would be possible, at the bottom of the niche, to provide an axial stem, so that the magnet to be introduced into the niche would have to have a corresponding bore in its head so that it could be introduced into the niche 22 .
In the case of a niche 22 and of a magnet 24 which are cylindrical, it would also be possible to provide these with complementary screw threads, possibly a special thread type, so that the magnet would have to be screwed into the body 10 of the valve. It would therefore be impossible for the shut-off to be neutralized with a magnet that could be sourced on the open market.
In the embodiment of FIGS. 3 and 4, the widened cross section 14 does not need to extend over 360° and may be restricted to a lateral notch in the region of the niche 22 . However, for reasons of ease of manufacture, it may be preferable for the widening 14 to also be provided, in the case of FIGS. 3 and 4, across the entire circumference.
FIGS. 3 and 4 also show, by way of a variation, a tube 26 provided in the passage 12 and the upper edge of which it intended to form the seat for the ball 16 . This tube may be made of synthetic substance, for example nylon, and its purpose is to ensure better shut-off at the ball 16 by comparison with metal-to-metal contact.
If, as is generally the case, the passage 12 is used for the passage of gas when filling the cylinder with gas and withdrawing gas there from, a problem may arise when withdrawing gas. Specifically, as FIG. 5 shows, when withdrawing gas, the gas pressure is enough to lift the ball 16 and hold it against the lower edge of the upper passage 28 which leads to the seat 30 of the non-depicted shut-off member of the valve, which would close the passage 28 and prevent the gas from being withdrawn. To solve this problem it is possible, in the lower part of the passage 28 , to provide an obstacle, for example in the form of a diametral stem which prevents the ball 16 from obstructing the passage 28 .
It is also possible to convert the circular cross section of the passage 28 , at least in the lower region 28 a , into a polygonal cross section, for example a square cross section as shown in FIGS. 3 to 5 and more particularly in the view in cross section that is FIG. 6 . Thus, when the ball 16 is forced against the lower end of the passage 28 there remain several, in this particular instance, four, passages 28 for the gas in the four corners.
FIG. 7 shows another means intended to prevent the passage 28 from being obstructed by the ball 16 when gas is being withdrawn. In this embodiment, there is a spring 34 provided between the ball 16 and the passage 28 which is, for reference, extended downwards by a circular axial flange 32 to ensure that the spring is held. The force of this spring 34 is great enough to keep the ball 16 in a floating state away from the flange 32 during a normal operation of withdrawing gas.
In one advantageous embodiment, it is possible to benefit from the presence of this spring 34 to design it as a flow limiter or safety valve. Such limiters are known per se and are used to shut off the flow of gas when the flow rate or the pressure exceeds a predetermined limit. This may, in particular, arise in the event of an accident, for example if the valve should break. All that is then required is simply for the force of the spring 34 to be rated such that it prevents the passage 28 from being shut off by the ball 16 under normal gas pressure and flow rate conditions but allows shut-off in the event of abnormal operation.
|
The shut-off device is intended for refillable gas cylinders. In order to be sure that only authorized persons can refill the cylinder, the filling device comprises a non-return valve element ( 16 ) which prevents filling and which can only be neutralized using a special magnet ( 18 ).
| 8
|
FIELD OF THE INVENTION
[0001] Embodiments of the present invention generally relate to fishing. Particularly, embodiments of the present invention relate to ice fishing. More particularly, embodiments of the present invention relate to utilities to make ice fishing more enjoyable.
BACKGROUND OF THE INVENTION
[0002] Ice fishing is an activity of catching fish with lines and fish hooks or spears through an opening in the ice on a frozen body of water. Ice anglers may sit on the stool in the open on a frozen lake, or in a heated cabin on the ice, some with bunks and amenities.
[0003] It is a popular pastime in Canada, Finland, Estonia, Norway, Sweden and Germany. In the United States, people from Alaska, Colorado, Montana, Minnesota, Wisconsin, Michigan, New York, the states of New England and other areas with lakes and long, cold winters enjoy the activity.
[0004] Ice fishing gear is highly specialized. First, an ice saw, auger or chisel is required to cut a circular hole or larger rectangular hole in the ice. Power augers are sometimes used. A skimmer is used to remove new ice as it forms and to clear slush left from making the hole. During colder periods most ice anglers choose to carry a heater of some type. The heater is for warmth and it also keeps an anglers fishing hole from freezing. When temperatures reach −20° F. or colder it becomes very hard to keep a fishing hole open.
[0005] Three main types of fishing occur. Small, light fishing rod with small, brightly colored lures or jigs with bait such as waxworms, fat heads or crappie minnows. Tip-ups, which carry a line attached to a flag which “tips up” when a strike occurs, allow unattended or less-intensive fishing. The line is dragged in by hand with no reel. In spear fishing a large hole is cut in the ice and fish decoys may be deployed. The fisherman sits in a dark ice shanty called a dark house. The fisherman then peers into the water while holding a large spear attached to a line waiting for fish to appear. This method is often used for lake sturgeon fishing. In the United States, many states allow only rough fish to be taken while spear fishing.
[0006] Becoming increasingly popular is the use of a flasher, similar to its summer cousin the fish finder. This is a sonar system providing depth information, as well as indicating the presence of fish or other objects. These flashers, unlike most typical fish finders, display the movement of fish and other objects almost instantaneously. The bait being used can often be seen as a mark on the flasher, enabling the angler to position the bait right in front of the fish. Underwater cameras are also now available which allow the user to view the fish and observe their reaction to the lure presentation.
[0007] Longer fishing expeditions can be mounted with simple structures. Larger, heated structures can make multi-day fishing trips possible, but these are eschewed by many seasoned fishers, who fish with no protective structure, attired only in heavy winter wear.
[0008] A structure with various local names, but often called an ice shanty, ice shack, fish house, shack, bobhouse, or ice hut, is sometimes used. These are dragged or trailered onto the lake using a vehicle such as a snowmobile, ATV or truck. The two most commonly used types are portable and permanent. The portable houses are often made of a heavy material which is usually water tight. The two most common types of portable houses are when your shelter flips behind the user when not needed, or a pop up shelter so the only means out is through a door. The permanent shelters are made of wood or metal and usually have wheels for easy transport. They can be as basic as a bunk heater and holes or having satellite TV, bathrooms, stoves, full size beds and may appear to be more like a mobile home than a fishing house.
[0009] In North America, ice fishing is often a social activity. Some resorts have fish houses rented out by the day, often; shuttle service via Snow Track or other vehicles modified to drive on ice is provided. In Finland, solitary and contemplative isolation is often the object of the pastime. In Finland, fishhouses are a rare occurrence, but wearing a sealed and insulated drysuit designed of space-age fabric is not. In North America, houses appear to create a city at locations where fishing is best.
[0010] When fishing in a trap-style portable ice shelter the user typically has ice as the floor. The ice, of course, can be very slippery and can melt when using a heater in the portable ice shelter. Prior trap-style portable shelters typically have a pull-over shelter with no floor. The ice can make entering and exiting the shelter dangerous as a slip hazard.
[0011] There currently exist portable ice shelters having floors, however they cannot be used for the trap-style ice shelters.
[0012] The present invention is different from the cabin-style ice shelter floors because it isn't attached to the ice shelters. It is lightweight and removable and can be used separately from the trap-style ice shelter. There isn't a removable, foldable floor on the market to be used with the trap-style portable ice shelters. Our two containers provide storage and convenience for transporting fishing equipment and live bait to and from your ice shelter. Past containers were placed behind the seats of the ice shelter which made organization and access hard to achieve.
[0013] Further, a fisherman would typically need many storage buckets to transport bait and fishing equipment. There are current containers/tackle boxes used for transporting fishing equipment and bait; however, they do not allow easy access to the equipment without the angler needing to reach behind himself or even get up and move. Present containers further do not allow for an angler's equipment to remain stored until the next time they fish.
[0014] It would be desirable to have a floor for ice fishing which would insulate the fisherman from the cold of the ice, prevent the fisherman from slipping on the ice and provide precut holes for directly drilling fishing holes in the ice. It would be desirable to have a floor for ice fishing which was portable. It would be desirable to have a chest for carrying bait and other fishing implements. It would be desirable to have a chest having lighting for shinning on an ice hole. It would be desirable to have a fishing chest having holders for ice fishing rods.
SUMMARY OF THE INVENTION
[0015] In some embodiments, a portable floor may include one or more of the following features: (a) a pre-cut hole for an ice fishing auger, (b) at least one handle attached to the top surface, (c) a plug to fit into and cover the pre-cut hole, and (d) a slot in a portion of the plug.
[0016] In some embodiments, a portable floor may include one or more of the following features: (a) a frame having a top surface and a bottom surface, (b) a pre-cut hole in the floor adapted to allow a ice-fishing auger, (c) a plug to cover the at least one hole, (d) a container which is attachable to the floor, the container having a hinged top lid providing access to the interior of the container and a fishing rod holder, (e) an insulated material located adjacent to the frame, (f) a non-slip material coupled to the top surface, and (g) a means for coupling the container to the floor.
[0017] In some embodiments, a container may include one or more of the following features: (a) a door providing access to the interior of the container, (b) a handle, (c) a fishing rod holder, (d) a battery-powered light protruding from an exterior of the container, (e) a removable false bottom, (f) an additional sealable compartment disposed in the interior of the container for accommodating live fishing bait, (g) at least one cup holder attached to the exterior of the container, and (h) a locking mechanism on the hinged top lid for securing the container lid.
DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a trap-style ice fishing house in an embodiment of the present invention;
[0019] FIG. 2 shows a portable ice fishing floor in an embodiment of the present invention;
[0020] FIG. 3 shows a portable ice fishing floor in an embodiment of the present invention;
[0021] FIG. 4 shows a portable ice fishing floor in an embodiment of the present invention;
[0022] FIG. 5 shows an upper front profile view of containers in an embodiment of the present invention;
[0023] FIG. 6 shows a rearview profile view of containers in an embodiment of the present invention;
[0024] FIG. 7 shows atop profile view of a container in an embodiment of the present invention; and
[0025] FIG. 8 shows a top profile view of a container in an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The following discussion is presented to enable a person skilled in the art to make and use the present teachings. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the present teachings. Thus, the present teachings are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the present teachings. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of the present teachings.
[0027] Embodiments of the present invention disclose a fold-up floor designed for trap-style portable ice shelters. Embodiments of the present invention provide relief from sitting on the ice. Embodiments of the present invention help insulate and provide a non-slip surface for entering and exiting an ice shelter. The fold-up floor could also be used as a flotation device if the user ever fell through the ice. The floor could also be used for fisherman without a shelter who wish to fish directly on the ice. Embodiments of the present invention can fold in half and fit into a case for an ice shelter making it convenient and easy to transport two storage containers used for transporting equipment, rods, live bait and lights.
[0028] Embodiments of the present invention disclose a removable, foldable and insulated floor which can fold and fit in a sled base of a trap-style portable ice shelter. Embodiments of the present invention also disclose storage containers used for transportation of fishing equipment and live baits (e.g., minnows).
[0029] Embodiments of the present invention disclose a foldable floor and two containers. The floor provides utility, warmth, safety and comfort. One container provides a portable way to transport live bait. Another container can provide a portable way to transport fishing equipment and rods to and from the ice house. The containers can set up on the floor providing the comforts of a permanent ice house without losing the versatility of a portable ice shelter.
[0030] Embodiments of the present invention provide a safe non-slip floor ice fisherman can use with or without trap-style ice shelters. The containers can limit the amount of cases or buckets needed to house fishing equipment and rods. The containers can be removable and fishing equipment can remain stored until the next outing. Another container can be a portable bait bucket allowing anglers to use multiple kinds of bait. Bait can be stored in the container until the fisherman's next outing. The floor can be transported within an ice shelter and the containers can eliminate the need for other storage containers. Everything you need for ice fishing would be contained and transported in our prototype.
[0031] With reference to FIG. 1 , a trap-style ice fishing house in an embodiment of the present invention is shown. Trap-style icehouse 10 (icehouse) is a portable icehouse. Icehouse 10 typically folds from front 12 to back 14 in an accordion-like fashion along a metal frame 16 . Icehouse 10 is shown fully erected; however, when icehouse 10 is broken down, as just described, it is typically small enough to be stored in tub 18 shown at the back of icehouse 10 . Tub 18 typically can support chairs 20 and allow the angler to store other items within tub 18 . Also shown in FIG. 1 , and in accordance with embodiments of the present invention is a portable ice fishing floor 22 (floor) and portable ice fishing containers 24 and 26 .
[0032] With reference to FIG. 2 , a portable ice fishing floor in an embodiment of the present invention is shown. Floor 22 is shown being substantially square; however, it is fully contemplated floor 22 could be most any shape, such as circular, triangular, rectangular or oval, without departing from the spirit of the invention. Floor 22 can have a handle 28 to make it easy for an angler to lift floor 22 off the ice when the angler is finished ice fishing. When picking up floor 22 for transport, floor 22 will typically fold in half along axis 30 which runs from side 32 to opposite side 34 . Also shown are plugs 36 which cover ice fishing precut holes 38 . FIG. 2 shows 4 precut holes 38 ; however, it is fully contemplated most any realistic number of precut holes 38 could be within floor 22 without departing from the spirit of the invention. Further, precut holes 38 could be arranged in most any geometric fashion, besides as shown in FIG. 2 . Precut holes could be placed anywhere on floor 22 .
[0033] As shown in the background icehouse 10 is shown broke down and placed within tub 18 for easy transport for the angler.
[0034] With reference to FIG. 3 , a portable ice fishing floor in an embodiment of the present invention is shown. Plugs 36 are shown removed to better show precut holes 38 . Precut holes 38 have an indented ridge 40 which runs along the periphery of precut holes 38 . Ridges 40 provide a ledge for plugs 36 to rest upon and allow plugs 36 to run smooth with floor 22 . Ridges 40 can also have a fastener, such as Velcro 42 , to hold plugs 36 within precut holes 38 . Plugs 36 can have a slot 44 within the body of plugs 36 to allow for the angler to easy remove plugs 36 from holes 38 when the angler would like to use floor 22 . It is fully contemplated other methods of removal for plugs 36 besides a slot 44 could be used without departing from the spirit of the invention, such as a string attached to a hole in plug 36 . Covering floor 22 can be a non-slip material 46 to prevent an angler from slipping should water get on floor 22 . Most any non-slip surface, such as a water resistant carpet, could be used without departing from the spirit of the invention.
[0035] In use, the angler could set floor 22 on the ice. After removing plugs 36 , the angler could drill a hole though the ice through precut holes 38 with an auger. The ice removed by the auger could then be pushed off of floor 22 . Precut holes 38 are typically 12″ in diameter, which is plenty of room to allow most augers to drill a hole though the ice. However, it is fully contemplated precut holes 38 could be most any diameter within reason without departing from the spirit of the invention. Icehouse 10 can be raised and the angler is ready to go fishing which still keeping warm with an insulated floor beneath him and feel safe from slipping with non-slip flooring 46 .
[0036] With reference to FIG. 4 , a portable ice fishing floor in an embodiment of the present invention is shown. Floor 22 has been folded in half and placed within tub 18 for easy transport. Floor 22 fits nicely within tub 18 . Floor 22 can be manufactured to fit with most any portable icehouse manufactures transportation device, such as tub 18 . With bottom side 48 exposed frame 50 is shown having a platform 52 on top of frame 50 . Frame 50 could be made from most any material, such as wood or metal; however, the inventors have found plastic to make floor 22 lighter and thus easier to transport. Platform 52 could also be made of most any material, such as wood or metal, but the inventor's have found plastic assists in making floor 22 lighter. An insulated plastic could be used to assist in keeping the cold of the ice away from the angler and yet also protecting the ice from melting should the angler have a heater in icehouse 10 . It is also contemplated an additional layer of insulation could be attached to bottom side 48 should frame 50 and platform 52 be made of other non-insulated materials.
[0037] With reference to FIG. 5 , an upper front profile view of containers in an embodiment of the present invention is shown. Lower container 60 and upper container 62 can be coupled to floor 22 or used separately. Lower container 60 can be coupled to floor 22 by most any means such as Velcro, a peg and slot fitting or even fastened with a bolt. Most any type of attachment is fully contemplated without departing from the spirit of the invention. Both containers 60 and 62 can have adjustable pivoting lights 64 which can be powered by a battery within container 60 or 62 . Typically, lights 64 could be focused upon most any ice fishing hole to provide a better visual fishing experience for the angler, especially if the angler is fishing at night. Containers 60 and 62 can also have other amenities such as cup holders 66 , an ashtray 68 or even fishing pole holders 70 . Each container has a door 72 which pivots upon an axis 74 . Each container 60 and 62 has handles 76 which allow the angler to easily carry both container 60 and 62 to and from the fishing events.
[0038] Container 60 is approximately 13″ inches across and lengthwise. Container 62 is approximately 13″ inches across and 16″ lengthwise.
[0039] With reference to FIG. 6 , a rearview profile view of containers in an embodiment of the present invention is shown. Coupled to the rear of container 62 can be a rod holder 80 for holding fishing rods 82 .
[0040] With reference to FIGS. 7 and 8 , a top profile view of a container in an embodiment of the present invention is shown. Container 62 has a false bottom 90 which can be pulled from container 62 . Underneath of false bottom 90 is a storage space for a battery (not shown) which can power lights 64 . Other items can be stored below false bottom 90 as well. In FIG. 8 , a bait holder 100 is shown. Bait holder 100 can hold most any type of bait for extended periods of time.
[0041] Thus, embodiments of the ICE FISHING UTILITIES are disclosed. One skilled in the art will appreciate the present teachings can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for functions of illustration and not limitation, and the present teachings are limited only by the claims follow.
|
In some embodiments, a portable floor may include one or more of the following features: (a) a frame having a top surface and a bottom surface, (b) a pre-cut hole in the floor adapted to allow a ice-fishing auger, (c) a plug to cover the at least one hole, (d) a container which is attachable to the floor, the container having a hinged top lid providing access to the interior of the container and a fishing rod holder, (e) an insulated material located adjacent to the frame, (f) a non-slip material coupled to the top surface, (g) a means for coupling the container to the floor, (h) a container to store live bait, (i) lights protruding from containers, and (j) cup holders.
| 0
|
The present invention relates to the use of iron salts as retention agents in the manufacture of paper, the primary purpose of which is to retain rosin size and thereby to cause the paper to become water repellent. The iron salts of the present invention also advantageously act as retention agents for other chemical additives and so-called "fines"--finely divided materials found in the process water of paper producing equipment.
The iron salts of the present invention have equal applicability to the production of paperboard, and as used herein, "paper" shall be deemed to include paperboard.
BACKGROUND OF THE INVENTION
Rosin and alum sizing of paper and paperboard has been well established in the art for many years, and is widely employed to produce water repellent paper products. The production of such papers uses rosin size, which is obtained from "tall oil," a naturally occurring product extracted from soft wood trees such as pines. This oil is saponified by the addition of caustic soda to produce the sodium salt of the oil, or rosin soap. Rosin soap is also produced as a byproduct of the alkaline pulping of soft woods, and is found in various concentrations in unbleached kraft soft wood pulp. This material is used extensively in food wraps and other papers and paperboard in which water repellence is desirable.
Although the pulp, or "stock" as it is called in the art, contains a certain concentration of rosin soap, it is common practice to disperse additional rosin soap in the stock, to further increase the water repellent characteristics of the paper to be produced. The rosin soap may be modified chemically to increase its ability to repel water, to promote dispersion into stock, to put the rosin in oil form before it is used, and to produce aqueous dispersions having high rosin content to facilitate shipping at low costs.
In order to retain, or set, the rosin in the paper during the manufacturing process, when water is removed from the stock, a retention agent is added to the stock. Such retention agents commonly include polymers and, more commonly, alum (Al 2 (SO 4 ) 3 ), which is typically provided in an aqueous solution 27 percent by weight anhydrous Al 2 (SO 4 ) 3 . When added to sufficient quantities of water, alum hydrolyzes to form aluminum hydroxide and sulfuric acid. The sulfuric acid thus formed lowers the stock pH. As the stock pH becomes acid, the rosin soap is converted to rosin oil, which is also commonly known as rosin size. The aluminum hydroxide retains the rosin size.
Rosin size may be chemically modified, as noted above to enhance certain characteristics such as water repellency. In addition, there are artificial sizes, such as AKD (alkyl ketene dimer) or ASA (alkynyl succinic anhydride), that are substitutes for rosin size.
At the same time, the aluminum hydroxide thus produced acts to flocculate rosin size onto the paper fibers in the wet stock. This compound also acts as a retention agent for anionic substances such as rosin size, retaining the size on the paper fibers even as water is removed from the stock; it most efficaciously serves this purpose at a pH range of 4.0 to 5.5. In order to lower the stock pH sufficiently to cause the aluminum hydroxide to act as a retention agent, additional sulfuric acid is commonly added to the stock. It has been shown that this process typically requires two pounds of alum (Al 2 SO 4 ) 3 ·18H 2 O) to set one dry pound of rosin size.
The rosin size thus retained in the dry paper is an oil that causes the finished paper to repel water.
The aluminum hydroxide also provides other functions resulting from flocculation of not only paper fibers but also fines. Notably, increased flocculation results in better drainage of water from the stock (measured as "freeness"), resulting in faster and easier drying of the stock into paper.
Another function of the addition of alum is that gums, fillers, starches, dry strength additives and other additives used to impart desirable properties in the finished paper are retained with the fibers, reducing the presence of such materials in the process water. In addition, as a result of retention of the materials in the paper, these additives may be used more effectively and economically.
All of this results in lower concentrations of pollutants in effluent waste streams, lower head box consistency, and lower head box freeness. This also results in less loss of stock and facilitates solid waste removal using clarifiers, savealls, screens or filters.
Unfortunately, alum is an expensive material, costing up to hundreds of dollars per ton of material. This represents an increase in the cost of materials employed in the production of water repellent papers, adding significantly to the cost of each ton of paper produced with alum.
Another problem is that alum also operates efficaciously as a flocculant only in a narrow, acidic pH range from 4.0 to 5.5. In this range, the acidic stock corrodes the extremely expensive paper making equipment, requiring repair or replacement of the equipment and shutting down production while repair or replacement is occurring. Alternatively, expensive acid resistant materials are used in such equipment, adding to their cost.
A problem also results from the deposition of aluminum hydroxide on the paper making equipment as the stock is converted to paper, frequently shutting down the equipment for cleaning. Expensive chemicals specially prepared for removal of aluminum hydroxide are required to clean the equipment and return it to service.
Moreover, alum is a very hygroscopic material, and as such detrimentally increases the time and cost to dry the paper.
For these reasons, it has long been felt by those in the paper industry that a cost-effective substitute for alum as a retention aid for rosin size was desirable.
Recently, it is also believed by some medical experts that aluminum and aluminum salts play a role in Alzheimer's disease, a serious affliction impairing the physical and mental abilities of thousands of persons each year. Since many of the products in which alum is employed as a retention agent are used in food packaging, a potential health threat resulting from the use of this material may exist. Alum is also present in the atmosphere surrounding paper production equipment, thereby posing a health risk to workers using such equipment.
SUMMARY OF THE INVENTION
It has now been demonstrated that iron salts that are hydrolyzable to ferric hydroxide (Fe(OH)3) may be used to retain rosin size in the production of water repellent paper. More specifically, it has been found that hydrolyzable ferric and ferrous salts may beneficially be employed as retention agents in paper production with substantial advantages over alum. These salts may be used to retain not only rosin size, but also modified rosin size, man-made sizing agents, starches, modified starches, gums, modified gums, and other additives and fines. These salts also enhance freeness and water removal by retaining fibers and fines, aiding in drying of the paper or paperboard.
Thus, the present invention provides a process for producing paper or paperboard, comprising the steps of providing stock suitable for making paper, adding rosin size to the stock, adding to the stock an iron salt hydrolyzable to ferric hydroxide, mixing the stock, size and iron salt, and forming paper from the stock.
It is an object of the present invention to employ hydrolyzable iron salts to produce water repellent paper products.
It is another object of the invention to provide a low cost additive, in the form of an iron salt, as a retention agent for rosin size.
It is still another object of the invention to provide such a retention agent that beneficially and substantially increases the retention of rosin size, fibers, fines, and other additives as compared to alum.
A further object of the invention is to provide a retention agent that improves the water quality from effluent streams of paper production facilities by reducing the presence of pollutants in such streams.
Another important object of the invention is to provide a retention agent that operates efficaciously at higher pH than alum, thereby to reduce corrosion resulting from low pH conditions.
These and other objects of the invention will be apparent from the detailed description of the invention provided below.
DETAILED DESCRIPTION OF THE INVENTION
The present invention uses iron salts that may be hydrolyzed to ferric hydroxide as retention agents for rosin size and other additives in the production of water repellent papers. Such salts include, without limitation, ferric and ferrous sulfate, ferric and ferrous chloride, and other iron salts. In addition, ferric hydroxide may itself be employed in the present invention.
In using ferrous salts, it is recognized that a oxidizing agent must be present in order to hydrolyze the salt to ferric hydroxide. Suitable oxidizing agents include, without limitation, dissolved air or oxygen, peroxides, and any other well-known substances that function as oxidizing agents.
Upon dissolving the iron salt in water (with an oxidizing agent if the salt is a ferrous derivative), the iron salt is hydrolyzed to form ferric hydroxide, which is insoluble in water. Hydrolysis is dependent upon pH, temperature, water hardness and the concentration of ferric ion in the water. In general, ferric hydroxide will form when the ferric ion content of the water is less than 0.6 grams per liter.
In the preferred embodiment, the iron salt employed is ferric sulfate. One commercial formulation of this salt is sold by Eaglebrook, Inc. under the trademark FERRICLEAR™ as an aqueous solution of Fe 10 (SO 4 ) 14 OH that is 12 percent ferric iron by weight.
For effective sizing, the ferric sulfate is added to the stock in quantities that vary in accordance with three factors: the pH desired, the type of size being added and the extent of substances that interfere with the retention of size. It is believed that the advantages of the present invention may be realized by using between 0.1 and 4.0 pounds of ferric iron per pound of dry sizing material depending upon these factors, and it conceivable that other quantities may successfull be employed.
It is anticipated that at least 2.4 pounds of liquid ferric sulfate having a 12 percent ferric iron content are needed to set one pound of dry rosin size. This corresponds to 0.29 pounds of ferric iron per pound of dry rosin size, as compared with 2 pounds dry alum per pound of rosin size.
For increased freeness of the stock, 0.6-2.4 pounds of ferric iron per ton of paper were evaluated, corresponding to a feed rate of 10-40 pounds of FERRICLEAR per ton of paper. This evaluation demonstrated substantial increases in freeness of the stock.
The iron salt may be added to the stock as a solution, a solid, or in a stream of water that is added to the stock.
As will be shown from the examples below, the sequence for combining the rosin size and the retention agent with the stock is unimportant. In general, either the retention agent or the rosin size may be added to the stock first, without deleterious effect upon the water repellence and other characteristics of the resulting paper. Specific modified rosin sizes, however, may have characteristics that require that either the size or the retention agent be added first to produce the desired retention and other effects, and certain equipment may also require or prefer a given sequence of addition.
The point at which the iron salt will be added will vary depending upon the particular paper being made and the fabrication process employed, but should in all cases be prior to the sheet forming area. Factors related to this determination include the type of size being used, the presence of substances that interfere with the retention of size, other desired effects, the type of paper being manufactured, the type of stock being used and the equipment employed.
Tests (Examples I-VI) were run on Ultrex 300 (Austell Box Board, Inc.) stock using NovaSperce 0935 (Georgia Pacific Corp.) modified rosin size. NovaSperce 0935 is an emulsion that is 35 percent modified rosin size by weight, and was employed in quantities of 10 wet pounds (3.5 dry pounds) per ton of dry stock. The stock had been washed with hot water and its temperature was 125° F. when the NovaSperce was added. After addition of NovaSperce, the stock was mixed well and divided into two portions. In the first portion, the pH was adjusted to 5.2 using alum; in the second portion, the pH was adjusted to 5.2 with FERRICLEAR. Additional quantities of alum or FERRICLEAR were added as summarized in Table I, and a water drop test was run on handsheets produced from each sample. As shown in Table I, the use of ferric sulfate resulted in a paper having superior water repellence when compared to an alum treated paper.
EXAMPLE I
Stock pH was returned to 5.2 using alum. No more alum was added to the stock.
EXAMPLE II
Stock pH was returned to 5.2 using alum. Additional alum was added at a ratio of 40 pounds per ton of dry stock.
EXAMPLE III
Stock pH was returned to 5.2 using alum. Additional alum was added at a ratio of 80 pounds per ton of dry stock.
EXAMPLE IV
Stock pH was returned to 5.2 using FERRICLEAR. No more FERRICLEAR was added the stock.
EXAMPLE V
Stock pH was returned to 5.2 using FERRICLEAR. Additional FERRICLEAR was added at a ratio of 40 pounds per ton of dry stock.
EXAMPLE VI
Stock pH was returned to 5.2 using FERRICLEAR. Additional FERRICLEAR was added at a ratio of 80 pounds per ton of dry stock.
TABLE I______________________________________ NovaSperce AdditiveExample Present Present Adsorption Time (minutes)No. (lb/ton dry stock) Top Bottom Average______________________________________I 10 0 (alum) 40 49 44.5II 10 40 (alum) 150 75 112.5III 10 80 (alum) 170 35 102.5IV 10 0 (iron) 205 117 156V 10 40 (iron) 162 117 144.5VI 10 80 (iron) 196 119 157.5______________________________________
In addition to retaining rosin size in such a way that it causes the paper to repel water, the ferric hydroxide flocculant also increases the freeness of the stock. In Examples VII-XII, stock was prepared in a commercial pulper from corrugated boxes. Pulper dilution water came from the underflow of the clarifier servicing a paper machine with alum in use. Refined stock samples were obtained prior to the addition of alum. Measured amounts of alum and iron salt (FERRICLEAR) were added to the stock and stirred for 30 seconds, and freeness was then measured using a Canadian Standard Freeness Tester. As summarized in Table II, the resulting data shows the freeness increases as a result of the use of iron salts as compared to the use of alum. This increase in freeness makes water removal easier, meaning that less energy will be expended in drying the paper, and associated costs will be reduced.
TABLE III______________________________________ QuantityExample added No. of Average increaseNo. Additive (lb/ton) tests in freeness______________________________________VII alum 10 6 1.3%VIII alum 20 5 4.6%IX alum 40 5 0.5%X FERRICLEAR 10 6 5.8%XI FERRICLEAR 20 5 8.7%XII FERRICLEAR 40 5 8.2%______________________________________
Additional testing has shown that clarification of effluent streams will be enhanced by use of iron salts as compared to alum, advantageously resulting in lower costs due to greater recovery of solids, and savings in pollution control as a result of the reduction of pollutants in waste streams. Examples XIII and XIV indicate the advantages of using iron treated stock to produce a greater quantity of supernatant, and a clearer supernatant, as compared to alum treated stock.
EXAMPLE XIII
1000 ml stock, consisting of 997 g water and 3 g dry stock (with 10 lb. size, 20 lb. liquid alum per ton of dry stock), and having a pH of 4.5, was placed in a graduated cylinder and allowed to settle for 10 minutes. At the end of that period, the stock had settled to the 950 line of the graduated cylinder, producing 50 ml supernatant. This supernatant was very cloudy.
EXAMPLE XIV
1000 ml stock, consisting of 997 g water and 3 g dry stock (10 lb. size, 20 lb. FERRICLEAR per ton dry stock), and having a pH of 6.0, was placed in a graduated cylinder and allowed to settle for 10 minutes. At the end of that period, the stock had settled to the 850 ml line of the graduated cylinder, producing 150 ml supernatant. This supernatant was quite clear, although brown in color (characteristic of the ferric iron present).
Importantly, the iron salts of the present invention may be used efficaciously at a pH range above 6.0, providing a substantial advantage over more acidic operations using alum. This will, it is believed, lower costs to paper manufacturers by prolonging the life of paper-making equipment, reducing the frequency of repairs due to acid corrosion of the equipment, allowing the equipment to be made from less expensive materials, and reducing down time resulting from corrosion.
The iron salts of the present invention also eliminate the health risks posed by the us of aluminum salts.
Another advantage of iron salts is their ability to enhance the color of unbleached papers. This is the result of the reddish-brown color of the iron salts, which compliments the gray or brown color of the unbleached paper. The resulting paper is an attractive brown shade.
The present invention has been described with respect to certain embodiments and conditions, which are not meant to and should not be construed to limit the invention. Those skilled in the art will understand that variations from the embodiments and conditions described herein may be made without departing from the invention a claimed in the appended claims.
|
Iron salts hydrolyzable to ferric hydroxide are provided as retention agents for size in the production of paper and paperboard to aid in water repellence, reduce pollutants, and create other beneficial effects.
| 3
|
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Contract No. DAAH01-03-C-0035 awarded by the U.S. Government.
FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION
Mobile multi-cell rocket launchers are used by the military to provide firepower during a combat situation. The launcher electronics (e.g., control, power, and targeting systems, etc.) and launch platform necessary to control and fire each rocket are bulky and expensive; therefore, modern multi-cell rocket launchers use modularity to reduce overall system cost and bulkiness.
A common infrastructure, which includes the launcher electronics and launch platform, is used in conjunction with replaceable canisters, which each contain a rocket. Each canister provides a substantially air-tight environment that reduces the rocket's exposure to dust, humidity, and other environmental factors. The canisters need to be easily replaced in a combat situation; i.e. it must be possible to quickly remove a spent canister and replace it with a fresh canister to replenish the total firepower of the launcher.
In the prior art, the loading of a canister into a launch platform requires complicated handling by the crew manning the platform. In particular, in order to connect the electronics contained within the canister to the launcher electronics (i.e., the electronics NOT contained in the canister), the crew must attach the electrical cables associated with the platform to the electrical cables associated with the canister. Furthermore, the crew must ensure that the cables are not severed or damaged while the canisters are loaded.
Therefore, the need exists for an electrical connection that avoids or mitigates some or all of these problems.
SUMMARY OF THE INVENTION
The present invention enables a docking system for a rocket-containing canister and a launch platform that avoids some of the disadvantages for doing so in the prior art. In particular, the illustrative embodiment of the present invention uses mechanical alignment features, spring-loaded electrical contacts, an environmental seal, and an electro-magnetic radiation shield to establish and maintain reliable electrical interconnection between the rocket and the launcher electronics.
The present invention enables a rocket-containing canister to be loaded into a multi-cell rocket launcher while also establishing electrical connection between the rocket and launcher electronics associated with the multi-cell rocket launcher. Once established, the electrical interconnection between the rocket and multi-cell rocket launcher is maintained even in the presence of the vibration associated with a rocket launch, dirt or other airborne contaminants, or external electro-magnetic radiation.
The illustrative embodiment comprises: a spring-loaded electrical contact, a seal for providing an environmental seal, and a shield for providing an electro-magnetic-interference shield, wherein both the environmental seal and the electro-magnetic-interference shield surround the spring-loaded contact so that when the electrical connector is mated, the spring-loaded contact is enclosed in an environment that is substantially isolated from the ambient environment and substantially isolated from external electro-magnetic radiation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a representational diagram of the salient components of a vehicle-borne multi-cell launcher in accordance with the illustrative embodiment.
FIG. 2 depicts a perspective view of the salient components of a multi-cell launcher in accordance with the illustrative embodiment of the current invention.
FIG. 3 depicts a perspective view of the salient components of a representative canister in accordance with the illustrative embodiment of the current invention.
FIG. 4 depicts an exploded view of the salient components of a canister and a receptacle in accordance with the illustrative embodiment of the current invention.
FIG. 5 depicts a top-down view of the salient components of a pallet connector and a bottom-up view of a canister connector in accordance with the illustrative embodiment of the current invention.
FIG. 6 depicts an exploded cross-sectional view of the salient components of a pallet connector and a canister connector in accordance with the illustrative embodiment of the current invention.
FIG. 7 depicts a cross-sectional view of the salient components of an alternative embodiment of the present invention.
FIG. 8 depicts a cross-sectional view of the salient components of a resilient contact according to the illustrative embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 depicts a representational diagram of the salient components of a vehicle-borne multi-cell launcher in accordance with the illustrative embodiment. Although multi-cell launcher 102 is mounted on vehicle 100 , it will be clear to those skilled in the art how to make and use alternative embodiments of the present invention in which multi-cell launcher 102 is mounted on another vehicle, such as a railroad car, warship, submarine, space vehicle, satellite, or stationary ground-based platform.
FIG. 2 depicts a perspective view of the salient components of multi-cell launcher 102 . Launcher 102 comprises eight canisters 206 1,1 through 206 2,4 , and launch pallet 216 . Launch pallet 216 comprises eight canister receptacles 217 1,1 through 217 2,4 , and pallet connectors 218 1,1 through 218 2,4 (for clarity, only receptacles 217 1,4 and 217 2,4 and pallet connectors 218 1,4 and 218 2,4 are shown). Although multi-cell launcher 102 comprises eight canisters and eight canister receptacles, it will be clear to those skilled in the art, after reading this disclosure, how to make and use embodiments of the present invention that comprise any number of canisters and canister receptacles.
Multi-cell launcher 102 is a system that has the capability of launching a plurality of rockets from its launch platform. Launch pallet 216 accepts and holds rocket-containing canisters 204 i,j in canister receptacle 206 i,j wherein i is a positive integer in the set {1, . . . 2}, and j is a positive integer in the set {1, . . . 4}. After a rocket is launched from canister 204 i,j , the spent canister can be replaced by an unused canister to replenish the fire power of multi-cell launcher 102 .
Launch pallet 216 comprises canister receptacles 206 1,1 through 206 2,4 , which provide mechanical structure to which canisters 204 1,1 through 204 2,4 are mounted. In addition, each canister receptacle 206 i,j includes pallet connector 208 i,j , which provides an electrical interface between canister 206 i,j and fire control.
FIG. 3 depicts a perspective view of the salient components of canister 204 i,j . Canister 204 i,j , comprises rocket 310 i,j , housing 312 i,j , connector plate 314 i,j , canister connector 316 i,j , canister-to-rocket umbilical 318 i,j , rear legs 320 , and front legs 322 .
Housing 312 i,j , fly-through cover 313 i,j , and connector plate 314 i,j are sheet metal that form a substantially weather-proof and dust-proof environment for rocket 310 i,j , such that rocket 310 i,j does not suffer from environmental conditions (e.g., dust, rain, dirt, etc.).
Connector plate 314 i,j comprises canister connector 316 i,j , rear legs 320 , and front legs 322 . Canister connector 316 i,j mates with pallet connector 208 i,j when rear legs 320 and front legs 322 are engaged with their respective alignment holes, rear slots 424 and front slots 426 (which are depicted in FIG. 4 ). When canister 204 i,j is inserted into receptacle 206 i,j , rear legs 320 and front legs 322 engage rear slots 424 and front slots 426 in a single orientation, and, as a consequence, canister connector 316 i,j is properly aligned with pallet connector 208 i,j to ensure the interconnection of their appropriate contacts.
FIG. 4 depicts an exploded view of the salient components of canister 204 2,4 and receptacle 206 2,4 in accordance with the illustrative embodiment of the current invention. Canister 204 2,4 includes connector plate 314 2,4 , which comprises canister connector 314 2,4 , rear legs 320 , and front legs 322 . Receptacle 206 2,4 comprises pallet connector 208 2,4 , rear slots 424 , and front slots 426 . Further, and as depicted in more detail in FIG. 5 , canister connector 316 2,4 comprises canister annulus 432 and canister contacts 434 , and pallet connector 208 2,4 comprises pallet annulus 428 and pallet contacts 430 .
As canister 204 2,4 engages receptacle 206 2,4 , rear legs 320 engage rear slots 424 such that canister 204 2,4 can only seat in receptacle 206 2,4 in a single orientation. Once rear legs 320 have engaged rear slots 424 , canister 204 2,4 rotates into position above receptacle 206 2,4 enabling front legs 322 to be inserted into front slots 426 . The insertion of rear legs 320 and front legs 322 into slots 424 and 426 aligns canister connector 316 2,4 and pallet connector 208 2,4 .
FIG. 5 depicts a top-down view of the salient components of pallet connector 208 i,j and a bottom-up view of canister connector 316 i,j in accordance with the illustrative embodiment of the current invention. Canister connector 316 i,j comprises canister annulus 432 , shield seat 544 , seal seat 546 , contacts 434 1,1 through 434 2,2 (collectively, contacts 434 ), canister connector face 539 , and canister key 538 .
Pallet connector 208 i,j comprises pallet annulus 428 , shield seat 540 , seal seat 542 , contacts 430 1,1 through 430 2,2 (collectively, contacts 430 ), pallet connector face 537 , and pallet key 536 .
Canister connector 316 i,j and pallet connector 208 i,j include pallet key 536 and canister key 538 , respectively, and are designed to mate in a single orientation that ensures proper interconnection of contacts 434 , which depend from canister connector face 539 , with contacts 430 , which depend from pallet connector face 537 , (i.e., contact 434 1,1 interconnected to 430 1,1 , . . . , 434 2,2 interconnected to 430 2,2 ). Additionally, correct alignment of pallet connector 208 i,j and canister connector 316 i,j ensures that shield seat 540 aligns with shield seat 544 , and seal seat 542 aligns with seal seat 546 such that when seat 648 and shield 650 are present (as depicted in FIGS. 6 and 7 ), shield 650 is located in shield seats 540 and 544 , and seal 648 is located in seal seats 542 and 546 .
FIG. 6 depicts an cross-sectional view of the salient components of pallet connector 208 i,j and canister connector 316 i,j , as taken through line a—a of FIG. 5 , in accordance with the illustrative embodiment of the current invention. Pallet connector 208 i,j comprises circuit board 652 , pallet annulus 428 that includes shield seat 540 and seal seat 542 , resilient contacts 430 1,1 and 430 1,2 , pallet key 536 , shield 650 , and seal 648 . Canister connector 316 i,j comprises printed circuit board 654 , canister annulus 432 that includes shield seat 544 and seal seat 546 , resilient contacts 434 1,1 and 434 1,2 , and pallet key 538 .
Circuit board 652 provides connection between resilient contacts 430 1,1 and 430 1,2 to the launcher electronics associated with multi-cell launcher 102 . Pallet annulus 428 and canister annulus 432 provide structure to hold shield 650 and seat 648 such that when pallet connector 208 i,j is mated to canister connector 316 i,j , resilient contacts 430 and 434 are enclosed in an environment that is substantially free of externally-generated electro-magnetic radiation and substantially isolated from the external ambient environment. Pallet key 536 and canister key 538 ensure proper alignment of pallet annulus 428 to canister annulus 432 and resilient contacts 430 to resilient contacts 434 .
Resilient contacts 430 1,1 , 430 1,2 , 434 1,1 , and 434 1,2 are flexible, spring-loaded electrical contacts. When pallet connector 208 i,j and canister connector 316 i,j are mated, resilient contacts 430 1,1 and 434 1,1 are compressed against each other, and resilient contacts 430 1,2 and 434 1,2 are compressed against each other, and at least one contact in each compressed pair deforms. During a rocket launch, although vibration causes canister 204 i,j and receptacle 206 i,j to move with respect to one another, the resiliency of resilient contacts 430 and 434 ensures that positive electrical contact is maintained.
FIG. 7 depicts a cross-sectional view, as taken through the line a—a of FIG. 5 , of the salient components of an alternative embodiment of the present invention. Referring to FIG. 7 , pallet connector 208 i,j comprises circuit board 652 , pallet annulus 428 that includes shield seat 540 and seal seat 542 , rigid contacts 756 1,1 and 756 1,2 , pallet key 536 , shield 650 , and seal 648 . Canister connector 316 i,j comprises printed circuit board 654 , canister annulus 432 that includes shield seat 544 and seal seat 546 , resilient contacts 434 1,1 and 434 1,2 , and pallet key 538 .
As in the illustrative embodiment, when pallet connector 208 i,j is mated to canister connector 316 i,j , printed circuit boards 652 and 654 , pallet annulus 428 , canister annulus 432 , shield 650 and seal 648 together enclose rigid contacts 756 and resilient contacts 434 in an environment that is substantially free of externally-generated electro-magnetic radiation and substantially isolated from the external ambient environment. Additionally, as in the illustrative embodiment, pallet key 536 and canister key 538 ensure that pallet connector 208 i,j mates properly to canister connector 316 i,j .
When pallet connector 208 i,j and canister connector 316 i,j are mated, resilient contact 430 1,1 is compressed against rigid contact 756 1,1 , and resilient contact 430 1,2 is compressed against rigid contact 756 1,2 such that resilient contacts 430 1,1 and 430 1,2 deform. During a rocket launch, although vibration causes canister 204 i,j and receptacle 206 i,j to move with respect to one another, the resiliency of resilient contacts 430 1,1 and 430 1,2 ensures that positive electrical contact with rigid contacts 756 1,1 and 756 1,2 is maintained.
FIG. 8 depicts a cross-sectional view of the salient components of resilient contact 434 i,j in accordance with to the illustrative embodiment of the present invention. Resilient contact 434 i,j comprises spring 858 i,j that includes free-end 864 i,j , and hold down 860 i,j .
Spring 858 i,j is formed from an electrically-conductive, resilient material, such as copper, gold-alloy, bronze, or aluminum, as is well-known by those skilled in the art. At one end, spring 858 i,j is fixidly-attached by hold down 860 i,j to via pad 862 i,j on printed circuit board 654 . At the other end, spring 858 i,j is left unattached in order to allow for flexibility and resiliency when mated to another contact.
Although the illustrative embodiment comprises two alignment features (i.e., (1) legs 320 and 322 and slots 424 and 426 , and (2) keys 536 and 538 ), it will be clear to those skilled in the art, however, after reading this specification, how to make and use alternative embodiments of the present invention that comprise any number of alignment features, alternative alignment features, or embodiments that rely on shield 650 , seal 648 , or both shield 650 and seal 648 to ensure the alignment of canister 204 i,j to receptacle 206 i,j .
Furthermore, it will be clear to those skilled in the art how to make and use alternative embodiments of the present invention in which shield 650 is located in shield seat 544 , or seal 648 is located in seal seat 546 , or shield 650 is located in shield seat 544 and seal 648 is located in seal seat 546 .
Moreover, it will be clear to those skilled in the art how to make and use alternative embodiments of the present invention in which resilient contacts are formed using spring-loaded shaft-type contacts, leaf-spring contacts, button contacts, etc.
It is to be understood that the above-described embodiments are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by those skilled in the art without departing from the scope of the invention. For example, in this Specification, numerous specific details are provided in order to provide a thorough description and understanding of the illustrative embodiments of the present invention. Those skilled in the art will recognize, however, that the invention can be practiced without one or more of those details, or with other methods, materials, components, etc.
Furthermore, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the illustrative embodiments. It is understood that the various embodiments shown in the Figures are illustrative, and are not necessarily drawn to scale. Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that a particular feature, structure, material, or characteristic described in connection with the embodiment(s) is included in at least one embodiment of the present invention, but not necessarily all embodiments. Consequently, the appearances of the phrase “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout the Specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments. It is therefore intended that such variations be included within the scope of the following claims and their equivalents.
|
An electrical connector that avoids some of the disadvantages associated with electrical connectors in the prior art. In particular, the illustrative embodiment of the present invention uses spring-loaded contacts to maintain connection in the presence of the vibration associated with a rocket launch, and also includes an environmental seal and electro-magnetic shield so as to provide an environment for the electrical contacts that is isolated from the ambient environment and external electromagnetic radiation. Furthermore, the illustrative embodiment avoids the possibility of bent connector pins, which would make mating between the electrical connectors.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 10-2007-0096570, filed on Sep. 21, 2007 which is hereby incorporated by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is related to a home appliance such as a dish washer, a laundry machine, a refrigerator, etc.
[0004] 2. Discussion of the Related Art
[0005] Generally speaking, home appliances are electric devices used at home.
[0006] Generally, dish washers are used for removing dirty and remaining food from food dishes and eating utensils (hereinafter, collectively referred to as dishes) by injecting wash water onto the dishes at a high pressure.
[0007] Such a dish washer includes a tub forming a cleaning chamber and a sump disposed at a lower portion of the tub for storing wash water. A pump is installed in the sump to pump the wash water to an injection nozzle connected to the sump. The wash water arrived at the injection nozzle is injected through a nozzle hole formed in an end of the injection nozzle at a high pressure. Two injection nozzles can be disposed at upper and lower portions of the tub, respectively, and the upper injection nozzle can be connected to the sump by a water guide.
[0008] Laundry machines are generally devices for treating laundry. Laundry machines may be clothes dryers or clothes washers.
[0009] Generally, clothes dryers are for drying wet laundry and clothes washers are for washing laundry.
SUMMARY OF THE INVENTION
[0010] One embodiment of a home appliance according to the present invention comprises a control panel and a controller.
[0011] The controller panel may include a power switch which allows a user to input a command for switching on or off a power of the appliance and an input device which allows the user to input a command in connection with an operation of the appliance.
[0012] The controller may be configured to reduce or switch off the power of the appliance when a command is not inputted through the input device within a predetermined period of time after the appliance has been switched on.
[0013] The input device may comprise a course selector which allows a user to select a course and an option selector which allows the user to select an option in connection with the course.
[0014] Taking a clothes washer as an example, the course may be a normal washing course, lingerie washing course, or the like.
[0015] There may be a plurality of courses which the user can select.
[0016] The user may select options for the selected course with the option selector. For instance, the user may select a temperature of water for washing clothes with the option selector. In a similar way, there may be plurality of options which the user can select through the option selector.
[0017] The power switch may comprise a touch switch which only has to be touched by the user to operate. Further, the touch switch may comprise a capacitance touch switch or a resistance touch switch.
[0018] A capacitance touch switch works using body capacitance, a property of the human body that gives it great electrical characteristics. When a person touches it, it increases the capacitance and triggers the switch.
[0019] A resistance touch switch works by lowering the resistance between two pieces of metal. Placing one or two fingers across the plates achieves a turn on or closed state.
[0020] Alternatively, the power switch may comprise a sensor which senses a user's touch. When the user touches the power switch, the sensor may sense the touch and send a signal to the controller. Then, the controller may reduce or switch off the power of the appliance.
[0021] The sensor may comprise a pressure sensor or a heat sensor. The pressure sensor senses the user's touch by pressure, and the heat sensor senses the user's touch by a transmitted heat from the user.
[0022] Another embodiment of a home appliance according to the present invention may comprise a controller to reduce or switch off a power of the appliance when a command for switching off the power is inputted twice or more.
[0023] The control panel of the previously presented embodiment may be comprised in this embodiment.
[0024] The controller may reduce or switch off the power when the command is inputted twice or more through the power switch.
[0025] Further, the controller may do so when the number of commands is inputted within a predetermined period of time.
[0026] An embodiment of a controlling method of a home appliance may comprises switching on a power of the appliance; and reducing or switching off the power of the appliance when a command in connection with an operation of the appliance is not inputted within a predetermined period of time after the appliance has been switched on.
[0027] Another embodiment of a controlling method of a home appliance may comprises switching on a power of the appliance; and switching off the power of the appliance when a command for switching off the power is inputted twice or more within a predetermined period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the invention. In the drawings:
[0029] FIG. 1 is a perspective view illustrating the external appearance of a dish washer according to the present invention;
[0030] FIG. 2 is a schematic longitudinal sectional view of the dish washer according to the present invention;
[0031] FIG. 3 is a constructional view illustrating an input unit of the dish washer according to the present invention; and
[0032] FIGS. 4 and 5 are flow charts illustrating a method of controlling the input unit of the dish washer according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. In an embodiment, a dish washer is described; however, the concept of the present invention is applicable to a laundry machine, for example a washer, a dryer, a washer and dryer, or a steam dryer.
[0034] FIG. 1 is a perspective view illustrating a dish washer according to the present invention.
[0035] Referring to FIG. 1 , the dish washer includes a case 10 forming the external appearance of the dish washer, the case 10 being opened at the front thereof, a door 11 for opening and closing the open front of the case 10 , a door grip 12 used for a user to open and close the door 11 , and a control panel 100 provided at the upper side of the door 11 for displaying and controlling the operation of the dish washer.
[0036] As shown in FIG. 1 , the door 11 is hingedly mounted at the lower part of the case 10 , and the control panel 100 is provided at the top side of the door 11 . When the dish washer is used in a built-in product, cooking equipment, including a microwave oven for cooking, may be mounted at the top of the case 10 . With the door 11 mounted by hinges at the lower part of the case 10 or with the control panel 100 provided at the top side of the door 11 , it is improved in a way of the user's convenience. That is, the user may open the door 11 and easily put dishes into the case 10 . Also, the user may easily input an operation command to operate the dish washer through the control panel 100 provided at the top of the door 11 while keeping the door 11 open.
[0037] Meanwhile, the control panel 100 includes a signal generator(or a power switch) 110 for generating a predetermined signal to apply electric power to the dish washer or release the electric power applied to the dish washer, an input device 140 for allowing a user to select a desired washing course, and a display device 150 for displaying the operation state of the dish washer.
[0038] The signal generator 110 allows the user to selectively apply electric power to the dish washer or release the electric power applied to the dish washer. The signal generator 110 may be configured in the form of a predetermined button which the user can push. Alternatively, the signal generator 110 may be configured in the form of a predetermined touch sensor or a predetermined touch pad which can sense a touch of the user. When the signal generator 110 is configured in the form of a predetermined button, the signal generator 110 generates a predetermined signal when the user pushes the button. On the other hand, when the signal generator 110 is configured in the form of a predetermined touch sensor or a predetermined touch pad, the signal generator 110 generates a predetermined signal when the user touches the touch sensor or the touch pad.
[0039] Also, the dish washer may further include a controller (not shown) for applying electric power to the dish washer or releasing the electric power when a predetermined signal is generated from the signal generator 110 . The controller will be described hereinafter in detail.
[0040] The input device 140 allows a user to input the detailed commands for a dish washing operation. The input device 140 may include a course selector 120 for allowing the user to select any one of a plurality of predetermined washing courses and an option selector 130 for allowing the user to select any one of a plurality of predetermined options.
[0041] The course selector 120 may have a plurality of buttons 121 for allowing the user to select any one of the plurality of predetermined washing courses. Similarly, the option selector 130 may have a plurality of buttons 131 for allowing the user to select any one of the plurality of predetermined options.
[0042] FIG. 2 shows a longitudinal section of the dish washer of FIG. 1 .
[0043] To describe the internal structure of the dish washer with reference to FIG. 2 , the dish washer includes a tub 18 mounted in the case 10 for defining a space where dishes are washed and a sump 16 mounted at the bottom of the tub 18 for collecting wash water to wash the dishes and filtering garbage out of the wash water such that the filtered water can be sprayed to the dishes again.
[0044] In the sump 16 is mounted a predetermined pump (not shown), such as an impeller, for pumping out the wash water stored in the sump 16 . A heater (not shown) is also mounted in the sump 16 for heating the wash water stored in the sump 16 . Consequently, detergent may be easily dissolved in the wash water, and food waste on the dishes may be easily soaked by the heated wash water, thereby improving washing efficiency.
[0045] In the tub 18 are mounted racks 13 in which dishes are received, spray arms 14 and 15 for spraying wash water toward the respective racks 13 , and a spray arm 24 for spraying wash water from the upper part to the lower part of the tub 18 .
[0046] At the bottom of the tub 18 may be mounted a filter 17 , which filters garbage out of the wash water. In the tub 18 , at one side thereof, may be provided a wash water tube 19 for supplying wash water to the spray arms 14 and 24 , located at the upper part of the tub 18 .
[0047] Also, the dish washer may further include a steam generator 50 having a predetermined heater 52 for heating water received in the steam generator 50 to generate steam to be supplied into the tub 18 , a steam tube 51 for supplying the steam generated by the steam generator 50 into the tub 18 , and at least one nozzle 60 for spraying the steam supplied from the steam tube 51 into the tub 18 .
[0048] Also, the dish washer may further include a water supply pipe 22 connected to the outside and branched into the tub 18 and the steam generator 50 for supplying water to the tub 18 and the steam generator 50 , a drainage pipe 23 for draining the contaminated wash water after the washing of the dishes, and a tub valve 40 and a steam valve 41 for opening and closing the water supply pipe 22 to control the amount of water supplied through the water supply pipe 22 . The tub valve 40 controls the amount of water supplied to the tub 18 , and the steam valve 41 controls the amount of water supplied to the steam generator 50 .
[0049] Hereinafter, the operation of the dish washer will be described briefly with reference to FIGS. 1 and 2 .
[0050] First, when dishwashing is required, a user pushes or touches the signal generator 100 to apply electric power to the dish washer.
[0051] Subsequently, the user opens the door 11 , puts dishes into the racks 13 , and manipulates the input device 140 , while keeping the door 11 open, to select a desired washing course of the dishwashing. Of course, it is possible for the user to manipulate the input device 140 after closing the door 11 .
[0052] Subsequently, when the user closes the door 12 and commences the dishwashing according to the selected washing course, the operation of the dish washer is carried out while the operation state of the dish washer is displayed on the display device 150 . The operation of the dish washer is carried out only while the door 12 is closed. Of course, an additional operation button (not shown) may be provided such that the operation of the dish washer can be carried out only when the operation button is pushed.
[0053] To describe the operation of the dish washer according to the flow sequence of the wash water flowing in the tub 18 , on the other hand, the wash water, sprayed from the spray arms 14 , 15 , and 24 , washes the dishes placed in the racks 13 , falls downward, and flows into the sump 16 . In the sump 16 is mounted a predetermined pump, such as an impeller. The pump pumps out the wash water such that the wash water is resupplied to the respective spray arms 14 , 15 , and 24 .
[0054] In this way, food waste is filtered out by the filter 17 , during the circulation of the wash water from the sump 16 to the spray arms 14 , 15 , and 24 , thereby preventing excessive contamination of the wash water or the clogging of the nozzle.
[0055] Also, the dish washer may carry out a washing process using steam. To carry out the washing process using steam, steam generated by the steam generator 50 is supplied into the tub 18 through the steam tube 51 and the nozzle 60 .
[0056] In the dish washer, therefore, it is possible to expect the improvement of washing efficiency of the dish washer which can be further obtained by high-temperature and high-humidity properties of the steam. For example, when the dishes are washed using the steam and the wash water, food waste fixed to the dishes is soaked by the steam, and the food waste is easily removed from the dishes by the high-pressure wash water.
[0057] FIG. 3 is a constructional view illustrating an input unit of the dish washer.
[0058] Referring to FIG. 3 , the input unit of the dish washer includes a signal generator 110 , an input device 140 , and a controller 200 .
[0059] The signal generator 110 generates a predetermined signal to apply electric power to the dish washer or release the electric power applied to the dish washer according to the manipulation of a user. Specifically, the user may push or touch the signal generator 110 to apply electric power to the dish washer or release the electric power applied to the dish washer. The signal generator 110 generates a predetermined signal according to the manipulation of the user. The predetermined signal is an electric signal.
[0060] The signal generator 110 may be configured to generate a predetermined signal by the user's touching the signal generator 110 . For example, the signal generator 110 may be configured in the form of a predetermined touch sensor or a predetermined touch pad which can sense a touch of the user. The touch sensor or the touch pad may sense the touch of the user through the sensing of a predetermined pressure or heat. That is, the signal generator 110 senses a touch of the user through the sensing of a predetermined pressure or heat, thereby generating a predetermined signal
[0061] When a predetermined signal is generated from the signal generator 110 according to the manipulation of the user, the controller 200 applies electric power to the dish washer or releases the electric power applied to the dish washer. For example, when a predetermined signal is generated from the signal generator 110 , while the electric power is being applied to the dish washer, the controller 200 releases the electric power applied to the dish washer. On the other hand, when a predetermined signal is generated from the signal generator 110 , while the electric power applied to the dish washer is being released, the controller 200 applies electric power to the dish washer. Of course, the signal generator 110 generates a signal to apply electric power to the dish washer and a signal to release the electric power applied to the dish washer while distinguishing between the signal to apply the electric power to the dish washer and the signal to release the electric power applied to the dish washer, and the controller applies electric power to the dish washer or releases the electric power applied to the dish washer when one of the two signals is generated while the signal to apply the electric power to the dish washer and the signal to release the electric power applied to the dish washer are distinguished from each other.
[0062] The input device 140 may be configured to have a plurality of buttons for allowing a user to select a desired washing course. Alternatively, the input device 140 may be configured in the form of a rotary knob that can be rotated by a predetermined angle for allowing the user to select the washing course. That is, it is possible for the user to select a desired washing course by pressing the button corresponding to the desired washing course or rotating the rotary knob.
[0063] As shown in FIG. 3 , the input device 140 includes a course selector 120 and an option selector 130 . The course selector 120 is an input device component that allows a user to select any one of a plurality of predetermined washing courses, and the option selector 130 is an input device component that allows the user to select any one of a plurality of predetermined options. The predetermined washing courses may include normal washing, strong washing, and rinsing. The predetermined options may include steam and drying. When one of the washing courses and one of the options are selected, dishwashing is carried out according to a course including the selected washing course and the selected option. Also, the input device 140 may further include a detail establisher for allowing a user to establish temperature, time, and the number of repetitions in the washing courses and the options in detail.
[0064] Meanwhile, the controller 200 releases the electric power applied to the dish washer when one of the washing courses is not selected within a predetermined time after the electric power is applied to the dish washer as a result of the generation of a predetermined signal from the signal generator 110 . This is because the electric power may be wasted when the application of the electric power to the dish washer is maintained in a case in which the electric power is applied to the dish washer without the intention of the user as in a case in which electric power is applied to the dish washer as a result of the generation of a predetermined signal from the signal generator 110 caused by the operation of the signal generator 110 due to a mistake or unintended action of the user or other unintended cause.
[0065] That is, a user touches the signal generator 110 to apply electric power to the dish washer, and select one of the washing courses through the input device 140 to perform the dishwashing. At this time, the controller 200 determines that the electric power has been applied to the dish washer without the intention of the user, when one of the washing courses is not selected within a predetermined time after the electric power is applied to the dish washer, and releases the electric power applied to the dish washer, thereby preventing the waste of the electric power.
[0066] Also, the controller 200 releases the electric power applied to the dish washer only when a predetermined signal is generated from the signal generator 110 during the dishwashing and then another predetermined signal is generated from the signal generator 110 within a predetermined time. This is because, the operation of the dish washer may stop without the intention of the user if the electric power applied to the dish washer is released when a predetermined signal is generated from the signal generator 110 during the dishwashing. If the electric power applied to the dish washer is released without the intention of the user during the dishwashing, whereby the operation of the dish washer stops, the user must apply electric power to the dish washer again to perform the dishwashing again from the beginning, which is troublesome and inconvenient.
[0067] Consequently, it is possible to prevent the electric power applied to the dish washer from being released without the intention of the user not by the controller 200 releasing the electric power applied to the dish washer immediately when a predetermined signal is generated from the signal generator 110 during the dishwashing but by the controller 200 releasing the electric power applied to the dish washer only when another predetermined signal is generated from the signal generator 110 within a predetermined time.
[0068] In this case, in order to release the electric power applied to the dish washer during the dishwashing, the user touches the signal generator 110 , such that a predetermined signal is generated from the signal generator 110 , and touches the signal generator 110 again within a predetermined time, such that the electric power applied to the dish washer is released.
[0069] FIG. 4 is a flow chart illustrating a method of controlling the input unit of the dish washer. Specifically, FIG. 4 illustrates a series of processes from the application of electric power to the performance of dishwashing.
[0070] The processes from the application of electric power to the performance of dishwashing will be described with reference to FIG. 4 .
[0071] First, when a predetermined signal is generated from the signal generator 110 , electric power is applied to the dish washer (S 110 ). When the electric power is applied to the dish washer, it is determined whether any one of the predetermined washing courses has been selected within a predetermined time (S 120 ).
[0072] When it is determined that one of the predetermined washing courses has not been selected within the predetermined time, it is determined that the electric power has been applied to the dish washer without the intention of a user, and the electric power is applied to the dish washer is released (S 130 ). On the other hand, when it is determined that one of the predetermined washing courses has been selected within the predetermined time, it is determined whether any one of the predetermined options has been selected within a predetermined time (S 140 ).
[0073] When it is determined the one of the predetermined options has not been selected within the predetermined time, it is determined whether the door 11 is closed (S 150 ). When it is determined that the door 11 is open, the dish washer is on standby (S 160 ). On the other hand, when it is determined that the door 11 is closed, the dishwashing is carried out according to the selected washing course without any option (S 170 ).
[0074] On the other hand, when one of the predetermined options has been selected within the predetermined time, it is determined whether the door 11 is closed (S 180 ). When it is determined that the door 11 is open, the dish washer is on standby (S 160 ). On the other hand, when it is determined that the door 11 is closed, the dishwashing is carried out according to a course including the selected washing course and the selected option (S 190 ).
[0075] In the method of controlling the input unit of the dish washer, therefore, it is possible to release the electric power applied to the dish washer when the application of the electric power to the dish washer is not intended by the user although the signal is generated from the signal generator 110 with the result that the electric power is applied to the dish washer, and therefore, it is possible to prevent the continuous application of the electric power to the dish washer, thereby preventing the waste of the electric power. That is, in the method of controlling the input unit of the dish washer, it is possible to release the electric power applied to the dish washer when a washing course or a washing course including an option is not selected although a predetermined signal is generated from the signal generator 110 with the result that the electric power is applied to the dish washer.
[0076] FIG. 5 is a flow chart illustrating a method of controlling the input unit of the dish washer. Specifically, FIG. 5 illustrates a process for releasing the electric power applied to the dish washer during the dishwashing.
[0077] The process for releasing the electric power applied to the dish washer during the dishwashing will be described with reference to FIG. 5 .
[0078] First, when a predetermined signal has been generated from the signal generator 110 during the dishwashing (S 210 ), it is determined whether another predetermined signal has been generated from the signal generator 110 within a predetermined time (S 220 ).
[0079] When it is determined that the another predetermined signal has been generated from the signal generator 110 within the predetermined time, the electric power applied to the dish washer is released with the result that the dishwashing stops (S 230 ).
[0080] On the other hand, when it is determined that the another predetermined signal has not been generated from the signal generator 110 within the predetermined time, the electric power applied to the dish washer is not released with the result that the dishwashing continues (S 240 ). That is, it is determined that the first signal has been generated from the signal generator 110 by a mistake of the user or the malfunction of the dish washer due to an external cause, and therefore, the electric power applied to the dish washer is not released.
[0081] In the method of controlling the input unit of the dish washer, therefore, it is possible to release the electric power applied to the dish washer only when a predetermined signal is generated from the signal generator 110 according to the intention of the user during the dishwashing, and therefore, it is possible to prevent the electric power applied to the dish washer from being released when the signal is generated from the signal generator 110 by a mistake of the user or the malfunction of the dish washer due to an external cause. That is, it is possible to release the electric power applied to the dish washer only when the user pushes or touches the signal generator 111 twice at predetermined time intervals, and therefore, it is possible to prevent the electric power applied to the dish washer from being released by a mistake of the user or the malfunction of the dish washer due to an external cause during the dishwashing.
[0082] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
|
The present invention is related to a home appliance such as a dish washer, a laundry machine, a refrigerator, etc. One embodiment of a home appliance according to the present invention comprises a control panel and a controller. The controller panel may include a power switch which allows a user to input a command for switching on or off a power of the appliance and an input device which allows the user to input a command in connection with an operation of the appliance.
| 3
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.